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
©KM
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
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

©KM
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
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
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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.
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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).
©KM
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
MX_MC6_V1.9_07.09.15_ENG
©KM
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)

MX_MC6_V1.9_07.09.15_ENG
A close correlation exists between the pressure curve in the mold and the quality
©KM
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)
MX_MC6_V1.9_07.09.15_ENG
4 Compression time (t2) 8 Compression along the flow path 3)

1) Thermal and mechanical stress of melt
©KM
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
• 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
• 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
MX_MC6_V1.9_07.09.15_ENG
(see section 2.5.1, page 2-118), including choosing the lowest possible
©KM
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).
MX_MC6_V1.9_07.09.15_ENG
©KM

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.
MX_MC6_V1.9_07.09.15_ENG
©KM
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)
MX_MC6_V1.9_07.09.15_ENG
©KM

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).
MX_MC6_V1.9_07.09.15_ENG
©KM

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
MX_MC6_V1.9_07.09.15_ENG
©KM
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.
MX_MC6_V1.9_07.09.15_ENG
©KM

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

MX_MC6_V1.9_07.09.15_ENG
©KM
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)
MX_MC6_V1.9_07.09.15_ENG
©KM
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
©KM

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
MX_MC6_V1.9_07.09.15_ENG
©KM

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)
MX_MC6_V1.9_07.09.15_ENG
©KM

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)
MX_MC6_V1.9_07.09.15_ENG
©KM

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)
MX_MC6_V1.9_07.09.15_ENG
©KM

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)
MX_MC6_V1.9_07.09.15_ENG
©KM

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)
MX_MC6_V1.9_07.09.15_ENG
©KM

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)
MX_MC6_V1.9_07.09.15_ENG
©KM

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)
MX_MC6_V1.9_07.09.15_ENG
©KM

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)
©KM

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)
MX_MC6_V1.9_07.09.15_ENG
©KM

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)
©KM

Clamping unit
LS⁄D ratio 23 23
Swept volume [cm3 ] 5195 6786 8588 7634 9662 11928
MACHINE OPTIONS 3)
MX_MC6_V1.9_07.09.15_ENG
©KM

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)
©KM

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
©KM

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)
MX_MC6_V1.9_07.09.15_ENG
©KM

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
©KM

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)
MX_MC6_V1.9_07.09.15_ENG
©KM
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)
MX_MC6_V1.9_07.09.15_ENG
©KM
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.
©KM
• 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
D
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
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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;
• 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
w
d
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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

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
medium.
Immediately contain any spilt oil and dispose of it in an environmentally
responsible manner.
5-196 Installation
e
d
D
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
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

5.3 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 5-199
5.7 Installing and aligning the machine
5.7.1 General Notes

• Installation and alignment should always be carried out by KraussMaffei
personnel. If the machine is installed and aligned by other personnel, the
installation and alignment of the machine must be inspected and approved by
KraussMaffei personnel for warranty purposes.
• Machines are always aligned by means of wedge shoes and compensation
plates.
• Use the current foundation drawing when installing the machine.
• The positions of the wedge shoes are defined in the foundation drawing.
• Inspect the installation area first with a levelling instrument.
The foundation must have a deviation not exceeding 10 mm over the entire
length of the machine.
• Any unevenness within the area of the machine base must not be more than
5 mm. Compensate for greater deviations using metal plates between the
machine frame and the wedge shoe, matching the size of the wedge shoe.
Weld the metal plates to the front of the machine base.
• Clean any paint from all measuring points and then strip them all with an oil
stone (contact areas, see Fig. 5.2 and Fig. 5.7).
• Position spirit levels without tilting.
• After the measurements are complete, apply rust inhibitor to the
measurement surfaces.
Tools
• Levelling instrument
• Levelling rod with mm scale
• 5 calibrated frame spirit levels with an accuracy of 0.1 mm⁄m
• Frame spirit level with accuracy of 0.1 mm⁄m
MX_MC6_V1.9_07.09.15_ENG
©KM
5-200 Installation
5.7.2 Position of the transport locks
W
Important
• After installing the machine, remove the transport locks on the clamping
unit and injection unit.
• The positions of the transport locks depend on the size of injector and
machine version. They may therefore deviate from the specified positions.
• Keep the transport locks for transporting the machine at a subsequent
date.
1
2 3
Fig. 5.1 Position of the transport locks

1 Transport locks, pressure cushions (4x) 3 Transport locks, upper clamping unit
2 Transport locks, lower clamping unit 4 Transport locks, injection unit
MX_MC6_V1.9_07.09.15_ENG
©KM
Installation 5-201
5.7.3 Installing and aligning the clamping unit

Mold
• Precision spirit levels, accuracy 0.1 mm/m
Inspection and setting value

• Deviation from the horizontal in longitudinal axis and transverse
axis < 0.2 mm⁄m.
A 1 2 3 4 2 5 B
Fig. 5.2 Aligning the clamping unit

1 Contact surfaces of machine base, transverse (2x) 4 Contact surfaces, longitudinal from KM 1600 (2x)
2 Contact surfaces, longitudinal (4x) 5 FP contact surface
3 MP contact surface 6 Distance x 1)
1) Distance between MP and FP
• A = Plus
MX_MC6_V1.9_07.09.15_ENG
• B = Minus
©KM
Prerequisites
• The floor load capacity at the installation location must meet the specifications
stated in the foundation drawing (see chapter 15 Parts lists/drawings).
• Power supply, cooling water connection, compressed air connection and
clearance around the machine must comply with the specifications in the
foundation drawing.
• The installation area must be cleaned.
5-202 Installation
Procedure
1) Mark the longitudinal and transverse axes (axes of co-ordinates = flange
attachment area to injection unit) according to the specifications (installation
drawing or customer specification) on the installation area.
2) Preparing wedge shoes:
a) Check wedge shoe for lubrication. Relubricate if necessary.
b) Set the wedge shoes to maximum height.
c) Remove grease and oil residue from the coatings and contact surfaces of
the wedge shoes for the foundation and the machine base.
d) Arrange the wedge shoes in accordance with the foundation drawing.
I
Note
Acetone is the preferred cleaning agent.
If necessary, other cleaning products (cold cleaner, dry cleaning solvent) can
be used.
3) Move the clamping unit over the foundation and align it with the axes.
4) Place the clamping unit on to the wedge shoes.
5) Remove the transport locks (see section 5.7.2, page 5-201) and lifting eyes
from clamping unit.
W
Important
Store the transport locks and lifting eyes.
6) Use the levelling instrument to determine the highest and lowest points on the
machine base for the contact areas (see fig. 5.2, page 5-202).
7) Align the clamping unit to the lowest point using the adjusting bolts of the
wedge shoes (5, fig. 5.3).
W
Important
• The maximum deviation on a precision spirit level must be 0.2 mm⁄m in the
longitudinal and transverse direction.
MX_MC6_V1.9_07.09.15_ENG
Check the precision levels for accuracy!

Do not place precision levels directly over wedge shoe!
©KM
• All the wedge shoes must be under pressure in the upper direction.
• Use only the contact areas specified (see fig. 5.2, page 5-202)!
Measurements on other surfaces lead to misalignment of the clamping unit.
Installation 5-203
8) Position the precision spirit level on the contact area (see fig. 5.2,
page 5-202) and adjust the horizontal position in the longitudinal and
transverse axes using the adjusting bolts of the wedge shoes.
9) Adjust the clamping unit, alternating between sides until it is exactly
horizontal.
10) Bolt wedge shoe together with machine base.
I
Note
If the distance x between MP and FP is small (6, fig. 5.2), this can result in load
relief at the end of the machine base (ejector area side). The machine base
rises at the last measurement point and exceeds the permissible tolerance.
Repeat measurement at maximum opening width.
W
Important
The alignment of the clamping unit may alter as a result of the installed mold.
After installing the mold, check the horizontal alignment of the clamping unit
and realign the clamping unit if necessary.
If there are shims on the wedge shoe, they have to be attached to the machine
base following alignment!
5.7.4 Vertical alignment of the fixed mold clamping platen

Prerequisites
• Mold installed
• Clamping unit aligned
MX_MC6_V1.9_07.09.15_ENG
©KM
5-204 Installation
Procedure
A
1 2 3 4
A-A
Fig. 5.3 Vertical alignment of the fixed mold clamping platen

1 Horizontal stop (4x) 4 Measuring surfaces, fixed mold clamping platen
2 Wedge shoe 5 Adjusting bolt
3 Fixed mold clamping platen (FP)
1) Clean the contact areas (4, fig. 5.3) on the fixed mold clamping platen.
2) Place the precision spirit level on the contact areas. If it shows an incline,
carry out the following steps.
a) Adjust the wedge shoes (2) below the area of the FP using the adjusting
bolts (5) on the operator side and operator rearside.
b) Check the horizontal alignment using the precision spirit level on the
contact areas of the ground bars on the machine base (see fig. 5.2,
page 5-202).
W
Important
MX_MC6_V1.9_07.09.15_ENG
• The incline must not exceed max. 0.1 mm⁄m.

• The alignment of the clamping unit must not change. Inspect the alignment
©KM
of the clamping unit again, if necessary.
W
Important
Correct the alignment of the machine during commissioning (see section 7.12,
page 7-323) because otherwise technical damage to the machine can occur.
Installation 5-205
5.7.5 Install horizontal stop
1
3
5
6
Fig. 5.4 Install horizontal stop

1 Wedge shoe (4x) 4 Securing nut (8x)
2 Securing nut (12x) 5 Anchor bolt (12x)
3 Horizontal stop (4x) 6 Flange of clamping unit
1) Mark distance A between the front edge of the horizontal stop (3, fig. 5.4) and
the flange of the clamping unit in accordance with the foundation drawing on
the floor.
2) Make three holes for anchor bolts (5) in accordance with the drilling pattern of
the horizontal stop in the foundation.
3) Place mortar cartridges into drilled holes in accordance with the instructions
for the mortar cartridges.
4) Screw in the anchor bolts (5).
5) Attach the wedge shoes (1) to the horizontal limit stop (3).
6) Screw the horizontal stop using anchor bolts and securing nuts (2) to the
MX_MC6_V1.9_07.09.15_ENG
foundation.
7) Tighten the wedge shoe.
©KM
5-206 Installation
5.7.6 Fitting on protective housing
W
Important
Before beginning to fit on the protective housing, the clamping unit must be
completely installed and the machine must be aligned exactly.
Documents required for assembly

The following documents are required for assembly of the panelling and can be
found in its packaging:
• Installation drawings for the protective housing and limit switches
• Floor plan with assembly drawings
• Parts lists
• Special version details and installation instructions
• Drilling templates
Prerequisites
• No damage in transit to the protective housing
• All parts present in their entirety in accordance with the packaging list
• Small parts, such as bolts and foundation dowels, secured until processing
• Check both the guides for the safety gates and the safety gates themselves
for exact alignment and realign if necessary.
I
Note
To make it easier to assemble the panelling, the step-on safety grids on the
operator side and operator rearside must be removed.
Procedure
1) Measure the dimensions according to the assembly drawing and transfer
them onto the floor:
• The centre of the machine axis on the FP and at the end of the machine
• The zero point starting from the FP and the width dimensions of the
panelling from operator side to operator rearside
2) Mark out the panelling outlines and support post positions using a chalk line
MX_MC6_V1.9_07.09.15_ENG
and an angle guide.

©KM
W
Important
The scribe line is required for visually inspecting the straightness of the overall
panelling.
Installation 5-207
Fig. 5.5 Fitting on protective housing 1

1 Foot plates 2 Reinforcement prop
3) Using the corner and normal templates, drill holes for the fastening anchors
of the foot plate and reinforcement uprights:
• Bore diameter = 10 mm
• Hole depth = 80 mm
I
Note
MX_MC6_V1.9_07.09.15_ENG
• For the KM 850 MX to KM 1150 MX only the reinforcement uprights are

©KM
screwed to the floor, not the foot plates.

• For the KM 1300 MX to KM 4000 MX only the reinforcement uprights and
the two foot plates in the corners at the back are screwed to the floor, but
not the remaining foot plates.
• The foot plates that are not screwed to the floor are equipped with an anti-
skid substrate.
• Observe the machine's foundation drawing (see section 15.3,
page 15-1041).
5-208 Installation
4) Install the foundation anchor and foot plates (1, fig. 5.5).
5) Insert M 20 threaded bolts for the foot plates into the panelling corner frame
and adjust them to the assembly height.
W
Important
Frame face end and side elements are assembled horizontally
1
2
3
4
17 5
6
4
7
16
15 8
18 9
19
10
11
9
2
14
13
8
12
MX_MC6_V1.9_07.09.15_ENG
Fig. 5.6 Fitting on protective housing 2

©KM
1 Rear panelling frame 11 Cover plates FP

2 Panelling plates 12 Operating/display panel
3 Side panel, operator rearside 13 Safety gate, operator side
4 Prop 14 Reinforcement prop
5 Window 15 Side panel, operator side
6 Plastic runners for safety gate guidance 16 Diagonal strut
7 Safety gate, operator rearside 17 Face end
8 Support with mounting angle 18 Upper guide sections
9 Service gates 19 Lower guide sections
10 Front panelling corner frames
Installation 5-209
6) Pre-assemble the panelling corner frame (10, fig. 5.6) for the operator side
and operator rearside.
7) Screw together the fronts for the operator side and operator rearside while
they lie flat on the floor.
8) Screw the lower guide section (19) and upper guide section (18) to the upright
(4) and corner piece.
• The lower guide sections for the safety gates are bolted and welded to the
intermediate members.
• The runners are preset to exact parallel running.
• The securing bolts are coated with Loctite.
9) Check that the guide sections and runners are straight—readjust them, if
necessary.
10) Bolt the cable duct tight.
11) Firmly install the mounting parts for the drive, belt tensioner, deflection pulley
and locking bolt holder.
12) Install the plastic runners for the safety gate guidance (6) in the upper frame
part.
I
Note
Optimum guidance cannot be set until the system has been installed and
levelled.
13) Assemble the safety gates (7 and 13) and check that the guide levels are
even and straight - readjust them, if necessary.
a) Pre-assemble the safety gates, without windows.
b) Firmly bolt in the trolleys with spacer plate and stud bolts (use long stud
bolts for lower trolley).
c) Insert or hang the gates in the frame.
14) Install the safety gates in the front sides for the operator side and operator
rearside that are laying on the ground.
15) Install the assembled fronts for the operator side and operator rearside.
16) Install the rear connection crossbars between the two fronts.
17) Install the preassembled limit switch holding panels.
18) Place the diagonal struts (16) or gusset plates in position and connect them
loosely.
MX_MC6_V1.9_07.09.15_ENG
The two corner connections must be relieved of any tension that has built up
©KM
by loosening tightened bolts.

19) Level the loosely installed frame to the height of the step-on safety grid.
It is already aligned parallel with the machine by means of the foot plates
preassembled on the floor.
20) Counter the thread of the adjustable feet to increase the stability.
21) Install the reinforcement uprights (14) for the operator side and operator
rearside, align them and screw them to the foundation.
22) After levelling and aligning the frame, tighten all connections.
5-210 Installation
23) Install the supports of the panelling (8, fig. 5.6) to the FP on the operator side
and operator rearside.
24) Bolt the securing brackets on the FP onto the struts.
25) Optimize the running of the safety gates without hydraulic motor.
26) Align the upper gate runners and tighten them.
27) Check the position of the switching plates and the position of the limit switches
and buffers on the MP and safety gate and optimize them.
28) Shorten protruding threaded bolts of the foot plates in the area of the gate
drive belt, in order to guarantee optimum belt-running.
29) Assemble the service gates (9), align them and set the limit switches.
30) Hook in the lower, then the upper panelling plates (2) and tighten the screws.
31) Bolt the cover plates to the FP on the face module and on the FP.
32) Inspect the gate control, the position of the limit switches, etc. during
commissioning and readjust them.
33) Clean the panelling and repaint any paint damage.
W
Important
The paint supplier for the panelling is the KM standard supplier.
34) Insert the window (5):

a) Affix the sponge rubber sealing profile on the steel of the profile surface.
b) Clamp in the acrylic glass panes with a putty beading strip and install
them.
MX_MC6_V1.9_07.09.15_ENG
©KM
Installation 5-211
5.7.7 Installing and aligning clamping unit

Mold
• Precision spirit level, accuracy 0.1 mm/m
• 2 straight edges

• Deviation from the horizontal in longitudinal axis and transverse axis <
0.2 mm/m.
1 1 2
Fig. 5.7 Aligning the injection unit, contact areas

1 Contact areas in longitudinal direction 2 Contact areas in transverse direction
Procedure
1) Move the injection unit over the installation area and align it with the axes.
W
Important
The clearance between clamping unit and injection unit must be at least
500 mm.
2) Clean the flange attachment area of the clamping unit and the injection unit
and strip them off with an oilstone if necessary.
3) Protect the flange attachment area from corrosion using lubricant.
MX_MC6_V1.9_07.09.15_ENG
I
©KM
Note
No lubricant is needed for connecting to the FP.
4) Feed the cables into the clamping unit.

5) Preparing wedge shoes:
a) Check wedge shoe for lubrication. Relubricate if necessary.
5-212 Installation
b) Set the wedge shoes to maximum height.

c) Remove grease and oil residue from the coatings and contact surfaces of
the wedge shoes for the foundation and the machine base.
d) Arrange the wedge shoes in accordance with the foundation drawing.
6) Lower the injection unit onto the wedge shoes.
7) Align the injection unit with the mark of the clamping unit and in accordance
with the side elevation.
If no mark is present, align the connecting bolts so that they are centred
relative to the screw hole.
8) Place the precision spirit level on the contact areas in the longitudinal and
transverse axes using rulers (see fig. 5.7, page 5-212).
W
Important
• Permitted deviation from the horizontal in longitudinal axis and transverse
axis: < 0.2 mm⁄m.
• If there are shims on the wedge shoe, they have to be attached to the
machine base following alignment!
9) Adjust the horizontal alignment in the longitudinal and transverse axes using
the adjusting bolts of the wedge shoes.
10) Record the position.
Enter the deviation of the spirit level from the zero position so that the rising
inclination in mm/m is visible.
11) SP 33000 or later: Aligning the screw barrel parallel to the injection unit
machine bed (see section 7.13.3.3, page 7-341) and support it
12) Attach the nozzle safety gates.
13) Bolt injection unit to clamping unit.
Position bolts, do not tighten them.
14) Remove the transport locks (see section 5.7.2, page 5-201) and lifting eyes
W
Important
Store the transport locks and lifting eyes.
MX_MC6_V1.9_07.09.15_ENG
©KM
15) Repeat the alignment several times, switching sides until the injection unit is
within the tolerance range.
16) Finish connecting the machine:
– Cooling water connection (see section 5.8, page 5-214)
– Electrical connection (see section 5.9, page 5-215)
– Compressed air connection
17) Add oil (see section 5.10, page 5-217).
18) Ensure that the alignment is checked after four weeks of operating.
Installation 5-213
5.8 Connection of cooling water
W
Important
• The cooling water must be located in a closed circuit.
• Clean water with a low lime content is an essential requirement for proper
operation of the automatic temperature control.
• Water which is polluted or has a high lime content adversely affects the
temperature control and reduces the cooling capacity.
• To ensure proper temperature control and cooling, the water must be
micro-filtered, either continuously or at periodic intervals. Install
appropriate filters in the water intake.
Water specification (see section 3.4.1, page 3-152).
• The cooling water must be chemically prepared such that all abrasive,
corrosive and aggressive constituents are precipitated and can be filtered
out mechanically. To do this, carry out a water analysis before
commissioning.
i
t
Environmental note
• Always dispose of the cooling water separately.
• Enquire at the manufacturer/supplier of the chemical additives about
disposal regulations and comply with them.
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 5.8 Machine cooling water connection

1 Return flow 2 Feed
1) Ensure that the valves for the water intake and return-flow have been
executed in accordance with the foundation drawing (see chapter 15 Parts
lists/drawings).
2) Connect water feed and return line, cooling water distributor, mold cooling
(ZE) to injection unit or clamping unit in accordance with the machine's
foundation drawing (see chapter 15 Parts lists/drawings).
5-214 Installation
5.9 Electrical connection of master switch

Prerequisites
• Master switch off
• Sufficient cross-section of the supply lines (according to local circumstances
and VDE 0113 or VDE 0298 regulations)
W
Important
• The connection of the power supply to the master switch must be carried
out by a qualified electrical specialist only.
• Observe the specifications of the relevant energy supply company as well
as any applicable national standards and regulations regarding such a
connection.
• Connect the master switch with clockwise rotating field.
• Do not switch on the pump motor until hydraulic oil has been poured in.
Failure to observe this instruction will result in damage to the pumps.
Procedure
3 5
Fig. 5.9 Electrical connection of master switch

1 Master switch 4 L2 = blue
MX_MC6_V1.9_07.09.15_ENG
2 Cover 5 L3 = brown
3 L1 = black
©KM
1) Remove the cover of the master switch (2, fig. 5.9).

2) Detach the strain relief in the supply cabinet.
3) Feed the power supply line into the supply cabinet from below and connect it
to the master switch.
Installation 5-215
I
Note
Note the correct phase sequence, z. B.:
• L1 = black (3, fig. 5.9)
• L2 = blue (4),
• L3 = brown (5).
4) Install the cover of the master switch.

5) Install the fuse in the distribution cabinet according to the type plate.
w
D
Warning!
The yellow service socket -XJ05 in the control cabinet is live even after the
master switch has been switched off!
MX_MC6_V1.9_07.09.15_ENG
©KM
5-216 Installation
5.10 Replenishing hydraulic oil
D
r
d
Warning of slipping hazard
Immediately use appropriate binding agents to remove any hydraulic oil that
has poured out.
W
Important
Only use hydraulic oil that meets the specifications and watch for compatibility,
specifications for operating materials (see section 3.4, page 3-152).
Failure to observe this instruction will result in damage to the machine and will
render the warranty void.
Always use a filter with a mesh size of  6 µm when pouring in the hydraulic oil.
B
G
Safety goggles
loss of eyesight.
W
Important
After emptying the hydraulic oil tank, considerable quantities of residual oil still
remain in the hoses, lines, cylinders and hydraulic components.
Mixing oils may cause a change in the specific characteristic data and impair
the filtering properties.
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.
i
t
Environmental note
Collect hydraulic oil pumped out in a suitable vessel and dispose of properly.
MX_MC6_V1.9_07.09.15_ENG
©KM
Installation 5-217
5.10.1 Venting the pump motor
W
Important
• Ensure that the hydraulic oil cooling circuit for the pump motor is connected
and active.
Operation without activated cooling circuit destroys the glide ring seals.
• Do not switch on the pump motor until hydraulic oil has been poured in.
2 3 4
1 2
5 5
Fig. 5.10 Pump motor

1 Drain plug (2x) 4 Cooling connection (2x)
2 Bleed screw (2x) 5 Leak oil connection (2x)
3 Pump motor
MX_MC6_V1.9_07.09.15_ENG
W
Important
©KM
Before switching on the pump motor or commissioning the hydraulic system

and after changing the hydraulic oil, make sure to carry out steps 1 to 7.
5-218 Installation
1) Open the pump chamber.

2) Have a suitable collecting vessel ready in the pump chamber.
3) Unscrew the bleed screws (2, fig. 5.10) on the pump motor (3).
4) Add filtered hydraulic fluid via the cooling connection (4) until hydraulic fluid
escapes from the bleed screws.
5) Connect the cooling connection and screw in the bleed screws.
6) Remove the collecting vessel from the pump chamber.
7) Close the pump chamber.
5.10.2 Replenishing hydraulic oil

Prerequisites
• A sufficient quantity of hydraulic oil provided (see section 3.2, page 3-131)
• Pump motor vented (see section 5.10.1, page 5-218)
Procedure
4
1
2
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 5.11 Hydraulic oil tank with filler filter and air admission filter
1 Hydraulic oil filler neck 3 Return-flow filter
2 Oil level inspection glass 4 Air admission and release filter
Installation 5-219
1) Remove the cover of the hydraulic oil filler neck (1, fig. 5.11) on the hydraulic
oil tank.
W
Important
• Due to the possibility of overflowing when filling/replenishing, note the
position of the injection barrels, clamping unit traversing cylinders and the
pressure piston (pressure cushions). To prevent overflows, move the
barrels/plungers into the retracted position (minimum pressurization).
• Remove the leakage pipes from the variable capacity pump and hydraulic
motor and completely fill both lines with filtered hydraulic oil, especially
after the pump or motor has been replaced. Always first fill the pump and
motor before filling the tank.
Then reattach the pipes.
2) Add hydraulic oil using a filter pump; while doing so, watch the oil level
inspection glass (2, fig. 5.11) on the main tank.
Fig. 5.12 Oil level inspection glass

1 Top marking 2 Oil level inspection glass
MX_MC6_V1.9_07.09.15_ENG
©KM
3) Filling is ended when the oil level on the inspection glass reaches the top
marking (1, fig. 5.12).
4) Close the hydraulic oil filler neck again.
5) Bleed the hydraulic system (see section 7.10, page 7-306).
W
Important
Check the oil level at the oil level inspection glass after commissioning.
5-220 Installation
5.11 Fill the pressure accumulator with nitrogen

Prerequisites
• Hydraulic oil filled
• Hydraulic system depressurized (pump motor switched off)
• Nitrogen cylinder/nitrogen charge battery
• Ambient temperature approx. 20 °C
• Oil temperature 45 °C
• Decompress the pressure accumulator on the oil side
• Pressure accumulator is disconnected from the system (connector unplugged
from valve QH581)
• Ensure the connections are free of grease and oil
• Filling valve of the pressure accumulator OK
• O-ring not damaged
• Protective caps available
Procedure
w
D
Warning!
• Use only nitrogen for filling the accumulator, on no account oxygen—
explosion hazard!
• The following steps should only be carried out if the special tool and filling
and test device FPU-1 of HYDAC TECHNOLOGY are used.
W
Important
If the gas pressure in the nitrogen cylinder/nitrogen charge battery is higher
than the maximum operating pressure of the pressure accumulator, a pressure
reducing valve (3, fig. 5.14) must be installed between the filling and test
device and the nitrogen cylinder/nitrogen charge battery.
For the prefill pressure for the pressure accumulator, refer to the hydraulic
circuit diagram in the chapter "Hydraulics/Pneumatics" (see chapter
17 Hydraulics/Pneumatics).
MX_MC6_V1.9_07.09.15_ENG
©KM
Installation 5-221
3
2

2 Pressure switch BP581 (blocking from/to the
system)
2 3 4 5
1
8
Fig. 5.14 Filling and test device connected to the nitrogen cylinder
1 Nitrogen cylinder 5 Actuation spindle (FPU-1)
2 Shut-off valve 6 Pressure indicator
3 Pressure reducing valve 7 Relief valve (FPU-1)
4 Filling hose 8 Pressure accumulator
MX_MC6_V1.9_07.09.15_ENG
©KM
5-222 Installation
1
2
Fig. 5.15 Filling and test device connected to the nitrogen charging battery
1 Pressure reducing valve 2 Shut-off valve
1) Provide a nitrogen cylinder/nitrogen charge battery.

2) Ensure that:
• The pump motor is switched off.
• The drain cock S5800 (3, fig. 5.13) is fully opened.
3) Unscrew the cap (5, fig. 5.16) and cap nut (4).
4) Fit the filling and test device on the following components:
a) Pressure accumulator (8, fig. 5.14)
b) Attach the nitrogen cylinder (1, fig. 5.14) or nitrogen charge battery
5) Close the pressure release valve (7, fig. 5.14).
6) Open the gas valve by turning in the actuation spindle (5, fig. 5.14).
W
Important
Open the shut-off valve slowly so that pressure equalization takes place and
the gas valve insert is not damaged.
Perform steps 7 and 8 after about 5 min in each case. Repeat waiting time
several times in the case of small filling quantities until the pressure has
stabilized.
Large filling quantities require that longer waiting times be used.
MX_MC6_V1.9_07.09.15_ENG
©KM
7) Open the shut-off valve slowly by hand while watching the pressure indicator
(6, fig. 5.14) on the following components:
– Nitrogen cylinder (2, fig. 5.14)
– Nitrogen charging battery (2, fig. 5.15)
8) When the prefill pressure is reached (see hydraulic diagram), close the gas
valve by unscrewing the actuation spindle (5).
Installation 5-223
W
Important
If the prefill pressure is too high, it is possible to release pressure through the
relief valve at the filling and test device.
9) Close the shut-off valve on the nitrogen cylinder (2, fig. 5.14).
10) Open the pressure release valve (7) for pressure discharge.
11) Remove the filling and test device.
12) Check the gas valve (2, fig. 5.16) for leaks using soapy water or leak test
spray.
13) If necessary, tighten the gas valve insert using a valve core extractor.
14) Screw on the cap nut (4) and cap (5) and tighten them.
15) Tighten the vertical holder of the pressure accumulator.
16) Vent the pressure accumulator on the oil side (see section 7.10, page 7-306).
17) Perform steps 1 to 16 for all pressure accumulators.
18) Attach the panelling in the area of the pressure accumulator(s).
19) Check the oil level and replenish hydraulic oil, if necessary.
5
3
2
Fig. 5.16 Pressure accumulator

MX_MC6_V1.9_07.09.15_ENG
1 Storage tank, pressure accumulator 4 Cap nut

2 Gas valve 5 Cap
©KM
3 O-ring
5-224 Installation
6 Operating/display elements
This chapter contains an overview of the operating elements on the
operating/display panel and how they are visualized on the flat display.
6.1 Operating pen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
6.2 Operating/display panel . . . . . . . . . . . . . . . . . . . . . . 227
6.3 Screen operating elements . . . . . . . . . . . . . . . . . . . 231
6.4 Machine function module . . . . . . . . . . . . . . . . . . . . . 268
6.5 Operating mode buttons . . . . . . . . . . . . . . . . . . . . . 270
6.6 Machine operating buttons . . . . . . . . . . . . . . . . . . . 273
6.7 Slider control "SlideX" (24″ Multitouch) . . . . . . . . . 288
6.8 Function buttons for additional components . . . . . 291
6.9 Additional modules . . . . . . . . . . . . . . . . . . . . . . . . . . 292

MX_MC6_V1.9_07.09.15_ENG
©KM
Operating/display elements 6-225

6.1 Operating pen
W
Important
Touch the touchscreen only with the special operating pen or (clean) finger.
Do not use sharp or metallic objects.
Do not touch the touchscreen with dirty gloves.
The operating pen is included in the scope of delivery. It is stored in the electrical
control cabinet.
Fig. 6.1 Touchscreen operating panel with operating pen

1 Operating pen 2 Pen mount
Fitting operating pen at touchscreen operating panel

1) Take operating pen from electrical control cabinet.
2) Peel off foil from adhesive surface of pen mount.
MX_MC6_V1.9_07.09.15_ENG
3) Affix pen mount to the side of the metal frame (see fig. 6.1, page 6-226).
W
©KM
Important
• The pen mount must not be secured to the plastic frame.
• The operating pen must not protrude beyond the upper edge of the
touchscreen operating panel.
• Assembly screws and chip card reading device must be freely accessible.
6-226 Operating/display elements

6.2 Operating/display panel
1
18 2
17 4
5
16
6
7
8
15
14
13
9
MX_MC6_V1.9_07.09.15_ENG
12 11 10
©KM
Fig. 6.2 Operating/display panel MC6 - 19" touchscreen

1 Header bar 10 Mode buttons for injection molding machine
2 Multi-select feature for favourites column 11 Mode buttons for robot
3 Tab bar 12 Function buttons for additional components
4 Favourites column 13 Machine function module
5 Screen 14 Keylock
6 Alarm hardkey 15 Split-screen button
7 Information field 16 Main navigation (main key, hard keys, soft keys)
8 Multi-select selections for machine operating buttons 17 Actual-value column
9 Machine operating buttons 18 Multi-select feature for actual-value column

1
18 2
17 4
5
16
6
8
15
14
13 9
10
12 11
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 6.3 Operating/display panel MC6 - 24″ Multitouch

1 Header 10 Operating mode buttons
2 Multi-select feature for favourites column 11 Selection buttons for slider control SlideX
3 Tabs 12 Guiding line with slider control SlideX
4 Favourites column 13 Machine function module
5 Alarm hardkey 14 Keylock
6 Information field 15 Split-screen button
7 Additional display area - screen pages 16 Main navigation (main key, hard keys, soft keys)
8 Multi-select feature for machine operating buttons 17 Actual-value column
9 Machine operating buttons 18 Multi-select feature for actual-value column

The operating and display panel is the central control element of an injection
molding machine. The MX machine can be equipped either with a 19″
touchscreen (see fig. 6.2, page 6-227) or with a 24″ Multitouch (see fig. 6.3,
page 6-228).
The 19″ touchscreen permits operation via touch functions with one contact point
respectively, such as "Slide" or "Tap" (see section "Touch functions", page 6-230).
Operation can be by hand or with an operating pen (see section 6.1, page 6-226)
included in the delivery.
The 24″ Multitouch is a capacitive glass touch screen with Multitouch feature. The
Multitouch characteristic provides a wide variety of additional operating options
for the MC6 control system. The operator can control complex production
processes just as easy as with a smart phone by means of touch gestures. The
Multitouch characteristic allows operators to actuate several buttons on the
operating/display panel at the same time. A total of 10 points can be touched at
the same time.
The Multitouch characteristic also makes zooming in by means of touch gestures

possible on the screen pages of the process designer, the hardware diagnostics
and the robot Wizard. In the same manner, you can also zoom in on curves in the
profile screens, or shift curves to change the profile.
In setting mode during execution of a machine movement via a machine

operating button (9, fig. 6.3), users have the option of actuating screen buttons.
This allows drive movements to be executed at the machine and, at the same
time, e.g. the selection of screen pages or pop-up windows.
Furthermore, the 24" Multitouch has a slider control "SlideX" (12, fig. 6.3) guiding
line engraved in the glass that gives the operator haptic control over machine
components on all moving axes without looking at the control panel.
MX_MC6_V1.9_07.09.15_ENG
©KM

Touch functions
Supported touch gestures Function
Tapping
• for tripping buttons
• for selecting in lists
• for opening files and pop-up windows
• for configuring the actual-value column
• for selecting and changing parameter values
• for acknowledging alarms
Pressing and holding in
• for operating machine operating buttons
Double-tap (only 24″ Multitouch)

• for displaying screen pages in the main screen area from the additional
display area
• for changing zoomed views back to their original size
• for calling up the detail view in the process designer
• for making selections in lists
Press and drag (sliding)

• in lists, trend graphs and screen pages in which the parameter display
extends beyond the display range
• for scrolling in images, lists and in the process designer
• for operating the slider control "SlideX" (24" Multitouch)
• for changing profile settings
• for configuring screen page views (24" Multitouch)
• for sliding pop-up windows
Swipe (24″ Multitouch)

• for scrolling through screen pages in the additional display range
Zoom (two-finger operation)

• in trend graphs
• in profile screens
• in the process designer
MX_MC6_V1.9_07.09.15_ENG
• in the technical documentation (PDF file in the Help menu)

©KM
Fig. 6.4 Supported touch gestures

6.3 Screen operating elements
6.3.1 Basic functions in the screen border of the operating/display panel

The objects arranged in the screen border include basic functions for general
operation of the screen area:
• Header bar (1, fig. 6.2)
– Date/time, page number
– User login
– Menu functions
– Help menu, symbol explanation
– Paging back/forward
– Status displays
– Software version
• Actual-value column (17)
– Freely assignable fields for actual value display
• Favourites column (2)
– Freely assignable fields for calling up screen pages
• Information field (7)
– Display of messages, information, warnings and alarms
• Main navigation (16)
– Main key with machine or robot operation and process designer
– Hardkeys for softkey and screen selection
– Softkeys for screen selection
6.3.1.1 Header bar

The header bar includes display objects and buttons with general settings or
functions. Some of the buttons of the header bar display pop-up menus when
pressed.
1 2 3 4 5 6 7 8
Fig. 6.5 Header bar

MX_MC6_V1.9_07.09.15_ENG
1 Date/Time 5 Paging forward/back

2 User login 6 Status displays
©KM
3 Menu functions 7 Software version1)

4 Help menu 8 KM logo
1) For the touch panel version of robot: Pop-up button for displaying the operating buttons

Displaying date/time and page number of a control page

Pressing the "Date/time" button in the header bar of the operating / display panel
opens a pop-up window (see fig. 6.6, page 6-232), in which the date, time and
page number of the current control page can be displayed.
Fig. 6.6 Date/time, page number
Operator side
When creating a hard copy (see section 8.4.2, page 8-383), a file with the
corresponding page number (e.g. P10.jpg) is created for the respective screen.
Current date / Current time

The date and time are displayed and can be set additionally. When the relevant
field is pressed, a numeric keypad (see section 6.3.3.1, page 6-246) open for
entering the date or time.
User login
Pressing the button opens a pop-up window. The user password can be entered
in this window. Further buttons can be used to define user settings
As a display in the header bar, the button includes the login designation of the
current user, his/her key group and the country flag for the configured language.
Menu functions
Pressing the "Menu functions" button opens a pop-up menu with buttons for
MX_MC6_V1.9_07.09.15_ENG
additional functions (see section 8.4, page 8-380).

©KM

Help menu ("?")

Pressing the "Help menu" button calls up a pop-up menu which displays
additional buttons for help functions (see section 8.5, page 8-397).
Paging back/forward
The buttons for paging (back or forward) in the header bar are intended for quick
navigation within the screen pages.
• "Page back" button:
Pressing this button calls up the previously visited page again.
• "Page forward" button:
Pressing this button calls up the last page visited, which was left before a
page change using the "Page back" button.
I
Note
If the "Page back" button still was not used to change pages, the "Page
forward" button is inactive.
The inactive button is highlighted in blue.
A pressed button is indicated by a yellow border.
Status displays
The status symbols in the header bar (6, fig. 6.5) act only as display objects
without any additional control function.
If more than seven status symbols have to be displayed, there is an animated line
change with an interval of 3-4 s.
Settings for switching functions of pump motor, barrel/mold heating etc. are
configured via the machine function module (see section 6.4, page 6-268).
Software version (MC6)

The machine or control designation is displayed in the field (7, fig. 6.5). For the
robot's touch panel, the field is configured as an additional pop-up button which
can be used to display the corresponding operating buttons.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.1.2 Actual-value column

The actual-value column on the left edge of the screen consists of a multi-select
feature (see section 6.3.2.8, page 6-244) with seven freely assignable display
fields in each level.
Creating actual-value fields

1) Press the display field in the actual-value column.
The pop-up window for parameter selection opens.
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 6.7 Parameter selection
2) Select the desired parameter.

3) To apply the selected parameter, press "OK".

6.3.1.3 Favourites column

The favourites column on the right edge of the screen consists of a multi-select
feature (see section 6.3.2.8, page 6-244) with seven freely assignable buttons in
each level. The screen pages stored there can be called up directly by pressing
the individual buttons.
I
Note
For the upper additional area displayed in split-screen mode,
(see section 6.3.6.2, page 6-258) only screen pages created with the buttons
of the favourites column can be called up.
Creating favourites
1) Select the desired screen via the main navigation (see section 6.3.1.5,
page 6-236).
2) Select and keep pressing the button in the favourites column.
The favourites button is assigned as soon as the corresponding symbol of the
selected screen appears on the button.
6.3.1.4 Information field

The information field under the main navigation is for displaying messages,
information, warnings and alarms, each with a corresponding message number.
Example: P00000 "Stop".
In case of an alarm the information field lights up red. The alarm and number of
current alarm messages are displayed.
At the same time, the alarm hard key is highlighted in colour (see section 6.3.5.1,
page 6-253).
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.1.5 Main navigation
1 2
6
5
4 3
Fig. 6.8 Main navigation for injection molding machine

1 Main key (multi-select feature for machine part) 5 Robot
2 Softkeys 6 Injection molding machine
3 Alarm hardkey with alarm signalling 7 Process designer
4 Hardkeys
Main key assignment

The main key (1, fig. 6.8) is used to select the main navigation:
• Process designer (7) and (see section 6.3.8, page 6-263)
• Injection molding machine (6)
• Robot (5) and (see section 6.3.9, page 6-264)
Depending on the selection, there is a changeover of the hard keys (4) and their
subordinate levels, of the soft keys (2) and screens.
Hardkey / softkey assignment

The following tables show the hard keys with their respectively subordinate soft
keys.
W
Important
The soft key assignments vary according to the user's input authorization
(see section 8.3, page 8-360). The screens that correspond to the soft keys are
described in the chapter "Machine operation" (see chapter 8 Operation of
MX_MC6_V1.9_07.09.15_ENG
Machine).
©KM

Mold/Ejector
Mold closing Mold opening Ejector Pneumatic Compression

valves molding,
Venting
Core-pulling
Core-pulling Interruptions Robot Ejector Unscrew the Core Core-pulling Core-pulling

signals for core enabling via settings configuration
core-pulling operating
panel without
sequence
Injection unit
Holding Plasticizing Injection unit Start- Nozzle Gas/water MuCell Adaptive Automatic
pressure/ movement up/lowering cascade systems, process feed unit
Injection control self-sufficient control
Barrel temperatures
Barrel Start- Barrel Barrel 7-day timer

temperatures up/Lowering temperatures heating
barrel control circuit
temperatures parameters monitoring
Mold temperatures
Mold Mold- Mold Mold heat. Dynamic Water External 7-day timer
temperatures temperatures temperatures circuit monit. mold heating manifolds heat-
MX_MC6_V1.9_07.09.15_ENG
graphic start- control balancing

up/lowering parameters units
©KM

Tolerance monitoring
Actual-value Trend graph Curve Quality

cycles computer statistics
Cycle/Times overview
Overview of Pieces Energy Cycle Eco assistant Overall Machine/

times counter analysis settings equipment production
effectiveness status
Machine preparation
Machine Screw coding Set-up and 7-day timer

calibration production
data
Peripherals
Freely Production Production Mold change Interface External Bolt-On Utilities Displaying Peripherals
programm- signals BDE signals CIMI Euromap alarm inputs interface Configuration image of a
able 67/SPI for camera
in/outputs teleservice
Configuration/Diagnosis
KM Service Diagnosis, Tuning Calibration of Calibration of Injector Calibration of System Calibration

calibration clamping unit ejector injection unit calibration pressure pressures Mold change
cushion,
locking
mechanism
MX_MC6_V1.9_07.09.15_ENG
Alarms/Events
©KM
Alarm Events log Overview of

overview machine
doors

6.3.2 Display objects/presentation forms on the screen
6.3.2.1 Fields for set value, actual value and notes
Set-value fields
Editable set-value fields

Fields in which a set value can be entered are highlighted in white. A selected set-
value field also gets a yellow border.
If a set value beyond the tolerance is entered, the field is highlighted in red.
Blocked set-value fields

Set-value fields which cannot be modified due to a default setting are displayed
in light grey. It is not possible to enter a value.
Depending on the default setting, a symbol with information about the access
requirement can also be displayed in the upper left of the field:
Examples:
• The set value is only editable in setting mode.
• When a number is displayed (e.g. "02"), the set value can only be edited in
the displayed key group.
Actual-value fields
Fields in which an actual value is displayed are displayed in light blue.
If an actual value is beyond the tolerance (e.g. temperatures), the field is
highlighted in red.
Information box
The notes fields highlighted in yellow display information texts.
Notes fields appear, for example, if an entered numeric value is beyond the
tolerance (i.e. not between the minimum and maximum values)
Notes fields are also used for detailed description in tabular presentations of
alarms and events (see section 8.17, page 8-672).
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.2.2 Buttons
Action button
• Pressing an action button (grey) activates a function. During the activation,
the button gets a yellow border.
• For a function that is switched on, the button is completely yellow.
Pressing a yellow action button deactivates the corresponding function.
• A faded action button (switched on or off) cannot be pressed.
Pushbutton
Pressing a pushbutton triggers a process or executes a function.
6.3.2.3 Selection elements
Tickbox
Functions on the screen can be activated and deactivated by pressing in a
tickbox.
Button
You can choose between various functions by pressing a toggle button. In each
case, only one function can be selected.
Selection menu
Pressing the arrow symbol on the right next to a selection menu opens a drop-
down menu, which displays the possible functions. Depending on the scope of the
available functions, the opened drop-down menu can be provided with a scrollbar
In the opened selection, pressing the corresponding line applies the desired
function.
When the function is applied or you press on the screen outside of the opened
selection, the drop-down menu closes by itself.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.2.4 Navigation elements

The following buttons are available for navigating the view within the screen:
Scrollbar up/down
These buttons can be used to scroll within a screen.
The function is also possible using scrollbars at the edge of the screen.
Go to beginning/end
At the press of the button, the screen portion being displayed jumps to the
beginning or end of the total screen.
Page up/down
At the press of the button, the screen portion being displayed can be moved one
page up or down within the total screen.
Zoom out/in
Pressing the button incrementally zooms out of or into the whole screen content.
If one of the two buttons is pressed longer, the screen content is again displayed
in the 1:1 scale.
Scrollbar
There are scrollbars at the edge of the screen for navigation within a page that is
larger than the displayable screen area. By pressing and shifting these you can
change the view for the whole area. Scrollbars can be aligned vertically as well
as horizontally.
6.3.2.5 Filter elements
Filtering a table
If the "Filter table" button is available in a table, the contents in a table column can
be filtered, depending on the default setting.
Filter functions can be used, for example, in the tabular presentations of alarms
and events (see section 8.17, page 8-672).
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.2.6 Pop-up operating elements
"OK" button
Press the "OK" button to close an opened pop-up window. The settings that were
made are adopted.
Button "x" / Button "Cancel"

Press the "x" button to close an opened pop-up window. The settings that were
made are not adopted.
Alternative, an addition "Cancel" button can be provided in some pop-up
windows.
Button "Yes" / "No"

Pop-up windows that open automatically and that display a safety prompt, are
closed using the "Yes" and "No" button. The queried function is then either
executed or not.
"Start" button
Pop-up windows used to execute a function contain the "Start" button. When the
button is pressed, the corresponding function is started and the pop-up window is
closed.
Button "Hard copy"

When the "Hard Copy" button is pressed, a hard copy can be created from a pop-
up window (see section 8.4.2, page 8-383).
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.2.7 Tabs
Tabs are used to call up screens.
Fig. 6.9 Tab versions
The active tab is highlighted in yellow.
I
Note
Tabs shown in pale blue without an image or symbol are not activated.
Tab expansion
If there are more screens than the screen width permits for displaying tabs, the
tab expansion is displayed. When the arrow symbol is pressed, the tabs are
shifted so that hidden tabs can now appear in their place.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.2.8 Modifiable displays (multi-select feature)
1 3
Fig. 6.10 Modifiable displays (multi-select feature)

1 Inactive selection option 3 Multi-select expansion
2 Active selection
If multiple levels for navigation, menu selection or machine operating buttons are
stacked, their display can be modified using a multi-select feature. Multi-select
selection fields can be put side-by-side or stacked.
Pressing the respective field calls up background levels (1, fig. 6.10) and brings
them to the foreground. In doing so, the field of the active level (2) is highlighted
in blue.
When pressing the active selection field (2), a pop-up menu (see section 6.3.2.9,
page 6-244) with all available menu elements opens.
If a multi-select feature has so many levels available that not all of its selection
fields can be displayed, a blue arrow symbol (3, fig. 6.10) is also displayed on the
outer edge, through which additional multi-select fields can be called up.
6.3.2.9 Pop-up menus
1 2
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©KM
Fig. 6.11 Pop-up menus (example "Menu functions")

1 Active pop-up button 2 Pop-up menu with selection buttons

Calling up pop-up menu

When a blue pop-up button (e.g. menu functions, help menu, machine functions
module) or the active field in a multi-select feature (see section 6.3.2.8,
page 6-244) is pressed, a pop-up menu which displays other functions is called
up.
The functions in a pop-up menu make it possible to:
• Activate or deactivate machine functions (see section 6.4, page 6-268)
• Carry out actions
• Navigate quickly
The active (opened) pop-up button (1, fig. 6.11) and the border of the associated
menu are highlighted in yellow and placed in the foreground. The size of the
opened pop-up is adapted to the space requirements of the buttons it contains.
Closing a pop-up menu

• By pressing a button available for selection (executing an action)
• By pressing within the background area outside of the pop-up menu
• After a certain time span has expired, if no selection has been made
Profile stages
In screens with a profile setting (mold closing/opening, ejector, holding
pressure/injection, plasticizing), the respective profile stages are displayed via
multi-select feature (see section 6.3.2.8, page 6-244).
Since not all existing profile stages can be displayed simultaneously, it is possible
to navigate quickly. Pressing the active multi-select feature opens a pop-up menu
which displays all profile stages. These can be directly selected by pressing the
respective button in the pop-up menu.
Safety-related entry
For functions which must by no means be pressed accidentally, and yet have to
be available at all times, there is the function of the extra-small pop-up dialogue
without OK and cancel.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.3 Value and text input
6.3.3.1 Numeric keypad, value input
12
1
11
10 2
4
9
8 7 6
Fig. 6.12 Numeric keypad, value input

1 "x" button 7 Button "-"
2 Maximum value 8 "Sign change +/-" button
3 "Back" button 9 Number buttons
4 Button "CL" 10 Minimum value
5 "Enter" button 11 Current input value
6 Button "+" 12 Name of the selected parameter value
When pressing an editable field that can contain only numeric values, the numeric
keypad opens. The name of the selected parameter value (12, fig. 6.12) is applied
as a title in the numeric keypad.
If minimum values (10) or maximum values (2) exist for the parameter, these are
also displayed.
The operability of the button adapts to the defined tolerances (2 and 10). On the
keypad, all buttons which would enable a value input beyond the tolerance
automatically fade. Only buttons which ensure an entry between the minimum
MX_MC6_V1.9_07.09.15_ENG
and maximum values can still be pressed.

©KM

Button "CL"
Pressing the "CL" button (4, fig. 6.12) resets a changed value to the original
value.
"x" button
Pressing the "x" button (1, fig. 6.12) closes an open pop-up window without
applying the configured settings.
When closing pop-up windows into which values are entered, the entry is rejected
and the original values are retained.
"Back" button
When an incorrect value has been entered, the "Back" button (3, fig. 6.12) can be
used to correct the value. Pressing the "Back" button once deletes the last
character of an entered value.
"Enter" button
A value which has been modified is not confirmed for application until the "Enter"
(5, fig. 6.12) button is pressed. The numeric keypad closes automatically.
I
Note
If an entered value is beyond the tolerance (i.e. not between the minimum and
maximum values) the "Enter" button is inactive and the entry cannot be
confirmed.
Button "+"
• A parameter is increased incrementally by pressing the "+" button
(6, fig. 6.12). When the "+" button is held down, the value is increased
continuously.
• Several values can be added by pressing this button (pocket calculator
principle).
Button "-"
• A parameter is decreased incrementally by pressing the "-" button
(7, fig. 6.12). Holding down the "-" button reduces the value continuously.
• Several values can be subtracted by pressing this button (pocket calculator
principle).
MX_MC6_V1.9_07.09.15_ENG
"Sign change +/-" button

©KM
When this button is pressed (8, fig. 6.12), a sign is added to a parameter after the
parameter has been entered.
Number buttons
The number buttons (9, fig. 6.12) are used to enter numeric values with or without
decimals.

6.3.3.2 Alphanumeric keypad, text input
1 2 3 4 5 6 7
9 8
Fig. 6.13 Alphanumeric keypad, text input

1 Text field 6 Button "Back"
2 "Ins" button 7 "x" button
3 "Pos 1" button 8 "Enter" button
4 Button "End" 9 "Left/right" buttons
5 Button "CL"
When an editable title block is pressed, the alphanumeric keypad opens. The text
entered via the keypad appears in the text field (1, fig. 6.13).
"Ins" button
By pressing the "Ins" button (2, fig. 6.13) you can change between "Overwrite
mode" (existing text is overwritten) and "Insert mode" (text is retained and
shifted).
"Pos 1" button

MX_MC6_V1.9_07.09.15_ENG
By pressing the "Pos 1" button (3, fig. 6.13) you can jump to the beginning of the
©KM
input line.
Button "End"
The "End" button (4, fig. 6.13) can be used to jump to the end of the input line.
Button "CL"
Pressing the "CL" button (5, fig. 6.13) resets a modified text to the original text.

Button "Back"
When text has been entered incorrectly, the "Back" button (6, fig. 6.13) can be
used to correct it. Pressing the "Back" button once deletes the last character of
an entered text.
"x" button
Pressing the "x" button (7, fig. 6.13) closes an open pop-up window without
applying the configured settings.
When closing pop-up windows into which text has been entered, the entry is
rejected and the original text is retained.
"Enter" button
A text which has been modified is not confirmed for application until the "Enter"
(8, fig. 6.13) button is pressed. The alphanumeric keypad closes automatically.
I
Note
If the text fields allowing input are not just editable title blocks, but also
extensive text bodies, the "Enter" button is used only for inserting a line break.
The entry is confirmed by pressing the additional "End entry" button.
"Left/right" buttons
The "left" and "right" buttons (9, fig. 6.13) are for shifting the input position one
space to the left or right within the line.
I
Note
If the text fields allowing input are not just editable title blocks, but also
extensive text bodies, two additional buttons ("up/down") are used for shifting
the input position across the individual lines.
Letter/number buttons
The letter/number buttons are used to enter texts and numeric values.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.4 Editing
Pressing the "Editing" button opens a pop-up window for editing screens and
settings. Depending on the screen, various functions are possible:
Profile stages
In screens with profile stages, pressing the "Editing" button opens a pop-up
window in which profile stages can be added or deleted (see section 6.3.4.1,
page 6-251).
Barrel and mold temperatures

In screens for the barrel and mold temperatures, pressing the "Editing" button
opens a pop-up window in which changes can be made for the heating zones of
a block (see section 6.3.4.3, page 6-252).
Curve computer
In screens with a curve representation, pressing the "Curve configuration" button
opens a pop-up window in which settings can be made for the appearance of the
curves.
Curve computer (see section 8.12.3, page 8-591).
Pre-settings for barrel temperatures

When the "Pre-settings for barrel temperatures" button is actuated on the "Pre-
settings for barrel temperatures" screen page, a pop-up window appears in which
the individual plastic materials can be selected. When the selection is made, the
temperature suggestions for the barrel heating saved in a database are displayed
(see section "Material selection", page 8-540).
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.4.1 Inserting/deleting profile stages

In screens with profile stages, pressing the "Editing" button opens a pop-up
window in which profile stages can be added or deleted.
1
2
Fig. 6.14 Inserting/deleting profile stages

1 "Insert profile stage" pushbutton 2 "Delete profile stage" pushbutton
1) Press the "Editing" button.

The "Insert/delete profile stages" window opens.
2) Pushbutton
a) "Insert profile stages" (1, fig. 6.14):
A new column containing suggested values is inserted behind the current
column.
b) "Delete profile stages" (2):
The current column is deleted.
6.3.4.2 Changing profile stages

Apart from the profile settings via input fields and pop-up windows, operators also
have the option of setting the profile stages via touch functions in screen with
profile screens.
The profile line in the graphic area is set by:
• touching the profile line at the marking for profile setting and
• dragging until the desired set value is reached.
MX_MC6_V1.9_07.09.15_ENG
For checking purposes during the "sliding" procedure, display fields showing the
©KM
current set values appear.
With a 24″ Multitouch, the Multitouch characteristic allows you to zoom the view
of profile screens with gesture control (see fig. 6.4, page 6-230).

6.3.4.3 Block changes for the barrel and mold temperatures

In screens for the barrel and mold temperatures, pressing the "Editing" button
opens a pop-up window in which changes can be made for several heating zones
at the same time.
1
2
3
4
Fig. 6.15 Block change

1 Zones 3 PID mode
2 +/- Offset 4 Set value
1) Press the "Editing" button.

The "Block change" window opens.
2) Enter the first and last heating zone (1, fig. 6.15) to be included in the block.
3) Enter "+/- Offset" and then press the (2) button to alter the set value by the
offset.
4) Select "PID mode" and then press the (3) button to change the control mode.
5) Enter "set value" and then press the (4) button to redefine the set value.
6) Check the changed settings in the screens for barrel and mold temperatures.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.5 Operation of functions
6.3.5.1 Alarm functions
Alarm hardkey
The alarm hard key is visible in each navigation selection via the main key
(1, fig. 6.8) as well as in each screen mode type (see section 6.3.6, page 6-255).
Depending on the appearance of the hardkey, the following situations are
signalled:
• Hard key is always blue. There are no alarm messages.
• Hard key flashes red-blue. There are new alarm messages which are
displayed on the "Alarm overview" screen page (see section 8.17.1,
page 8-672).
• Hard key flashes red-yellow. There are new alarm messages. The screen
page for displaying the current alarms is called up.
• Hard key is always yellow. There are no alarm messages. The hard key was
pressed only to call up the "Alarms/events" screen pages.
If an alarm occurs, it is displayed with the corresponding alarm number and the
number of the alarm messages currently in the information field
Acknowledging alarms
Pressing the "Acknowledge" button on the "Alarm overview" screen page
(see section 8.17.1, page 8-672) acknowledges the current alarm.
Alarm bypass
The alarm bypass can be switched on or off (see section 8.4.1, page 8-381).
6.3.5.2 Switch functions

Pressing the I/O button opens a pop-up window in which switching functions can
be defined (see section 8.4.1, page 8-381) for appropriate machine equipment.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.5.3 Activation/Acknowledgement of core-pulling setting

To make changes in the core-pulling setting or the programming of core-pullings,
this has to be activated or the completed entry/programming has to be
acknowledged.
In the default screens of the core-pulling, which can be called up by the hard keys
and soft keys (see section 8.8.1 to 8.8.6), the "Activation/Acknowledgement of
core-pulling setting" button is for being able to make changes in the core-pulling.
Using the process designer, the "Editing mode" and "Open detail view" buttons
defined there activate/acknowledge the core-pulling programming
Default screens Process designer

("Activation/Acknowledgement of core- ("Editing mode", "Open detail view")
pulling setting")
Activation
Acknowledgement
I
Note
If the core-pulling input is not acknowledged via the activated button, the "Core
program setting not confirmed" message is displayed in the information field
step P00005.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.6 Screen mode types
6.3.6.1 Keylock
By activating the keylock, all buttons for operating machine movements (machine
operating buttons, function buttons for additional components) are hidden and
thereby blocked.
1
MX_MC6_V1.9_07.09.15_ENG
4
©KM
Fig. 6.16 Keylock mode

1 Parameter display 3 Keylock active
2 Operating mode buttons 4 Machine function module

The area covered with blue by the keylock provides a parameter display as an
overview (1, fig. 6.16).
In addition, on the left beside the parameter display live images from a video
camera at the injection molding machine from the screen page "Display image of
camera" (see section 8.15.6, page 8-651) are shown.
The keylock button (3) and machine function module (4) move to the lower area.
The mode buttons (2) continue to be displayed.
• Keylock inactive:
All buttons for machine movements on the operating/display panel are
enabled (see fig. 6.2, page 6-227).
Pressing the keylock button activates the keylock.
• Keylock active:
The buttons for machine movements are hidden and blocked (see fig. 6.16,
page 6-255).
Pressing the active keylock button deactivates the keylock.
MX_MC6_V1.9_07.09.15_ENG
©KM

Parameter display selection

In the display, up to two parameters can be defined and shown in a large size.
1) To select the parameter, press the respective field in the display (1, fig. 6.16).
The pop-up window for parameter selection opens.
2) Select the desired parameter.

MX_MC6_V1.9_07.09.15_ENG
3) To apply the selected parameter, press "OK".

©KM

6.3.6.2 Split-screen
By activating the split-screen, all buttons for operating machine movements
(machine operating buttons, function buttons for additional components) are
hidden and thereby blocked. Instead, the acquired area is used to expand the
area of the screen.
5
MX_MC6_V1.9_07.09.15_ENG
4
©KM
Fig. 6.18 Split-screen mode

1 Upper additional screen 4 Split-screen button active
2 Movable area 5 Machine function module
3 Operating mode buttons 6 Divider bar

In split-screen mode, the main screen—including main navigation and information

field—becomes a movable area (2, fig. 6.18). The SplitScreen button (4) and
machine function module (5) also move downwards accordingly. The mode
buttons (3) continue to be displayed.
Pressing the split-screen button arranges the area of the screen in such a way
that an additional screen division (1) is displayed above the movable area (2).
There is a divider bar (6) between the two screen segments. This can be moved
by pressing and dragging to adjust the height of the two screen pages.
I
Note
For reasons of space, no more than one of the two screens can be completely
displayed. Depending on where the divider bar is set, both screens are
provided with a scrollbar at the right edge if necessary (see section 6.3.2.4,
page 6-241).
I
Note
• The lower area of the screen can continue to be toggled via the main
navigation (see section 6.3.6.1, page 6-255).
• For the upper additional area displayed in split-screen mode, only screen
pages created with the buttons of the favourites column can be called up
In activated split-screen mode, the button is displayed as yellow. Pressing the

button deactivates the split-screen mode again.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.3.7 Configuration of screen (24" Multitouch)

The large surface of the 24″ Multitouch provides an additional display area for two
screen pages respectively, which can be configured individually by the operator.
5 2
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 6.19 Configuration of screen (1/4)

1 Start point for touch gesture "Slide" 4 Main navigation
2 Coloured highlighting in the main area 5 Screen main area
3 Additional display area - screen pages

Procedure
1) Select the desired screen page via the main navigation (4, fig. 6.19).
2) Touch the screen at top right below the header bar (1, fig. 6.19) with one
finger and slide in direction of the lower screen area (see section "Touch
functions", page 6-230).
3) During the sliding procedure, a light-red transparent border appears on the
screen page (2, fig. 6.19).
4) Guide the border over the screen to the desired position in the additional
display area (3, fig. 6.19).

1 Coloured highlighting with additional screens
5) When a valid target position in the additional display area is reached, the
colour (1, fig. 6.20) of the border changes to light-green transparent.
6) Release the screen. The screen page is positioned.
MX_MC6_V1.9_07.09.15_ENG
©KM

I
Note
If a screen page cannot be positioned in the additional display area (e.g. screen
pages of the process designer), a red prohibitory sign (see fig. 6.21,
page 6-261) appears if a touch movement is made.
If there is already a screen page at the desired position, it will be overwritten with
the newly positioned page.
Screen pages can be arranged in an individual order in the additional screen area
(3, fig. 6.19). By means of "Slide" or "Swipe" touch movements (see Section,
"Touch functions", page 6-230) in horizontal direction, you can toggle between the
individual screen pages. Two screen pages can always be displayed at the same
time.
Double-tap on a screen page (see section "Touch functions", page 6-230) in the
additional display area (3, fig. 6.19) to open this page in the main area of the
screen (5).
1 1

1 Additional designation of screen pages (additional display area)
Above all of the screen pages in the additional display area in the upper bar, a
Designation is provided in the form of a symbol (1, fig. 6.22). Users thus receive
MX_MC6_V1.9_07.09.15_ENG
an instrument for improved orientation with regard to the arrangement of the

©KM
screen pages.
Configuration of the actual-value column (see section 6.3.1.2, page 6-234) and
favourites column (see section 6.3.1.3, page 6-235)

6.3.8 Process designer
2
MX_MC6_V1.9_07.09.15_ENG
Fig. 6.23 Main navigation for process designer (in keylock mode)
©KM
1 Process designer screen 2 Main navigation for process designer (main key)
The whole machine cycle is displayed in the process designer selected via the
main navigation (2, fig. 6.23). This can be edited and programmed via the
included editing tools. To configure parameters, fast access to the corresponding
screens is possible without first having to select the hard keys and soft keys.
Description of process designer (see section 8.6, page 8-402).

6.3.9 Robot operating screens
4
MX_MC6_V1.9_07.09.15_ENG
Fig. 6.24 Main navigation for robot

©KM
1 Robot screen 4 Robot operating buttons

2 Hard keys and soft keys for robot screens 5 Main navigation for robot (main key)
3 Multi-select selection robot operating buttons
I
Note
Operation: See external technical documentation for robot.

6.3.10 Colour scheme of display fields and buttons
6.3.10.1 LEDs
The screens can show LEDs in the following colours to display input and output
signals:
Colour Signal
LED on LED off
Yellow High signal digital output Low signal digital output
Pink High signal digital (optionally configurable Low signal digital (optionally configurable
as input or output) as input or output)
Blue Not defined (on) Not defined (off)
Green High signal digital input Low signal digital input
Red Power supply error or error at input/output No error at power supply or input/output
- No assignment Configured, but no cable connected
6.3.10.2 Cycle steps/nodes in the process designer

The following options for colour combinations appear for the individual cycle steps
and nodes in the process designer (see section 8.6, page 8-402):
Border colour Surface colour

Blue Orange Green Red
None Simple - Process start - Process end
step/node OR
Step/node - Function
cannot be interrupted by a
selected selected core
step
Orange Core Selected - -
interruption step/node
active (flashing
MX_MC6_V1.9_07.09.15_ENG
border)
©KM
Green Currently Currently - -

running running
process step process step for
(flashing selected node
border)

6.3.10.3 Machine function buttons and mode buttons

The following options for colour combinations appear for machine function
buttons (see section 6.4, page 6-268) as well as for mode buttons
(see section 6.5, page 6-270):

Blue Green Red
Blue Activatable function - -
button
Yellow Function button was Activatable function Stop button was pressed
pressed button was pressed
Orange Function button has to be - -
activated to be able to
start fully automatic
mode
Green Function button Activated function button -
activated, process still
not completed;
Exception: green
flashing border for
setting mode
Red Function button is Function button Activatable stop function
activated, process still activated, fault at
not completed component
Function buttons, e.g. for additional components (see section 6.9, page 6-292),
can be made circular. The colour combinations for the functions also correspond
to those in the table.
Status displays
In the status display of the machine function module (see section 6.4,
page 6-268), the following functions can be displayed in colour:
Colour Status of the machine function

Blue Free status field
MX_MC6_V1.9_07.09.15_ENG
Grey Function deactivated

©KM
Yellow Function activated, start-up phase (e.g. barrel/mold heating)
Green Function activated, all settings in the tolerance range
Red Function activated, error/tolerance has been exceeded

6.3.10.4 Machine operating buttons

Machine operating buttons (see section 6.6, page 6-273) can have a semi-
circular or circular design. The following options for colour combinations appear
for both variants:

Blue Yellow Green
Blue Pressable machine - -
operating button,
standard
Yellow Machine control button Machine control button Machine control button
pressed, standard pressed during contact pressed and engaged
period
Green - - Pressable machine
operating button, can be
engaged
MX_MC6_V1.9_07.09.15_ENG
©KM

6.4 Machine function module

The status displays on the right next to the keylock button are configured as a
closed pop-up button.
Pressing the pop-up button opens the machine function module, which shows the
buttons for activating or deactivating machine functions.
Fig. 6.25 Machine function module
The following functions can be switched on or off by pressing the respective

button within the open pop-up window:
• Pump motor/drives
• Injector barrel heating
• Mold heating
• Mold heat balancing
• Oil preheating
• etc.
Colour schemes of machine function buttons and status displays

W
Important
• The buttons have an actuation delay feature. To actuate, press and hold
the button for 1 second.
• When red alarm messages are present, the drives are deactivated. In
manual, semi-automatic and fully automatic mode, the drives cannot be
• Only in the setting mode can the pump motor be switched on for 5 min after
MX_MC6_V1.9_07.09.15_ENG
alarm bypass (see section 8.4.1, page 8-381) when an alarm message on
a red background is displayed in order to move the machine via the
©KM
operating buttons.
I
Note
If more than twelve functions have to be displayed in the status display or in the
pop-up window of the machine function module, there is an animated line
change with an interval of 3-4 s.

The 7-day timer (see section 8.14.5, page 8-639) can be used to automatically
start the individual functions.
Automatic oil preheating

The oil preheating function is only effective in manual, semi-automatic and fully
automatic modes.
When the pump motor is switched on and the oil temperature is below 32 °C, the
oil preheating function is started until the set value is reached once.
Another oil preheating cycle is only started when the oil temperature drops
below 32 °C.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.5 Operating mode buttons
6.5.1 Mode buttons for the injection molding machine
1 2 3 4 5
Fig. 6.26 Mode buttons for injection molding machine

1 Setting mode 4 Fully automatic mode (FA mode)
2 Manual mode (M mode) 5 Stop button (zero operating mode)
3 Semi-automatic mode (SA mode)
If manual, semi-automatic or fully automatic mode is activated, the pressed button

is illuminated in green. In setting mode (1, fig. 6.26), its activity is indicated by a
flashing green border. The stop button (5) is illuminated in red when pressed.
Colour scheme of mode buttons (see section 6.3.10.3, page 6-266).
6.5.1.1 Setting mode

Any machine movement in this mode of operation remains active only as long as
a machine operating button is actuated.
The mold, injection unit, screw and ejector movements can be limited in setting
mode.
W
Important
• The "setting mode" button must only be operated by authorized personnel.
• Selection programs can only be switched off or on in the setting mode.
• If an alarm is displayed, the drives can be switched on for 5 min after alarm
bypass (see section 8.4.1, page 8-381) in order to move the machine via
the machine operating buttons. Machine functions can then be executed
without setting zero points.
MX_MC6_V1.9_07.09.15_ENG
• In setting mode, the fault signal lamp is deactivated.

©KM
I
Note
When changing from setting mode into another mode of operation, the stop
button (5, fig. 6.26) may have to be pressed first. The default setting for this
function is configured on the "Cycle settings" screen (see section 8.13.4,
page 8-618).

6.5.1.2 Manual mode

In this mode of operation, machine movements end when they are switched off
by a position transducer or a pressure transducer signal.
The following functions can be started by pressing the machine operating buttons
in this mode of operation:
• Mold closing / opening
• Injection unit forward/back
• Plasticizing
• Ejector forward/back
Injection/holding pressure function also runs in this mode of operation as in the
setting mode for safety reasons.
6.5.1.3 Semi-automatic mode

In this mode of operation, a single complete operating cycle is started when the
"Start machine cycle" button (see section 6.6.13.1, page 6-286) is pressed when
the safety gates are closed.
Each additional operating cycle must be started by again pressing the "Start
machine cycle" button.
6.5.1.4 Fully automatic mode

In this mode of operation, fully automatic mode is started by pressing the "Start
machine cycle" button (see section 6.6.13.1, page 6-286) when the safety gates
are closed.
All work cycles are started when the "fully automatic" pause time is over or by an
enabling signal from the robot.
6.5.1.5 Stop button (zero operating mode)

Machine movements cannot be started in this mode of operation.
In general you can change between the modes of operation as desired. When
changing from setting mode into another mode of operation, the stop button may
have to be pressed first. The default setting for this function is configured on the
"Cycle settings" screen (see section 8.13.4, page 8-618).
MX_MC6_V1.9_07.09.15_ENG
©KM

6.5.2 Mode buttons for robot
I
Note
The mode buttons for the robot are displayed only if a robot is installed on the
machine.
Robot operation is described in the external technical documentation for the
robot.
1 2 3
Fig. 6.27 Mode buttons for robot

1 Robot fully automatic mode 1) 3 Robot movement fast/slow
2 Setting mode, robot
1) With robot fully automatic mode activated, additional function buttons are displayed (see section 6.8, page 6-291).
If a mode of operation is activated, the pressed button lights up green. If an active

button is pressed again, the robot mode is deactivated.
Colour scheme of mode buttons (see section 6.3.10.3, page 6-266).
MX_MC6_V1.9_07.09.15_ENG
©KM

6.6 Machine operating buttons

The machine operating buttons (9, fig. 6.2) are divided into three areas:
• Injection molding machine mold (left)
• Injector(s) of the injection molding machine (right); for more than one injector,
with additional multi-select selection field (8)
• Variable area with multi-select feature (8) (centred), which can include various
machine operating buttons for additional features (e.g. core-pulling, mold
change/clamping device, robot)
I
Note
The functions of the individual machine operating buttons depend on the
selected operating mode. The buttons are only displayed on the
operating/display panel if a function can be executed.
Colour scheme of machine operating buttons (see section 6.3.10.4, page 6-267)
MX_MC6_V1.9_07.09.15_ENG
©KM

6.6.1 Open/close safety gate (ZE)
6.6.1.1 Open safety gate
W
Important
During the "Open safety gate" function, the fixed limit switch "Move in locking
bolt" is operated, which activates the "Move in locking bolt" function. This
prevents the safety gate from being closed unintentionally.
Setting mode / manual mode

The "Open safety gate" button must be held down until the safety gate is open all
the way. The fixed limit switch initiates the slow opening process up until the
"Safety gate open" limit switch is reached.
Semi-automatic/fully automatic mode

"Open safety gate" is started when mold open is reached or, depending on the
program selected, also in parallel to the mold opening process. The speeds of the
movement of the safety gate are factory-set.
6.6.1.2 Close safety gate
W
Important
Prior to closing the safety gate, the "Locking bolt" button (see section 6.6.10,
page 6-285) must be actuated. Now press the "Close safety gate" button within
3 seconds.
In all operating modes, the safety gate is closed using the "Close safety gate"
button. The button must be held down until the safety gate is fully closed.
The safety gate closes rapidly up to the permanently set limit switch. When the
limit switch has been reached, the safety gate closes slowly.
If one of the safety strips is actuated during the "Close safety gate" procedure, the
closing operation stops and the locking bolt moves in. The function then has to be
activated again using the "Locking bolt" and "Close safety gate" buttons.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.6.2 Ejector back/forward
I
Note
The "Ejector" function must be activated in the corresponding screen
(see section 8.7.3, page 8-435) and be processed in accordance with the
machine equipment.
Setting mode
The "Ejector back movement" button or "Ejector forward movement" button
enables ejector movement only as long as the appropriate button is pressed. The
movement ends when the limit position is reached.
Manual mode
The "Ejector back movement" button is not displayed.
Pressing the "Ejector forward movement" button initiates a complete ejector
movement (forward and back).

The "Ejector back movement" and "Ejector forward movement" button are not
displayed.
If the "Ejector back movement" button is actuated in the current cycle, before the
ejector starts up the cycle will be stopped at "Mold open" and the ejector will not
be moved forward. Step P00338 "Cycle ended without ejection" is shown.
The ejector movement only takes place if, with the safety gate closed (not with
keyswitch -S016), the "Move ejector forward" button is actuated.
After the ejector movement, the "Start machine cycle" button
(see section 6.6.13.1, page 6-286) must be actuated to initiate the cycle start.
In robot operation, the following signals are ignored for this function in the current
cycle:
• Ignored robot signals:
– Ejector forward movement
– Ejector return
– Enabling mold closing
• Ignored signals to the robot:
MX_MC6_V1.9_07.09.15_ENG
– Part injected
– Start robot
©KM
This ensures that the robot does not detect this cycle. The robot continues as
usual with the next cycle.

6.6.3 Mold opening/closing
6.6.3.1 Mold opening
Setting mode
By pressing the "Moving pressure piston back" button the clamping force is
released, the pressure cushions are positioned and locking plates are moved out.
"Locking plate is out" is displayed as last step. The mold still remains closed.
By pressing the "Mold opening" button, the mold is opened at the set speed
(see section 8.7.3, page 8-435) to the corresponding position "Mold open". In
setting mode, both buttons must be pressed one after the other.
W
Important
• The ejector is not started.
• If a core-pulling program is active, it is also executed in setting mode with
the defined values.
Manual mode
I
Note
Prerequisites
• Pump motor switched on
• Mold is not open
Once the "Mold opening" button has been pressed, the mold begins to open. The
mold opens at the entered speeds in the opening profile and switches over at the
profile stages to the following speed as a function of the stroke. Towards the end
of the opening stroke, the speed is reduced automatically so that the mold stops
in a reproducible manner and without significant overrun at the opening stroke.
The beginning of the braking procedure is calculated automatically and is
dependent on the speed and stroke settings.

MX_MC6_V1.9_07.09.15_ENG
The "Mold closing" button is not displayed. Instead, the "Mold opening" or "Stop
©KM
machine cycle" buttons are displayed (see section 6.6.13.2, page 6-287).
By pressing the "Mold opening" button, the current cycle is run to the end. Upon
expiration of the cooling time (holding pressure), the clamping force is released
and the mold opens with the values entered on the "Mold opening" screen
When the "Stop machine cycle" button is actuated, "Mold opening" is triggered by
the machine cycle. The current cycle is run to the end. After the cooling time has
elapsed and the clamping force is released, the mold is opened.

6.6.3.2 Mold closing
I
Note
Prerequisites
• Safety gate closed
• Ejector in rear limit position
• Auxiliary devices:
– Core-pullers moved out
– Robot in safety position
– Quick mounting system OK
Setting mode
Pressing the "Mold closing" button will close the mold at the set speed and setting
drive force (see section 8.7.1.6, page 8-425).
Mold closing in setting mode takes place over the entire closing stroke with
"Setting movement force for mold closing" and "Setting speed for mold closing"
from the "Mold set-up / calibration" screen (see fig. 8.44, page 8-425). There is no
mold safety so that the "Setting movement force for mold closing" has to be set
correspondingly low. If the mold is closed, the pressure cushions are positioned
if necessary and the locking bars are moved in. The last step "Locking plates in
clamping position" is displayed.
The "Pressure piston forward" button is actuated, the clamping force set in the
"Mold closing" screen is built up. The speed for the clamping force build-up is the
same in all operating modes and cannot be adjusted. The clamping force is
measured and switched off by a pressure sensor until the specified setpoint is
reached.
W
Important
If a core-pulling program is active, this will also be executed in setting mode as
programmed.
Manual mode
After pushing the "Mold closing" button, the mold closes at the programmed
MX_MC6_V1.9_07.09.15_ENG
speeds and movement forces of the closing profile on the "Mold closing" screen
(see fig. 8.38, page 8-413). If the set movement force in the profile stage is
©KM
reached, a monitoring time is started. If the movement force is still limited, the
closing movement is stopped with the "Mold safety" alarm (see section 8.7.1.2,
page 8-416) after the time "Maximum duration of movement force limitation" has
elapsed.
If the clamping unit reaches a new profile stage before the "Maximum duration of
movement force limitation", the monitoring time starts from the beginning again if
the movement force of the current stage is reached. Mold safety can thus be
adjusted in every closing profile stage.

When the mold is closed, the locking plates are moved into clamping position and
the set clamping force is built up.
The machine cycle is completed with step P00020 "Clamping force reached".
W
Important
The core-pulling sequences are executed under program control if the
selection program "Core-pulling program ON" has been activated.

The "Mold closing" button is not displayed. Instead, the "Start machine cycle"
button is displayed (see section 6.6.13.1, page 6-286).
6.6.4 Moving pressure pistons back/forward, releasing/building up clamping

pressure
6.6.4.1 Moving back pressure pistons, releasing clamping pressure
Setting mode
When the "Move back pressure pistons" button is operated, the clamping
pressure is reduced and the pressure pistons move back as far as the "released"
position.
When the pressure has dropped to 20 bar at the pressure sensor, the locking
elements are moved out. When the limit position of the locking elements is
reached, the function is switched off.
Manual / semi-automatic / fully automatic mode

The "Moving pressure piston back" button is not displayed.
Reducing clamping pressure and moving back pressure pistons are performed
automatically with the "Mold opening" button in manual mode, or after the end of
the cooling time, in semi-automatic and fully-automatic mode.
When the pressure has dropped to 20 bar, the locking elements are moved out.
When the locking elements are moved out, the mold opens at the defined speeds.
After the mold has been closed again, the pressure pistons are repositioned
depending on the position of the locking elements so that the locking procedure
can be carried out.
MX_MC6_V1.9_07.09.15_ENG
6.6.4.2 Move pressure pistons forward, build up clamping pressure

©KM
Setting mode
I
Note
Prerequisites
• Mold closed
• Locking elements moved in

By pressing the "Move pressure pistons forward" button, the pressure pistons are
moved with moved-in locking elements against the tooth profiles of the column
until the set clamping force is reached.
The "Move pressure pistons forward" button must be pressed and held until a
signal from the pressure sensor switches off the clamping force build-up.
Manual / semi-automatic / fully automatic mode

The "Moving pressure piston forward" button is not displayed.
The pressure piston moves forward and clamping pressure builds up
automatically after the mold is closed and the locking elements are moved in. The
clamping force build-up is switched off by a signal from the pressure sensor when
the clamping pressure is reached.
W
Important
If the "Move in locking bolt" limit switch is no longer operated, the safety gate
must be fully opened first of all before the closing operation can be restarted.
6.6.5 Moving locking elements out/in
6.6.5.1 Moving out locking elements
Setting mode
When the "Move out locking elements" button is pressed, the locking elements
can be moved out manually as soon as clamping pressure has fallen below
20 bar.
6.6.5.2 Move in locking elements
Setting mode
The locking elements can be moved in manually with the "Move in locking
elements" button as soon as the limit switches are reached.
W
Important
The button is required only for service operations (e.g. setting limit switches).
MX_MC6_V1.9_07.09.15_ENG
©KM

6.6.6 Injection unit forward/back
6.6.6.1 Injection unit forward
Setting mode
I
Note
Prerequisites
• Nozzle safety gate is closed
• Safety gates closed
Press the "Injection unit forward" button to move the injection unit forward at the
"Set-up speed" entered (see section 8.9.3.3, page 8-507) until the nozzle contact
and nozzle contact pressure at the mold have been reached.
Manual mode
I
Note
Prerequisites
• Mold is closed (note comment line)
Once the "Injection unit forward" button has been pressed, the injection unit is
moved towards the mold with the defined speed set values.
When the corresponding position is reached, the movement switches from the
fast to the slower speed.
When the nozzle contacts the mold, the nozzle contact pressure is built up. The
"Injection unit forward" valve remains activated so that the contact pressure is
maintained for manual injection.
W
Important
MX_MC6_V1.9_07.09.15_ENG
"Injection unit forward" can only be carried out once in the manual mode. If the
function is interrupted or the mode of operation is changed, the mold must be
©KM
opened and closed before the injection unit can be moved forward the next
time.

6.6.6.2 Injection unit back
Setting mode
I
Note
Prerequisites
• Injection unit is not in rear limit position
Press the "injection unit back" button to move the injection unit back at the "setting
speed" entered (see section 8.9.3.3, page 8-507).
The injection unit can be moved close to the rear mechanical stop via the
"injection unit back" button (electrical limit position). The defined "Injection unit
stroke" is not effective in setting mode.
Manual mode
I
Note
Prerequisites
• Injection unit is not in "injection unit stroke" position
The return movement of the injection unit begins when the button is pressed. The
movement is executed with the defined "Speed 1" speed and, starting at the
corresponding position, with the "Speed 2" speed up to the programmed "injection
unit stroke".
Pressing and holding the button again moves the injection unit to the limit position
with the setting values (as in setting mode).

The "injection unit back" function is triggered by the machine cycle. The sequence
is set with the selection programs.
If the "Injection unit back" button is pressed before the start of "Injection unit back"
independent of the selection programs, the injection unit will move back to the
rear limit position during this machine cycle.
MX_MC6_V1.9_07.09.15_ENG
W
©KM
Important
The functions described above can be used to return the injection unit during
the cycle in order to clean the nozzle area.
The next cycle time will be extended due to the increased distance of the
injection unit movement.

6.6.7 Injection
Setting mode
I
Note
Prerequisites
• Barrel temperature above "-" tolerance
Press the "Injection" button to purge the screw barrel. The forward screw
movement is performed with the values entered for "Set-up speed, injection" and
"Setting pressure, injection" (see section 8.9.1.4, page 8-494). Holding pressure
is not performed.
W
Important
The injection process in the setting mode is only performed with the constant
values for injection pressure and injection speed even if a profile for the
injection speed and/or injection pressure has been selected for the cycle.
Manual mode
I
Note
Prerequisites
• Mold is closed, clamping force reached
• Injection unit at front, nozzle contact pressure built up.
Press the "Injection" button to initiate the injection process with the values defined
for injection pressure and injection speed (constant speed) (as in setting mode).
The injection is only carried out while the "Injection" button is pressed.
MX_MC6_V1.9_07.09.15_ENG
Another injection process can only be initiated when the mold is opened and
©KM
closed again and the nozzle contact pressure on the injection unit has again been
built up.
Independently of the programmed holding pressure change-over options (melt
pressure or mold cavity pressure), changing over to holding pressure is
performed via the holding pressure change-over stroke. The set holding pressure
(also profiles) is performed for as long as the button is pressed.

W
Important
The injection process in the manual mode is only carried out with the constant
values for injection pressure and injection speed even if a profile for the
injection speed and/or injection pressure has been selected for the cycle.

The "Injection" button is not displayed.
The injection/holding pressure phase is triggered by the cycle sequence and
executed with the parameters (also profiles) configured on the "Holding
pressure/injection" screen (see section 8.9.1, page 8-481).
6.6.8 Screw decompression
I
Note
Prerequisites
Setting mode
Press the "Screw decompression" button to retract the screw (without rotary
motion) to the mechanical limit position. There is no electrical switch-off.
The speed can be adjusted (see section 8.9.2.1, page 8-495).
MX_MC6_V1.9_07.09.15_ENG
©KM

6.6.9 Plasticizing
I
Note
Prerequisites
• Plasticizing stroke not made
Plasticizing is performed in all operating modes at the programmed speed. The

plasticizing process can be executed with the reduced back-pressure defined
Setting mode / manual mode

Press the "Plasticizing" button to execute plasticizing in setting and manual mode.

The "Plasticizing" button is not displayed.
Plasticizing takes place after the holding pressure time or delay time depending
on the activated selection programs.
If the delay time is set to "0" (see section 8.13.1.1, page 8-600), plasticizing takes
place immediately after the holding pressure time has elapsed.
W
Important
• The hydr. motor pressure can be read on the pressure indicator in position
"2" of the selector switch.
Pressure indicator with selector switch (see fig. 7.17, page 7-322).
• Reduced material consumption with production stop:
If the "Plasticizing" button is pressed in semi-automatic or fully automatic
mode before expiration of the holding pressure time, the machine ends the
cycle without plasticizing and stops production.
If the "Plasticizing" button is pressed in semi-automatic or fully automatic
mode during or after plasticizing, the machine only stops during the next
cycle without plasticizing.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.6.10 Locking bolt
W
Important
For safety reasons, a locking bolt is installed on the mold area safety gate,
operator side. This prevents the safety gate from being closed unintentionally.
The locking bolt must first of all be moved out in order to be able to close the
safety gate. The locking bolt is operated electrically using the "Locking bolt"
button.
When the "Locking bolt" button is pressed, the locking bolt moves out. The "Close
safety gate" button (see section 6.6.1.2, page 6-274) must be actuated with 3 s.
The locking bolt moves in automatically provided one of the following conditions
is met:
• "Close safety gate" function not activated within 3 s after pushing the "Locking
bolt" button.
• Power supply interrupted.
• "Close safety gate" function interrupted.
• The fixed limit switch "Move in locking bolt" is activated during the "Open
safety gate" function.
6.6.11 Pneumatic valves

The pneumatic valves can be operated independently of the mode of operation
with the "Pneumatic valves" button.
I
Note
The pneumatic valves function must be activated in the corresponding screen
(see section 8.7.4, page 8-446) and be processed in accordance with the
machine equipment.
6.6.12 Mold nozzles

Setting mode
MX_MC6_V1.9_07.09.15_ENG
When pressing the "Open mold nozzle in setting mode" button, all cascade
©KM
nozzles activated in the "Cascade control" screens (see section 8.9.5,

page 8-514) are activated.

6.6.13 Starting/stopping machine cycle
I
Note
The operating buttons for starting and stopping the machine cycle are only
displayed in semi-automatic and fully automatic mode.
6.6.13.1 Starting machine cycle

Press the "Starting machine cycle" button in semi-automatic or fully automatic
mode to start the cycle. The machine then runs in production mode.
The mold closes at the programmed speeds and driving forces of the closing
profile on the "Mold closing" page (see fig. 8.38, page 8-413). If the set movement
force in the profile stage is reached, a monitoring time is started. If the movement
force is still limited, the closing movement is stopped with the "Mold safety" alarm
is stopped after the time "Maximum duration of movement force limitation" has
elapsed.
If the clamping unit reaches a new profile stage before the "Maximum duration of
movement force limitation", the monitoring time starts from the beginning again if
the movement force of the current stage is reached. Mold safety can thus be
adjusted in every closing profile stage.
When the mold is closed, the locking plates are moved into clamping position and
the set clamping force is built up.
The machine cycle is completed with step P00020 "Clamping force reached".
Press the button to execute the following functions:
• Semi-automatic mode: After cycle start, a complete machine cycle is run.
• Fully automatic mode: After cycle start, the cycles run fully automatically.
W
Important
• Each additional cycle in semi-automatic mode can be initiated without
pressing the "Start machine cycle" button by opening and closing the safety
gate.
• If the safety gate is opened in fully automatic mode, the next cycle must
again be initiated by pressing the "Start machine cycle" button.
MX_MC6_V1.9_07.09.15_ENG
• The core-pulling sequences are executed under program control if the

selection program "Core-pulling program ON" has been activated.
©KM

6.6.13.2 Stopping machine cycle

If the machine is running in production mode, the "Stop machine cycle" button is
displayed.
"Mold opening" is triggered by the machine cycle. Upon expiration of the cooling
time (holding pressure), the clamping force is released and the mold opens with
the values entered on the "Mold opening" screen (see section 8.7.2.1,
page 8-426).
Press this button to run the current cycle to the end and demold the part.
Production can be continued by pressing the "Start machine cycle" button.
6.6.14 Special functions
6.6.14.1 Skinform
On machines with the Skinform application, an injection molded part in the
machine is coated with a foaming material to obtain a soft surface.
When the button is pressed, a release agent is sprayed manually onto the mold
so that the part is easily removed from the mold. The release agent can also be
applied automatically in the cycle.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.7 Slider control "SlideX" (24″ Multitouch)
3
MX_MC6_V1.9_07.09.15_ENG
5 4
©KM
Fig. 6.28 Guiding line with slider control SlideX

1 Current mold positions 4 SlideX selection buttons
2 Machine operating buttons 5 Guiding line with slider control SlideX (active)
3 "Operating mode" buttons
The slider control SlideX guiding line engraved in the glass is a new development
of the 24" Multitouch that gives the operator haptic control over machine

components on all moving axes without looking at the control panel. The user
feels axis speeds on the axes and can configure them intuitively.
The slider control SlideX (5, fig. 6.28) with the associated selection buttons (4) is
at the bottom edge of the screen. All machine component movements, including
robot movements in its three axes, can be executed with the SlideX. The
movement axis and activation of the "SlideX" are selected via the selection button
(4, fig. 6.28) on the right beside the guiding line.
The slider control "SlideX" is operated with the touch gesture "Slide". The
machine movement is tripped by touching and dragging the button to the left or
right. When "sliding" the SlideX button, the colour changes to yellow. The
movement of the selected machine component on the movement axis takes place
in accordance with the direction in which the slider control is moved. The
individual machine components and movement axes with movement directions
are listed in the table Fig. 6.29.
SlideX - selection of movement axes and directions
Selection Machine component/ Direction of movement

button movement axis
Mold • SlideX to the left: Mold opening

• SlideX to the right: Mold closing
Ejector • SlideX to the left: Ejector back

• SlideX to the right: Ejector forward
Screw barrel • SlideX to the left: Injection

• SlideX to the right: Screw
decompression
Injection unit • SlideX to the left: Injection unit forward

• SlideX to the right: Injection unit back
Robot X-axis • SlideX to the left: Back

• SlideX to the right: Forward
MX_MC6_V1.9_07.09.15_ENG
©KM
Robot Y-axis • SlideX to the left: Up

• SlideX to the right: Down
Robot Z-axis • SlideX to the left: Left

• SlideX to the right: Right
Fig. 6.29 SlideX - movement axes and directions

The further the button of the slider control SlideX is shifted from its start position,
the higher the speed at which the machine component driving movement is
executed. This operation can be compared with actuation of a car accelerator
pedal. The more the pedal is pushed in, the higher the driving speed of the
vehicle. If the pedal travel is shorter, the driving speed is reduced. However, the
direction of movement remains the same. When the SlideX is released, the
driving movement stops immediately.
The SlideX is only operated in setting mode. The maximum speed at which a
movement can be executed with the SlideX corresponds to the maximum setting
speed from the screen page "Mold set-up/calibration" (see fig. 8.44, page 8-425).
Procedure with example "Mold closing"

1) Select Setting mode (3, fig. 6.28)
2) Actuate selection button "Mold" (4).

The selection button is highlighted yellow.
The slider control SlideX (5) appears in blue.
3) Press the button of the slider control SlideX (5) and hold it in.
The colour of button changes to yellow.
4) Carefully drag the button to the right and hold it in.
Observe the driving movement of the mold at the machine or on the
corresponding screen page (1). If necessary, adapt the driving speed by
sliding the button.
5) When the desired mold position has been reached, release the slider control.
The SlideX button jumps back to the start position and switches colour to blue.
The driving movement of the mold is stopped immediately.
I
Note
The Multitouch characteristic of the 24″ Multitouch allows you to actuate the
slider control SlideX and further screen buttons, e.g. the main navigation, at the
same time. MX_MC6_V1.9_07.09.15_ENG
©KM

6.8 Function buttons for additional components

Depending on expansion status and condition of the machine, function buttons
(12, fig. 6.2) for any additional components that may be present are shown on the
left beside the operating mode. They are not positioned until after machine start.
I
Note
Robot operation is described in the external technical documentation for the
robot.
MX_MC6_V1.9_07.09.15_ENG
©KM

6.9 Additional modules
6.9.1 Core-pulling module (ZE)
1 2
7
4
5
6
Fig. 6.30 Core-pulling module

1 Core-pulling module MP (active selection) 5 "Move core IN" button
2 Core-pulling module FP (inactive) 6 "Move core OUT" button
3 Selection of hydraulic core 7 "Core-pulling activation" button
4 Selection of pneumatic core
W
Important
The mold and cores can be damaged when the cores are moving.
I
Note
The buttons for the ejector controlled by the core-pulling program are not
displayed in the core-pulling module. When core-pulling (7, fig. 6.30) is
activated, they are displayed under the machine operating buttons instead of
the "Ejector movement back/forward" (see section 6.6.2, page 6-275) buttons.
MX_MC6_V1.9_07.09.15_ENG
©KM
Colour scheme of buttons (see section 6.3.10, page 6-265)

Symbols for "Move core in/out"
FP
• Hydraulic core FP
• Pneumatic core FP
MP
• MP hydraulic core
• MP pneumatic core
• Ejector controlled by core-pulling program
I
Note
If the ejector is controlled by the core-pulling program, the buttons "Move core
in" and "Move core out" of the ejector are displayed in the machine operating
buttons instead of the buttons "Ejector back movement" and "Ejector forward
movement".
Moving cores in/out

2) Select the core-pulling module via the multi-select feature:
• MP cores (1, fig. 6.30)
• FP cores (2)
3) Press the "Core-pulling activation" button (7).
The "Core-pulling activation" button (7) flashes.
The hydraulic area of the core-pulling is depressurized at the MP/FP.
The buttons for moving the activated cores in and out (5/6) are displayed.
MX_MC6_V1.9_07.09.15_ENG
I
Note
©KM
Only the activated cores can be moved out or in.

Core-pulling activation (see section 8.8.1, page 8-453).
4) Press the desired core in the respective "Core selection" (3/4) field.
The selected core is highlighted in yellow.
5) Move cores in or out by pressing the corresponding buttons (5/6).

6.9.2 Mold change/clamping assembly module

The clamping assembly module can be used to lock or unlock mold/clamping
assemblies.
1
2 3 4 5 6 7
Fig. 6.31 Mold change/clamping assembly module

1 Mold change/clamping assembly module 5 Button "Clamp/magnetize MP"
2 "Activation of mold change/clamping assembly 6 Button "Release/demagnetize FP"
module" button 7 Button "Clamp/magnetize FP"
3 "Pressure release" display 8 Button "Release/move out bar"
4 Button "Release/demagnetize MP" 9 Button "Move bar in/clamp"
W
Important
If the equipment includes a mold clamping assembly, after actuation of the
button "Activation of mold change/clamping assembly module" (2, fig. 6.31) the
clamping assembly can be unlocked via the buttons "Release/demagnetize
MP" (4) and "Release/demagnetize FP" (6).
Ensure that the transport locks are attached to the mold and that the load lifting
tackle is attached.
Mold and injection molding machine may be damaged.
MX_MC6_V1.9_07.09.15_ENG
©KM

Buttons for mold change/clamping assembly module
Clamping assembly, MP
• Clamp/demagnetize MP:
Press the button to clamp the mold half on the MP.
The clamping assembly device on the MP side is clamped / magnetized.
• Release/demagnetize MP:
Press the button to release the mold half on the MP.
The clamping assembly device on the MP side is released / demagnetized.
Clamping assembly, FP
• Clamp/magnetize FP:
Press the button to clamp the mold half on the FP.
The clamping assembly device on the FP side is clamped / magnetized.
• Releasing/demagnetizing FP:
Press the button to release the mold half on the FP.
The clamping assembly device on the FP side is released / demagnetized.
Pressure relief
• With the button "Activation of mold change/clamping assembly module"
activated, the "Pressure release" display is green. Depending on the
machine's equipment, in the mold installation space pressure is released for
the hydraulic area core-pulling at the FP/MP and the cascade control area.
Magnetic clamping system connection

• The button is displayed in the mold change/clamping assembly module if the
magnetic clamping system is not controlled from the machine.
• Press the button to establish the connection to the magnetic clamping system.
Bar-pulling
• Move bar in/clamp:
Press the button to move the bar in.
The bar moves in the direction of MP until the limit position is reached.
The bar clamping elements are clamped.
• Releasing/moving bar out:
Press the button to release the bar clamping elements and the bar is moved
out.
The bar moves in the direction of the FP until the limit position is reached.
MX_MC6_V1.9_07.09.15_ENG
Operation
©KM
• Magnetic clamping systems (see section 12.14, page 12-968)

• Bar-pulling (see section 12.12, page 12-949)

MX_MC6_V1.9_07.09.15_ENG
©KM

7 Commissioning
This chapter contains information about safe commissioning of the machine.
7.1 Safety precautions for commissioning . . . . . . . . . . 298

the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
7.3 Cleaning of machine prior to commissioning . . . . 299
7.4 Electric screw drive, inspecting oil level . . . . . . . . 299
7.5 Inspecting central lubrication system . . . . . . . . . . . 300
7.6 Switching on/off, injection molding machine . . . . . 301
7.7 Grant/revoke input authorization . . . . . . . . . . . . . . . 302
7.8 Switching machine components on/off . . . . . . . . . 303
7.9 Inspecting direction of running of pump motor . . . 304
7.10 Bleeding the hydraulic system . . . . . . . . . . . . . . . . 306
7.11 Inspect pump running . . . . . . . . . . . . . . . . . . . . . . . 321
7.12 Checking the alignment of the machine . . . . . . . . . 323
7.13 Installation of screw barrel . . . . . . . . . . . . . . . . . . . . 324
7.14 Centring nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
7.15 Check the nozzle insertion depth . . . . . . . . . . . . . . 347
7.16 Mold installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
7.17 Zero point calibration . . . . . . . . . . . . . . . . . . . . . . . . 351

MX_MC6_V1.9_07.09.15_ENG
7.18 Starting the machine . . . . . . . . . . . . . . . . . . . . . . . . . 355

©KM
Commissioning 7-297
7.1 Safety precautions for commissioning
e
d
D
Contact with electric cables or components may result in severe harmful
effects, including fatal injury.
Observe the specifications of the relevant energy supply company as well as
any applicable national standards and regulations regarding such a
connection.
Only persons with professional qualifications in the electrical/electronic field
may perform any work on the electrical/electronic components of the machine.
r
d
D
Risk of slipping
medium.
Immediately contain any spilled oil and dispose of it.
f
d
D
Fire hazard
The temperature on the surface of the heating bands of the plasticizing unit is
significantly higher than the displayed actual temperature at the
operating/display panel.
Keep the heater band surfaces free of any objects or dirt (e.g. plastic, cloths,
etc.).
h
d
D
When working on the hydraulic system, note that subsections of the hydraulic
system can still be pressurized when the machine is electrically switched off.
test connections in accordance with the hydraulic diagram.
MX_MC6_V1.9_07.09.15_ENG
©KM
b
B
When carrying out commissioning work, hazardous situations may occur which
can result in injury.
When carrying out such work, always wear protective clothing conforming with
currently valid accident prevention regulations (e.g. safety shoes, protective
gloves, etc.).
7-298 Commissioning
w
D
Caution - adopt the correct procedure
Initial commissioning is carried out by KraussMaffei.
For subsequent commissioning:
• First obtain information from KraussMaffei.
• Observe the applicable safety regulations at the place of work.

7.3 Cleaning of machine prior to commissioning
W
Important
• If corrosion protection agent on moving parts and sliding surfaces is not
completely removed, this will result in the destruction of sealing elements.
• Remove any corrosion protection agent on all movable parts and sliding
surfaces.
• Clean with brushes and cleaning cloths only. Do not use cleaning wool.
• Do not clean with aggressive and paint-stripping cleaning products.
7.4 Electric screw drive, inspecting oil level

Check the oil level at the inspection glass and add oil if necessary
The oil level must reach the middle of the inspection glass when the machine is
warmed up.
MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-299
7.5 Inspecting central lubrication system
W
Important
Inadequate lubrication below the MP results in damage to the sliding bands.
Before commencing any movements of the MP, inspect the central lubrication
system and carry out a lubrication operation.
1) Check the filling level of the storage container.

2) Check that the supply lines are secure.
1
2
Fig. 7.1 Mold opening settings

MX_MC6_V1.9_07.09.15_ENG
1 "Carry out centralized lubrication" pushbutton 2 Actual value "Stroke counter centralized lubrication"
©KM
3) Switch to the "Mold opening settings" screen.

4) Press the "Carry out centralized lubrication" pushbutton (1, fig. 7.1).
The centralized lubrication is tripped and the stroke counter (2) is reset
automatically.
5) Check the lubricating efficiency of the central lubrication system.
7-300 Commissioning
7.6 Switching on/off, injection molding machine
7.6.1 Switching on
W
Important
After the master switch has been connected and switched on and the system
test is completed, the control of the injection molding machine is then switched
on.
It is now possible to make entries provided that "Input authorization" has been
granted (see section 7.7, page 7-302).
Prerequisites
• Master switch connected (see section 5.9, page 5-215)
• The cooling water supply and, if necessary, compressed air supply are
connected and switched on (see section 5.8, page 5-214)
• Hydraulic oil replenished (see section 5.10, page 5-217)
Procedure
1) Switch on the machine at the master switch.
After the system test, the operating system and the program are loaded.
3) Open safety gate on operator side and operate step-on safety grid.
The message box is closed.
Step P00076 "Step-on safety grid actuated switches to step P00000 "Stop".
W
Important
If the operational test is not successfully completed, message box and step
display continue to be shown. In this case, close the message box and switch
to the "Alarm overview" screen in order to display any alarms present and to
carry out fault finding and fault rectification.
7.6.2 Switching off

MX_MC6_V1.9_07.09.15_ENG
1) Switch off any switch functions which are on (see section 7.8, page 7-303).
©KM
2) Switch off master switch and secure.
Commissioning 7-301
7.7 Grant/revoke input authorization
W
Important
Control system data can only be changed with the required input authorization.
The passwords are preset to 0 - 4.
User login (see section 8.3, page 8-360)
7.7.1 Granting input authorization

1) Switch master switch on.
W
Important
If the "Chip card reader" auxiliary device is fitted, the input authorization is
granted or revoked by inserting and removing the chip card. The "User login"
button is not active.
2) Press the "User login" button in the header bar of the operating/display panel.
The keypad "Login: password" appears.
2
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 7.2 Login: Password

1 "x" button (abort) 3 Input field
2 "Enter" button (confirmation)
3) Enter a defined password in the input field (3, fig. 7.2).

4) Press the "Enter" button (2) to confirm.
The key group authorized for the password is displayed on the "User login"
button.
7-302 Commissioning
7.7.2 Revoking input authorization

The keypad "Login: password" appears (see fig. 7.2, page 7-302).
2) Press the "Enter" button to confirm (2, fig. 7.2).
No authorization is shown on the "User login" button.
7.8 Switching machine components on/off

Prerequisites
• Master switch switched on
1 2 3 4
Fig. 7.3 Machine function module

1 Pump motor/drives on/off 3 Mold heating on/off
2 Injector barrel heating on/off 4 Mold temperature control on/off
W
Important
The buttons have an actuation delay feature. To actuate, press and hold the
button for 1 second.
The activated function is indicated by the colour of the respective button.
The functions are switched on or off by pressing the corresponding button.

MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-303
7.9 Inspecting direction of running of pump motor
W
Important
• When commissioning, ensure that the hydraulic oil cooling circuit for the
pump motor is connected and active. Operation without activated cooling
circuit destroys the glide ring seals.
• The operating safety of the machines is dependent on compliance with the
oil service life and the approved oil quantity in relation to the inlet
temperature.
1) Inspect hydraulic oil level and ensure that hydraulic oil is poured in and that
the suction filter is opened (see section 10.9.5, page 10-733).
2) Ensure that the master switch is switched on.
3) Ensure that setting mode is selected.
4) Fit the hose with collecting vessel to the T-piece on the pump motor
(1, fig. 7.4).
1 2
Fig. 7.4 Pump motor

MX_MC6_V1.9_07.09.15_ENG
1 T-piece 2 Pump motor

©KM
5) Switch the pump motor on only briefly.
W
Important
If the pump motor runs for a lengthy period of time in the wrong direction of
rotation, the pump will be damaged.
7-304 Commissioning
6) Switch off the pump motor immediately using the EMERGENCY STOP
button.
The pump motor runs to a stop at an increasingly slower speed.
7) Check whether oil is flowing out of the hose.
Oil flows out only if direction of rotation is correct.
a) When oil flows out, remove the hose with collecting vessel from the pump
motor and fit the cap onto the T-piece.
b) Otherwise, carry out steps 10 to 13.
8) Unlock emergency-stop button.
D
e
d
Hazard from electrical voltage exists in the control cabinet.
Steps 10 to 13 must only be carried out by a properly qualified electrician.
W
Important
Carry out steps 10 to 13 only if no oil is flowing out of the hose at the pump
motor.
10) Switch master switch off and interrupt the power supply to the machine by
removing the pre-fuses.
11) Switch around the two phases (wires) of the connection cable.
12) Reconnect the power supply and switch on the master switch.
13) Carry out steps 5 to 8 and ensure that the correct direction of rotation is
confirmed by oil flowing out.
i
t
Environmental note
Consumed oils/lubricants must be collected and disposed of in an
MX_MC6_V1.9_07.09.15_ENG
environmentally compatible way.

Observe the relevant nation regulations for dealing with oils/lubricants.
©KM
Commissioning 7-305
7.10 Bleeding the hydraulic system
B
G
Eye protectors
Hydraulic oil which splashes out may result in severe eye injury or even in the
loss of eyesight.
W
Important
Bleed the system prior to initial commissioning, after the injection molding
machine has been out of operation for a lengthy period of several weeks and
after carrying out maintenance work on the hydraulic system.
During the bleeding operation, an authorized person must operate the machine
in the manual mode and a second person must observe the bleeding operation
at the bleed hose in the oil collecting tank.
i
t
Environmental note
MX_MC6_V1.9_07.09.15_ENG
©KM
7-306 Commissioning
7.10.1 Bleed points of the hydraulic system
1 2 3 4 5 6 7 8 9
1 2 3 4 4 12 12 11 10
1 2 3 4 4
Fig. 7.5 Bleed points of the hydraulic system

1 Clamping unit locks (8x) 1) 2) 7 Pump motor (2x)
2 Clamping unit posit positioning cylinder (4x) 1) 2) 8 Low-pressure pump
3 Clamping unit, pressure plunger (4x) 1) 2) 9 Injection barrel
4 Traverse cylinder (4x) 1) 2) 10 Pump control (3x)
5 Variable capacity pump (2x) 11 Pressure accumulator shaft
6 High-pressure pump 12 Intake filter (2x)
1)
Operator rearside
2) Operator side
MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-307
7.10.2 Block pump unit
W
Important
• Prior to switching on the pump motor, the hydraulic pumps must be vented.
• Remove the oil leakage lines from the motor and pump before switching on
the pump motor. Fill it with clean, filtered hydraulic fluid and reinstall it.
Prerequisites
• Pump motor switched off
• Setting mode selected
• Oil collecting tank provided
1 2 2 3 4
1 3 4
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 7.6 Block pump unit bleed points

1 Screw plug, low-pressure pump 3 Screw plug, high-pressure pump
2 Bleed screw, pump motor (2x) 4 Screw plug, variable capacity pump (2x)
7-308 Commissioning
7.10.2.1 Bleeding the pumps

1) Unscrew the screw plugs (1, 3, 4) on the pumps (see fig. 7.6, page 7-308).
2) As soon as hydraulic oil flows out free of bubbles, tighten the screw plug
again.
4) Pay attention to any noises, repeat bleeding operation if necessary.
5) Let the pump motor run for about 10 minutes.
7.10.2.2 Venting the pump motor
1 1
Fig. 7.7 Pump motor

1 Bleed screw (2x)
1) Open the bleed screws (1, fig. 7.7).

2) Switch the pump motor on and off repeatedly for a short time until oil flows out
free of bubbles.
3) Close the bleed screws.
MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-309
7.10.2.3 Bleeding the hydraulic pumps with asynchronous motor
Fig. 7.8 Hydraulic pumps with asynchronous motor

1 Leak oil hose (3x) 2 Pump (3x)
1) Unscrew leak oil hose (1, fig. 7.8) at every pump and tilt slightly downwards.
2) The oil runs into the pump.
3) When oil runs out of the pump, screw the leak oil hose back on.
MX_MC6_V1.9_07.09.15_ENG
©KM
7-310 Commissioning
7.10.3 Venting the intake area

Prerequisites
• Machine aligned
• Mold or thrust piece installed that corresponds to at least the minimum mold
installation height
• Pumps and pump motor vented
7.10.3.1 Venting Bleeding the intake filter
1
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 7.9 Intake filter

1 Adjusting bolt 3 Vacuum switch
2 Bleed screw 4 Thermocouple connection
Commissioning 7-311
1) Unscrew the bleed screw (2, fig. 7.9) on the intake filter.
2) Slowly open the foot valve in the intake filter via the adjusting bolt (1). (During
commissioning, the foot valve is already completely opened.)
3) As soon as hydraulic oil flows out free of bubbles, tighten the bleed screw
again.
4) Unscrew the adjusting bolt (1) until the stop.
7.10.4 Venting at the pump control

1) Connect the bleed hoses to the Minimess connections X010, X020, X040 on
the pump control.
2) Guide the bleed hoses into the oil collecting tank.
3) Switch the pump motor on and off repeatedly for a short time until oil flows out
free of bubbles.
4) Remove the bleed hoses.
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 7.10 Block pump control

1 Minimess connection
7-312 Commissioning
7.10.5 Venting the pressure accumulator

Prerequisites
• Hydraulic system is depressurized
• The pressure accumulator is filled with nitrogen
• Drain cock S5800 (3, fig. 7.11) is fully opened
• No pressure is displayed at the pressure indicator S580 (1).
1 3

system)
1
MX_MC6_V1.9_07.09.15_ENG
©KM

1 Storage tank 2 Bleed screw
Commissioning 7-313
Procedure
1) Remove the panelling in the area of the pressure accumulator, operator
rearside.
w
D
Caution - adopt the correct procedure
The pressure indicator on the accumulator must not display any oil pressure.
2) Unscrew the bleed screws (2, fig. 7.12) at the connection shaft of the
pressure accumulator by 1⁄2 a revolution.
Note the charge status of the accumulator.
3) Select "setting mode".
4) Turn the pump motor on and let it run.
W
Important
Tightening torque is valid for 10 l to 50 l pressure accumulators.
5) As soon as the oil flows out free of bubbles, tighten the bleed screws to a
torque of 30 Nm.
6) Close drain cock S5800 (3, fig. 7.11).
7) Install the panelling in the area of the pressure accumulator, operator
rearside.
8) Check the oil level and replenish hydraulic oil if necessary.
7.10.6 Bleeding the clamping unit
7.10.6.1 Bleeding the pressure plunger and positioning cylinders
Prerequisites
MX_MC6_V1.9_07.09.15_ENG
• Mold or test block piece installed

• Zero points set for the position transducers of the clamping unit and pressure
©KM
cushions
• Safety gates on the clamping unit closed
• Mold closed
• Locks fully extended
• "Mold closing" screen called up
7-314 Commissioning
Procedure
1) Connect the bleed hoses with the 4 Minimess connections for the pressure
pistons (3, fig. 7.14) and with the 4 Minimess connections for the positioning
cylinders (2, fig. 7.14) of the pressure cushions on the movable mold
clamping platen.
W
Important
During "Move pressure piston forward", do not move against the mechanical
stop of the pressure piston combination.
3) Move the pressure cushion package alternately with the buttons "Move
pressure piston forward" and "Move pressure piston back".
Note the following when doing this:
I
Note
Only move the pressure cushion package in each direction in increments of
20 mm respectively.
Excessively large increments can result in the air remaining in the barrel mixing
with the hydraulic fluid and delay the bleeding operation significantly.
a) After each step, check whether air is escaping from the bleed hoses.
Before air escapes, hydraulic oil could emerge for a short while.
b) Only initiate the next step when no more air is detected emerging from the
bleed hoses.
c) Bleeding is completed as soon as hydraulic oil flows out free of bubbles
at all bleed hoses into the oil reservoir.
4) Remove the bleed hoses while hydraulic fluid emerges and seal the Minimess
connections.
7.10.6.2 Bleeding the locking mechanisms
Prerequisites
MX_MC6_V1.9_07.09.15_ENG

©KM

• Mold closed
• All pressure cushions in position
Procedure
1) Manually select "Setting stroke encoder zero points" on the "Machine
calibration" screen page (see fig. 7.32, page 7-352).
Commissioning 7-315
Fig. 7.13 Pressure cushion and locking mechanism calibration
2) On screen page "Calibrate pressure cushion and lock" select "Calibrate and
move all pressure cushions" in the selection field.
3) Connect the bleed hoses to the 8 Minimess connections (1, fig. 7.14) of the
locks on the interlock cylinder.
G
B
Wear safety goggles
When connecting the bleed hoses on the plunger side, a residual pressure is
released.
Hydraulic oil which splashes out may result in severe eye injury or even in the
MX_MC6_V1.9_07.09.15_ENG
loss of eyesight. Wear safety goggles.

©KM
5) Actuate "Move in locking elements" button and "Move out locking elements"
button alternately and move to the mechanical limit positions in each case:
a) After each step, check whether air is escaping from the bleed hoses.
Before air escapes, hydraulic oil could emerge for a short while.
b) Only initiate the next step when no more air is detected emerging from the
bleed hoses.
c) Bleeding is completed as soon as hydraulic oil flows out free of bubbles
at all bleed hoses into the oil reservoir.
7-316 Commissioning
6) Remove the bleed hoses and seal the Minimess connections.

1 2 3
Fig. 7.14 Minimess connections, movable mold clamping platen

1 Minimess connection, lock (8 x) 3 Minimess connection pressure plunger (4x)
2 Minimess connection positioning cylinder (4x)
7.10.6.3 Bleeding the MP traverse cylinder
Prerequisites
• Hydraulic connections established
MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-317
Procedure
1 3
2
5 4
6 7
Fig. 7.15 Bleeding the MP traverse cylinder

1 Oil supply, Mold closing 5 Movable mold platen (MP)
2 Bleed screws (each 2x) 6 Piston rod of the MP traverse cylinder
3 Oil supply, Mold opening 7 MP traverse cylinder operator side
4 Fixed mold clamping platen (FP) 8 MP traverse cylinder operator rearside, bottom
1) Loosen the four bleed screws (2, fig. 7.15) of the traverse cylinder operator
side (7).
2) Operate the "Mold opening" and "Mold closing" buttons alternately until the oil
flows out free of bubbles.
3) Close the bleed screws.
4) Perform working steps 1 to 3 for the traverse cylinder operator rearside (8).
MX_MC6_V1.9_07.09.15_ENG

©KM
7-318 Commissioning
7.10.7 Bleeding the injection barrel
W
Important
The screw must not be moved until the barrel heater has heated up for at least
hour to 230 °C as there is still possibly residual material in the screw barrel.
Pay attention to information plate on screw barrel.
W
Important
High speeds can mix the air remaining in the barrel with the hydraulic fluid and
delay the bleeding operation significantly.
Prerequisites
• Mold/test block piece installed
• Mold installation height of the installed mold/test block corresponds to the
min. mold installation height
Procedure
1 2
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 7.16 Mini measuring connections at injection unit

1 Minimess connection (barrel back) 2 Minimess connection (injection pressure)
1) Adjust "Set-up speed, injection" to 10 mm/s.

2) Adjust "Setting pressure, injection" to 50 bar.
3) Adjust all active speed level for the "Screw decompression" function to
10 mm/s.
4) Connect bleed hoses to mini measuring connections on injection barrel.
Commissioning 7-319

6) Move the injection unit with "Injection unit back" button into the rear limit
position.
7) Press the "Injection" button and move the injection plunger forwards in
100 mm increments.
8) After each increment, check whether air is escaping from the bleed hose.
9) Do not proceed to the next increment until you no longer notice air escaping
from the bleed hose.
10) When the front end position of the injection plunger is reached, move the
injection plunger into the rear end position using the "Screw decompression"
button.
11) Repeat steps 6 through 9 until hydraulic oil flows out from the bleed hose free
of bubbles.
In addition, during the bleeding process the injection plunger must always be
moved to the front end stop before being moved to the rear end position using
the "Screw decompression" button.
12) Remove the bleed hose when hydraulic oil flows out free of bubbles and seal
the Minimess connection.
14) Seal Minimess connections.
MX_MC6_V1.9_07.09.15_ENG
©KM
7-320 Commissioning
7.11 Inspect pump running

Prerequisites
• Hydraulic oil replenished
• Input authorization granted
Procedure
Pump motor/pumps run.
2) Observe the pressure indicator (1, fig. 7.17) and check the pumps for running
noises.
W
Important
Irregular, rattling operating noise and jerky movements of the pointer on the
pressure indicator are a sign that the pumps are drawing in air.
Carry out step 3 only if irregular, rattling noises and jerky movements of the
pointer exist.
3) Inspect the intake lines for leaks and the hydraulic oil for entrapped air.
Eliminate any leaks or entrapped air.
4) Carry out steps 1 to 3 and ensure that the fault has been rectified.
I
Note
If you cannot be certain that the fault is rectified, notify KraussMaffei Customer
Service (see section 0.10, page 0-36).
MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-321
9 3
8
5
7 6
Fig. 7.17 Pressure indicator with selector switch

1 Pressure indicator 6 Not assigned
2 Nozzle contact pressure 7 System pressure
3 Injection pressure 8 Selector switch
4 Back-pressure 9 Core-pulling/Ejector
5 Not assigned
W
Important
The pressure indicator (1, fig. 7.17) is used to monitor the actual working
MX_MC6_V1.9_07.09.15_ENG
pressures.
©KM
To do this, turn selector switch (8) to the desired indicator, press and hold.
7-322 Commissioning
7.12 Checking the alignment of the machine
W
Important
Once the requirements for moving the movable mold clamping platen are met
and before further work is carried out on the machine, check and, if necessary,
correct the alignment of the machine.
Failure to observe this instruction can lead to damage to the machine.
Opening stroke between the mold clamping platens
Type Distance MP - FP [mm]

KM 850 MX 1000
KM 1000 MX 1000
KM 1150 MX 1100
KM 1300 MX 1100
KM 1600 MX 1250
KM 2000 MX 1250
KM 2300 MX 1250
KM 2700 MX 1400
KM 3200 MX 1400
KM 4000 MX 1400
Fig. 7.18 Opening stroke between the mold clamping platens
1) Move the movable mold clamping platen to the opening stroke assigned to the
machine model
2) Check and, if necessary, correct the alignment of the clamping unit
3) Check and, if necessary, correct the vertical alignment of the fixed mold
clamping platen (see section 5.7.4, page 5-204).
4) Check the alignment again once after the machine has been running for four
weeks.
MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-323
7.13 Installation of screw barrel
7.13.1 Notes on installation of screw barrel
f
d
D
Fire hazard
The temperature on the surface of the heating bands of the screw barrel is
Therefore, keep the heater band surfaces free of any objects and dirt (e.g.
plastic, cloths, etc.).
H
d
D
regulations.
Z
B
Personal protective equipment when working on plasticizing units
When working on heated screw barrels, suitable personal protective
• Protection of face
W
Important
If the mold is not installed, the nozzle insertion depth as specified in the "Mold
connection dimensions" (see chapter 15 Parts lists/drawings) must not be
exceeded when using longer screw barrels (longer than base equipment of
machine).
Allow for change in length accordingly in the case of the injection unit stroke.
MX_MC6_V1.9_07.09.15_ENG
W
Important
©KM
• The screw must not be moved until the barrel heater has heated up for at
least 1 hour to 230 °C as there is still possibly residual material in the screw
barrel.
Pay attention to information plate on screw barrel.
• The screw barrel is preassembled, i.e. nozzle, heating bands, thermo
sensors, screw with return flow lock and heat protective jacket, are
installed.
7-324 Commissioning
1) Ensure that the machine base is aligned and that the safety gate and nozzle
guard are closed.
position.
4) Remove the cover at the mechanical screw stroke indicator (access to screw
coupling).
5) Fit the lifting eyes on the screw barrel.
6) Ensure that the following components are cleaned and free of corrosion
protection agents:
• Screw barrel
• Screw
• Screw coupling
• Barrel flange mounting
7) Pull back screw coupling with "Screw decompression" button.
8) Secure the lifting rope to the lifting eyes.
w
D
Caution
During transport, the screw can slide out of the screw barrel and injure
personnel or damage components.
• Secure the screw with a rope to prevent it slipping out.
• Match the lengths of the lifting ropes.
• Do not undershoot the minimum stop angle bracket  mi n (see fig. 7.19,
page 7-325)
1 2
3 4
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 7.19 Matching the lengths of the lifting ropes (rope/chain lengths)
1 Length A 3 Centre of gravity
2 Length B 4 Minimum angle  mi n
Commissioning 7-325
Screw cylinder, type dia. [mm] Minimum length A 1) Minimum length B 1) Minimum angle
[mm] [mm]  mi n 1) 2)
SP 4300 MX 80 800 800 15
90 800 800
100 800 800
SP 6100 MX 85 700 1100 30
95 900 1300
105 1000 1400
SP 8100 MX 95 900 1300 30
105 1000 1400
115 1100 1500
SP 12000 MX 105 900 1400 30
120 900 1600
135 1100 1800
SP 17200 MX 120 900 1600 30
135 1100 1800
150 1400 2000
SP 24500 MX 135 1100 1900 30
150 1400 2100
165 1600 2300
SP 33000 MX 160 1300 1600 15
175 1400 1800
195 1500 2000
SP 55000 MX 185 1800 2200 15
205 2000 2300
220 2200 2400
SP 75000 MX 215 2200 2200 15
230 2300 2300
245 2400 2400
1)
Minimum length, values rounded
2) Minimum angle at the attachment point far from the centre of gravity
W
Important
• Ensure that the screw barrel is horizontal when lowered into the barrel
flange mounting.
MX_MC6_V1.9_07.09.15_ENG
• Guide the cable loom when inserting the screw barrel so that the cable
loom does not obstruct insertion or cause damage.
©KM
• Only SP 33000 to SP 75000: The screws of the lifting ring (4, 5, Fig. 7.27)
must not twist or jam the screw barrel during installation. Back off screws
in direction screw barrel if necessary. The screws (4) must not butt against
the pull stanchion.
7-326 Commissioning
7.13.2 Installation of screw barrel SP 4300 to SP 24500
7.13.2.1 Installation of screw barrel SP 4300
1 2 3 4
6 7 8 9 10
13
14
15
11 12
Fig. 7.20 Installation of screw barrel SP 4300

1 Barrel wedge 9 Screw mount
2 Clamping wedge 10 Injection plunger
3 Bolt (2x) 11 Stud bolt (2x)
4 Gap A 12 Splines of the screw mount
5 Screw 13 End face
6 Screw nut 14 Splines on screw shaft
7 Half shell (2x) 15 Barrel flange mounting
8 O-ring
1) Only SP 4300: place precision spirit level (accuracy of 0.1 mm/m) horizontally
on injection plunger (10, fig. 7.20), read off and note.
2) Coat the contact surfaces of the following components with Molykote paste:
• barrel wedge (1),
• clamping wedge (2),
MX_MC6_V1.9_07.09.15_ENG
• screw thread (3),

©KM
• splines on the screw shaft (14),

• barrel flange mounting (15).
W
Important
The flat surface (13) on the screw shaft must remain free of grease.
Commissioning 7-327
3) Move the screw barrel to the installation position and carefully lower it into the
barrel flange mounting.
W
Important
The gap A (4, fig. 7.20) between the barrel flange mounting (15) and the barrel
wedge (1) must be the same on the operator side and on the operator rearside.
The barrel wedge must not be resting on the barrel flange mounting.
If the gap is not the same on both sides, or if the barrel wedge is touching the
barrel flange mounting, the wedge effect for attaching the screw barrel is not
ensured.
4) Hand-tighten bolts (3, fig. 7.20) on clamping wedge (2).

5) Remove rope from lifting eye of clamping wedge (2).
6) Move the injection unit as far forward as possible, nozzle must not be
touching. The guide (5, fig. 7.23) must make contact on the front of the
eccentric (7). If necessary, back off eccentric, rear (8).
7) Provide support for screw barrel (see section 7.13.2.3, page 7-331).
MX_MC6_V1.9_07.09.15_ENG
©KM
7-328 Commissioning
7.13.2.2 Installation of screw barrel SP 6100 to SP 24500
1 2 3 4 5 6
10
9 8 7
Fig. 7.21 Installation of screw barrel SP 6100 to SP 24500

1 Screw barrel 6 Locking mechanism with locknut (2x)
2 Cover 7 Splines of the screw mount
3 Cylinder-head bolts (4x) 8 Groove
4 Cylinder-head bolts (3x) 9 Barrel flange mounting
5 Clamping wedge (2x) 10 Parallel button (bottom)
W
Important
For some sizes, two wedges (2, fig. 7.22) are used to support the cover (4). In
this case, the cover is provided with a bevelled contact surface on both sides
(3).
MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-329
1 2 3
Fig. 7.22 Wedge support of the cover (using the SP 17200 as an example)
1 Bolts (4x) 3 Bevelled contact surface
2 Wedges (2x) 4 Cover
• barrel flange mounting (9, fig. 7.21) at injection unit housing,
• splines on screw shaft (3, fig. 7.25),
• clamping wedge (5, fig. 7.21),
• cylinder-head bolts (3, fig. 7.21) on the thread.
W
Important
The contact areas of the wedges (2, fig. 7.22) must remain free of grease.
2) If necessary, release the locks (6, fig. 7.21) for the screw barrel at the injection
unit.
MX_MC6_V1.9_07.09.15_ENG
3) On screw barrels with wedge support for the cover, release the bolts
©KM
(1, fig. 7.22), push wedges (2, fig. 7.22) outwards (1, fig. 7.24) and hand-
tighten bolts.
4) Place a precision spirit level (accuracy of 0.1 mm⁄m) on the upper contact
surface on the injection unit housing, read it and make a note of the reading.
7-330 Commissioning
W
Important
The feather key (10, fig. 7.21) on the screw barrel must slide without
mechanical resistance into the groove (8) in the injection unit housing. If
necessary, release the three cylinder-head bolts (4) on the cover (2) and
retighten them.
5) Move the screw barrels (1, fig. 7.21) into the installation position.
Carefully lower the screw barrel until the feather key (10) slides into the slot
(8) of the barrel flange mounting.
6) Release locknut on locking mechanism (6) and tighten lock lightly in axial
direction by screwing in.
7) Tighten cylinder-head bolts (3) lightly diagonally and evenly.
8) Remove rope from lifting eye of locking mechanism (6, fig. 7.23).
9) Move the injection unit as far forward as possible. The nozzle must not be
touching.
10) The guide (5) must make contact on the front of the eccentric (7). If necessary,
back off eccentric, rear (8).
11) Provide support for screw barrel (see section 7.13.2.3, page 7-331).
7.13.2.3 Supporting the screw barrel SP 4300 to SP 24500
1 2 3 4 5 6
MX_MC6_V1.9_07.09.15_ENG
7 8
©KM
Fig. 7.23 Supporting the screw barrel SP 4300 to SP 24500

1 Screw barrel 5 Guide
2 Heating band 6 Lifting eye on clamping wedge/locking mechanism
3 Lifting eye at lifting ring 7 Eccentric, front
4 Lifting ring 8 Eccentric, rear
Commissioning 7-331
1) Remove the heating band (2, fig. 7.23) at the lifting ring (4) and clean the
screw barrel there.
2) Lay the precision spirit level on the screw barrel.
3) Align screw barrel flush to injection unit housing:
a) Use the rope at the lifting ring (3, fig. 7.23) to relieve the eccentric, front
(7) during the setting.
b) If necessary, screw eccentric, rear (8) into lower position.
c) Only SP 4300:
Use the eccentric, front, (7) to move the screw barrel into the same
alignment as read and noted in step 1 (see section 7.13.2.1, page 7-327).
d) Only SP 6100 to SP 24500:
Use the eccentric, front, (7) to move the screw barrel into the same
alignment as read and noted in step 4 (see section 7.13.2.2, page 7-329).
e) Screw rear eccentric (8) back into contact position at guide (5).
f) Check alignment of screw barrel once again with precision spirit level and
repeat work steps b to e if necessary.
4) Only SP 4300:
a) Hand-tighten bolts (3, fig. 7.20) on clamping wedge (2).
b) Inspect the alignment of the screw barrel again using the precision spirit
level.
c) If the alignment is not correct, repeat the setting after releasing the
bracing between barrel wedge (1, fig. 7.20) and clamping wedge (2)
(work steps 3 and 4).
5) Only SP 6100 to SP 24500:
a) Tighten the locks (6, fig. 7.21) evenly with a tightening torque of
max. 250 Nm. The locknuts of the lock (6) must be released.
W
Important
The distance between the lower edge of the cover (2, fig. 7.21) and the contact
surface of the injection unit housing must be the same on the operator side and
on the operator rearside.
Correct any deviation caused by the cylinder-head bolts (3) being tightened at
different strengths.
b) With screw barrels with wedge support for the cover: push both wedges
MX_MC6_V1.9_07.09.15_ENG
(2, fig. 7.24) without force to contact position below the cover (3) and
tighten bolts (6).
©KM
c) Check the alignment once again using the precision spirit level.
d) If alignment is not correct, release locks (6, fig. 7.21), cylinder-head bolts
(3, fig. 7.21) and wedges (2, fig. 7.24).
e) Repeat work steps 3 and 5.
7-332 Commissioning
1 2 3
4 5 6
Fig. 7.24 Position of the wedges before and after installing the screw barrel (using the SP 17200 as an
example)
1 Wedge position on the outside of the injection unit housing (before 3 Screw barrel cover
installing the screw barrel) 4 Injection unit housing
2 Wedge in resting position on the cover (after installing the screw 5 Screw barrel
barrel) 6 Bolts
6) Provide locknut for locking mechanism (6, fig. 7.21) and apply sealing varnish
to locknut.
7) Install heating band (2, fig. 7.23) on lifting ring (4) of screw barrel (1).
8) Remove the lifting tackle, rope and lifting eyes.
touching.
11) Establish plug connections for heating bands and thermo sensors.
w
D
Warning!
There is a danger of scalding through escaping hot steam or leaking hot water.
• Before connecting or disconnecting the cooling water hoses, the flange
MX_MC6_V1.9_07.09.15_ENG
control zone (see section 8.10, page 8-531) must be set to "Off" so that the
water supply is interrupted by a solenoid valve.
©KM
• To set up the cooling water supply, the return line must first be connected
and then the advance line.
• To disconnect the cooling water supply, the advance line must first be
disconnected and then the return line.
Commissioning 7-333
W
Important
If the hopper temperature exceeds 105 °C, the red alarm A02169 "Flange
temp. too high" is issued and barrel heating is switched off. Production is not
interrupted. Flange cooling remains active.
12) Establish plug connections for coolant supply at the barrel flange.
f
d
D
Fire hazard

14) Switch barrel heating on at the operating/display panel and heat up screw
barrel for about 2 hours to 230 °C.
H
d
D
regulations.
15) Check horizontal alignment. Eliminate possible inclination due to incorrect

adjustment of eccentric, front (7, fig. 7.23).
MX_MC6_V1.9_07.09.15_ENG
©KM
7-334 Commissioning
7.13.2.4 Coupling the screw to SP 4300
1 2 3 4 5 6
8 7
Fig. 7.25 Coupling the screw to SP 4300

1 Screw barrel 5 Screw nut
2 Screw 6 Screw mount
3 Splines on screw shaft 7 Stop
4 Stud bolt 8 Half shells with O-ring
H
d
D
regulations.
1) Remove the screw nut (5, fig. 7.25) and the half shells (8) from the screw
mount (6).
2) Pull the screw towards the screw mount (6). When doing this, make the
splines on the screw shaft flush with the toothing in the screw mount. Correct
offset by adjusting eccentric, front (7, fig. 7.23).
MX_MC6_V1.9_07.09.15_ENG
3) Tighten cylinder-head bolts (3, fig. 7.21) diagonally and evenly in small steps
©KM
up to the specified tightening torque. Check with feeler gauge to ensure that
the distance between the lower edge of the cover (2, fig. 7.21) and the contact
surface of the injection unit housing is the same on the operator side and on
the operator rearside.
4) Use the feeler gauge to check that the gap between screw shaft and screw
barrel is the same.
5) Pull the screw towards the screw barrel and slide screw nut (5, fig. 7.25) over
the screw shaft.
Commissioning 7-335
6) Lay both half shells (8, fig. 7.25) over the screw shaft before the splines (3)
and secure with an O-ring.
7) Push the screw nut (5) over the half shells (8).
8) Push the screw all the way to the stop (7) in the screw mount (6). Ensure ease
of movement and alignment of the toothing of the screw shaft and screw
mount.
W
Important
Screw coupling has left-hand thread.
9) Tighten the screw nut by hand as far as possible.

10) Tighten the stud bolts (4).
11) Fit the thermal jacket.
12) Mount the cover on the mechanical screw stroke indicator.
13) Move the injection unit into the rear limit position.
14) Configure nozzle centre (see section 7.14, page 7-343).
W
Important
Check the screw coupling weekly to ensure that it is secure
MX_MC6_V1.9_07.09.15_ENG
©KM
7-336 Commissioning
7.13.3 Installation of screw barrel SP 33000 to SP 75000
7.13.3.1 Installation of screw barrel SP 33000 to SP 75000
1
2
3
9 10 11 12
4
7 6 5
Fig. 7.26 Installation of screw barrel SP 33000 to SP 75000

1 Clamping wedge 7 Barrel flange mounting
2 Splines on screw shaft 8 Feather key
3 Locking mechanism with locknut (4x) 9 Cylinder-head bolts (4x)
4 Bolt (2x) 10 Cover
5 Splines of the screw mount 11 Lifting eyes on locking mechanism
6 Groove 12 Cylinder-head bolts (4x)
• barrel flange mounting (7, fig. 7.26) at injection unit housing,
• splines of the screw mount (5),
• splines on the screw shaft (2),
• clamping wedge (1),
• cylinder-head bolts (12) at thread.
2) If necessary, release the locks (3) for the screw barrel at the injection unit.
MX_MC6_V1.9_07.09.15_ENG
3) Place a precision spirit level (accuracy of 0.1 mm⁄m) on the upper contact
©KM
surface on the injection unit housing, read it and make a note of the reading.
W
Important
The feather key (8) on the screw barrel must slide without mechanical
resistance into the groove (6) in the injection unit housing. If necessary, release
the four cylinder-head bolts (9) on the cover (10) and retighten them.
Commissioning 7-337
4) Move the screw barrels into the installation position.

Carefully lower the screw barrel until the feather key (8, fig. 7.26) slides into
the slot (6) of the barrel flange mounting (7).
5) Align screw barrel flush to injection unit housing.
6) Release locknut on locking mechanism (3) and tighten lock lightly in axial
direction by screwing in.
7) Remove rope from lifting eye of locking mechanism (11).
7.13.3.2 Supporting the screw barrel SP 33000 to SP 75000
7
4
6 5
Fig. 7.27 Supporting the screw barrel SP 33000 to SP 75000

1 Lifting eye at lifting ring 5 Vertical adjusting screw (2x)
2 Lifting ring 6 Pull stanchion
3 Screw barrel 7 Gap approximately 0.2 mm
4 Side screw (2x)
MX_MC6_V1.9_07.09.15_ENG
1) Remove the heating bands at the measuring points (see fig. 7.28,
©KM
page 7-341) of the screw barrel and clean the screw barrel there.
W
Important
The screws (4, fig. 7.27) are used only for laterally fixing the screw barrel. They
must not be used to align the screw barrel or to adjust the nozzle centre.
The screws must not be touching the pull stanchion (gap of about 0.2 mm).
7-338 Commissioning
2) Check the parallelism from the injection unit bed top edge to the bottom side
of the screw barrel (between the heating bands) using a measuring strip and
a micrometer (see section 7.13.3.3, page 7-341). In case of parallelism
deviation:
a) Use the rope at the lifting ring (1, fig. 7.27) to relieve the vertical adjusting
screws (5) during the setting.
b) Use the vertical adjusting screws (5) at lifting ring (2) to align screw barrel
parallel to the injection unit bed.
3) Tighten the locks (3, fig. 7.26) evenly with a tightening torque of
max. 250 Nm. The locknuts of the locking mechanisms (3) must be released.
W
Important
The distance between the lower edge of the cover (10, fig. 7.26) and the
contact surface of the injection unit housing must be the same on the operator
side and on the operator rearside.
Correct any deviation caused by the cylinder-head bolts (12) being tightened
at different strengths.
4) Tighten cylinder-head bolts (12, fig. 7.26) diagonally and evenly in small steps
up to the specified tightening torque. Check with a feeler gauge to ensure that
the distance between the lower edge of the cover (10) and the contact surface
of the injection unit housing is the same on the operator side and on the
operator rearside.
5) Check the parallelism again at the measuring points of the screw barrel. In
case of parallelism deviation, repeat the setting as follows:
a) Release locking mechanisms (3, fig. 7.26) and cylinder-head bolts (12).
b) Repeat work step 2 to 4.
6) Attach the heating bands to the measuring points of the screw barrel.
touching.
9) Establish plug connections for heating bands and thermo sensors.
w
D
Warning!
MX_MC6_V1.9_07.09.15_ENG

©KM
Commissioning 7-339
W
Important
If the hopper temperature exceeds 105 °C, the red alarm A02169 "Flange
temp. too high" is issued and barrel heating is switched off. Production is not
interrupted. Flange cooling remains active.
10) Establish plug connections for coolant supply at the barrel flange.
f
d
D
Fire hazard
Therefore, keep the heater band surfaces free of any objects and dirt
(e.g. plastic, cloths, etc.).

12) Switch barrel heating on at the operating⁄/display panel and heat up screw
barrel for about 2 hour to 230 °C.
H
d
D
regulations.
13) Check the parallelism again at the measuring points of the screw barrel. In
case of parallelism deviation, repeat the setting as follows:
a) Release locking mechanisms (3, fig. 7.26) and cylinder-head bolts
(12, fig. 7.26).
b) Repeat work step 2 to 4.
14) Provide locknuts for locking mechanisms (3, fig. 7.26) and apply sealing
varnish to locknuts.
15) Remove the lifting tackle, rope and lifting eyes.
MX_MC6_V1.9_07.09.15_ENG
©KM
7-340 Commissioning
7.13.3.3 Checking and setting screw barrel parallelism to the SP 33000 to SP 75000 injection unit
machine bed
Mold
• Measuring strip
• Micrometer

• Difference from measuring point 1(=zero point) to measuring
point 3 < 0.3 mm
3 2 1
Fig. 7.28 Checking screw barrel parallelism for SP 33000 or later
Measuring and setting in a cold state

of the screw barrel (between the heating bands) using a measuring strip and
a micrometer.
2) If necessary, use the adjusting bolts (5, fig. 7.27) to re-align the pull stanchion
(see section 7.13.3.2, page 7-338) and seal.
Measuring and setting in a hot state
H
d
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Risk of scalding on heated components of the screw barrel.
MX_MC6_V1.9_07.09.15_ENG
regulations - wear safety gloves.

©KM
1) Heat screw barrel up to 230 °C.

2) Ensure that the side screws (4, fig. 7.27) are not touching the pull stanchion
(0.2 mm gap).
of the screw barrel (between the heating bands) at the measuring points (see
arrows) using a measuring strip and a micrometer.
4) If necessary, use the adjusting bolts (5, fig. 7.27) to re-align the pull stanchion
(see section 7.13.3.2, page 7-338) and seal.
Commissioning 7-341
7.13.3.4 Coupling the screw SP 33000 to SP 75000
D
H
d
regulations.
W
Important
Screw coupling has left-hand thread.
1) Ensure that the bolts (4, fig. 7.26) have been unscrewed as far as the stop.
2) Ensure that the tensioning bolts on the screw coupling have been slackened
and the screw coupling has been slackened by half a turn.
3) Push the screw all the way into the screw mount. Ensure ease of movement
and alignment of the toothing of the screw shaft and screw mount.
4) Screw in the bolts (4) as far as they will go.
5) Tighten the screw coupling as far as possible.
6) Tighten the tensioning bolts on the screw coupling.
W
Important
Check the screw coupling weekly to ensure that it is secure
7) Fit the thermal jacket.

8) Mount the cover on the mechanical screw stroke indicator.
9) Move the injection unit into the rear limit position.
10) Configure nozzle centre (see section 7.14, page 7-343).
MX_MC6_V1.9_07.09.15_ENG
©KM
7-342 Commissioning
7.14 Centring nozzle
S
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Risk of spraying
• Hot melt can be ejected at high speeds from the nozzle or fill opening.
Before centring the nozzle, the screw barrel must be purged
(see section 10.12.3.2, page 10-754)!
• For adjustment work when the system is heated up, the material in the
barrel must be known. Observe the safety data sheet of the plastic.
H
d
D
regulations.
Z
B
W
Important
When moving forwards towards sensitive parts such as heater bands, thermo
sensors, nozzle shut-offs, etc., ensure that these are not damaged.
MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-343
Testing/measuring equipment:
• Calliper gauge
Measuring points
• Nozzle centre up to the inner diameter of the centring ring.
Prerequisites
• Injection unit aligned
• Screw barrel parallelism to the injection unit machine bed checked for
SP 33000 or later (see section 7.13.3.3, page 7-341)
• Screw barrel installed and heated up to 230 °C
• Injection unit moved forwards until nozzle tip is level with the FP
W
Important
• Permitted deviation from the horizontal in longitudinal axis and transverse
axis: < 0.2 mm⁄m.
• Centring ring must not protrude over the working plate (check using a
straightedge).
• Measure diagonally across from the nozzle opening to the centring ring.
The max. deviation must be 0.2 mm.
Procedure
W
Important
• The two eccentrics (7, 8, Fig. 7.23) must not be used for height adjustment
when setting the nozzle centre.
• The bolts at the pull stanchion (2, fig. 7.30) of the screw barrel must not be
used for aligning the nozzle middle.
MX_MC6_V1.9_07.09.15_ENG
I
Note
©KM
Always set the vertical nozzle centre first. Only after this has been done can
the horizontal nozzle centre be set.
7-344 Commissioning
Fig. 7.29 Setting the nozzle centre for SP 4300 to SP 24500

1 Injection unit 3 Bolt (12x)
2 Adjusting bolt (6x)
1 2 3
Fig. 7.30 Setting the nozzle centre for SP 33000 to SP 75000

1 Adjusting screw on the injection unit flange 3 Injection unit wedge shoe adjusting screw
2 Pull stanchion
MX_MC6_V1.9_07.09.15_ENG
©KM
1) Using a calliper gauge, determine the nozzle centre in vertical and horizontal
directions. While doing so, measure from the centre of the nozzle to the inner
diameter of the centring ring.
2) If deviations from the nozzle centre are present, carry out the following steps.
3) Unscrew the securing bolts between the injection unit and the clamping unit.
4) Eliminate the vertical deviation by altering the position of the adjusting screws
at the wedge shoes of the injection unit.
5) Correct the horizontal deviation:
Commissioning 7-345
• SP 4300 to SP 24500:
a) Slacken two bolts (3, fig. 7.29) on each guide carriage on both sides of the
injection unit (1).
b) On the side from which the injection unit is to be moved away, fully back
off the two adjusting screws (2).
c) On the side to which the injection unit is to be pushed, insert the two
adjusting bolts (2) corresponding to the nozzle centre adjustment. Ensure
that the adjusting bolts (2) are screwed in evenly.
Example: to displace the injection unit in direction operator side:
– back off the two adjusting screws (2) on the operator rearside.
– screw in the two adjusting screws (2) on the operator side.
• SP 33000 to SP 75000:
a) Eliminate the horizontal deviation by turning the adjusting bolts
(1, fig. 7.30) at the injection unit flange.
6) Check the nozzle centre again.
7) If deviation exists, repeat steps 4 through 6.
If no deviation exists, continue with step 8.
8) Tighten all bolts (3, fig. 7.29).
9) Repeat the alignment several times, switching sides until the injection unit is
within the tolerance range.
10) Securely bolt injection unit to clamping unit.
11) Ensure that the alignment of the machine is inspected once again after
machine has been in operation for four weeks.
MX_MC6_V1.9_07.09.15_ENG
©KM
7-346 Commissioning
7.15 Check the nozzle insertion depth

Set values
• Dimension C = 40 mm (standard)
Prerequisites
• Hydraulic sliding shut-off element must be closed (thrust rod at front)
Procedure
W
Important
When moving forwards towards sensitive parts such as heater bands, thermo
sensors, nozzle shut-offs, etc., ensure that these are not damaged.
1) Move injection unit forward until it contacts.

2) Measure dimension C (1, fig. 7.31) between nozzle tip and FP.
3) Compare value with the specifications in the technical data sheet.
Fig. 7.31 Nozzle insertion depth

1 Dimension C
MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-347
7.16 Mold installation
w
d
D
When installing or removing molds, there is a danger that the molds may fall
down.
The mold parts must continue to be supported by the transport ropes until all
screw connections specified by the manufacturer are secure.
H
d
D
Risk of burns on heated mold components.
regulations.
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.
• When installing molds, observe the valid accident prevention regulations.
Mold installation and removal must only be carried out by trained specialist
personnel.
k
B
Wear protective helmet with mask
of eyesight.
W
Important
MX_MC6_V1.9_07.09.15_ENG
• Heat molds up to service temperature prior to setup.

• With the mold closed, do not switch off the machine or lower the service
©KM
temperature because this could result in distortion/damage to the mold and

the machine.
• The injection unit can be moved to the mold half with increasing force when
the mold is open. Ensure that the attachment force is greater than the mold
opening force (see section 3.2, page 3-131).
If the securing force is insufficient, the mold can be pushed of the clamping
platen and destroyed.
7-348 Commissioning
W
Important
• Water/oil channels of molds that are not used must be rinsed and
preserved. Before the molds are reinstalled into the injection molding
machine, rinse the water/oil channels with clean medium.
• There must be no contamination brought into the circuit as a result of molds
that have just been installed into the machine.
Prerequisites
• Machine switched on
• Input authorization granted (see section 7.7, page 7-302)
• Pump motor activated
Procedure
2) Press the "Mold opening" button until the step P00007 "Mold open" is
displayed.
3) Press the "Machine preparation" hard key on the operating/display panel.

The "Machine-calibration" screen (see fig. 7.32, page 7-352) is displayed.
4) In the "Setting position transducer zero points" selection menu (1, fig. 7.32),
select "Manual".
Pushbuttons are displayed to set the zero points.
5) Position the movable mold clamping platen for installing the mold.
6) Switch off the pump motor.
7) Insert mold, centre and attach to fixed mold platen.
8) Close the safety gate on the operator side and operator rearside.
10) Move the movable mold clamping platen up against the mold with the "Mold
closing" button.
11) Perform calibration of the clamping unit (see section 7.17.2.2, page 7-353).
12) Set the zero points for the ejector (see section 7.17.2.1, page 7-353) and
injection unit (see section 7.17.2.3, page 7-354).
13) Select "off" for setting stroke encoder zero points.
MX_MC6_V1.9_07.09.15_ENG

15) Open the safety gate on operator side/operator rearside.
©KM
16) Attach the mold to the movable mold platen.

17) Remove the lifting equipment and transportation plates from the mold.
18) Establish the electrical plug connections, cooling water connections and
hydraulic connections between the mold and machine.
Commissioning 7-349
20) Open the mold and make the machine settings.
W
Important
The hydraulic cascade valves are preset to 60 bar and must be readjusted
depending on the mold.
MX_MC6_V1.9_07.09.15_ENG
©KM
7-350 Commissioning
7.17 Zero point calibration
7.17.1 Information on zero point calibration

The machine is equipped with position transducers for controlling and monitoring
the movements of the mold, ejector and injection unit.
In order for the machine to operate free of problems and in reproducible operating
cycles, it is necessary to define the zero points from which the maximum strokes
are specified for the control of the machine so that the programmed change-over
points also correspond to the actual strokes.
For this reason, it is necessary to set the zero points again every time the mold is
changed.
Perform the zero point calibration using the "Machine calibration" (see fig. 7.32,
page 7-352) screen.
I
Note
Zero points are not taken over into the data record.
Zero positions of machine

• Mold closed
• Hydraulic ejector in mechanical limit position.
• Injection unit forward, nozzle making contact with mold
MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-351
7.17.2 Setting position transducer zero points

Prerequisites
• Movable mold clamping platen moved back.
• Hydraulic ejector in mechanical limit position.
• New mold inserted and attached to fixed mold clamping platen.
• Input authorization granted
Input procedure
2
3
4
Fig. 7.32 Machine calibration

1 Selection of "Setting position transducer zero points" 3 "Setting clamping unit zero point" pushbutton
MX_MC6_V1.9_07.09.15_ENG
2 "Setting ejector zero-point" pushbutton 4 "Setting zero point injection unit" pushbutton
©KM
1) Switch to screen page "Machine calibration".

2) In the "Setting position transducer zero points" selection menu (1, fig. 7.32),
select "Manual".
The following pushbuttons are displayed to set the zero points:
• Setting ejector zero point
• Setting clamping unit zero point
• Setting injection unit zero point
7-352 Commissioning
W
Important
Zero points can be set independently of one another.
To enter the zero points, switch the "Setting stroke encoder zero points"
program to "off".
7.17.2.1 Hydraulic ejector calibration

1) Operate the "Ejector back movement" button to move the hydraulic ejector
into the mechanical limit position.
2) Press the pushbutton for the ejector (2, fig. 7.32).
The zero point for ejector is stored.
W
Important
If the hydraulic ejector was previously moved to the limit position, it is not
necessary to re-specify the zero point.
If the hydraulic ejector is to be coupled with the mold ejector platen, then, after
setting the clamping unit zero point and the attachment of the movable mold
part:
• the mold should be opened,
• the ejector moved forward, coupled, retracted, and
• the zero point then set.
7.17.2.2 Calibration of clamping unit
Clamping unit zero-point calibration

1) Operate the "Mold closing" button to move the movable mold platen forward
until the mold is closed and the movable mold platen is touching the mold.
2) Actuate the pushbutton for the clamping unit (3, fig. 7.32).
The zero point for the clamping unit is stored.
Stroke limitation during mold change
I
Note
If the opening stroke cannot be reached with a newly installed, larger mold, it
will be limited automatically during adjustment.
MX_MC6_V1.9_07.09.15_ENG
A note appears on the screen indicating that strokes are limited automatically.
©KM
The Events log (see section 8.17.3, page 8-675) lists the limited strokes.
Commissioning 7-353
7.17.2.3 Calibration of injection unit

1) Press the "Injection unit forward" button in order to move the injection unit
forward until the nozzle is touching the mold.
2) Actuate the pushbutton for the injection unit (4, fig. 7.32).
The zero point for the injection unit is thus stored.
7.17.2.4 Calibration of mold venting (ZE)

1) Perform calibration of the clamping unit (see section 7.17.2.2, page 7-353).
2) Actuate the pushbutton for Mold breathing.
The zero point for mold venting is stored.
7.17.2.5 Completion of calibration

Zero points that have been set become effective in the control system only when
the "Setting stroke encoder zero points" program has been switched off.
1) In the selection menu "Setting stroke encoder zero points" (1, fig. 7.32), select
"off".
All the zero-points stored are transferred to the control system.
2) Perform machine optimization or read in existing program.
MX_MC6_V1.9_07.09.15_ENG
©KM
7-354 Commissioning
7.18 Starting the machine

1) Ensure that all the sliding surfaces on the clamping unit and injection unit are
cleaned and free of corrosion protective agents.
2) Ensure that the supplies listed below are connected and switched on:
• Electricity supply
• Compressed air supply for the pneumatic valves if necessary
• Cooling water supply for barrel flange cooling, hydraulic oil cooling and, if
fitted, mold cooling.
3) Ensure that the mold is installed.
4) Ensure that the material conveyor is ready and is in the filling position.
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Risk of slipping
There is a risk of slipping on granulate which has spilt.
Eliminate any spilt granulate immediately.
5) Ensure that safety gate and nozzle guard are closed.

6) If necessary, open shut-off valves for feed and return flow at connection of
cooling water supply.
8) Switch on pump motor, mold heating, mold temperature control, barrel
heating and, if fitted, robot operating mode as well as switching functions
1 to 3.
MX_MC6_V1.9_07.09.15_ENG
©KM
Commissioning 7-355
9) Check "Alarm overview" screen for alarm messages and rectify any faults
which exist.
10) Ensure that all heating bands of the screw barrel are cleaned and free of any
deposits (plastic, cloths, etc.).
W
Important
Carry out the next steps only after alarm A00642 "Hydraulic oil temperature
min./max." disappears from the display.
MX_MC6_V1.9_07.09.15_ENG
©KM
11) Inspect the safety devices (see section 1.5, page 1-92).
12) Carry out optimization of the melt as follows:
a) Position collecting vessel in the area of the nozzle opening.
b) Select setting mode.
c) Operate "Injection" and "Plasticizing" button alternately and continue

repeating until the melt flows out free of bubbles and without any
discolouration.
13) Perform machine optimization.
7-356 Commissioning
8 Operation of Machine
This chapter describes all the functions required for machine setting on the
monitor. The settings and parameters used here are examples intended to
illustrate the machine functions.
8.1 Safety precautions for operation . . . . . . . . . . . . . . . 358

the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
8.3 User login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
8.4 Menu functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
8.5 Help menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
8.6 Process designer . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
8.7 Mold/Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
8.8 Core-pulling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
8.9 Injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
8.10 Barrel temperatures . . . . . . . . . . . . . . . . . . . . . . . . . 531
8.11 Mold temperatures (ZE) . . . . . . . . . . . . . . . . . . . . . . 554
8.12 Tolerance monitoring . . . . . . . . . . . . . . . . . . . . . . . . 584
8.13 Cycle/Times overview . . . . . . . . . . . . . . . . . . . . . . . . 600
8.14 Machine preparation . . . . . . . . . . . . . . . . . . . . . . . . . 628
8.15 Peripherals (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
8.16 Configuration/Diagnosis . . . . . . . . . . . . . . . . . . . . . 654

MX_MC6_V1.9_07.09.15_ENG
8.17 Alarms/Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672

©KM
8.18 Notebook (ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
Operation of Machine 8-357

8.1 Safety precautions for operation
e
d
D
Hazard from electrical current
r
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Risk of slipping
medium.
responsible manner.
S
d
D
Risk of spraying
Mold temperature controllers as well as the connecting lines to the mold carry
hot fluids, which may be pressurized. This is also possible when the heat-
balancing units are switched off.
There is a danger of injury through burning.
• Never carry out work on mold temperature controllers when they are hot,
or release the connecting lines.
• Allow heat-balancing units to cool down to a harmless temperature.
b
B
When operating machine, hazardous situations may arise that may result in
injury.
When carrying out such work, always wear protective clothing conforming with
currently valid accident prevention regulations (e.g. safety shoes, protective
gloves, etc.).
MX_MC6_V1.9_07.09.15_ENG
©KM
w
D
Caution - adopt the correct procedure.
Incorrect operation of the machine may result in hazardous situations.
Observe the instructions in this chapter.
Observe the applicable safety regulations at the place of work.
8-358 Operation of Machine

L
p
R
Prohibition of people wearing pacemakers
persons fitted with heart pacemakers. Such persons must not enter the work
area.
W
Important
The setting value examples on the screens are for explanatory purposes only.
In concrete cases, the exact setting values must be obtained from the machine
configuration data.
W
Important
Touch the touchscreen with a special operating pen or (clean) finger. Do not
use sharp or metallic objects.
For your daily safety

• Intervention in the machine impossible at all sides?
• Limit switch at safety gate operational?
• Safety strip at safety gate operational?
• Stops and guides of safety gate operational?
• Step board protection operational?
• Light barrier/curtains, if fitted, operational?
• Heating matched to plastic to be processed?
• Injection molding machine free of oil and water leaks?
• Place of work free of stumbling points, granulate and other impurities?

MX_MC6_V1.9_07.09.15_ENG
©KM

8.3 User login

With the "User login" button in the header bar of the operating/display panel, the
functions for all user settings can be accessed. Pressing the button opens a pop-
up menu for password entry (see fig. 8.1, page 8-360). The buttons contained
within it lead to more pop-up menus in which the selection of display settings, user
data, access rights and language can be made.
Password input / input authorization
1 2 3 4 5 6

1 "Units - setting" button 6 "Language" button 3)
2 "User data" button 1) 7 "x" button (abort)
3 "Access rights" button 1) 8 "Enter" button (confirmation)
4 "Program chip card" button 1) 2) 9 Input field
5 "Login settings" button
1) The button is only displayed to users from key group 4 onwards.
2) Program the chip card (see section 12.2.3, page 12-828).
3)
The button is only displayed to users in key groups 1 to 3 or with chip card access activated (see section 12.2.3, page 12-828) for all key groups.
MX_MC6_V1.9_07.09.15_ENG
Control system data can only be changed with the required input authorization.
©KM

The keypad "Login: password" appears (see Fig. 8.1).
Operating the alphanumeric keypad (see section 6.3.3.2, page 6-248).
2) Enter a defined password in the input field (9, fig. 8.1).
I
Note
For management of user data / assignment of passwords (see section 8.3.1,
page 8-362).
3) Press the "Enter" button (8, fig. 8.1) to confirm password input.
The keypad "Login: password" closes automatically.
The assigned user and rights are activated.
On the "User login" button, users are shown their key group and the national
flag matching the set language.
I
Note
To cancel input authorization in the keypad "Login: password" (see fig. 8.1,
page 8-360), press the "Enter" (8, fig. 8.1) button only.
Input authorization with chip card

The input authorization is granted when the chip card is inserted into the chip card
reader (see section 12.2, page 12-825).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.3.1 User data
I
Note
The screen and its functions can only be accessed with key group 4 and 6.
In the pop-up window "List of users" (see fig. 8.2, page 8-362), user data can be
entered and changed. It is protected by passwords.
User data is composed as follows:
• User number
• User name
• Key group
• Language (ISO3)
• Password (locked)
1
5 2
4 3
Fig. 8.2 List of users

MX_MC6_V1.9_07.09.15_ENG
1 "Create new user" button 4 Key group (No.)

2 "Delete user" button 5 User number (No.)
©KM
3 "Editing" button (edit user)

The keys are used to enable or disable screens and functions related to display
or setting. The respective keys are combined into key groups and are assigned to
the user.
Existing users and key groups can be edited and new ones created.
The numbers 0 to 9 are defined for users and key group with the same name
(visible and hidden), which cannot be deleted, or only have to be edited to a
limited extent:
0 = No authorization
1 = Operator
2 = Setter
3 = Setter with control panel
4 = Production manager
5 = Service
6 = Commissioning (additional authentication required)
7 = Maintenance
8 = Measuring technology (additional authentication required)
9 = Development (additional authentication required)
MX_MC6_V1.9_07.09.15_ENG
©KM

8.3.1.1 Creating new user

2) Press the "User data" button
The "List of users" pop-up menu opens (see fig. 8.2, page 8-362).
3) Press the "Create new user" button (1, fig. 8.2).
The keypad "Input of user number" opens.
4) Enter the user number in the input field and press the "Enter" button to
confirm.
The keypad closes automatically.
The "Input of user data" pop-up menu opens (see fig. 8.3, page 8-364).
1
2
3
4
5
Fig. 8.3 Input of user data

1 User number 5 Password 1)
2 User name 6 "Language" button
3 Input of key group 7 "OK" button
4 Password invalid with chip card
1) If a new user is created with activated chip card, the password can be omitted as an option by activating the tickbox "Password invalid for chip card!" (4). Subsequent access is then
only possible via chip card (see section 12.2.3.4, page 12-833)!
5) Press the "User name" (2, fig. 8.3) input field. Enter the user name in the
MX_MC6_V1.9_07.09.15_ENG
keypad and press the "Enter" button to confirm.

©KM
6) Press the "Input of key group" (3) input field.

The pop-up menu "Selection of key group" opens (see fig. 8.4, page 8-365).

Fig. 8.4 Selection of key group

1 "OK" button
7) Selecting key group:

• Assigning existing key group:
Press the line of the desired key group and press the "OK" (1, fig. 8.4)
button to confirm.
The pop-up menu "Selection of key group" closes automatically.
• Create a new key group (see section 8.3.1.4, page 8-368).
8) Via the tickbox "Password invalid with chip card" (4, fig. 8.3), define the
invalidity of the password with inserted chip card:
• With the tickbox activated, the password is ignored if a user logs in via
chip card.
• With the tickbox deactivated, a password has to be entered even if a user
logs in with a chip card.
9) Press the "Password" (5) input field in the pop-up window "Input of user data".
Enter the desired password in the keypad and press the "Enter" button to
confirm.
MX_MC6_V1.9_07.09.15_ENG
©KM

10) Press the "Language" (6, fig. 8.3) button.

The pop-up window for language selection opens (see fig. 8.5, page 8-366).
I
Note
The languages available for selection depend on the options ordered with the
machine.
Fig. 8.5 Selection of language
11) Select the desired language by pressing the corresponding button.

The pop-up menu closes automatically.
The language is changed over after the next login.
12) Press the "OK" (7, fig. 8.3) button in the pop-up menu "Input of user data".
The pop-up window "List of users" (see fig. 8.2, page 8-362) displays the
newly created user. The user can log in with immediate effect with the
password assigned in work step 9.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.3.1.2 Editing existing users

3) Press the "Edit" (3, fig. 8.2) button in the line of the desired user.
4) Edit user data (user name, key group, password, language). Perform work
steps 5 to 10 (see Section 8.3.1.1) when doing this.
I
Note
• The user number cannot be altered.
• It has to be entered again even if the password remains the same.
The changed user data can be adopted.
8.3.1.3 Deleting existing user

3) Select the line of the desired user.
4) Press the "Delete user" (2, fig. 8.2) button.
A pop-up window with a safety prompt opens.
5) Press the "Yes" button to confirm the pop-up window.
The user is deleted.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.3.1.4 Creating a new key group

3) Creating/editing user:
• Edit existing user: press the "Edit" (3, fig. 8.2) button in the line of the
desired user.
• Creating new user: press the "Create new user" (1, fig. 8.2) button.
Perform work steps 4 to 5 (see Section 8.3.1.1).
Fig. 8.6 Input of user data

1 Input of key group
4) Press the "Input of key group" (1, fig. 8.6) input field.
The pop-up menu "Selection of key group" opens (see fig. 8.7, page 8-369). MX_MC6_V1.9_07.09.15_ENG
©KM

7 1
6 2
3
5

1 "Create new key group" button 5 Key
2 Button "Delete key group" 6 Name of key group
3 Button "Edit" (editing key group) 7 Number of key group (No.)
4 "OK" button
5) "Create new key group" (1, fig. 8.7) button.

The keypad "Input of key group" opens.
6) Enter the number of key group in the input field and press the "Enter" button
to confirm.
The pop-up menu "Input of key group" opens (see fig. 8.8, page 8-370).
MX_MC6_V1.9_07.09.15_ENG
©KM

1
2
6 3
5
Fig. 8.8 Input of key group

1 Number of key group 4 "OK" button
2 Name of key group 5 Key name
3 Tickboxes for key 6 Key number (No.)
7) Press the "Name of key group" (2, fig. 8.8) input field. Enter the name of the
key group in the keypad and press the "Enter" button to confirm.
8) Define the keys (access rights) by corresponding selection of the
tickboxes (3).
9) Press the "OK" (4) button.
The newly created key group is displayed in the pop-up window "Selection of
key group" (see fig. 8.7, page 8-369).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.3.1.5 Editing existing key group
I
Note
Key groups 5, 6, 8 and 9 cannot be changed.
1) Perform work steps 1 to 4 (see Section 8.3.1.4).

2) Press the "Edit" (3, fig. 8.7) button in the line of the desired key group.
The pop-up menu "Input of key group" opens (see fig. 8.8, page 8-370).
3) Define the access rights by corresponding selection of the tickboxes
(3, fig. 8.8).
I
Note
The number and name of the key group cannot be changed.
4) Press the "OK" (4, fig. 8.8) button.

The changed key data is adopted.
8.3.1.6 Deleting existing key group
I
Note
Key groups 3, 4, 5, 6, 8 and 9 cannot be changed.
1) Perform work steps 1 to 4 (see Section 8.3.1.4).

2) Select line of the desired key group.
3) Press the "Delete key group" (2, fig. 8.7) button.
A pop-up window with a safety prompt opens.
MX_MC6_V1.9_07.09.15_ENG
4) Press the "Yes" button to confirm the pop-up window.

The selected key group is deleted.
©KM

8.3.2 Access rights to screens
I
Note
The screen and its functions can only be accessed with key group 4 and 6.
In the "Set access to screens" pop-up menu, the rights for screen selection or
parameter input can be defined for the individual key groups.
5 2
4
Fig. 8.9 Set access to screens (operator screen 10)

1 Access authorization for page selection 4 Key group
2 Parameter input access rights 5 Access enabled
3 "Default settings" button
MX_MC6_V1.9_07.09.15_ENG
©KM

Setting access
1) Select the desired screen on the operating/display panel.
3) Press the "Access rights" (3, fig. 8.1) button.
The pop-up window for setting the access rights opens (see fig. 8.9,
page 8-372).
4) By selecting the tickboxes, the access levels for the rights for screen selection
and parameter input for the selected screen can be defined for the individual
key groups.
I
Note
With access authorization activated, the screen selection or parameter input is
enabled automatically for the respective higher key groups.
Default settings
Press the "Default settings" (3, fig. 8.9) button to reset the access rights for all
screens to the ex-works setting.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.3.3 Login settings

In the "Settings" pop-up window, the currently logged in user can make login-
related settings.
Fig. 8.10 Login settings

1 "Automatic reset after specified time" tickbox 4 "Reset of robot variables after loading data record" tickbox
2 "Time for resetting access in minutes" input field 5 "Synchronous robot change-over of screens and machine
3 "Remember last selected screen page" tickbox buttons" tickbox
Defining settings
2) Press the "Login settings" (5, fig. 8.1) button.
MX_MC6_V1.9_07.09.15_ENG
The pop-up window for setting the login opens (see fig. 8.10, page 8-374).
3) By selecting the tickboxes and parameter input, the login settings can be
©KM
made for the currently logged in user.

Automatic reset after specified time

When the function "Automatic reset after specified time" is activated, the currently
logged in user is logged out after a specified time has elapsed. The time is defined
in the input field "Time for resetting access in minutes" (2, fig. 8.10).
Last selected screen page

If the setting "Remember last selected screen page" is activated, the screen page
selected when the user logged off appears as first screen page the next time the
user logs on.
Reset of robot variables after loading data record

When this tickbox is selected, the robot variables are reset after a data record
(see section 8.4.3, page 8-388) has been loaded.
Synchronous robot change-over of screens and machine buttons

When this tickbox is selected, if a hand-held unit is used the screen pages of both
operating devices are changed over synchronously.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.3.4 Language selection
8.3.4.1 Users in key groups 1 to 3

For users in key groups 1 to 3 or with activated chip card access
(see section 12.2.3, page 12-828) for all key groups the selection of the language
is made with the separate button "Language" (6, fig. 8.1) in the keypad "Login:
password" (see fig. 8.1, page 8-360).
The pop-up window for language selection opens.
3) Select the desired language by pressing the corresponding button
(see fig. 8.11, page 8-376).
The language now changes over.
I
Note
MX_MC6_V1.9_07.09.15_ENG
machine.
©KM

8.3.4.2 Users from key group 4 onwards

For user as of key group 4, the language selection is made by editing the user
data ("Editing existing users", also see section 8.3.1.2).
3) Press the "Edit" (3, fig. 8.2) button in the line of the desired user. The "Input
of user data" pop-up menu opens (see fig. 8.3, page 8-364).
The pop-up window for language selection opens (see fig. 8.12, page 8-377).
I
Note
machine.

MX_MC6_V1.9_07.09.15_ENG
©KM

The language now changes over.
In the pop-up window "List of users" (see fig. 8.2, page 8-362), the national
flag of the set language is displayed beside the user name.
7) Close the pop-up window "List of user". To do this, press the "x" button.

8) Close the keypad "Login: password" (see fig. 8.1, page 8-360). To do this,
press the "x" button.
I
Note
The language is not switched over until the user logs in again (see fig. 8.3,
page 8-360).
8.3.5 Units - setting

In the pop-up window, you can make language-specific and general settings and
define physical measuring units.
I
Note
Changes to the language-specific units are saved with the currently set
language.
Language-specific units include:
• Date format MM/DD/YY
• Decimal point instead of comma
• Physical units in US format
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 8.13 Units - setting
2) Press the "Units - setting" (1, fig. 8.1) button.
The pop-up window for setting the date format and measuring units opens.
3) The tickboxes can be used to make settings for output in the screens.

Date format MM⁄DD⁄YY

If selected, the date output on the screen will switch from DD⁄MM⁄YY to the
MM⁄DD⁄YY format.
Decimal point instead of comma

If selected, numerical values on all screens will be separated with decimal points
instead of a comma.
Physical units in US format

If selected, physical units will be output to all affected screens in US format.
Units of injection pressure as hydraulic pressures

When this is selected, the melt pressure [bar] is converted into hydraulic pressure
[bar*] on all screens concerned.
The melt pressure is used as the default setting and can be converted into
hydraulic pressure.
I
Note
To set machines and pumps during commissioning, the selection of the units of
injection pressure as hydraulic pressures is required!
Units of plasticizing as peripheral velocities

When this is selected, the plasticizing unit of the screw rotation is switched from
rotational speed [1 rpm] to peripheral velocity [mm⁄s] on all screens.
Units of injection as volumes and volumetric flow rates

If this is selected, the units of injection are converted from strokes [mm] and
velocity [mm⁄s] of the screw to volume [cm3] and volume flow [cm3⁄s] of the screw.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.4 Menu functions

With the "Menu functions" button in the header bar of the operating/display panel,
the main functions for all screens and their parameters can be accessed.
Pressing the button opens a pop-up menu. The pop-up menu contains buttons
which lead to more screens and pop-up windows with the corresponding
functions.
1 2 3 4
5 6 7 8 9
Fig. 8.14 Menu functions, pop-ups

1 "I/O" button 6 Diagnostic files, copying onto USB stick
2 Hard copy 7 Touch calibration
3 Data record loading/saving 8 System settings
4 Network settings 9 Upkeep
5 Screen cleaning
MX_MC6_V1.9_07.09.15_ENG
©KM

8.4.1 Switch functions

Pressing the "I/O" button" opens a pop-up window in which, with appropriate
machine equipment, the following functions can be turned on and off with the
screen button:
• Robot mode of operation
• Switch function 1/2/3 (assigned on a job-specific basis)
• Alarm bypass
1
2
Fig. 8.15 Switch function

1 Ignore alarms in setting mode (except for machine safety-related) 2 Test cycle without injection
MX_MC6_V1.9_07.09.15_ENG
©KM

Alarm bypass
W
Important
• Alarm bypass is only possible in setting mode.
• Alarm bypass does not apply to safety devices.
Selecting the alarm bypass (1, fig. 8.15) causes pending alarms, which lead to
the machine being switched off, to be ignored. This means the alarm bypass is
switched on and off.
The pump motor can be switched on for 5 min in order to move the machine via
the machine operating buttons. Machine functions can then be executed without
setting zero points.
Test cycle without injection
MX_MC6_V1.9_07.09.15_ENG
©KM

8.4.2 Create hard copy

Press the "Hard copy" button to make a hard copy of the display screen. Output
is via the USB port onto a USB stick (see section 8.4.2.1, page 8-384).
Fig. 8.16 Hard copy

1 "System settings" button 3 Button "Output as bitmap on USB stick"
MX_MC6_V1.9_07.09.15_ENG
2 Button "Output as print file on USB stick"

©KM
I
Note
The creation of a hard copy by means of the menu function in the header bar
(see fig. 8.14, page 8-380) is only possible for screens that are not covered by
a pop-up window.
"Hard copy for pop-up window" (see section 8.4.2.4, page 8-387).

8.4.2.1 System settings

Presettings for the "Hard Copy" function are made in the pop-up window "System
settings".
Fig. 8.17 System settings

1 "Printer setting" button 3 Display format bmp/jpg/png
2 Display setting: hard copy backed up on external
medium
Printer setting
The "Printer setting" button (1, fig. 8.17) is used to call up the printer options for
output as a print file on a USB stick (see section 8.4.2.2, page 8-385).
Display setting: hard copy backed up on external medium

With the tickbox selected (2), filing of a hard copy as a bitmap (bmp, jpg, png)on
the external medium is indicted by an additional message.
Display format
By selecting a tickbox (3), the file format can be defined for output as a bitmap on
a USB stick.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.4.2.2 Printer setting

The "Printer setting" button (1, fig. 8.17) is used to call up the printer options for
output as a print file on a USB stick.
7
6
5
1
4
Fig. 8.18 Printer setting

1 Print preview 5 Page orientation
2 Page display, forward/back buttons 6 Page size
3 Settings for "Page header" / "Page footer" 7 Printer name
4 Edge distances (left/right/top/bottom edge)
MX_MC6_V1.9_07.09.15_ENG
©KM

8.4.2.3 Screen output of hard copy
Output as bitmap on USB stick

1) Insert USB stick into USB port.
2) Press the "Menu functions" button.
3) Press the "Hard copy" button.
The "Hard copy" pop-up window (see fig. 8.16, page 8-383) opens.
4) If necessary, configure data output:
a) Press the "System settings" (1, fig. 8.16) button.
b) In the opened pop-up window (see fig. 8.17, page 8-384), select the
desired file format (bmp, jpg, png).
c) Close the "System settings" pop-up window.
5) Press the button "Output as bitmap on USB stick" (3, fig. 8.16).
The displayed screen is stored on the USB stick in the selected file format.
Output as print file on USB stick

2) Press the "Menu functions" button.
4) Configure the printer setting if necessary:
b) Press the "Printer setting" (1, fig. 8.17) button in the opened pop-up
window.
c) Set the printer options (see section 8.4.2.2, page 8-385) in the opened
pop-up window.
d) Close the "Printer setting" pop-up window.
e) Close the "System settings" pop-up window.
5) Press the button "Output as print file on USB stick" (2, fig. 8.16).
The displayed screen is saved as a print file with the selected printer setting
(e.g. in "xps" format) (see fig. 8.18, page 8-385) on USB stick.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.4.2.4 Hard copy for pop-up window

Some pop-up windows provide an option for a hard copy. These pop-up windows
contain the "Hard Copy" button.
Output as bitmap on USB stick

3) If necessary, configure data output:
b) In the opened pop-up window (see fig. 8.17, page 8-384), select the
desired file format (bmp, jpg, png).
c) Close the "System settings" pop-up window.
4) Press the button "Output as bitmap on USB stick" (3, fig. 8.16).
The displayed screen is stored on the USB stick in the selected file format.
Output as print file on USB stick

3) Configure the printer setting if necessary:
b) Press the "Printer setting" (1, fig. 8.17) button in the opened pop-up
window.
c) Set the printer options (see section 8.4.2.2, page 8-385) in the opened
pop-up window.
d) Close the "Printer setting" pop-up window.
e) Close the "System settings" pop-up window.
4) Press the button "Output as print file on USB stick" (2, fig. 8.16).
The displayed screen is saved as a print file with the selected printer setting
(e.g. in "xps" format) (see fig. 8.18, page 8-385) on USB stick.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.4.3 Data record loading/saving

The control and operating data is saved on a Compact Flash.
The set-value data and tolerances you entered can be saved as a complete data
record (mold and robot data record, where applicable) on the Compact Flash. The
data records can be imported selectively according to components (3, fig. 8.19).
Furthermore, it is possible to exchange data records with a USB stick.
1
2
3
4
5
6
12
7
8
9
10
11
Fig. 8.19 Data record

1 "Data carrier" selection menu 7 "Read in data record" pushbutton
2 Importing data record selection 8 "Save data record" pushbutton
3 Component selection 9 "Delete data record" pushbutton
MX_MC6_V1.9_07.09.15_ENG
4 Data record 10 "Target data carrier" selection menu

5 Data record title 11 "Copy data record" pushbutton
©KM
6 "Data records index" pushbutton 12 List of contents
I
Note
For maximum safety, it is advisable to save the data additionally on a USB
stick.

Data carrier
In the selection menu (1, fig. 8.19), the corresponding data carrier from/to which
the required data records are to be loaded/saved can be selected.
Importing data record selection

An indication is provided in the tickbox (2) as to whether the data record contains
machine data (mold data record), robot data, or both.
For importing, the data record must either be selected in the list of contents (12)
or the name (5) must be entered directly.
Data record
If a data record is loaded for the mold of the injection molding machine or the
robot, the name of the selected data record (4) is displayed in the respective field.
Data record title

To save a data record, a name (5) can be entered.
If data records have already been stored on a medium, you can accept an existing
data record title after selecting it from the list of contents (12).
For the functions "Import/save/delete data record" (7/8/9/11), entry of a record
name (5) is required. This can be done by entering it or by selecting it from the list
of contents (12).
Data records index

After actuation of the pushbutton (6), a list of available data records is created in
the list of contents (12) and displayed with corresponding symbols.
Importing data record
I
Note
• When a mold is changed, the machine must be calibrated before a data
record is read in.
Information on installing mold (see section 7.16, page 7-348).
• A data record can only be read-in in the setting mode.
• Before a data record is read in, the data record currently effective in the
control system should be saved.
MX_MC6_V1.9_07.09.15_ENG
By pressing the "Read in data record" pushbutton (7), the data record selected in
the "Data record title" field (5) is transferred to the control system.
©KM
Before the current data record in the control system is overwritten, overwriting
must be confirmed in the message box.

Save data record
I
Note
If the machine is set up for production, the data record should be saved.
After entering a data record name (5, fig. 8.19), a data record in the control
system can be saved by pressing the "Save data record" (8) pushbutton.
Enter another name or confirm overwriting if the data record title already exists.
Delete data record

After entering a data record name, a data record in the control system can be
deleted by pressing the "Delete data record" (9) pushbutton.
Deletion must be confirmed in the message box before the data record is erased.
Target data carrier

In the selection menu (10), the corresponding data carrier from/to which the
required data records are to be saved/copied can be selected.
Copying data record

After entering a data record name, a data record in the control system can be
copied by pressing the "Copy data record" (11) on the target data carrier (10).
If the name of the data record already exists, you must confirm in the message
box that the data record is to be overwritten.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.4.4 Screen cleaning
Fig. 8.20 Screen cleaning

1 Cleaning time for Touch 2 "Start" pushbutton
1) Enter cleaning time (1, fig. 8.20).

2) Press Start pushbutton (2).
The screen is dimmed for the entered time period (1).
3) Cleaning the touch surface:
• The touch surface of the operating/display panel must only be cleaned
with a damp, soft cloth.
• Only use monitor cleaning agents to moisten the cloth, e.g. antistatic foam
cleaners, water with washing-up liquid or alcohol.
I
Note
Do not use caustic cleaning agents, chemicals, scouring agents or hard objects
that could damage to touch surface.
• Do not apply the cleaning agent directly onto the screen surface but spray
it on the cloth. When cleaning, prevent cleaning agent from penetrating
the electronics, e.g. through the ventilation slots on the housing of the
operating panel.
W
MX_MC6_V1.9_07.09.15_ENG
Important
©KM
Clean the touch surface at regular intervals to remove contamination. In the

case of contamination with toxic or caustic chemicals, carefully clean the touch
surface immediately to prevent chemical burns.

8.4.5 Diagnostic files, copying onto USB stick

For service purposes, the Start pushbutton (1, fig. 8.21) can be pressed to copy
diagnostic files onto a USB stick.
Fig. 8.21 Diagnostic files, copying onto USB stick

1 "Start" pushbutton
MX_MC6_V1.9_07.09.15_ENG
©KM

8.4.6 Display calibration
I
Note
Calibration of the touch display must be carried out in accordance with the
calibration instructions from KraussMaffei!
Calibration of the touch display is only possible with key group 5 and 6
possible.
Press the "Calibration" button in the menu functions of the operating/display panel
to select the calibration of the touch display.
When the button is pressed, the "Touch calibration" pop-up menu appears:
Fig. 8.22 Touch calibration, pop-up window
Procedure
1) Press the "Yes" button to confirm and to start the calibration tool. (The
procedure is cancelled by pressing the "No" button.) On the display, at least
4 calibration points appear one after the other.
2) Proceed as follows for each of the calibration points:
MX_MC6_V1.9_07.09.15_ENG
a) Use the operating pin to touch the middle circle and hold it in.
The surrounding marking contracts and the text "Release" is displayed.
©KM
b) Correct pressure point if necessary.

c) Release pressure point.
The position of the calibration point is saved.

3) The calibration positions are saved. Note is displayed.
Fig. 8.23 Touch calibration, note
I
Note
Do not touch the screen during the saving process!
4) The calibration is complete after the saving process. The screen page
(see fig. 8.23, page 8-394) is closed automatically.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.4.7 System settings

Press the "system settings" button in the menu functions of the operating/display
panel to select the screen saving function of the touch display.
When the button is pressed, the "System settings" pop-up window appears.
1
2
Fig. 8.24 System settings, pop-up window

1 Tickbox "Screen saving" 2 Set value "Time for screen saving"
Screen saving
Via the "Screen saving" (1, fig. 8.24) tickbox, the screen saving function is
activated after a defined time has elapsed.
Time for screen saving

The time after which the screen saving function is activated is set via the input
field "Time for screen saving" (2).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.4.8 Upkeep
The "Upkeep" button in the menu functions of the operating/display panel is used
to define the deletion of temporary directories in the system.
When the button is pressed, the "Upkeep" pop-up window appears.
Fig. 8.25 Upkeep, pop-up window

1 Selection field "Delete temporary directories" 3 Pushbutton "Run"
2 Tickbox "Delete temporary directories"
Deleting temporary directories

MX_MC6_V1.9_07.09.15_ENG
A prerequisite for the deletion of the temporary directories is the selection "Delete
©KM
temporary directories" via the selection field (1, fig. 8.25) and the selection in the
tickbox (2). When the "Run" pushbutton is actuated, deleting of the temporary
directories is triggered.

8.5 Help menu

Via the "?" button in the header in the operating/display panel all help functions
for displaying PDF documents, symbol legends and alarm information can be
accessed. Pressing the button opens a pop-up menu. The pop-up menu contains
buttons which lead to more pop-up windows with the corresponding help displays.
1 2 3
Fig. 8.26 Help menu ("?")

1 Displaying a PDF document 3 Alarm information
2 Symbol explanation
MX_MC6_V1.9_07.09.15_ENG
©KM

8.5.1 Displaying a PDF document
4
7 5
Fig. 8.27 PDF display

1 "Load PDF file" button 5 Button for switching to entered page
2 Scroll up/down in document 6 Zoom document view out/in
3 Jump to beginning/end of document 7 Display area for imported PDF document
MX_MC6_V1.9_07.09.15_ENG
4 Input field for page selection

©KM
1) Press the "?" button in the header bar of the operating/display panel.
A pop-up menu with additional help buttons is called up.
2) Press the "PDF" button.
The pop-up menu for PDF display opens (see fig. 8.27, page 8-398).
3) Press the "Load PDF file" (1, fig. 8.27) button.
The pop-up menu for selecting the PDF file opens (see fig. 8.28, page 8-399).

1
2
3
4
Fig. 8.28 Selecting PDF file

1 Data carrier selection menu 4 "Copy PDF file" pushbutton
2 Selectable files 5 "Delete PDF file" pushbutton
3 "Load PDF file" pushbutton
4) In the selection menu (1, fig. 8.28), select the required data carrier.
A list of selectable PDF files (2) is displayed.
I
Note
When displaying a file from the USB stick:
• The USB stick must have a name.
Otherwise it is available in the selection menu but not visible.
• The PDF file to be displayed must be filed in a folder with the name
"PdfFiles" directly on the USB stick.
MX_MC6_V1.9_07.09.15_ENG
©KM
5) Select the PDF file in the list and press the "Load PDF file" pushbutton to load
it.
The document is opened in the "PDF display" window (see fig. 8.27,
page 8-398).

8.5.2 Symbol explanation

On screens that use special symbols, a symbol legend can be called up for
explanation purposes.
Press the "Symbol legend" button in the Help menu and a pop-up window
appears listing all possible symbols with their definition.
Depending on the selected screen, a symbol legend can be displayed for:

• Pneumatic valves (see section 8.7.4.1, page 8-449)
• Cascade control (see section 8.9.5.5, page 8-519)
• Water manifold (see section 8.11.5.2, page 8-574)
• Status and fault messages for:
– Barrel temperatures (see section 8.10.3.1, page 8-547)
– Mold temperatures (see section 8.11.1.1, page 8-557)
– Heating circuit monitoring (see section 8.11.4.2, page 8-570)
– Mold temperature controllers (see section 8.11.6.6, page 8-580)
– Events log (see section 8.17.3.1, page 8-677)
MX_MC6_V1.9_07.09.15_ENG
©KM

8.5.3 Alarm information

The pop-up window lists all possible alarms in accordance with their numbering.
The display is for information purposes only, i.e. there does not have to be an
alarm pending.
Fig. 8.29 Alarm information

1 "Alarm description" notes field
Press a line (1, fig. 8.29) in Alarm information and a field opens below it, which
provides an explanation of the alarm.
Sorting
MX_MC6_V1.9_07.09.15_ENG
The table can be sorted in both columns – ascending or descending as required.

• When the "No." header is pressed, the alarms are arranged according to their
©KM
alarm number.
• When the "Explanation" header is pressed, the alarms are arranged
alphabetically according to their designation.

8.6 Process designer
1 2 3 4
11
10
9
8
6
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 8.30 Process designer

1 Tools and navigation buttons 7 Main navigation for process designer (main key)
2 Main cycle steps 8 Docking point
3 Core-pulling cycle steps 9 Cycle step/node (selected)
4 Library 10 "Open detail view" button
5 Detail view of the selected cycle step 11 "Editing mode" button
6 Detail button
Colour scheme of cycle steps/nodes (see section 6.3.10.2, page 6-265).

The process designer selected via the main navigation (7, fig. 8.30) opens a
display for the entire machine cycle (main cycle (2) and accessory programs, for
example core-pulling (3)).
As the complete cycle sequence cannot be displayed in full on the screen section,
navigation is possible using the navigation buttons (see section 6.3.2.4,
page 6-241) which can be used to adapt the size and position in the screen.
Furthermore, the screen section can be shifted by touch operation within the
display area for the machine cycle (2/3). The scrollbars at the edge of the display
area are for orientation purposes. The Multitouch characteristic of the 24″
Multitouch allows you to zoom the screen section to be displayed by means of
two-finger operation.
In the case of enlargement, an additional pop-up window appears for orientation.

The currently displayed screen section is marked by a black frame. The "Slide"
touch function can be used to alter the position of the black frame within the pop-
up preview window and thus change the screen section to be shown.
Fig. 8.31 Position in the machine cycle

MX_MC6_V1.9_07.09.15_ENG
©KM
Changes in the cycle sequence (see section 8.6.1, page 8-404) are possible by
means of the corresponding editing tools and the detail view created by them in
the lower area of the screen.

I
Note
• The detail view (5, fig. 8.30) provides quick access to the setting
parameters of the selected function in the main cycle.
• The parameter setting of the core-pulling steps (see section 8.8.7,
page 8-467) can be made exclusively via the detail view in the lower screen
area of the process designer!
Individual cycle steps can be moved within the cycle sequence or added from the
library (4, fig. 8.30).
All possible elements for integration in the cycle sequence are in the library. Only
logical options for the insert locations are offered by the labelled dock points (8)
in the machine cycle.
After ending the parameter settings and core-pulling programming, the detail view
(5) is closed again by pressing the Detail button (6).
8.6.1 Changes in the cycle sequence
I
Note
Changes in the process designer are only possible if all three of the following
are true:
• The machine is at a standstill
• The authorization is granted via the corresponding key group
• Setting mode is selected
Editing mode
By pressing the "Editing mode" button, the functions to carry out changes in the
process designer are enabled. Individual cycle steps can be integrated in the
sequence, moved and processed. More settings can be shown and changed with
the buttons "Show core interruptions", "Open detail view" and "Delete step".
Show core interruptions

If a cycle step is selected in the sequence that is interrupted by travelling cores,
all currently pending interruptions in the selected cycle step can be shown in the
MX_MC6_V1.9_07.09.15_ENG
detail view (5, fig. 8.30), by pressing the button "Show core interruptions".
©KM
I
Note
• In the diagrammatic display of the selected cycle step/node, only the first
two programmed interruptions are displayed.
Process designer cycle example (see section 8.6.3, page 8-412).
• Interruptions (see section 8.8.7.1, page 8-469).

Open detail view

If a cycle step is selected in the sequence or the library, a detail view will open in
the lower area of the screen upon pressing the "Open detail view" button
(5, fig. 8.30). In it, the respective screen with settings and core-pulling details are
shown and changes can be configured.
I
Note
• To display the various screens in the lower area of the screen (without
changing settings), the "Open detail view" button can be pressed in all
modes of operation.
• Opening the detail view is also possible by double-clicking on a cycle
step/node.
Delete step
If a step in the machine cycle is selected in editing mode (9), this is deleted by
pressing the "Delete step" in the cycle sequence.
Delete all core steps (with mold opening/closing)

If a core step (3) is selected in editing mode, you can press the "Delete all core
steps" button to delete all existing core steps for "Mold opening" and "Mold
closing" from the cycle sequence.
I
Note
Delete all displayed core steps before programming a new core-pulling
program.
8.6.1.1 Change sequence of the cycle steps

1) Press the "Editing mode" (11, fig. 8.30) button.
2) Select cycle step (9) that should be moved within the cycle.
One or more possible cycle step (9) dock points (8) are set.
3) Press the dock point (8) for the desired location in the cycle.
The cycle step (9) is moved to the selected location in the cycle.
8.6.1.2 Change settings and parameters of individual cycle steps

MX_MC6_V1.9_07.09.15_ENG
1) Select cycle step (9, fig. 8.30).

2) Press the "Open detail view" button (10).
©KM
In the lower area of the screen (5), the respective screen opens.
3) Carry out changes:
• Changing the parameter settings of the main cycle (see Section 8.7
to 8.11).
• Programming core-pulling (see section 8.8.7, page 8-467).
4) After the end of the parameter settings and core-pulling programming, press
the Detail button (6, fig. 8.30).
The detail view (5) in the lower area of the screen is again closed.

8.6.1.3 Insert a new cycle step
4
1
Fig. 8.32 Insert a new cycle step and process designer

1 Multi-select feature, library 3 Docking point
2 Insert a cycle element (selected in the library) 4 "Editing mode" button

2) Use the multi-select feature (1) of the library to select the corresponding
category of the cycle elements (mold, cores MP/FP, injection unit).
3) Select the cycle element (2) in the library that should be integrated in the
cycle.
For the new cycle step, one or multiple possible dock points (3) are set.
MX_MC6_V1.9_07.09.15_ENG
The cycle element (2) from the library is taken up as a step at the selected
©KM
location in the cycle sequence.

8.6.2 Wait function
8.6.2.1 Basic principles of the function

The wait function can be used to interrupt the sequence in the machine cycle with
a wait condition.
2
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 8.33 Process designer - inserting wait function

1 Cycle elements to be inserted 3 Selection of wait categories
2 Detail window for parameterization of the wait function 4 Possible docking points
(example: wait time) 5 Inserted wait function

The desired interruption condition can be parameterized in a detail window of the

wait function (2, fig. 8.33). The machine cycle or machine movement waits at this
position during the sequence until the wait condition has been met.
The wait function is an Interruption which can be inserted before all important
movements in the machine sequence. The machine sequence is interrupted and
the wait condition is shown in the step display.
A total of nine wait functions are possible (1).
In Edit mode of the process designer (see section 8.6.1.3, page 8-406), the
possible interruption points in the machine cycle are displayed as docking points
(4, fig. 8.33).
I
Note
At a possible docking point (4, fig. 8.33), a maximum of three wait functions can
be inserted.
Insertion of a wait function in the machine sequence (see section "Insert a new
cycle step", page 8-406)
8.6.2.2 Wait categories

The interruptions by waiting functions are divided into the following categories
(3, fig. 8.33):
• "No interruption", page 8-408
• "Wait time", page 8-409
• "Robot signals", page 8-410
• "Freely programmable input", page 8-411
No interruption
If the category "No interruption" is selected, the defined wait function is
deactivated.
MX_MC6_V1.9_07.09.15_ENG
©KM

Wait time
1
2
Fig. 8.34 Detail window "Wait time"

1 Selection of the wait category "Wait time" 4 Selection/deselection of operating mode
2 Delay time [s] (fully automatic/semi-automatic/manual mode/setting mode)
3 Activation (continuous signal/pulse)
Delay time
The duration of the wait time is defined in the input field "Delay time" (2, fig. 8.34).
Activation
In the "Activation" (3) selection field, the operator can choose between activation
as a continuous signal or pulse.
Effective in operating mode

The operating mode in which the interruption is to be effective is defined by its
selection or deselection (4).
MX_MC6_V1.9_07.09.15_ENG
©KM

Robot signals
1
5 2
Fig. 8.35 Detail window "Robot signals"

1 Selection of the wait category "Robot signals" 4 Selection/deselection of operating mode (fully automatic/semi-
2 Signal position (= 0/= 1) automatic/manual mode/setting mode)
3 Activation (continuous signal/pulse) 5 Selection of robot signals
Selection of robot signals

The following robot signals (5, fig. 8.35) are available for selection:
• No robot signal
• Operation without robot
• Robot safety position
• Enabling mold closing
• Enable mold fully opened
• Enabling ejector forward
• Enabling ejector return
• Robot signal 1 move cores in
• Robot signal 2 move cores in
• Robot signal 1 move cores out
• Robot signal 2 move cores out
Signal position
In the selection field (2), the operator can choose between the signal position "0"
or "1" for the robot signal.
MX_MC6_V1.9_07.09.15_ENG
Activation
©KM

The operating mode in which the interruption is to be effective is defined by its
selection or deselection (4).

Freely programmable input
1
5 2
Fig. 8.36 Detail window "Freely programmable input"

1 Selection of wait category "Freely programmable input" 4 Selection/deselection of operating mode (fully automatic/semi-
2 Signal position (= 0/= 1) automatic/manual mode/setting mode)
3 Activation (continuous signal/pulse) 5 Selection of inputs
Selection of inputs
Up to nine freely programmable inputs (5, fig. 8.36) can be selected:
• No input
• Input 1
• Input 2
• Input 3
• Input 4
• Input 5
• Input 6
• Input 7
• Input 8
• Input 9
Signal position
In the selection field (2), the operator can choose between the signal position "0"
or "1" for the signal.
MX_MC6_V1.9_07.09.15_ENG
Activation
©KM

The operating mode in which the interruption is to be effective is defined by
its selection or deselection (4).

8.6.3 Cycle example
1 7
8
2 9
10
11
3
12
13
Fig. 8.37 Process designer, cycle example (excerpt)

1 Process start 7 Interruptions to core-pulling
2 Mold closing 8 Core 1 FP hydraulic
3 Clamping force 9 Core 2 FP hydraulic (running parallel to the core
build-up (currently running) step position 8)
4 Drive injection unit forward 10 Core 3 MP hydraulic
5 Injection (interrupted by selected core step 11 Core 1 FP pneumatic
position 12) 12 Core 1 MP hydraulic (selected)
6 Holding pressure 13 Core 2 MP hydraulic
I
Note
The first two interruptions to core-pulling of each cycle step are shown as small
core symbols in the cycle element.
Example: cycle elements (2, 3, 5) in Fig. 8.37.
MX_MC6_V1.9_07.09.15_ENG
©KM
1) The cycle starts (1, fig. 8.37).

2) The cycle step "Mold closing" (2) is interrupted by the three core functions
(8, 9, 10).
3) The "clamping force build-up" (3) is interrupted by the core function (11).
4) The cycle step "injection" (5) is interrupted by the core functions (12) and (13).
5) The cycle is started with the "Holding pressure" function (6) and subsequent
functions.

8.7 Mold/Ejector
All movement-related functions are specified below for:
• the mold
• the hydraulic ejector
• the pneumatic valves
8.7.1 Mold closing/Mold safety
8.7.1.1 Mold closing/Mold safety with limit value profile
1
14
13 2
12 3
11 4
10 5
9
8
6
7
Fig. 8.38 Mold closing/Mold safety with limit value profile

1 Current mold positions 8 Set value for "Opening stroke"
MX_MC6_V1.9_07.09.15_ENG
2 Maximum movement force limitation 9 "Stroke position" profile setting

3 Zero point 10 "Closing speed" profile setting
©KM
4 "Clamping force" actual value 11 "Movement force limitation" profile setting

5 "Clamping force" set value 12 Set opening stroke
6 Set value, "Max. duration of the movement force limitation" 13 Maximum closing speed
7 "Edit" button 1) 14 Marking for profile setting 2)
1) Inserting/deleting profile stages (see section 6.3.4.1, page 6-251)
2) Changing profile stages (see section 6.3.4.2, page 6-251)

The closing movement changes at the defined mold positions.
The closing movement is initiated by a start signal, e.g. "Mold closing" button.
After brief acceleration, the mold moves with different movement force limitations
and closing speeds.
If incorrect settings (force too low) or molded parts stuck to the mold prevent the
correct sequence of the closing movement, the max. duration of the movement
force limitation is exceeded.
The closing procedure is aborted and the alarm A00007/A00009 "Mold safety" is
displayed. The machine does not switch to clamping force build-up, and the mold
is protected against damage.
The mold safety program can be set flexibly and is effective over the entire closing
procedure.
If, for example, a mold involves a mechanical jaw movement, very low force and
speed settings can be chosen for the first profile stage. If a jaw jams, the mold is
protected.
If the mold continues to close and, for example, springs are compressed, the force
can be increased in the profile stage in order to guarantee safe clamping.
Profile stages
In the "Profile settings" window, up to 16 profile stages can be selected and
configured.
Number of profile stages = 1

The movement takes place with a uniform speed. The movement force limitation
is limited to a value.
Number of profile stages > 1

Different movement force limitations and speed values are used for the
movement.
I
Note
The inputs for each profile stage must be complete (values for stroke position,
closing speed and movement force limitation).
Profile stages are only effective in manual, semi-automatic and fully automatic
MX_MC6_V1.9_07.09.15_ENG
modes.
©KM
Inserting/deleting profile stages

(see section 6.3.4.1, page 6-251)
Display all profile stages via pop-up menu


Clamping force, locking force

The clamping force is built up when the clamping force build-up stroke position is
reached during the closing movement. The clamping force remains in effect up to
the end of the cooling time.
Movement force limitation
W
Important
If max. movement force is set, mold safety is not effective. The mold can be
damaged.
Setting for the permitted movement force in the profile stage.

If max. movement force is set, no movement force limitation is effective and the
machine can build up max. movement force.
I
Note
If a core-pulling program has been entered, the closing movement can be
interrupted until the core-pulling function is complete. For core-pullling
functions, see "Core-pulling" (see section 8.8, page 8-452).
Closing speed
Setting for the selected closing speed in the profile stage.
I
Note
The transitions between the individual speed set values are never abrupt but
are controlled via ramps. Soft transitions between the different speeds are
achieved in this manner. The ramps are generated by the control system.
Stroke positions
I
Note
The mold positions are needed to activate various speeds, movement force
MX_MC6_V1.9_07.09.15_ENG
limitation or additional functions (e.g. cores) during the mold closing process.
The mold positions are entered relative to the zero point of the clamping unit.
©KM
The zero point (0 mm) is the "Mold closed" position.

Zero point calibration (see section 8.14.1, page 8-628).
Opening stroke
Mold position to switch off the opening movement. During closing, the start ramp
begins to accelerate on the opening stroke to the selected closing speed in profile
stage 1.

Max. duration of the movement force limitation, monitoring time

The monitoring time is effective in every profile stage.
It starts when the current closing speed is only 50% of the respective profile
stage's set speed.
If the next profile stage is reached in the selected monitoring time, the time is
reset. If the next profile stage is not reached in the selected monitoring time, the
monitoring time triggers the alarm A00007/A00009 "Mold safety". The closing
movement is aborted.
8.7.1.2 Mold safety alarms
A00007 "Mold safety"

The white A00007 alarm is displayed when the monitoring time has been
exceeded.
If repeat processes for the closing operation are programmed with the counter
"Repeat-procedures mold safety", these are then performed (refer to A00009).
A00009 "Mold safety"

The red A00009 alarm is displayed when the last attempt at clamping cannot be
completed properly. The machine is stopped, and the fault signal lamp is switched
on.
I
Note
"Repeat-procedures mold safety" are only effective in the fully automatic mode.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.7.1.3 Mold closing settings
1
2
Fig. 8.39 Mold closing settings

1 Selection mold safety 3 Operation with spring-loaded mold
2 Set value "Repeat procedures mold safety"
Selection mold safety
Mold safety without opening

If the mold safety time is exceeded, the mold does not open. The alarm
A00007⁄A00009 "Mold safety" is displayed immediately.
Mold safety with opening

The mold is opened if the mold safety time is exceeded (ejector and core-pulling
MX_MC6_V1.9_07.09.15_ENG
programs are executed if programmed).

©KM
The alarm A00007⁄A00009 "Mold safety" is displayed.

Repeat-procedures mold safety

The function is only effective in fully automatic mode when a set value greater
than 0 has been entered. If the monitoring time is exceeded due to a failed closing
movement, the machine opens again, and another closing attempt is made
(ejector and core-pulling program run, if programmed).
If this or further closing operations are not successful, alarm A00007/A00009
"Mold safety" is displayed and the mold remains in the alarm position, or stops
while still open.
Selection program "Operation with spring-loaded mold"

For molds with strong springs, it is not possible to overcome the spring force with
the drive cylinder when the mold is closing. A spring-loaded mold is used for safe
closing of the mold. If the machine is equipped with a spring-loaded mold, the
function "Operation with spring-loaded mold" appears on the screen. If a spring-
loaded mold is to be used, this function must be switched on to make sure that
the mold is closed safely.
• Spring-loaded stroke
• Mold speed within spring-loaded range
• Travel force in the spring range
Mold safety alarms

MX_MC6_V1.9_07.09.15_ENG
©KM

8.7.1.4 Mold closing auxiliary devices
Mold vacuum (ZE 45.35)
1
2
3
Fig. 8.40 Mold closing auxiliary devices

1 Selection menu "Mold vacuum selection program 1" 3 Input "Timing for mold vacuum"
2 Selection menu "Mold vacuum selection program 2"
Mold vacuum selection program 1
No mold vacuum control

In the machine cycle, the vacuum valve is not activated and taken into
consideration.
MX_MC6_V1.9_07.09.15_ENG
Mold vacuum with injection unit forward

The vacuum valve is switched on when the "Injection unit forward" position has
©KM
been reached. The vacuum valve is switched off again at the end of holding
pressure.
Mold vacuum with mold closed

The vacuum valve is switched on when the "Mold closed" position has been
reached. The vacuum valve is switched off again at the end of holding pressure.

Mold vacuum with mold gap

The vacuum valve is switched on when the "Mold gap" position has been
reached. The vacuum valve is switched off again at the end of holding pressure.
Mold vacuum with screw position

The vacuum valve is switched on when the position "Open vacuum valve with
screw position" has been reached. When the position "Close vacuum valve with
screw position" or, at the latest, the end of holding pressure has been reached,
the vacuum valve is switched off again.
With the selection "Mold vacuum with screw position", the second selection
program is not active. The reason for this is that with this option control is only via
stroke and not via time or pressure switch.
Mold vacuum selection program 2
Mold vacuum via time

The Subsequent movement, in the machine cycle is enabled when the set time
(3, fig. 8.40) has elapsed.
Mold vacuum via pressure switch

The Subsequent movement in the machine cycle is enabled when the pressure
switch "Mold vacuum" has been reached.
Mold vacuum via time with pressure switch monitoring

The Subsequent movement in the machine cycle is enabled when the set time (3)
has elapsed. If the pressure switch is not reached within the set time (3), a white
cyclical quality alarm is tripped.
Mold vacuum via pressure with time monitoring

The Subsequent movement in the machine cycle is enabled when the pressure
switch "Mold vacuum" has been reached. If the pressure switch is not reached
within the set time (3), a white cyclical quality alarm is tripped.
I
Note
If an MC5 data record is read in, the function is divided automatically into the
two new selection programs.
MX_MC6_V1.9_07.09.15_ENG
©KM

Inserting mold vacuum
5 1
4
2
Fig. 8.41 Process designer - inserting mold vacuum

1 Multi-select feature, library 4 Docking point
2 Insert a cycle element (selected in the library) 5 "Editing mode" button
3 Main key
1) Use the main key (3, fig. 8.41) to switch to the screen page "Process
designer" (see fig. 8.41, page 8-421).
3) Use the multi-select feature (1) of the library to select the category "Mold" of
the cycle elements.
4) Select cycle element "Mold vacuum" (2) in the library.
MX_MC6_V1.9_07.09.15_ENG
For the new cycle step, one or multiple possible dock points are set.
©KM
The cycle element "Mold vacuum" from the library is taken up as a step at the
selected location in the cycle sequence.
6) After positioning of the cycle element, a pop-up window (see fig. 8.42,
page 8-422) appears for selection of the settings of the 2nd selection program
(1, fig. 8.42).

Fig. 8.42 Mold vacuum pop-up window

1 Selection menu "Mold vacuum selection program 2"
7) If necessary, make settings on screen page "Mold closing auxiliary devices"

(see fig. 8.40, page 8-419).
Switching on mold vacuum

Press the "Mold vacuum" button to start the mold vacuum in setting and manual
mode. The button lights up brightly when vacuum is activated in setting and
manual mode.
The vacuum valve is switched off again at the end of holding pressure.
In semi-/fully automatic mode, "Mold vacuum" is started in the machine cycle in

accordance with the programmed cycle sequence.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.7.1.5 Mold cavity pressure
1
2
Fig. 8.43 Mold cavity pressure

1 Multi-select feature "Measuring mold cavity pressure" 2 Selection menu "Mold cavity pressure transducer"
Selection menu "Mold cavity pressure transducer"
External measurement of mold cavity pressure with external device

The existing external mold cavity pressure transducer is selected.
Force – mold cavity pressure measurement with force transducer

In this case, the pressure transducer is not installed at the surface of the cavity
but, for example, behind an ejector pin. It is operated as a force transducer.
MX_MC6_V1.9_07.09.15_ENG
©KM
I
Note
Refer to the technical documentation of the mold for the value of the sensitivity.

Pressure – mold cavity pressure measurement with pressure transducer

The active measuring surface of the pressure transducer is in direct contact with
the melt.
Sensitivity of transducer
Sensitivity of the transducer used after selection.
Set Measuring mold cavity pressure with external device.
Diameter of force transducer

Sets the diameter of the force transducer used.
Charge amplifier type

Once "Measuring mold cavity pressure" with Priamus charge amplifier has been
selected, the type of measuring device is technically determined and entered.
Auto-Range
Automatic range search for power limitation.
Charge amplifier measuring range

Select the measurement range of the charge amplifier according to the default
values.
Measuring range (actual value)

After setting the charge amplifier measurement range, it is confirmed with the
corresponding actual value.
Mold cavity pressure

Display of actual value. The actual value can also be displayed in the actual value
column.
Test signal charge amplifier

This function is switched on to test the pressure transducer. Switch the function
off again after testing.
Monit. temperature for charge amplifier
Actual temp. of charge amplifier

The temperature measured in the mold with the combined sensor is displayed.
MX_MC6_V1.9_07.09.15_ENG
Temperature status
Display of the corresponding temperature rating (see section 8.11.1.1,
©KM
page 8-557).
Measuring range of temperature

Selection of the required temperature range for a measurement.

8.7.1.6 Mold set-up/calibration
Fig. 8.44 Mold set-up/calibration
Set-up speed, Mold closing

Input of speed at which the mold is closed in setting mode.
Setting movement force, Mold closing

Input of drive force at which the mold is closed in setting mode.
Set-up speed, Mold opening

Input of speed at which the mold is opened in setting mode.
Setting movement force, Mold opening

Input of drive force at which the mold is opened in setting mode.
MX_MC6_V1.9_07.09.15_ENG
Adjustment speed mold closing

©KM
Input of the speed at which the mold is closed during calibration.
Calibration movement force, Mold closing

Input of the drive force with which the mold is closed during calibration.
Mold opening adjustment speed

Input of speed at which the mold is opened during calibration.
Calibration movement force, Mold opening

Input of the drive force with which the mold is opened during calibration.

8.7.2 Mold opening
8.7.2.1 Mold opening
2
12
11 3
10
9 4
8
5
6
7
Fig. 8.45 Mold opening

1 Current mold positions 7 Set value for "Tear open"
2 Maximum opening speed 8 Set value for "Opening stroke"
3 Zero point 9 "Stroke position" profile setting
4 "Edit" button 1) 10 Profile setting "Opening speed"
5 Mold opening selection 11 Set opening stroke
6 Set value for "Mold opening position for part removal start" 12 Marking for profile setting 2)
1)
Inserting/deleting profile stages (see section 6.3.4.1, page 6-251)
MX_MC6_V1.9_07.09.15_ENG
The clamping force is released shortly before the end of the cooling time
(see section 8.7.2.2, page 8-429). If the tear-open stroke (7, fig. 8.45) is set to
©KM
0 mm, the pressure cushions are positioned in zero position and the locking
plates are moved out. The mold opening procedure begins after this.
If a tear-open stroke higher than 0 mm is set, with the locking plates moved in the
pressure cushions push open the mold until the mold position has reached the
tear-open stroke. Due to the pressure cushions, high tear-open forces are
possible although only low tear-open speeds can be achieved. At the tear-open
stroke, the locking plates are moved out and the mold opens according to the
entered opening profile.

Where possible, the input of a tear-open stroke should be omitted because the
method of operation leads to a lengthening of the cycle time.
I
Note
If a core-pulling program has been entered, the opening movement can be
interrupted until the core-pulling function is complete.
Core-pulling (see section 8.8, page 8-452).
Profile stages
configured.

The movement takes place with a uniform speed.

The movement is executed using different speed values.
I
Note
The inputs for each profile stage must be complete (values for stroke position,
opening speed).
modes.
I
Note


MX_MC6_V1.9_07.09.15_ENG

©KM
Mold positions
W
Important
Mold positions are used to activate various speeds, stop positions or additional
functions during the opening movement. The travel values are entered relative
to the zero point of the clamping unit. The zero point (0 mm) is the "Mold
closed" position.

Opening stroke
Mold position to switch off the opening movement.
Mold opening selection
Robot function switched OFF during mold opening

The "Start part removal" signal is reported to the robot when the opening stroke
is reached.
Mold intermediate stop for article removal
W
Important
If the "Mold opening position for part removal start" mold position is incorrectly
selected, this can lead to damage to the parts removal unit and mold.
The opening movement is interrupted at the defined mold position, "Mold opening
position for part removal start". The "Start part removal after mold intermediate
stop" signal is sent to the robot. The opening movement is resumed after an
enable signal from the robot.
Start article removal during mold opening
W
Important
If the "Mold opening position for part removal start" mold position is incorrectly
selected, this can lead to damage to the parts removal unit and mold.
At the set mold position "Mold opening position for part removal start", the "Start
article removal after mold intermediate stop" signal is sent to the robot. The
opening stroke is not interrupted.
Tear open (tear-open stroke)

For the selected tear-open stroke, the mold is opened with the pressure pistons
(large tear-open force). After the tear-open stroke, the mold is opened via the
traverse cylinder and the selected profile stages.
I
Note
MX_MC6_V1.9_07.09.15_ENG
The tear-open stroke is intended for molds whose functional design requires a
©KM
large tear-open force.

If the tear-open stroke = 0, the opening movement starts with profile stage 1 for
molds that open easily.

8.7.2.2 Mold opening settings
2
3
Fig. 8.46 Mold opening settings

1 Input field "Start clamping force release before end of cooling time" 3 Input field "Stroke counter centralized lubrication"
2 "Carry out centralized lubrication" pushbutton
Start clamping force release before end of cooling time

The time for initialization of start of clamping force release before end of cooling
time is entered in the input field (1, fig. 8.46).
Carry out centralized lubrication

When the (2) pushbutton is pressed, a lubrication cycle is tripped by the operator.
Lubrication takes place via the central lubrication system at the sliding belts of the
MX_MC6_V1.9_07.09.15_ENG
MP.
©KM
Stroke counter centralized lubrication

The number of machine cycles to the next automatic lubrication by the central
lubrication system can be set in the input field (3). The number can be changed
from access level 1.
The number of completed machine cycles and automatic lubrication with an
electric lubrication pump are monitored. If the lubrication pump malfunctions, an
alarm stops the machine.

8.7.2.3 Mold opening auxiliary devices
6
3
4
5
Fig. 8.47 Mold opening auxiliary devices

1 Selection menu for "Discharge monitoring" 4 "Mold cooling water" selection menu
2 Selection menu, "Conveyor-belt control" 5 Coolant shut-off delay time
3 Selection menu for "Discharge-/sprue-sorting chute" 6 Note "No selection possible with active quality monitoring of cycle time!"
Selection menu for "Discharge monitoring"
Discharge control standard

Ex.: Light barrier, photo cell, scales, etc.
This function is only effective in the fully automatic mode.
The next machine cycle is started by a signal from the discharge monitoring
MX_MC6_V1.9_07.09.15_ENG
facility.
©KM
The pause time setting must exceed the demolding time required for the part.
For input of pause time (see section 8.13.1, page 8-600).
If the signal is only generated after expiration of the pause time, the alarm A00060
"Discharge monitoring" is displayed and the new cycle is started.
If the molded part is not removed from the mold within the cycle monitoring time,
the machine is switched off with alarm A00013 "Cycle time monitor".

Activate discharge monitoring cycle

If the part is dropped before or during the pause time, the pause time is not
observed and the mold is started.
Discharge monitoring stroke-dependent during Mold closing

Mold closing is enabled immediately after the pause time without observing the
discharge monitoring.
If the discharge monitoring does not report that a part has been dropped by the
set monitoring stroke, the mold is stopped immediately.
Selection menu, "Conveyor-belt control"
Conveyor-belt control OFF

The conveyor belt control is switched off.
Conveyor belt indexing mode (ZE)

When the ejected part has been placed on the conveyor, the conveyor belt starts
up and stops to receive the next part. Sorting according to good and reject parts
is possible when tolerance monitoring is activated according to the "Actual-value
cycles" screen (see section 8.12.1.1, page 8-584).
Conveyor-belt run-time for part within tolerance

• If a part is within the tolerance (good part), the conveyor belt then moves
forward in the running direction for the duration of the operating cycle.
Conveyor-belt run-time for part outside tolerance

• If a part is not within the tolerance (bad part), the conveyor belt then first
moves in the running direction backward and then forward in the running
direction for an identical time.
Conveyor belt continuous belt forward movement

The conveyor belt starts moving forward at the beginning of the machine cycle.
Conveyor belt continuous belt reverse movement

The conveyor belt starts moving backward at the beginning of the machine cycle.
Conveyor belt control via robot

The conveyor belt is controlled by means of robot signals.
Robot conveyor belt controlled by injection molding mach.

The control system of the injection molding machine controls the conveyor belt of
MX_MC6_V1.9_07.09.15_ENG
the robot.
©KM
Selection menu for "Discharge-/sprue-sorting chute"

The sprue sorting chute flap is in the sprue or bad part position when the valve is
not activated.
When sorting reject parts, the tolerance monitoring on the "Actual-value cycles"
screen (see section 8.12.1.1, page 8-584) must be switched on.
The flap is always in the sprue or bad part position in the setting and manual
modes.

I
Note
When tolerance monitoring is active and the cycle time is also being monitored,
the good article/reject sorting is not possible since the cycle time is only
determined after the article is ejected.
Discharge/Sprue sorting chute off

The sorting chute flap is in the sprue or bad part position.
Ejector forward movement — article — ejector forward movement — sprue

• The sorting chute is set to the good part position by Mold opening.
• The ejector moves forward to the defined position.
• The molded part drops.
• The sorting chute turns upon expiration of the change-over delay.
• When the residence time has expired, the ejector moves forward to the
ejector stroke.
• The sprue drops.
Ejector forward movement — article — ejector back movement — ejector forward

movement — sprue
• Subsequently the ejector moves back to the zero point and then forward to
the ejector stroke.
Ejector forward movement — sprue — ejector forward movement — article

• When the residence time has expired, the ejector moves forward to the
ejector stroke.
Ejector forward movement — sprue — ejector back movement — ejector forward

MX_MC6_V1.9_07.09.15_ENG
movement — article
©KM
• Subsequently the ejector moves back to the zero point and then forward to
the ejector stroke.

I
Note
Perform the programming below if only a good/bad part sorting is required.
Only good/reject part sorting

• Start of sorting chute 0 mm
• Change-over delay 20 s
• Residence time ejector 0 s
This results in the following sequence of movements:

With the mold open, the flap is in the good or reject part position, depending on
the result of the tolerance monitoring, and remains in this position until the next
mold opening.
Sorting chute, start
Change-over delay
Residence time ejector
Position monitoring, sorting chute

The ejector movements are enabled depending on the limit switches.
I
Note
If the limit position has not yet been reached, step P00846 "Sorting chute not
in position" is displayed.
If the two limit switches "Ejector and sorting chute limit switch position, reject
part" and "Ejector and sorting chute limit switch position good part" are
actuated at the same time, alarm A02168 "Contact monitoring fail/sort. chute"
is tripped.
"Mold cooling water" selection menu
Mold cooling water permanent ON (ZE)

The mold cooling function is activated when the machine is switched on.
Central shut-off for mold cooling water

MX_MC6_V1.9_07.09.15_ENG
If the safety gate is still open after expiration of the pause time in semi-automatic
or fully automatic mode, the mold cooling water is switched off by a central valve.
©KM
This prevents cooling off of the mold.

The mold cooling water is switched on again when the safety gate is closed.
Mold cooling water ON after start-up (ZE)

The mold cooling function is only activated upon execution of the defined number
of "start-up cycles".
The mold cooling water is switched off if the "Monitoring time during production
interruption" time expires (see fig. 8.89, page 8-509).
Coolant shut-off delay time (ZE)

Settable delay time after which the water valve switches off.

8.7.2.4 Mold opening configuration
Fig. 8.48 Mold opening configuration

1 Selection menu "Open safety gate automatically"
Selection menu "Open safety gate automatically"
Safety gate autom. opening, standard
Safety gate autom. opening at end of cycle
Do not open safety gate automatically MX_MC6_V1.9_07.09.15_ENG

©KM

8.7.3 Ejector
8.7.3.1 Ejector
8 1
4
8 5
6
7
Fig. 8.49 Ejector

1 LED display of limit switch input (ejector forward movement) 5 LED display of limit switch input (ejector at rear)
2 LED display of valve output (move ejector forward) 6 LED display of valve output (move ejector back)
3 Ejector stroke 7 Marking for profile setting 2)
4 "Edit" button 1) 8 Actual-value display of ejector position
2)
Changing profile stages (see section 6.3.4.2, page 6-251)
The ejector stroke (3, fig. 8.49) can be adjusted. It can be time-limited
MX_MC6_V1.9_07.09.15_ENG
LEDs indicate the limit switch (1, 5) and the valve (2, 6) of the ejector.
©KM
The ejector movements are done through configured force and speed values.
Profile stages
configured.

The movement takes place with a uniform speed.
The ejector force is limited to a value.


Different ejector forces and speed values are used for the movement.
I
Note
The inputs for each profile stage must be complete (values for speed, ejector
force and stroke position).
modes.


Ejector stroke
The "forward" ejector movement is deactivated when the ejector stroke
(3, fig. 8.49) is reached. Input is in millimetres relative to the mold-dependent zero
point of the hydraulic ejector position measuring system. If the ejector movement
is to be stroke-dependent only, this time must be set to zero.
Ejector speed
Setting for the selected ejector speed in the profile stage.
I
Note
Position
I
Note
The ejector positions are required in order to switch on various speeds and
forces during the ejector movement.
MX_MC6_V1.9_07.09.15_ENG
The ejector positions are entered relative to the zero point of the ejector.
The zero point (0 mm) is the "Ejector at rear" position.
©KM

8.7.3.2 Ejector settings
Fig. 8.50 Ejector settings

1 "Ejector" selection
Depending on the selection made, the ejector remains moved out until the
beginning of the next machine cycle, or it returns to its limit position (ejector at
rear).
"Ejector" selection
No ejector
The ejector is switched off. The ejector can be controlled by the core-pulling
program (see section 8.7.3.3, page 8-440).
MX_MC6_V1.9_07.09.15_ENG
Ejector return at start of new cycle

©KM
The ejector moves forward with the programmed forces and speeds when the
opening stroke mold position is reached or starting with "Ejector start by mold
position" (on machines equipped with pressure accumulator).
The forward movement is limited by the defined ejector stroke or by expiration of
the time defined for "ejector forward movement, time-dependent".
The ejector remains moved out and only returns at the start of the next cycle.

Ejector in limit position before start of new cycle

The ejector moves forward with the programmed forces and speeds when the
opening stroke mold position is reached or starting with "Ejector start by mold
position" (on machines equipped with pressure accumulator).
The forward movement is limited by the defined ejector stroke or by expiration of
the time defined for "ejector forward movement, time-dependent".
Then the return movement with the defined forces and speeds begins.
Ejector back movement independent of pause time

The "Ejector back" movement starts at the same time as the pause time. At the
start of the new cycle, the ejector must not be in its limit position. This means that
the ejector (depending on the duration of the selected pause time) can still move
back even though the new cycle has already been started and the mold is already
closing.
Opening stroke
Start by mold position

The ejector movement can be run parallel to the mold movement. If the mold
reaches the defined mold position during the opening movement, "Ejector forward
movement" starts.
Input is relative to the clamping unit zero point.
I
Note
The input "Start by mold position" under ejector setting is only possible with an
arrangement of the "Ejector forward movement" symbol beside the "Mold
opening" symbol in the process designer (see section 8.6, page 8-402).
Delay time for start ejector forward

Once the set delay time has elapsed, the ejector starts.
Ejector fwd., time-dependent

The forward ejector movement is limited by a timer.
However, an ejector stroke value must always be specified; this is a value which
cannot be exceeded even with a large time value.
MX_MC6_V1.9_07.09.15_ENG
If the ejector movement is to be stroke-dependent only, this time must be set to

zero.
©KM
W
Important
For the ejector functions, the signal from this limit switch has priority over the
"stroke-dependent" and "time-dependent" ejector functions and the defined
repeat stroke if the limit switch "Ejector monitoring in fwd. pos." is connected.
Make sure that the desired ejector functions are not prevented by the signal
from the limit switch.

Hold ejector at front
Repeat stroking
Repeat stroke setting smaller than ejector stroke
The ejector moves back to the ejector stroke. The execution of the repeat strokes
is between the set ejector stroke and repeat stroke. The ejector moves all the way
back after the repeat strokes.
Repeat stroke setting greater than ejector stroke

The ejector first moves to the ejector stroke and then back to the zero point. It then
returns to the set repeat stroke. The execution of the repeat strokes is between
the set ejector stroke and repeat stroke. The ejector moves all the way back after
the repeat strokes.
This function is only effective in manual, semi-automatic and fully automatic
modes.
Repeat-stroking counter
The repeat-stroking counter specifies the number of times the ejector movement
is to be repeated. The ejector movement can be repeated up to 10 times.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.7.3.3 Ejector controlled by core-pulling program
1
2
3
4
5
Fig. 8.51 Ejector settings, ejector controlled from the core-pulling program
1 Notes field "Ejector controlled from core-pulling program" 5 Ejector repeat stroking
2 Opening stroke 6 Intermediate position 1-3
3 LED display of ejector direction 7 Ejector at rear and limit switch reached
4 Ejector stroke (ejector in forward position)
Core-pulling with ejector position is entered on the "Ejector" screen.

• Ejector in forward position corresponds to the ejector stroke or limit switch
(4, fig. 8.51).
• Ejector at rear corresponds to the zero point and limit switch (7).
If only the core-pulling is programmed, and the ejector remains switched off, then
MX_MC6_V1.9_07.09.15_ENG
it is monitored for "rear" position. If the ejector is not in the "rear" position, step
©KM
P00075 "Ejector not in final position" is shown and the mold remains opened.
The force profile, speed profile and the LED ejector direction displays (3) for the
core-pulling programming are located on the "Ejector" screen. The direction
reached by moving forward and back is presented via green LEDs.

Opening stroke
Ejector stroke
The "forward" ejector movement is deactivated when the ejector stroke is
reached. Input is relative to the mold-dependent zero point of the hydraulic ejector
position measuring system. If the ejector movement is to be stroke-dependent
only, this time must be set to zero.
Repeat stroking
Repeat stroke setting smaller than ejector stroke
The ejector moves back to the ejector stroke. The execution of the repeat strokes
is between the set ejector stroke and repeat stroke. The ejector moves all the way
back after the repeat strokes.
Repeat stroke setting greater than ejector stroke

The ejector first moves to the ejector stroke and then back to the zero point. It then
returns to the set repeat stroke. The execution of the repeat strokes is between
the set ejector stroke and repeat stroke. The ejector moves all the way back after
the repeat strokes.
This function is only effective in manual, semi-automatic and fully automatic
modes.
8.7.3.4 Ending semi/fully automatic mode without ejector

If the "Move ejector back" button is actuated in semi- and fully automatic mode in
the current cycle, before the hydraulic ejector starts up the cycle will be stopped
at "Mold open" and the ejector will not be moved forward. Step P00338 "Cycle
ended without ejection" is shown.
The ejector movement only takes place if, with the safety gate closed (not with -
S016), the "Ejector forward movement" button is actuated.
After the ejector movement, the "Start machine cycle" button must be actuated to
initiate the cycle start.
In robot operation, the following signals are ignored for this function in the current
cycle:
• Ignored robot signals:
MX_MC6_V1.9_07.09.15_ENG
– Ejector forward movement

©KM
– Ejector return
– Enabling mold closing
• Ignored signals to the robot:
– Part injected
– Start robot
This ensures that the robot does not detect this cycle. The robot continues as
usual with the next cycle.

8.7.3.5 Ejector configuration
1
2
3
Fig. 8.52 Ejector configuration

1 Monitoring of end pos for ejector 3 Monitoring stroke for ejector return during mold closing
2 Retain ejector at rear
Limit position monitoring for ejector (ZE)

The ejector is monitored in the limit position and intermediate position by two limit
switches. If an error occurs, alarm A00079 "Ejector limit switch FP" or alarm
A00080 "MP ejector limit switch" is displayed.
Retain ejector at rear

The ejector is retained in the moved-in position.
W
MX_MC6_V1.9_07.09.15_ENG
Important
©KM
If the ejector is controlled via the core-pulling program, "Ejector controlled by

core-pulling program" is displayed instead of the text "Retain ejector at rear".
The function "Retain ejector at rear" must then be programmed in the core-
pulling program using the hold function.
Core-pulling programming (see section 8.8.7, page 8-467).
Monitoring stroke for ejector return during mold closing (ZE)

The closing movement is interrupted if the ejector does not reach the limit position
within the monitoring stroke.

8.7.3.6 Ejector set-up/calibration
Fig. 8.53 Ejector set-up/calibration
Setting speed, ejector forward

Input of the speed at which the ejector is moved forward in setting mode.
Setting force, ejector forward

Input of the force with which the ejector is moved forward in setting mode.
Setting speed, ejector back

Input of the speed at which the ejector is moved back in setting mode.
Setting force, ejector back

MX_MC6_V1.9_07.09.15_ENG
Input of the force with which the ejector is moved back in setting mode.
©KM
Calibration speed, Ejector forward

Input of speed at which the mold is moved forward during adjustment.
Calibration movement force for ejector forward movement

Input of the force with which the mold is moved forward during adjustment.
Calibration speed, Ejector back

Input of speed at which the ejector is moved backward during adjustment.
Ejector back movement calibration movement force

Input of the force with which the ejector is moved backward during adjustment.

8.7.3.7 Sprue compression and removal with ejector (ZE 71.05)
2
3
4
Fig. 8.54 Sprue compression and removal with ejector

1 Selection menu "Ejector forward movement" 3 Ejector compression delay forward off
2 Ejector compression delay forward on 4 Stroke monitoring for enable Mold opening
Selection menu "Ejector forward movement"
Standard ejector
Sprue compression and removal with ejector is deactivated.
Ejector forward during holding pressure

The injection cycle then continues until start of holding pressure as in the
standard. Injection plunger reaches screw stroke during holding pressure. The
MX_MC6_V1.9_07.09.15_ENG
ejector is pushed forward at the speed and pressure of the standard profile.
©KM
If the ejector has been moved back, "Mold opening" is enabled. The cycle
continues as normal.

Ejector forward after holding pressure

The injection cycle then continues until end of holding pressure as in the standard.
Parallel to the start of cooling time (end of holding pressure), the time "Ejector
compression delay forward on" starts up (2, fig. 8.54).
After the time "Ejector compression delay forward on" (2) has elapsed, the ejector
moves forward at the speed and pressure of the standard profile and the time
"Ejector compression delay forward off" (3) starts up.
After the time "Ejector compression delay forward off" (3) has elapsed, the ejector
is moved back and "Mold opening" is enabled. The cycle continues as normal.
Startpt. ejector fwd during holding pressure

If the "Ejector forward during holding pressure" function is selected in the
selection menu (1), the stroke for the start of the ejector can be entered at the
screen.
Ejector compression delay forward on

If the "Ejector forward after holding pressure" function is selected in the selection
menu (1), the delay time (2) after which the ejector moves forward can be entered
at the screen.
Ejector compression delay forward off

If the "Ejector forward after holding pressure" function is selected in the selection
menu (1), the delay time (3) after which the ejector moves back can be entered at
the screen.
Stroke monitoring for enable Mold opening

If the tickbox (4) is activated, stroke monitoring takes place for enabling the
opening of the mold. The corresponding stroke is entered via the value "Ejector
stroke monitoring".
Ejector stroke monitoring

If the monitoring stroke is not reached during the separation or compression
phase for the sprue, "Mold opening" is not enabled.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.7.4 Pneumatic valves
1
3
2
Fig. 8.55 Pneumatic valves

1 Selection "Limit position configuration forward" 3 "Starting condition" selection 1)
2 Selection "Limit pos. configuration back"
1)
Programming the starting condition in setting mode
Up to 18 pneumatic valves (or blow-off devices) can be tripped by the control

system. The pneumatic valves are activated by means of variable mold positions
in the opening movement of the mold. The blowing duration is limited via time
stages. A delay time can be set for each pneumatic valve.
The individual pneumatic valves are selectable by the various starting conditions.
MX_MC6_V1.9_07.09.15_ENG
Symbol explanation (see section 8.7.4.1, page 8-449)

©KM
The pneumatic valves can be operated independently of the mode of operation

with the "Pneumatic valves" button.

Starting condition
I
Note
The starting condition can be programmed in setting mode (see fig. 8.55,
page 8-446) or via the process designer (see fig. 8.56, page 8-447).
Basic principles of the process designer (see section 8.6, page 8-402).
1
8
2
MX_MC6_V1.9_07.09.15_ENG
3
©KM
Fig. 8.56 Pneumatic valves, programming the starting conditions (example)

1 Pneumatic valve 2 MP inactive 5 Pneumatic valve 1 MP starts by mold position
2 Detail view of the selected pneumatic valve 6 Docking point
3 Selection menu, "Starting condition" 7 Pneumatic valve 1 FP starts with clamping force reduction
4 Main navigation for process designer (main key) 8 "Open detail view" button

After selection of the Process designer with the main key (4, fig. 8.56), the starting
condition of the selected pneumatic valve (5) can be defined in different manners:
• via the selection menu "Starting condition" (3) in the detail view (2)
• by inserting/shifting at the suggested docking points (6)
The starting condition is then displayed in the "Pneumatic valves" screen

(see fig. 8.55, page 8-446).
Mold position
Position of the mold with selected starting condition "Start by mold position".
Delay time
Delay of start.
Activation time
Time until start control.
Forward after-run
Delay of the blowing duration.
Number of repetitions
The new cycle is postponed until the "Blowing" function is completed. Step
P00197 "Pneumatic valve interrupts mold closing" is displayed. When the
"Blowing" function is finished, the new cycle is started.
Return time
Duration of time between the individual repetitions.
Back after-run
Delay of the return time.
Activation with buttons

Each pneumatic valve can be operated by entering "1" with the "Pneumatic
valves" button.
If a value for the "return time" is entered for the pneumatic valve, the valve can be
actuated in any mode of operation.
If a value is entered for "Number of repetitions" (scraper function), the valve can
only be actuated in setting mode when the mold is open.
MX_MC6_V1.9_07.09.15_ENG
"Limit position configuration forward/back" selection

©KM
• Only input: Stroke-dependent

• Only time: Time dependent
• Input and time: Stroke and time-dependent
• Input or time: Stroke or time-dependent

8.7.4.1 Symbol explanation for pneumatic valves

1) Select the "Pneumatic valves" screen (see fig. 8.55, page 8-446).
3) Press the "Symbol explanation" button.
A pop-up window with the symbol explanation of the pneumatic valves opens.
MX_MC6_V1.9_07.09.15_ENG
Fig. 8.57 Symbol explanation for pneumatic valves

©KM

Symbols, starting conditions

The selected starting conditions (3, fig. 8.56) for actuating the pneumatic valves
are displayed by means of the following symbols.
By mold position By special 1

Mold position at which the activated pneumatic Pneumatic valve is activated by the customer-
valve is actuated. Adjustable across the entire defined starting condition 1.
mold opening stroke.
By end of holding pressure By special 2
Pneumatic valve is activated by the end of Pneumatic valve is activated by the customer-
holding pressure. defined starting condition 2.
By air ejector forward Robot signal 1
Pneumatic valve is activated by the ejector as it With the robot integrated, the pneumatic valve is
moves forward. activated by robot signal 1.
Before end of cooling time Robot signal 2
Pneumatic valve is activated before end of With the robot integrated, the pneumatic valve is
cooling time. activated by robot signal 2.
With clamping force reduction
Pneumatic valve is activated with clamping force
reduction.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.7.5 Compression molding
1
2
3
4
Fig. 8.58 Compression molding

1 "Compression function" selection menu 3 Locking position for compression molding (offset)
2 Compression injection stroke mold 4 Velocity 1 injection-compression molding
All compression molding versions are only effective in semi-automatic and fully
automatic modes.
"Compression function" selection menu
Compr. inj. molding sequentially to holding pressure

• Mold closing up to compression injection stroke (compression gap).
MX_MC6_V1.9_07.09.15_ENG
• Injection until start of holding pressure.

• Holding pressure is not started.
©KM
• Mold closing.
• Compression molding is carried out with the set speeds.
• When the "End mold safety" is reached, the clamping force is built up.
• Holding pressure is performed.
• Cycle continues as normal.

Compr. inj. molding sequentially to inj. molding

• Mold closing up to compression injection stroke (compression gap).
• Injection until start stroke for compression molding.
• Injection is interrupted.
• Mold closing.
• Compression molding is carried out with the set speeds.
• When the "End mold safety" is reached, the clamping force is built up.
• Injection until start of holding pressure.
• Holding pressure is performed.
• Cycle continues as normal.
Compression injection stroke mold

Set the size of the compression injection stroke (compression injection gap).
W
Important
The "Compression injection stroke" setting must be greater than the "End mold
safety" setting.
If this is not the case, then the compression injection stroke has no function,
and the closing movement is stopped when "End mold safety" is reached.
The "Injection unit forward" and "Injection" movements are triggered.
Locking position for compression molding (offset)
Velocity 1 injection-compression molding

Set the starting speed.
8.8 Core-pulling
Each core is provided with limit switches for limit positions and times for
intermediate positions (limit switch option). Depending on the programming, the
core-pulling can be activated a number of times in the machine cycle.
There are hydraulically and pneumatically actuated core-pullings on the fixed and
movable mold platen.
MX_MC6_V1.9_07.09.15_ENG
The number of core-pulling units depends on the equipment.

©KM

8.8.1 Core-pulling activation
1 2 3 4 5
15
14
13
12
11 10 9 8 7 6
Fig. 8.59 Core-pulling

1 Activation of core-pulling 9 "Move-out intermediate position" input LED indicator (limit switch)
2 "Move out limit position" core/ejector direction display 10 "Move out" output LED indicator (solenoid valve)
3 "Move out intermediate position" core/ejector direction display 11 "Move-out limit position" input LED indicator (limit switch)
4 "Move in limit position" core/ejector direction display 12 "Core not activated" display
5 "Move-in intermediate position" core/ejector direction display 13 Core/ejector activation
6 "Move-in intermediate position" input LED indicator (limit switch) 14 Writeable display field
7 "Move in" output LED indicator (solenoid valve) 15 "Activation/acknowledgement of core-pulling setting" button
8 "Move-in limit position" input LED indicator (limit switch)
MX_MC6_V1.9_07.09.15_ENG
©KM
On the screen, the complete core-pulling and the individual cores and the ejector
are activated.
Depending on the number of cores available, other screens are provided for core-
pulling activation via additional tabs.

I
Note
Selection of the tickboxes (1 or 13, Fig. 8.59) for activation/deactivation and
writing in display fields (14) is only possible if the button
"Activation/acknowledgement of core-pulling input" (15) has been pressed.
By pressing a writeable display field (14), the alphanumeric keypad

(see section 6.3.3.2, page 6-248) over which the user-defined names can be
assigned opens.
Solenoid valves, limit switches and core/ejector direction of intermediate positions

and end positions are shown with LEDs. Two inputs (8 and 11) and two outputs
(7 and 10) are displayed for the ejector. Four inputs (6, 8,9 and 11) and two
outputs (7 and 10) are displayed for each core.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.8.2 Interruptions
4 1
2
Fig. 8.60 Interruptions 1

1 Selection field, interruptions 3 Tickboxes
2 Text input field 1) 4 "Activation/acknowledgement of core-pulling setting" button
1)
The text input field is only shown with selected special interruption.
For easier operation, the most important interruptions (KM:****) are already
predefined. They can neither be changed in function nor in name.
"Interruptions 1" screen via the Process designer (see section 8.8.7.1,
page 8-469).
MX_MC6_V1.9_07.09.15_ENG
©KM

Special interruptions have to be defined by the corresponding requirements.

1) Select special interruption (1, fig. 8.60).
2) Switch tickboxes (3) on/off.
I
Note
The selection of tickboxes (3) is only possible if the button
The customer-specific interruptions can be compiled as desired in function and

name.
By pressing a writeable display field (2, fig. 8.60), the alphanumeric keypad
(see section 6.3.3.2, page 6-248) via which a user-defined name can be assigned
opens.
I
Note
No interrupt may be programmed before the start of the corresponding core,
relative to the machine movement (mold closing/opening).
Independent of the interruptions, the core-pulling program for "Mold closing or

Mold opening" must be ended before switching between these two in the cycle.
• Step P00315 "Core-pulling not moved out" is displayed if "Mold closing" can
start but the program for "Move cores at Mold opening" is not finished.
• Step P00314 "Core-pulling not moved in" is displayed if "Mold opening" could
start but the program for "Move cores at Mold closing" is not finished.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.8.2.1 Symbols of interruptions
Start mold closing up to Start clamping force Stroke, Decompression before plasticizing up to
build-up Start plasticizing
Start mold closing stroke 1 1) up to Start clamping Start plasticizing up to Start decompression 2
force build-up
Start mold closing stroke 2 2) up to Start clamping Stroke, Plasticizing up to Start decompression 2
force build-up
Start clamping force build-up up to clamping force Start decompression after plasticizing up to End
reached of decompression 2
Clamping force reached up to Subsequent Stroke, Decompression after plasticizing up to
movement e.g. injection unit End of decompression 2
Start injection unit forward up to Nozzle contact Start injection unit return up to Injection unit at
pressure reached rear
Stroke, Injection unit forward up to Nozzle contact Stroke, Injection unit return up to Injection unit at
pressure reached rear
Start injection up to start of holding pressure Start clamping force release up to Start mold
opening
Stroke, Injection up to start of holding pressure Start mold opening up to Mold open
Start holding pressure up to end of holding Stroke 1 3), Mold opening up to Mold open
pressure
End of holding pressure up to Subsequent Stroke 2 2) Mold opening up to Mold open
movement, e.g. plasticizing
Locking slide during locking slide movement Mold open up to Subsequent movement, e.g.
(2-comp. machines) Start cycle
Start decompression before plasticizing up to Ejector, the ejector movement is not started until
Start plasticizing the core limit position is reached. This is only
effective if the ejector is not controlled via the
core-pulling program.
1) Stroke 1: stroke for interruption with mold closing, common value for all core steps (1, fig. 8.61), (5, fig. 8.74)
2)
Stroke 2: stroke for starting condition, can be redefined in every core step (1, fig. 8.61), (6, fig. 8.74).
3) Stroke 1: stroke for interruption with Mold opening, common value for all core steps (2, fig. 8.61)(5, fig. 8.74).
W
Important
• The limit position must be reached, or the activation time for a time-
controlled core must have elapsed.
• For the interruptions, ensure that the interruption in the machine cycle is set
MX_MC6_V1.9_07.09.15_ENG
in sequence after the start of the step. Otherwise, the interruption is not
©KM
revoked.
Programming the core steps (see section 8.8.7, page 8-467).

8.8.2.2 Core monitoring
1
2
Fig. 8.61 Interruptions 2

1 Set value, "Monitoring cores moved IN (inj. position)" 1) 2 Set value, "Monitoring cores moved OUT (demolding pos.)" 2)
1)
Stroke 1: stroke for interruption with Mold closing, common value for all core steps (5, fig. 8.74)
2) Stroke 1: stroke for interruption with Mold opening, common value for all core steps (5, fig. 8.74)
"Interruptions 2" screen via the Process designer (see section 8.8.7.1,
page 8-469).
MX_MC6_V1.9_07.09.15_ENG
Monitoring cores moved IN (inj. position)

©KM
By pressing the button "Mold closing", the core-pulling travels corresponding to

the configured programming (see section 8.8.7.3, page 8-475). For core
monitoring, a set value (1, fig. 8.61) can be defined.
Monitoring cores moved OUT (demolding pos.)

By pressing the button "Mold opening", the core-pulling travels corresponding to

8.8.3 Ejector
8 1
4
8 5
6
7
Fig. 8.62 Ejector

1 LED display of limit switch input (ejector forward movement) 5 LED display of limit switch input (ejector at rear)
2 LED display of valve output (move ejector forward) 6 LED display of valve output (move ejector back)
3 Ejector stroke 7 Marking for profile setting 2)
4 "Edit" button 1) 8 Actual-value display of ejector position
Basic profile settings for the ejector can be defined on the screen. Other settings
for the ejector can only be defined directly using the "Mold/ejector" screen pages.
Description (see section 8.7.3, page 8-435)

MX_MC6_V1.9_07.09.15_ENG
©KM

8.8.4 Core enabling via operating panel without sequence
3 1
2
Fig. 8.63 Core enabling via operating panel without sequence

1 Move in 3 "Activation/acknowledgement of core-pulling setting" button
2 Move out
Selection of "Operating panel for moving in/out without sequence"

MX_MC6_V1.9_07.09.15_ENG
I
Note
©KM
The selection of the tickboxes (1 or 2,Fig. 8.63) is only possible if the button

8.8.5 Core-pulling settings
8.8.5.1 Core-pulling default settings 1
1
2
3
4
5
Fig. 8.64 Core-pulling default settings 1

1 Selection of operating panel 4 Set value, "Monitoring cores moved IN (inj. position)"
2 Ejector additionally monitored in the operating panel 5 Set value, "Monitoring cores moved OUT (demolding pos.)"
3 Core-pulling expert mode
Selection of operating panel
Operating panel according to opening/closing program

If many cores move, the selected core runs the selection steps "Starting
conditions core/ejector" corresponding to the configured programming
MX_MC6_V1.9_07.09.15_ENG

©KM
Operating panel with sequence

When core-pulling module with sequence is used, the cores have to be selected
via keys according to the order in the core-pulling programming (see fig. 8.68,
page 8-468).
Without sequence, every individual core-pulling is moved independent of the
others according to its own programming.

Operating panel for moving in/out without sequence

Each button is assigned a direction of movement.
W
Important
Automatic moving-out cannot be specified because the sequence of other
possible cores is not known, or the free programming would be restricted.
"Core enabling via operating panel without sequence" (see section 8.8.4,
page 8-460).
Ejector additionally monitored in the operating panel

Limit position monitoring of the ejector during operation of the cores/ejector in the
"Core-pulling module" function.
If the limit position is not plausible, alarm A00941 "Monitoring ejector forward
movement/back" is displayed.
Core-pulling expert mode
I
Note
Activating and deactivating the tickbox "Core-pulling expert mode" is only
possible with key group 4.
Selection for limit position monitoring, core deactivation logic and Observe/Ignore
auxiliary signals is only possible in the core-pulling expert mode.


MX_MC6_V1.9_07.09.15_ENG
©KM

8.8.5.2 Core-pulling default settings 2
I
Note
Access to the "Core-pulling default settings 2" screen is only possible in the
core-pulling expert mode (see fig. 8.64, page 8-461).
2
1
Fig. 8.65 Core-pulling default settings 2

1 On in setting mode 2 "Activation/acknowledgement of core-pulling setting" button
The settings for activating/deactivating travel and monitoring functions for core-
MX_MC6_V1.9_07.09.15_ENG
pulling are made on the screen.

Depending on the number of cores available, other screen pages are provided via
©KM
additional tabs.

On in setting mode
If a programmed core-pulling is not to move and not to be monitored in setting
mode, the core-pulling can be switched off by deselecting the tickbox
(1, fig. 8.65).
This function continues to be active in manual, semi-automatic and fully automatic
mode.
I
Note
The selection of tickboxes (1) is only possible if the button
Core-pulling module (see section 6.9.1, page 6-292)
MX_MC6_V1.9_07.09.15_ENG
©KM

8.8.6 Core-pulling configuration
I
Note
The screen and its functions can only be accessed with key group 6.
The selection of screen functions is only possible if the button
"Activation/acknowledgement of core-pulling input" (3, fig. 8.66) has been
pressed.
3
1
Fig. 8.66 Core-pulling configuration

1 "Proportional valve" selection 3 "Activation/acknowledgement of core-pulling setting" button
2 Display/selection "Pump/battery" 1)
1)
MX_MC6_V1.9_07.09.15_ENG
The selection Pump/battery is only possible if the proportional valve (1) has been selected.
©KM
The setting for configuring the core-pulling is made on the screen.

Depending on the number of cores available, other screens are provided via
additional tabs.

Fig. 8.67 Core-pulling pump, request

1 "Core-pulling" actual value 2 "Pump" actual value
This screen page provides information on the pressure supply of the hydraulically
controlled core-pullings. The actual values issued from the pump due to core-
pulling are displayed.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.8.7 Core-pulling programming
W
Important
Faulty programming can cause the machine to come to a standstill or can lead
to the mold being damaged.
Particular care must be taken when programming the core-pulling.
In co-operation with the mold manufacturer, compile work instructions for the
injection molding cycle-dependent programming of the core movements.
I
Note
The core-pulling programming is only possible via the process designer
(see fig. 8.68, page 8-468)!
Basic principles of the process designer (see section 8.6, page 8-402).
I
Note
Programming the core-pulling is only possible if:
• The machine is at a standstill
• The authorization is granted via the corresponding key group
• Setting mode is selected
• Or the core-pulling setting is activated.
I
Note
Delete all displayed core steps before programming a new core-pulling
program.
MX_MC6_V1.9_07.09.15_ENG
©KM

12 1
11
10 2
9
3
Fig. 8.68 Core-pulling programming

1 Multi-select feature, library 7 "Delete all core steps" button
MX_MC6_V1.9_07.09.15_ENG
2 Selected core step 8 "Delete step" button

3 Available (activated) cores in the library 9 Cycle step main cycle
©KM
4 Detail view of the selected core step (core step programming 10 "Open detail view" button
(see section 8.8.7.3, page 8-475)) 11 "Show core interruptions" button
5 Detail button 12 "Editing mode" button
6 Main navigation for process designer (main key)
Colour scheme of cycle steps/nodes (see section 6.3.10.2, page 6-265).
Process designer cycle example (see section 8.6.3, page 8-412).

Changes to the core-pulling and its programming are possible by means of the
corresponding editing tools and the detail view (4, fig. 8.68) created by them in the
lower area of the screen.
I
Note
Editing tools and general changes in the cycle sequence (see section 8.6.1,
page 8-404).
After ending the core-pulling programming, the detail view (4) is closed again by
pressing the Detail button (5).
8.8.7.1 Interruptions
Interruptions to core-pulling
Fig. 8.69 Detail view (4, fig. 8.68), interruptions 1
With selected core step (2, fig. 8.68) and activated button "Open detail view" (10),
the setting for interrupting core-pulling can be displayed and changed on the
screen.
If a core step is selected (2, fig. 8.68), the cycle steps are displayed in the cycle
MX_MC6_V1.9_07.09.15_ENG
steps (9) that are interrupted by the core step.

©KM
Parameters and description (see section 8.8.2, page 8-455).

Core monitoring
1
2
Fig. 8.70 Detail view (4, fig. 8.68), interruptions 2

1 Set value, "Monitoring cores moved IN (inj. position)" 2 Set value, "Monitoring cores moved OUT (demolding pos.)"
With selected core step (2, fig. 8.68) and activated button "Open detail view" (10),
the setting for core monitoring can be displayed and changed on the screen.
Parameters and description (see section 8.8.2, page 8-455).


MX_MC6_V1.9_07.09.15_ENG
©KM

Programmed core interruptions
Fig. 8.71 Detail view, programmed core interruptions
If a cycle step is selected in the sequence that is interrupted by travelling cores,

all currently pending interruptions in the selected cycle step can be shown in the
detail view, by pressing the button "Show core interruptions" (11, fig. 8.68).
I
Note
In the diagrammatic display of the selected cycle step/node, only the first two
programmed interruptions are displayed.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.8.7.2 Inserting/deleting core step
Insert core step
I
Note
All possible cores for integration in the cycle sequence are in the library.
The cores available for MP and FP in the library must be activated so that they
can be integrated and programmed in the process.
"Core-pulling activation" (see section 8.8.1, page 8-453).
5 1
2
3
Fig. 8.72 Insert core step

1 Multi-select feature, library 4 Core inserted (selected in library)
MX_MC6_V1.9_07.09.15_ENG
2 Docking point for sequentially travelling core 5 "Editing mode" button

3 Docking point for parallel travelling core
©KM


2) Use the multi-select feature (1) of the library to select the corresponding
category of the cycle elements (cores MP or FP).
3) Select the core to be inserted (4) in the library.
The core can be inserted sequentially (2) or parallel (3).
One or more possible docking points (2/3) are set in the sequence. Only
logical options for the insert locations are offered in the sequence.
4) Press the desired docking point (2/3).
The selected core (4) is shown as a core step in the sequence.
5) If necessary, program the core step (see section 8.8.7.3, page 8-475).
MX_MC6_V1.9_07.09.15_ENG
©KM

Delete core step
1
3
Fig. 8.73 Delete core step

1 Selected core step 3 "Delete" button
2 "Delete all core steps" button 4 "Editing mode" button

2) Select the core step (1) to be deleted in the sequence.
3) Press the "Delete" button (3).
The selected core step is deleted from the sequence.
I
Note
MX_MC6_V1.9_07.09.15_ENG
By pressing the button "Delete all core steps" (2) all available core steps for
"Mold opening" or "Mold closing" (depending on the selected core step (1)) are
©KM
deleted from cycle sequence.

8.8.7.3 Core-step programming

2) Press the "Editing mode" button in the upper area of the process designer
screen.
3) Select core step:
• If necessary, add core step from library (see section 8.8.7.2, page 8-472).
• Select core step in the sequence.
4) Press the "Open detail view" button in the upper area of the process designer
screen.
In the lower area of the screen, the screen for programming the selected core
step (see fig. 8.74, page 8-475) opens.
14 1
13 2
3
12 4
11 10 9 8 7 6 5
Fig. 8.74 Core-step programming

1 Selection interruption 1) 8 Pressure for core movement [p] 5)
2 Selection of limit position monitoring 2) 9 Activation time for core movement [tS] 6)
3 Selection of core deactivation logic 2) 10 Quantity for core movement [Q] 5)
4 Selection of Observe/Ignore auxiliary signals 2) 11 Delay time for core activation [tV]
5 Stroke for interruption 3) 12 Selection of core/ejector starting condition
6 Stroke for starting condition 4) 13 Selection of core/ejector direction
7 After-run time for core activation [tN] 14 Core/ejector display
1) Interruptions predefined by KraussMaffei with the designation "KM: ****" cannot be changed.
2)
Selection is only possible in the core-pulling expert mode (see section 8.8.5.1, page 8-461).
3) Parameters only with selection of the interruption "KM: Mold closing position" / "KM: Mold opening position" (1). The actual-value display in each case corresponds to the parameter
MX_MC6_V1.9_07.09.15_ENG
entered in "Monitoring cores moved IN (inj. position)/OUT (demolding pos.)" (see fig. 8.70, page 8-470).
4)
Parameters only with selection of the starting conditions "KM: Stroke mold closing" / "KM: Stroke mold opening" (12).
©KM
5) Parameters only with selection of cores (14).

6) Parameters only with selection of the core/ejector direction "Move in core time-dependently" / "Move out core time-dependently" / "Ejector forward time-dependently" / "Ejector back
time-dependently" (13).

W
Important
For the selected cores/ejectors, suggested values for the respective conditions
(interruptions, limit position monitoring, core deactivation logic or
observe/ignore additional signals) are displayed.
In the case of uncertainty during programming, keep the suggested values
displayed.
Symbols for core step programming (see section 8.8.7.5, page 8-479).
I
Note
In the selection menus for interruptions, limit position monitoring, core
shutdown logic or observe/ignore additional signals, the permissible and
selectable fields are marked black.
5) Select core/ejector direction (13, fig. 8.74).

6) Select the starting conditions (12) for which the machine status starts the core
step.
7) Select the interruption (1) for which machine status ends the core step.
8) Select limit position monitoring (2).
9) Select core deactivation logic (3).
10) Select observe/ignore the additional signals (4).
11) Depending on the configured selection of the conditions, enter the
parameters for:
• Stroke for starting conditions (6)
• After-run time for core activation (7)
• Pressure for core movement (8)
• Activation time for core movement (9)
• Quantity for core movement (10)
• Delay time for core activation (11)
• Monitoring cores moved IN (inj. position)//OUT (demolding pos.)
(see fig. 8.70, page 8-470).
W
Important
For the Monitoring cores moved IN (inj. position)/OUT (demolding pos.), the
MX_MC6_V1.9_07.09.15_ENG
limit position must be reached. Otherwise the mold stops at the entered stroke.
©KM
I
Note
The listed parameters can also be entered with deactivated core-pulling
settings, in other words, during production.

12) After ending the core step programming, the detail view (4, fig. 8.68) in the
lower screen area is closed again by pressing the Detail button (5).
13) To close the programming, close the detail display and exit editing mode.
I
Note
During core step programming, the validity of the starting conditions
(12, fig. 8.74) and interruptions (1) is checked. Incorrect programming is
highlighted red.
Fig. 8.75 Core step programming - verification

1 Permissible parameter 2 Impermissible parameter
During programming, a check is always carried to determine whether the previous

core steps permit the programming. If programming of a core step is changed,
MX_MC6_V1.9_07.09.15_ENG
programming of the following core steps can be incorrect. The impermissible

parameters (2, fig. 8.75) of the following core steps are shown in red.
©KM
The starting conditions are checked to determine which conditions can be

selected. Starting conditions that existed before the preceding core steps cannot
be selected.

8.8.7.4 Moving cores at Mold closing/opening
Fig. 8.76 Moving cores at Mold closing/opening

1 Move cores at Mold closing 3 Programmed core step
2 Move cores at Mold opening
The screens "Move cores at Mold closing" (1, fig. 8.76) or "Move cores at Mold
opening" (2) display all programmed core steps as a tabular overview for Mold
closing and Mold opening respectively.
The defined settings (see section 8.8.7.3, page 8-475) are displayed partly only
as symbols.
Symbols for core step programming (see section 8.8.7.5, page 8-479).
MX_MC6_V1.9_07.09.15_ENG
©KM
Depending on the conditions that were selected, the following parameters are
also be freely entered on the screen:
• Stroke for starting condition (6, fig. 8.74)
• After-run time for core activation (7)
• Pressure for core movement (8)
• Activation time for core movement (9)
• Quantity for core movement (10)
• Delay time for core activation (11)

8.8.7.5 Symbols for core step programming
Core/ejector direction
Move core in, end-position Ejector forward, intermediate position 3
Move core out, end-position Ejector forward, time-dependent
Move in core time-dependently Ejector back, zero position
Move core out, time-dependent Ejector back, repeat position
Move core in, intermediate position Ejector back, stroke position
Move core out, intermediate position Ejector back, intermediate position 1
Ejector forward, repeat position Ejector back, intermediate position 2
Ejector forward, ejector stroke Ejector back, intermediate position 3
Ejector forward, intermediate position 1 Ejector back, time-dependent
Ejector forward, intermediate position 2 Ejector, sorting chute
Starting conditions for moving cores

Only the mold-related starting conditions and interruptions of the cores are
processed in setting, manual, semi-automatic and fully automatic mode. The
remaining starting conditions and interruptions are processed only in semi-
automatic and fully automatic mode.
W
Important
If a core is moved out during injection, and is to be moved out at Mold opening,
then this core also has to be programmed at Mold opening or Clamping force
release.
The same applies to cores that are moved out again at Mold closing.
Move cores at Mold closing
Without mold status Injection unit forward stroke

MX_MC6_V1.9_07.09.15_ENG
Start mold closing Start injection

©KM
Mold closing stroke Injection stroke
Start clamping force build-up Start holding pressure
End clamping force build-up End of holding pressure
Start injection unit forward

Move cores at Mold opening
Without mold status Stroke mold opening
Start clamping force release End mold opening
Start mold opening
Limit position monitoring
Without limit position monitoring With limit position monitoring

Limit position monitoring of the core for advancing Limit position monitoring of the core for advancing
the cores. If a core leaves its limit position, this has the cores. If a moved core leaves its limit position,
no effect on other cores. then all subsequently programmed cores are
stopped.
Core deactivation logic
Standard Ejector/unscrewing device

The cores remain activated when the limit position The cores are switched off when the limit position
is reached and are pressurized during injection and is reached.
holding pressure.
With hold function 1)
The cores remain activated until the
countermovement of the core.
1) Hold function can be used for "Retain ejector at rear" (see section 8.7.3.5, page 8-442) and for "Ejector return on mold closing" (see fig. 8.52, page 8-442).
Parallel/sequential start
Parallel Sequential
Core is activated parallel to the preceding core Core is activated after completion of the preceding
step. core step.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9 Injection unit
8.9.1 Holding pressure – injection

The "Holding pressure - injection" screen contains all the parameters that are
needed to control the speed and pressure for the injection process.
8.9.1.1 Injection
1 2 3
5
15 6
7
8
10
14 13 12 11
MX_MC6_V1.9_07.09.15_ENG
Fig. 8.77 Injection

©KM
1 Maximum injection speed 9 "Screw travel" set value

2 Melt cushion 10 "Melt pressure" actual value
3 "Screw travel" actual value 11 "Edit" button 3)
4 Maximum injection pressure 12 "Screw travel" profile setting
5 Start position of screw for injection (set value) 13 "Injection pressure" profile setting
6 "Injection time" actual value 14 "Injection speed" profile setting
7 "Monitoring time" set value 1) 15 Marking for profile setting 4)
8 Enabling stroke 2)
1) Parameter only with selection of change-over criterion "Stroke" / "Melt pressure" / "Mold cavity pressure" (4, fig. 8.78).
2)
Parameter only with selection of change-over criterion "Melt pressure" / "Mold cavity pressure" / Temperature (4, fig. 8.78).

During injection, the screw, acting as a plunger, pushes the plastic melt into the
closed mold using the defined pressure (injection pressure) and speed (injection
speed).
Depending on the material or geometry of the article, the screw advance speed
and the injection pressure limit can be influenced.
The screw moves forward with the defined injection speed to the change-over to
holding pressure position. The holding pressure phase starts.
The injection process can be executed with uniform or with different pressure
limits and speed values across the entire stroke.
Up to 16 pressure and speed values can be entered in the "Injection" screen half
which can be triggered at positions during the injection stroke.
If the "hand symbol" appears on the screen, the input is incomplete or not
plausible.
Profile stages
configured.

The movement takes place with a uniform speed. The injection pressure is limited
to one pressure set value.

Different pressure limits and speed values are used for the movement.
I
Note
The inputs for each profile stage must be complete (values for speed, pressure
limiting and stroke).
Profile stages are only effective in semi-automatic and fully automatic modes.


MX_MC6_V1.9_07.09.15_ENG
©KM

Injection pressure
w
D
Caution
injection pressure.
Within the injection stroke, the injection pressure can be influenced using up to 16
different set values. Set values in the range from 0 to maximum pressure can be
entered for limitation of injection pressure.
Stroke positions
Stroke positions within the injection stroke to define the change-over from one
speed/pressure value to the next.
The speed/pressure value assigned in the "Profile settings" window is used from
one change-over point to the next.
Monitoring time
The monitoring time starts with "Start injection".
If the change-over point to holding pressure is reached before the monitoring time
has expired, machine operation continues as usual.
However, if the monitoring time expires before the change-over point is reached,
the machine is switched to holding pressure, and the current cycle is completed.
In view of the fact that the cycle was not performed properly, however, the
machine stops at the end of the cycle with alarm A00064 "Switch off holding
pressure".
The cycle can be started by eliminating the cause of the problem and resetting the
alarm.
If no value is entered here (set value = 0), there is no time monitoring.
Enabling stroke
The enabling stroke is only adjustable if Start holding press. through melt
pressure, mold cavity pressure or temperature is set.
When the enabling stroke has been reached, the system checks whether the
change-over measurement value is reached. Only then does the holding pressure
phase start.
MX_MC6_V1.9_07.09.15_ENG
©KM

Alarms
A00120 "Injection speed out of tolerance"

The injection speed cannot be controlled.
A00122 "Injection pressure profile 1 reached"

The injection pressure increased so much during the injection process that the
defined pressure limit value was reached. The speed can no longer be controlled.
A00123-A00133 "PV control: pressure limitation at profile nn"

The injection pressure increased so much during the injection process that the
defined pressure limit value was reached. The speed can no longer be controlled.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.1.2 Holding pressure
1
2
10
5
6
7
8
Fig. 8.78 Holding pressure

1 "Holding pressure" actual value 6 "Holding pressure time" profile setting
2 Maximum holding pressure 7 "Edit" button 1)
3 Total holding pressure time 8 "Cooling time" actual/set value
4 Selection "Start holding press. through" (Switching criteria) 9 Holding pressure profile interpolated
5 "Holding pressure" profile setting 10 Marking for profile setting 2)
2)
Changing profile stages (see section 6.3.4.2, page 6-251)
If the injection conditions match the defined change-over criterion, the system
switches to holding pressure.
During the holding pressure phase the screw, limited by pressure and time
MX_MC6_V1.9_07.09.15_ENG
values, acts on the melt injected in the mold. The holding pressure initially
balances the volume contraction of the article due to cooling and mainly affects
©KM
quality features of the articles, such as weight, sink points, shrinkage and
deformation.
Pressure and time values can be entered in up to 16 selectable profile stages on

the "Holding pressure" half of the screen.
plausible.

Profile stages
configured.

The movement is executed using a uniform holding pressure.

The movement is executed using different holding pressure and time values.
I
Note
The inputs for each profile stage must be complete (values for holding pressure
and time).
A constant holding pressure (stage 1) is used in the setting and manual modes.


Holding pressure
Within the holding pressure time, the holding pressure can be influenced using up
to 16 different set values.
Holding pressure time

The holding pressure time can be set using up to 16 different stages.
The total holding pressure time is the sum of the individual times.
For display (see section 8.13.1, page 8-600).
Selection "Start holding press. through" (Switching criteria)
Start holding press. through stroke

When the screw reaches the defined stroke during the injection process, the
system switches to holding pressure.
Start holding pressure through time

When the time defined for the injection process expires, the system switches to
MX_MC6_V1.9_07.09.15_ENG
holding pressure.
©KM
Start holding pressure through temperature

When the screw reaches the enabling stroke during the injection process, the
measured temperature is interrogated.
The microprocessor detects the change-over moment using the temperature
signal measured at the end of the flow path in real time and outputs it as a logic
signal.

Start holding pressure through melt pressure

pressure is interrogated.
When the melt pressure in the screw tab reaches the defined value, the system
switches to holding pressure.
Holding pressure through melt pressure, flow chart:
1 2 5 6 7
16
3 8
15
14 9
10
11
12
13
Fig. 8.79 Holding pressure through melt pressure, flow chart

1 Holding pressure 9 Screw decompression 2 after plasticizing
2 Change-over point 10 Enabling stroke pressure switching
3 Actual-value of melt pressure 11 Plasticizing stroke
4 Injection phase 12 Actual-value injection time
5 Screw efficiency direction 13 Monitoring time, injection
6 Change-over melt pressure 14 Zero point
7 Injection pressure 15 Melt cushion
8 Start injection 16 Pressure rise 1)
1)
The pressure increase is only evaluated and used for change-over to holding pressure when the screw position is less than the enabling stroke.
As the mold cavity is filled during injection, the melt pressure in the screw tab and
therefore also the pressure in the hydraulic cylinder increases.
The pressure increase in the hydraulic cylinder is sensed by a pressure
transducer, converted to the melt pressure and compared to the melt pressure
set-value. If the change-over melt pressure is reached and the screw position is
MX_MC6_V1.9_07.09.15_ENG
less than the enabling stroke, the system switches to holding pressure.
©KM
The enabling stroke value to be entered should be larger than the value entered
for stroke-dependent change-over. This is necessary to avoid interpretation of
peak pressures at the beginning of the injection process as a change-over signal.
The monitoring time is entered to allow the cycle to be terminated in the event of
problems with the injection process.

Start holding pressure through mold cavity pressure

pressure is interrogated.
When the pressure in the mold reaches the defined value, the system switches to
holding pressure.
Holding pressure through mold cavity pressure, flow chart:
1 2 4
3 5
14 6
13
12
10
7
11
9
8
Fig. 8.80 Holding pressure through mold cavity pressure, flow chart
1 Switch-over pr. mold cavity pressure 8 Monitoring time, injection
2 Enabling stroke pressure switching 9 Actual-value injection time
3 Actual-value mold cavity pressure 10 Injection phase
4 Screw efficiency direction 11 Zero point
5 Plasticizing stroke 12 Melt cushion
6 Start injection 13 Holding pressure
7 Screw decompression 2 after plasticizing 14 Pressure rise 1)
1) The pressure increase in the mold is only evaluated and used for change-over to holding pressure when the screw position is less than the enabling stroke.
The actual value of the mold cavity pressure is sensed by a special pressure
transducer built into the mold.
As the mold cavity is filled during injection, the mold cavity pressure increases.
When the change-over pressure to mold cavity pressure is reached and the screw
MX_MC6_V1.9_07.09.15_ENG
position is less than the enabling stroke, the system changes over to holding
pressure.
©KM
The enabling stroke value to be entered should be larger than the value entered
for stroke-dependent change-over. This is necessary to avoid interpretation of
peak pressures at the beginning of the injection process as a change-over signal.
The monitoring time is entered to allow the cycle to be terminated in the event of
problems with the injection process.
Cooling time
Entry of time value for the cooling time. This time stage starts at the end of holding
pressure and enables mold opening when the defined time value is reached.

Profile interpolated
If this function is activated (9, fig. 8.78), a continuous progression is generated or
interpolated as of the first profile stage.
When using non-controlled machines, the holding pressure is always
interpolated.
For holding pressure interpolation, maximum pressure is requested from the
pump, so that the first profile stage can be moved to with max. possible temporal
pressure change.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.1.3 Injection/holding pressure auxiliary devices
I
Note
Machines can be equipped with an auxiliary device used to control a shut-off
nozzle.
1
2
3
4
Fig. 8.81 Injection/holding pressure, auxiliary devices 1 and 2

1 Selection "Nozzle shut-off" 4 Selection "Mold nozzle"
2 Selection "Open nozzle with delay" 5 Selection "Open mold nozzle"
3 Shut-off nozzle left open in automatic mode
MX_MC6_V1.9_07.09.15_ENG
Selection "Nozzle shut-off"

©KM
No nozzle shut-off
The nozzle shut-off is not activated.
Nozzle shut-off after decompression 1

The nozzle is opened in semi-automatic and fully automatic modes when "Screw
decompression 1" takes place before plasticizing. Note injection unit movement
settings.

Nozzle shut-off after end of holding pressure

The shut-off nozzle is open during "Injection" and "Holding pressure".
The nozzle closes at the end of holding pressure and is not opened during screw
decompression.
Nozzle shut-off after plasticizing

The nozzle also opens during "Screw decompression 1" before plasticizing.
Nozzle shut-off after decompression 2

The nozzle opens during "Screw decompression 2" after plasticizing.
W
Important
If the nozzle is opened with the "Screw decompression" signal when one of the
functions is activated, the hydraulic/mechanical screw decompression
movement can only take place if the "Nozzle open" limit switch is actuated.
This limit switch is checked for the "open" state during the entire injection and
holding pressure phase. If the "open" signal goes off, the current cycle is
interrupted and the screen shows step P00079 "Shut-off nozzle not open".
Selection "Open nozzle with delay"
No nozzle early opening

The nozzle will not be opened early.
Delayed mold nozzle opening with beginning of mold closing

The delay time is started at the beginning of "Mold closing". Upon expiration of the
delay time, the nozzle is opened.
Open nozzle with delay at start of clamping force build-up

At the start of "clamping force build-up" the delay time is started. The nozzle shut-
off is opened after the delay time has elapsed or with the start of injection at the
latest.
Delayed nozzle opening

The delay time is started with the "Open nozzle early" function.
MX_MC6_V1.9_07.09.15_ENG
Delayed mold-nozzle closing

©KM
The delay time is started at the end of "Screw decompression 1".
Shut-off nozzle left open in automatic mode

Setting mode
The "Injection" or "Screw decompression" signal first opens the nozzle ("Nozzle
open" limit switch actuated) before "Injection" or "Screw decompression" is
performed.
The nozzle closes when the "Injection" button or "Screw decompression" button
is released.
The following functions can only be performed when the nozzle is closed (limit
switch "Nozzle closed" actuated):
• Mold opening
• Injection unit return
• Plasticizing
Open nozzle shut-off

The "Injection" signal activates the "Nozzle opening" function.
The injection process is not enabled until the nozzle is open (limit switch "Nozzle
open").
Close nozzle shut-off

The nozzle is closed in semi-automatic or fully automatic mode depending on the
set function - however, at the latest with lifting injection unit or mold opening.
Selection "Mold nozzle"

If the function of a mold nozzle is activated in the selection field (4, fig. 8.81), the
opening and closing of the mold nozzle is controlled via a time delay depending
on the operating mode selected.
Mold nozzle OFF

The mold nozzle is not activated.
Pneumatic mold nozzle

The mold nozzle is actuated via a pneumatic valve.
Hydraulic mold nozzle

The mold nozzle is actuated via a hydraulic valve.
Delay time injection, mold nozzle

The delay time is started by pressing the "Injection" button in setting and manual
MX_MC6_V1.9_07.09.15_ENG
modes, and then the mold nozzle is opened. The nozzle is closed when the
"Injection" button is no longer pressed.
©KM
The delay time is started in semi-automatic and fully automatic modes with "Start
injection", and then the mold nozzle is opened.
Delay time injection (see section 8.13.1.1, page 8-600).
Delayed nozzle 1 closing at end of holding pressure

At the end of holding pressure, the delay time is started. Upon expiration of the
delay time, mold nozzle 1 is closed.

Delayed nozzle 2 opening from start of injection

The delay time is started with "Start injection". Upon expiration of the delay time,
mold nozzle 2 is opened.
Delayed nozzle 2 closing at end of holding pressure

At the end of holding pressure, the delay time is started. Upon expiration of the
delay time, mold nozzle 2 is closed.
Selection "Open mold nozzle"
Open mold nozzle after end of closing-force buildup

The mold nozzle is opened with "Clamping force reached".
Delayed mold nozzle opening during Mold closing

The delay time is started at the beginning of Mold closing. Upon expiration of the
delay time, mold nozzle is opened.
Delayed mold nozzle opening at start of clamping force build-up

The delay time is started with "Mold closed". Upon expiration of the delay time,
mold nozzle is opened.
Delay time for opening mold nozzle

The delay time is started according to the selection criterion. Upon expiration of
the defined time, the mold nozzle is opened.
Selection "Open mold nozzle"
Open mold nozzle after end of closing-force buildup

The mold nozzle is opened with "Clamping force reached".
Delayed mold nozzle opening during Mold closing

The delay time is started at the beginning of Mold closing. Upon expiration of the
delay time, mold nozzle is opened.
Delayed mold nozzle opening at start of clamping force build-up

The delay time is started with "Mold closed". Upon expiration of the delay time,
mold nozzle is opened.
Delay time for opening mold nozzle

The delay time is started according to the selection criterion. Upon expiration of
the defined time, the mold nozzle is opened.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.1.4 Injector set-up/calibration
Fig. 8.82 Injector set-up/calibration
Set-up speed, injection

Input of the speed at which injection is carried out in setting mode.
Setting injection pressure

Input of the injection pressure to which injection is limited in setting mode.
Calibration speed, injection

Input of the speed at which injection is carried out during calibration.
Injection calibration pressure

MX_MC6_V1.9_07.09.15_ENG
Input of the injection pressure to which the pressure is limited during the
©KM
calibration process.

8.9.2 Plasticizing
8.9.2.1 Plasticizing
1
18
17 2
16
15 3
14 4
13 5
12 6
11 7
10 8
9
Fig. 8.83 Plasticizing

1 "Plasticizing stroke" actual value 10 "Speed at screw decompression 1" set value
2 Maximum plasticizing stroke 11 "End screw decompression 1" set value
3 Configured plasticizing stroke including screw decompression 2 12 "Plasticizing stroke" profile setting
4 "Plasticizing RPM" actual value 13 "Melt pressure" profile setting
5 "Melt pressure" actual value 14 "Plasticizing RPM" profile setting
6 "Plasticizing stroke" set value 15 Set plasticizing RPM
7 "Screw decompression 2" set value 16 Marking for profile setting 2)
8 "Speed at screw decompression 2" set value 17 Maximum plasticizing RPM
9 "Edit" button 1) 18 Display of melt cushion
MX_MC6_V1.9_07.09.15_ENG
©KM
This screen contains all parameters necessary to set the RPM and back-
pressure. The back-pressure or profile values refer to the melt pressure built up
in the screw tab during plasticizing.
After the plasticizing process, the melt in the screw tab is under pressure. In order
to relieve the pressure on the melt, the screw can be pulled back hydraulically
after the end of the plasticizing process. This is "compression relief" or "screw
decompression 2".

After the injection process and completion of the holding pressure phase, the melt
in the entire sprue system (hotrunner) and in the screw tab is under pressure. This
pressure can be relieved by pulling the screw back hydraulically before the
beginning of the plasticizing process (= "Screw decompression 1").
Rotational speed and back pressure on the screw plasticizing stroke can be
entered in up to 16 selectable profile stages on the screen.
plausible.
Profile stages
configured.

The RPM and back-pressure values used are uniform.

Different RPM and back-pressure values are used.
W
Important
The inputs for each profile stage must be complete (values for RPM and back-
pressure).
Uniform RPM and back pressure values are used in the setting mode.


RPM values
Stroke positions are used to switch from one RPM set value to the next during
plasticizing, i.e. the screw speed changes.
Back pressure values

Stroke positions are used to switch from one back-pressure value to the next
MX_MC6_V1.9_07.09.15_ENG
during plasticizing.
©KM
The pressure set values are used to influence the melt pressure in the screw tab
during plasticizing. The pressure is generated by the return of the injection
plunger and oil displaced.
Start plasticizing delayed

The plasticizing procedure can be delayed. The delay time can be directly
changed on the "Overview times" screen (see section 8.13.1, page 8-600).
The "Start plasticizing delayed" timer is started at the end of holding pressure and
is only active in semi-automatic or fully automatic mode.

Stroke positions
I
Note
The screw moves from low to higher stroke positions during plasticizing. The
stroke position input values therefore start with low values.
Up to 16 stroke positions can be input which are used to switch from one
RPM/back-pressure value to the next.
Plasticizing stroke
This parameter determines the volume of the plasticized material that is injected
during the next cycle.
The stroke value is relative to the zero point of the screw (= front limit position) up
to beginning of screw decompression 2.
Screw decompression 1
Screw decompression distance between the melt cushion and the beginning of
plasticizing.
Input is relative to the screw zero point.
Speed at screw decompression 1

Speed at decompression of the screw after injection.
Screw decompression 2
Screw decompression distance after plasticizing.
The input depends on the plasticizing stroke position.
Speed at screw decompression 2

Speed at decompression of the screw after plasticizing.
MX_MC6_V1.9_07.09.15_ENG
©KM

Display of melt cushion

Display of the minimum screw position reached during "Holding pressure".
Actual-value display of melt cushion (see section 8.12.1.1, page 8-584).
"Plasticizing RPM" actual value

Display of the screw speed during "plasticizing".
I
Note
Different screw diameters in identical injection unit sizes are possible. This
means that the injection volume for the same screw stroke may be different.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.2.2 Plasticizing configuration
1
2
3
4
Fig. 8.84 Plasticizing configuration

1 Plasticizing at reduced back-pressure (S- and M-mode) 3 Max. monitoring time of plasticizing
2 Reduced back-pressure during plasticizing (S- and M-mode) 4 Monitoring time of plasticizing
Plasticizing at reduced back-pressure (S- and M-mode)

When the tickbox is selected, the back-pressure is limited to the set value in
setting mode and manual mode.
Reduced back-pressure during plasticizing (S- and M-mode)

Pressure value with which plasticizing is to be performed in setting mode and
manual mode.
MX_MC6_V1.9_07.09.15_ENG
Max. monitoring time of plasticizing

©KM
I
Note
Input of monitoring time is only possible in key group 5 and beyond.
The maximum monitoring time is used to protect the machine.

If plasticizing is not complete within the selected time, the alarm "Plasticizing time
monitor" is issued.
Monitoring time of plasticizing

The monitoring time for plasticizing can be entered.
The minimum input value is 0.1 s.
If plasticizing is not complete within the selected time, the alarm "Plasticizing time
monitor" is issued.
8.9.2.3 Plasticizing auxiliary devices
1
2
3
Fig. 8.85 Plasticizing auxiliary devices

1 Selection of "Extrusion" 3 Extrusion time
2 RPM for extrusion
MX_MC6_V1.9_07.09.15_ENG
©KM
Extrusion-injection
Only possible in the semi-automatic and fully automatic modes. The plasticizing
stroke must have been reached.
The mold is partially filled by additional extrusion.
RPM for extrusion

Entering the RPM for extrusion speed and transported quantity of plastic are
determined.

Extrusion time
When the nozzle contact pressure has been reached during the cycle, plasticizing
and the extrusion timer are started.
Upon expiration of the extrusion time the cycle continues normally with injection,
holding pressure and plasticizing.
Extrusion
Only possible in the semi-automatic and fully automatic modes.
The screw must be in the front position.
The position must be less than the change-over point to holding pressure (Start
holding pressure through stroke must have been selected).
The extrusion process starts when the nozzle contact pressure has been reached
in the cycle.
The melt pressure built up by the mold filling process moves the screw back.
When the enabling stroke for holding pressure change-over is reached, the
extrusion is switched off, and the machine switches to holding pressure (with or
without profile).
The screw remains in the front position at the end of the holding pressure time,
plasticizing is not performed.
RPM for extrusion

Entering the RPM for extrusion determines the duration of the mold filling
process.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.3 Injection unit
8.9.3.1 Injection unit movement
1
2
3
9 4
8 5
7 6
Fig. 8.86 Injection unit movement

1 "Injection unit movement" selection menu 6 Set value "Injection unit return, speed 2"
2 Set/actual value "Injection unit stroke" 7 Set value "Injection unit forward, speed 2"
3 Set value "Nozzle contact force" 8 Set value "Injection unit forward, changeover point"
4 Set value "Injection unit return, speed 1" 9 Set value "Injection unit forward, speed 1"
5 Set value "Injection unit return, changeover point"
This screen shows all the parameters related to the forward and backward
movement of the injection unit (nozzle).
MX_MC6_V1.9_07.09.15_ENG
If moving with injection unit movement, the injection unit advances to the change-
©KM
over point at speed 1. Then speed 2 is used for the remainder of the movement
up to nozzle contact. The nozzle contact force is built up.
The injection unit return movement starts at speed 1. Speed 2 is used from the
change-over point on to the "Injection unit stroke" position.

"Injection unit movement" selection menu
Without injection unit movement (cycle with nozzle contact)

The nozzle remains in the front position during the entire cycle and is not lifted off.
Decompression 1: screw decompression 1 before plasticizing
Decompression 2: screw decompression 2 after plasticizing
Injection unit return — decompression 1 — plasticizing — decompression 2

After the end of the holding pressure time, the injection unit is first moved back.
Then the screw movement starts. The injection unit movement is not started until
the "Delay time, Injection unit return" has elapsed.
For input of "Delay time, Injection unit return", see "Overview times"
Decompression 1 — injection unit return — plasticizing — decompression 2

At the end of holding pressure time, screw decompression 1 takes place. The
injection unit then moves back. Subsequently the screw movement continues.
The injection unit movement is not started until the "Delay time, Injection unit
return" has elapsed.
Decompression 1 — plasticizing — injection unit return — decompression 2

The end of the holding pressure time is followed by screw decompression 1 and
plasticizing. Then the injection unit moves back. This is followed by screw
decompression 2. The injection unit movement is not started until the "Delay time,
Injection unit return" has elapsed.
Decompression 1 — plasticizing — decompression 2 — injection unit return

The screw movements take place after the end of the holding pressure time.
Subsequently the injection unit moves back. The injection unit movement is not
started until the "Delay time, Injection unit return" has elapsed.
I
Note
MX_MC6_V1.9_07.09.15_ENG
If the mold is not installed, the nozzle insertion depth as specified in the "Mold
connection dimensions" must not be exceeded when using longer screw
©KM
barrels (longer than base equipment of machine).

The change in length is to be taken into account for the injection unit stroke.
Mold connection dimensions (see chapter 15 Parts lists/drawings).

Injection unit stroke

Distance between nozzle contact and the rear injection unit position.
Nozzle contact force (ZE)

If the injection unit is in the nozzle contact position, the nozzle contact pressure is
built up until the defined value is reached.
Injection unit forward
Speed 1
Effective from the "Injection unit stroke" position up to the "Injection unit forward"
change-over point.
Change-over point
This is the position where the transition from speed 1 to speed 2 takes place.
Speed 2
Effective from the "injection unit forward" change-over point up to nozzle contact
with the mold.
Injection unit return
Speed 1
Effective from nozzle contact up to the "injection unit return" change-over point.
Change-over point
This is the position where the transition from speed 2 to speed 1 takes place.
Speed 2
Effective from the "injection unit return" change-over point up to the injection unit
stroke position.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.3.2 Injection unit auxiliary devices
Fig. 8.87 Injection unit auxiliary devices

1 "Injection unit forward" selection menu 2 Cold-slug ejection
"Injection unit forward" selection menu

The following starting conditions can be selected for injection unit movement:
• Injection unit forward after end of clamping force build-up
• Injection unit forward at start of clamping force build-up
• Injection unit forward at start of mold closing
Minimum clamping force for enabling inj. unit

Definition of the smallest possible clamping force for enabling the nozzle contact
MX_MC6_V1.9_07.09.15_ENG
pressure build-up.
©KM
Delay time for Injection unit forward

Definition of the time to the start of injection unit movement.

Cold-slug ejection
The function is only effective for movement with lift-off nozzle. Otherwise, "No
cold-slug expulsion, during nozzle contact" is displayed in the screen.
The cold slug is ejected when the clamping pressure is built up and the injection
unit is moved back.
The screw is moved forward with a fixed speed value and injection pressure by
the defined "ejecting stroke".
When the screw has moved the defined distance, "Cold slug ejection" is switched
off, the injection unit moves forward to the nozzle contact position, and the
machine cycle continues.
Ejecting stroke
Stroke of screw for cold slug ejection.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.3.3 Injection unit set-up/calibration
Fig. 8.88 Injection unit set-up/calibration
Setting-speed injection-unit forward

Input of the speed at which the injection unit moves forward in setting mode.
Injection unit setting force

Input of the force at which the injection unit moves forward in setting mode.
Setting-speed injection-unit return

Input of the speed at which the injection unit moves back in setting mode.
Setting force, Inj. unit back

MX_MC6_V1.9_07.09.15_ENG
Input of the force at which the injection unit moves back in setting mode.
©KM
Calibration speed, Injection unit forward

Input of the speed at which the injection unit moves forward during the adjustment
process.
Calibration force, Inj. unit forward

Input of the force with which the injection unit moves forward during the
adjustment process.

Calibration speed, Injection unit return

Input of the speed at which the injection unit moves backward during the
adjustment process.
Calibration force, Inj. unit return

Input of the force with which the injection unit moves backward during the
adjustment process.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.4 Start-up/lowering, purging control
8.9.4.1 Start-up/lowering
Fig. 8.89 Start-up/lowering

1 "Machine start-up switching" selection menu
Values for injection, holding and back-pressure and for the plasticizing stroke that
deviate from the production values can be entered here for the machine start-up
phase.
The duration of the start-up phase is determined by an adjustable number of
machine cycles (strokes). Then the control system automatically switches to the
production values.
MX_MC6_V1.9_07.09.15_ENG
When the start-up switching is active, the activated tolerance monitoring function
©KM
is ignored and "bad parts" are signalled.

The "Reject" signal is output at the robot interface.
The activated tolerance monitoring function is automatically reactivated upon
completion of the start-up switching.
The machine start-up circuit is enabled in the following cases:

• the production was interrupted for longer than the set time.
• the temperature lowering function has been active.

"Machine start-up switching" selection menu
Start machine with start-up values

When the start-up circuit is enabled, the machine performs the defined number of
cycles with the start-up values.
The screen displays the corresponding message.
Start machine with production values

When the start-up circuit is enabled, the defined number of manual purging
strokes must be carried out manually.
The screen displays the corresponding message.
Number of manual purging strokes

Enter the number of purging strokes before an automatic cycle can be started.
Purging must be carried out manually (in setting mode). If the required number of
injection strokes is not performed, the step P00121 "Start-up circuit: Material not
fully injected" appears in the status line when a cycle is initiated.
If the counter is set to "0", the automatic cycle can start immediately (no manual
purging).
Number of cycles for start-up switching

The machine switches to the production parameters when the preselected
number of start-up cycles is reached.
Monitoring time during production interruption

The start-up circuit is activated upon expiration of this time.
The monitoring time starts when the following preconditions are met:
• The operating mode "Stop", Oil preheating, setting or manual is selected.
• Alarms causing cycle interruption are pending (alarm messages on red
background).
• The cycle has not been restarted in semi-automatic or fully automatic mode
after the pause time expires.
The pause time is entered in the "Overview times" screen (see section 8.13.1,
page 8-600) (also in semi-automatic mode).
MX_MC6_V1.9_07.09.15_ENG
©KM

Constant start-up injection pressure

Injection pressure limit value for the start-up cycles with start-up values.
Start change-over pt. to holding pr.

Change-over point for start-up switching
Monitoring time, start-up/holding-pressure change-over

Monitoring time, start-up/holding-pressure change-over for start-up switching.
Constant start-up holding pressure

Holding pressure value for the start-up cycles with start-up values.
Constant start-up back-pressure

Back-pressure value for the start-up cycles with start-up values.
Start-up plasticizing stroke

Plasticizing stroke during the start-up cycles with start-up values.
Start-up cooling time

Cooling time for start-up switching.
Max. duration of the movement force limitation for start-up switching

Mold safety monitoring time for the start-up cycles
It starts when the current closing speed is only 50% of the respective profile
stage's set speed.
If the next profile stage is reached in the selected monitoring time, the time is
reset. If the next profile stage is not reached within the selected monitoring time,
the monitoring time triggers the A00007/A00009 "Mold safety" alarm. The closing
movement is aborted.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.4.2 Purging control
W
Important
The purging program is only active in manual mode. Stroke point for "Start
plasticizing" must be set to a smaller value than the plasticizing stroke.
Fig. 8.90 Purging control

1 "Plasticizing with/without purging" selection menu 2 "Start purging program" bar
"Plasticizing with/without purging" selection menu
Plasticizing without purging

MX_MC6_V1.9_07.09.15_ENG
If the "Start purging program" pushbutton (2, fig. 8.90) is pushed, the injection unit
©KM
automatically travels back. The screw positions itself automatically by calling up

the function "Injection" (with setting values) or "Screw decompression" to the
stroke point "Start plasticizing". Following this, plasticizing is carried out at the set
speed and back-pressure until the plasticizing time entered has elapsed. When
the time has elapsed, the function is ended and can be called up again by
actuating the pushbutton.

Plasticizing with purging

In addition to the above-mention function, during "Plasticizing without purging"
slow purging (at set-up speed) is started after the plasticizing time has elapsed.
When the change-over stroke from injection to holding pressure (see fig. 8.78,
page 8-485) is reached, injection is ended.
If a value > 0 is entered for the repeat counter, screw decompression is carried
out up to the stroke "Start plasticizing". Here, plasticizing is carried out again,
followed by purging. After the last purging procedure, the screw comes to a stop
on the change-over stroke from injection to holding pressure.
Start plasticizing
Input of the position at which the plasticizing unit starts.
RPM
Input of the speed (rpm) at which plasticizing takes place.
Back-pressure
Input of the pressure at which plasticizing takes place.
Plasticizing time
Input of the time in which plasticizing takes place.
Repeat counter for plasticizing/purging

Input of the number of repeats of plasticizing/purging (only with "Plasticizing with
purging".
Start purging program

The purging program (2, fig. 8.90) is started manually by pushing the button.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.5 Cascade control

Up to 32 mold nozzles can be activated pneumatically or hydraulically. The
activation for Open mold nozzle or Close mold nozzle can be stroke-dependent
or time-dependent.
The mold nozzles can each be opened and closed twice both during injection and
in holding pressure.
The Injection delay time can be entered to ensure that the mold nozzle is opened
with Start injection.
Z
B
Protective clothing
Wear personal protective equipment when working with a safety gate open.
I
Note
With the cascade control active, at least one mold nozzle must always be
opened. Otherwise alarm A00200 "Injector: no nozzle open during injection" is
displayed.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.5.1 Nozzle cascade control (injection)
11 2
10 3
9 8 7 6 5 4
Fig. 8.91 Nozzle cascade control (injection)

1 Cascade control, mold-nozzle 7 Open mold nozzle after time
2 Open/close mold nozzle for the second time 8 "Open mold nozzle" selection field
3 Open mold nozzle in setting mode 9 Open mold nozzle after stroke
4 Close mold nozzle after time 10 Selection field "Mold nozzle inactive/pneumatic/hydraulic"
5 "Close mold nozzle" selection field 11 LED display "Output valve pneumatic/hydraulic"
6 Close mold nozzle after stroke
Functions and parameters (see section 8.9.5.4, page 8-518)

MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.5.2 Nozzle cascade control (holding pressure)
11 2
10 3
9 8 7 6 5 4
Fig. 8.92 Nozzle cascade control (holding pressure)

1 Cascade control, mold-nozzle 7 Open mold nozzle after time
2 Open/close mold nozzle for the second time 8 "Open mold nozzle" selection field
3 Open mold nozzle in setting mode 9 Open mold nozzle after stroke
4 Close mold nozzle after time 10 Selection field "Mold nozzle inactive/pneumatic/hydraulic"
5 "Close mold nozzle" selection field 11 LED display "Output valve pneumatic/hydraulic"
6 Close mold nozzle after stroke
Functions and parameters (see section 8.9.5.4, page 8-518)

MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.5.3 Cascades configuration
1
2
3
4
5
Fig. 8.93 Cascades configuration

1 Cascade control, mold-nozzle 4 Cascade control, mold-nozzle with position monitoring
2 "Cascade control, Delay time injection" set value 5 No monitoring for open nozzle in holding pressure
3 "Cascade control, Close nozzle with delay as of end of holding
pressure" set value
Cascade control, mold-nozzle

When the tickbox (1, fig. 8.93) is selected, the cascade control is activated.
Cascade control, delay time injection

The set value for injection delay as of open mold nozzle is entered in the field (2).
MX_MC6_V1.9_07.09.15_ENG
Cascade control, close nozzle with delay as of end of holding pressure

©KM
The set value for the delay for mold nozzle closing after end of holding pressure
is entered in the field (3).
All mold nozzles that are still open are closed.
Cascade control, mold-nozzle with position monitoring

With the tickbox (4) activated, the position of the mold nozzles is monitored via
limit switches.

No monitoring for open nozzle in holding pressure

If, for a certain applications, all nozzles have to be closed already before the end
of holding pressure, the monitoring for open nozzles can be deactivated by
selecting the tickbox (5, fig. 8.93). This means that alarm A00200 "Injector: no
nozzle open during injection" is bypassed.
8.9.5.4 Functions and parameters of the cascade control
Cascade control, mold-nozzle

When the tickbox (1, fig. 8.91)/(1, fig. 8.92) is selected, the cascade control is
activated.
Open mold nozzle in setting mode

When pressing the "Open mold nozzle in setting mode" button in setting mode,
all mold nozzles that are selected in the "Nozzle cascade control
(injection/holding pressure)" screen and the tickbox "Open mold nozzle in setting
mode" (3) are opened.
Mold nozzle
If the function of a mold nozzle is activated in the selection field (10), the opening
and closing of the mold nozzle is controlled via a time delay depending on the
operating mode selected.
Mold nozzle inactive

The mold nozzle is not activated.
Pneumatic mold nozzle

The mold nozzle is actuated via a pneumatic valve.
Hydraulic mold nozzle

The mold nozzle is actuated via a hydraulic valve.
"Open/close mold nozzle" selection field

In the selection field, the selection criterion for opening (8) or closing (5) the
respective nozzle is defined.
• Only stroke (s), stroke-dependent:
When the set stroke position of the screw is reached, the mold nozzle is
opened/closed.
• Only time (t), time-dependent:
MX_MC6_V1.9_07.09.15_ENG
The time is started with Injection start or with Start holding pressure.
©KM
After the set time has elapsed, the mold nozzle is opened/closed.
• Conjunction (&), stroke and time reached:
If both starting conditions (stroke and time) are fulfilled, the mold nozzle is
opened/closed.
• Disjunction (OR) (I), stroke or time reached:
If a starting condition (stroke or time) is fulfilled, the mold nozzle is
opened/closed.

Nozzle opening/closing delay time

The delay time for nozzle opening (7, fig. 8.91) or closing (4) is started in
accordance with the selection criterion (8 or 5). Upon expiration of the defined
time, the mold nozzle is opened.
8.9.5.5 Cascade control symbol explanation

1) Select the "Nozzle cascade control" screen (Fig. 8.91 / Fig. 8.92).
A pop-up window with the cascade control symbol explanation opens.
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 8.94 Cascade control symbol explanation

8.9.6 Adaptive Process Control - injection/holding pressure
8.9.6.1 Batch change control (ZE 89.528)
1
2
3
4
5
6
7
Fig. 8.95 Adaptive Process Control - injection/holding pressure (1/2)

1 Selection "Batch change control" 5 Selection of "Control intervention limit"
2 Selection switch "Batch change control on" 6 Selection of "Holding pressure correction"
3 Actual value for "Holding pressure adaptation" 7 Selection "Batch change control measuring point"
4 Input for "Maximum holding pressure adaptation"
These screen pages are provided for adjusting the APC values (Adaptive Process
Control) that are normally adapted automatically via the Batch change control
function.
MX_MC6_V1.9_07.09.15_ENG
The "Batch change control" function keeps a selected mold cavity pressure
constant by changing the holding pressure. This permits automatic balancing of
©KM
influences such as changed material batches or temperature changes.
Selection field "Batch change control"
Batch change control

If the "Batch change control" function is selected in the selection field
(1, fig. 8.95), the setting of the following listed parameters can be made and the
function can thus be operated (see fig. 8.95, page 8-520).

When the function is deselected, with Batch change control (see "Batch change
control on") activated a pop-up window opens with the query (see fig. 8.96,
page 8-521) as to which parameter values are to be adopted in the screen
window.
Batch change control on

Selection of the tickbox (2, fig. 8.95) activates the "Batch change control" function
and the associated change in holding pressure. The green LED beside the
selection field (1) signals whether the function is activated. If the function is
deactivated via the tickbox (2), a pop-up window "Adaptive Process Control -
injection/holding pressure" (see fig. 8.96, page 8-521) appears. This warning
serves to prevent undesired deactivation of the function.
3
MX_MC6_V1.9_07.09.15_ENG
Fig. 8.96 Pop-up window "Adaptive Process Control - injection/holding pressure"

©KM
1 Selection switch "Machine settings" 3 Actual values "Holding pressure profile: pressure 1-5"
2 Selection switch "APC settings"
Furthermore, the operator can take over current automatically determined holding
pressure values. In the pop-up window, the selection switches "Machine settings"
(1, fig. 8.96) and "APC settings" (2) can be used to select whether the original
machine settings or the current automatically determined APC settings are to be
used.

• When the "Cancel" button is actuated, the function remains active.

• The function is ended by actuating the "OK" button. If the "APC settings"
option (2) is selected, the values currently set via the "Adaptive Process
Control" function are taken over. The active values for the holding
pressure profile stages (3) also continue to be used after deactivation.
Holding pressure adaptation

The actual value display of the control deviation is shown in the field (3, fig. 8.95).
The value indicates the percentage of control compensation per stage that took
place. This value can also be selected in the "Actual-value cycles" (see fig. 8.126,
page 8-584) screen.
When the control intervenes, the LED beside the selection field (1) for the
following cycle is green (active). When control is active at the control limit, the
LED is red (active) for the following cycle. At the same time, a white alarm
indicates that the control is no longer capable of compensating for the deviation.
Maximum holding pressure adjustment

The "Maximum holding pressure adaptation" is the maximum percentage value
by which the holding pressure can be adapted. At a value of 25%, holding
pressure can only be increased or lowered by a maximum of a quarter of the
respective stage.
The set value input for the maximum holding pressure adaptation is made in the
input field (4, fig. 8.95).
Selection field "Control intervention limit"

In the selection field (5), you can select between the parameters "Fine", "Medium"
and "Coarse".
• "Fine": control becomes active from +/-10% of the entered tolerance
• "Medium": control becomes active from +/-25% of the entered tolerance
• "Coarse": control becomes active from +/-50% of the entered tolerance
The control changes the holding pressure profile. The set values remain
unchanged.
Selection field "Holding pressure correction"

The holding pressure correction defines how much of the deviation is adjusted.
If "Very high" is selected, an attempt is made to compensate for the total deviation
immediately. This can lead to vibrations. If "Low" is selected, only 20% of the
MX_MC6_V1.9_07.09.15_ENG
deviation is adjusted for holding pressure.

©KM
In the selection field (6), you can select between the parameters "Very high",
"High", "Medium" and "Low".

2
3
4
Fig. 8.97 Pressure thresholds

1 Upper waste tolerance 4 Lower control intervention limit
("Set value" plus "+Tolerance") 5 Lower waste tolerance
2 Upper control intervention limit ("Set value" minus "-Tolerance")
3 Set value of measurement point
Selection field "Batch change control measurement point"

Via the selection field (7, fig. 8.95), you can define the measurement point to
which the batch change control is to relate.
The measurement point Mold cavity pressure 1 to 4 or the Hydraulic pressure can
be selected as a reference value.
I
Note
The control is always based on one selected sensor value only.
Mold cavity pressure 1

If "Measurement position Mold cavity pressure 1" is selected, the set value and
the tolerance must be entered in the "Actual-value cycles" (see fig. 8.126,
page 8-584) screen in the column "MaxWkzDr1".
Mold cavity pressure 2, 3 and 4

If "Measurement position Mold cavity pressure 2" is selected, the set value and
the tolerance must be entered in the same manner in the "Actual-value cycles"
(see fig. 8.126, page 8-584) screen in the column "MaxWkzDr2". For
MX_MC6_V1.9_07.09.15_ENG
measurement points "Mold cavity pressure 3" and "Mold cavity pressure 4", input
must be made in the columns "MaxWkzDr3" or "MaxWkzDr4".
©KM
Hydraulic pressure
If "Measurement position hydraulic pressure " is selected, the set value and the
tolerance must be entered in the "Actual-value cycles" (see fig. 8.126,
page 8-584) screen in the column "MaxMasDr".

Example of batch change control

1) Activate the batch change control (1, 2 Fig. 8.95).
2) Select measurement point: Mold cavity pressure transducer 2 (7, fig. 8.95)
3) In the "Actual-value cycles" (see fig. 8.126, page 8-584) screen, enter the
following values in the column "MaxWkzDr2":
• Set value: 200 bar
• +Tolerance: 12 bar
• -Tolerance: 8 bar
4) Set the control intervention limit (5, fig. 8.95) to "Medium".
This results in the following values:

• Upper waste tolerance: 212 bar
• Upper control intervention limit: 203 bar
• Set value of measurement point: 200 bar
• Lower control intervention limit: 198 bar
• Lower waste tolerance: 192 bar
If the measured maximum pressure at mold cavity pressure transducer 2 falls

below 198 bar or rises above 203 bar, intervention will be adapted. If it remains
within these limits, nothing will be changed.
The magnitude of this change and the extent of the complete intervention can be
adjusted using the parameters "Holding pressure correction" (6) and "Maximum
holding pressure adaptation" (4).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.9.6.2 Adaptive Process Control (ZE 89.529)
1
2
3
4
5
6
7
8
9
10
11
12
13
Fig. 8.98 Adaptive Process Control - injection/holding pressure (2/2)

1 Selection "APC: Adaptation type" 8 Set value, actual value "Molded part volume equivalent"
2 Pushbutton "Record reference cycle" 9 Input "Adjust shot volume"
3 Display "Reference cycle": Number, point in time 10 Input "Shot volume during start-up"
4 Selection switch "Activate Adaptive Process Control" 11 Actual value for "Holding pressure adaptation"
5 Actual value "Viscosity index" 12 Input for "Maximum holding pressure adaptation"
6 Actual value "Holding pressure-change-over adaptation" 13 Selection of "Holding pressure correction"
7 Input "Maximum holding pressure-change-over adaptation"
These screen pages are provided for setting the parameters for the "Adaptive
Process Control" (APC) function. The function can detect viscosity fluctuations in
the same shot and compensate for them by adapting the holding pressure
MX_MC6_V1.9_07.09.15_ENG
change-over stroke and holding pressure. This makes the shot volume more
constant.
©KM
Selection "APC: Adaptation type"
APC: Measurement
(function also available without ZE)
When this option is selected, all process intervention is deactivated. Only the
viscosity index and the molded part volume equivalent are measured and
displayed. This function can be selected in all machines.

APC: Adaptation of holding pressure change-over and holding pressure

The parameters for the viscosity-based holding pressure-change-over adaptation
(6, fig. 8.98) and the adaptation of the holding pressure value (11) are displayed.
When the "Adaptive Process Control" function is activated (4), both parameters
are adapted to keep the shot volume more constant.
APC: Adaptation of holding pressure

The parameters for adaptation of the holding pressure level (11) are displayed. If
the "Adaptive Process Control" function is activated (4), the holding pressure level
(11) is adapted to keep the shot volume more constant.
APC: Adaptation of holding pressure change-over

If this option is selected, the relevant parameters for adaptation of the Holding
pressure change-over stroke are displayed. If the "Adaptive Process Control"
function is activated (4), the holding pressure change-over stroke (6) is adapted
to keep the shot volume more constant.
I
Note
The display of the following parameters depends on the selection of the
adaptation type (1).
Pushbutton "Record reference cycle"

If the pushbutton "Record reference cycle" (2) is actuated, the characteristic
values of the next shot are saved and used as a reference for all others. The cycle
number, date and time (3) of the reference cycle are shown in the following line.
If a good cycle has been learnt, the viscosity index and the molded part volume
equivalent are measured.
The LED beside the "Record reference cycle" pushbutton (2) indicates the
controller function:
• A yellow LED signals that the controller is in the learning phase.
• A green LED indicates that a control or measurement function is active.
• A red LED indicates that the controller has detected a problem.
Activate adaptive process control

MX_MC6_V1.9_07.09.15_ENG
The control is activated by selecting the tickbox (4, fig. 8.98). If the control is
©KM
active, injection parameters such as "Holding pressure", "Temperatures" and

"Injection speed" should not be changed.
The "Adaptive Process Control" function adapts holding pressure change-over
stroke and/or holding pressure level and cascade opening strokes automatically
depending on the selection.
If the "Adaptive Process Control" function is deactivated via the tickbox (4), a pop-
up window "Adaptive Process Control - injection/holding pressure" (see fig. 8.99,
page 8-527) appears. This warning serves to prevent undesired deactivation of

the function. Furthermore, the operator can take over current automatically
determined and used change-over position and holding pressure values.
2
3
Fig. 8.99 Pop-up window "Deactivate Adaptive Process Control - injection/holding pressure"
1 Selection switch "Machine settings" 3 Actual value "Holding pressure change-over stroke"
2 Selection switch "APC settings" 4 Actual values "Holding pressure - profile 1-4"
In the pop-up window, the selection switches "Machine settings" (1, fig. 8.99) and
"APC settings" (2) can be used to select whether the original machine settings or
the current automatically determined APC settings are to be used.
• When the "Cancel" button is actuated, the function remains active.
• The function is ended by actuating the "OK" button. If the "APC settings"
MX_MC6_V1.9_07.09.15_ENG
option (2) is selected, the values currently set via the "Adaptive Process
Control" function are taken over. The active values for "Holding pressure
©KM
change-over stroke" (3) and "Holding pressure - profile stages" (4) are
also used following deactivation.

Viscosity index
The viscosity index is a measure for the flowability of the material at a given
injection speed, temperature and other variables. The currently measured value
is shown in the actual-value display (5, fig. 8.98). A change in the value
characterizes a changing process.
Holding pressure change-over adaptation

The actual value "Holding pressure-change-over adaptation" (6, fig. 8.98)
indicates the current deviation from the set change-over stroke.
The LED indicates the controller function:
• If the LED is off, the controller is not active.
• A green LED indicates that a control function is active.
• A red LED indicates that the controller is at the intervention limit or has
detected a problem.
Maximum holding pressure change-over stroke adaptation

By entering a "Maximum holding pressure change-over stroke adaptation"
(7, fig. 8.98), you can limit the extent of the controller intervention (positive or
negative deviation).
Molded part volume equivalent

The molded part volume equivalent characterizes (8, fig. 8.98) the volume of the
mold at constant machine settings (injection parameters, temperatures, etc.). A
change is an indication of a changed mold filling, e.g. different material.
The displayed current set value (8) is formed from the value of the reference shot
and the shot volume adaptation. The displayed actual value (8) is the value
measured in the last shot.
Adjust shot volume

The "Adjust shot volume" parameter (9) can be used to make a fine adjustment
of the Reference molded part volume equivalent (corresponds to 100%). When
doing this, the control does not need to be deactivated, nor do the reference
values have to be rejected.
Shot volume during start-up

MX_MC6_V1.9_07.09.15_ENG
The parameter "Shot volume during start-up" (10) permits a separate adaptation
©KM
of the molded part volume equivalent to safely prevent over-injection with the
start-up circuit and control active.

Holding pressure adaptation

The "Holding pressure adaptation" value (11) indicates the current change in the
holding pressure level.
The LED indicates the controller function:
• With the LED switched off, the controller is not active.
• A green LED indicates that a control function is active.
• A red LED indicates that the controller is at the intervention limit or has
detected a problem.
Maximum holding pressure adjustment

When a value for the parameter "Maximum holding pressure adaptation" (12) has
been defined, the extent of the controller intervention (positive or negative
deviation) can be limited.
Holding pressure correction

An adaptation stage of controller intervention for the mold is defined in the
selection field "Holding pressure correction" (13, fig. 8.98). Possible selection
stages are:
• "Low"
• "Medium"
• "High"
• "Very high".
If a change in viscosity is determined, the holding pressure is adapted to a greater
extent if the setting is "High" than with the "Low" selection.
Procedure
I
Note
• The "Adaptive Process Control" function requires a holding pressure
change-over via stroke (4, fig. 8.78).
• The required injection stroke is at least 1 screw diameter.
• During injection:
– the set speeds must be reached
– the pressure limitation must not be reached.
MX_MC6_V1.9_07.09.15_ENG
©KM

1) Select setting mode

2) On the screen "Adaptive Process Control - injection/holding pressure"
(see fig. 8.98, page 8-525) in the selection field "APC: Adaptation type"
(1, fig. 8.98), select the type of adaptation.
3) Enter the value for "Maximum holding pressure adaptation" (intervention limit)
(12).
If necessary, this value can be adapted at a later time.
4) Select selection stage for "Holding pressure correction" (intervention level)
(13).
If necessary, this value can be adapted at a later time.
5) Carry out the injection cycle (see section 6.6.7, page 6-282) and check the
mold filling according to the quality requirements.
6) Repeat work step 5 if necessary with adapted parameters until the desired
mold filling and quality requirements are achieved.
7) Actuate the "Record reference cycle" pushbutton.
8) Start several consecutive injection cycles. The viscosity index and molded
part volume equivalent are measured and saved as a reference. The injection
procedure is used as a reference.
9) Select selection switch "Activate Adaptive Process Control" (4, fig. 8.98).
W
Important
If "Adaptive Process Control" is activated (4), none of the parameters related
to the injection process, e.g. Holding pressure, Temperatures and Injection
speed, can be changed.
If all LEDs are green, the "Adaptive Process Control" function automatically
adapts the values "Holding pressure change-over stroke" (6) and the "Holding
pressure values" (11) depending on the setting to achieve the shot volume of
the reference shot.
A red LED indicates that a controller is at the intervention limit. This can be
recognised by a comparison of the actual adaptation value (6/11) with the
maximum value (7/12). Furthermore, a red LED indicates when the controller
has detected a problem with the process.
10) If necessary, the "Adjust shot volume" parameter (9) can still be used to make
a fine adjustment of the Reference molded part volume equivalent.
MX_MC6_V1.9_07.09.15_ENG
If the "Adaptive Process Control" function is deactivated (4), the process

©KM
parameters adapted by the control can be taken over in a dialogue (see

section "Activate adaptive process control").

8.10 Barrel temperatures
8.10.1 Barrel temperatures
6 1
5
4
Fig. 8.100 Barrel temperatures

1 Representation of heating bands 5 "Edit" button 1)
2 Selection switch "Priority" 6 Button "Pre-settings for barrel temperatures" 2)
3 Actual value "Remaining warmup time" 7 Diagrammatic display of the actual and set values
4 Input of barrel temperatures set values
1) Block change (see section 6.3.4.3, page 6-252)
2) Material selection (see section 8.10.1.2, page 8-538)
This screen contains the parameters for the adjustment and display of the
temperatures at the screw barrel and flange and the hydraulic oil.
MX_MC6_V1.9_07.09.15_ENG
The temperature values of the barrel heating zones are visualized as lines and
©KM
bars (7, fig. 8.100). Set values are shown as horizontal lines. The defined
tolerances are illustrated by a dotted line.
If the actual values are within the tolerance (in the range of the dotted lines), the
corresponding bars are green. If an actual value is outside the tolerance
(undershooting the lower dotted line or exceeding the upper dotted line), the bars
are displayed as red.
The operating modes "Control", Cycle via "OD setter", "Measure" and "Off" can
be selected for the heating zones.

Barrel heating zones 1 to 9
w
D
Caution
injection pressure.
The barrel heating zones illustrated are dependent on the length of the screw
barrel. Each barrel heating zone is equipped with one or two heating bands and
a temperature sensor.
The set value can be input in a range between 50 [°C] and the maximum
temperature.
Heating bands
The respective number of heating bands per barrel (1, fig. 8.100) is shown
graphically.
The following is included in a heating band:
• The diagrammatic display of the switch-on duration (red = heating,
blue = cooling)
• The status and error symbols for the temperatures
Shut-off heating zone 10 (ZE)

If the system is equipped with nozzle shut-off, the screw barrel is equipped with
shut-off heating zone 10.
Nozzle heating zone 11

The nozzle of the screw barrel is equipped with nozzle heating zone 11 as
standard.
Nozzle heating zone 12 (ZE)

If the system is equipped with a magnetic clamping platen, the screw barrel is
equipped with shut-off heating zone 12.
Nozzle heating zone 13 to 15 (ZE)

The nozzle heating zones are designed as controllers by the manufacturer.
MX_MC6_V1.9_07.09.15_ENG
Equipping with heating bands and temperature sensors is performed by the

customer.
©KM

Oil temperatures
I
Note
The oil temperature must be at least 18 °C. At an oil temperature below 18 °C,
all machine movements are disabled. Safety gate movements and the "Oil
preheating" function are still possible.
When the machine is started up, preheating takes place automatically.
The temperature of the hydraulic oil must be kept as constant as possible in order
to guarantee a reproducible machine cycle.
The set-value can be entered in a range between 32 °C and 57 °C. The
recommended oil temperatures lie between 40 °C and 50 °C.
At an oil temperature above 18 °C, the machine can be operated in setting or

manual mode.
• If the oil temperature is below 18 °C, "Oil and heater not OK" is displayed in
step display P00103. In all operating modes, all machine operating buttons
are faded out with the exception of the buttons "Mold closing" and
"Opening/closing safety gate".
• When the "Mold closing" button is actuated, the "Oil preheating" function
starts up. Step P00101 "Oil preheating selected" appears in the step display.
The function is executed until the oil has reached the set target temperature.
The machine can only be started in semi-automatic (SA) or fully automatic (FA)
mode if the oil temperature is at least 32 °C.
• If the oil temperature falls below 32 °C, alarm A00642 "Hydr. oil temperature
Min.-Max." is displayed.
After the set delay time has elapsed, the "Oil preheating" function starts up
automatically. Note messages on the status display on the screen.
• If the oil temperature exceeds the set-value, then the oil cooler is switched on
via a water valve.
W
Important
The oil temperature has a fixed tolerance range of +/±3 °C.
An oil temperature of 60 °C indicates a problem (e.g. water supply shut off, oil
MX_MC6_V1.9_07.09.15_ENG
cooler soiled). The machine is switched off immediately.

©KM
Flange temperature
The flange is heated by the screw barrel. The flange temperature is measured
underneath the material filling hole.
W
Important
Excess temperature can block the material outlet on the material filling hole.

1) Enter the set temperature.

The set value can be entered in a range between 5 °C and 90 °C.
2) Select "Control" mode.
The temperature is controlled by closing and interrupting the water circuit.
Mode
Heating zone off

The heating zone is not heated. The temperature can be displayed with the
Measure function.
M Measure
The temperature of the heating zone is measured (only possible if temperature
sensor is intact).
C Control
The heating zone is heated to the entered set temperature and controlled.
OD setter
Each individual heating zone can be cycled without control using the OD setter.
Enter switch-on duration [%] in the OD field.

A change in temperature is achieved by raising or lowering the percentage value.
Examples:
• OD = 100%
Heating element always switched on
• OD = 50% at TaH* of 2 s
Heating element switched on for 1 s
Heating element switched off for 1 s
Heating element switched on for 0.5 s
Heating element switched off for 1.5 s
* TaH: See control parameters (see section 8.10.3, page 8-546).
Changing over the controller to OD setter:

If the temperature sensor is damaged, the heating is switched off with alarm
A00402 "Barrel heating faulty".
The damage is displayed by the "Sensor break" symbol in the status field of the
MX_MC6_V1.9_07.09.15_ENG
affected controller.
©KM
1) Select the OD setter in the mode field.

The controller is switched off and the OD setter is activated.
The "OD setter" symbol is displayed in the heating/cooling field.
2) Switch barrel heating on.
The controller is switched on and off at fixed times.

W
Important
When the OD setter is active, the set value for the heating zone is not
displayed.
Priority
A higher priority is defined for selected barrel heating zones.
If "Prioritized barrel heating" (3, fig. 8.106) is chosen, the selected barrel heating
zones are heated up first.
Remaining warmup time

The heating time prevents premature start-up when the screw barrel is not
heated.
The remaining warmup time (3, fig. 8.100) for the heating zones of the screw
barrel is displayed on the screen "Barrel temperatures".
I
Note
Melt temperatures have no influence on the heating-up time.
Before and during the heating time sequence, all screw movements (plasticizing,
decompression, injection) and the function of the nozzle shut-offs are blocked to
prevent damage, for example to the shut-off needle or lever.
I
Note
The following have fixed definitions:
• Heating-up time for injectors up to SP 24500 = 9:00 mins
• Heating-up time for injectors from SP 33000 = 30:00 mins
• Temperature tolerance to start of heating time = 10 °C below set
temperature
The heating time cannot be deactivated.

MX_MC6_V1.9_07.09.15_ENG
Initial heating
©KM
• The heating time begins when all control zones have reached a temperature
of at least 10 °C below the respective set temperature.
• The heating-up time is 9:00 mins (up to SP 24000) or 30:00 mins (from
SP 33000) and runs backwards.

• During the heating time, all screw movements (plasticizing, retraction,

injection) are blocked.
Criteria for enabling the screw movement: heating time expired and
temperatures of all heating zones are within the variable, configurable system
tolerance of maximum 30 °C below set temperature (see section 8.10.2.1,
page 8-545).
I
Note
Input of the system tolerance in the screen
"Barrel temperatures start-up/lowering" (see fig. 8.106, page 8-542).
Short-term temperature drop

If at least one of the control zones falls 10 °C below the set value and reaches the
lower tolerance limit, the time from this point until reaching 10 °C below the set
temperature is recorded.
The new heating-up time is the same length as this recorded time but does not
exceed 9:00 mins (up to SP 24000) or 30:00 mins (from SP 33000).
This regulation enables the system to be run with under temperatures of up to
30 °C (once the heating time has expired).
I
Note
If the machine was switched off via the master switch, screw movement is
possible immediately after switching on again if two preconditions are met:
• the heating time had already elapsed prior to switch-off and
• the temperatures of all heating zones are within the system tolerance.
Otherwise the heating-up time of 9:00 mins (up to SP 24000) or 30:00 mins
(from SP 33000) must be repeated.
Display on the screen

• A constant red value of 9:00 mins (up to SP 24000) or 30:00 mins (from
SP 33000) (3, fig. 8.100) indicates that the heating-up time has still not
elapsed. The temperatures of all heating zones are outside the system
tolerance and the "Set temperature -10 °C" temperature range.
• Running of the remaining warmup time is shown as an active actual value in
MX_MC6_V1.9_07.09.15_ENG
white and starts up when the temperatures of all heating zones are within the
system tolerance and the "Set temperature -10 °C" temperature range.
©KM
• When the heating time reaches the value 0:00 min., the screw movements of
the machine are enabled. From this point on movement is possible up to the
entered system tolerance (see fig. 8.106, page 8-542).
I
Note
On machines with more than one injection unit, the heating times of the screw
barrels are processed and displayed independently of one another. The cycle
is enabled only when the heating times for all screw barrels have elapsed.

8.10.1.1 Melt temperature (ZE)
1
2
3
4
5
Fig. 8.101 Melt temperature

1 Zones 4 Mode
2 Target 5 Status
3 Actual
Melt temperature 1 and 2

The melt temperature is measured with the temperature sensors for melt
temperature in the screw tab and surface temperature of the melt.
1) Select "M Measure" mode.
The temperature is displayed in the actual value column.
2) Enter the set value.
MX_MC6_V1.9_07.09.15_ENG
The set value can be input in a range between 50 [°C] and the maximum
temperature of the plasticizing unit.
©KM
The parameters are monitored with system tolerances parameters.
I
Note
Melt temperatures have no influence on the heating-up time (see fig. 8.100,
page 8-531).

8.10.1.2 Barrel temperatures pre-settings
1 2 3 4 5 6
Fig. 8.102 Barrel temperatures pre-settings

1 Material 4 Suggested value for temperature "Centre" [°C]
2 Suggested value for temperature of "Nozzle" [°C] 5 Suggested value for temperature "Feed" [°C]
3 Suggested value for temperature of "Barrel head" [°C] 6 Suggested value for temperature "Flange" [°C]
In the MC6 control system, temperature suggested values for the individual
temperature ranges for plasticizing (flange, deed, centre, barrel head, nozzle) are
saved in a database for the most common plastic materials.
The data is displayed in a list on the screen page "Barrel temperatures pre-
settings".
MX_MC6_V1.9_07.09.15_ENG
©KM

Range setting, plasticizing unit
Fig. 8.103 Screw coding 2

1 "Range" selection
The temperature range (1, fig. 8.103) is set for each barrel zone on the screen
page "Screw coding 2" (see fig. 8.156, page 8-632). The settings are saved in the
EEPROM of the screw coding. "Screw coding programming mode" is only
available to users in key group 6.
Description of screen page "Screw coding 2" (see section 8.14.3, page 8-631)
MX_MC6_V1.9_07.09.15_ENG
©KM

Material selection
1 2 3 4 5 6
Fig. 8.104 Barrel temperatures pre-settings

1 "Material" selection 5 Display of "Feed" temperature
2 Display of "nozzle" temperature 6 Display of "Flange" temperature
3 Display of "Barrel head" temperature 7 Button "Adopt temperature values in barrel heating"
4 Display of "Centre" temperature 8 Information box
On the "Barrel temperatures" (see fig. 8.100, page 8-531) screen page, you can
actuate the button "Barrel temperatures pre-settings" (6, fig. 8.100) to call up the
pop-up window "Barrel temperatures pre-settings".
The desired plastic material is selected in the pop-up window via the "Material"
selection menu (1, fig. 8.104). When the material is selected, the temperature
suggestions for the barrel heating (2 - 6) that are saved in the database are
displayed.
W
MX_MC6_V1.9_07.09.15_ENG
Important
©KM
• A change in the material selection still has no direct influence on the barrel
temperatures.
• Observe safety information in the notes field (8)!
When the button "Adopt temperature values in the barrel heating" (7) is actuated,
the suggested temperatures are taken over in the associated temperature zones
and the window is closed.

W
Important
• The temperature suggested values are guide values that may have to be
adapted by the machine operator depending on the process!
• The guide values relate to screw geometry, plasticizing speed and dwell
time and must be analyzed accordingly.
• The guide values are experience values and may deviate in individual
cases.
• KraussMaffei Technologies GmbH shall not be liable in any way for
damage caused because the guide values have not been adapted as
required.
If no area (1, fig. 8.103) is set for a required barrel zone during screw encoding,
after pressing the "Barrel temperature presettings" (6, fig. 8.100) button the
"Barrel temperatures presettings" (see fig. 8.104, page 8-540) pop-up window will
not be displayed. Instead of this an "Error" (see fig. 8.105, page 8-541) pop-up
window appears with the following fault message:
• Barrel zone xx: area setting missing for screw encoding.
• Barrel temperature presettings not possible!
Fig. 8.105 Barrel temperatures presettings, fault message
Adaptation of barrel temperatures

If the temperature values suggested via the material selection are not suitable for
the current processing procedure, they can be adapted via a set value change
MX_MC6_V1.9_07.09.15_ENG
(4, fig. 8.100) (see section "Barrel heating zones 1 to 9", page 8-532).
©KM

8.10.2 Approaching/Lowering barrel temperatures
5 1
3
4
Fig. 8.106 Start-up/Lowering barrel temperatures

1 "Lowering/switch-off" selection menu 4 System tolerances, barrel heating
2 "Reset reduction" pushbutton 5 "Start-up switching" selection menu
3 Prioritized heating barrel heating
"Start-up switching" selection menu
Start-up switching OFF

The barrel heating is heated with the full heating capacity during start-up.
Start-up switching ON
The barrel heating is not heated with the full heating capacity but with the defined
MX_MC6_V1.9_07.09.15_ENG
barrel heating-up capacity for the defined start-up duration.

The "Start-up mode active" symbol is displayed in the status fields.
©KM

Heating up circuit via automatic ramp on

During the heating-up phase, all control zones automatically remain at the same
temperature level. All zones are oriented automatically to the respective slowest
control zone. Its actual value is used as a reference for the set values of the
remaining zones.
Mechanical stress is avoided during heating up.
The "Start-up mode active via automatic ramp" symbol is displayed in the status
fields.
Start-up duration
During the sequence of the time entered, heating takes place with the configured
start-up capacity. The full heating capacity is used after expiration of the time.
This function is only effective when the start-up circuit is enabled.
Heating-up capacity barrel heating

The barrel heating is switched on and off using a pulse/pause ratio adjustable
between 0% and 100%.
This function is only effective when the start-up circuit is enabled and only for the
defined start-up duration.
"Lowering/switch-off" selection menu

The barrel heating can be lowered to a specific value or switched off completely
after the delay time.
No lowering/Switching OFF
No lowering/switch-off program is activated.
Lowering ON
When the delay time expires, the machine switches from the production
temperature to the lowering temperature. This applies to all barrel heating zones.
The "Temperature lowering mode active" symbol is displayed in the status fields.
Switching OFF active

Barrel heating is switched off completely upon expiration of the delay time.
10-stage lowering ON
The difference in temperature between the actual value and the lowering
MX_MC6_V1.9_07.09.15_ENG
temperature setting is divided up into 10 even temperature stages. Upon

©KM
expiration of the defined delay time, the temperature of all heating zones is
lowered step-by-step. The transition from one stage to the next lower stage only
takes place when all heating zones have reached the preceding temperature
stage.
Lowering in semi-automatic/fully automatic mode only

The automatic temperature reduction only takes place in semi-automatic and fully
automatic modes.

10-stage lowering in semi-automatic and fully automatic modes only

The automatic temperature reduction in 10 stages only takes place in semi-
automatic and fully automatic modes.
Delay time
Upon expiration of the delay time, the machine switches to the lowering
temperature. In the case of the "Switching OFF active" function, barrel heating is
switched off completely after the delay time.
The delay time is started when:

• the operating mode is changed.
• The cycle has been stopped at the end and the pause time has expired in
semi-automatic or fully automatic mode.
• an alarm condition with cycle interruption occurs.
The function is switched off again if a switch takes place to semi-automatic or fully
automatic mode and there is no alarm with cycle interruption.
Lowering temperature
Value to which the temperature is lowered upon expiration of the delay time. All
active heating zones are lowered to this value.
Lowering capacity OD-value

All heating zones controlled with OD values are lowered to the defined OD value
upon expiration of the delay time (see section 8.10.1, page 8-531).
Barrel heating: continuous lowering

If the selection function is set, lowering remains continuously active.
Reset reduction
Prioritized heating barrel heating

If "Prioritized heating" (3, fig. 8.106) is chosen, the barrel heating zones selected
with the Prio switch (2, fig. 8.100) are heated up first.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.10.2.1 System tolerances, barrel heating
+ System tolerance barrel heating

A plus tolerance up to max. 30 °C can be specified for all control positions.
Alarms in the case of tolerance violation

If the actual temperature value of a control position lies outside the defined
tolerance range, a separate alarm message is generated for each controller.
If the upper (+) tolerance limit is exceeded, the entire barrel heating system is
deactivated and alarm A00402 "Barrel heating system faulty" is displayed.
- System tolerance barrel heating

A minus tolerance up to max. 30°C can be specified for all control positions.
I
Note
If the actual temperature values are not within the defined tolerance range, the
machine cycle cannot be initiated (started).
On the screen, step P00103 "Oil and heating not OK" is shown.
I
Note
The oil temperature has a fixed tolerance range of +/±3 °C.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.10.3 Barrel temperatures control parameters
Fig. 8.107 Barrel temperatures control parameters

1 Barrel heating optimization
In this screen you can enter values in order to adapt the control behaviour of the
individual barrel heating zones.
In the "Status" field located under the control parameters, status and fault symbols
can be displayed (see section 8.10.3.1, page 8-547).
The control parameters are determined automatically by switching on "Barrel
heating optimization" (1, fig. 8.107).
Control parameters (H = Heating, K = Cooling)

MX_MC6_V1.9_07.09.15_ENG
• XsH: Hysteresis (dead zone) heating

©KM
• TaH: Sampling time (control interval) heating

• KpH: Proportionality factor (gain) heating
• TnH: Integral action time, time constant for integral action component, heating
• TvH: Derivative action time, time for differential component, heating
• TaK: Sampling time (control interval), cooling
• KpK: Proportionality factor (amplification), cooling
• TnK: Integral action time, time constant for integral action component, cooling
• TvK: Derivative action time, time constant for differential share cooling

I
Note
The barrel heating must be adapted to the specific requirements of the
respective injector. In most cases, the control can be carried out reliably with
the suggested values from the control system.
8.10.3.1 Symbol explanations for temperature status and fault messages

A pop-up window with the symbol explanation of the temperatures opens.
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 8.108 Symbol explanation, temperatures

8.10.3.2 Barrel heating optimization
I
Note
After the barrel-heating optimization, the calibration data must be saved to the
USB stick!
Prerequisites
• Barrel heating off
• Set value/actual value difference in temperature is greater than 80 °C
• Actual temperature is constant over an extended period of time (room
temperature)
Function sequence
1) Activate the "Barrel-heating optimization" (1, fig. 8.107) tickbox on the screen.
2) Switch barrel heating on.
When barrel heating optimization is switched on, the controller calculates the
optimal values for all heating zones that are enabled.
During the optimization phase, the "Optimization active" symbol appears in the
"Status" field of the control zone.
The individual heating zones are operated with 100% heat capacity.
The controller uses the temperature curve to determine the response time and
slew rate of the process.
These distance parameters are then used to calculate the controller parameters
and transfer them to the control system. The controller then controls the
temperature to obtain the set value.
If a value other than 0 has been set for KpK, a set value change to 1°C is
simulated after the set value has been reached. This temperature curve is then
used to calculate the controller parameters for cooling.
The "Status" field of each heating zone which has been completely optimized
displays the "Optimization complete" symbol.
Heating zones optimized completely are controlled to the defined set value using
the optimized parameters.
When all heating zones have been optimized, the barrel heating optimization
MX_MC6_V1.9_07.09.15_ENG
function can be switched off.

©KM

Fault messages and faults during optimization

In the event of faults in the optimization, the symbol "Optimization cancelled" is
shown in the "Status" field.
If the optimization is cancelled immediately after being switched on, the controller
cannot carry out an optimization for the selected heating zones due to too low
temperature differences between set and actual value temperatures. The
controller cannot calculate any sensible parameters after an appropriate period of
time (e.g. due to insufficient heating capacity or excessive temperature of the
heating zone at the start of optimization). The heating zone continues working
with the original parameters.
The optimization is aborted during the optimization phase if:

• Barrel heating optimization is switched off
• The system is switched to OD setter.
• A new temperature is entered which results in an insufficient minimum
temperature difference.
• the "lowering" mode of operation is selected.
Heating zones completely optimized at this point in time will work with the newly
determined parameters while the remaining zones will continue working with the
original values.
When the barrel heating optimization function is switched off, the status field
display is cleared. Another optimization run can only be carried out when the
prerequisites are fulfilled.
More status and error symbols (see section 8.10.3.1, page 8-547).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.10.4 Barrel heating circuit monitoring (ZE 89.3801)
1
2
3
4
5
6
7
8
Fig. 8.109 Barrel heating circuit monitoring

1 Set values for "Heating capacity" 6 "Accepting actual values as set values" pushbutton
2 Actual values for "Heating capacity" 7 Pushbutton "Adopt output values standardized to mains voltage
3 "Status" display from screw encoding"
4 Selection "Fault heating circuit monitoring blocks cycle" 8 Input field "Mains voltage"
5 "Tolerance" input field
The purpose of the heating circuit monitoring function is to more rapidly pinpoint
faults in the heating system.
Each controller is monitored with a current transformer.
MX_MC6_V1.9_07.09.15_ENG
©KM
W
Important
Defective controllers cause erroneous actual power values.
Before actuating the pushbutton "Accepting actual values as set values"
(6, fig. 8.109), ensure that all controllers are faultless.

Fault heating circuit monitoring blocks cycle

If the function "Fault heating circuit monitoring blocks cycle" (4, fig. 8.109) is
activated via the tickbox, in the event of a deviation from the set value an alarm
is tripped and the next machine cycle is blocked.
W
Important
If alarm A00720 "Barrel heating: heating circuit faulty" is displayed, notify
KraussMaffei service.
Tolerance
In the (5) field, you can enter the tolerance [%] by which the actual values are
permitted to deviate from the output set values.
Accepting actual values as set values
I
Note
The actual values can only be accepted as set values with the barrel heating
switched on.
By actuating the pushbutton "Accepting actual values as set values" (6), the
output actual values recorded after a measurement are taken over as set values.
If modifications to the barrel heating are made, the procedure must be restarted.
Pushbutton "Adopt output values standardized to mains voltage from

screw encoding"
When this pushbutton is actuated, the operator can take over the values
(6, fig. 8.156) standardized to the main voltage from the "Screw encoding 2"
(see fig. 8.156, page 8-632) screen page. These are determined from the entered
manufacturer's specifications for Heating capacity (1, fig. 8.156) and main
voltage (5) and the entered mains voltage (8, fig. 8.109) of the machine.
Mains voltage
The mains voltage present at the machine (suggested value: 230 V) can be
MX_MC6_V1.9_07.09.15_ENG
entered in the (8, fig. 8.109) field.

©KM
Symbol legend for heating circuit monitoring status and fault messages

Function
The barrel heating circuit monitoring system requires the definition of the set
values of the heating capacity. On the "Barrel heating circuit monitoring" screen
page (see fig. 8.109, page 8-550), the set values for the heating capacity can be
specified in three different ways:
• The operator can enter the set values for the heating capacity
(1, fig. 8.109) for the individual barrel heating zones.
• The operator can adopt the actual values recorded after a measurement
as set values (6, fig. 8.109).
• The output values standardized to the mains voltage from the screw
encoding can be adopted (7, fig. 8.109).
If heating circuit monitoring is activated, the heating capacity actual value is

recorded at defined time intervals for each individual activated zone and is
compared with the heating capacity defined as set value, making allowance for
the entered tolerance. If the heating capacity actual value is outside the tolerance,
a corresponding alarm is generated. The "Zone defective" alarm is displayed if the
actual value of the heating capacity is equal to zero.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.10.5 7-day timer
Fig. 8.110 7-day timer
The 7-day timer can be used to program the machine to be automatically heated
before beginning production.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.11 Mold temperatures (ZE)
8.11.1 Mold temperatures graphic
1
3
Fig. 8.111 Mold temperatures graphic 1

1 Diagrammatic display of the actual and set values 3 "Edit" button 1)
2 Selection switch "Priority"
1)
Block change (see section 6.3.4.3, page 6-252)
The control system can be equipped with a controller for mold heating systems.
The system is modular and can control from a minimum of 1 control zone to a
maximum of 200 control zones.
MX_MC6_V1.9_07.09.15_ENG
The parameters for setting and displaying the mold temperatures are shown on
these screens.
©KM
If the machine is equipped accordingly, the mold wall temperatures can be

measured (see fig. 8.113, page 8-558).
The set value can be entered in a range between 5 °C and 450 °C.

The temperature values of the heating zones are visualized as lines and bars
(1, fig. 8.111). Set values are shown as horizontal lines. The defined tolerances
are illustrated by a dotted line.
If the actual values are within the tolerance (in the range of the dotted lines), the
corresponding bars are green. If an actual value is outside the tolerance
(undershooting the lower dotted line or exceeding the upper dotted line), the bars
are displayed as red.
The operating modes "Control", Cycle via "OD setter", "Measure" and "Off" can
be selected for the heating zones.
In the Status field, status and error symbols are displayed below the control zone
in question (see section 8.11.1.1, page 8-557).
Mode
Heating zone off

The heating zone is not heated. The temperature can be displayed with the
Measure function.
M Measure
The temperature of the heating zone is measured (only possible if temperature
sensor is intact).
C Control
The heating zone is heated to the entered set temperature and controlled.
OD setter
Each individual heating zone can be cycled without control using the OD setter.
The switch-on duration (red = heating, blue = cooling) is displayed graphically in
the Heating/cooling field.
Enter switch-on duration [%] in the OD field.

A change in temperature is achieved by raising or lowering the percentage value.
Examples:
• OD = 100%
Heating element always switched on
Heating element switched on for 1 s
MX_MC6_V1.9_07.09.15_ENG
Heating element switched off for 1 s

©KM
Heating element switched on for 0.5 s
Heating element switched off for 1.5 s
* TaH: See control parameters (see section 8.11.3, page 8-563).

Changing over the controller to OD setter:

If the temperature sensor is damaged, the heating is switched off with alarm
A00406 "Barrel heating faulty".
The damage is displayed by the "Sensor break" symbol in the status field of the
affected controller.
1) Select the OD setter in the mode field.

The controller is switched off and the OD setter is activated.
The "OD setter" symbol is displayed in the heating/cooling field.
2) Switch on mold heating.
The controller is switched on and off at fixed times.
W
Important
When the OD setter is active, the set value for the heating zone is not
displayed.
Priority
A higher priority is defined for selected control zones of the mold heating by
means of the Prio switch (2, fig. 8.111).
If "Prioritized heating" (2, fig. 8.114) is chosen, the selected control zones of the
mold heating are heated up first.
MX_MC6_V1.9_07.09.15_ENG
©KM


MX_MC6_V1.9_07.09.15_ENG
Fig. 8.112 Symbol explanation, temperatures

©KM
Symbol legend for KM/PSG mold heating (see section 12.15.9, page 12-1002).

8.11.1.2 Mold wall temperatures
Fig. 8.113 Mold wall temperatures

1 Heating zone 4 Selection field for "Measurement on/off"
2 Input field for "Set value" 5 Field for "Status and error symbols"
3 Display field for "Measured value"
If the machine is equipped accordingly, the mold wall temperatures can be

measured. On the screen, the set and actual values can be displayed from up to
4 temperatures per mold half.
The reference value (2, fig. 8.113) can be entered in a range between 5 °C and
450 °C.
The "Status" (5) field may display status and error symbols below the heating
MX_MC6_V1.9_07.09.15_ENG
zone in question (see section 8.11.1.1, page 8-557).

The mold wall temperatures can be recorded in the actual value cycle table
©KM
(see fig. 8.126, page 8-584) for each production cycle. Depending on the setting,
production is stopped if the tolerance is exceeded or undershot.

8.11.2 Mold-temperatures start-up/lowering
5 1
Fig. 8.114 Mold-temperatures start-up/lowering

1 Selection lowering/switching off 4 Selection "Observe -tolerance"
2 Prioritized heating 5 Start-up switching selection
3 System tolerances mold heating
"Start-up switching" selection menu
Start-up switching OFF

The mold heating is heated with the full heating capacity during start-up.
Start-up switching ON
The mold heating is not heated with the full heating capacity but with the defined
MX_MC6_V1.9_07.09.15_ENG
mold heating heating-up capacity for the defined start-up duration.

©KM
The "Start-up mode active" symbol is displayed in the status fields.


Heating up circuit via automatic ramp on

During the heating-up phase, all control zones automatically remain at the same
temperature level. All zones are oriented automatically to the respective slowest
control zone. Its actual value is used as a reference for the set values of the
remaining zones.
Mechanical stress is avoided during heating up.
The "Start-up mode active via automatic ramp" symbol is displayed in the status
fields.
Start-up duration
During the sequence of the time entered, heating takes place with the configured
start-up capacity. The full heating capacity is used after expiration of the time.
This function is only effective when the start-up circuit is enabled.
Heating-up capacity mold heating

The mold heating is cycled between 0% and 100% using an adjustable
pulse/pause ratio.
This function is only effective when the start-up circuit is enabled and only for the
defined start-up duration.

The mold heating can be lowered to a specific value or switched off completely
after the delay time.
Lowering ON
When the delay time expires, the machine switches from the production
temperature to the lowering temperature. This applies to all mold heating
systems.
The "Temperature lowering mode active" symbol is displayed in the status fields.

Mold heating is switched off completely upon expiration of the delay time.
10-stage lowering ON
MX_MC6_V1.9_07.09.15_ENG
The difference in temperature between the actual value and the lowering
©KM
temperature setting is divided up into 10 even temperature stages. Upon

expiration of the defined delay time, the temperature of all heating zones is
lowered step-by-step. The transition from one stage to the next lower stage only
takes place when all heating zones have reached the preceding temperature
stage.
Lowering in semi-automatic/fully automatic mode only

The automatic temperature reduction only takes place in semi-automatic and fully
automatic modes.

10-stage lowering in semi-automatic and fully automatic modes only

The automatic temperature reduction in 10 stages only takes place in semi-
automatic and fully automatic modes.
Delay time
temperature.
In the case of the "Switching ON" function, mold heating is switched off
completely after the delay time.

active heating zones are lowered to this value.
Lowering capacity OD-value

All heating zones controlled with OD values are lowered to the defined OD value
upon expiration of the delay time (see section 8.11.1, page 8-554).
Continuous lowering
If the selection function is set, lowering remains continuously active.
Prioritized heating
If "Prioritized heating" (2, fig. 8.114) is chosen, the control zones of the mold
heating selected with the selection switch (2, fig. 8.111) are heated up first.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.11.2.1 System tolerances mold heating
Selection "Observe -tolerance"
Ignore -Tol.
Undershooting of the "-" tolerance is ignored.
-Tol. blocks cycle

The selection "-Tol. blocks cycle" switch is used to prevent the cycle start when
the "-" tolerance value is undershot.
-Tol. blocks cycle, injection units and mold nozzles

The following is prevented in the "-" tolerance value is undershot:
• the cycle start
• injection with nozzle contact
• activation of the mold nozzles (Mouldmaster and cascade)
+ System tolerance, mold heating

For the mold heating zones, a plus tolerance of up to 30 °C maximum is defined.

If the actual temperature value of a controller lies outside the defined tolerance
range, a separate alarm message is generated for each mold heating zone.
If the upper (+) tolerance limit is exceeded, the entire mold heating system is
disabled and the alarm A00406 "Mold heating system faulty" is displayed.
- System tolerance, mold heating

For the mold heating zones, a minus tolerance of up to 30 °C maximum is
defined.
If the tolerance drops below the "-" tolerance, the cycle is interrupted. The status
display on the screen shows step P00103 "Oil and heater not OK".
I
Note
If the actual temperature values are not within the defined tolerance range, the
machine cycle cannot be initiated (started).
On the screen, step P00103 "Oil and heating not OK" is shown. MX_MC6_V1.9_07.09.15_ENG
©KM

8.11.3 Mold temperatures control parameters
Fig. 8.115 Mold temperatures control parameters 1
The control action of the heating zones of the mold heating can be adapted on
this screen by adjusting the desired values.
In the "Status" field located under the control parameters, status and fault symbols
can be displayed (see section 8.11.1.1, page 8-557).
The control parameters are determined automatically by activating "Mold heating

optimization" on the screen "Mold temperatures control parameters 2"
(see fig. 8.116, page 8-564).
MX_MC6_V1.9_07.09.15_ENG
©KM


1 Mold heating optimization
Control parameters (H = Heating, K = Cooling)

• XsH: Hysteresis (dead zone) Heating (only with heat-balancing unit)
• TaH: Sampling time (control interval) heating
• KpH: Proportionality factor (gain) heating
• TnH: Integral action time, time constant for integral action component, heating
• TvH: Derivative action time, time for differential component, heating
• TaK: Sampling time (control interval), cooling
• KpK: Proportional action factor (gain) for cooling (only with heat-balancing
unit)
MX_MC6_V1.9_07.09.15_ENG
• TnK: Integral action time, time constant for integral action component, cooling
• TvK: Derivative action time, time constant for differential share cooling
©KM
I
Note
The mold heating must be adapted to the mold. The control system provides
suggested values. Optimization normally has to be carried out to adapt these
values (see section 8.11.3.1, page 8-566).

Recommended settings
The following settings have proved themselves in practice:
• Cartridges with built-in sensor, e.g. beam heater in the mold
TaH = 1.28, KpH = 30, TnH = 100 s, TvH = 25 s; all other values "0".
• Nozzles with built-in sensor, e.g. ITRON Ò hotrunner system
TaH = 1.28, KpH = 20, TnH = 25 s, TvH = 5 s; all other values "0".
• Pipe heater
TaH = 2.56, KpH = 30, TnH = 150 s, TvH = 30 s; all other values "0"
• Snorkel heater
TaH = 2.56, KpH = 50, TnH = 360 s, TvH = 70 s; all other values at "0".
• Mold temperature controllers: heating capacity kW, cooling capacity
1500 kcal/h
TaH = 2.56, KpH = 10, KpK = 10, XsH = 0, TnK = 50 s, TvK = 10 s.
In the case of unknown systems (molds) to be controlled, it may take a

considerable amount of time to find stable control parameter settings for the
individual heating zones.
The latest mold heating controller generation therefore has the ability to optimally
adapt to the system.
If a suitable parameter record exists, this should be used to save time.
The mold heating function (see section 8.11.3.1, page 8-566) should be
optimized in the following cases:
• first-time installation of controller (e.g. new mold)
• installation of a new heating element with a different heat capacity
• input of a new, completely different set value (e.g. 200°C instead of 400°C)
MX_MC6_V1.9_07.09.15_ENG
©KM

8.11.3.1 Mold heating optimization
Prerequisites
• Mold heating off
• Set value/actual value difference in temperature is greater than 80 °C
• Actual temperature is constant over an extended period of time (room
temperature)
W
Important
When optimizing the mold heating, make sure that the mold is supplied with
cooling water (cooling water connected and switched on).
Function sequence
1) Activate the "Mold heating optimization" (1, fig. 8.116) tickbox on the screen.
2) Switch on mold heating.
After switching on the optimization, the optimal values for all switched on-heating
zones of the mold heating are calculated by the controller.
During the optimization phase, the "Optimization active" symbol appears in the
"Status" field of the control zone.
The individual heating zones are operated with 100% heat capacity.
The controller uses the temperature curve to determine the response time and
slew rate of the process.
These distance parameters are then used to calculate the controller parameters
and transfer them to the control system. The controller then controls the
temperature to obtain the set value.
If a value other than 0 has been set for KpK, a set value change to 1°C is
simulated after the set value has been reached. This temperature curve is then
used to calculate the controller parameters for cooling.
The "Status" field of each heating zone which has been completely optimized
displays the "Optimization complete" symbol.
Heating zones optimized completely are controlled to the defined set value using
the optimized parameters.
When all heating zones have been optimized, the mold heating optimization
MX_MC6_V1.9_07.09.15_ENG
function can be switched off.

©KM

Fault messages and faults during optimization

In the event of faults in the optimization, the symbol "Optimization cancelled" is
shown in the "Status" field.
If the optimization is cancelled immediately after being switched on, the controller
cannot carry out an optimization for the selected heating zones due to too low
temperature differences between set and actual value temperatures. The
controller cannot calculate any sensible parameters after an appropriate period of
time (e.g. due to insufficient heating capacity or excessive temperature of the
heating zone at the start of optimization). The heating zone continues working
with the original parameters.
The optimization is aborted during the optimization phase if:

• Optimization of the mold heating is switched off.
• The system is switched to OD setter.
• A new temperature is entered which results in an insufficient minimum
temperature difference.
• the "lowering" mode of operation is selected.
Heating zones completely optimized at this point in time will work with the newly
determined parameters while the remaining zones will continue working with the
original values.
Or if when the mold heating optimization function is switched off, the status field
display is cleared. Another optimization run can only be carried out when the
prerequisites are fulfilled.
More status and error symbols (see section 8.11.1.1, page 8-557).
I
Note
The control parameters for the mold heating are saved with the machine data
record. If the mold is reinstalled after a mold change and the associated data
record is read in, the associated control parameters are also entered again.
Optimization does not need to be repeated.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.11.4 Mold heating circuit monitoring
8.11.4.1 Mold heating circuit monitoring (ZE 89.385)
1
2
3
4
5
6
7
Fig. 8.117 Mold heat. circuit monit.

1 "Current" set values 5 "Accepting actual values as set values" pushbutton
2 "Current" actual values 6 "Tolerance" input field
3 "Leak current" actual values 7 "Fault heating circuit monitoring blocks cycle" tickbox
4 "Status" display
The purpose of the heating circuit monitoring function is to more rapidly pinpoint
faults in the heating system.
Each controller is monitored with a current transformer.
MX_MC6_V1.9_07.09.15_ENG
©KM
W
Important
Defective controllers cause erroneous actual power values.
Before actuating the pushbutton "Accepting actual values as set values"
(5, fig. 8.117), ensure that all controllers are faultless.


If the function "Fault heating circuit monitoring blocks cycle" is activated via the
selection field (7, fig. 8.117), in the event of a deviation from the set value an
alarm is tripped and the next machine cycle is blocked.
W
Important
If alarm A00719 "Mold heating: heating circuit defective" is displayed, notify
KraussMaffei Service.
Tolerance
In the (6) field, you can enter a tolerance [%] between 0% and 50% by which the
actual values are permitted to deviate from the output set values.
If, for example, a value of 10% is entered, this means that all heating zones of the
heating system are monitored with a (+) tolerance of 10% and with a (-) tolerance
of 10%.
I
Note
The actual values can only be accepted as set values with the mold heating
switched on.
By actuating pushbutton "Accepting actual values as set values" (5), the output
actual values are accepted as set values.
If modifications to the mold heating are made, the procedure must be restarted.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.11.4.2 Symbol legend for heating circuit monitoring status and fault messages
A pop-up window with the symbol explanation of the heating circuit monitoring
system opens.
Fig. 8.118 Symbol legend, heating circuit monitoring
Symbol legend for KM/PSG mold heating (see section 12.15.9, page 12-1002).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.11.4.3 Monitoring mold heating circuit (ZE 89.3852)
I
Note
The actual values can only be accepted as set values with the mold heating
switched on.
By actuating pushbutton "Accepting actual values as set values" (5, fig. 8.117),
the output actual values are accepted as set values.
If modifications to the mold heating are made, the procedure must be restarted.
Tolerance
In the (6) field, you can enter a tolerance [%] between 0% and 50% by which the
actual values are permitted to deviate from the output set values.
If, for example, a value of 10% is entered, this means that all heating zones of the
heating system are monitored with a (+) tolerance of 10% and with a (-) tolerance
of 10%.

If the function "Fault heating circuit monitoring blocks cycle" (7, fig. 8.117) is
activated via the tickbox, in the event of a deviation from the set value an alarm
is tripped and the next machine cycle is blocked.
W
Important
If alarm A00719 "Mold heating: heating circuit defective" is displayed, notify
KraussMaffei Service.
System set-up
When the "System set-up" pushbutton is actuated, all output sensing modules
perform a test.
In the course of this test, the master modules determine how many slave modules
there are. This pushbutton is actuated once during commissioning when all the
sensing modules have been wired.
MX_MC6_V1.9_07.09.15_ENG
If a faulty module is subsequently replaced, a Set-up must be executed once

©KM
again.
Nominal voltage
When the machine is started up for the first time (commissioning), the nominal
voltage for each heating system must be entered. When the values have been
entered, they should be stored on the USB stick. Value range of nominal voltage:
0 to 500 V.

8.11.5 Water manifolds (ZE)
8.11.5.1 Water batteries FP and MP
1 9
2
3
5
6
Fig. 8.119 Water manifold FP

1 Selection of water manifold FP 6 Actual value display "Temperature"
2 Actual value display "Supply temperature" 7 Set value/actual value "Energy"
3 Actual value display "Supply pressure" 8 Mode
4 Selection of water manifold circuit 9 Graphic display of actual values "Flow", "Energy"
5 Set value/actual value "Flow"
Selection of water manifold

One page of the machine control system always displays an individual water
MX_MC6_V1.9_07.09.15_ENG
distribution block (water manifold). For FP and MP, a maximum of eight water
batteries are provided.
©KM
If more than one water manifold is enabled on the FP, a navigation element
(1, fig. 8.119) can be used to select between the water manifolds.
Supply pressure and temperature

At each individual water distribution block, one sensor is installed in the supply
line for recording temperature (2) and pressure (3), the actual values of which are
displayed on the screen.

Return flow and temperature

In each cooling circuit in the return line, one sensor is provided for temperature
and flow, the actual values of which are displayed on the screen. The parameters
"Flow" (5, fig. 8.119), "Temperature" (6) and "Cycle time" are used to calculate the
cooling water energy (7) for each cycle. All actual value parameters of the water
manifolds cannot be used as cycles actual values.
Tolerances for return line actual values

A set value is provided for the actual values "Flow" (5) and "Cooling water energy"
(7) and a tolerance range is specified for the complete water manifold.
The set value parameters and superimposed tolerances can be used to monitor
the cooling circuits. The type of monitoring system is selected in a monitoring
menu under "Mode" (8).
The coolant temperature cannot be monitored with tolerance values.
Graphic for flow and cooling energy

The flow and energy are visualized as lines and bars (9). The flow is shown on
the left half and energy is on the right half.
Set values are shown as horizontal lines. The defined tolerances are illustrated
by a dotted line. If the actual values are within the tolerance (in the range of the
dotted lines), the bars are green. If actual value are outside the tolerance, the bars
are red.
Mode
For the water manifold, set values for the flow volume for each individual cooling
circuit and the total cooling energy output in the cycle can be specified and limited
by means of a tolerance window. Various options are available for selection for
monitoring (see section 8.11.5.2, page 8-574).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.11.5.2 Symbol legend for water manifold mode

A pop-up window with the symbol explanation of the water manifolds opens.
Fig. 8.120 Symbol legend, mode of water manifolds

MX_MC6_V1.9_07.09.15_ENG
©KM
Off
The selected cooling circuit is not monitored.
Cooling energy tolerance monitoring, only display alarm

The cooling energy is compared with the entered set value and monitored with
regard to the tolerance. In case of a violation, a white alarm is generated per
cooling circuit. The tolerance violation is not handled in the quality monitoring
system.

Cooling energy tolerance monitoring with display alarm and quality monitoring
system.
Cooling energy tolerance monitoring with display alarm and stop at end of cycle
cooling circuit and a red combined alarm is generated that stops the injection
molding machine at the end of the cycle. The tolerance violation is not handled in
the quality monitoring system.
Flow tolerance monitoring, only display alarm

The cooling water flow is compared with the entered set value and monitored with
system.
Flow tolerance monitoring with display alarm and quality monitoring

system.
Flow tolerance monitoring with display alarm and stop at end of cycle
cooling circuit and a red combined alarm is generated that stops the injection
molding machine at the end of the cycle. The tolerance violation is not handled in
the quality monitoring system.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.11.5.3 Water manifolds, settings
Fig. 8.121 Water manifolds, settings

1 Selection of water manifold 3 "Alarm delay" input field
2 Input fields for System tolerances "Flow", "Cooling energy"
System tolerance
Tolerance input can be made for all zones of a water manifold for parameters
"Flow" and "Cooling energy" (2, fig. 8.121).
Alarm delay
If a tolerance violation occurs, an alarm will only be tripped after the delay time (3)
has elapsed. If the tolerance limit is violated for longer than the time defined in
MX_MC6_V1.9_07.09.15_ENG
"Alarm delay", the system reacts in accordance with the set mode
©KM

8.11.6 External heat-balancing units (ZE)
S
d
D
Risk of spraying
Mold temperature controllers as well as the connecting lines to the mold carry
hot fluids, which may be pressurized. This is also possible when the heat-
balancing units are switched off. There is a danger of injury through burning.
• Never carry out work on mold temperature controllers when they are hot,
or release the connecting lines.
• Allow heat-balancing units to cool down to a harmless temperature.
1
2
3
4
5
6
7
8
9
10
11
12
Fig. 8.122 External heat-balancing units

MX_MC6_V1.9_07.09.15_ENG
1 Graphic Actual/set value display "Temperature" 7 Display of "DMH-TK"

2 Selection of heat balancing 8 Selection field "Interface"
©KM
3 Input of "Temperature" set value 9 Input of "Parameter number (Par. No.)"

4 Actual value display "Temperature" 10 Tickbox "Evacuat."
5 Display of "Flow" 11 Display "Heating/cooling"
6 Selection field "Mode" 12 "Status" display
The control system can be equipped with a controller for heat-balancing units.
The data is exchanged via the 20 mA or VARAN interface (8, fig. 8.122).

Apart from the set and actual values, the selection menu for "Mode" and the field
for heating/cooling and status displays, the screen also displays other parameters
for "D-flow", "DMH-TK", "Interface", "Par. No." and "Evacuat.".
A control parameter record that is permanently stored in the heat-balancing unit

is selected in the Parameter number (Par. no.) (9, fig. 8.122) line. This control
parameter record cannot be changed by the control system.
The switch-on duration (red = heating, blue = cooling) is displayed graphically in

the Heating/cooling field (11, fig. 8.122).
The operating modes "Control", "Measure" or "off" can be selected for the heating
zones (6, fig. 8.122).
Description of the control parameters (see section 8.11.3, page 8-563).
In the Status (12, fig. 8.122) field, where applicable fault symbols are displayed
below the control zone in question (see section 8.11.6.6, page 8-580).
8.11.6.1 Switch on the heat-balancing unit

1) Enter the parameter number of the heat-balancing unit (9, fig. 8.122).
2) In the "Mode" (6) field, select "Control".
3) Enter the set temperature (3).
The heat-balancing unit is switched on and the actual temperature is
displayed.
8.11.6.2 Switch off the heat-balancing unit

1) Select "Off" in the "Mode" (6, fig. 8.122) field.
The control system switches the heat-balancing units off.
Depending on the heat-balancing unit used, the heat-balancing unit cools
below the safety limit and then switches off.
8.11.6.3 Evacuating heat-balancing medium (mold evacuation)

1) Select the "Evacuat." tickbox (10, fig. 8.122).
The heat-balancing unit carries out the following activities:
• Cooling to pump after-run temperature
• Evacuating heat-balancing medium
MX_MC6_V1.9_07.09.15_ENG
• Switching off pump (heating and cooling)

©KM
When the "Evacuat." function is finished, the heat-balancing unit resumes

controlled operation.

8.11.6.4 Idling mode/temperature lowering mode

If the idling/lowering value is 0, then all heat-balancing units are controlled with a
normal temperature set value in the temperature lowering mode.
Temperature lowering/idling parameters used:
• Heat balancing reduction
• Shutdown
• Delay time for production interruption
• Idling temperature
8.11.6.5 Optimizing external heat-balancing units

The optimization of these heat-balancing units is performed externally.
MX_MC6_V1.9_07.09.15_ENG
©KM

I
Note
If a fault occurs several times in succession, all heat-balancing units are
switched off. Alarm A00408 "Mold heat balancing faulty" is displayed.
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 8.123 Symbol explanation, temperatures (20 mA)

8.11.6.7 Mold temperature controllers lowering
Fig. 8.124 Mold temperature controllers lowering

The mold temperature control can be specifically reduced to a lower value after
the delay time has elapsed, or switched off fully.
Lowering ON
In the event of an alarm that switches off the machine, the delay time starts
regardless of the operating mode. Upon expiration of the time, the machine
MX_MC6_V1.9_07.09.15_ENG
reduces the temperature to the lowering temperature. The temperature lowering

©KM
mode is quit when the alarm is acknowledged after the fault has been eliminated.

Mold heating is switched off completely upon expiration of the delay time.

Delay time
temperature.
In the case of the "Switching ON" function, the heat-balancing units are switched
off completely after the delay time.

active mold heating channels are lowered to this value.
Heat-balancing: continuous reduction

If the selection function is set, the selection function remains continuously active.
Reset reduction
8.11.6.8 System tolerances, heat-balancing

A tolerance range of up to +/- 30°C can be defined for the mold temperature
controllers. The "plus" and "minus" tolerances can be changed independently of
each other.
Heat-balancing: -Tol. blocks cycle

With the tickbox "Heat-balancing: -Tol. blocks cycle" activated, a cycle start is
prevented when the "-" system tolerance value is undershot.

If the actual temperature value of a controller lies outside the defined tolerance
range, a separate alarm message is generated for each mold heating zone.
If the upper (+) tolerance limit is exceeded, the entire mold temperature control
function is disabled and the alarm A00408 "Mold heat-balancing faulty" is
MX_MC6_V1.9_07.09.15_ENG
displayed.
©KM
I
Note
If the actual temperature values are not within the defined "minus" tolerance
ranges, the machine cycle cannot be started.
On the screen, step P00103 "Oil and heating not OK" is shown.

8.11.7 7-day timer
MX_MC6_V1.9_07.09.15_ENG
©KM

8.12 Tolerance monitoring

All the tolerance-related functions and all functions concerning the curve
computer are described below.
8.12.1 Actual-value cycles and quality monitoring
8.12.1.1 Actual-value cycles
5
4
Fig. 8.126 Actual-value cycles

1 Vertical scrollbar 4 "Tolerance monitoring" selection menu
2 Horizontal scrollbar 5 "Deviations" selection menu
3 Start date/time, Finish date/time
MX_MC6_V1.9_07.09.15_ENG
On the "Actual-value cycles" screen, actual values can be selected that are listed
©KM
cycle for cycle. This listing permits conclusions to be drawn regarding the causes
of variations among the individual cycles.
If green actual values are shown in the "Cycle" column, the cycle is within the
tolerance. If there are red actual values, the cycle is out of tolerance.

By wiping in horizontal direction or via the horizontal scrollbar (2, fig. 8.126),
further table columns of the individual actual values can be displayed. By means
of the vertical scrollbar (1) or vertical wiping, you can scroll in the table view in
chronological order.
The chronological arrangement of the table can be ascending or descending.
Press the "Date/time" header to arrange the actual-value cycles that have
occurred.
The lower section shows the set values of the individual values with the variations
from the actual value. Upon changing a set value, the corresponding last actual
value is red and all other actual values of the lines (without set value changes) are
shown in grey.
The set values can be adapted to the actual values by comparison. This means
values for which there are no set values (e.g. product-dependent times) are
adopted from the actual value measured over several cycles in order to be able
to observe deviations for future cycles. For each value, a tolerance range can be
configured.
"Deviations" selection menu
Upper deviation
Deviation above set value of all cycles after the last reset.
Lower deviation
Deviation under set value of all cycles after the last reset.
Fluctuation band
Sum of upper and lower deviation of all cycles after the last reset.
Mean value
Calculated mean value from the last 100 cycles after the last reset.
Standard deviation
Determined value for the standard deviation (68.26% of the realizations in the
interval) from the last 100 cycles after the last reset.
3-Sigma (standard deviation)

Determined value for the three-fold standard deviation (99.73% of the realizations
in the interval) from the last 100 cycles since the last reset.
MX_MC6_V1.9_07.09.15_ENG
4-Sigma (standard deviation)

Determined value for the four-fold standard deviation (99.994% of the realizations
©KM
in the interval) from the last 100 cycles since the last reset.
Reset
All cycles that were used for computation are erased from the computer memory.

"Tolerance monitoring" selection menu
Tolerance monitoring off

The tolerance is not monitored.
Tolerance monitoring on
The tolerance monitoring for the production has to be activated with this selection.
The tickboxes can be used to activate each individual actual value for tolerance
monitoring.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.12.1.2 Quality monitoring failure rate
Fig. 8.127 Quality monitoring failure rate
Number of cycles to be monitored

Set value input and actual value display of the number (lot size) of the cycles to
be monitored in which the error rate may not be exceeded.
Failure rate (cycles out of tolerance)

Set value entry and actual value display of the error rate that is allowed per lot
size with tolerance of the quality parameters (or the curves) exceeded. If the
failure rate within a lot size is reached, the machine stops at the end of the current
cycle and displays the red alarm A00140 "Permissible fault rate exceeded
A00140".
MX_MC6_V1.9_07.09.15_ENG
The actual values are reset to "0" when the failure rate is not reached within a lot
©KM
size. The count is started anew.
W
Important
The monitoring set values are to be adapted when the machine settings are
changed. If, for example, a monitoring tolerance band has been superimposed
on the actual-value injection time and the injection speed is changed, this may
result in a "cycle out of tolerance". In this case, the monitoring set value for
injection must be readjusted.

8.12.1.3 Actual values exporting/printing
1
2
3
4
Fig. 8.128 Actual values exporting/printing

1 Start date/time 3 Export data file title
2 Finish date/time 4 Pushbutton "Export actual-value cycles onto USB stick"
The actual values (see section 8.12.1.1, page 8-584) on the screen can be
exported in a file in onto the USB stick.
Start date/time, Finish date/time

Date and time interval for which the actual values are to be output can be entered.
Input format: DD⁄MM⁄YY and HH⁄MM.
The input values of the time interval are also displayed on the screen "Actual-
MX_MC6_V1.9_07.09.15_ENG
value cycles" (see section 8.12.1.1, page 8-584).

©KM
Export data file title

The file name must be entered to output the actual values on the USB stick.
Export actual-value cycles onto USB stick

1) Insert the USB stick into the USB port.
2) Press pushbutton (4, fig. 8.192).
The actual-value cycles selected on the screen are exported.

8.12.2 Trend graph (ZE)
1
7
2
6
3
4 4
Fig. 8.129 Trend graph 1

1 Minimum, maximum, measured values 5 Display area for curve screens
2 Button "Printer S" 6 Measuring line
3 Button "Printer M" 7 "Parameter" selection field
4 "Move measuring line" buttons
The trend diagrams can display selected parameters (7, fig. 8.129) graphically.
The display range of the individual parameters is limited by entering minimum and
maximum values. The trend graph represents the actual values of the last cycles
from the actual value cycle memory.
Measuring line
MX_MC6_V1.9_07.09.15_ENG
A measuring line is displayed with tickbox activated (6). The measuring line can
©KM
be used to approach individual cycles in order to read the exact measured values.
The measuring line is shifted to the left/right by:
• Pressing the button "Move measuring line" (4)
• Touching and dragging the measuring line
• Touching the desired point on the graphic surface
Print
"Printer S" (2) prints the trend graphs of all four selected parameters together on
one sheet in an xps file on the USB stick.

"Printer M" (3) prints the trend graphs of each parameter on a separate sheet in
an xps file on the USB stick.
I
Note
Graphical presentations of curve screens can be adapted quickly and easily
with the 24″ Multitouch. The Multitouch characteristic makes intuitive zooming
and shifting of graphics possible via gesture operation:
• Press and drag within the graphic area (5, fig. 8.129) to shift the curve
presentation in x- and y-direction. The scrollbar serves as an orientation
aid.
• Two-finger operation (see fig. 6.4, page 6-230) can be used to zoom the
presentation of the curves. Zooming can take place both at the
measurement curves themselves as well as at the measured value axes at
the edge of the display range (5, fig. 8.129). The minimum and maximum
values (1) are adapted automatically at the same time.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.12.3 Curve computer (ZE)
1 2 3 4 5 6
14 7
13
8 8
9
12
11 10
Fig. 8.130 Curve computer (example: mold cavity pressure 1)

1 Predefined curve screens 8 "Move measuring line" button
2 Actual value, "X-value" 9 "Curve configuration" button 1)
3 Actual value, "Maximum Y-value" 10 Set value, "End of recording range, X-axis"
4 Actual value, "Area" 11 Set value, "Start of recording range, X-axis"
5 Freely assignable curve screen 12 Set value, "Start of recording range, Y-axis"
6 Tab expansion for more curves 13 Measuring line
7 X/Y value, curve/measuring line intersection 14 Set value, "End of recording range, Y-axis"
1) Curve configuration (see section 8.12.3.5, page 8-596)
MX_MC6_V1.9_07.09.15_ENG
The curve computer can display actual-value cycles in the form of curves on
channels.
©KM
The following curve screens are preset (1, fig. 8.130):

• Mold cavity pressure 1
• Melt pressure
• Injection stroke
• Injection speed
• Injection capacity

Additionally, there are up to five available assignable curve screens (5) that are
generated from a selection of actual values (see section 8.12.3.6, page 8-598).
The curves can be integrated in quality monitoring by assigning tolerances and

enabling the tolerance monitoring function (see section 8.12.1.1, page 8-584).
The following functions and displays can be triggered and presented on the curve
screens:
• Change of X/Y scale for representing or comparing curves
• Representation of generated reference curve/tolerance band
• Display of actual curves of the last six cycles per channel
• Measuring line for determination of X/Y curve values
• Magnifying glass function (zoom) for expanding curve details
• Limiting the monitoring range with the aid of the "Mark area" function and
using the marked area as a parameter for quality monitoring
• Limiting the monitoring range with the aid of the "Delete tolerance range"
function
• Adjustable smoothing factor for suppression of interference peaks on the
display
• Selection of the start and end condition
• Setting the tolerance band
• Showing a reference curve
• Displaying a group of curves
• Displaying the holding pressure change-over fluctuation band
8.12.3.1 Functions and parameters of the curve screens
X/Y axis
The recording range of the X-axis and Y-axis can be entered for each curve.
In order to compare several curves on the "Curve selection"
(see section 8.12.3.7, page 8-599) screen, the curves must have comparable
recording ranges.
If the start of the recording range of the X-axis (11, fig. 8.130) is set to zero, then
curve recording is carried out at the start of "Starting condition".
If the start of the recording range of the X-axis is larger than zero, then curve
recording is carried out at the time corresponding to the delay after the start of
MX_MC6_V1.9_07.09.15_ENG
"Starting condition".
©KM
The recording range becomes effective with the next curve displayed.
Display of "X value"

X-value of the maximum Y-value in the recording range.
Display "Maximum Y-value"

Maximum Y value in the recording range.
Display of "Area"
Area computed in the monitoring window.

8.12.3.2 General functions
Tolerance monitoring
The tolerance monitoring can be selected separately for each curve. The cycle is
monitored for the defined time according to the tolerance settings.
W
Important
For alarm generation, waste separation and machine shut-off, the tolerance
monitoring must also be activated on the "Actual-value cycles" screen
When the tolerance monitoring function is enabled, those curves that have been
assigned tolerance ranges are integrated in the production monitoring function. If
an actual curve is out of the tolerance range, violation of a defined maximum
failure rate causes the machine to be switched off and the corresponding alarm
to be displayed.
Curve setting
Current
This function is used to display the current cycle as the actual curve.
The curve is updated with each cycle.
No new one
This function is used to store the displayed actual curve.
The actual curve is not updated on the screen.
n-1 to n-6
The actual curves of the last six curve cycles per channel are stored in the curve
computer. This function can be used to display the last six actual curves on the
screen.
Synchronization end
With this tickbox activated, the end of the recording range of the X-axis of the
curve recording is determined by the control system through a synchronous
signal.
With a deactivated tickbox, the curve recording is ended with the end of the
recording range of the X-axis.
MX_MC6_V1.9_07.09.15_ENG
©KM
Grid
A horizontal grid can be displayed on the screen for better viewing.

Measuring line
The measuring line (13, fig. 8.130) can be moved to the desired point on the
actual curve. The co-ordinates of the intersection on the X/Y (7) axis are
displayed.
The measuring line is shifted to the left/right by:
• Pressing the button "Move measuring line" (8)
• Touching and dragging the measuring line
• Touching the desired point on the graphic surface
8.12.3.3 Graphic functions
Produce tolerance
I
Note
If the "Tolerance band invalid" message is displayed, a new tolerance has to be
produced.
According to the defined +/- tolerance, a tolerance band is laid around the
displayed curve or group of curves.
If the "Group of curves" tickbox is selected in the "Curve configuration" pop-up
menu, the curve computer produces an envelope curve as a tolerance band
around the max./min. values of the group of curves (see section 8.12.3.5,
page 8-596). The curve or group of curves used here is saved as a reference
curve.
Delete tolerance range

The monitoring range of a curve can be narrowed down by deleting unimportant
sections.
The deleted sections are not included in the quality monitoring.
This limits the tolerance monitoring of the curve to partial sections.
Procedure (see section 8.12.3.4, page 8-595).
Select monitoring window

The area underneath a curve (integral) can be additionally used for tolerance
monitoring.
MX_MC6_V1.9_07.09.15_ENG

©KM
I
Note
In order to activate the marked area (tolerances) for monitoring, tolerance
monitoring for the appropriate value must be switched on in the "Actual-value
cycles" screen (see section 8.12.1.1, page 8-584). The actual value displayed
there corresponds to the actual value of the "Area" display on the
corresponding curve screen. The required set values/tolerances can be
entered on the "Actual-value cycles" screen.
If another monitoring window is to be marked, the process must be repeated.

Reset monitoring window

The selected monitoring window is deleted.
Select magnifying glass area

The curves can be visually spread in the horizontal direction within a selected
range.
I
Note
Spread curves cannot be adopted as reference curves and no tolerance bands
can be produced over them.
Spread curves are not included in the memory or quality monitoring.
If the tolerance monitoring function is active, only curves that have not been
spread are monitored.
If the curve in the selected range is very flat, i.e. the Y values are nearly identical,
the resolution of the Y-axis cannot be increased. In this case, identical Y values
will appear in the curve legend.
8.12.3.4 Procedure during area selection for graphic functions

1) Select graphic function (see section 8.12.3.3, page 8-594).
A measuring line (13, fig. 8.130) and the "Enter" button are displayed on the
screen.
2) Move the measuring line (13) with the arrow buttons (8) or by dragging it to
the starting point of the desired area.
3) Press the "Enter" button to confirm.
The measuring line is displayed in red and a new measuring line is displayed.
4) Move the measuring line (13) with the arrow buttons (8) or by dragging it to
the end point of the desired area.
5) Press the "Enter" button to confirm.
The marked area is selected or deleted corresponding to the selected graphic
function (see section 8.12.3.3, page 8-594).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.12.3.5 Curve configuration

Pressing the "Curve configuration" (9, fig. 8.130)/(4, fig. 8.132) button opens a
pop-up menu in which settings for the appearance of the curves can be made.
2
3
4
5
7
8
9
10
Fig. 8.131 Curve configuration

1 "Curve (data source)" selection menu 1) 7 Show tolerance band
2 Selection menu, "Starting condition" 8 Show reference curve
3 Selection menu, "End condition" 9 Group of curves
4 + Tolerance 10 Displaying the holding pressure change-over
5 -Tolerance fluctuation band
6 Selection menu, "Smoothing"
1) The selection menu is only shown during the curve configuration of the freely assignable curve screens.
Curve (data source)

During the curve configuration of the freely assignable curve screens
MX_MC6_V1.9_07.09.15_ENG
(see section 8.12.3.6, page 8-598), the desired data source that is to be shown
©KM
as a curve is selected in the selection menu (1, fig. 8.131). Pressing the selection
menu opens a pop-up menu with all available parameters.
Starting condition
The starting condition (2) can be selected.
When using a "user-defined" starting condition, the start button is displayed on the
curve screen. The curve recording is initiated by pressing the "Start" button at any
desired time in the cycle.

End condition
The end condition (3, fig. 8.131) can be selected. When using the "No selection"
end condition, the curve recording ends after the defined time or by means of a
synchronization signal of the control system.
+/- tolerance
The upper (4) and lower (5) tolerance range can be set in percent [%].
Smoothing
Actual curves can be smoothed out. Spikes that make the curve look very "rough"
on the screen can be visually suppressed. They can be smoothed (6) on 1 to 3
levels.
Show tolerance band

According to the defined +/- tolerance (4)(5, fig. 8.131), a tolerance band is laid
around the displayed curve or group of curves in the case of an activated
tickbox (7).
If group of curves is activated, the curve computer produces an envelope curve
around the max./min. values.
Show reference curve

With the tickbox activated (8), the reference curve saved with the "Generate
tolerance" function is displayed.
Group of curves
A group of curves displays the dispersions of the process. With an activated group
of curves (9), an additional curve is recorded and displayed for each cycle. When
a curve screen is selected once again, registration is restarted.
Displaying the holding pressure change-over fluctuation band
I
Note
Graphical presentations of curve screens can be adapted quickly and easily
with the 24″ Multitouch. The Multitouch characteristic makes intuitive zooming
and shifting of graphics possible via gesture operation:
• Press and drag within the graphic area to shift the curve presentation in x-
MX_MC6_V1.9_07.09.15_ENG
and y-direction.
©KM
• Two-finger operation (see fig. 6.4, page 6-230) can be used to zoom the
presentation of the curves. Zooming can take place both at the
measurement curves themselves as well as at the measured value axes at
the edge of the display range.

8.12.3.6 Freely assignable curve screens
1 2 3
Fig. 8.132 Freely assignable curve screens

1 Predefined curve screens 3 Tab expansion for more curves
2 Freely assignable curve screens 4 "Curve configuration" button 1)
1) Curve configuration (see section 8.12.3.5, page 8-596)
Alongside the preset curve screens (1, fig. 8.132), there are up to five available
assignable curve screens (2) that are generated from a selection of actual values.
The screens are available by selecting the individual tabs (2) and their
extensions (3).
MX_MC6_V1.9_07.09.15_ENG
Curves are selected by means of the selection menu "Curve (data source)" in the
©KM
"Graph configuration" pop-up menu (see section 8.12.3.5, page 8-596), which is
opened by pressing the "Curve configuration" button (4, fig. 8.132).
Parameters, settings and functions on the screens correspond to those of the

predefined curve screens (see section 8.12.3, page 8-591).

8.12.3.7 Curve selection
1 2 3
6
5
Fig. 8.133 Curve selection 1 and 2

1 Predefined curve screens 4 Measuring line
2 Freely assignable curve screens 5 "Curve" selection menu
3 Curve selection 1 and 2 6 Cycles
On this screen, up to 4 curves from among the actual curves can be selected.
These curves are then displayed simultaneously per cycle on one curve screen.
Each of these up to 4 curves is displayed in a different colour.
The legends of the co-ordinates and the curve designation are displayed in the
MX_MC6_V1.9_07.09.15_ENG
same colour as the colour used to display the curve.

The selected curves can be measured simultaneously with the "measuring line"
©KM
tickbox activated (4, fig. 8.133).
I
Note
The selected actual curves should all be displayed with the same X scale (time
axis) to permit optimal comparison.
The X scale is set on the individual curve screens (1)⁄(2).

8.13 Cycle/Times overview
8.13.1 Overview of times and machine
8.13.1.1 Overview of times
1
10
2
3
9
4
8 5
7 6
Fig. 8.134 Overview of times

1 "Transfer current actual values as reference" pushbutton 6 Set value "Delay time plasticizing"
2 Set value "Cycle monitoring time" 7 Set value "Pause time"
3 "Current" bar 8 Set value "Cooling time"
4 "Reference" bar 9 Comparison value "Reference"
5 Set value "Delay time for injection unit return" 10 Actual value "Current"
MX_MC6_V1.9_07.09.15_ENG
This screen contains all the times relevant for the cycle time. The individual times
are displayed as bars to allow for better visualization.
©KM
An optimization of the cycle time should be started on values with long bars first.
Parameters without input fields can only be modified on the respective screens.

I
Note
A change in the times may have negative consequences for both the machine
and the quality.
Therefore, efforts to optimize the process should be concentrated on the
economical areas.
"Transfer current actual values as reference" pushbutton

The pushbutton (1, fig. 8.134) is used to adopt the times from the actual value
column into the reference time column.
Cycle monitoring time

The cycle monitoring time (2) must be set greater than the displayed cycle time
(cycle value).
If the "Cycle value cycle time" of the machine is shorter than the value defined for
cycle monitoring time, the system will continue to operate normally. If, however,
the machine cycle is longer, the machine is switched off immediately upon
expiration of the cycle monitoring time, and the "A00013 Cycle time monitoring"
alarm is displayed.
Injection
Injection settings (see section 8.9.1.1, page 8-481)
Delay time injection (see section 8.9.1.3, page 8-490).
Holding pressure
Total holding pressure time (see section 8.9.1.2, page 8-485).
Cooling
The cooling time begins if the mold is closed and all selected injection units are
finished with the holding pressure.
When operating with a locking slide, the cooling time begins once the locking slide
program has elapsed. The display bar ends at the start of Mold opening.
Mold opening can be delayed by plasticizing, backward movement of the injection
unit, core pulling, and cooling time.
The target value of cooling time can be entered on the screen (see section "Delay
times", page 8-603).
MX_MC6_V1.9_07.09.15_ENG
If the cooling times = 0, then movement is performed only with the process cooling
©KM
times (cooling time and locking slide cooling time).

The actual-times on the injection pages are always active.
When an injection-unit-dependent cooling time is entered, the cooling time is
started on the actual value cycles at the start of the first cooling time.
Mold opening starts when all cooling times are finished.
Actual-value cycles (see section 8.12.1.1, page 8-584)

1 2 3
13
12
11
10
9
8
7
6
5
4
Fig. 8.135 Injection-unit-dependent cooling times

1 Start of first cooling time 8 Actual cooling time of auxiliary injection unit
2 All injectors finished with holding pressure 9 Cooling time of auxiliary injection unit
3 All cooling times finished 10 Holding pressure of auxiliary injection unit
4 Clamping force release 11 Actual cooling time of main injection unit
5 Actual cooling time of the actual value cycles 12 Cooling time of main injection unit
6 Actual cooling time bar diagram 13 Holding pressure of main injection unit
7 Cooling time
1 2 3
13
12
11
10
9
8
7
6
5
MX_MC6_V1.9_07.09.15_ENG
4
©KM
Fig. 8.136 Without injection-unit-dependent cooling times

1 Start of first cooling time 8 Actual cooling time of auxiliary injection unit
2 All injectors finished with holding pressure 9 Cooling time of auxiliary injection unit (= 0)
3 All cooling times finished 10 Holding pressure of auxiliary injection unit
4 Clamping force release 11 Actual cooling time of main injection unit
5 Actual cooling time of the actual value cycles 12 Cooling time of main injection unit (= 0)
6 Actual cooling time bar diagram 13 Holding pressure of main injection unit
7 Cooling time

Delay times
I
Note
The display of these delay times depends on the values entered on the
corresponding screens.
Cooling time
Entry of time value for remaining cooling time.
This time stage starts at the end of holding pressure and enables mold opening
when the defined time value (8, fig. 8.134) is reached. If the cooling time is shorter
than the duration of the plasticizing process, the machine only opens after
plasticizing end.
Plasticizing delay time

This parameter (6) can be used to delay the plasticizing process. The "Start
plasticizing delayed" timer is started at the end of holding pressure and is only
active in semi-automatic or fully automatic mode.
Start plasticizing delayed (see section 8.9.2, page 8-495).
Delay time for injection unit return

Entry of the delay time (5) until the injection unit retracts.
Pause time
The pause time (7) is the time from the end of a cycle until the start of the next
cycle. In normal cases, this is used in fully automatic mode. However, it is also
required for certain monitoring functions in semi-automatic mode. The pause time
can be changed directly on the screen.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.13.1.2 Machine-overview
1
2
3
4
5
7
8
Fig. 8.137 Machine-overview

1 Operating hours total (machine switched ON) 5 Operational performance, injector
2 Operating hours in production 6 Operational performance, injection unit
3 Absolute cycle counter 7 Clamping unit operational performance
4 Date "First cycle on …" 8 Ejector operational performance
The screen displays the total time for the operating hours with the machine
switched on and for operating hours in production [hour : minutes] as well as the
absolute cycle counter and the date of the first cycle.
In addition, the respective operational performance of injector, injection unit,
clamping unit and ejector are recorded.
The total cycle counter cannot be reset.
MX_MC6_V1.9_07.09.15_ENG
©KM
All values are saved permanently in the SRAM and the machine EEPROM.

8.13.2 Pieces/Shift counter
8.13.2.1 Pieces counter
Fig. 8.138 Pieces counter

1 "Reset" pushbutton 2 Switch-Off at end of production
Product-specific data is acquired and monitored on this screen.

Information on the commission, customer and article can be input in the text
fields.
The current counts of the cycle counters are displayed in the actual value fields.
MX_MC6_V1.9_07.09.15_ENG
The counters are reset to zero after the "Reset " (1, fig. 8.138) pushbutton is
©KM
pressed.
Cavities
Number of articles to be produced in one cycle (shot).

Number of prod. articles within tol.

The set value can be entered in the input field.
I
Note
If the tolerance monitor in the "Actual-value cycles" is switched on
(see section 8.12.1.1, page 8-584), only the cycles within the tolerance are
counted under the actual value, i.e. only the good parts.
Number of prod. articles out of tol.

Only active if tolerance monitoring is switched on in the "Actual-value cycles"
(see section 8.12.1.1, page 8-584) screen. Number of cycles during which a
tolerance violation of monitoring parameters has been detected.
Total number of produced articles

Number of articles produced within and out of tolerance.
Reject → Good
Manual resorting of reject parts to good parts. Input of the quantity determined by
visual inspection.
Good → Reject
Manual resorting of good parts to reject parts. Input of the quantity determined by
visual inspection.
Pieces/Hour
Following entry of the number of cavities, the cycle time is used to calculate the
quantity of articles produced per hour.
Remaining production time

Following entry of the desired number of articles, the "Pieces/hour" quantity is
used to calculate the remaining production time.
Switch-Off at end of production

When the tickbox is actuated, the machine switches off at the end of the quantity
set under "Number of parts produced within tolerance".
Alarm A00063 "No. of pieces switch-off" is displayed.
MX_MC6_V1.9_07.09.15_ENG
This function is only effective in semi-automatic and fully automatic modes.

©KM

8.13.2.2 Shift counter
2
3
Fig. 8.139 Shift counter

1 Pushbutton "Reset" (Shift) 3 Operating hours in production
2 Operating hours total (machine switched ON)
Data on the parts produced per shift is recorded on the screen.

Furthermore, the total times for operating hours with the machine switched on
(2, fig. 8.139) and for operating hours in production (3) [hours : minutes] are
displayed.
"Reset" pushbutton
By pressing the pushbutton (1), the piece count of the produced parts is set to
MX_MC6_V1.9_07.09.15_ENG
zero.
©KM

8.13.2.3 EUROMAP 63
1
2
3
4
5
6
Fig. 8.140 EUROMAP 63

1 "Job" input field 4 Pushbutton for "Save and copy current data record"
2 "Marking new job" pushbutton 5 Pushbutton for "Load data record from the mainframe computer"
3 "Data record title" input field 6 Pushbutton for "Delete data record on the mainframe computer"
The "Euromap 63" screen is used to load and save product-specific data records
from and to the server computer. Furthermore, data records that are already
saved on the server computer can be selected and deleted.
Order
The product-specific customer order number can be entered in the text field.
MX_MC6_V1.9_07.09.15_ENG
"Marking new job" pushbutton

©KM
When the pushbutton (2, fig. 8.140) is pressed, a corresponding marking is set as
to whether a new job is involved.
Data record title

The name of the data record can be entered in the text field.
Pushbutton for "Save and copy current data record"

The current data record with the data recorded in the screens "Pieces counter"
and "Shift counter" is saved under the data record name entered in the text field
"Data record title" (3, fig. 8.140) and the customer order number (1) is saved.

Pushbutton for "Load data record from the mainframe computer"

Following input of data record title (3, fig. 8.140) and customer order number (1),
the pushbutton "Load data record from the mainframe computer" can be actuated
to load the specified data record from the server computer.
Pushbutton for "Delete data record on the mainframe computer"

Following input of data record title (3, fig. 8.140) and customer order number (1),
the pushbutton "Delete data record on the mainframe computer" can be actuated
to delete the specified data record from the server computer.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.13.3 Energy
8.13.3.1 Energy analysis (ZE)
1
2
3
4
5
6
7
Fig. 8.141 Energy analysis

1 Display "IMM energy consumption since" 5 Cycle time (cycle value)
2 Display "Total plant energy consumption since" 6 Melt throughput
3 "Reset" pushbutton 7 Selection "Display of energy consumption in [Wh]/[kWh]"
4 Shot weight
This screen shows the energy/power consumption of the machine.

The selection field (7, fig. 8.141) can be used to select whether the energy
consumption is displayed in [Wh] or [kWh] (see sections 8.13.3.3 and 8.13.3.2).
MX_MC6_V1.9_07.09.15_ENG
Reset
©KM
This function is only available in setting mode.

When the "Reset" (3) pushbutton is actuated, the displays for energy
consumption (1 and 2) are reset to 0 (zero) and the time and date are updated.

Shot weight
To calculate the energy consumption per shot weight [g] (4), it is necessary to
enter the weight of the workpiece to be produced. (The power consumption [kWh]
based on the shot weight [kg] corresponds to the specific power
consumption [kWh⁄kg].)
Cycle time (cycle value)

The actual value (5, fig. 8.141) of the time for a cycle is displayed.
Overview of times (see section 8.13.1, page 8-600).
Melt throughput
MX_MC6_V1.9_07.09.15_ENG
©KM

8.13.3.2 Energy balance - individual evaluation (ZE 89.77, BluePower)
5 4 3 2
Fig. 8.142 Energy balance - individual evaluation

1 Selection of average determination 4 Mean output
2 Mean specific energy 5 Current output
3 Mean energy
The screen displays the individual evaluation of the energy balance.
The display of the average determination depends on the selection made

(1, fig. 8.142):
• no filter
MX_MC6_V1.9_07.09.15_ENG
• current cycle (no average determination)

©KM
• last 8 cycles
• last 16 cycles

8.13.3.3 Energy balance - reference (ZE 89.77, BluePower)
1 2
3
Fig. 8.143 Energy balance - reference

1 "Energy" pushbutton 3 Energy consumption [Wh] (current)
2 "Transfer current actual values as reference" pushbutton 4 Energy consumption [Wh] (reference)
The screen displays energy consumption [Wh] and specific energy consumption
[kWh⁄kg] (energy consumption referenced to the shot weight) during a cycle.
You switch between energy consumption and specific energy consumption using
the "Energy" pushbutton (1, fig. 8.143).
MX_MC6_V1.9_07.09.15_ENG
©KM
I
Note
In order to calculate the specific energy consumption, the shot weight [kg] first
has to be entered on the screen page "Energy analysis" (see section 8.13.3.1,
page 8-610).

Energy of drives per cycle section

The energy consumption of the drives during a cycle stage is presented:
• Clamping/clamping force build-up
• Injection
• Holding pressure
• Cooling time
• Opening/ejecting
Injection molding machine (IMM)

The energy consumption of the injection molding machine is calculated from the
sum of the energy consumption of the drives and the barrel heaters.
Drives
• with hydraulic machines:
– main drive (=pump)
– EPlast drive (where applicable)
– sliding table and/or rotary table (where applicable)
• with electric machines:
– sum of all electric main axes of the machine (clamping unit, mold height,
ejector, injector, plasticizing drive, injection unit drive)
Complete system
The energy consumption of the complete system comprises the energy
consumption of:
• Injection molding machine incl. heaters (barrel heating zones)
• Mold heating (where applicable)
• Peripherals/automation (where applicable)
• Extruder (where applicable)
• RPM (reaction technology plant) (if available)
In addition, the energy consumption of the individual consumers is displayed as

a percentage of the total consumption.
"Transfer current actual values as reference" pushbutton

The pushbutton (2, fig. 8.143) is used to adopt the times from the actual value
column into the reference time column.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.13.3.4 Energy logging DEE021
1
2
Fig. 8.144 Energy logging DEE021

1 Energy logging module 1 phase 3 Frequency
2 Effective voltage
The diagnosis of energy logging module DEE021 is shown on the screen.

MX_MC6_V1.9_07.09.15_ENG
©KM

8.13.3.5 Energy logging, drives
Fig. 8.145 Energy logging, drives 1 and 2

1 Main drive phase
The diagnosis of the current transformer data of drives is shown on the screens.
Hydraulic axes have a symmetrical consumption. Hydraulic axes therefore only
use one drive with a current transformer. The phase of this drive (main drive) is
displayed on the screen.
For the individual phases, the following parameters are displayed:

• Current transformers
• Current path phase
MX_MC6_V1.9_07.09.15_ENG
• Power factor (cos. phi)

©KM
• Effective current
• Effective power

8.13.3.6 Energy logging, peripherals and heaters
Fig. 8.146 Energy logging, barrel heating, mold heating and peripherals
1 Barrel heating phase
The following screen are used for diagnosis of the current transformer data of
heaters and the peripherals:
• Energy logging, barrel heating
• Energy logging, mold heating
• Energy logging, peripherals
• Energy logging RPM (reaction technology machine) and extruder
For the individual phases, the following parameters are displayed:

MX_MC6_V1.9_07.09.15_ENG
• Current transformers
©KM
• Current path phase

• Power factor (cos. phi)
• Effective current
• Effective power

8.13.4 Cycle settings
1
2
3
4
5
6
7
Fig. 8.147 Cycle settings

1 Deactivate fully automatic mode 5 Input field for "Maximum value for plasticizing stroke overshoot"
2 Selection "Interruption quality alarm" 6 Automatic plasticizing before start of cycle
3 "Delay time, Start oil preheating" input field 7 Operating mode change via zero operating mode
4 Plasticizing stroke monitoring for cycle start
Deactivate fully automatic mode

The machine can be operated only in semi-automatic mode.
The "Fully automatic mode" button has no function.
Selection menu, "Quality alarm"

MX_MC6_V1.9_07.09.15_ENG
No interruption with quality alarm

Machine continues running in spite of quality alarm.
©KM
Do not open mold in event of quality alarm

Mold remains closed in event of quality alarm.
Do not move ejector forward in event of quality alarm

Ejector is blocked in event of quality alarm.
Delay time, Start oil preheating

Configurable delay time after which "Oil preheating" is started when the machine
is cold.

Plasticizing stroke monitoring for cycle start

This function monitors whether the screw reaches the plasticizing stroke. No
cycle can be started when the plasticizing stroke is not reached. Step P00168
"Plasticizing stroke not made" is displayed.
Maximum value for plasticizing stroke overshoot

Input of a tolerance value for the plasticizing stroke monitoring.
Automatic plasticizing before start of cycle

After the barrel set-temperatures are reached, plasticizing is started
automatically.
Operating mode change via zero operating mode

In general, you can change between the setting, manual, semi-automatic and fully
automatic operating modes as desired via the mode buttons (see section 6.5.1,
page 6-270).
With an activated tickbox (7, fig. 8.147) on the screen, the change from setting
mode to another mode of operation is only possible if the stop button has been
pressed (see section 6.5.1.5, page 6-271).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.13.5 Eco assistant
1
2
3
4
5
Fig. 8.148 Eco assistant (1/2)

1 Optimization of plasticizing time 5 Optimization of injection force
2 Minimum rotational speed (set value input) 6 Pushbutton "Optimization start" / "Cancel optimization"
3 Optimization of clamping force 7 Energy savings after last optimization (actual value display)
4 Minimum clamping force (set value input)
The setting parameters on the screen can be optimized so that the machine
consumes less energy where possible without a loss in quality and speed.
Optimization can be carried out in fully automatic mode. The operator selects the
desired parameters with the tickboxes (1, 3 and 5, Fig. 8.148).
MX_MC6_V1.9_07.09.15_ENG
The suggested values can be taken over as fixed settings or your own set values
can be entered.
©KM
After selection of the desired optimization parameters, press the "Optimization

start" (6) pushbutton to carry out the optimization.
I
Note
If the machine has energy logging, the energy savings (7, fig. 8.148) achieved
during the last optimization run are displayed on the screen.

8.13.5.1 Optimization parameter
Plasticizing time
When the plasticizing time is optimized, the plasticizing rpm is set so that the total
cooling time (except for a reserve) is used for plasticizing. A lower limit can be
specified for the plasticizing rpm.
I
Note
In the case of fluctuations in the melt cushion, it may be necessary to adapt the
metering stroke or the back-pressure.
Clamping force
Optimization in this case involves a reduction to the required clamping force. A
lower limit can be specified. It must be higher than half of the maximum clamping
force of the machine.
W
Important
During adaptation of the clamping force, it is possible that the mold opens
slightly (mold breathing). This can lead to over-injection!
Limitation of injection pressure

The function can only be activated if no accumulator is active for the injection
process. Depending on the current actual pressure during the injection process,
the injection pressure is reduced.
I
Note
• For a better adaptation, it is advisable to set several injection stages
(3-5 stages).
• A slight increase in injection times is possible!
Accumulator charging pressure

MX_MC6_V1.9_07.09.15_ENG
The function can only be activated if an accumulator is active for the injection
process. The charging pressure is lowered to the stage required for the injection
©KM
process or shut down completely (if injection speeds are low).
I
Note
A slight increase in injection times is possible!

8.13.5.2 Symbol explanation
Not yet optimized.
Optimization active.
Optimization complete. Value are optimized.
Optimization error.
I
Note
In addition to the symbols on the Eco assistant screen, the status of the
optimization is also displayed in the status displays of the header
8.13.5.3 Performing optimization
Prerequisites
• Fully automatic mode
• Current cycle
• Machine already set for production
Procedure
1) Activate desired Functions using the tickboxes (1, 3, 5, Fig. 8.148). Set limit
values for optimization parameters if necessary.
2) Press the "Start optimization" pushbutton (6).
The pop-up window "Optimization start" (see fig. 8.149, page 8-623) opens.
W
Important
The Eco assistant changes process parameters of the selection optimization
routines.
This can influence the quality of the parts!
MX_MC6_V1.9_07.09.15_ENG
©KM

Fig. 8.149 Optimization start
3) Confirm/cancel start of optimization in the pop-up window (see fig. 8.149,

page 8-623) with "Continue? - Yes/No".
– After confirmation of the warning, the optimization process starts for the
active functions.
W
Important
During optimization:
• Do not change any settings!
• The machine runs with parameters other than those displayed.
Separate some parts during optimization if necessary.
I
Note
The start and end of optimization is recorded on the screen "Events log"
– The energy savings are determined upon the completion of the

optimization.
MX_MC6_V1.9_07.09.15_ENG
– The pop-up window "Adoption of optimized parameters" (see fig. 8.150,

©KM
page 8-624) open (also in case of cancellation, change in operating mode

or stopped machine).

1
2
3
7
8
9
10
Fig. 8.150 Adoption of optimized parameters

1 Info field "Please check quality of parts!" 6 Injection pressure profile 1/2/3, energy savings
2 Selection/deselection of all optimized parameters 7 Energy savings thanks to Eco Assistant
3 Old value, new value 8 Cycle time before optimization
4 Plasticizing rpm profile 2, energy savings 9 Cycle time after optimization
5 Clamping force, energy savings 10 Buttons "Adopt optimized values? - Yes/No"
– After a successful optimization run, the found values are displayed.

MX_MC6_V1.9_07.09.15_ENG
– The cycle times before (8, fig. 8.150) and after optimization (9) are
©KM
displayed.
I
Note
If the machine has energy logging, the respectively achieved energy savings
(4, 5, 6 and 7) are also displayed on the screen.
4) Check parts quality and process parameters.

5) Adapt displayed values if necessary.

6) Press the respective button (10, fig. 8.150) to adopt or reject the values.
– When the pop-up window is confirmed, the values are adopted. The
machine runs with the selected parameter settings.
– If the window is exited after pressing Cancel, the machine continues
running with the old settings.
8.13.5.4 Adoption of optimized parameters
Fig. 8.151 Eco assistant (2/2)

1 Pushbutton "Adoption of optimized parameters"
The values from the completed optimization (see fig. 8.150, page 8-624) can still
MX_MC6_V1.9_07.09.15_ENG
be displayed on this second screen of the Eco assistant until the next optimization
©KM
run and can be adopted if necessary.

8.13.6 Machine/production status
Fig. 8.152 Machine/production status

1 "Resetting of downtimes" pushbutton
The duration of the production downtime is recorded on the screen. When the
reason for the interruption is selected, the interruption time is assigned
accordingly. The graphical part of the screen shows the ratio between production
and the individual reasons for interruption.
If the machine produces in semi-automatic or fully automatic mode, the
production time is registered.
MX_MC6_V1.9_07.09.15_ENG
©KM

Machine standstill
If the user selects a reason for interruption in the event of a production stop within
5 minutes, the time expired since the stoppage is added to the time total for the
selected reason for interruption.
If a reason for the stoppage is not selected within 5 minutes, the time is
automatically added to the "Non-assigned stoppage" time total.
I
Note
When the production manager resets the selected reason for stoppage even
though the machine is not yet producing, the assignment of the time to "Non-
assigned stoppage" continues after 30 seconds.
It is possible to retroactively change a reason for stoppage within these 30
seconds.
The totalling is terminated when production is resumed.

When the same reason for stoppage is selected once more, the individual times
continue to be totalled.
Reset standstill times

Pressing the pushbutton (1, fig. 8.152) resets all standstill times to zero and the
date and time of recording are reset.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.14 Machine preparation
8.14.1 Machine calibration
Fig. 8.153 Machine calibration

1 Selection of manual zero point calibration 3 "Setting zero point" pushbutton
2 Actual-value display of zero point
The zero-points of the position transducers must be reset after a mold change or
injection unit change (see section 7.17, page 7-351).
Setting position transducer zero points

In "manual" (1, fig. 8.153), the zero points are set by pressing the respective
MX_MC6_V1.9_07.09.15_ENG
pushbutton (3). With that, the corresponding actual value display (2) is set to zero.
©KM

8.14.2 Mold coding (ZE)
2
3
Fig. 8.154 Machine calibration, mold coding

1 Mold coding actual value 3 Exponent binary coding
2 Set value mold coding data record 4 "Save inputs" pushbutton
The mold coding function is used to assign a data record which has been read in,
to a mold.
W
MX_MC6_V1.9_07.09.15_ENG
Important
©KM
The inputs 1 to 16 must not have been assigned at the mold coding plug
connector.
This assignment must only be used for a dummy connector if a mold without
mold coding and a data record with mold coding are used.

The mold can be identified with a mold number at the mold coding plug connector
by means of jumpers (+24 V  contact 1 to 16, binary encoding). After machine
calibration, the actual value (1, fig. 8.154) is continuously compared with the set
value (2).
If actual and set values are not identical, the alarm A00017 "Mold coding fault" is
generated and the pump motor is switched off.
W
Important
Zero points which have not been correctly set can result in damage to the mold
and machine.
After installing mold, carry out machine calibration.
Installation of a new mold

If a new mold is used, the inputs of the mold coding which are read in must be
transferred to the data record as a set value with the "Transfer inputs" pushbutton
(4, fig. 8.154).
Only after this may the machine be operated and optimized outside of machine
calibration.
When the data record is stored, this set value is also stored in the screen "Data
record loading/saving" (see section 8.4.3, page 8-388).
Installation of a coded mold

After a mold is installed, the corresponding data record must be loaded in the
"Data record loading/saving" screen (see section 8.4.3, page 8-388).
Element Description
Inputs mold-coding Actual value display mold coding. Actual value display assignment of
inputs and actual value display coding.
Mold coding data Set-value display, Mold-coding data-record. Set-value display,
record assignment of the inputs and set-value display coding.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.14.3 Screw coding (ZE)
If the plasticizing unit is equipped with screw coding, the saved parameters are
read in and displayed on the screens (Fig. 8.155 and Fig. 8.156) once the barrel
heating is switched on. Parameters that cannot be read or are missing are set to
zero. All parameters (except heating) are accepted into the control system as limit
values.
MX_MC6_V1.9_07.09.15_ENG
©KM

1
2
3
4
5
6
7
8
9
10

1 Set values for "Heating capacity" 6 Actual values for "Standardized heating capacity"
2 Set values for "Cooling capacity" 7 Selection field "Nozzle shut-off type"
3 Set values for "Heating bands" 8 Tickbox "Screw coding programming mode"
4 "Range" selection field 9 Pushbutton for "Save data to EEPROM" 1)
5 Set values for "Nominal voltage" 10 "Mains voltage" actual value
1) This pushbutton is only displayed to users in key group 6.
The "screw encoding 2" screen is used to enter the values for the heating capacity
for the individual heating zones specified by the manufacturer at the specified
nominal voltage (5, fig. 8.156). These are standardized to the mains voltage (10),
which was entered on the "Barrel heating circuit monitoring" (see fig. 8.109,
page 8-550) screen.
The data is saved on the machine EEPROM at the plasticizing unit on the screw
MX_MC6_V1.9_07.09.15_ENG
coding. "Screw coding programming mode" is only available to users in key

©KM
group 6.

8.14.4 Production data

In the production data screens all production and mold-specific data can be
entered. The production data is also saved when the data record is written
The data has no effect on the machine.
8.14.4.1 Set-up and production data 1
Fig. 8.157 Set-up and production data 1
Details on the following data can be entered on the screen:

• Customer
MX_MC6_V1.9_07.09.15_ENG
• Order
• Article
©KM
• Material
• Colour
• Machine
• Mold
• Plasticizing unit
• Number of cavities
• Screw diameter
• Article weight

Details on the following data can be entered or selected on the screen:

• Mold insert 1-5
• Nozzle/bore characteristics
– Nozzle bore
– Nozzle radius
– Nozzle open (yes/no)
• Nozzle type (yes/no)
– Nozzle HSVS
– Nozzle SVS
MX_MC6_V1.9_07.09.15_ENG
– Nozzle SVN
©KM
– Special nozzle


• Quick-release clamping strip (yes/no)
• Clamping shoes
– Total number
– Number of MP
– Number of FP
• Centring MP/FP
• Bolts
– Number
MX_MC6_V1.9_07.09.15_ENG
– Length
©KM
– Thread
• Energy coupling (yes/no)
– Number of energy couplings
• Quick-action coupling (yes/no)
• Robot (yes/no)
• Discharge scales (yes/no)
• Air

8.14.4.4 Production set data 1
Fig. 8.160 Production set data 1

• Operating mode (semi-automatic mode / fully-automatic mode)
• Shot weight
– Shot weight without sprue
– Shot weight with sprue
• Operating personnel
• Times
– Cycle time (actual value)
– Injection time (act.-value)
MX_MC6_V1.9_07.09.15_ENG
– Plasticiz. time (act.-value)

©KM
• Torque stage
• Injection unit contact force
• Clamping force
• Mold safety force

8.14.4.5 Production set data 2
Fig. 8.161 Production set data 2

• Pieces/Hour
• Box content; pallet; carton
• Material pre-treatment (yes/no)
– Temperature
– Duration in hours
• Ground material (yes/no)
– Content
– Colour number
MX_MC6_V1.9_07.09.15_ENG
©KM

8.14.4.6 Production data, mold temperatures
Fig. 8.162 Production data, mold temperatures
Details on the following data can be entered on the screen:
Mold heat-balancing (heating/cooling circuits)

• Controller
• Temperature
• Flow rate
MX_MC6_V1.9_07.09.15_ENG
©KM

8.14.5 7-day timer
8.14.5.1 7-day timer

1 "7-day timer" selection menu 2 Input/display "Heating up starting time"
Whether or not the functions on this screen are enabled depends on the specific
equipment.
MX_MC6_V1.9_07.09.15_ENG
©KM
I
Note
The real-time clock module in the control system always assigns the correct
day of the week to the date. The date and time must be set correctly (see
section "Current date / Current time", page 6-232).

"7-day timer" selection menu

In the selection menu (1, fig. 8.163), the programmable 7-day timer is activated
or deactivated. The activation times (2) for the different machine functions can be
set individually for every day of the week.
Motor
The pump motor starts up at the defined time (2). The hydraulic oil is heated to
the temperature set value ("Oil preheating" function) by means of circulation.
Barrel heating
The barrel heating system is switched on and heated to the set values at the
defined time (2).
Mold heating
The mold heating (heating bands, heating cartridges, etc.) is switched on at the
defined time (2) and heated up to the set values.
This function is only available when the machine is equipped with the mold
heating option.
Heat balancing
The heat-balancing function (mold temperature controllers) is switched on at the
defined time (2) and controlled to obtain the set values.
This function is only available when the machine is equipped with the "Heat-
balancing" option.
I
Note
Depending on the existing auxiliary devices, further machine functions can also
be activated and time-controlled.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.14.5.2 Control 7-day timer via start of production
1
2
3
Fig. 8.164 Control 7-day timer via start of production

1 "Start of production" input 3 "Barrel heating" selection field
2 "Motor" selection field
The 7-day timer is controlled on this screen page via the input of the time for the
start of production.
For heating up the barrel heating and preheating the hydraulic oil, exact points in
time for completion of the heating-up procedure or the start of production can thus
be specified. This permits better planning of the start of production and energy
savings through targeted heating up.
MX_MC6_V1.9_07.09.15_ENG
Procedure
1) In the "Start of production" (1, fig. 8.164) line, specify the time of the start of
©KM
production.
2) Activate motor (2) and barrel heating (3) for this weekday via the selection
field.

3) Switch to the screen page "7-day timer" (see fig. 8.163, page 8-639).
If the motor (2, fig. 8.164) and barrel heating (3) are activated, the input on the
screen page is replaced by the display of the planned start of heating up
(2, fig. 8.163). The starting time for heating up was determined according to
the current temperature. The pump motor is started and the barrel heating is
switched on when the time calculated and displayed in the 7-day timer (2) has
been reached. The hydraulic oil and the barrel heating are thus heated up and
thoroughly warmed at the start of production.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.15 Peripherals (ZE)

All the functions related to the peripherals (interfaces, signals) are described in
the following sections.
8.15.1 Inputs and outputs
8.15.1.1 Freely programmable inputs
Fig. 8.165 Freely programmable inputs 1 to 3
Several functions may be assigned simultaneously to the inputs.

• If an input is assigned via a function, then the corresponding function is
MX_MC6_V1.9_07.09.15_ENG
disabled at the input when the signal is 0.

• In setting mode, the function is also stopped while the function is active.
©KM
• In the manual, semi-automatic and fully automatic modes, the function cannot
be started but a function that is being executed is not interrupted.
I
Note
The connector assignments can be derived from the enclosed circuit diagram
(see chapter 16 Electrical system).

8.15.1.2 Freely programmable outputs
Fig. 8.166 Freely programmable outputs 1 to 3
If an output is assigned via a function, then the output is activated by the

corresponding function.
• Activation time (run time) = 0:
Output is activated as long as the function is active.
• Activation time (run time) > 0:
Time and output are activated with the start of the function. The output is
deactivated upon expiration of the activation time.
MX_MC6_V1.9_07.09.15_ENG
I
Note
©KM
The connector assignments can be derived from the enclosed circuit diagram
(see chapter 16 Electrical system).

8.15.2 Production signals BDE
Fig. 8.167 Production signals BDE
The production signals of the Production Data Acquisition (BDE) can be selected
on the screen for 5 outputs.
The switch-off delay is used to define at which time interval the production signals
are acquired for the respective output.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.15.3 Production signals CIMI (ZE)
Fig. 8.168 Production signals CIMI
The production signals of the CIMI can be selected on the screen for 6 outputs.
The switch-off delay is used to define at which time intervals the production
signals are acquired for the selected output.
Also, set values can be entered on the screen for:

• Screw stroke at 10 V
• Injection speed at 10 V
• Injection pressure at 10 V
• Screw RPM at 10 V
MX_MC6_V1.9_07.09.15_ENG
• Mold cavity pressure 1 at 10 V

©KM

8.15.4 Interface EUROMAP 67 (ZE)
Fig. 8.169 Interface EUROMAP 67
The connector assignment of the EUROMAP 67 interface with the pending

signals is shown on this screen.
Interface assignment (see chapter 11 Peripherals / Interfaces).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.15.5 External alarm inputs (ZE 89.9696)
2 1
Fig. 8.170 External alarm inputs 1-2

1 Alarm type "Display alarm" 2 Alarm type "Shutdown at end of cycle"
Input signal
Inactive
Input is ignored.
0-signal / 1-signal
If there is a 0-signal or 1-signal at the input, the alarm is tripped. The LED displays
the input signal.
MX_MC6_V1.9_07.09.15_ENG
The input of time for which the respective signal has to be pending to generate
the alarm is made in the "Signal duration" field.
©KM

Alarm type
Display alarm
A white alarm without shutdown is generated.
Shutdown at end of cycle

A red alarm is generated and production is stopped at the end of the cycle.
By screen selection (2, fig. 8.170), the motor, heaters and heat-balancing units
can also be switched off.
Immediate shutdown
A red alarm is generated.
By screen selection (2, fig. 8.170), the motor, heaters and heat-balancing units
can also be switched off.
An immediate shutdown without ending the cycle takes place if the following
conditions are met:
• Shutdown option "Motor shutdown" is selected.
• At least one further shutdown option is selected, e.g. "Barrel heating
shutdown".
• One of the "-" tolerances of the other shutdown options has been undershot.
If no other shutdowns are selected under "Immediate shutdown", the cycle

continues running.
Shutdown options
If alarm type "Shutdown at end of cycle" or "Immediate shutdown" was selected,
the units can be shut down by means of screen selection (2, fig. 8.170):
• Motor
• Barrel heating
• Mold heating
• Heat balancing
Fault message signal
Lamp at stop
The function can only be selected if alarm type "Display alarm" (1, fig. 8.170) is
selected. With selection of alarm types "Shutdown at end of cycle" (2) or
"Immediate shutdown", the function is set automatically.
MX_MC6_V1.9_07.09.15_ENG
The lamp lights up if the machine is not running in the cycle.

©KM
Lamp in cycle
selected. With selection of alarm types "Shutdown at end of cycle" (2) or
"Immediate shutdown", the function is set faded out.
The lamp is switched on immediately after the alarm is tripped.
Signal buzzer
The "Signal buzzer" function can always be selected.

Quality alarm
The function can only be selected if alarm types "Display alarm" and "Shutdown
at end of cycle" are selected. The part will be evaluated as a reject part when the
alarm occurs.
Cyclic generation
selected. The alarm is recorded again in every cycle.
I
Note
With quality alarms, the function "cyclic generation" should be selected.
Otherwise, only the first part will be evaluated as a reject part.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.15.6 Displaying image of a camera
Fig. 8.171 Displaying image of a camera
The video camera is provided for optical monitoring of inaccessible or concealed

areas. It is delivered with a wall mount and can be installed in a freely selectable
position.
The camera covers has field viewing angle of 37°. The display is on the
visualization of the machine control system.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.15.7 Scales (ZE)
1
2
3
4
Fig. 8.172 Scales

1 Selection menu "Name" 3 Button, actual value display for "Weight scales (cycle value)"
2 Button "Weighing scales taring (zeroing)" 4 "Step text" input field
On the "Scales" screen, weighing system or gravimetric metering systems can be

parametrised.
Depending on the system, the following operating functions are possible, e.g.:
• Weighing scales taring (zeroing)
• Weight scales (cycle value)
• Step text
MX_MC6_V1.9_07.09.15_ENG
©KM
Furthermore, settings for the data transmission can be defined:

• Baud rate
• Parity
• Stop bits
• FIFO
• Interface
• Weight of scales (measuring unit)

8.15.8 Laminar flow box (ZE)
Fig. 8.173 Laminar flow box
In setting mode, the laminar flow box can be switched on with the selection
program "Operation with laminar flow box".
Interface, laminar flow box (ZE) (see section 11.10, page 11-815)
MX_MC6_V1.9_07.09.15_ENG
©KM

8.16 Configuration/Diagnosis
8.16.1 Service and configuration
8.16.1.1 KM Service (KraussMaffei Service)
2
1 3
Fig. 8.174 KM Service

1 Machine type 3 Order number
2 Machine number
The software versions used in the machine for sequence, visualization and Safety
CPU are displayed on the screen.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.16.1.2 Inspection intervals
9 2
8 3
7
6 4
5
Fig. 8.175 Inspection intervals

1 List of inspections 6 "Premature servicing" pushbutton
2 Runtime/ Remaining time until the next inspection is due 7 "Customer" pushbutton
3 Information box 8 "KM-Service" pushbutton
4 Operating hours total (machine switched ON) 9 Production hours per week
5 Operating hours in production
All inspections performed and requested are displayed on this screen

(1, fig. 8.175).
The following are listed in a table:
• Consecutive number
• Type of inspection
• Note on inspection request (date, drive motor operating hours counter)
MX_MC6_V1.9_07.09.15_ENG
• Note on implementation (date, drive motor operating hours counter, person

carrying out the inspection)
©KM
Furthermore, the total times for operating hours with the machine switched on
(4, fig. 8.175) and for operating hours in production (5) [hours : minutes] are
displayed.
The bar (2) proportionally represents the running time or remaining time until the
next inspection is due. The orange area in the bar indicates the duration, which
has already expired until the next inspection is due. The area to the right of it
shows the remaining time until the next inspection is due.

Type of inspection
The inspections I1 or I2 are alternately every 3000 h and the inspection I3 is due
after every 30000 h of machine runtime. Accordingly, the inspections I1, I2 and I3
are reported due for the following machine runtimes:
after 12000 h
after 15000 h
after 18000 h
after 21000 h
after 24000 h
after 27000 h
after 30000 h
after 33000 h
after 36000 h
after 3000 h
after 6000 h
after 9000 h
Machine
runtime
...
I1 = Inspection 1 x x x x x
I2 = Inspection 2 x x x x x x
I3 = Inspection 3 x
The hour data for the maintenance intervals are guidelines. Depending on the ma-
chine load (operating hours and cycle time), maintenance intervals are calculated
automatically and displayed on the "Inspection intervals" screen to indicate that
an inspection is due.
Status of the inspection

The inspection status is shown in the notes field (3, fig. 8.175).
Commissioning
The new machine was turned on for the first time.
DD.MM.YY: Delivery, servicing in one year at the latest

The machine has been delivered and the commissioning concluded. The delivery
date is shown.
DD.MM.YY: Time adaptation according to load

The machine is heavily loaded: Thereby there is an earlier maintenance period. If
the production hours per week change, the maintenance period changes too. The
date of the projected maintenance is displayed.
DD.MM.YY: Time adaptation according to load, 90% warning

90% of the time until the maintenance period has already expired. If the
production hours per week change, the maintenance period changes too. The
date of the projected maintenance is displayed.
MX_MC6_V1.9_07.09.15_ENG
DD.MM.YY: Servicing date reached, next maintenance cycle is running

©KM
The maintenance date has been reached, but the maintenance has not yet been
carried out. The date of the maintenance is displayed.
DD.MM.YY: Maintenance I2 carried out, next servicing in one year at the latest
The maintenance period has been reached and the maintenance carried out. The
date of the next maintenance is displayed.

Acknowledge maintenance
I
Note
Pressing the pushbuttons to acknowledge an inspection carried out is only
possible with key group 4.
By pressing the respective pushbutton, the person carrying out the inspection is
defined in the table (8)/(7, fig. 8.175); this also defines whether this is before-
schedule servicing (6).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.16.1.3 Configuration
1
2
3
4
5
6
7
Fig. 8.176 Configuration

1 Machine type 5 "Machine configuration list of contents" pushbutton
2 Order number 6 "Read machine configuration from USB stick" pushbutton
3 Machine number 7 "Save machine configuration on the USB stick" pushbutton
4 List of contents
The machine model (1, fig. 8.176), order number (2) and machine number (3) are
shown on the screen.
List of contents
By pressing the "List of contents machine configuration" pushbutton (5), the list of
contents (4) of the configuration data is called up.
MX_MC6_V1.9_07.09.15_ENG
Read machine configuration from USB stick

©KM
Pressing the pushbutton (6) saves the machine configuration data on the USB
stick.
Save machine configuration on the USB stick

Pressing the pushbutton (7) saves the machine configuration data on the USB
stick.

8.16.1.4 Calibration
1
2
3
4
5
6
7
8
9
Fig. 8.177 Calibration

1 Machine type 6 "Index of calibration data" pushbutton
2 Order number 7 Calibration selection
3 Machine number 8 "Read calibration data from USB stick" pushbutton
4 Machine index 9 "Save calibration data onto USB stick" pushbutton
5 Robot index
The machine model (1, fig. 8.177), order number (2) and machine number (3) are
shown on the screen. The current calibration data can be backed up or new data
can be loaded on this screen.
List of contents
MX_MC6_V1.9_07.09.15_ENG
Actuate the pushbutton "Index of calibration data" (6) to call up the list of contents
(4/5) of the calibration data for machine or robot.
©KM
Reading calibration data from USB stick

Pressing the pushbutton (8) reads the machine or robot calibration data from the
USB stick.
Save calibration data onto USB stick

Pressing the pushbutton (9) saves the machine or robot calibration data on the
USB stick.

8.16.2 Diagnosis
8.16.2.1 Diagnosis, injection molding machine
7
6 1
5
4
3
Fig. 8.178 Diagnosis (graphic view)

1 Detail view 5 "Modules" button
2 "Details" pushbutton (see fig. 8.182, page 8-664) 6 "Graphic" button
3 "CTMS" button 7 Module (selected)
4 "CWB" button
The voltages present at the analogue inputs and outputs as well as active digital
inputs and outputs when the machine is running are displayed on the diagnosis
screens.
MX_MC6_V1.9_07.09.15_ENG
Refer to the circuit diagram for the set values and the assignment of the plug
connectors (see chapter 16 Electrical system).
©KM
There are three different viewing options for diagnostics:

• Graphic view (default when calling up the screen) (see fig. 8.178,
page 8-660)
• Module view (see fig. 8.179, page 8-661)
• CWB view (see fig. 8.180, page 8-662)
• CTMS view (see fig. 8.181, page 8-663)

Module view
Fig. 8.179 Diagnosis (module view)

1 "Modules" button 2 "Details" pushbutton (see fig. 8.182, page 8-664)
If the "Module" (1, fig. 8.179) button is pressed, the diagnostic representation
changes to the module view.
MX_MC6_V1.9_07.09.15_ENG
©KM

CWB view
Fig. 8.180 Diagnosis (CWB view)

1 "CWB" button
If the "CWB" (1, fig. 8.180) button is pressed, the diagnostic representation
changes to the CWB view.
MX_MC6_V1.9_07.09.15_ENG
©KM

CTMS view
Fig. 8.181 Diagnosis (CTMS view)

1 "CTMS" button 2 "Details" pushbutton (see fig. 8.182, page 8-664)
If the "CTMS" button is pressed (1, fig. 8.181), the diagnostic representation
changes to the CTMS view.
MX_MC6_V1.9_07.09.15_ENG
©KM

Details
Fig. 8.182 Diagnosis, detail

1 Selection of language
By pressing the "Details" pushbutton, a pop-up window with the entire detail view
opens.
The text in the pop-up window can be displayed by pressing the respective button
"Selection of language" (1, fig. 8.182) optionally in two languages:
MX_MC6_V1.9_07.09.15_ENG
• Language 1: German
• Language 2: English
©KM

8.16.2.2 Robot diagnosis
Fig. 8.183 Robot diagnosis
Description of the buttons and functions (see section 8.16.2.1, page 8-660)
MX_MC6_V1.9_07.09.15_ENG
I
Note
©KM
Description of diagnosis: see external technical documentation for robot.

8.16.3 Step display diagnosis
1
2
3
4
5
6
Fig. 8.184 Step display diagnosis

1 Clamping unit 4 Ejector
2 Injection unit 5 Remaining machine / misc.
3 Injector 6 Core-pulling
In addition to the status display, all running steps are displayed on the screen.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.16.4 Diagnosis, servo pumps and electric screw drive
8.16.4.1 Settings/diagnosis, converter 1
Fig. 8.185 Settings/diagnosis, converter 1

1 Selection menu, "Servo pump" 2 Torque actual value
Two different servo drives can be displayed on this page on different halves of the
screen.
In the selection menu (1, fig. 8.185), the drive whose converter is to be observed
is selected. For the selected drive, the following converter actual values are
displayed:
MX_MC6_V1.9_07.09.15_ENG
• Motor temperature
©KM
• Converter temperature
• Speed set value
• Speed actual value
• Torque actual value
• Mains voltage actual value
• Utilization Ixt actual value of power element
• Drive maximum current

I
Note
Ixt value = result of the calculation of an internal temperature model of heat sink
and IGBT (bipolar transistor with insulated gate electrode).
If the Ixt value of the overload monitoring

• = 100%, the current is limited to the power element rated current.
• < 95%, the current limit is set back to the power element maximum current.
The LED displays signal the current status of the selected converter:
Online
The converter is connected via a bus cable with the control system. If the
converter communicates with the MC6 controller, the LED lights up.
Fast stop input

The 24V signal is present at hardware input "Fast stop".
Pulse enable
The 24V signal is present at hardware input "Pulse block".
Controller enable
The drive is enabled by the software.
Activate drive
The drive has been activated by the controller.
Drive active
Feedback from the drive.
Torque actual value

The torque [%] (2, fig. 8.185) is displayed graphically and as a percentage actual
value.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.16.4.2 Settings/diagnosis, converter 2
1
2
Fig. 8.186 Settings/diagnosis, converter 2

1 Selection menu, "Servo pump" 3 Data record title
2 Drive control
On the screen, more information on the diagnosis of the converter is displayed.

This data is primarily relevant to KM Service. It can be changed for commissioning
and correct setting of the converter by a KM service technician.
Drive control
• Synchronous machine control
• Asynchronous machine control
MX_MC6_V1.9_07.09.15_ENG
• Asynchronous machine open loop control

©KM

Check of water circuits and motor speed

For checking purposes, the KM service technician can change the following
parameters:
• Drive maximum speed
• Warning temperature (motor cooling):
If the motor temperature exceeds the set warning temperatures, the motor's
cooling circuit is switched on.
• Power section cooling
– Cooling on:
If the converter temperature exceeds the entered value, the cooling of the
power element is switched on.
– Cooling off:
If the converter temperature falls below the entered value, the cooling of
the power element is switched off.
I
Note
The changed values are not saved! They are deleted when the machine is
restarted.
Data record title

The title of the data record saved in the converter (3, fig. 8.186) is displayed.
8.16.4.3 Diagnosis of electric screw drive

The electric plasticizing drive is activated via the Varan bus.
The diagnosis of the drive is identical to the diagnosis of the servo pumps
(see sections 8.16.4.1 and 8.16.4.2).
In the selection menu (1, fig. 8.185), the drive for plasticizing must be selected.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.16.5 System pressures, hydraulic pressure transducer
2
3
Fig. 8.187 System pressures

1 Hydraulic pressure pump 1/2 3 Clamping pressure
2 Hydraulic pressure
The screen displays the actual values of the system pressure.

MX_MC6_V1.9_07.09.15_ENG
©KM

8.17 Alarms/Events
8.17.1 Alarm overview
6 2
3
4

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
This screen shows all the alarms (malfunctions) that are pending on the machine
and the corresponding peripherals.
Depending on situation and alarm status, the alarm hardkey appears differently
MX_MC6_V1.9_07.09.15_ENG

©KM
If the alarm hardkey (3, fig. 8.188) is pressed while a current alarm is pending, the
"Alarm overview" softkey (5) additionally gets a flashing red border.
The chronological arrangement of the table can be ascending or descending.

Press the "Date/time" header to arrange the alarms that have occurred.
If the same alarm has been triggered several times, the number of occurrences
is indicated in the "*" column.

Priority of the alarms

The alarms are displayed with the following colours, depending on priority:
• Red = The motor is switched off immediately or at the end of the cycle.
• Pink = Machine can be switched off, interface monitoring, communication
error between sequence computer and operating computer.
• White = Machine continues operating, tolerance limit exceeded, maintenance
instructions.
Occurrence and acknowledgement of an alarm

If an alarm occurs, it can immediately be called up via the alarm hardkey from
every screen page:
1) Press the alarm hardkey.

The "Alarm overview" screen (see fig. 8.188, page 8-672) opens.
2) To display exact information in an expanded detail view, press the line of the
corresponding alarm.
A notes field (1, fig. 8.188), in which the cause of the alarm and options for
rectifying it are described in detail, opens under the line pressed.
3) Eliminate the cause of the alarm.
W
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
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 button.

The alarm message is acknowledged and goes out when the fault has been
eliminated.
If the fault is not successfully eliminated, the machine remains in the alarm
status.
W
MX_MC6_V1.9_07.09.15_ENG
Important
©KM
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.

8.17.2 Settings alarm overview
2
3
Fig. 8.189 Settings alarm overview

1 Delay time for pump shutdown during malfunction 3 Signal buzzer activation time
2 Selection menu "Signal buzzer"
Settings for alarms and the view of the alarm overview can be made on these
screens.
Delay time for pump shutdown during malfunction

The delay time is only effective when the alarm in question does not pose any
danger for the personnel and the machine.
Selection menu "Signal buzzer"

Buzzer off
MX_MC6_V1.9_07.09.15_ENG
The signal buzzer is inactive.

©KM
Buzzer permanently on
The signal buzzer switches on continuously in the event of U alarms (immediate
shut-off) and Z alarms (shut-off at the end of cycle) in semi-/fully automatic mode.
Buzzer with timeout

The signal buzzer is switched off again after the time set under "Signal buzzer
activation time" has elapsed.
Signal buzzer activation time

Settable time after which the signal buzzer is switched off again.

8.17.3 Events log
Fig. 8.190 Events log

1 "Event description" notes field
All changes and malfunctions that occur on the machine are recorded in the
events log. By referring to it, it is possible to retroactively determine which
changes to the machine settings may have caused production problems.
By pressing a line in the events log, a notes field opens underneath it

(1, fig. 8.190) in which the events are described in detail with the troubleshooting
options for faults.
MX_MC6_V1.9_07.09.15_ENG
Sorting
©KM
The table can be sorted in the columns "Date/Time", "T" and "L" – ascending or
descending as required. By pressing the respective header, the events are
arranged accordingly.

Making entries in the events log

1) Enter the chip card (ZE) specifying the code number.
2) Depending on the equipment of the machine, the following changes can be
configured:
• Parameter changes made via the keyboard with specification of old
value/new value for all standard parameters
• Changes of parameter groups with general note for:
– Core-pulling units
– Production data
– Curve computer
– 7-day timer
– Statistics
– Machine calibration
– USB stick reading/writing.
• Alarms that recur if still present in subsequent cycles:
– Reset of alarms
– Operating mode changes
– Change from "production" to "stop"
– Control ON/OFF
– Parameter access from the server computer
MX_MC6_V1.9_07.09.15_ENG
©KM

8.17.3.1 Symbol legend for events log

1) Select the "Events log" screen (see fig. 8.190, page 8-675).
A pop-up window with the symbol explanation of the events log opens.
MX_MC6_V1.9_07.09.15_ENG
Fig. 8.191 Symbol legend for events log

©KM

8.17.3.2 Events log exporting/printing
1
2
3
4
Fig. 8.192 Events log exporting/printing

1 Start date/time 3 Export data file title
2 Finish date/time 4 Export log list to USB stick
On the screen, the events log (see section 8.17.3, page 8-675) can be exported
in a file onto the USB stick.
Start date/time, Finish date/time

The data and time of the desired time interval for which the events log is to be
output can be entered.
Input format: DD⁄MM⁄YY and HH⁄MM.
MX_MC6_V1.9_07.09.15_ENG
The input values of the time interval are also displayed on the screen "Events log"
©KM
Export data file title

The file name must be entered to output the events log on the USB stick.
Export log list to USB stick

1) Insert the USB stick into the USB port.
2) Press pushbutton (4, fig. 8.192).
The log entries selected on the screen are exported.

8.17.4 Overview of machine doors
Fig. 8.193 Overview of machine doors
This screen shows a schematic of all machine doors. The status of the respective
door is displayed by means of various symbols.
Pressed EMERGENCY STOP buttons and errors that have occurred appear on
the screen via a symbol at the corresponding position.
MX_MC6_V1.9_07.09.15_ENG
©KM

Symbol explanation
Door properly closed
Door properly open
Fault in switching sequence
Door closed but not yet acknowledged
Door cannot be evaluated
EMERGENCY STOP
Door available but not active

(e.g. takeover of function by robot protective fence)
MX_MC6_V1.9_07.09.15_ENG
©KM

8.18 Notebook (ZE)

The Notebook function is used to save notes that can be assigned to different
categories. Furthermore, the notes can be assigned to specific screen pages, or
document attachments can be connected to the note text via links.
The Notebook function can be reached via the "Notebook" button on the left
beside the title on every screen page. When the button is pressed, the "Notebook"
(see fig. 8.194, page 8-681) pop-up window appears.
The number in the button indicates how many notes are linked with the respective
screen page. If no note is available, no number appears and the icon in the button
is grey.
1
2 4
6
MX_MC6_V1.9_07.09.15_ENG
7
©KM
Fig. 8.194 Notebook, pop-up window

1 Title of the opened screen page 5 Area of current selection (Navigation, Search, Edit)
2 Multi-select feature: Navigation, Search, Edit 6 Edit field
3 Selected category 7 Attachments to currently selected note
4 Selected note

Edit and display mode

Depending on user's key group, the "Notebook" pop-up window opens in Edit or
Display mode. Display mode only allows users to view notebook entries. Editing
functions are only enabled in Edit mode. The pop-up window in Fig. 8.194 is
shown in Edit mode.
I
Note
Notes and categories can only be created or changed if the user is in key group
"2" or higher.
8.18.1 Navigation
4
2 5
6
MX_MC6_V1.9_07.09.15_ENG
3
©KM
Fig. 8.195 Navigation

1 "Navigation" selection 4 Selected category (orange)
2 Category tree 5 Chain symbol
3 "Navigation" menu 6 Notes of selected category (yellow)
If "Navigation" (1, fig. 8.195) is selected in the multi-select feature, the currently
available categories are displayed in a category tree (2).

Category
The category tress (2) lists all created categories with their designations. The
example uses the following categories (see fig. 8.195, page 8-682):
• Category Machine
• Category Mold
• Category Heat-balancing unit
• Category Setting mode
• Category Robot
The currently selected category (4, fig. 8.195) is shaded orange. A number is
displayed beside the category designation. The number indicates how many
notes in this category are linked with the screen page opened in the background.
Note
The yellow area lists all available notes (6, fig. 8.195) belonging to the selected
category (4), including their designations. A chain symbol (5) beside the note
designation indicates whether the note is linked with the screen page opened in
the background.
If a note is currently selected (4, fig. 8.194), it is displayed in the Edit field (6) of
the note texts and its designation appears in the category tree in bold letters.
1 2 3 4
5 6 7 8 9
Fig. 8.196 "Navigation" menu

1 "Change to previous category" button 6 "Create" button
2 "Change to next category" button 7 "Export" button
3 "Change to previous note" button 8 "Delete category" button
4 "Change to next note" button 9 "Delete note" button
5 "Edit" button
MX_MC6_V1.9_07.09.15_ENG
Category change
©KM
The buttons "Change to previous category" and "Change to next category" are
used to switch between categories.
Note change
Actuation of the buttons "Change to previous note" and "Change to next note"
results in a jump to the previous or next note also beyond a single category.

Edit
The name of a category and title of a note can be changed by selecting them and
then actuating the "Edit" button.
Create
In Edit mode, the "Create" button can be used to prepare a new category or note.
Export
A note can be saved onto a USB stick via the "Export" button provided an external
storage medium is connected (see section 8.18.1.3, page 8-688).
Delete category
This button is used to delete a previously selected category with all associated
notes. When this button is actuated, a pop-up window appears with a safety
prompt (see fig. 8.197, page 8-684):
• "Do you really wish to delete the following category?"
• Designation of the category (e.g. Category Robot)
• "All notes contained in it will also be deleted!"
The delete operation only takes place after the safety prompt has been confirmed.
Fig. 8.197 Safety prompt

1 Designation of category/note
MX_MC6_V1.9_07.09.15_ENG
Delete note
©KM
When this button is actuated, a selected note is deleted. The delete operation is
only started after a safety prompt (see fig. 8.197, page 8-684) has been
confirmed. The safety prompt shows the name of the note (1, fig. 8.197).
8.18.1.1 Creating and renaming categories and notes

Categories are divided into two different groups, which differ according to their
storage location:
• Local storage in the injection molding machine (local archive)
• Storage in the mold data record

I
Note
Each storage location is subject to memory capacity limitation. If, when editing
a note, the memory capacity of the respective storage location (local archive or
mold data record) is exceeded, an information window is displayed and the
action is aborted.
In Edit mode (see pate 8-682), the "Create" button can be used to prepare a new
category or note. In the "Create" pop-up window that appears, you can select
between the creation of a new category or a new note.
Creating a category
Fig. 8.198 Create, pop-up window (category)

1 "New category" button 3 Selection menu "Enter storage location"
2 "Category" input
1) Select the "New category" button (1, fig. 8.198).

2) Enter the category name in the "Category" input box (2).
MX_MC6_V1.9_07.09.15_ENG
3) Select storage location in selection menu (3).

©KM

Create note
Fig. 8.199 Create, pop-up window (category)

1 "New note" button 3 "Note" entry
2 Selection menu "Category"
1) Select the "New note" button (1, fig. 8.199).

2) Enter note title in the "Note" input box (3).
3) Select Assignment to a category in the selection menu (2).
Renaming category/note
The name of a category and title of a note can be changed by selecting them and
then actuating the "Edit" button.
MX_MC6_V1.9_07.09.15_ENG
©KM

Fig. 8.200 Edit, pop-up window (Category)

1 Selection menu "Enter storage location" (blocked)
1
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 8.201 Edit, pop-up window (Note)

1 Selection menu "Category" (blocked)
The respective selection menu can no longer be selected in the "Edit" pop-up
window so that the storage location of a category and assignment of a note to a
category can no longer be changed.

8.18.1.2 Linking a note

A selected note can be linked using the "Link" with the screen page opened in the
background.
Fig. 8.202 Navigation - linking a note

1 "Link" button 2 Number of notes 1)
1)
Notes linked to the screen page opened in the background
When the background of the "Link" (1, fig. 8.202) is orange, this indicates that a
link exists with the screen page opened in the background. Click on the button
again to cancel the link. The button then turns grey again.
The numbers (2) in the category tree indicate whether a category contains notes
that are linked to the screen page opened in the background.
8.18.1.3 Exporting note

A note can be exported onto a USB stick via the "Export" button provided an
external storage medium is connected.
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 8.203 Safety prompt - export note
When this button is actuated, a pop-up window appears with a safety prompt
• "export current note?".

After confirmation of the safety prompt, the export procedure starts. The note is
saved as a zip file with all attachments. After the export, an information window
appears with the path and name of the target file.
8.18.2 Editing
Fig. 8.204 Editing

1 Multi-select feature 4 Attachments
2 Text operations 5 Text marking aids
3 Writing operations
Editing of notes is possible after actuation of the "Edit" button in the multi-select
feature (1, fig. 8.204). In Edit mode, the virtual keyboard required for editing
appears.
MX_MC6_V1.9_07.09.15_ENG
©KM

8.18.2.1 Text operations

The text operations (2, fig. 8.204) can be used to edit text phrases that were
selected in the box of the note text (6, fig. 8.194). Buttons of operations that can
currently not be executed are shown in grey.
Copy
Copy selected text lines.
Cut
Cut out selected text lines.
Paste
Insert selected text lines at a different point in the text.
Save
If a change was made to the note text, the note can be saved using the Save
buttons.
Fig. 8.205 Safety prompt - saving note
If you exit a note without saving it manually, a pop-up window appears with a
safety prompt:
• "Current note contains unsaved changes - save?"
I
Note
MX_MC6_V1.9_07.09.15_ENG
If, when editing a note, the memory capacity of the respective storage location
©KM
(local archive or mold data record) is exceeded, an information window is

displayed and the action is aborted.

8.18.2.2 Writing operations

The various writing operation functions (2, fig. 8.204) can be used to edit a
selected text passage.
1 6
2 3 4 5
Fig. 8.206 Editing - writing operations

1 Font selection field 4 Font colour selection field
2 Font weight button 5 Background colour selection field
3 "Underline text" button 6 Font size selection field
Font weight
A selected text passage is shown with font weight "bold" when this button is
actuated.
Underline
When this button is pressed, the previously marked characters are underlined.
Via the selection fields, you can select the font (1, fig. 8.206), font size (6), font
colour (4) and the background colour (5).
MX_MC6_V1.9_07.09.15_ENG
©KM

8.18.2.3 Attachments
Add attachments
Fig. 8.207 Adding an attachment file

1 "Drive" selection field 3 "Add" button
2 List of selectable files
The "Add attachments" button can be used to add attachments to the note:
1) Actuate the "Add attachments" button.
The pop-up window "Add attachment file" (see fig. 8.207, page 8-692)
appears.
2) Select the drive via the selection menu (1, fig. 8.207) in the pop-up window
3) Select file to be attached (2).
4) Actuate the "Add" (3) button to complete the procedure.
2
MX_MC6_V1.9_07.09.15_ENG
1
©KM
Fig. 8.208 Added attachments

1 List of added attachments 2 "Delete" button
Attachments (1, fig. 8.208) that have already been added are displayed below the
edit box (7, fig. 8.194) for the note text. Attachments can be removed again by
actuating the "Delete" (2, fig. 8.208) button.

Linking attachments
Fig. 8.209 Entering link title

1 "Link title" input box 2 Added attachments
Attachments can also be added as a link in the note text:

1) Place the cursor at the corresponding point in the note text box (6, fig. 8.194).
2) Actuate the "Add link" button.
The pop-up window "Enter link title" (see fig. 8.209, page 8-693) appears.
3) In the "Link title" pop-up window, select a file (2, fig. 8.209) from the added
attachments.
4) Enter the link title in the input box (1, fig. 8.209). When the link title has been
entered, the link is displayed in a blue font and underlined in the note.
I
Note
MX_MC6_V1.9_07.09.15_ENG
If, when editing a note, the memory capacity of the respective storage location
(local archive or mold data record) is exceeded, e.g. when adding an
©KM
attachment, an information window is displayed and the action is aborted.

8.18.2.4 Text marking aids

The text marking aids can be used to select text passages. If the cursor is
positioned in the Text Editor and a "Text marking aid" button is selected, the arrow
buttons on the screen keyboard can be used to select the letters on the right and
left.
8.18.3 Search
1
5
2 6
Fig. 8.210 Search

1 "Search" selection 4 "Navigation" menu
MX_MC6_V1.9_07.09.15_ENG
2 Tickbox "Search in all texts" 5 "Search" button

3 Hit list 6 Input box for search term
©KM
The notebook provides a search function that can be selected using the multi-
select feature "Search" (1, fig. 8.210):
1) Enter search term in input box (6).
2) Where applicable, select tickbox "Search in all texts" (2).
3) Actuate the "Search" (5) button or "Enter" button on the keyboard.
A list of hits (3) is displayed.

If the tickbox "Search in all texts" (2, fig. 8.210) is not selected, the search will only
be carried out in the selected note. Otherwise, the search covers all available
categories and notes. The search is not case-sensitive. The search term can be
found both in note titles as well as note texts. Category titles are not covered by
the search function.
The search term is emphasised in italics in the hit list (3). The search term is
highlighted in the note text.
The respective note can be selected and displayed in the hit list. Buttons are
available for selecting the previous/next search hits.
8.18.4 Other functions
8.18.4.1 Opening attachments
Fig. 8.211 Added attachments

1 Attachment name
Attachments (7, fig. 8.194) can be opened by clicking once on the attachment
name (1, fig. 8.211). The content of the selected document is visualized in a
separate window.
8.18.4.2 Selection of note when opening the notebook

Every time the notebook is closed, the display of the last selected note and
category is saved. In addition, the current search term is also noted. When the
notebook is opened again, the stored information is called up again.
The following applies to opening the notebook:

• When the notebook is opened, the note that is linked to the current screen
page (see section 8.18.1.2, page 8-688) is opened. If several notes are linked
MX_MC6_V1.9_07.09.15_ENG
to a screen page, the first linked note in the category tree (2, fig. 8.195) is
selected.
©KM
• If no note is linked to the current screen page, the note that was open, and the
last saved note when the notebook was closed, will be called up.
• If neither of these first two conditions apply, the first note in the category tree
will be called up.
• The box for the note text (6, fig. 8.194) is empty if no note is available.

MX_MC6_V1.9_07.09.15_ENG
©KM

9 Rectifying Faults
If faults exist on the machine, please follow the instructions shown on the screens
of the control system or contact KraussMaffei Service (see section 0.10,
page 0-36).
MX_MC6_V1.9_07.09.15_ENG
©KM
Rectifying Faults 9-697

MX_MC6_V1.9_07.09.15_ENG
©KM
9-698 Rectifying Faults

10 Maintenance
This chapter contains the maintenance instructions for the machine.
10.1 Maintenance agreement . . . . . . . . . . . . . . . . . . . . . . 700
10.2 Safety precautions for maintenance and repair . . . 700

the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
10.4 General maintenance instructions . . . . . . . . . . . . . 703
10.5 Maintenance scheme . . . . . . . . . . . . . . . . . . . . . . . . 704
10.6 Maintenance record . . . . . . . . . . . . . . . . . . . . . . . . . 707
10.7 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
10.8 Lubrication/oil change . . . . . . . . . . . . . . . . . . . . . . . 708
10.9 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
10.10 Cooling water system . . . . . . . . . . . . . . . . . . . . . . . . 743
10.11 Compressed air system . . . . . . . . . . . . . . . . . . . . . . 746
10.12 Plasticizing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748
10.13 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778
10.14 Changing the backup battery . . . . . . . . . . . . . . . . . . 779
10.15 Replacing protective film on touchscreen . . . . . . . 783
10.16 Changing pressure accumulator . . . . . . . . . . . . . . . 784

MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-699
10.1 Maintenance agreement

As part of our preventive maintenance, we offer the possibility of concluding a
Maintenance Agreement with us through KraussMaffei Customer Service.
This can significantly increase the operating safety and service-life of the injection
molding machine. In addition, it is also possible to considerably reduce the costs
for comprehensive maintenance work.
The inspections are carried out at regular intervals by our qualified personnel, or
personnel we have authorized to carry out such work, within the contractually
agreed scope.
For more information, please contact KraussMaffei Customer Service. They will
pleased to send you an offer if you so wish.
10.2 Safety precautions for maintenance and repair

It is essential that you inform yourself of the specifications regarding safety before
commencing any maintenance and repair operations (see chapter 1 Safety).
w
d
D
w
d
D
Risk from machine starting unexpectedly
When carrying out work on the machine, movements may be started at
assemblies as a result of persons stepping onto the machine.
Switch the machine off at the master switch before commencing any servicing
or maintenance operations and secure the master switch with a padlock to
prevent it from being switched on again unintentionally.
The key for this padlock must be kept by the person who performs the work or
who is exercising an appropriate supervisory function. MX_MC6_V1.9_07.09.15_ENG
H
d
D
©KM
There is a major risk of injuries and the possibility of damage to the machine
when working with plasticized injected melt, injection molding parts and all the
heated components of the injection molding machine.
Ensure appropriate protection by wearing safety gloves or using other suitable
aids (supports, bases etc.).
10-700 Maintenance
f
d
D
Fire hazard
• 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.
responsible manner.
• The temperature on the surface of the heating bands of the screw barrel is
significantly higher than the actual-temperature displayed on the
h
d
D
When performing maintenance or repair work, note that subsections of the
hydraulic system can still be pressurized when the machine is electrically
switched off.
test connections in accordance with the hydraulic diagram.
a
B
Observe shop safety instructions and legal accident prevention regulations for
working with the following equipment/operating materials:
• Injection molding machines
• Lifting tackle
• Pressure accumulators
• Cleaning products
• Greases and lubricants
MX_MC6_V1.9_07.09.15_ENG
Protective clothing
©KM
y
B
Protective gloves
The injection molding process produces workpieces with high temperatures
and which may also have sharp edges.
Never grasp workpieces, molds or remaining material with your bare hand.
Do not wear safety gloves if there is a risk of the gloves being caught, e.g. by
rotating parts of electric drills.
Maintenance 10-701
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 and at the centralized lubrication, safety
goggles must be worn at all times.
Hydraulic oil or grease which splashes out may result in severe eye injury or
even in the loss of eyesight.
k
B
Protection of face
of eyesight.
E
B
Hearing protection
A constantly high noise level results in damage to your hearing.
Wear ear protection when in the area of the operating machine.
Do not remove any noise protection devices at the machine.
N
B
Protective helmet
A protective helmet must always be worn when
• 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.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-702 Maintenance

10.4 General maintenance instructions

The maintenance operations described in this chapter on the injection molding
machine describe the following activities:
• Cleaning
• Replenishing operating materials,
• procedure for maintaining operation (e.g. purging mold),
• replacing and setting components.
• Troubleshooting and fault elimination
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-703
10.5 Maintenance scheme
W
Important
Repair or maintenance work is essential as the result of wear-and-tear resul-
ting from normal operation. KraussMaffei declines any warranty for proper ope-
ration of the machine if such repair or maintenance work is not carried out in
accordance with our specifications.
I
Note
• Depending on machine load (operating hours and cycle time), mainte-
nance intervals are calculated automatically and displayed on the "Ins-
pection intervals" screen (see fig. 8.175, page 8-655) as an indication that
maintenance and inspection work is due (information or alarm).
• In addition to these inspections, the other maintenance tasks listed in the
maintenance plan must be carried out on a regular basis.
Assembly see
every 3000 h or 0.5 years
every 8000 h or 2 years Chapter/Page

every 500 h or monthly
every 6000 h or 1 year

when mold changed
as alarm message
as required
weekly /
Safety devices x x
Inspection of emergency-stop buttons x x 1.5.1 / 93
Inspection of safety gates, mold area x x 1.5.2 / 94
Inspection of the locking bolt monitoring x x 1.5.3 / 96
Inspecting the safety strip x x 1.5.4 / 96
Inspecting the service gate (core-pulling and clamping block) x x 1.5.5 / 97
Inspection of the safety gate, nozzle area x x 1.5.6 / 98
Inspecting the safety gate, ejector area x x 1.5.7 / 99
MX_MC6_V1.9_07.09.15_ENG
Checking the step-on safety grid x x 1.5.8 / 100

Inspecting the clamp safety circuit x x 1.5.9 / 101
©KM
Inspection of fixed protective panelling x x 1.5.11 / 103

Inspecting the robot safety gates (ZE) x x 1.5.12 / 103
Machine - general
Aligning the machine x 5.7 / 200
Central lubrication system x x x x 10.8.1 / 709
10-704 Maintenance
Assembly see
every 8000 h or 2 years

Chapter/Page

when mold changed
as alarm message
as required
weekly /
Hydraulic system
Visual inspection of hose lines, connections x x 10.9.1 / 723
Inspect pump running x x 7.9 / 304
Inspect oil level of hydraulic oil tank x x 10.8 / 708
Change hydraulic oil x x 10.9.2 / 724
Clean hydraulic oil tank x x 10.9.2 / 724
Clean oil cooler x x 10.9.4 / 730
Cleaning intake filter x x x 10.9.5 / 733
High pressure filter: Change filter element x x x 10.9.6 / 735
Return-flow filter: Replace filter element x x x 10.9.7 / 737
Bypass flow filter, internal: Replace filter element x x x 10.9.8 / 739
Air admission and release filter: Clean/replace filter element x x 10.9.9 / 741
Pressure accumulator
Drain the nitrogen x 10.16.1 / 784
Changing pressure accumulator x 10.16 / 784
Fill the pressure accumulator with nitrogen x 5.11 / 221
Check pressure accumulator x x x x 10.16.5 / 787
Cooling water system

Inspect the function of the barrel flange cooling x 10.10.1.1 / 744
Clean water filter x x 10.10.3 / 745
Compressed air system

Clean servicing unit x 10.11 / 746
Maintenance unit: drain condensate x 10.11.1 / 746
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-705
Assembly see
every 8000 h or 2 years

Chapter/Page

when mold changed
as alarm message
as required
weekly /
Plasticizing unit
Setting zero points (operational check) x x x 7.17 / 351
Check nozzle centre setting x x 7.14 / 343
Inspecting the firm fitting of screw coupling x x 10.12.4 / 761
Change oil of spur flat gear unit/CMG gearbox x 10.8.4.3 / 721
Clean CMG gearbox, check oil level and tight sealing x 10.8.4.2 / 719
CMG gearbox, clean bleed screw x 10.8.4.3 / 721
Clean return-flow lock x 10.12.7 / 768
Clean central ball - return-flow lock x 10.12.9 / 772
Replace heating bands x 10.12.11 / 776
Nozzle and injection area, cleaning x 10.12.3.1 / 753
Clean screw barrel x 10.12.3.4 / 760
Pintle catch
• check and adjust x 10.12.10.1 / 774
• Lubricate joint of actuation cylinder x 10.8.3 / 717
Lubricate injection plunger guides x x 10.8.2.1 / 712
Lubricate screw barrel support x x 10.8.2.2 / 713
Lubricating the piston rod bearings x x 10.8.2.3 / 714
Lubricate the profile rail guides x x 10.8.2.4 / 715
Electrical system
Control cabinet: clean/replace filter mats in the fan x 10.13.1 / 778
Changing battery x x 10.14 / 779
Control cabinet: visual inspection of control cabinet connections x
Visual inspection of connections x
Visual inspection of plug connections x
Visual inspection of limit switches x
MX_MC6_V1.9_07.09.15_ENG
Auxiliary devices
©KM
Medium monitor function check x 12.9.1 / 888

Clean flow controller, replace seal rings, visually inspect connections x x 12.8.2 / 887
Bypass flow filter: Replace filter element x x x 12.5 / 878,
12.6 / 880
Check/service magnetic clamping system x 12.14.8 / 988
Check bar-pulling device x 12.12.7 / 962
10-706 Maintenance
10.6 Maintenance record

• Keep a maintenance record for entering maintenance or cleaning work.
Who carried out what tasks and when?
• Inspections carried out on screen „Inspection Intervalls“ acknowledge.
(see fig. 8.16.1.2, page 8-655)
10.7 Maintenance work

Conscientious maintenance and care of the injection molding machine, critical
evaluation of noise emissions and a daily visual inspection of the entire machine,
are essential criteria for long and trouble-free life of the injection molding
machine.
• Check bolts and nuts for firm seating and tighten if necessary.
• After initial operating hours under production conditions, carry out a visual
inspection of the pipe and hose connections and retighten if necessary.
• Abnormal running noises of the pumps, hydraulic shocks, jerky movements,
which, among other things, may be an indication of air trapped in the hydraulic
system, should be inspected without delay to determine the cause of the fault
and rectified, if possible (contact KraussMaffei service, if necessary
(see section 0.10, page 0-36)).
• Before lengthy breaks in production (e.g. weekends), perform basic cleaning
of the machine and rectify any noticeable deficiencies.
• Use only clean cloths to clean the sliding surfaces and guides. Do not use
cleaning wool or solvents.
• Only hydraulic oils and lubricants which have the required characteristic
values (see section 3.4, page 3-152) must be used.
• Keep the cooling ribs of the heating cabinet clean, do not place objects down
on it. It is important to ensure an unobstructed heat exchange.
• Check smooth opening and closing of the MP, correct alignment if necessary.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-707
10.8 Lubrication/oil change
G
B
Eye protectors
When working with hydraulic oil and at the centralized lubrication, safety
goggles must be worn at all times.
Hydraulic oil or grease which splashes out may result in severe eye injury or
even in the loss of eyesight.
i
t
Environmental note
MX_MC6_V1.9_07.09.15_ENG
©KM
10-708 Maintenance
10.8.1 Central lubrication system

The central lubrication system supplies the sliding shoes below the movable mold
clamping platen with grease.
It consists of a central lubrication pump, a progressive distributor with proximity
switch and connection lines.
11
10
1
2
3
9
8
5 4
6
Fig. 10.1 Central lubricating pump

1 Metal screen 7 DC motor
2 Eccentric 8 Lubricating nipples
3 Check valve 9 Pump
4 Pressure relief valve 10 Agitator blade
5 Delivery plunger 11 Transparent reservoir
6 Thrust ring
The central lubrication system operates with a system pressure of 280 bar and is
able to transport commercially available greases and oils.
MX_MC6_V1.9_07.09.15_ENG
The lubricant is distributed to the individual lubrication points by a progressive

©KM
distributor. The pressure relief valve (4, fig. 10.1) protects the pump.
Maintenance 10-709
Lubricant
The Tribol 3020/1000-2 lubricating grease from CASTROL is used for
commissioning the machine (see section 3.4.3.2, page 3-159).
W
Important
If other types of lubricating/low-viscosity greases or mixtures are used, refer to
the analysis data of the manufacturer.
Filling and inspecting the central lubrication system

1) Inspect the level of the lubricant in the storage container (11, fig. 10.1) and, if
necessary, replenish it via the lubrication nipple (8).
2) Check the lubricant lines and progressive distributors for leaks.
3) Switch to screen "Mold opening settings" (see section 8.7.2.2, page 8-429).
4) Initiate the lubrication process.
5) Check that this is working at all lubrication points.
Setting delivery
Fig. 10.2 Pump, central lubrication system

1 Screw plug with seal ring 2 Adjusting bolt
MX_MC6_V1.9_07.09.15_ENG
W
©KM
Important
The delivery of the central lubrication system pump is pre-set to maximum
delivery.
10-710 Maintenance
1) Unscrew the screw plug with seal ring (1, fig. 10.2).
2) Turn the adjusting bolt (2) with a screwdriver as follows:
• clockwise to reduce the delivery rate
• counterclockwise to increase the delivery rate
3) Screw in the screw plug with seal ring.
10.8.2 Injection unit lubrication
1 2 3 4 5 4 6
Fig. 10.3 Injection unit lubrication

1 Piston rod bearings (see section 10.8.2.3, page 10-714) 4 Profile rail guides (see section 10.8.2.4, page 10-715)
2 Screw barrel support (see section 10.8.2.2, page 10-713) 5 Injection plunger guides (see section 10.8.2.1, page 10-712)
3 Pintle shut-off and actuation cylinder joint (see section 10.8.3, 6 Electric screw drive (see section 10.8.4, page 10-718)
page 10-717)
Pos. Machine part Lubricant Interval

1 Piston rod bearings CASTROL TRIBOL® 4020⁄220-2 every 500 h or monthly and
(see section 3.4.3.1, page 3-158) as required
2 Screw barrel support CASTROL TRIBOL® 4020⁄220-2 every 500 h or monthly and
as required
3 Actuation cylinder for pintle catch CASTROL TRIBOL® 4020⁄220-2 every 500 h or monthly and
as required
4 Injection unit profiled rail guides CASTROL TRIBOL® 4020⁄220-2 every 500 h or monthly and
as required
5 Injection plunger guide CASTROL TRIBOL® 4020⁄220-2 every 500 h or monthly and
MX_MC6_V1.9_07.09.15_ENG
as required
©KM
6 Electric screw drive Gear oil CLP 220 (see section 3.4.3.3, Every 8000 h or 2 years, as
page 3-160) needed
Maintenance 10-711
10.8.2.1 Lubricating injection plunger guides from SP 6100
Lubricant
CASTROL TRIBOL® 4020/220-2
Lubricant specification (see section 3.4.3.1, page 3-158).
W
Important
If another grease is used, contact the supplier to determine whether it is
suitable for mixing with other greases.
Lubricating
Fig. 10.4 Injection plunger guides

1 Lubricating nipple (2x) 2 Injection plunger guide rods
1) Remove covers on the screw coupling if necessary.

2) Clean injection plunger guides and injection plunger guide rods (2, fig. 10.4).
3) Lubricate the injection plunger guides at the lubricating nipple (1) with the
MX_MC6_V1.9_07.09.15_ENG
hand grease gun until unused grease flows out at the front end of the injection
plunger guide.
©KM
10-712 Maintenance
10.8.2.2 Support for screw barrel, lubricating
Lubricant
Lubricant specification (see section 3.4.3.1, page 3-158).
W
Important
Lubricating
1 2 3
Fig. 10.5 Screw barrel support

1 Screw barrel 3 Rear guide roller (2x)
2 Front guide roll (2x)
Lubricate the bearings of the guide rollers (2 and 3, Fig. 10.5) of the screw barrel
support on the operator side and operator rearside via grease nipples.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-713
10.8.2.3 Lubricating the piston rod bearings from SP 2000
Mold
Hand grease gun
Consumable material
Lubricant specification (see section 3.4.3.1, page 3-158)
W
Important
Lubricating
Fig. 10.6 Piston rod bearings

1 Plunger rod bearing pin 2 Lubricating nipples
1) Clean the area around lubrication nipple (2, fig. 10.6).

2) Lubricate the plunger rod bearings via lubrication nipple (2) using the hand
MX_MC6_V1.9_07.09.15_ENG
grease gun until unused grease flows out at the injection plunger bearing
pin (1).
©KM
10-714 Maintenance
10.8.2.4 Lubricate the profile rail guides
Lubricant
W
Important
• If another grease is used, contact the supplier to determine whether it is
• If the lubricant has taken on a red-brown colour due to excessively long
lubrication intervals or an insufficient lubricant quantity, relubricate
immediately.
Lubricating
1 2
3 4
Fig. 10.7 Lubrication of profiled rail guide

1 Profiled rails 3 Scraper
2 Profiled rail guide (guide carriage) 4 Lubricating nipples
MX_MC6_V1.9_07.09.15_ENG
©KM
1) Clean the following components with a non-linting cloth:

• Profiled rails (1, fig. 10.7)
• Profiled rail guides (2)
• Lubricating nipples (4)
2) Fill a clean hand grease gun with universal grease.
3) Use the grease gun to force the grease into the lubricating nipples until it flows
out at the face side of the particular profiled rail guide.
Maintenance 10-715
W
Important
• Stop filling immediately after grease emerges for the first time at the
scraper (3, fig. 10.7) of the profiled rail guide. Excess grease causes
damage to the lateral covers.
• The profiled rails (1) themselves must not be lubricated to prevent dust
from sticking to them.
4) Move each profiled rail guide by the carriage length and apply grease again
until it emerges at the scraper.
5) Repeat work step 4 a total of four times to ensure the profiled rail guide is
completely full of grease.
6) Check grease film for continuity.
7) Check the effectiveness of the scraper (3) on the profiled rail guides.
W
Important
After the machine has been out of operation for a lengthy period (more than
one week), carry out lubrication once again.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-716 Maintenance
10.8.3 Actuation cylinder joint for the nozzle pintle shut-off

Lubricant
Lubricating grease CASTROL TRIBOL® 4020⁄220-2
W
Important
Fig. 10.8 Pintle shut-off, nozzle

1 Pivot pin locking lever 3 Lubricating nipples
2 Actuation cylinder joint
1) Lubricate the joint of the actuation cylinder (2, fig. 10.8) at the lubricating
nipple (3) with the hand grease gun until unused grease flows out on both
MX_MC6_V1.9_07.09.15_ENG
sides of the joint.

©KM
Maintenance 10-717
10.8.4 Electric screw drive (ZE)
10.8.4.1 Spur flat gear unit

The electric screw drive consists essentially of the flat-type spur gear unit and the
drive motor.
Fig. 10.9 Spur flat gear unit

1 Bleed/filing screw 3 Oil drain plug
2 Inspection glass
Inspecting oil level

Inspect the oil level with the drive motor switched off. The oil level must extend up
to the top edge of the inspection glass (2, fig. 10.9). Top up oil at bleed screw (1)
if necessary.
Change oil (see section 10.8.4.3, page 10-721).
Oil fill capacity

MX_MC6_V1.9_07.09.15_ENG
Oil specification (see section 3.4.3.2, page 3-159).

The quantity of oil and size of the flat-type spur gear unit depends on the injection
©KM
unit installed.
Injection unit Flat-type spur gear unit type Oil fill capacity approx. [l]
SP 4300 FZ501.3 23
SP 6100-SP 8100 FZ1201.3 50
SP 12000 FZ1601.3 56
SP 17200-SP 24500 FZ2401.3 125
10-718 Maintenance
10.8.4.2 CMG gear unit
Oil fill capacity

Oil specification (see section 3.4.3.2, page 3-159).
Gear type Oil fill capacity approx. [l]

CMG 05.1/CMG 05.2 1.5/2.1
CMG 10.1/CMG 10.2 3.5/2.8
CMG 20.1/CMG 20.2 3/5
CMG 30.1/CMG 30.2 2.2/5 - 7
CMG 60.1/CMG 60.2 14/14
CMG 120.1/CMG 120.2 7/25
CMG 240.1/CMG 240.2 43/37
CMG 400.3 90
W
Important
• The specified oil quantities are only points of reference. The oil quantity to
be added is decided by the oil level in the inspection glass.
• The oil quantity is specified on the type plate of the gear unit.
• Special models may differ from the table.
Checking CMG gear unit for leaks

1) Check the gear unit housing for leaking gear oil or coolant.
2) Tighten the securing bolts on the housing cover if necessary.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-719
Inspecting oil level
Fig. 10.10 CMG gear unit

1 Oil filler cap 4 Oil drain plug
2 Bleed screw 5 Cooling water connection
3 Oil level indicator glass
1) The oil level must reach the middle of the inspection glass (3, fig. 10.10) when
the machine is warmed up.
2) If necessary, add gear oil until the level reaches the middle of the inspection
glass.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-720 Maintenance
10.8.4.3 Changing oil, electric screw drive
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Hazard
All work may be carried out only while the motor is at a standstill, de-energized,
and protected from being switched on again.
Check to ensure that it is de-energized.
f
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D
Fire hazard
medium.
responsible manner.
D
r
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Risk of slipping
Any spilt oil must be cleaned up immediately in an environmentally compatible
way using oil binding agent.
H
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D
Depending on operating conditions, the CMG compact gear motor can reach
substantial surface temperatures of up to 90 °C.
Wear protective gloves.
B
G
Safety goggles
loss of eyesight.
MX_MC6_V1.9_07.09.15_ENG
©KM
W
Important
• When changing oil, always fill the gear unit with the same kind of oil as that
used previously.
• Synthetic oils must not be mixed with mineral oils or different synthetic oils.
• When switching from mineral oil to synthetic oil, the gear unit must be
thoroughly flushed with the new kind of oil.
Maintenance 10-721
I
Information on CMG gear unit
Replace the screw plug indicated in red with the bleed screw provided.
Prerequisites
• Gear unit warmed up
Procedure
1) Place a suitable collecting vessel below the gear unit.
2) Flush the housing with oil to remove sludge, fines and oil residue.
3) Remove bleed screw (1, fig. 10.9)/(2, fig. 10.10) and oil drain screw
(3, fig. 10.9)/(4, fig. 10.10).
4) Allow the gear oil to drain completely.
5) If necessary, flush out deposits on the gear unit bottom with new gear oil.
6) Clean the magnetic insert of the oil drain plug and clean the oil drain plug.
7) Screw in the oil drain screw with new seal ring.
8) Unscrew the oil filler cap (1, fig. 10.10) and add gear oil until the level reaches
the middle of the inspection glass.
9) Screw in the bleed screw and oil filler cap.
i
t
Environmental note
Only certain grades of oil may be intermixed for disposal.
Enquire at manufacturer/supplier regarding the requirements for disposing of
the oil used. Observe the relevant nation regulations for dealing with
oils/lubricants.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-722 Maintenance
10.9 Hydraulic system

Securing bolts on hydraulic components, tightening torques (see section 3.6.1,
page 3-161)
W
Important
Do not use any washers or lock washers; otherwise, the tightening torque will
be falsified.
10.9.1 Route
W
Important
The recommended period for the service life of hydraulic hose lines in
conformity with DIN 20066 is a maximum of 6 years.
The hose lines of the hydraulic system should be inspected visually every 500
operating hours for the following criteria:
• Damage to outer layer through to steel liner (e.g. chafing points, cuts, splits).
• Embrittlement of outer layer (e.g. cracking).
• Deformations in pressureless state, and in pressurized state or in the event of
bends (e.g. blistering, kinks).
• Leaks.
• Damage, deformation or corrosion to the hose fitting (sealing function
impaired).
• Hose partially slipped out of hose fitting.
• Check the date of manufacture (1, fig. 10.11):
– Storage life (max. 2 years)
– Service life (max. 6 years incl. max. storage life)
1
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 10.11 Hydraulic hose

1 Date of manufacture
Maintenance 10-723
10.9.2 Changing hydraulic oil/cleaning hydraulic oil tank
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Fire hazard
medium.
responsible manner.
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d
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Risk of slipping
If oil leaks out there will be danger of slipping.
has poured out.
B
G
Safety goggles
loss of eyesight.
W
Important
After emptying the hydraulic oil tank, considerable quantities of residual oil still
remain in the hoses, lines, cylinders and hydraulic components.
Mixing oils may cause a change in the specific characteristic data and impair
the filtering properties.
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.
W
Important
MX_MC6_V1.9_07.09.15_ENG
The hydraulic oil should be changed and the hydraulic oil tank cleaned every
©KM
8000 operating hours.

Longer intervals may be possible after regular examinations of the oil.
10-724 Maintenance
i
t
Environmental note
Collect hydraulic oil that is pumped out in suitable containers.
10.9.2.1 Tank return-flow shut-off valve

The tank return-flow shut-off valve is closed only when replacing components of
The closed shut-off valve is displayed by the alarm A00071 "Ball-type shut-off
valve".
W
Important
On the injection units SP 4300, SP 6100, SP 8100, the tank return-flow shut-
off valve is used as a non-return valve.
MX_MC6_V1.9_07.09.15_ENG
Fig. 10.12 Tank return-flow shut-off valve

©KM
Maintenance 10-725
10.9.2.2 Cleaning hydraulic oil tank, changing hydraulic oil
Fig. 10.13 Hydraulic oil tank

1 Tank cap seal 3 Cap nut
2 Tank cap
1) Ensure that the tank return-flow shut-off valve is open.

2) Remove the cover of the hydraulic oil filler neck and of the air admission and
release filter.
3) Empty the main tank using a barrel pump.
4) Remove the tank cap (2, fig. 10.13).
5) Check the tank cap seal (1) for damage and replace seal if damaged.
w
D
Caution
If cleaning products are used, pay attention to the manufacturer's instructions.
MX_MC6_V1.9_07.09.15_ENG
Failure to observe these instructions may result in slight injuries or cause

material damage.
©KM
6) Clean the hydraulic oil tank with a cleaning product and blow it dry with
compressed air.
7) Fit the tank cap with tank cap seal.
10-726 Maintenance
W
Important
The tank cover seal (1, fig. 10.13) must not be excessively compressed.
Tightening the cap irregularly or excessively can result in leaks.
8) Insert the new filter element for the air admission and release filter.
9) Install tank cap (2) with new tank cap seal (1).
10) Tighten cap nuts (3) uniformly in diagonally opposite sequence.
11) Add hydraulic fluid until the level reaches the top mark of the oil level
inspection glass (see section 5.10, page 5-217).
12) Fasten the cover to the hydraulic oil filler neck.
10.9.2.3 Inspect oil level of hydraulic oil tank

The hydraulic system does not have any operational-related consumption of
hydraulic oil. Any leakages which occur may result in a loss of oil.
Before replenishing the missing hydraulic oil, determine the cause of the leakage
and rectify the fault.
Fig. 10.14 Oil level inspection glass

1 Top marking
MX_MC6_V1.9_07.09.15_ENG
©KM
The oil level must reach the top marking (1, fig. 10.14) on the oil-level inspection
glass.
10.9.2.4 Replenishing oil in the hydraulic oil tank

Pouring in hydraulic oil (see section 5.10, page 5-217).
Maintenance 10-727
10.9.3 Pump motor oil change
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Caution
There is a risk of an accident as a result of rotating parts at the pump motor.
Perform the lubrication work according to the accident prevention regulations.
In the hydraulic-oil-cooled pump motor, the hydraulic pumps are connected

directly to the pump motor via tooth bosses. This connection is an integral
component of the hydraulic-oil cooling circuit.
2 3 4
1 2
5 5
Fig. 10.15 Pump motor

MX_MC6_V1.9_07.09.15_ENG
1 Drain plug (2x) 4 Cooling connection (2x)

2 Bleed screw (2x) 5 Leak oil connection (2x)
©KM
3 Pump motor
1) Open the pump chamber.

2) Have a suitable collecting vessel ready in the pump chamber.
3) Unscrew the bleed screws (2, fig. 10.15) and drain plugs (1) on the pump
motor (3) to drain the hydraulic oil.
4) Screw in the drain plugs.
5) Add filtered hydraulic fluid via the cooling connection (4) until hydraulic fluid
escapes from the bleed screws (2).
10-728 Maintenance
6) Connect the cooling connection and screw in the bleed screws.

7) Remove the collecting vessel from the pump chamber.
8) Close the pump chamber.
W
Important
• When commissioning, ensure that the hydraulic oil cooling circuit for the
pump motor is connected and active. Operation without activated cooling
circuit destroys the glide ring seals.
• The operating safety of the machines is dependent on compliance with the
oil service life and the approved oil quantity in relation to the inlet
temperature.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-729
10.9.4 Oil cooler
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If necessary, allow the device to cool down before removing or cleaning the oil
cooler.
10.9.4.1 Cleaning water-bearing parts

The part of the oil cooler which conveys water can be cleaned when installed.
1) Separate the "cooling water feed and return-flow" (3, fig. 10.16) connections
at the oil cooler for this purpose.
2) Connect a circulation pump with a suitable scale removing product.
3) Flush the water-bearing part of the oil cooler using descaling agent.
10.9.4.2 Cleaning oil-bearing parts
Prerequisites
• Hydraulic system is depressurized
• Cooling water supply shut off
• Main tank emptied
• Suitable collecting vessel provided for hydraulic oil
• Suitable supports/rests are provided
• Suitable collecting vessel provided for cooling water
MX_MC6_V1.9_07.09.15_ENG
©KM
10-730 Maintenance
Removal
Fig. 10.16 Removing the oil cooler

1 Oil cooler 3 Cooling water feed and return-flow, oil cooler
2 Securing bolt (4x) 4 Hydraulic oil feed and return-flow, oil cooler
W
Important
The oil drain plug is positioned at the rear flange of the oil cooler.
I
Note
The weight of the oil cooler is 21.80 kg for KM 850 MX⁄KM 1000 MX.
Provide suitable aids (supports, bases etc.).
MX_MC6_V1.9_07.09.15_ENG
©KM
1) Unscrew the oil drain screw.

2) Disconnect the hydraulic oil feed and return flow of the oil cooler
(4, fig. 10.16), place it upwards and secure it. Mount the dummy plug.
3) Disconnect the cooling water feed and return flow of the oil cooler (3) so that
the oil cooler is emptied.
4) Unscrew the four securing bolts (2) and remove the oil cooler (1).
5) Replace porous or damaged O-rings with new ones.
Maintenance 10-731
Oil-side cleaning of the oil cooler

1) Soak oil cooler (1, fig. 10.16) for approx. 2 hours in Orfacarb HK or
perchloroethylene.
2) Then rinse the oil cooler thoroughly several times with fresh water.
Perform a final rinse with warm water.
3) Blow the oil cooler dry using compressed air and flush it using operating oil.
Cleaning the oil cooler on the water side

1) Rinse the oil cooler (1, fig. 10.16) on the water side with a 10% solution of
Parozink.
2) Allow the solution to act for approx. 30 minutes at room temperature.
3) Then rinse the oil cooler thoroughly several times with fresh water.
4) Perform a final rinse with warm water.
5) Purge the oil cooler with compressed air.
Installation
1) Remove all dummy plugs.
2) Screw in and tighten the attaching screws (2, fig. 10.16).
3) Connect the hydraulic fluid and cooling water connections (4 and 3).
4) Fill main tank (see section 5.10, page 5-217).
5) Switch cooling water supply on.
6) Pressurize the hydraulic system.
7) Check the flange of the oil cooler and connections for hydraulic oil and cooling
water for leaks. Eliminate any leaks by tightening the securing bolts or the
connections.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-732 Maintenance
10.9.5 Cleaning intake filter
W
Important
Servicing intake filter: every 6000 operating hours, at least once a year
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Risk of slipping
Any spilt hydraulic oil must be removed immediately, in an environmentally
compatible way, with an appropriate binding agent.
1 2 3 4 5 6 7 8 9
14 13 12 11 10
Fig. 10.17 Intake filter

1 Foot valve 8 Filter cover
2 Valve cone 9 Adjusting bolt
3 Thermocouple connection 10 Oil drain plug
4 Magnet system 11 Hydraulic oil connection
5 Filter strainer 12 Hydraulic oil connection
6 Vacuum switch connection 13 Connection for cooling pump unit
7 Bleed screw connection 14 Seal (customer-provided)
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-733
Removal of filter strainer

1) Ensure that the pump motor is switched off and the hydraulic system is
pressureless.
2) Have a suitable collecting vessel ready.
3) Unscrew the adjusting bolt (9, fig. 10.17) until the stop.
W
Important
Avoid any impurities in the intake area from particles which flow out of the filter
element.
4) Unscrew the oil drain screw (10).

5) Unscrew the bleed screw (7).
6) Allow the oil to drain completely.
7) Unscrew filter cover (8).
8) Pull the filter cover with magnet system (4) and filter strainer (5) horizontally
out of the housing.
9) Separate filter strainer by knocking slightly on the filter cover.
10) Clean adjusting bolt (9), filter cover (8) and filter strainer with petroleum ether.
While doing so, remove the metal fines from the sleeve of the bar magnet.
Blow-dry parts using compressed air.
11) Replace seals.
12) Examine sealing surfaces for damage and replace any damaged parts if
necessary.
Installation
1) Screw in the oil drain screw (10, fig. 10.17) and bleed screw (7).
2) Ensure that the adjusting bolt (9) has been unscrewed as far as the stop.
3) Attach the filter strainer (5) to the middle of the taper of the filter cover (8).
4) Insert filter strainer and magnet system into housing.
5) Screw in filter cover.
6) Unscrew the bleed screw (7) sufficiently until oil can flow out.
7) As soon as the oil flows out, tighten bleed screw fully again.
8) Unscrew the adjusting bolt (9) until the stop.
W
Important
MX_MC6_V1.9_07.09.15_ENG
When the adjusting bolt (9) is screwed in, the inlet of the intake filter is opened.
©KM
9) Switch on the pump motor and pressurize the hydraulic system with pressure.
10) Inspect the intake filter for leaks.
10-734 Maintenance
10.9.6 Fine filter
10.9.6.1 Replacing the filter element
1 2
Fig. 10.18 High-pressure filter set

1 Filter head 4 Filter bell
2 Seal ring 5 Seal ring
3 Filter cartridge 6 Supporting ring
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Important
Alarm A00044 "Fine filter xxx" indicates that the filter element must be changed
within the next 150 operating hours. After this, only restricted operation is
possible.
The filter element must be changed after 6000 operating hours even if alarm
A00044 "Fine filter xxx" has not been displayed.
Installation location
Pressure side of the uniform hydraulic pump.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-735
Removal
pressureless.
3) Unscrew filter bell (4, fig. 10.18) at hexagon and drain filter bell into collecting
vessel.
4) Take filter cartridge (3) and seal ring (2) off filter head (1) and replace.
5) Inspect supporting ring (6) and seal ring (5) of filter bell for damage, replace
if necessary.
W
Important
Filter cartridge (3, fig. 10.18) and seal ring (2) must not be reused as they no
longer assure adequate filtering efficiency. Dispose of filter element in
environmentally correct way.
6) Flush the filter bell with dry cleaning solvent and blow it dry using compressed
air.
Installation
1) Moisten new filter cartridge (3, fig. 10.18) as well as seal rings (2 and 5) with
hydraulic oil.
2) First install the seal ring (5), then the supporting ring (6) into the filter head (1).
3) Push the filter cartridge, together with the seal ring (2) onto the mounting stud
in the filter head.
4) Screw on filter bell (2) and tighten to a tightening torque of max. 20 Nm.
5) Switch on the pump motor and pressurize the hydraulic system with
circulation pressure.
6) Examine filter for leakage between filter head and filter bell, proceed as
follows if leak exists:
a) Remove filter cartridge.
b) Replace seal ring (5) together with supporting ring (6).
c) Examine sealing surfaces for damage and replace any damaged parts.
d) Reinstall filter cartridge. MX_MC6_V1.9_07.09.15_ENG
©KM
10-736 Maintenance
10.9.7 Return-flow filter
10.9.7.1 Replace filter element
3 4 5 6 7
8
1 2 9
10
11
Fig. 10.19 Return-flow filter

1 Filter element 7 Hexagon nut (4x)
2 Filter tube 8 O-ring
3 Locking plate 9 O-ring
4 Filter head part 10 Handle
5 Filter cover 11 Filter unit
6 Spring-lock washer (4x)
In the case of oil-cooled pump motor, a return-flow filter is installed vertically in the
hydraulic oil reservoir.
W
Important
Replace the filter element following alarm A00044 "Fine filter xxx" and
according to the manufacturer's specifications, but at least once a year.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-737
Removal
pressureless.
2) Clean the machine in the adjoining area of the high-pressure filter.
4) Unscrew hexagon nuts (7, fig. 10.19), remove spring-lock washers (6) and
take off filter cover (5).
5) Pull the filter unit (11), using the handle (10), out of the head part of the filter
(4), pay attention to the O-ring (9).
6) Place filter unit down at filter head part onto a suitable collecting vessel and
allow oil to drain out.
7) Cover over filter opening at hydraulic oil tank.
8) Place the filter unit (11, fig. 10.19) down onto a firm base, press the handle
(10) down, turn to the left or right about 60° and remove the handle together
with the bypass valve attached to it. Clean with cleaning product (e.g. diesel
oil) and place down on a clean base.
9) Remove filter element (1) from filter tube (2) and dispose of in environmentally
proper manner.
10) Drain the residual oil from the filter tube (2).
11) Flush filter tube with cleaning product.
12) Replace O-ring (8) and (9).
13) Examine sealing surfaces for damage and replace parts if necessary.
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Environmental note
Dispose of the filter element and hydraulic oil which has poured out in an
environmentally proper manner. Observe the corresponding regulations for
dealing with oils/lubricants.
Installation
W
Important
Use only genuine ARGO filter elements otherwise proper operation of the
entire system in compliance with specifications cannot be assured.
1) Insert a new filter element (1, fig. 10.19) into the filter tube (2).
MX_MC6_V1.9_07.09.15_ENG
2) Fit handle (10) together with bypass valve onto filter element.
3) Push handle down and turn sufficiently until the handle engages in the slots
©KM
of the locking plates (3).

4) Push filter unit (11) into the head part of the filter (4), pay attention to the O-
ring (9) when doing this.
5) Fit filter cover (5) onto the head part of the filter, ensure that the O-ring (8) is
correctly located when doing this.
6) Screw on hexagon nuts (7) together with spring-lock washers (6) and tighten
diagonally and evenly to a torque of 45 ±5 Nm.
7) Switch pump motor on and pressurize hydraulic system.
8) Inspect return-flow filter for leaks.
10-738 Maintenance
10.9.8 Internal bypass flow filter, replacing filter element (ZE 63.65)
Prerequisites
Pump motor switched off
1
2
Fig. 10.20 Bypass filter V05

MX_MC6_V1.9_07.09.15_ENG
1 Hexagon nut (4x) 5 Bypass valve handle

©KM
2 Spring-lock washer (4x) 6 Filter element

3 Filter cover 7 Filter head part
4 O-ring 8 Filter tube
W
Important
Replace the filter element following alarm A00044 "Fine filter xxx" and
Maintenance 10-739
Removal
2) Clean the machine in the adjoining area of the bypass filter.
3) Unscrew hexagon nuts (1, fig. 10.20), remove spring-lock washers (2) and
take off filter cover (3).
4) Press handle (5) downwards, turn approx. 60° to the left and remove handle
with bypass valve.
5) Withdraw the filter element (6) from filter tube (8) and dispose of it in
accordance with the environmental regulations.
6) Replace the O-ring (4, fig. 10.20).
Installation
W
Important
Use only genuine ARGO filter elements otherwise proper operation of the
entire system in compliance with specifications cannot be assured.
7) Insert a new filter element (6, fig. 10.20) into the filter tube (8).
8) Fit handle (5) together with bypass valve onto filter element.
9) Press handle downwards and turn until the handle is engaged.
10) Fit filter cover (3) onto the head part of the filter, ensure that the O-ring (4) is
correctly located when doing this.
11) Screw on hexagon nuts (1) together with new spring-lock washers (2) and
tighten diagonally and evenly to a tightening torque of 45 ± 5 Nm.
13) Check the bypass filter for leaks.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-740 Maintenance
10.9.9 Air admission and release filter, clean/replace filter element

• Clean the air admission and release filter (see fig. 10.21, page 10-741) under
normal operating conditions for the first time after 500 operating hours of the
injection molding machine.
• If the inducted air has a high level of contamination, repeat the cleaning cycle
more frequently.
• Replace the filter each time the oil is changed, but no later than after 2 years
of operation.
4
2
Fig. 10.21 Air admission and release filter

1 Wing nut 3 O-ring
2 Filter housing 4 Filter element
W
MX_MC6_V1.9_07.09.15_ENG
Important
Do not wash out filter with cleaning petroleum, alkaline solutions or similar.
©KM
Maintenance 10-741
Cleaning the filter

1) Clean the surrounding area of the machine and the air admission and release
filter.
2) Remove the air admission and release filter and uncover the tank opening.
3) Clean the filter housing (2, fig. 10.21).
4) Blow off the filter element (4) with dry compressed air (max. 5 bar) obliquely
from the outside in the fold direction.
Then blow through from the inside out.
5) Inspect the filter element for deformation, splits, soiling from oil or grease;
replace filter if necessary.
Replacing the filter cartridge

1) Clean the surrounding area of the machine and the air admission and release
filter.
2) Remove the air admission and release filter and uncover the tank opening.
3) Unscrew the wing nut (1, fig. 10.21) and remove the filter housing (2).
4) Inspect the O-ring (3) and replace if necessary.
5) Clean the filter housing (2) with dry cleaning solvent and blow it dry using
compressed air.
6) Replace the filter element (1).
7) Secure the filter housing using the wing nut.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-742 Maintenance
10.10 Cooling water system

The cooling water feed and return flow are designed according to the type of
machine. For more information, refer to the relevant foundation drawing
(see chapter 15 Parts lists/drawings).
10.10.1 Hydraulic oil cooling/Barrel flange cooling

The oil temperature (operating temperature = 45 °C) is entered on the screen
"Barrel temperatures" (see fig. 10.23, page 10-744).
The temperature of the hydraulic oil is regulated automatically within the
temperature limits set.
The barrel flange is equipped with a control cooling system in order to prevent
clotting (formation of bridges) of the melt in the area of the feed zone.
The water feed is connected to the cooling water distributor on the operator
rearside of the machine (see section 5.8, page 5-214).
1 2
3 4
5 6
9
8
Fig. 10.22 Hydraulic oil and barrel flange cooling

1 Thermocouple 6 Solenoid valve
MX_MC6_V1.9_07.09.15_ENG
2 Barrel flange 7 Oil cooler

3 Solenoid valve 8 Cooling water
©KM
4 Distributor block 9 Hydraulic oil

5 Water filter
Maintenance 10-743
10.10.1.1 Inspect the function of the barrel flange cooling

Fig. 10.23 Barrel temperatures
2) Switch to the "Barrel temperatures" screen page.

3) Enter the hopper temperature 10 °C lower than the displayed actual value.
Cooling must be displayed, the hopper temperature must fall. MX_MC6_V1.9_07.09.15_ENG
©KM
10-744 Maintenance
10.10.2 Mold cooling (ZE)

The cooling water feed and return flow are connected to the flow controller.
The individual cooling circuits of the mold cooling are connected with DN12 hose
connections to the flow control.
The flow rate can be monitored by visually inspecting the floating ball in the flow
controller. An insufficient flow rate can be readjusted.
Water manifold (see section 12.8, page 12-886)
10.10.3 Water filter maintenance
2 1
Fig. 10.24 Water filter

1 Filter strainer 3 O-ring
2 Cover
Removal
1) Ensure that the cooling water feed to the machine is closed.
2) Place the collecting vessel for water under the water filter.
3) Unscrew the cover (2, fig. 10.24).
4) Remove the O-ring (3).
5) Pull out the filter strainer (1) and clean it.
Installation
1) Replace the O-ring (3, fig. 10.24).
MX_MC6_V1.9_07.09.15_ENG
2) Insert the filter strainer (1) into the cover (2).

3) Install and tighten the cover.
©KM
4) Connect the cooling water supply and check the water filter for leaks.
Maintenance 10-745
10.11 Compressed air system
W
Important
To guarantee safe and clean operation, the machine must be connected to the
compressed air system, or be supplied with compressed air.
I
Note
Pneumatic components on the injection molding machine should be operated
preferably with oil-free air. The oiled air is used, a subsequent switch to oil-free
air must be avoided.
10.11.1 Maintenance unit (ZE)
7
5
6
Fig. 10.25 Maintenance unit

MX_MC6_V1.9_07.09.15_ENG
1 Pressure setting knob 5 Oil cup

2 Oil drip adjusting screw 6 Condensate drain plug
©KM
3 Oil drip sight glass 7 Condensate cup

4 Bleed valve 8 Pressure indicator
Setting pressure
For the pressure to be set, refer to the foundation drawing (see chapter 15 Parts
lists/drawings).
1) Ensure that the compressed air supply is established.
2) Set the pressure at the pressure setting knob (1, fig. 10.25).
10-746 Maintenance
Drip quantity for the pneumatic oiler

Set the drip quantity for the pneumatic oiler at the oil drop adjusting screw
(2, fig. 10.25) (delivery condition: adjusting screw closed).
In practice, 1 to 12 drops for 1000 l of air are adequate.
Example
A system consumes an average of 100 l⁄min. 1000 l are to be enriched with 5
drops of oil.
Setting: 1 drop every 2 min.
The interval of the drops can be observed in the oil drip inspection glass (3).
W
Important
Regularly check whether there is condensate present in the maintenance unit
and drain condensate, if necessary.
Condensate draining
1) Release the condensate drain plug (6, fig. 10.25).
2) Drain condensate.
3) Tighten the condensate drain plug (6).
Filling
1) Bleed the oil cup (5) by actuating the bleed valve (4); while doing so, rotate
the oil cup by 45 ° and pull it off by pulling downwards.
2) Release the bleed valve.
3) Clean the oil cup and fill it with oil.
4) Latch the oil cup by pressing and holding the bleed valve.
5) Release the bleed valve.
Cleaning
1) Disconnect the compressed air supply.
2) Loosen the condensate drain plug (6) and drain the condensate.
3) Rotate the condensate cup (7) 45° and pull it off by pulling downwards.
4) Cleaning condensate cup with water
5) Dry condensate cup.
6) Allow the condensate cup to latch into place.
7) Tighten the condensate drain plug (6).
MX_MC6_V1.9_07.09.15_ENG
8) Establish the compressed air supply.

©KM
Maintenance 10-747
10.12 Plasticizing unit
10.12.1 Dangers when working on heated plasticizing units
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Risk of spraying
• Hot melt can be ejected at high speeds from the nozzle or fill opening.
Before maintenance work (e.g. cleaning, centring the nozzle, changing
nozzles, removing the hopper block), the screw barrel must be purged
(see section 10.12.3.2, page 10-754)!
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).
Z
B
H
d
D
regulations.
f
d
D
Fire hazard
MX_MC6_V1.9_07.09.15_ENG
©KM
Keep the heater band surfaces free of any objects or dirt (e.g. plastic, cloths,
etc.).
10-748 Maintenance
10.12.2 Checking and setting the screw barrel support
10.12.2.1 Checking and setting the support for SP 4300 to SP 24500
Mold
• Precision spirit level
1 2
3
6 5 4
7
Fig. 10.26 Screw barrel support for SP 4300 to SP 24500

1 Thermal jacket 5 Supporting roller
2 Heating band 6 Clamping bolt
3 Lifting ring 7 Eccentric shaft
4 Guide
Inspecting the support

1) Check the adjusting bolts for flaking paint.
2) The screw barrel must move in a horizontal position and must not bend when
MX_MC6_V1.9_07.09.15_ENG
heated up.
©KM
Setting the support

1) Remove the thermal jacket (1, fig. 10.26).
2) Fit the lifting eyes on the screw barrel.
3) Remove the heater band (2) on the lifting ring (3).
Maintenance 10-749
I
Note
Attach the screw barrel for setting the support on the crane.

5) Unscrew the clamping bolt (6).
6) Configure the supporting roller (5) for the screw barrel via the eccentric
shaft (7).
7) Tighten the clamping bolt.
8) Reattach the heater band and thermal jacket.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-750 Maintenance
10.12.2.2 Checking and setting the support for SP 33000 to SP 75000
Mold
• Precision spirit level
5 2
3
4
Fig. 10.27 Screw barrel support for SP 33000 to SP 75000

1 Screw barrel 4 Vertical adjusting screw (2x)
2 Lifting ring 5 Side adjusting screw (2x)
3 Pull stanchion 6 Thermal jacket
Inspecting the support

1) Check the adjusting bolts for flaking paint.
2) The screw barrel must move in a horizontal position and must not bend when
heated up.
Setting the support

1) Switch barrel heating off.
2) Remove the thermal jacket (6, fig. 10.27).
3) Remove the heater band on the lifting ring (2).
5) Release the locknuts.
6) Adjust the screw barrel via the adjusting bolts (4).
MX_MC6_V1.9_07.09.15_ENG
©KM
I
Note
• The side adjusting screws (5, fig. 10.27) must not be touching the pull
stanchion (gap of about 0.2 mm).
• Only adjust the vertical adjusting screws (4, fig. 10.27) to set the horizontal
(see section 10.12.2.3, page 10-752).
7) Secure and seal the adjusting screws with locknuts.
Maintenance 10-751
10.12.2.3 Checking and setting screw barrel parallelism to the SP 33000 to SP 75000 injection unit
machine bed
Mold
• Measuring strip
• Micrometer

• Difference from measuring point 1(=zero point) to measuring point 3
< 0.3 mm
3 2 1
Fig. 10.28 Checking screw barrel parallelism for SP 33000 or later
Measuring and setting in a cold state

of the screw barrel (between the heater bands) at the 3 measuring points (see
arrow) using a measuring strip and a micrometer.
2) If necessary, use the adjusting bolts (4, fig. 10.27) to re-align the pull
stanchion (see section 10.12.2.2, page 10-751) and seal.
Measuring and setting in a hot state
H
d
D
Risk of scalding on heated components of the screw barrel.
MX_MC6_V1.9_07.09.15_ENG
regulations - wear safety gloves.

©KM
1) Heat screw barrel up to 230 °C.

2) Ensure that the side screws (5, fig. 10.27) are not touching the pull stanchion
(0.2 mm gap).
of the screw barrel (between the heating bands) at the measuring points (see
arrows) using a measuring strip and a micrometer.
4) If necessary, use the adjusting bolts (4, fig. 10.27) to re-align the pull
stanchion (see section 10.12.2.2, page 10-751) and seal.
10-752 Maintenance
10.12.3 Screw barrel
W
Important
The nozzle heating bands, heating cables and thermo sensors may be
damaged from solidified injection melt which has flowed out.
W
Important
When processing technical plastic materials, in particular, polycarbonate, the
plasticizing unit must not be allowed to cool down to room temperature when it
is filled. Hardening plastic can result in damage to the screw. Prior to switching
off the barrel heater, it is advisable to flush the plasticizing unit with HDPE or to
use the barrel heater lowering function. The recommended lowering
temperature for polycarbonate is 180 °C.
10.12.3.1 Cleaning the nozzle and the injection area
I
Note
If necessary, clean the injection area between nozzle and sprue gate regularly
during production to remove any injection melt which has flowed out.
The injection melt can be best removed when it is in the warm, plastic state.
2) Move back the injection unit.

3) Open the nozzle safety gate.
4) Clean the injection area with a steel hook.
5) Clean the nozzle with a steel wire brush.
6) Close the nozzle safety gate again.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-753
10.12.3.2 Purging screw barrel
H
d
D
regulations.
S
d
D
Risk of spraying
Wear your personal protective equipment (protective helmet with face mask,
safety gloves, protective clothing, etc.) and take suitable safety precautions in
compliance with the accident prevention regulations.
I
Note
It is mandatory to empty the screw barrel when changing the injected material,
for removing the screw barrel or the screw and for taking the machine out of
service.
1) Ensure that the safety gates in the plasticizing and nozzle areas are closed.
2) Ensure that setting mode is selected.
position.
4) Position collecting vessel in the area of the nozzle opening. If necessary,
dismantle the nozzle.
I
Note
The screw barrel is purged once the screw stroke indicator is in the front limit
position and no further injected melt flows out.
MX_MC6_V1.9_07.09.15_ENG
©KM
5) Press the "Injection" and "Plasticizing" buttons alternately. Repeat the

process until the screw barrel is emptied.
I
Note
The injected melt can be easily removed when it is warm and plastic.
10-754 Maintenance
10.12.3.3 Replacing the screw barrel
H
d
D
regulations.
S
d
D
Risk of spraying
Wear your personal protective equipment (protective helmet with face mask,
safety gloves, protective clothing, etc.) and take suitable safety precautions in
compliance with the accident prevention regulations.
1) Ensure that:
• the screw barrel is purged,
• the barrel heating is still switched on.
2) Swivel the material conveyor out of the filling position; take it off, if necessary.
3) Fit the lifting eyes to the screw barrel.
4) Secure the lifting tackle to the lifting eyes. While doing so, ensure that the
cable lengths match (see section 7.13, page 7-324).
5) Remove the cover at the mechanical screw stroke indicator (access to screw
coupling).
6) Loosen the stud bolts at the screw nut.
7) Unscrew screw nut and push back onto the screw shaft.
8) Remove the half shells from the screw nut, if necessary pull off O-ring.
9) Remove screw nut from screw shaft.
I
Note
If the screw barrel is installed again without being cleaned, the screw must be
pulled back by about to 50 mm before decoupling. Pulling back the screw
makes it easier to engage the screw when it is reinstalled.
MX_MC6_V1.9_07.09.15_ENG
10) Move the screw coupling into the rear end position by pressing the "Screw
©KM
decompression" button.
11) Ensure that the screw shaft is free.
12) If necessary, use the "Injection unit return" button to move the injection unit to
the rear limit position.
Maintenance 10-755
13) Switch barrel heating off.
14) Switch off the machine at the master switch.

15) Separate the plug connections for heating and thermo sensor of the injection
unit.
w
D
Warning!
16) Separate the quick-couplings for barrel flange cooling.

17) Attach the wiring to the injection unit.
w
D
Warning!
After the screw barrel has been taken out of the injection unit, the screw may
slip out of the screw barrel and injure persons or damage components.
Secure the screw, so that it cannot slide out.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-756 Maintenance
Removing SP 4300
1 2 3 4
6 7 8 9
14 13 12 11 10
Fig. 10.29 Screw barrel SP 4300

1 Barrel wedge 8 O-ring
2 Clamping wedge 9 Screw mount
3 Bolt (2x) 10 Splines of the screw mount
4 Gap A 11 Stud bolt
5 Screw 12 End face
6 Screw nut 13 Splines on screw shaft
7 Half shell (2x) 14 Barrel flange mounting
1) Unscrew the bolts (3, fig. 10.29) on the clamping wedge and remove them.
2) Lift the screw barrel off of the injection unit.
3) Secure the screw with a rope to prevent it slipping out.
4) Put down the screw barrel.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-757
Removing SP 6100 to SP 24500
1 2 3 4 5 6
10
9 8 7
Fig. 10.30 Screw barrel SP 6100 to SP 24500

1 Screw barrel 6 Lock (2x)
2 Cover 7 Splines of the screw mount
3 Cylinder-head bolts (4x) 8 Groove
4 Cylinder-head bolts (3x) 9 Barrel flange mounting
5 Clamping wedge (2x) 10 Parallel button (bottom)
1) Release the locks (6, fig. 10.30) on the injection unit.

2) Unscrew cylinder-head bolts (3) on cover (2).
MX_MC6_V1.9_07.09.15_ENG
6) If present, push the wedges (2, fig. 7.22) into the outer position (1, fig. 7.24).
©KM
10-758 Maintenance
Removing SP 33000 to SP 75000
1
2
3
9 10 11
4
7 6 5
Fig. 10.31 Screw barrel SP 33000 to SP 75000

1 Clamping wedge 7 Barrel flange mounting
2 Splines on screw shaft 8 Feather key
3 Lock (4x) 9 Cylinder-head bolts (4x)
4 Bolt (2x) 10 Cover
5 Splines of the screw mount 11 Cylinder-head bolts (4x)
6 Groove
1) Release the locks (3, fig. 10.31) on the injection unit.

2) Unscrew cylinder-head bolts (11) on cover (10).
Installation
Install screw barrel (see section 7.13, page 7-324).
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-759
10.12.3.4 Cleaning the screw barrel after removing
H
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regulations.
• Before starting cleaning work, remove return-flow lock (see sections 10.12.7
to 10.12.9).
• The cleaning work should be carried out if possible when the individual parts
are still hot.
• If it is necessary to reheat parts, they must not be heated to more than 300 °C.
• Most of the plastic injection melt can be scraped out of the screw barrel with
a metal scraper.
f
d
D
Fire hazard
W
Important
When installing new parts, ensure that all of the preservative products have
been completely removed.
I
Note
For final cleaning, use a round steel wire brush matching the bore of the barrel.
Optimal cleaning of the bore of the barrel can be achieved with an extended
steel wire brush which is slowly rotated by an electric drill.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-760 Maintenance
10.12.4 Inspecting the firm fitting of screw coupling

The screw coupling consists of the screw nut (3, fig. 10.32), two shell halves (7)
with O-ring (8) and two stud bolts (2) for securing the screw nut.
1 2 3 4 5
8 7 6
Fig. 10.32 Screw coupling

1 Screw 5 Test block
2 Stud bolt (2x) 6 Screw mount
3 Screw nut 7 Half shell (2x)
4 Injection plunger 8 O-ring
W
Important
The screw coupling has left-hand thread.
1) Release both stud bolts (2, fig. 10.32) at the screw coupling.
2) Check the screw coupling to ensure that it is secure.
W
MX_MC6_V1.9_07.09.15_ENG
Important
The screw (1) must always make firm contact at the test block (5) to prevent
©KM
damage to the screw or test block.
3) Tighten both stud bolts (2) again.
Maintenance 10-761
10.12.5 Screw
10.12.5.1 Cleaning screw with cleaning material
w
D
Caution
Ensure the cleaning material and injected melt are compatible.
Incompatibility results in overheating, explosive-like reactions and damage.
1) Make cleaning material available.

2) Ensure that the safety gates in the plasticizing and nozzle areas are closed.
3) Ensure that the screw barrel is purged (see section 10.12.3.2, page 10-754).
position.
6) Swivel the material conveyor out of the filling position; take it off, if necessary.
7) Position collecting vessel in the area of the nozzle opening. If necessary,
dismantle the nozzle.
8) Move the screw into the front limit position.
9) Start plasticizing.
a) Slowly feed in cleaning material.
b) If necessary, change the screw speed on the "Plasticizing" screen
(see section 8.9.2.1, page 8-495) accordingly.
I
Note
The screw barrel is emptied once the screw stroke indicator is in the front limit
position and no further cleaning material flows out.
10) Press the "Injection" and "Plasticizing" buttons alternately and repeat the
MX_MC6_V1.9_07.09.15_ENG
procedure until the screw barrel is emptied.

©KM
10-762 Maintenance
10.12.5.2 Cleaning the screw after removing
H
d
D
regulations.
• Before starting cleaning work, remove return-flow lock (see sections 10.12.7
to 10.12.9).
• The cleaning work should be carried out if possible when the individual parts
are still hot.
• If it is necessary to reheat parts, they must not be heated to more than 300 °C.
• Clean screw with a hand-held steel wire brush.
W
Important
• When installing new parts, ensure that all of the preservative products have
• In the case of armoured/coated screws, reheating with a flame should be
avoided because localized, high temperature fluctuations can result in
spalling of the coating.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-763
10.12.6 Nozzle and barrel head
H
d
D
regulations.
f
d
D
Fire hazard
1 2 3 4 5 6
Fig. 10.33 Nozzle and barrel head

1 Nozzle 4 Bolt
2 Nozzle heating band 5 Barrel head heating band
3 Barrel head 6 Barrel
MX_MC6_V1.9_07.09.15_ENG
©KM
10-764 Maintenance
10.12.6.1 Removing/installing the nozzle
Removing the nozzle

1) Heating up screw barrel
Set the temperature for the respective melt. Set a somewhat lower
temperature for thermally sensitive melts (PVC, POM, CA, CAB, etc.) or moist
PA.
2) Set low injection flows and low pressure.
3) Purge the barrel by both injection and metering (see section 10.12.3.2,
page 10-754).
4) Retract the screw.
5) Move the injection unit to its rear position.
6) Switch off the nozzle heater band (2, fig. 10.33) (remaining heater bands stay
heated).
7) Unscrew thermo sensor from nozzle heating band.
8) Remove the nozzle heater band (2).
9) Unscrew the nozzle (1).
Installing the nozzle

1) Thoroughly clean nozzle (1, fig. 10.33) including thermo sensor bore.
2) Coat the thread and the fit lightly with heat-resistant grease, e.g.
Molykote P74.
3) Screw the nozzle (1) back in. Do not tighten it yet.
4) Leave the nozzle to heat up for approx. 10 minutes and then tighten it to a
torque of 200 Nm.
5) Fit the nozzle heater band (2) again (tighten the tensioning bolts consistently).
6) Screw in thermo sensor tightly.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-765
10.12.6.2 Barrel head connection

The SP 4300 to SP 17200 injection units have a moving threaded ring on the
screw barrel. Together with the cylinder-head bolts, this ensures optimal sealing
between the barrel end surface and barrel head.
1 2 3 4
7 6 5
Fig. 10.34 Barrel head connection

1 Cylinder-head bolt 5 Screw barrel
2 Barrel heating band 6 Sealing surface
3 Gap 7 Barrel head
4 Threaded ring
W
Important
• The threaded ring (4, fig. 10.34) must not be touching the barrel head (7).
The gap (3) must be at least 3 mm.
Tip: Turn the threaded ring back by one threaded hole pitch.
• Always tighten cylinder-head bolts (1) diagonally and evenly.
– During pre-assembly: manually
– During final assembly: using torque spanner
• When removing and reinstalling the barrel head (7), the cylinder-head bolts
(1) must be retightened after approx. 100 operating hours after they have
cooled down to specified torque (see section 3.6.3, page 3-163).
MX_MC6_V1.9_07.09.15_ENG
©KM
10.12.6.3 Removing/installing the barrel head
Removing the barrel head

1) Heat up screw barrel (temperature for respective melt).
Set a somewhat lower temperature for thermally sensitive melts (PVC, POM,
CA, CAB, etc.) or moist PA.
2) Set low injection flows and low pressure.
3) Purge the barrel by both injection and metering (see section 10.12.3.2,
page 10-754).
10-766 Maintenance
4) Retract the screw.

5) Move the injection unit to its rear position.
6) Switch off nozzle heater band (2, fig. 10.33) and barrel head heater band (5)
(remaining heater bands remain heated).
7) Unscrew thermo sensor.
8) Remove nozzle heating band and barrel head heating band.
9) Unscrew the nozzle (1).
10) Unscrew bolts at barrel head (3).
11) Remove barrel head and, if applicable, threaded ring (4, fig. 10.34).
Installing the barrel head

1) Thoroughly clean barrel head (3, fig. 10.33), barrel and, if applicable,
threaded ring (4, fig. 10.34).
2) Carry out visual inspection of the sealing surfaces of barrel head and barrel.
W
Important
Do not coat the bolt head of stress bolts with Molykote paste; otherwise, the
3) Coat the thread of the bolts (4, fig. 10.33) using Molykote paste.
4) Move barrel head and, if applicable, threaded ring into installation position
and screw in bolts (4) manually. Remove the Molykote paste which is forced
out of the threaded holes, so that the bolts are making dry contact.
W
Important
Tighten stress bolts fully only when cold, do not retighten when warm;
5) Insert the bolts and tighten in diagonally opposite sequence and evenly to the
specified torque (see section 3.6.3, page 3-163).
W
Important
When removing and reinstalling the barrel head, the bolts (4, fig. 10.33) must
be retightened after approx. 100 operating hours after they have cooled down
MX_MC6_V1.9_07.09.15_ENG
to a torque of (see section 3.6.3, page 3-163).

©KM
6) Fit the nozzle (see section 10.12.6.1, page 10-765).

7) Fit the heater bands and thermo sensors.
8) Fit the heat protective panelling.
Maintenance 10-767
10.12.7 Return-flow lock
f
d
D
Fire hazard
The temperature on the surface of the heater bands of the screw barrel is
significantly higher than the actual temperature at the operating/display panel.
D
H
d
regulations.
W
Important
The return-flow lock can be removed with the screw installed.
Carry out the cleaning work if possible when the individual parts are still hot.
If it is necessary to reheat parts, they must not be heated to more than 300°C.
10.12.7.1 Cleaning
The parts of the return-flow lock can be properly cleaned using a hand-held steel
wire brush.
• Before installing, the parts can be reworked with emery cloth, roughness 280.
10.12.7.2 Removal
1 2 3 4
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 10.35 Return-flow lock

1 Screw head 3 Thrust ring
2 Locking ring 4 Centring device
10-768 Maintenance
2) Remove the heat protective panelling.
3) Remove the nozzle heater band and, if necessary, barrel head heater band
and thermo sensor.
4) Clean the nozzle and barrel head heating band.
5) Remove the nozzle and barrel head and clean the parts immediately.
6) Open the screw coupling and slide the screw forwards.
7) Carry out preliminary cleaning of screw head (1, fig. 10.35).
W
Important
Carry out steps 8 and 9 only if the standard return-flow lock is installed. The
screw head has a left-hand thread.
8) Detach screw head by striking with a copper drift and unscrew.

9) Clean screw head (1), thrust ring (3) and locking ring (2) immediately.
W
Important
Carry out steps 10 to 12 only if the ball return-flow lock is installed.
10) Remove the balls (6, fig. 10.36) and locking ring (5).
11) Use a spanner on the hexagon of the screw head, slacken the screw head
and unscrew it.
12) Clean the screw head, balls and locking ring.
W
Important
Screw barrel, screw and return-flow lock are wear parts.
Depending on the injection material used, inspect components of the return-
flow lock regularly and replace any components which are worn.
13) Inspect components for wear and replace the components, if necessary.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-769
10.12.7.3 Installation
1) Ensure that the following parts are cleaned and free of corrosion inhibitor or
any deposits (plastic, cloths, etc.):
• Barrel head
• Return-flow lock
• Heating bands
• Screw
• Screw barrel
2) Coat the thread of the screw head, centring element (4, fig. 10.35) and the
centring surface in the screw lightly with Molykote paste.
3) Install and tighten the return-flow lock.
4) Install the screw head with thrust ring and locking ring, assemble the ball
return-flow lock, if necessary (see section 10.12.8.1, page 10-771).
W
Important
Do not coat the bolt head of stress bolts with Molykote paste; otherwise, the
5) Coat the thread of the stretch bolts with Molykote paste.

6) Move the barrel head into the installation position and insert the bolts.
7) Remove the Molykote paste that is forced out of the threaded holes, so that
the stretch bolts are making dry contact.
W
Important
Tighten stress bolts fully only when cold, do not retighten when warm;
8) Insert the bolts and tighten in diagonally opposite sequence and evenly to the
specified torque (see section 3.6.3, page 3-163).
9) Fit the nozzle, heating bands and thermo sensors.
10) Fit the heat protective panelling. MX_MC6_V1.9_07.09.15_ENG
©KM
10-770 Maintenance
10.12.8 Ball return-flow lock
10.12.8.1 Assembly of ball return-flow lock
W
Important
When installing new parts, ensure that all of the preservative products have
1 2 3 4
6 5
Fig. 10.36 Assembly of ball return-flow lock

1 Screw head 4 Assembly ring
2 Screw 5 Locking ring
3 Screw barrel 6 Ball
• Screw head (1, fig. 10.36)
• Balls (6),
• Locking ring (5)
• Screw barrel (3)
2) Coat the thread of the screw head and as of SP 1000 the centring surface in
the screw lightly with Molykote paste.
3) Move the screw forward far enough until the screw head can be screwed in
and tightened.
4) Screw in screw head.
5) Tighten screw head.
6) Pull the screw back sufficiently far to enable the locking ring (5) to be inserted
and the balls (6) to be filled in with the aid of the assembly ring (4).
MX_MC6_V1.9_07.09.15_ENG
7) Insert the balls via the opening on the mounting ring.

8) Press the assembly ring against the front barrel flange and hold it in place.
©KM
Pull the screw back far enough until the balls are in the bore of the barrel.
9) Remove the mounting ring.
Maintenance 10-771
10.12.9 Central ball - return-flow lock (SP 4300 MX to SP 24500 MX)

Removal
1 2 3 4
Fig. 10.37 Central ball - return-flow lock

1 Outlet piece 3 Inlet piece
2 Ball 4 Centring device
W
Important
The return-flow lock can be removed complete or in individual parts.
Return-flow lock and outlet piece have left-hand thread.
1) Ensure that the screw is in the forward position and the barrel head is
detached.
2) Release return-flow lock with clamp wrench or with copper drift inserted into
the inlet opening at the inlet piece (1, fig. 10.37), and unscrew.
3) Release inlet piece (3) with a copper drift and unscrew.
4) Clean the outlet piece (1), ball (2) and inlet piece (3).
MX_MC6_V1.9_07.09.15_ENG
©KM
10-772 Maintenance
Installation
• Barrel head
• Central ball - return-flow lock
• Heating bands
• Screw
• Screw barrel
2) Insert the ball (2, fig. 10.37) into the outlet piece (1).
3) Coat the thread and centring at the inlet piece (3) with Molykote paste, screw
in and tighten.
4) Coat the thread and centring at the outlet piece (1) with Molykote paste, screw
in return-flow lock and tighten it.
5) Attach the barrel head (see steps 5 to 10, page 10-770).
f
d
D
Fire hazard
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-773
10.12.10 Screw barrel nozzle shut-off
10.12.10.1 Checking and adjust pintle catch
Prerequisites
• Barrel temperature heated to processing temperature
1 2
3 4
7 8 7 6 5 MX_MC6_V1.9_07.09.15_ENG
Fig. 10.38 Pintle catch

©KM
1 Marking on barrel head 6 Lubricating nipples

2 Marking on pintle catch lever 7 Locknut (2x)
3 Heat protective panelling 8 Adjusting bolt
4 Heat protective mats 9 Tab washer (2x)
5 Indicator lamp (2x), position transducer, actuation cylinder
10-774 Maintenance
Inspecting
1) Check that the markings match.
The marking on the barrel head (1, fig. 10.38) and the marking on the pintle
catch lever (2) must be flush in the "Nozzle shut-off open" position.
I
Note
Check that the nozzle bore goes all the way through by inserting a thin object
(wire) from the front.
2) If necessary, adjust the nozzle shut-off.
Setting
1) Ensure that the two indicator lamps (5, fig. 10.38) are illuminated (Shut-off
nozzle open).
2) Unlock the locknuts (7) on the adjusting bolt (8).
3) Turn the adjusting bolt until the markings (1 and 2) at the turn-lock are aligned.
4) Tighten locknuts fully.
5) Check setting, repeat steps 3 and 4 if necessary.
6) Secure locknuts with tab washers (9).
Lubricate joint of actuation cylinder

Lubrication (see section 10.8.3, page 10-717)
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-775
10.12.11 Heating bands
10.12.11.1 Removing heating bands
Prerequisites
• Injection unit in rear limit position
• Screw barrel if possible, cooled down
• Machine switched off
Procedure
H
d
D
regulations.
f
d
D
Fire hazard
1) If necessary, use the "Injection unit return" button to move the injection unit to
the rear limit position.
2) Switch off the machine at the master switch.
3) Remove the heat protective panelling.
4) If necessary, remove the cable straps.
5) Open the terminal box and disconnect the heating cable.
6) Loosen the tensioning bolts, fold open the heating band and remove it.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-776 Maintenance
10.12.11.2 Installing heating bands
Prerequisites
• Injection unit in rear limit position
• Screw barrel if possible, cooled down
• Machine switched off
• Ensure that the heating capacity of the new heating band is the same as the
one being replaced
• Heating band is free of contamination

• Heater band, tensioning bolt 3 - 4 Nm
Procedure
1) Move the heating band to the installation position. When doing this, ensure
that the leadthrough openings and the installation opening for the thermo
sensor are aligned and the heater band is making proper contact.
W
Important
The heating band must make proper contact around the entire circumference
of the injection barrel in order to ensure proper heat transfer.
2) Insert the clamping bolts evenly and tighten them to a tightening torque of
3 - 4 Nm.
3) Connect the heating cables.
4) Fit the cover on the terminal box.
5) Install the thermo sensor.
6) Switch on the machine.
f
d
D
Fire hazard
The temperature on the surface of the heater bands of the screw barrel is
significantly higher than the actual temperature at the operating/display panel.
MX_MC6_V1.9_07.09.15_ENG
7) Heat up the heating band.

©KM
8) Retighten the clamping bolts to a tightening torque of 3 - 4 Nm.

9) Fit the heat protective panelling.
Maintenance 10-777
10.13 Control cabinet
e
d
D
• Before beginning work, disconnect the power supply and secure it from
being switched on again without authorization.
• Only persons with professional qualifications in the electrical/electronic
field may perform any work on the electrical/electronic components of the
machine.
10.13.1 Cleaning/replacing the filter mats in the fan
W
Important
Soiled filter mats can result in components overheating.
Regularly clean the filter mats or replace them if necessary and check the fan for
function.
1) Pull of the ventilation grille.
2) Remove the filter mat.
3) Wash the filter mat with lukewarm water (max. 40 °C) with a grease-dissolving
additive.
W
Important
Replace filter mats that are severely soiled, have oil stains or are soiled with
grease.
Do not install a moist filter mat as moist air drawn into the control cabinet can
result in short circuits and in corrosion of the switching contacts.
4) Dry the filter mat.

5) Insert the filter mat.
MX_MC6_V1.9_07.09.15_ENG
6) Put on the ventilation grille.

7) Switch on the machine.
©KM
8) Check that the fan is working.
10-778 Maintenance
10.14 Changing the backup battery
10.14.1 General Notes

The replaceable backup battery ensures that programs and data in the user
program memory (RAM) are retained, even if the supply voltage is switched off.
The capacity of the buffer battery is sufficient to back up the data for 3 years with
the supply voltage switched off.
i
t
Environmental note
Dispose of the old battery in an environmentally proper manner, while taking
the prevailing national regulations into account.
D
w
Caution
The machine must be switched off when the battery is replaced.
W
Important
Once the +24 V power supply is disconnected, the battery is buffered for
15 minutes. The battery must be replaced within this time because otherwise
data can be lost.
W
Risk of destruction from electrostatic
Immediately before touching the battery, discharge your body by touching the
earth of the control cabinet.
MX_MC6_V1.9_07.09.15_ENG
©KM
Maintenance 10-779
10.14.2 Battery change

The visualization computer contains a lithium buffer battery of type CR2032. The
buffer battery keeps the internal computer clock in operating mode and provides
the correct time and date. The battery is located on the motherboard of the
computer and must be changed once a year.
D
w
Caution
The machine must be switched off when the battery is replaced.
W
Important
The battery for backing up the S-RAM memory in the touchscreen operating
panel must be changed once a year to prevent data loss due to a flat battery.
Procedure
1) Switch off the main switch.
2) Remove visualization computer (see fig. 10.39, page 10-780) from the control
system.
2
3
Fig. 10.39 Visualization computer PC301, battery change MC6

MX_MC6_V1.9_07.09.15_ENG
1 PC cover 3 Safety flap

©KM
2 Battery
3) Release screws on PC cover (1, fig. 10.39) of the visualization computer and
remove the cover.
10-780 Maintenance
Fig. 10.40 Battery change (1/4)

1 Battery 2 Safety flap
4) Use a suitable tool to carefully push away the safety flap (2, fig. 10.40) on the
battery holder.
The spring-loaded battery (1) jumps out of the holder.

MX_MC6_V1.9_07.09.15_ENG
5) Remove battery (1) and dispose of it.

©KM
W
Risk of destruction from electrostatic
The new battery must only be inserted by hand or with a non-conducting tool!
Immediately before touching the battery, discharge your body by touching the
earth of the control cabinet.
Maintenance 10-781
I
Note
• The positive terminal of the battery is on the top side.
• The battery must engage at the safety flap (2, fig. 10.40) in the battery
holder.
6) Insert new battery of type CR 2032 with your fingers or a non-conducting tool.
7) Mount PC cover (1, fig. 10.39) of the visualization computer and screw on
cover.
8) Install visualization computer in control system.
10) Wait until the control system powers up.
MX_MC6_V1.9_07.09.15_ENG
©KM

1 "Date/Time" button
11) Check the date and time on the screen of the operating/display panel
(1, fig. 10.43) and update if necessary (see section 6.3.1.1, page 6-231).
10-782 Maintenance
10.15 Replacing protective film on touchscreen

If the protective film is damaged, it must be replaced.
I
Note
To avoid fingerprints on the protective film, work should be carried out with lint-
free textile gloves.
Fig. 10.44 Protective film on touchscreen

1 Touchscreen edge 3 Backing film (thin, flexible film)
2 Protective film (firm, stable film)
1) Remove damaged protective film from touchscreen.

2) Clean touchscreen with a lint-free, dry textile cloth (dust cloth).
3) Peel backing film (3, fig. 10.44) off one side of the protective film (2).
4) Position the exposed side of the protective film (2) at right angles in the upper
area of the touchscreen so that the foil edge makes contact at the edge of the
touchscreen (1).
5) Hold protective film (2) at upper edge and carefully peel backing film (3)
MX_MC6_V1.9_07.09.15_ENG
downwards to remove. When affixing, ensure that no air bubbles are created.
©KM
6) Smooth the protective film with a clean cloth.

Any air bubbles that are present can be scraped towards the outside with a
chip card.
Maintenance 10-783
10.16 Changing pressure accumulator
w
D
Warning!
• The pressure accumulator is subject to the pressure equipment directive
97/23/EC.
For operation, the workplace safety regulations or the corresponding
national regulations must be observed.
• No welding, brazing and no machining operations may be carried at the
pressure accumulator.
• Instructions for pressure accumulator (see section 1.6, page 1-104).
w
D
Warning!
Prior to maintenance tasks, ensure the following at the pressure accumulator:
• The master switch of the machine is switched off and secured against
reactivation
• Pressure in the pressure accumulator is released at drain cock SH580
(3, fig. 10.45) and the nitrogen precharging pressure is reduced with the
aid of the filling and test device at the relief valve (8, fig. 10.47).
10.16.1 Drain the nitrogen

Prerequisites
• Nitrogen cylinder/nitrogen charge battery provided
• Special tool FPU-1 from HYDAC TECHNOLOGY provided
H
d
D
The storage element can heat up to 80 °C during operation.
pressureless.
MX_MC6_V1.9_07.09.15_ENG
2) Remove the panelling in the area of the pressure accumulator (operator

rearside).
©KM
3) Ensure that:
• the pressure accumulator is separated from the system: the connector is
unplugged from pressure switch BP581 (2, fig. 10.45).
• The drain cock S5800 (3) is fully opened.
10-784 Maintenance
Pressure accumulator valve block
3
2

system)
3 4 5 6
1
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©KM
7
8 9 10

1 Cap 6 Bladder
2 Cap nut 7 Fluid valve
3 Gas valve 8 Bleed screw
4 Seal ring 9 Seal ring
5 Storage tank 10 Flat
Maintenance 10-785
2 3 4 5 6
1
9
Fig. 10.47 Filling and test device

1 Nitrogen cylinder-nitrogen charge battery 6 Actuation spindle (FPU-1)
2 Shut-off valve 7 Pressure indicator
3 Pressure reducing valve 8 Relief valve (FPU-1)
4 Filling hose 9 Pressure accumulator
5 Check valve
I
Note
Do not remove seal ring (4, fig. 10.46) from gas valve.
5) Fit the filling and test device on the gas valve (3) and move the actuation
spindle (6, fig. 10.47) to the right until the precharging pressure is displayed
on the pressure indicator of the device.
6) Release the precharging pressure by carefully opening the relief valve
(8, fig. 10.47). Observe the pressure indicator (7) and wait until the
accumulator has emptied.
10.16.2 Removing the pressure accumulator

1) Ensure that:
• Nitrogen has been released (see section 10.16.1, page 10-784).
MX_MC6_V1.9_07.09.15_ENG
• The pump motor is switched off and the hydraulic system is pressureless.
©KM
• The vertical mount of the pressure accumulator is released and does not
obstruct removal.
2) Unscrew the bleed screw (8, fig. 10.46) from the fluid valve (7).
3) Slacken the bolts at the securing clamp of the accumulator.
4) Unscrew the pressure accumulator at the flats (10) and remove it.
5) Remove the seal ring (9) from the valve block.
6) Put the pressure accumulator down.
10-786 Maintenance
10.16.3 Installing the pressure accumulator

1) Ensure that:
• The pump motor is switched off and the hydraulic system is pressureless.
• The connector is unplugged from pressure switch BP581 (2, fig. 10.45).
2) Oil the new seal ring (9, fig. 10.46) and insert it into the adapter.
3) Place the accumulator vertically on the valve block and screw it into place.
4) Tighten the bolts on the fixing clip.
5) Vent the pressure accumulator on the oil side (see section 7.10, page 7-306).
6) Attach the panelling in the area of the pressure accumulator (operator
rearside).
7) Check the oil level and replenish hydraulic oil, if necessary.
10.16.4 Fill the pressure accumulator with nitrogen

(see section 5.11, page 5-221)
10.16.5 Check pressure accumulator
10.16.5.1 Fill pressure

After each installation or repair, the specified prefill pressure must be reset. For
the precharge pressure, refer to the "Hydraulic circuit diagram" (see chapter
17 Hydraulics/Pneumatics).
• The prefill pressure must be checked at least once during the first week of
use.
• If there is no evidence of pressure loss, carry out the next check 4 months
later.
• If the pressure remains unchanged at the time of this check, an annual check
is sufficient.
Prerequisites
• Accumulator disconnected from the pressurized system.
• Accumulator discharged on the fluid side.
• Special tool FPU-1 from HYDAC TECHNOLOGY provided
Procedure
MX_MC6_V1.9_07.09.15_ENG
pressureless.
2) Remove the panelling in the area of the pressure accumulator (operator
©KM
rearside).
3) Ensure that:
• The drain cock S5800 (3, fig. 10.45) is fully opened.
Maintenance 10-787
I
Note
Do not remove seal ring (4, fig. 10.46) from gas valve.
5) Fit the filling and test device on the gas valve (3). When doing so, ensure that
the relief valve (8, fig. 10.47) of the filling and test device is closed.
6) Turn the filling and test device so that the pressure indicator (7) is in a position
where it can be easily read.
7) Open the valve by turning the actuation spindle (6).
8) After the needle deflection begins, turn the actuation spindle one more
complete turn.
• The pressure indicator (7) indicates the precharge pressure.
• The check valve (5) prevents the nitrogen from escaping.
9) If a loss of nitrogen is evident, refill the pressure accumulator if necessary
10.16.5.2 Condition
Check the pressure accumulator regularly for corrosion and damage.
MX_MC6_V1.9_07.09.15_ENG
©KM
10-788 Maintenance
11 Peripherals / Interfaces
This chapter provides you with information regarding the contacts and the contact
assignment for the external equipment of the machine.
11.1 Description of interface, parts removal unit

(ZE 89.5901⁄ZE 89.5902) . . . . . . . . . . . . . . . . . . . . . . 790
11.2 Interface EUROMAP 73 . . . . . . . . . . . . . . . . . . . . . . . 796
11.3 Description of interface, hot runner system . . . . . . 800
11.4 Description of interface, heat-balancing units

via control system (ZE 88.56xx) . . . . . . . . . . . . . . . . 802
11.5 Description of interface, heat-balancing units

20 mA (ZE 89.965) . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
11.6 Description of interface, production data

acquisition (BDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
11.7 Description of interface, cascade control . . . . . . . . 806
11.8 Terminal assignment, touchscreen operating

panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
11.9 Interfaces, control cabinet PC . . . . . . . . . . . . . . . . . 811
11.10 Interface, laminar flow box (ZE) . . . . . . . . . . . . . . . . 815

MX_MC6_V1.9_07.09.15_ENG
©KM
Peripherals / Interfaces 11-789

11.1 Description of interface, parts removal unit

(ZE 89.5901⁄ZE 89.5902)
11.1.1 Interface map for plug-in connection (-XY100A)

The injection molding machine is connected to the parts removal unit via the plug-
in connection (-XY100), Type HAN 50 D (Harting), as per EUROMAP 67. The
plug-in connection (25 pins and 25 sockets) is fitted to the face end of the sound
insulating cabin on the operator rearside of the injection molding machine.
The interface is the result of consultation with robot manufacturers HEKUMA,
Wittmann-Kuffer GmbH, Remak and Colortronik as well as machine
manufacturers Mannesmann-Demag, Klöckner-Ferromatik, Engel and
KraussMaffei.
11.1.2 Contact assignment
From injection molding machine From parts removal unit

Contact Signal designation Contact Signal designation
ZA1⁄ZC1 EMERGENCY STOP channel 1 machine A1⁄C1 EMERGENCY STOP channel 1 robot
ZA2⁄ZC2 EMERGENCY STOP channel 2 machine A2⁄C2 EMERGENCY STOP channel 2 robot
ZA3⁄ZC3 Safety gates shut Channel 1 A3⁄C3 Parts removal unit safety position
ZA4⁄ZC4 Safety gates shut Channel 2 A4⁄C4 Euromap reserve
ZA5 Reject A5 Euromap reserve
ZA6 Mold closed A6 Enabling mold closing
ZA7 Start robot A7 Open mold fully after intermediate stop
ZA8 Start robot after mold intermediate stop A8 Euromap reserve
ZA9 Voltage supply outputs (external) A9 Voltage supply inputs (internal)
ZB2 Semi-automatic and fully automatic mode B2 Operation without robot
ZB3 Ejector at rear (injection position) B3 Enabling ejector return
ZB4 Ejector is forward (demolding position) B4 Enabling ejector forward
ZB5 Core moved in B5 Move cores in
ZB6 Core moved out B6 Move cores out
ZB7 Euromap reserve B7 Euromap reserve
ZB8 Euromap reserve B8 Euromap reserve
ZC5 Euromap reserve C5 Euromap reserve
MX_MC6_V1.9_07.09.15_ENG

ZC8 Part injected C8 Reject
©KM
ZC9 Voltage supply outputs (external) C9 Voltage supply inputs (internal)
11-790 Peripherals / Interfaces

1 2
Fig. 11.1 Interface, parts removal unit-injection molding machine

1 Parts removal unit 2 Injection molding machine
11.1.3 Voltage supply

The voltage is supplied along a separate cable from the 3 x 400 V 16 A (or 32 A,
ZE) HAN socket (-XJ100) through the master switch of the parts removal unit.
MX_MC6_V1.9_07.09.15_ENG
©KM

11.1.4 Description of signals
11.1.4.1 Injection molding machine
Contact Signal designation

ZA1⁄ZC1 EMERGENCY STOP channel 1
If the "EMERGENCY-STOP" function is activated at the injection molding machine, the "EMERGENCY-
STOP" signal is interrupted, contacts ZA1 and ZC1 are de-energized.
ZA2⁄ZC2 EMERGENCY STOP channel 2
If the "EMERGENCY-STOP" function is activated at the injection molding machine, the "EMERGENCY-
STOP" signal is interrupted, contacts ZA2 and ZC2 are de-energized.
ZA3⁄ZC3 Safety gates shut Channel 1
The signal exists when the safety gates of the injection molding machine are closed.
ZA4⁄ZC4 Safety gates shut Channel 2
The signal exists when the safety gates of the injection molding machine are closed.
ZA5 Reject
Injection molding machine signals to parts removal unit that the part removed is a reject part.
The signal exists with "Mold open" and is cancelled with "Start mold closing".
ZA6 Mold closed
Injection molding machine signals to parts removal unit that the closing operation is completed (mold
closed). The "Mold closing" signal is hereby deleted.
ZA7 Start robot
Start parts removal unit moving in. The position transducer signal is supplied by the injection molding
machine once the opening stroke is reached. Signalling is safeguarded in such a way that the signal is only
supplied once the set opening stroke has been reached.
An unintentional adjustment to smaller mold opening widths than is required for moving in, is not possible.
The signal continues to exist until the mold is open and must not be interrupted by changing over the
operating mode or by opening the safety gate.
W
Important
If the opening stroke has been set too small, there is a risk of damage to mold
and parts removal unit.

MX_MC6_V1.9_07.09.15_ENG
ZA8 Start robot after mold intermediate stop

Injection molding machine signals to parts removal unit that the mold is in an intermediate position and
©KM
transmits start signal to parts removal unit. The "Open mold" function is restarted with the "Open mold fully"
signal from the parts removal unit.
Mold does not stop in an intermediate position; a start signal is nevertheless transmitted to the robot.
ZA9 Voltage supply outputs (external)
24 V DC


ZB2 Semi-automatic and fully automatic mode
Injection machine signals to parts removal unit that the semi-automatic or fully automatic mode is selected.
ZB3 Ejector at rear (injection position)
Injection molding machine signals to parts removal unit that the ejector is in the "rear" position (injection
position) irrespective of the position of the movable mold platen (MP).
ZB4 Ejector is forward (demolding position)
Injection molding machine signals to parts removal unit that the ejector is in the "forward" position
(demolding position).
ZB5 Core moved in (injection position)
Injection molding machine signals to parts removal unit that the core which is controlled via the parts removal
unit, is in the "Core moved in" position (injection position).
ZB6 Core moved out (demolding position)
Injection molding machine signals to parts removal unit that the core controlled via the parts removal unit, is
in the "Core moved out" position (demolding position).
ZB7 Euromap reserve
ZB8 Euromap reserve
ZC5 Euromap reserve
ZC6 Euromap reserve
ZC8 Part injected
Injection molding machine signals to robot that the part has been injected. The signal exists with start of
injection and is cancelled with mold open.
ZC9 Voltage supply outputs (external)
0V
11.1.4.2 Parts removal unit

A1⁄CF1 EMERGENCY STOP channel 1
If the signal does not exist, the control system of the injection molding machine is switched off. The signal is
supplied in series with the EMERGENCY STOP of the injection molding machine.
A2⁄C2 EMERGENCY STOP channel 2
If the signal does not exist, the control system of the injection molding machine is switched off. The signal is
supplied in series with the EMERGENCY STOP of the injection molding machine.
A3⁄C3 Parts removal unit safety position
Monitoring, Mold closing⁄opening.
MX_MC6_V1.9_07.09.15_ENG
If the signal does not exist, neither a closing nor an opening movement of the injection molding machine may
©KM
be performed.
The signal indicates that the parts removal unit is no longer within the hazardous area of the machine. The
signal must also be supplied even if the injection molding machine is operated without a parts removal unit.
A4⁄C4 Euromap reserve
A5 Euromap reserve

W
Important
The signal "Enabling mold closing" exists for the duration of the mold closing
operation; if the signal no longer exists, the closing movement must be
interrupted.

A6 Enabling mold closing
The signal is pending as soon as the parts removal unit has moved out far enough to permit the mold to be
closed and if other monitoring devices of the parts removal unit supply the enable signal for mold closing.
The signal must likewise be supplied even if the injection molding machine is operated without a parts
removal unit.
A7 Open mold fully (after intermediate stop)
The signal exists if the parts removal unit has moved out far enough to allow the mold to be fully opened.
A8 Euromap reserve
A9 Voltage supply inputs (internal)
24 V DC
B2 Operation without robot
If the signal does not exist, "Operation with parts removal unit".
If the signal exists, "Operation without parts removal unit".
B3 Enabling ejector return
If the signal exists, the parts removal unit informs the injection molding machine that the ejector should be
moved back into the "Ejector back movement" position. Continuous signal exists until "Ejector at rear" signal
received.
B4 Enabling ejector forward
If the signal exists, the parts removal unit informs the injection molding machine that the ejector should be
moved into the "Ejector forward" position.
Continuous signal until signal acknowledged.
B5 Move core in (injection position)
If the signal exists, the parts removal unit informs the injection molding machine that the core controlled by
the parts removal unit is to be moved in (into injection position).
B6 Move core out (demolding position)
If the signal exists, the parts removal unit informs the injection molding machine that the core controlled by
the parts removal unit should be moved into out (into demolding position).
B7 Euromap reserve
B8 Euromap reserve
MX_MC6_V1.9_07.09.15_ENG
C5 Euromap reserve
©KM
C6 Euromap reserve
C7 Euromap reserve
C8 Reject
C9 Voltage supply inputs (internal)
0V

11.1.5 Contact type

The signals are generated both in the injection molding machine and in the robot
by contacts, e.g. by relays, switches, semiconductors, etc.
The contact is either established as a floating contact or refers to a reference
potential that is forwarded to a contact in the plug, that is located on the injection
molding machine or on the robot.
11.1.6 Contact specification

EMERGENCY STOP, safety devices
• The voltage of the signals must not exceed 50 V DC or 250 V AC.
• When a signal is switched on, at least 6 mA must be present.
• The maximum amperage is 6 A.
Logic signals
• These signals must comply with EN 61131-2, Point 3.3.1, Table 9, Type 2 or
Point 3.3.3, Table 11, max. 0.1 A.
Reference potential
Voltage 18–36 V DC
Overvoltage protection up to 60 V: min. 10 ms
Amperage ZA9, ZC9 max. 1 A
Amperage CA9, C9 max. 200 mA
11.1.7 Ejector with robot synchronization

Repeat-stroking counter
Not all ejector repeat strokes can be synchronized with the robot. For this reason,
only the first ejector stroke is synchronized with the robot. After this, the ejector
waits until the robot supplies the signal "Parts removal unit safety position" and,
after this, the remaining ejector repeat strokes are carried out without
synchronization with the robot.
I
Note
For the "Move ejector forward" movement, the enable signal B4 "Ejector
MX_MC6_V1.9_07.09.15_ENG
forward movement" must be pending. For the "Move ejector to rear"

©KM
movement, the enable signal B3 "Ejector back movement" is required

(see section 11.1.4.2, page 11-793). When programming the ejector via the
core-pulling program, you can set whether the enable signal is to be checked.

11.2 Interface EUROMAP 73

This EUROMAP recommendation defines the connection between injection
molding machine and the external safety devices, e.g. gates in the protective
housings, which prevent access to the dangers areas of the injection molding
machine.
11.2.1 Contact type

The signals are generated both in the injection molding machine and in the
external safety device (e.g. robot housing door) by contacts, e.g. by relays,
switches, semiconductors, etc.
The contact is either established as a floating contact or refers to a reference
potential that is forwarded to a contact in the plug, which, in turn, is located on the
All signals that are not freely selectable must be safeguarded via the injection
molding machine and the external safety device.
11.2.2 Plug connections

The connection between the injection molding machine and external safety
device is via a connector (see fig. 11.2, page 11-796).
The plug contacts for the injection molding machine (2, fig. 11.2) and external
safety device (1) should be suitable for at least 250 V and 10 A.
MX_MC6_V1.9_07.09.15_ENG
©KM
1 2
Fig. 11.2 Arrangement of plug connections

1 Connector for external safety device 2 Connector for injection molding machine


Unless specified to the contrary, all pending signals are constant.
The signals are forwarded from the signal source to the respective connector.
Connector for external safety device (1, fig. 11.2)

Contact no. Contact Signal designation Description
name
a1-a6 Spare Reserved for further use of EUROMAP.
a7-a12 Spare Not defined by EUROMAP, dependent on
manufacturer.
Connector for injection molding machine (2, fig. 11.2)

name
c1/c3, c2/c4 S1 1) External safety device closed The external safety device is closed. Limit switch or
safety switch is not activated.
safety switch is activated.
safety switch is not activated.
d1 Supply of injection molding machine 24 V DC / 2A
d2 Supply of injection molding machine 0 V DC / 2A
d3/d4 S1 Checkback signal Signal of a manual switch or safety circuit when all
operators have exited the protected area.
Signal: pulse, normally open contact
d5/d7 S0 EMERGENCY STOP channel 1 The switching contact must be open when the
safety device emergency-stop of external safety device is activated.
Opening of the switching contact results in the
emergency-stop of the injection molding machine. The
switching contact must be active when the safety
device is inactive.
d6/d8 S0 EMERGENCY STOP channel 2 The switching contact must be open when the
safety device emergency-stop of external safety device is activated.
Opening of the switching contact results in the
emergency-stop of the injection molding machine. The
switching contact must be active when the safety
MX_MC6_V1.9_07.09.15_ENG
device is inactive.
d9 (optional) Unlocking the interlock of the High signal to the external safety device to unlock it.
©KM
external safety device Maximum charge: 1 A / 24 V DC

d10 (optional) S1 Display of interlock of the external Contact is closed when external safety device is
safety device closed and locked.

Connector for injection molding machine (2, fig. 11.2)

name
d11 (optional) S1 Request to open the external safety Request signal to open the external safety device.
device Signal: pulse, normally open contact
d12 Operation with external safety Low signal when the external safety device is inactive.
device
b1-b6 Spare Reserved for further use of EUROMAP.
b7-b12 Spare Not defined by EUROMAP, dependent on
manufacturer.
1) When the external safety device is closed (open), the contact must switch within a time frame of < 1 s.
11.2.4 Contact specification

EMERGENCY STOP, safety devices
• The voltage of the signals must not exceed 50 V DC or 250 V AC.
• When a signal is switched on, at least 6 mA must be present.
• The maximum amperage is 6 A.
Logic signals
These signals must comply with EN 61131-2, Point 3.3.1, Table 9, Type 2 or
Point 3.3.3, Table 11, max. 0.1 A.
Reference potential
Voltage 18–36 V DC
Modulation max. 2.5 Vpp
Overvoltage protection up to 60 V: min. 10 ms
Amperage max. 2 A
MX_MC6_V1.9_07.09.15_ENG
©KM

11.2.5 Interface Euromap 73 and lateral removal (ZE)
W
Important
The door stop must be disassembled for lateral demolding.
Description of the door stop (see section 1.4.10.6, page 1-89).
11.2.5.1 Lateral demolding, operator rearside (ZE 89.5924⁄5921)

Shutdown mold opening and ejector/core movement via hardware contact:
Two safety relays are activated when machine safety gate on operator rearside is
closed or housing door (robot) is closed and acknowledged. Ejector and core
movement in combination with ZE X89.08 keyswitch S016 are not possible either.
11.2.5.2 Later demolding, operator side (ZE 89.5925⁄5922)

Shutdown mold opening and ejector/core movement via hardware contact:
Two safety relays are activated when an operator side machine safety gate is
closed or housing door (robot) is closed and acknowledged.
Ejector and core movement in combination with ZE X89.08 keyswitch S016 are
not possible.
MX_MC6_V1.9_07.09.15_ENG
©KM

11.3 Description of interface, hot runner system
11.3.1 Interface map for plug-in connection (-XJ701 to -XJ7xx / -XT701 to -XT7xx)
In the hotrunner system, the plug-in connectors -XJ701 to -XJ7xx are used for
connection for the heating elements and the plug-in connectors -XT701 to -XT7xx
are used for connection for the thermo sensors.
Plug-in connection conforming to EUROMAP 14:
Injection molding machine
• -XJ701 to -XJ7xx (e.g. Han 16E, make: Harting)
Socket insert
Attached housing
• -XT701 to -XT7xx (e.g. Han 16A, make: Harting)
Pin insert
Attached housing
11.3.2 Contact assignment, heating elements

1⁄9 Heating element 1, PEN conductor to contact 9
MX_MC6_V1.9_07.09.15_ENG
©KM
1 2
Fig. 11.3 Heating elements, interface

1 Heating element 2 Injection molding machine

11.3.3 Contact assignment, thermo sensors

1⁄9 Thermo sensor 1, POS conductor to contact 1
1 2
Fig. 11.4 Thermo sensors, interface

1 Injection molding machine 2 Thermocouple
MX_MC6_V1.9_07.09.15_ENG
©KM

11.4 Description of interface, heat-balancing units via control

system (ZE 88.56xx)
11.4.1 Interface map for plug-in connection (-XJ801 to -XJ8xx)

Plug-in connection:
• Injection molding machine
(e.g. Han 10E, make: Harting).
Pin insert
Attached housing
• Heat-balancing unit
Socket insert
Grommet housing

1 Common voltage feed for floating heating/cooling contacts
2 Switched relay contact for heating
3 Switched relay contact for cooling
4 +24 V for floating alarm contact in heat-balancing unit (NC contact with cable parting
protection)
5 Switched relay contact for "Mold temperature controller alarm"
6 Thermo sensor Fe⁄CuNi (+)
7 Thermo sensor Fe⁄CuNi (-)
8 Spare
9 Spare
10 Spare
11.4.3 Contact type, power rating

The floating contacts of the injection molding machine have a rated loading of
230 V⁄500 mA. MX_MC6_V1.9_07.09.15_ENG
©KM
1 2
Fig. 11.5 Mold temperature controller, interface

1 Heat-balancing unit 2 Injection molding machine

11.5 Description of interface, heat-balancing units 20 mA

(ZE 89.965)
11.5.1 Plug-in connection (-XYV24T)
Number Designation Type

1 Grommet housing HAN 10 A
1 Insulating body Male multipoint connector pin
1 Adapter plate HAN 16 A
2 Crimp contact Pin
1
2
Fig. 11.6 Plug-in connection

1 Injection molding machine 2 Heat-balancing unit
MX_MC6_V1.9_07.09.15_ENG
©KM

-AEE SIEEX.04
20 mA /TG
20 mA
GND
Rx+
Tx+
Rx-
Tx-
X7:1 X7:2 X7:3 X7:4 X7:5 X7:6
50 mm2 BU
SH
AWG22 50 mm2 BU
AWG22
1WH
2BN
3SH
-WXYV24T
1x2x0.25 mm2
+M4
24
10 SH
XYV24T s
Fig. 11.7 Interface, heat-balancing unit 20 mA (ZE 89.965)
MX_MC6_V1.9_07.09.15_ENG
©KM

11.6 Description of interface, production data acquisition (BDE)
11.6.1 Interface map

The signals for the production data acquisition are available at the terminal
strip -X52. The conductor size is max. 1.5 mm2.
Contact assignment: the contacts have a rated loading of 125 V⁄2 A.

1-2 Production data acquisition 1
MX_MC6_V1.9_07.09.15_ENG
©KM

11.7 Description of interface, cascade control

An electrical interface is installed on the fixed mold platen on the operator rearside
for cascade control of hotrunner needle shut-off nozzles. The interface enables
the activation of pneumatic/hydraulic valves.
The valves are can be selected in stages of 2 from 2-fold to 16-fold.
The selection between a pneumatic and hydraulic connection is made on the
"Cascade control, Nozzle 1 to 16 (injection)/(holding pressure)" screen. If
available, hydraulic valves are always started with.
In the delivery status, the valves are assigned manually.
11.7.1 Design of the sensor-actuator box
4
5
Fig. 11.8 Sensor-actuator box

1 Main cable 4 LED yellow (16x)
2 LED green (1x) 5 Identification plate
3 Double occupied slot
LED green Supply voltage per module (without function)

LED yellow Status display I⁄0
MX_MC6_V1.9_07.09.15_ENG
©KM

3 4
5
2 1
Fig. 11.9 Contact assignment

1 Not assigned 4 "Close cascade" function (S1)
2 "Open cascade" function (S2) 5 Not assigned
3 0V
11.7.3 Specifications
Specifications Parameters
Type SACB-8/16-L-5.0PUR
Nominal voltage UN [V DC] 24
Number of poles 5
Max. current carrying capacity per path [A] 2
Number of slots 8
Type of sensor-actuator connection M12 socket
MX_MC6_V1.9_07.09.15_ENG
©KM

11.8 Terminal assignment, touchscreen operating panel
11.8.1 Interface on front side
Fig. 11.10 Interface on front side, X7
Pin Function
1 +5V
2 D0-
3 D0+
4 GND
Fig. 11.11 X7: USB2.0 type A
Status displays
LED status Meaning

LED flashes Connection setup
LED lights up green Connection is established
MX_MC6_V1.9_07.09.15_ENG
©KM

11.8.2 Interfaces on rearside
Fig. 11.12 Interfaces on rearside

1 X1: Power supply 4 X4: Audio IN
2 X2: USB 2.0 type A 5 X5: Audio Out
3 X3: Display IN (RJ45) 6 X6: COM 1 (male)
Pin Function
1 + 24 V power supply
2 + 24 V power supply
3 GND
4 GND
Fig. 11.13 X1: Power supply (FK-MCP 1.5/4-ST-3.5)
Pin Function
1 +5V
2 D0-
3 D0+
4 GND
Fig. 11.14 X2: USB2.0 type A
Pin Function
1 DA+
2 DA-
3 DB+
4 DC+
MX_MC6_V1.9_07.09.15_ENG
5 DC-
6 DB-
©KM
7 DD+
8 DD-
Fig. 11.15 X3: Display IN (RJ45)

Pin Function
1 Microphone IN
2 GND
Fig. 11.16 X4: Audio IN
Pin Function
1 Stereo, left
2 Stereo, right
3 GND
Fig. 11.17 X5: Audio OUT
Pin Function
1 -
2 RX
3 TX
4 -
5 GND
6 -
7 -
8 -
9 -
Fig. 11.18 X6: COM 1 (male)
MX_MC6_V1.9_07.09.15_ENG
©KM

11.9 Interfaces, control cabinet PC
11.9.1 PC 322-K
The PC 322-K is a control cabinet PC with an Intel Celeron G540T processor. The
PC 322-K is completely PC-compatible and works with a standard PC BIOS.
Fig. 11.19 PC 322-K
11.9.1.1 Performance data

• Processor INTEL Celeron G540T
• Hard disk 16 GB Solid State Disk.
• Main memory 4 GB RAM
MX_MC6_V1.9_07.09.15_ENG
• Graphics, Intel HD Graphics

• Supply voltage 24V DC
©KM

11.9.1.2 Terminal assignment
11
4
5 12
6 13
7 14
8
15
10
Fig. 11.20 Terminal assignment PC 322-K

MX_MC6_V1.9_07.09.15_ENG
1 X2: PS/2 mouse 9 X17: Power supply

2 X1: PS/2 keyboard 10 Status display
©KM
3 X3-X6: USB 2.0 11 PCI slots

4 X7: Display port 12 X15: Ethernet
5 X8: DVI 13 X12: Ethernet
6 X10-X11: USB 2.0 14 X9: RS232
7 X13-X14: USB 2.0 15 SSD (Solid State Disk)
8 X16: Audio

Connection Function
X3 - USB port 1 Memory expansion for diagnosis and machine data records
X4 - USB port 2 to signal extender for USB and touch mouse
X7 - display port for external projector or monitor
X8 - DVI output to signal extender for video signal
X12 - Ethernet connection to Ethernet hub or edge CPU of machine control system
X13/X14 - USB ports for external mouse and keyboard
X15 - Ethernet connection as EUROMAP 63 interface
X17 - voltage supply
Pin Signal Function

1 PE Earthing
2 N Neutral conductor
3 L Phase
4 PE Earthing
I
Note
The status displays (10, fig. 11.20) are not active.
11.9.1.3 USB memory expansion

MX_MC6_V1.9_07.09.15_ENG
1
2
©KM
Fig. 11.21 PC 322-K

1 USB memory expansion 2 Memory expansion slot

USB memory expansion module for continuous saving of diagnosis files and
setting data at the visualization PC.
When replacing the PC, the module remains in the control cabinet and is inserted
in the new PC.
The memory size is 2 GB.
11.9.2 Signal extender plug-in module

• Module for implementation of the video signal and USB port on an Ethernet
cable CAT5e to the display unit TAE1922-K.
• Extender as plug-in module for PC 322-K.
• Video connection via display port, USB port connector type B.
• Voltage supply via internal PC connection.
11.9.2.1 Terminal assignment
MX_MC6_V1.9_07.09.15_ENG
Fig. 11.22 Terminal assignment of signal extender plug-in module PC 322-K

©KM
1 HMI link 3 DP IN
2 USB IN

11.10 Interface, laminar flow box (ZE)
1
2
3
4
5
6
Fig. 11.23 Laminar flow box

1 Lighting 5 Night setback on (with selection "Night setback over time")
2 Operation with laminar flow box 6 Night setback off (with selection "Night setback over time")
3 Ionization 7 Status of laminar flow box
4 Selection "Night setback"
In setting mode, the laminar flow box can be switched on with the selection
program "Operation with laminar flow box".
When the laminar flow box is switched on and there is a 0 signal at one of the
inputs, an alarm is issued.
In semi- and fully-automatic mode, the next cycle is blocked with the following
MX_MC6_V1.9_07.09.15_ENG
alarms:
• A02261 "Laminar flow box main filter clogged"
©KM
• A02262 "Laminar flow box not in production position"

• A02264 "Laminar flow box fan does not function"
Operation with/without laminar flow box is logged in the events log.
The status display shows the status of the inputs:
Red Fault (0-signal)

Green Ready for operation (1-signal)

Lighting
(1, fig. 11.23)
Switch lighting on/off.
Operation with laminar flow box

(2, fig. 11.23)
Switch laminar flow box on/off.
Ionization (option)
(3, fig. 11.23)
Switch ionization on/off.
Selection "Night setback"

(4, fig. 11.23)
Night setback off

The fan runs at standard speed.
Night setback on
The fan runs at lowered speed.
Night setback over time

The night setback speed is switched on and off according to week days and time.
11.10.1 Status of laminar flow box
11.10.1.1 Inputs
Input Function
-FFU_F_PREF Prefilter fault
-FFU_F_MAINF Main filter fault
-FFU_MONIT Fan monitoring
-FFU_POS_SW Switch position
-FFU_F_ION Ionization monitoring
11.10.1.2 Outputs
Output Function
MX_MC6_V1.9_07.09.15_ENG
-FFU_FON Fan on
-FFU_ION Ionization on
©KM
-FFU_LON Lighting on
-FFU_REVLO Night setback speed

11.10.1.3 Alarms
Alarm no. Alarm text

A02261 Laminar flow box main filter clogged
A02262 Laminar flow box not in production position
A02263 Laminar flow box prefilter
A02264 Laminar flow box fan does not function
A02265 Laminar flow box ionization fault
11.10.1.4 Step display
Step no. Alarm text

P01100 Laminar flow box fault
MX_MC6_V1.9_07.09.15_ENG
©KM

MX_MC6_V1.9_07.09.15_ENG
©KM

12 Auxiliary devices
In the order confirmation of the injection molding machine (scope of supply), the
installed auxiliary devices are identified by ZE numbers. The ZE numbers can be
used in these operating instructions as a search aid for accessing the descriptions
of the associated auxiliary devices.
12.1 Material hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820
12.2 Chip card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825
12.3 Quality statistics (ZE 89.6705) . . . . . . . . . . . . . . . . . 835
12.4 Master computer interface EUROMAP 63/SPI

(ZE 89.9485, 89.9486) . . . . . . . . . . . . . . . . . . . . . . . . 852
12.5 Bypass flow filter, replacing the filter element

(ZE 63.662) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 878
12.6 Bypass flow filter from SP 24500 (ZE 63.66) . . . . . . 880
12.7 Keyswitch (-S016) ejector/cores with open

safety gate (ZE 89.08), foot switch . . . . . . . . . . . . . 882
12.8 Water manifold (ZE 76.5xx, 76.7xx) . . . . . . . . . . . . . 886
12.9 Medium monitor (ZE 64.50) . . . . . . . . . . . . . . . . . . . 888
12.10 Display core-pulling, ejector and mold

clamping assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 890
12.11 Automatic feed unit (ZE 12.80, 12.81) . . . . . . . . . . . 893
12.12 Bar-pulling device . . . . . . . . . . . . . . . . . . . . . . . . . . . 949
12.13 Self-sufficient gas/water systems

(EUROMAP 62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 964
MX_MC6_V1.9_07.09.15_ENG
12.14 Magnetic clamping system

©KM
(ZE 45.695x, 89.57x) . . . . . . . . . . . . . . . . . . . . . . . . . 968
12.15 Mold heating KraussMaffei/PSG (ZE) . . . . . . . . . . . 989
12.16 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1011
Auxiliary devices 12-819

12.1 Material hopper
S
d
D
Risk of spraying
• Hot melt can be ejected at high speeds from the fill opening on the material
hopper.
Before removing the hopper block, the screw barrel must be purged
(see section 10.12.3.2, page 10-754)!
barrel must be known. Observe the instructions included in the safety data
sheet for the plastic.
Z
B
W
Important
The material hopper must be used for automatic material filling.
12.1.1 Attaching material hopper
w
D
Caution
• When mounting/dismantling the material hopper on the hopper sliding
mechanism, a secure and sturdy ladder or work platform must be used.
This must be provided by the owner/operator in accordance with the
directive on use of work equipment (89/655/EEC).
• Ensure that the clamping sleeve (1, fig. 12.1) is present and the stop bolt
(2) is inserted.
MX_MC6_V1.9_07.09.15_ENG
Failure to observe these instructions may result in the material hopper

falling down.
©KM
W
Important
• Tare weight of material hopper:
–  440 mm 12 kg,
–  540 mm 19.5 kg.
• The material hopper can be locked in three positions with the detent pin
(5, fig. 12.1).
12-820 Auxiliary devices

1) If necessary, strike in the clamping sleeve (1, fig. 12.1).

2) Secure the material hopper (4) with four securing bolts (6) to the guide
shoe (7).
3) Pull the detent pin (5) and, when doing so, push the material hopper with
guide shoe (7) onto the hopper sliding mechanism.
4) Coat the thread of the stop bolt (2) with Loctite.
5) Screw in stop bolt (2) and tighten it to a torque of 35 Nm.
3
1
7
5
Fig. 12.1 Material hopper

1 Clamping sleeve 5 Detent pin
MX_MC6_V1.9_07.09.15_ENG
2 Stop bolt 6 Securing bolt (4x)

3 Hopper cover 7 Guide shoe
4 Material hopper 8 Hopper sliding mechanism
©KM
r
d
D
Risk of slipping

12.1.2 Ladder (ZE 12.90)
12.1.2.1 Use of the ladder

The ladder (see fig. 12.2, page 12-822) is used for manual filling of the material
hopper on horizontal injection molding machines without robot bar pulling.
For this purpose, the ladder is attached to the top side of the control cabinet
beside the material hopper. The material hopper is filled from the ladder.
W
Important
• The machine or control cabinet must never be entered.
• Usage other than that described above is prohibited.
Fig. 12.2 Ladder

1 Material hopper 3 Control cabinet
2 Injection unit 4 Ladder
MX_MC6_V1.9_07.09.15_ENG
©KM
W
Important
• If the machine is filled manually, a suitable climbing aid must be used
(ladder). This must be available on site before the start of production and
must comply with local safety regulations.
• Never simply lean a ladder against the equipment.
• Observe safety distances in accordance with ISO 13857.

q
d
D
Danger of crushing
Moving components can cause crushing injuries.
The ladder must be positioned such that it is impossible to place your hands
into a machine danger area.
r
d
D
Risk of slipping
Risk of falling due to oily surfaces and scattered granulate.
The ladder must be safely secured against falling, tripping and slipping.
The area around the ladder must be kept clean.
12.1.2.2 Height compensation for ladder
Fig. 12.3 Ladder height compensation

1 Bar extension for height compensation
MX_MC6_V1.9_07.09.15_ENG
©KM
Bar extensions (1, fig. 12.3) are used to compensate the ladder height.

12.1.2.3 Support for ladder
Fig. 12.4 Support for ladder

1 Rubber buffer (on both sides)
I
Note
When installing the ladder, ensure that the rubber buffers bear against the
control cabinet.
12.1.2.4 Folding joint of ladder
1
2
3
4
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 12.5 Folding joint

1 Bracket locked 3 Platform
2 Folding joint 4 Bracket pressed down to release the folding joint
The platform (3, fig. 12.5) of the climbing aid can be adjusted by a folding joint (3)
by 65° and latches firmly into this position.
1) To unlock the folding joint, press the bracket (4) downwards.

12.2 Chip card

If the "Chip card reader" auxiliary device is fitted, the input authorization is granted
or revoked by inserting or removing the chip card.
Using the optional chip card protects the parameters of the MC6 control system
against unauthorized alteration. The key group enables access to screens and
parameters in a graded form. The user login (see section 8.3, page 8-360)
programmed on the card is entered into the logbook when the chip card is
inserted.
The card contains a chip and an magnetic strip on which the authorizations of the
control system can be programmed so that they can be used with a single card.
Access to the MC5 and MC6 control systems is via the chip. The magnetic strip
is used for access to the control systems MC4, MC3F and MC3.
1 2
Fig. 12.6 Chip card

1 Chip card, front 2 Chip card, rear
MX_MC6_V1.9_07.09.15_ENG
©KM

12.2.1 Control system-dependent user login

If a user with the same number is present on the control system as well as the
inserted chip card, only the user number from the chip card will be read.
The programmed data from the control system is used for user settings and
access rights.
If no user with the same number is defined on the control system, when the chip
card is inserted the key group of the user and the set language are adopted from
the chip card. Only the user number will be displayed.
I
Note
With a chip card programmed in MC5, a key group with the number of the
highest MC5 access level is generated automatically. All lower keys are added
in the MC6 control system of this group.
There is no automatic language change-over.
12.2.2 Input authorization with chip card
I
Note
Programming of the chip card is only possible if the tickbox "Chip card:
deactivated" is deactivated in the "Program chip card" pop-up window
(see fig. 12.9, page 12-829)!
The input authorization is granted when the chip card is inserted into the chip card
reader. The assigned user and rights are activated.
I
Note
• In an invalid chip card is inserted, the following fault message is displayed
in the information field: "Chip card not programmed or invalid".
• If the chip card is incorrectly inserted, the fault message "Chip card
incorrectly inserted." appears in the information field.
MX_MC6_V1.9_07.09.15_ENG
©KM

When the chip card is read in, the key group is activated and the following entry
is made in the events log:
• "Chip card inserted"
• "Code number: xxxxx"
• Text for active key group (operator, foreman, etc.)
On the "User login" button, users are shown their key group and the national flag
matching the set language in the header of the operating/display panel.
When the "User login" button is pressed, the "Login chip card" pop-up menu
appears:
4 1
3 2
Fig. 12.7 Login chip card

1 "Access rights" button1) 3 "User data" button 1)
2 "Language" button 4 "Units - setting" button
1) The button is only displayed to users in key group 4 or 6.
Buttons and functions (see section 8.3, page 8-360).
Removing chip card

When the chip card is withdrawn, level "0" (= no authorization) is activated. The
following entry is made in the events log:
• "Chip card withdrawn"
• "Code number: xxxxx"
MX_MC6_V1.9_07.09.15_ENG
©KM

12.2.3 Programming the chip card
I
Note
Programming of the chip card is only possible with key group 4 and 6.
12.2.3.1 Activating chip card

The "Login: password" pop-up window opens.
1 2 3 4 5 6

1 "Units - setting" button 6 "Language" button2)
2 "User data" button 1) 7 "x" button (abort)
3 "Access rights" button 1) 8 "Enter" button (confirmation)
4 "Program chip card" button 1) 9 Input field
5 "Login settings" button
MX_MC6_V1.9_07.09.15_ENG
1) The button is only displayed to users from key group 4 onwards.

2)
The button is only displayed if chip card access (1, fig. 12.9) is activated.
©KM
I
Note
Programming of the chip card is only possible if the tickbox "Chip card:
deactivated" is deactivated in the "Program chip card" pop-up window
(see fig. 12.9, page 12-829)!

2) Press the "Chip card" button (4, fig. 12.8).

The "Program chip card" pop-up window opens.
2
3
Fig. 12.9 Chip card, programming

1 "Chip card: deactivated" tickbox 4 Input of key group
2 User number 5 "Program chip card: start" button
3 "Language" button
3) Deactivate the tickbox "Chip card: deactivated" (1, fig. 12.9).

4) Proceed as follows to program:
• "Direct programming of the chip card (without user data from the control
system)" (see section 12.2.3.2, page 12-830)
• "Programming user data from the control system onto the chip card"
• "New creation of user data on the control system with activated chip card"
MX_MC6_V1.9_07.09.15_ENG
©KM

12.2.3.2 Direct programming of the chip card (without user data from the control system)
1) Perform work steps 1 to 3 in section 12.2.3.1.
2) Press the "User number" input field (2, fig. 12.9). Enter the user number in the
keypad and press the "Enter" button to confirm.
The pop-up window for language selection opens (see fig. 12.10,
page 12-830).
I
Note
machine.

MX_MC6_V1.9_07.09.15_ENG
The language is changed over after the next login.

5) Press the "Input of key group" (4, fig. 12.9) input field.
©KM
The pop-up menu "Selection of key group" opens (see fig. 12.11,
page 12-831).

1
2

1 "Create new key group" button 3 "OK" button
2 Button "Delete key group"
6) Selecting key group:

• Assigning existing key group:
Press the line of the desired key group and press the "OK" (3, fig. 12.11)
button to confirm.
The pop-up menu "Selection of key group" closes automatically.
• Creating a new key group
(see works steps 5 to 9 in section 8.3.1.4, page 8-368)
I
Note
Editing of already existing key groups is only possible by creating user data
7) Insert new chip card in the chip-card reader.

MX_MC6_V1.9_07.09.15_ENG
8) Press the "Program chip card: start" (5, fig. 12.9) button.
©KM
The chip card is programmed with the configured user data.

12.2.3.3 Programming user data from the control system onto the chip card
I
Note
Creating user data on the control system (see section 8.3.1, page 8-362).
Fig. 12.12 List of users

1 "Create new user" button 2 "Chip card programming" button
The pop-up window "Login: password" opens (see fig. 12.8, page 12-828).
MX_MC6_V1.9_07.09.15_ENG
5) Select existing user from the list.

©KM
6) Press the "Chip card programming" (2, fig. 12.12) button in the line of the
desired user.

12.2.3.4 New creation of user data on the control system with activated chip card
The pop-up window "Login: password" opens (see fig. 12.8, page 12-828).
4) Press the "Create new user" button (1, fig. 12.12).
Procedure for entering user data (see section 8.3.1.1, page 8-364).
I
Note
If a new user is created with the chip card activated, the password can be
omitted as an option. In this case, the password is declared invalid when the
user data is entered.
Subsequent access is then only possible via chip card.
With new created users without password, the programming of the chip card
must be complete. Otherwise no functions are available to the newly created
user.

6) Select user from the list (see fig. 12.12, page 12-832).
7) Press the "Chip card programming" (2, fig. 12.12) button in the line of the
desired user.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.2.4 RFID chip card

The 24″ Multitouch is equipped with an RFID system (Radio Frequency
IDentification).
The RFID transponder on the chip card allows permits non-contact user
authentication at the display.
1 2
Fig. 13 Authentication with RFID chip card

1 RFID symbol at the glass display 2 Chip card with RFID transponder
Logging in with RFID chip card

1) Ensure that the 24″ Multitouch is switched on.
2) Hold the chip card with RFID transponder for one to two seconds in front of
the RFID symbol on the glass display at the bottom left (see Fig. 13).
The chip card contains personalized settings of the operator, such as

• Access rights
• Language setting
• Screen configuration.
These settings are personalized and activated during login at the glass display.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.3 Quality statistics (ZE 89.6705)
12.3.1 Quality statistics overview
1 2 3 4 5 6 7
8
9
Fig. 12.14 Quality statistics overview (1/2)

1 Column "Number" 6 Column "Start / stop quality statistics"
2 Column "Parameter" 7 Column "Start / stop calibration"
3 Column "Configuration of control chart" 8 Button "Start all synchronously"
4 Column "Configuration of test data" 9 Button "Start all synchronously (calibration)"
5 Column "Current random samples"
MX_MC6_V1.9_07.09.15_ENG
Within quality statistics it is possible to combine the actual values of selected

parameters (actual value cycles) in accordance with the specified test schedule
©KM
to form random samples (batches).

Mean values and standard deviations are calculated from the values of the
random sample and shown in curve charts as x/s control charts.
Trend monitoring and calculation of the intervention limits allows the calculated
values to be assessed in terms of their process capability.
The aim is to assess the harmonization of the process with the specified quality
requirements using mathematical-statistical evaluation methods (Ensuring
Quality before Series
Application, VDA 1986).

Only "statistically relevant" parameters (actual values) may be selected for

monitoring.
Control parameters, e.g. temperatures, are not statistically relevant as a control
compensation is made if a variation exists between actual value and set value.
These parameters can be monitored with the trend graph (see section 8.12.2,
page 8-589).
The quality statistics settings are configured and the control charts are activated
for all 10 quality statistics screens on the screen page "Quality statistics overview"
(see fig. 12.14, page 12-835).
Number
Number of quality statistics (1, fig. 12.14)
Parameters
Display of selected parameters (2)
Configuration of control chart

The control chart is configured using the button in the (3) column.
Configuration of test data

The test data is configured using the button in the (4) column.
Current random samples

Display of the current number of random samples (5)
Start / stop quality statistics

Pressing the button in column (6) starts and stops the quality statistics. The
current status of the quality statistics is displayed by the green LED next to the
button. If the quality statistics have started, this is indicated by a green illuminated
LED. The LED is not illuminated when the quality statistics have stopped.
Start / stop calibration

Pressing the button in column (7) starts and stops the quality statistics calibration.
The current status of the quality statistics calibration is displayed by the green
LED next to the button. If the calibration has started, this is indicated by a green
illuminated LED. The LED is not illuminated when the calibration has stopped.
With the button "Start all synchronously" (8) and "Start all synchronously
MX_MC6_V1.9_07.09.15_ENG
(calibration)" (9) all quality statistics (control charts) can be started synchronously
©KM
in normal operation or in calibration operation.

Fig. 12.15 Quality statistics overview (2/2)

1 Button "Stop all synchronously"
As soon as quality statistics are started in normal operation or custody transfer

operation, the buttons "Start all synchronously" (8, fig. 12.14) and "Start all
synchronously (calibration)" (9) are no longer displayed. Instead the button "Stop
all synchronously" appears (1, fig. 12.15), which can synchronously stop the
quality statistics (control charts).
MX_MC6_V1.9_07.09.15_ENG
©KM

12.3.2 Configuration of control chart
4
5
6
7
Fig. 12.16 Quality statistics, configuration of the control chart (1/2)

1 Button "Parameter selection" 5 Input field "Upper size specification"
2 Selection field "Cycle or time interval" 6 Input field "Lower size specification"
3 Input field "Random sample volume" 7 Input field "Random sample calibration"
4 Input field "After cycle / time interval"
The control chart configuration is shown on the "Quality statistics overview"

screen page (see fig. 12.14, page 12-835) by pressing the button in the
"Configuration control chart" column (3, fig. 12.14). The following settings can be
configured in the open dialogue window:
• Parameter selection
• Random sample selection based on cycle or time interval
• Random sample volume
• After cycle or time interval
• Upper specification limit (OSG)
• Lower specification limit (USG)
• Random samples for calibration
MX_MC6_V1.9_07.09.15_ENG
©KM

12.3.2.1 Parameter selection

1 Parameter list
In the "Configuring the control chart" dialogue window, pressing the "Parameter
selection" button (1, fig. 12.16) opens the "Parameter selection" pop-up window.
In the parameter list (1, fig. 12.17) the parameter to be monitored in the control
MX_MC6_V1.9_07.09.15_ENG
chart can be selected.

The control chart last saved in the history for the specified parameter supplies the
©KM
control chart default values.

If no chart has been stored in the history, all values are populated with the default
settings. The input range for upper and lower specification limits (OSG, USG), as
well as upper and lower input limits (OEG, UEG) is limited by the input range of
the selected parameter.

12.3.2.2 Test schedule inputs
Fig. 12.18 Quality statistics, configuration of the control chart (2/2)

1 Selection field "Cycle or time interval" 2 Input field "After cycle / time interval"
Selection of cycle or time interval
Based on cycle interval

With the selection "After cycle interval" a random sample is formed after a set
number of cycles have elapsed.
The designation on input field (4, fig. 12.16) opens up "After cycle interval". In
input field (4) a value between 1 and 99 can be entered.
Example:
If the input is 20, the formation of a random sample commences after 20 cycles.
After a random sample has been formed, the commencement of the next random
sample begins after 20 cycles, etc.
Based on time interval

With the selection of "After time interval" a random sample is formed after a set
time has elapsed.
MX_MC6_V1.9_07.09.15_ENG
The designation on input field (2, fig. 12.18) opens up "After time interval". In input
©KM
field (2) a value between 0 and 10000 can be entered.

If 10 is entered, the formation of a random sample commences after 10 s, etc.
Random sample volume

Number of cycle measured values from which a random sample is formed.
Example:
If 10 is entered, a random sample is formed from 10 successive cycles of actual
values in accordance with the cycle and time interval settings.

Upper specification limit (OSG)

Upper specification limit based on customer specification
Lower specification limit (USG)

Lower specification limit based on customer specification
Upper intervention limit (OEG)

Upper tolerance limit, which should be set about 10% below the upper
specification limit (OSG). If the upper intervention limit is exceeded, a white alarm
is activated.
Lower intervention limit (UEG)

Lower tolerance limit, which should be set about 10% below the lower
specification limit (USG). If the lower intervention limit is exceeded, a white alarm
is activated.
Random sample calibration

The calibration is automatically completed after the configured number of random
samples.
12.3.3 Function selection, control chart

The control charts in normal operation or calibration operation can be individually
(6, fig. 12.14) or synchronously started (8/9) or stopped (1, fig. 12.15) on the
"Quality statistics" overview screen page.
The aim of calibration is to determine the intervention limits, "Lower intervention

limit" and "Upper intervention limit", as well as the machine capability indices Cm
and Cmk automatically for the parameter which is being monitored.
The intervention limits are automatically determined in calibration or they can be
manually entered on individual control charts and on control charts which have
already started.
During calibration, the number of random samples (7, fig. 12.16) can be entered
in addition to all other control chart settings.
Once the calibration has been activated, the defined number of random samples
is collected according to the set test schedule. The number of measured values
for each random sample (3, fig. 12.16) must be defined in such a way as to
MX_MC6_V1.9_07.09.15_ENG
minimize the natural fluctuation band within the random sample. A typical random
©KM
sample volume, both for calibration as well as for process monitoring, is 4-5.
After each random sample is detected, the intervention limits as well as machine
capability indices "Cm" and "Cmk" are recalculated. Calibration is completed
automatically after the specified number of random samples (7, fig. 12.16)
provided it is not terminated manually (7, fig. 12.14) before this.

12.3.4 Configuration of test data
Fig. 12.19 Configuration of test data (1/2)

1 Selection field "Test data"
On the "Quality statistics overview" screen page, the test data is configured by
pressing the button in the "Test data configuration" column (4, fig. 12.14).
From the assessment of the SPC software according to Ford, Test 1 and Test 3
have been incorporated into the MC6 control system as permanent test data
records. Both can be selected in the selection field (1, fig. 12.19).
Fig. 12.20 Configuration of test data (2/2)

MX_MC6_V1.9_07.09.15_ENG
©KM
In addition, any raw data in the form of a text file (with the extension "TXT") can
be imported for evaluation from a USB stick (see fig. 12.20, page 12-842) into the
quality statistics as test data (no random samples).
These raw data items must be separated from each other by a separating
character such as a blank character or TAB. After the test data have been
imported, it is possible to start quality statistics for any desired control chart.

Example for the contents of a test file:

19.993
19.995
19.997
19.995
19.999
20.006
20.010
20.010
20.022
20.002
19.958
19.982
I
Note
A comma is not recognized as separating character as it is used for comma
places in the raw data.
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 12.21 Configuration of test data (external test data)

After the selection of external test data from a USB stick, an additional pop-up
window (see fig. 12.21, page 12-843) appears, into which the following settings
for test data can be entered:
• Unit (select from the pool of available MC6 units)
• Test data designation (text is applied in the parameter column
(2, fig. 12.14)
• Customer
• Article
• Order
12.3.5 Quality-statistics, control chart
1 2 3 4 5 6 7
13
12
11 8
10
9
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 12.22 Quality statistics, x control chart

1 Selection "Quality statistics overview" 8 Display control chart results
2 Production data 9 Selection of Histogram
3 Display the selected parameters 10 Selection x/s control chart
4 Status display control chart 11 x control chart
5 Button "Quality statistics history" 12 Line for random sample selection
6 Tabs for Selection of quality statistics 1-10 13 Display of the random sample values
7 Display random sample selection

The selection of quality statistics (control chart) from 1-10 can be made by means
of the tabs (6, fig. 12.22).
Production data
The production data (2) such as Order, Customer and Article are specified on the
"Set-up and production data 1" screen page (see fig. 8.157, page 8-633).
Display quality statistics

The upper and lower intervention limits are each displayed as a continuous line
in the x/s diagrams.
The number of random sample is stated at the X axis. Up to 150 random samples
can be shown as a graph in a control chart. If there are more than 150 random
samples illustrated, these are automatically stored. The graphic representation in
the control chart is repeated at 1.
Parameter Description
Cycle from ... to ... No. Display of cycle number for the first/last random sample.
3 Display of total mean value of the calculated random sample mean
values.
2 Display of mean value of the random sample last detected.
Xmax./Xmin Maximum/minimum value of the recorded random sample mean
values.
Measuring line A measuring line is shown in the control chart (see section 12.3.7,
page 12-849)
4 Display of mean value of all random sample standard deviations.
s Display of standard deviation of the random sample last carried out.
Cp/Cpk Display of process capability.
Cm/Cmk Display of machine capability.
X/s control chart

By touching the left thumbnail (10, fig. 12.22) with the letter "X" below the image,
the X control chart is selected and enlarged in the centre of the screen. The
random sample mean values and the mean value of the random sample mean
values are displayed in the x control chart (11, fig. 12.22) (light blue line in the
diagram) (12, fig. 12.22).
MX_MC6_V1.9_07.09.15_ENG
By touching the centre thumbnail (10, fig. 12.22) with the letter "S" below the
©KM
image, the S control chart is selected and enlarged in the centre of the screen.
The random sample standard deviations and the mean value of the random
sample standard deviations are shown in the s control chart.

Histogram
Fig. 12.23 Quality statistics, Histogram
By touching the right thumbnail (9, fig. 12.22) in the lower part of the screen, the
histogram is selected and enlarged in the centre of the screen (see fig. 12.23,
page 12-846).
Distribution of the measured values (raw data) for the selected control chart is
displayed in the histogram.
The distribution of the measured values can be compared with the curve of the
normal distribution which is shown.
This display makes it possible to determine whether the monitored parameter has
a normal distribution.
MX_MC6_V1.9_07.09.15_ENG
If a major deviation exists from normal distribution, the quality statistics

©KM
statements are irrelevant.
Display of quality statistics
-/+ 4 s
Number of measured values (raw data) in [%] in the histogram range displayed
from -4s up to +4s (s = standard deviation).
The mean value of the mean values and the highest point of the curve for the
normal distribution lie in the middle of the histogram.

12.3.6 Quality-statistics history

A maximum of 20 control charts per quality statistics screen (1-10) can be
recorded. For additional control cards, for each quality statistics screen (1-10), the
oldest will always be deleted and cannot be restored.
Fig. 12.24 Quality statistics history
Touching the button (5, fig. 12.22) opens a pop-up window (see fig. 12.24,
page 12-847) with the selection of quality statistics history. In the scroll list, the
desired control chart can be chosen from a maximum of 20 control charts.
The selected control chart from the history is displayed after pressing the "OK"
button. A number between n-1 and n-19 (2, fig. 12.25) appears on the button
(5, fig. 12.22) based on the control chart selected.
MX_MC6_V1.9_07.09.15_ENG
©KM

Fig. 12.25 Quality statistics history

1 "Export" button 2 Number of the control chart
For a control chart displayed from the history, an additional "Export" button
appears (1, fig. 12.25), allowing the control chart to be exported to a USB stick in
text format (readable by MS Excel).
What is exported is the set test schedule, the results of measurements and all
random samples.
I
Note
These exported files can be stored or used for evaluations e.g. in Excel.
Exported files cannot be imported into the quality statistics.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.3.7 Measuring line
1
2
Fig. 12.26 Quality statistics, measuring line

1 "Measuring line" checkbox 2 Diagram header
A measuring line can be activated in the control chart using the "Measuring line"
checkbox (1, fig. 12.26). When the measuring line is activated this appears
simultaneously in both control charts x and s. According to the position of the
measuring line, random sample data are displayed in the diagram header
(2, fig. 12.26):
• Cycle number
• Date and time of the random sample (first single value of a random
MX_MC6_V1.9_07.09.15_ENG
sample)
• Random sample value
©KM
Forming a random sample

The mean value and the standard deviation are calculated from several
successive cycle actual values, and the time stamp and cycle number of the first
cycle actual value are also registered.

12.3.8 Process capability and stability investigation

If the following criteria in respect of the mean value and standard deviation are
met, we talk of a statistically not controlled process:
• one or several points are outside of the intervention limits
• 7 points in succession are on one side of the mean value curve
• 7 points in succession rise or drop constantly.
The following applies to the mean value:

• fewer than 2/3 of the points are within the mid-range between the intervention
limits.
A separate white alarm A00321-A00330 "Quality statistics" is generated for each

control chart if the stability conditions are violated.
Fig. 12.27 Quality statistics, stability display

1 "Stable" LED 2 "Process capable" LED
The points in the control chart are marked in red if at least one criterion applies.
In addition, the status is indicated by the "Stable" LED (1, fig. 12.27). In the event
that the stability is violated, the LED lights up red.
After each random sample the following values are recalculated:
• Mean of mean values
MX_MC6_V1.9_07.09.15_ENG
• Mean value of the standard deviations s,

• Process capability indices Cp and Cpk.
©KM
The two current mean values are displayed and entered in the relevant chart as
a mean value curve.
The process capability investigation can only be carried out in the case of a
process which is statistically controlled and only if OSG > 0. If these prerequisites
are not met, the status is indicated by the "Process capable" LED (2, fig. 12.27).
If the status "Not process capable" occurs, the LED lights up red.
The process capability indices Cp and Cpk are calculated and displayed.

I
Note
The Cp index takes into account only the scatter of a process.
The Cpk index takes into account not only the scatter of the process but also
the position of the mean value of the frequency distribution in relation to the
specification limits.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.4 Master computer interface EUROMAP 63/SPI

(ZE 89.9485, 89.9486)
12.4.1 Description of standard EUROMAP 63/SPI

The standard EUROMAP 63 aims to standardize the central computer interfaces
of the injection molding machines from different manufacturers and thus facilitate
communication between these machines.
The standard describes an interface, the commands and data of which are
transferred by means of files.
EUROMAP 63 defines the following functions:

• Transfer of the setting data to the master computer (upload).
• Transfer of the setting data to the machine control system (download).
• Production of reports with set value, actual value and status outputs
according to freely programmable criteria;
e.g.: the Cycle time, Melt cushion, Mold cavity pressure measurement values
are to be logged in a report file for each machine cycle.
• Setting (changing) configuration parameters.
The parameter names of the machine are only partially defined in the standard.
Other parameters must be treated as manufacturer-specific parameters
(see section 12.4.7.2, page 12-870).
Machine with the EUROMAP 63/SPI option have the following components:
• Hardware interface
– 10/100 BaseT ETHERNET
– RJ45 connector
• Software interface
– TCP/IP protocol (Transmission Control Protocol/Internet Protocol)
– FTP protocol (File Transfer Protocol)
– EUROMAP 63 protocol
12.4.2 Contact assignment Ethernet 2 X4

MX_MC6_V1.9_07.09.15_ENG
1 Tx+
2 Tx-
©KM
3 Rx+
8 1 4-5 Not assigned
6 Rx-
7-8 Not assigned

12.4.3 File transfer
I
Important
The EUROMAP 63 interface is not real-time-compatible. For this reason, the
data transfer time may exceed the time that is necessary for certain partial
cycles of the production cycle.
The file transfer between the machine control system and the master computer
takes place via the Ethernet interface (network connection). The machine control
system retrieves the data from the Session directory in the master computer by
means of polling. The response files are written directly by the machine control
system onto the hard disk of the master computer.
Fig. 12.28 Ethernet interface
There are two options for the file transfer:

• FTP server
• Enabled drive at server computer.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.4.3.1 Requirements for the master computer
W
Important
Trouble-free FTP communication can only be guaranteed with FTP servers
approved by KraussMaffei. Recommendations for FTP servers for different
operating systems are available from KraussMaffei Service.
Requirements for the master computer:

• If data exchange is to take place via FTP, an FTP servers recommended by
KraussMaffei must be installed.
• If data exchange is to take place via an enabled drive, the drive has to be
enabled at the master computer.
• The master computer must arrange the commands in accordance with
EUROMAP 63 in files and save them in a specific area (Session directory in
the master computer).
12.4.3.2 Requirements for the machine control system and the network
Requirements for the machine:
• File transfer protocol EUROMAP 63/SPI (ZE 89.9485)
• The interface function EUROMAP 63/SPI must be configured in the machine
control system (see section 12.4.4.2, page 12-859).
MX_MC6_V1.9_07.09.15_ENG
©KM

12.4.4 Interface function at the machine
12.4.4.1 Network (network settings)

The network settings are selected from the menu functions in the header of the
operating/display panel. Access level 4 is required to make the network settings.
Press the "Network settings" button and the pop-up window "Network settings,
Ethernet INTERNAL" opens.
Fig. 12.29 Network settings, Ethernet INTERNAL

1 Button "Ethernet INTERNAL"
If no options for network connections or functions are set, access is possible to

the machine-internal network only. The machine-internal network occupies the
address range 10.100.100.xxx. This address range is thus reserved and cannot
be used for further network connections.
When the "Ethernet INTERNAL" (1, fig. 12.29) button is actuated, the pop-up
window for setting Euromap 63/SPI: ETHERNET Internal (see fig. 12.30,
MX_MC6_V1.9_07.09.15_ENG
page 12-856) opens.

©KM

1
2
3
4
6
5
Fig. 12.30 Settings for Euromap 63/SPI, Ethernet INTERNAL

1 "MAC address" display 5 "All (no filter)" tickbox
2 "Own TCP/IP address" display 6 Button "Ethernet INTERNAL"
3 "Subnetwork mask" display 7 Button for connected devices
4 "Router/Gateway address" display
Press the "Ethernet INTERNAL" (6, fig. 12.30) button to send a ping to all
predefined Ethernet addresses. In the lower section of the pop-up window, the
connected devices (7) with their addresses and designations are displayed.
The buttons (7) send a ping to the devices and display a positive response with a
green LED.
If "All (no filter)" (5) is selected, pings are sent one after the other to all addresses
in the internal address range from 10.100.100.1 to 10.100.100.255 and all
MX_MC6_V1.9_07.09.15_ENG
recorded devices are displayed. This also permits the detection of auxiliary
©KM
devices and external devices in the internal network that were not predefined.

Fig. 12.31 Network settings, Ethernet EXTERNAL

1 Button "Ethernet INTERNAL" 3 Button "Euromap 63"
2 Button "Ethernet EXTERNAL"
If option 787 (Ethernet EXTERNAL) and option 856 (Euromap 63), their settings
can also be selected.
Actuate the "Ethernet EXTERNAL" (2, fig. 12.31) button to open the pop-up
window for setting Euromap 63 (see fig. 12.32, page 12-858).
MX_MC6_V1.9_07.09.15_ENG
©KM

1
2
3
4
Fig. 12.32 Settings for Euromap 63/SPI, Ethernet EXTERNAL

1 "MAC address" display 4 "Router/Gateway address" display
2 "Own TCP/IP address" display 5 Button "Ethernet EXTERNAL"
3 "Subnetwork mask" display 6 Button for connected devices
In the (1, fig. 12.32) field, the MAC address (hardware address of the Ethernet
interface) is displayed.
The following details can be set:
• Own TCP/IP address (2)
• Subnetwork mask (3)
• Router/Gateway address (4)
The input is made by actuating the respective button beside the display field via
a value input window (see fig. 12.33, page 12-859). The input data is accepted by
MX_MC6_V1.9_07.09.15_ENG
actuating the "OK" button.

©KM
The operation of your own interface (Ethernet EXTERNAL) can be tested using
the "Ethernet EXTERNAL" (5, fig. 12.32) button. If target addresses are defined
from the function (e.g. Euromap 63), a ping can be sent to it by actuating the
assigned button. A positive response is indicated by a green LED in the button (6).

Fig. 12.33 Value input
A special input window "Value input" with a numeric keyboard is used for address
setting. Each address consists of four input values. When the OK button is
actuated, the set values are adopted in the pop-up window that appears.
Text input, e.g. the designation of the session list, is made on the alphanumeric
keyboard (see section 6.3.3.2, page 6-248).
12.4.4.2 Euromap 63 (network settings)
2
MX_MC6_V1.9_07.09.15_ENG
3
©KM
Fig. 12.34 Network settings, Euromap 63

1 Button "Ethernet INTERNAL" 3 Button "Euromap 63"
2 Button "Ethernet EXTERNAL"

Access to the data for setting the "Euromap 63" function is made possible via the
pop-up window "Network settings". Actuate the "Euromap 63" (3, fig. 12.34)
button to open the pop-up window "Settings Euromap 63/SPI: Euromap 63"
(see fig. 12.35, page 12-860).
1 7
2 8
9
3 10
4 11
5
12
6
13
14
15
16
Fig. 12.35 Settings Euromap 63/SPI: Euromap 63

1 "Network drive" tickbox 9 "Time delay for request" input
2 "FTP server" tickbox 10 "Euromap 63 on/off without monitoring" tickbox
3 Network drive input "Name" 11 "With recording in logbook, reduced" tickbox
4 "Network drive" list input 12 "With recording in logbook, extended" tickbox
5 "Login: user name" input 13 "With saving of logbook for diagnostics data" tickbox
6 "Login: password" input 14 Button for saving "Additional parameters (USB stick)"
7 Input of Euromap 63 data file "Name" 15 Button for loading "Additional parameters (USB stick)"
8 "List of SESSION-datafiles" input 16 Button for "Test page for Euromap 63/SPI"
On the left half of the screen page "Settings Euromap 63/SPI: Euromap 63", the
settings for access to the master computer can be made. Access is possible via:
• FTP server (2, fig. 12.35)
MX_MC6_V1.9_07.09.15_ENG
• Enabled drive at server computer (1).

©KM
Depending on the selection of access via FTP server or network drive, the view
of the pop-up window adapts (see fig. 12.36, page 12-861)/(see fig. 12.37,
page 12-861).
All entries and changes that were made in the pop-up window are only adopted
after the OK button has been actuated.

Access via FTP server
2
3
4
5
Fig. 12.36 Settings Euromap 63/SPI, access via FTP server

1 "FTP server" tickbox 4 "Login: password" input
2 "TCP/IP-address" display/input 5 "Send ping" tickbox
3 "Login: user name" input
1) Specifying TCP/IP-address of FTP server.

Actuate button beside the display field (2, fig. 12.36) and enter via value input
window that appears.
2) Enter user name (3) and password (4).
3) Send ping to the server if necessary via the selection "Send ping" (5) (for
detection of the server and if permitted by the firewall rules).
Access via network drive
2
3
MX_MC6_V1.9_07.09.15_ENG
4
©KM
Fig. 12.37 Settings Euromap 63/SPI, access via network drive

1 "Network drive" tickbox 4 "Login: user name" input
2 "Name" input 5 "Login: password" input
3 "Network drive" input

1) Enter the network drive with server name in the network and the name of
enabled list in the field (3, fig. 12.37).
2) If necessary, enter user name (4) and password (5) to secure access.
Fig. 12.38 Settings Euromap 63/SPI: Euromap 63 data

1 "List of SESSION-datafiles" input 2 "Euromap 63 on/off without monitoring" tickbox
The Euromap 63 data is displayed on the right screen half of the pop-up window
"Settings Euromap 63/SPI: Euromap 63" (see fig. 12.38, page 12-862):
Name
Name of the Euromap 63 file with settings data
List of SESSION-datafiles
In the "List of SESSION-datafiles" input field, the following formats are permitted
for specifying the lists:
• The session list is empty.
– FTP server
The root directory of the user defined in the FTP server is also the
MX_MC6_V1.9_07.09.15_ENG
session list.
©KM
– Enabled network drive:

The enabled network drive is the session list.
I
Note
When entering a session list, empty input areas are not permitted. If no input is
made, at least one blank must be entered. If only one blank is entered, this is
interpreted as an empty session list.

• D:\xxxx\yyyy
This specification, starting with a drive letter, designates an absolute list.
This version is available with one FTP server only.
• Xxx\yyyy
This input designates a relative list.
– FTP server
The specified list is based on the root directory of the user in the FTP
server.
– Enabled network drive:
The specified list is relative to the enabled network drive.
Time delay for query

This parameter defines the sampling times [s] at which the session files are read
by the FTP server. The default time is set to 4 s.
Euromap 63 on/off without monitoring

The Euromap 63 function is activated if the function is selected via the tickbox
(2, fig. 12.38).
With recording in logbook, reduced

When this function is activated, recording of the communication in the logbook is
started. The reduced recording only shows the commands and the transferred
files.
With recording in logbook, extended

The extended recording additionally shows file contents.
I
Note
Recording into the logbook places an additional load on the control system, i.e.
communication becomes slower. For this reason, recording should only be
activated when necessary.
With saving of logbook for diagnostics data

When this function is selected, the data is saved in the MC6 logbooks.
Additional parameters (USB stick)

MX_MC6_V1.9_07.09.15_ENG
The "Load" and "Save buttons can be used to import additional parameters from
©KM
a USB stick or to save onto a USB stick.
Test page Euromap 63/SPI

When this button is actuated, the pop-up window "Test page Euromap 63/SPI:
Euromap 63" (see fig. 12.39, page 12-864) appears.

Fig. 12.39 Test page Euromap 63/SPI: Euromap 63
Status display
In the header of the screen page in the area of the status displays (6, fig. 6.5), the
status of the Euromap 63 interface is displayed.
Fig. 12.40 Euromap 63, status display

1 Status symbol Euromap 63
The status symbol has a coloured background:

MX_MC6_V1.9_07.09.15_ENG
• Grey: The Euromap 63 function is deactivated.

• Green: The Euromap 63 function is active.
©KM
• Red: fault, the Euromap 63 function is inactive.

12.4.4.3 Configuration for teleservice (network settings)
Fig. 12.41 Configuration for teleservice (network settings)
The address of the machine and its network access is set in the screen in the
"Configuration for Service box" area.
MAC address of the service box

The MAC address is the Ethernet plug-in card address. It is required for setting
routers or gateways.
Own address used

The device's own address has to be specified.
MX_MC6_V1.9_07.09.15_ENG
Serial number of the service box

©KM
The serial number of the service box is displayed.
Setting for addressing

The addressing is set in the selection menu:
• DHCP
• Address

Own TCP/IP address

TCP/IP address in the network for unique identification and addressing of the
machine.
Subnetwork mask
For addressing the necessary subnet mask.
Router/Gateway address
Address of router or gateway and subnet mask.
Setting new data

Settings are adopted by actuating the pushbutton.
SCEP connection
The SCEP connection is activated and deactivated in the selection menu.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.4.5 Notes for the programmer of the master computer
Master computer FTP server /

program network activation
Session file
with session command Response files
in session list
Job file
Master computer with job commands
MC6 control system
Session phase Get job Execute job
MC6 polling
Session file
N Session file Job condition

Get job file
available? testing
OK
N N
Get OK? Start?
Session file
get
OK OK
OK
Get OK? Test syntax Execute job
N
OK OK OK?
Fault warning Job OK?
Session response N
N
Fault warning
MX_MC6_V1.9_07.09.15_ENG
Job response
Fault warning
©KM
Job response
OK
Cyclic?
Session response
OK
N
Fig. 12.42 Diagram of communication flow

12.4.5.1 Measures for safe communication

All jobs are deleted when the machine is switched off.
The master computer must, therefore, monitor whether the communication is
running, i.e. whether the machine is switched off or not reacting. For this, there
are the commands CONNECT and GETINFO.
The simplest method is to start a job that regularly (e.g. every 30 s) generates a
monitoring REPORT.
If the report file is not present after the time, then the connection has been
interrupted. If there is no connection, CONNECT should be used to check
whether communication is possible. If the connection is available again, then
GETINFO should be used to check whether the monitoring REPORT is still active.
If it is not active, the machine was switched off and all jobs have been deleted.
If communication restarts and jobs are restarted, the status of the available data
files from the last communication must first be checked or the data must be saved
and all files in the session list and in the data reception list must be deleted.
The MC6 transfers files with a temporary name and does not rename them until
the content has been written completely. In the event of an abnormal interruption
to the communication, temporary files are located in the target directories. To be
safe, these files should be deleted.
All session and job response files must be deleted immediately when they have
been checked. If a file does then not exist, it is generated anew by the MC6
control system. If the file exists, this indicates that a response has been received.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.4.6 General Notes
12.4.6.1 Language
The standard language of the Euromap 63/SPI is English. All fault messages for
communication via the interface in the session or job response files are, therefore,
in English. Each fault message is identified according to Euromap 63 with a
unique number and can be converted to a language-specific text by the master
program.
12.4.6.2 Code set

The current code set of the machine control system is used. In foreign languages
(i.e. not English), it may be necessary to adapt the special characters in the
master computer software.
12.4.6.3 File access and maintenance of the master computer

All files are first generated with a temporary name and then renamed to the
original name when the system has finished writing them. This regulates the
access between the master computer program and the machine control system,
in order to ensure that no data is lost.
W
Important
The data stored in the master computer must be reorganized regularly, in order
to make optimum use of the storage capacity of the master computer.
12.4.6.4 Communication faults

Switching off the machine control systems and the master computer causes faults
in the network. The Euromap 63 software attempts to compensate for the effects
of these faults by repeating and reconstructing. Nevertheless, the master
computer program should also have a disposal and restart strategy.
Once the control system has been switched off, all jobs are deleted. The
CONNECT command must be used to test whether the control system is still
connected to the network. If there was a failure, the jobs have to be transferred to
the machine again.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.4.6.5 Comments on list and file names

According to Euromap 63, all string specifications must be identified with "...".
This also applies to list and data file names.
The FTP communication does not allow spaces in the name. The names must be
set in FAT16 format, i.e. max. 8 characters and 3 characters after a dot
(e.g: 12345678.DAT).
W
Important
All directories used must exist. The Euromap function does not create
directories. The read and write access to the directories must be enabled.
12.4.7 Restrictions, special features and extensions for MC6 control systems
12.4.7.1 Sequence of session file processing

The SESSION files are not processed in the same sequence as their numbering.
If several jobs are to be started, whose sequence is important (e.g. ABORT and
then restart of the job), the session response has to be waited for.
12.4.7.2 Parameter names and values

There are 2 types of parameter values labelled as follows:
Numerical only numbers and commas

Text alphanumeric characters, max. 20 characters long
In addition to the Euromap 63 parameters, there is also access to MC6-specific

parameters. These parameters must always begin with the @ symbol. Not all
MC6-specific parameters have a parameter name text. The list of KraussMaffei-
specific parameters can be found in the master computer documentation or it can
be obtained with the GETID command.
12.4.7.3 Wildcard parameter names

Parameter names with [*.*] are not permitted.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.4.7.4 Upload and download

Key words are defined for upload and download functions instead of a data file
name. KraussMaffei-specific key words begin with the _ symbol
(e.g.: _MESSAGE).
ACTIVE Upload of current setting data.

On the MC6, the setting data can consist of several files.
Download of setting data
Automatic loading of setting data is not permitted.
Therefore, the setting data on the Compact Flash is
created with the name ACTIVE, which can then be loaded
and started by the operator.
KraussMaffei-specific keywords
_MESSAGE only with download command

For loading a notification text, which must be located in the
specified file. The text can be an ASCII text (see also
Unicode) with maximum 39 characters.
If a message is loaded to the MC6 with download, a

message window opens on the MC6 operating panel and
displays the notification text.
_LISTMASKS only upload command
List of screen masks of the MC6 control system.
_SCREENSHOT only upload command
<no> Opening the screen mask <no>, storing as a BMP file and
upload of the BMP file. Without <no> the current screen
mask is displayed.
_SAVECYCFILE only upload command
Get export file for cycle data

The first time the file is acquired, all data is acquired and
the time of acquisition is stored. Every time the data is
acquired subsequently, the stored time is set as the
starting time and the current time is stored. The current
MX_MC6_V1.9_07.09.15_ENG
time is always the end time.

©KM
_SAVELOGFILE only upload command

Get export file of the protocol data
SAVECYCFILE acquisition time
_RESET only upload command
Reset of the starting times for SAVECYCFILE and
SAVELOGFILE

Upload and download setting data
I
Note
The source file name must always be specified without an extension, i.e.
<name> and not <name>.<extension>.
When downloading, it is not possible to overwrite the target file in the archive. If
the target file name starts with a minus sign, the target file is deleted. The data
record is written to the Compact Flash.
The data record is loaded on the "Load/Save data record" screen
On the MC6 control system, a data record consists of several files.
Once the last file has been transferred, a completion message is entered in the
response file (log file) of the job:
COMMAND 0 PROCESSED "UPLOAD FILES"

or
COMMAND 0 PROCESSED "DOWNLOAD FILES"
MX_MC6_V1.9_07.09.15_ENG
©KM

12.4.8 Examples of Euromap 63/SPI commands
12.4.8.1 Syntax session file
1. Session file 00000000 CONNECT;
12.4.8.2 Syntax job files
2. Session file 00000001 EXECUTE "GETINFO.JOB";

Job file //
// Get information via the control system and interface
//
JOB GETINFO RESPONSE "GETINFO.LOG";
GETINFO "INFO.DAT";
3. Session file 00000001 EXECUTE "UPL_ACT.JOB";
Job file //
// Get the current data record
//
JOB UPL_ACT RESPONSE "UPL_ACT.LOG";
UPLOAD "DATA" ACTIVE START IMMEDIATE;
4. Session file 00000001 EXECUTE "DWN_ARCH.JOB";
Job file //
// Download the DATA data record to the
// Compact Flash of the control system with the name TEXTDWN
//
JOB DWN_ARCH RESPONSE "DWN_ARCH.LOG";
DOWNLOAD "DATA" "TESTDWN" START IMMEDIATE;
5. Session file 00000001 EXECUTE "DWN_ACT.JOB";
Job file //
// Download the DATA data record with the
// name ACTIVE. The actual activation of the data record
// must be carried out manually at the machine
//
JOB DWN_ACT RESPONSE "DWN_ACT.LOG";
DOWNLOAD "DATA" ACTIVE START IMMEDIATE;
6. Session file 00000001 EXECUTE "UPL_ARCH.JOB";
MX_MC6_V1.9_07.09.15_ENG
Job file //
©KM
// Get a data record from the archive.

//
JOB UPL_ARCH RESPONSE "UPL_ARCH.LOG";
UPLOAD "d:\eu63\DATEN3" "TESTDAT"
START IMMEDIATE;

7. Session file 00000001 EXECUTE "DWN_MESS.JOB";

Job file //
// The MESSAGE.DAT file is downloaded for display.
// The file must exist in the session directory.
//
JOB DWN_MESS RESPONSE "DWN_MESS.LOG";
DOWNLOAD "MESSAGE.DAT" MESSAGE START IMMEDIATE;
8. Session file 00000001 EXECUTE "GETID.JOB";
Job file //
// Get all parameter definitions of the machine.
//
JOB GETID RESPONSE "GETID.LOG";
GETID "PARAM.DAT";
9. Session file 00000001 EXECUTE "ACTALARM.JOB";
Job file //
// Get the current alarms. Then an
// ABORT command must end this job, in order for the
// function to be called up again later.
//
JOB ACTALARM RESPONSE "ACTALARM.LOG";
EVENT ACTALARMS CURRENT_ALARMS REWRITE "ACTALARM.DAT"
START IMMEDIATE
STOP NEVER;
10. Session file 00000001 EXECUTE "ABORTJOB.JOB";
Job file //
// End the ACTALARM job
//
JOB ABORT RESPONSE "ABORT.LOG";
ABORT JOB ACTALARM;
11. Session file 00000001 EXECUTE "ABORTALL.JOB";
Job file //
// End all jobs
//
JOB ABORT RESPONSE "ABORT.LOG";
ABORT ALL;
12. Session file 00000001 EXECUTE "CHANGES.JOB";
Job file //
MX_MC6_V1.9_07.09.15_ENG
// Start the logging of all data changes

©KM
//
JOB CHANGES RESPONSE "CHANGES.LOG";
EVENT PROTOCOL CHANGES APPEND "PROT.DAT"
START IMMEDIATE
STOP NEVER;

13. Session file 00000001 EXECUTE "ALARMS.JOB";

Job file //
// Start the logging of all alarm changes
//
JOB ALARMS RESPONSE "ALARMS.LOG";
EVENT ALLALARMS ALARMS APPEND "ALARMS.DAT"
START IMMEDIATE
STOP NEVER;
14. Session file 00000001 EXECUTE "REPORT1.JOB";
Job file //
// Report when parameter changes
//
JOB REPORT1 RESPONSE "REPORT1.LOG";
REPORT REPORT1 APPEND "REPORT1.DAT"
START IMMEDIATE
STOP NEVER
CYCLIC TIME 00:00:01
IF SetTimCyc CHANGE
PARAMETERS
TIME DATE COUNT ActTimCyc SetTimCyc;
Job file //
// Report with every machine cycle
//
REPORT SPC APPEND "REPORT2.DAT"
START IMMEDIATE
STOP NEVER
CYCLIC SHOT 1
PARAMETERS
DATE TIME COUNT
@SCRW1_H_BAR_Z01.ACT.VAL;
MX_MC6_V1.9_07.09.15_ENG
©KM


Job file //
// A report is started every 2nd minute, consisting of three
// following machine cycles
//
REPORT REPORT_3 APPEND "REPORT3.DAT"
START IMMEDIATE
STOP NEVER
CYCLIC TIME 00:02:00
SAMPLES 3
PARAMETERS
TIME
DATE
COUNT
ActTimCyc;
Job file //
// Always start the report after 5 machine cycles, consisting
// of 2 machine cycles, max. 10 reports (=20 report entries)
//
REPORT REPORT4 APPEND "REPORT4.DAT"
START IMMEDIATE
STOP NEVER
CYCLIC SHOT 5
SAMPLES 2
SESSIONS 10
PARAMETERS
ActTimCyc;
MX_MC6_V1.9_07.09.15_ENG
©KM


Job file //
// For the first shift (6:00-14:00) and when the order
// "Part2" is not running, a cycle is recorded every
// 5 cycles.
//
REPORT REPORT_5 APPEND "REPORT5.DAT"
START TIME>=06:00:00
STOP TIME>=14:00:00
IF NOT SetDescJob == "Part2"
CYCLIC
SHOT 5
SAMPLES 1
PARAMETERS
ActTimCyc;
19. Session file 00000001 EXECUTE "SET.JOB";
Job file //
// Change individual parameters
//
JOB SET RESPONSE "SET.LOG";
//
// Parameter with field designation
SET SetDescMat[1.1] "Material1"
//
// generates the response Parameter OK
SET @SCRW1_H_BAR_Z01.SET.VAL 240;
//
// generates the response Fault too high
SET @SCRW1_H_BAR_Z01.SET.VAL 840;
MX_MC6_V1.9_07.09.15_ENG
©KM

12.5 Bypass flow filter, replacing the filter element (ZE 63.662)
W
Important
Replace the filter element VH009 following alarm A00039 "Filter pump 9" and
1
4
1
5
Fig. 12.43 Bypass filter VH009

1 Shut-off cock (2x) 4 Filter element
2 Housing cover 5 Connection for the clogging indicator
3 Seal ring
Removal
MX_MC6_V1.9_07.09.15_ENG
pressureless.
2) Seal off the intake and pressure line with shut-off cocks (1, fig. 12.43).
©KM
3) Unscrew the housing cover (2).
r
d
D
Risk of slipping
has poured out.

4) Carefully pull the housing cover together with filter element out of housing and
allow the hydraulic oil which flows out to drip into the housing.
5) Separate the filter element (4, fig. 12.43) from the housing cover by pushing
it to the side.
6) Pull the sealing ring (3) from the housing cover.
W
Important
The filter element (4) must not be reused as adequate filtering would no longer
assured.
Also replace the seal ring (3).
Dispose of the filter element and seal ring in an environmentally compatible
way.
Installation
Fig. 12.44 Housing cover and housing

1 Gap A: 0 - 4 mm
1) Install the new seal ring (3, fig. 12.43) on the housing cover (2) and wet with
hydraulic fluid.
2) Attach the new filter element (4) to the housing cover. There must be a gap A
(1, fig. 12.44) between the housing cover and housing.
3) Screw in the housing cover with filter element into the housing and tighten it.
4) Open the intake and pressure lines at the stop valves (1, fig. 12.43).
5) Clean the ventilation slots at the electric motor.
6) Switch on the pump motor and check the seal on the bypass flow filter.
MX_MC6_V1.9_07.09.15_ENG
©KM
I
Note
If no oil is drawn in when the system is commissioned, open the cover on the
filter housing and add approximately 0.3 l hydraulic fluid.

12.6 Bypass flow filter from SP 24500 (ZE 63.66)
5
1
2
4
Fig. 12.45 Bypass flow filter (from SP 24500)

1 Filter cover with filter element and seal ring 4 Oil supply line with stop valve
2 Housing 5 Pump unit
3 Oil supply line with stop valve 6 Contamination indicator (pressure gauge)
CJC High-pressure filter element B

Oil CJC High- CJC High-pressure Absorption capacity 1) Contents Pump Motor
capacity pressure filter element output power
max. filter Volume Surface Contamin Water [l] [l/min] [kW]
[l] model [l] [m²] ation [l]
MX_MC6_V1.9_07.09.15_ENG
[kg]
1500 15 / 27 3 0.50 0.4 0.3 6 0.35-6.0 0.08-0.18
©KM
3000 27 / 27 9.6 2.05 2.0 0.9 18 0.75-9.0 0.09-0.25

5000 27 / 54 19.2 4.10 4.0 1.8 35 3.0-16.0 0.25-0.55
7000 27 / 81 28.8 6.15 6.0 2.7 60 4.5-21.0 0.18-0.55
10000 27 / 108 38.4 8.20 8.0 3.6 80 6.0-32.0 0.18-0.55
35000 427 / 108 153.6 32.80 32.0 14.4 385 32.0-100.0 0.55-2.20
70000 727 / 108 268.8 57.40 56.0 25.2 621 45.0-200.0 1.10-5.00
1) Test contamination: spherical iron oxide pigments with a predominant particle size of 0.5 µm

12.6.1 Replacing the filter element
I
Note
The filter contamination is monitored at the pressure gauge (6, fig. 12.45). The
operating pressure is displayed in bar.
Replacing the filter cartridge

• According to maintenance schedule
• If, due to the degree of contamination of the filter, operating pressure has
reached the permissible limit value (pointer on pressure gauge (6) in red
area).
Removal
pressureless.
2) Seal off the intake and pressure lines (3 and 4) with stop valves.
3) Release shut-off at filter cover (1) and remove filter cover.
r
d
D
Risk of slipping
has poured out.
4) Carefully pull the filter element out of the housing (2) and allow the hydraulic
oil which flows out to drip into the housing.
5) Remove seal ring from filter cover (1).
W
Important
The filter element must not be reused as adequate filtering would no longer
assured.
Also replace the seal ring.
Dispose of the filter element and seal ring in an environmentally compatible
MX_MC6_V1.9_07.09.15_ENG
way.
©KM
Installation
1) Install new seal ring on filter cover (1, fig. 12.45) and coat with hydraulic oil.
2) Insert new filter cartridge in housing (2).
3) Mount filter cover (1) on housing (2) and fasten with shut-off.
4) Open intake and pressure lines (3 and 4) at shot-off cocks.
5) Clean ventilation slots on electric motor.
6) Switch on the pump motor and check the seal on the bypass flow filter.

12.7 Keyswitch (-S016) ejector/cores with open safety gate

(ZE 89.08), foot switch
w
D
Warning!
Working with the safety gate open leads to a high risk of accidents.
The key for the keyswitch must only be handed to specially trained personnel,
and only this personnel may work on the machine in this mode of operation.
In position "I" on the ejector/cores with open safety gate (-S016) keyswitch and
simultaneous actuation of the foot switch, the safety function of the safety gate
for ejector/core-pulling unit movement is deactivated.
In the case of cycles and mold movements which are subsequently started,
unforeseeable shearing and crushing edges may occur due to ejector and
core-pulling unit movements.
The operator must only make use of this lockable switch if the design of the
mold, core-pulling units, ejectors and their drives make access to shearing and
crushing points impossible.
When working on the machine with the safety gate open, extra caution is
required, and access by third parties must be prohibited.
w
D
Caution
If the injection molding machine has a keyswitch for moving hydraulic ejectors
and core-pullings with the gate open (ZE X89.08), the following must be
observed:
The operating company is responsible for designing molds, cores and ejectors
such that crushing and shearing points cannot be accessed when they are
moving.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.7.1 Function of the keyswitch -S016

Keyswitch -S016 is at "0".
• In all operating modes, the functions "Move core out/in" and "Ejector
forward/back movement" are not possible with the safety gate open.
• Any available air ejectors, Mouldmaster and needle shut-off nozzles cannot
be moved.
Keyswitch is at "I" and foot switch is actuated

• In all operating modes (except fully automatic mode), the functions "Move
core out/in" and "Ejector forward movement" (not back) are possible with the
safety gate open.
• Any available air ejectors, Mouldmaster and needle shut-off nozzles cannot
be moved.
• When the keyswitch is switched on, this is indicated via the illumination of the
indicator lamp next to the keyswitch.
I
Note
In the "0" position of the keyswitch and with simultaneous actuation of the foot
switch, movements of the core-pulling, ejector, air ejector where applicable,
Mouldmaster and needle shut-off nozzles are not possible with the safety gate
open.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.7.2 Function of the foot switch
1 2
Fig. 12.46 Foot switch

1 Three-stage pedal 2 Pushbutton for manual release
The foot switch is actuated by a three-stage pedal (1, fig. 12.46) with safety
latching and manual release.
• OFF:
In the pedal starting position, ejector⁄core movement is deactivated.
• ON:
If the pedal is actuated up to the pressure point (middle position), ejector⁄core
movement is enabled.
I
Note
The pedal must be held in.
If the pedal is released, the ejector⁄core movement is interrupted.
• STOP:
As an additional safety function, if the pedal is actuated beyond the resistance
of the pressure point the pedal is mechanically locked. In this pedal position,
MX_MC6_V1.9_07.09.15_ENG
ejector⁄core movement is stopped. Uncontrolled continued movement is not

©KM
possible.
I
Note
If the pedal is fully depressed, the foot switch must be released manually.

Releasing the foot switch

1) Eliminate the dangerous situation.
2) Release the foot switch by actuating the pushbutton (2, fig. 12.46) manually.
• The foot switch pedal is returned to its initial position (OFF).
• The ejector⁄core movement is possible again by actuating the pedal in
middle position (pressure point).
12.7.3 Inspecting core-pulling/ejector function with open safety gate

3) Set keyswitch -S016 to 0-position.

If a safety gate is open, movement of the ejectors, core-pulling, air ejectors if
applicable, Mouldmaster and needle shut-off nozzles must not be possible.
4) Select semi-automatic mode.

5) Start the cycle.
The clamping unit opens.
The ejector moves forward or cores move back (removal position).
The safety gate then opens.
7) Set keyswitch -S016 to position "I".
I
Note
The screen displays the information "Keyswitch for core-pulling and ejector
movement with open safety gate actuated".
8) Actuate foot switch up to pressure point (see section 12.7.2, page 12-884):
MX_MC6_V1.9_07.09.15_ENG
• Ejector can only be moved forward and not back with the safety gate
open.
©KM
• Cores can be moved in and out with the safety gate open.
• Any available air ejectors, Mouldmaster and needle shut-off nozzles
cannot be moved.

12.8 Water manifold (ZE 76.5xx, 76.7xx)

The cooling of the mold is set with the water manifolds.
These are located on the rearside in the panelling area of the clamping unit near
the fixed (mold) platen.
The cooling water feed and return flow are connected to the flow controller.
The individual cooling circuits of the mold cooling are connected with DN12 hose
connections to the flow control.
12.8.1 Flow rate monitor

1) Visual inspection of the floating ball in the flow controller.
2) Adjust for insufficiency in flow rate using the regulating valve.
Fig. 12.47 Water manifold (1x 10-fold)

1 Return flow 3 Slide mark for floating ball
2 Regulating valve 4 Feed
MX_MC6_V1.9_07.09.15_ENG
©KM

12.8.2 Clean/replace flow controller
2
4
1
5
8
7
Fig. 12.48 Flow controller

1 Measuring tube 5 Seal ring
2 Seal ring 6 Slide mark
3 Floating ball 7 Seal ring
4 Screw plug 8 Regulating valve
1) Ensure that the water supply is closed.

2) Close the upper regulating valve (8, fig. 12.48).
3) Unscrew the screw plug (4) and remove the seal ring (5).
4) Remove the slide mark (6).
5) Pull out the measuring tube (1) by pulling it upwards and pay attention to the
floating ball (3) as you do so.
6) Clean the measuring tube with the supplied pipe brush and replace it, if
necessary.
7) Grease the new seal rings (2 and 7) with silicone grease and fit them on the
MX_MC6_V1.9_07.09.15_ENG
measuring tube.
©KM
8) Install the measuring tube with floating ball.

9) Insert the screw plug with a new seal ring lubricated with silicone grease and
tighten it.
10) Fit the slide mark.
11) Open the upper regulating valve.

12.9 Medium monitor (ZE 64.50)

A medium monitoring device is installed in the oil collecting pan for monitoring
leakage of hydraulic oil.
The distance between the induction surface of the monitoring device and the
bottom of the oil collecting pan is between 10-20 mm.
The calibration is carried out when the machine is commissioned.
The installation position of the monitoring device is marked by bolt locking
varnish.
12.9.1 Function check of the medium monitor

The medium monitoring device must be checked regularly for proper operation.

• 10 to 20 mm distance to the oil pan floor
Prerequisites
• Machine switched on
• The green LED lights up
• The yellow LED lights up
Fig. 12.49 Medium monitor

1 Potentiometer 3 Induction surface
2 Oil collecting pan
MX_MC6_V1.9_07.09.15_ENG
©KM

1) Determine the distance between the induction surface (3, fig. 12.49) of the
monitor and the floor of the oil collecting pan (2).
The distance must lie between 10 and 20 mm.
2) Place a thin object (e.g. cable strap, piece of cardboard) under the induction
surface.
The yellow LED goes out.
3) Remove the object.
The yellow LED lights up.
Alarm A00065 "Medium monitor pump chamber" is displayed on the screen.
Setting the medium monitor

Only set if voltage is present and the yellow LED is not lit.
1) Use a small screwdriver through the bore on the top of the medium monitor to
turn the potentiometer (1, fig. 12.49) anticlockwise until the yellow LED lights
up.
2) Set the exact switching point by turning back and forth.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.10 Display core-pulling, ejector and mold clamping assembly

In addition to the display and operating panel, additional indicators for core-
pulling, ejector and mold clamping assembly are provided.
The status of the core-pulling, ejector and clamping assembly is monitored by
means of limit switches and indicated by LEDs (5, fig. 12.50).
14 2
3
13 4
12
5
11
7
8
10
Fig. 12.50 Display panel for core-pulling and ejector

1 Display hydraulic cores 8 Ejector (MP)
2 Move core IN 9 Fixed mold platen (FP)
3 Display core/ejector direction, end position 10 Core number
4 Display core/ejector direction, intermediate 11 Ejector forward movement (MP)
position 12 Display core/ejector direction, intermediate
MX_MC6_V1.9_07.09.15_ENG
5 LED position
6 Movable mold platen (MP) 13 Display core/ejector direction, end position
©KM
7 Ejector back movement (MP) 14 Move core OUT

11 2
10 4
9 5
8
7
Fig. 12.51 Display panel, pneumatic core-pulling

1 Display pneumatic cores 7 Fixed mold platen (FP)
2 Move core IN 8 Core number
3 Display core direction, end position 9 Display core direction, intermediate position
4 Display core direction, intermediate position 10 Display core direction, end position
5 LED 11 Move core OUT
6 Movable mold platen (MP)
1 2
B172 B182
3
4
B171 B181
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 12.52 Display panel, mold clamping assembly

1 Display mold clamping assembly unlocked 4 Movable mold platen (MP)
2 Display mold clamping assembly locked 5 Fixed mold platen (FP)
3 LED

13 1
12
2
11
3
10
9
8
7
6
5
4
Fig. 53 Display core pulling, ejector and cascade - 24" Multitouch

1 Display of cascade closed 8 Core number
2 Display of cascade open 9 Move out core, core/ejector direction limit position
3 LED 10 Move out core, core/ejector direction intermediate position
4 Core display, pneumatic 11 Move in core, core/ejector direction limit position
5 Core display, hydraulic 12 Move in core, core/ejector direction intermediate position
6 Cores, fixed mold clamping platen (FP) 13 Cores, movable mold clamping platen (MP)
7 Ejector
The additional displays for core-pulling, ejector and cascade are integrated in the
24″ Multitouch in the MC6 control system as a screen page.
The status of the core-pulling, ejector and clamping assembly is monitored by
means of limit switches and indicated by LEDs (3, fig. 53).
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11 Automatic feed unit (ZE 12.80, 12.81)
Fig. 12.54 Automatic feed unit (AF 100)
Certain mold masses, e.g. doughy, glass fibre-reinforced polyester and vinyl ester
melts, require forced delivery. For this purpose, KraussMaffei offers continuously
operating screw feeders (automatic feed unit).
The charging system is designed for volumes of 50 l (AF 50) and 100 l (AF 100)
and, with a stuffing pressure of up to 50 bar, is also designed for extremely
viscous melts. Post-charging is carried out without interrupting injection molding
production.
12.11.1 Safety devices/information plates

MX_MC6_V1.9_07.09.15_ENG
L
8
R
©KM
Open flame prohibited

As a result of combustible vapours which are expelled from the hopper, there
is a risk of injuries, explosion and fire.
Smoking and open flames are prohibited.
through to fatal injuries and leads to damage to property.
Note accident prevention regulations.

w
D
Caution
When mounting/dismantling the automatic feed unit, a secure and sturdy
ladder or work platform must be used.
This must be provided by the owner/operator in accordance with the directive
on use of work equipment (89/655/EEC).
12.11.1.1 Safety devices/information plates AF 50
3
1 2
Fig. 12.55 Safety devices/information plates AF 50

1 Feed cover limit switch 4 Guide roller on both sides with cover (2x)
MX_MC6_V1.9_07.09.15_ENG
2 Information plate "Open flame prohibited" 5 Hopper drive cover

3 Feed cover
©KM
The automatic feed unit is sealed with a feed cover (3, fig. 12.55). The feed cover
is monitored by a limit switch (1). When the cover is open, the message P00131
"Feed cover open" is displayed and the "Rotate feed screw" and "Rotate hopper"
functions are blocked in all operating modes.

12.11.1.2 Safety devices/information plates AF 100
1 2 3
Fig. 12.56 Safety devices/information plates AF 100

1 Feed cover limit switch 4 Hopper drive cover
2 Information plate "Open flame prohibited" 5 Guide roller with cover
3 Feed cover
The automatic feed unit is sealed with a feed cover (3, fig. 12.56). The feed cover
is monitored by the limit switch and -B572 (1). When the cover is open, the
message P00131 "Feed cover open" is displayed and the "Rotate feed screw"
and "Rotate hopper" functions are blocked in all operating modes.
12.11.1.3 Functional check of limit switches

1) Check the seating of limit switch -B572 and condition of the wiring.
3) Open the feed cover.
4) Actuate the "Rotate feed screw" button.
It must not be possible to start the "Rotate feed screw" function.
P00131 "Feed cover open" is displayed.
MX_MC6_V1.9_07.09.15_ENG
5) Close the feed cover.

6) The "Rotate feed screw" function can be started again.
©KM

12.11.2 Design and function of the AF 50/100
1 2 3
11
10
4
7 6 5
Fig. 12.57 Design of AF 50

1 Feed cover 7 Hopper drive gear unit
2 Screw drive gear unit 8 Flange
3 Drive motor, feed screw 9 Prefilling barrel
4 Feed screw 10 Hopper
5 Swivel device 11 Light barrier, material monitoring
6 Drive motor, hopper
The automatic feed unit AF conveys wet polyester BMC (BULK MOLD
COMPOUND) or SMC (SHEET MOLD COMPOUND) from the hopper
(10, fig. 12.57) via the feed screw (4) to the injection barrel or the injection unit.
The hopper rotates during production either clockwise, anticlockwise, or
oscillates.
MX_MC6_V1.9_07.09.15_ENG
In setting mode, the hopper and the feed screw can be rotated manually using
©KM
buttons.

1 2
8 9
3
6 7
4
Fig. 12.58 Design of AF 100

1 Feed cover 6 Pressure transducer
2 Ultrasonic sensor, material monitoring 7 Elbow
3 Drive motor, feed screw 8 Drive motor, hopper
4 Feed screw 9 Hopper
5 Prefilling barrel
The hopper and the feed screw are driven by electric drive motors (3 and 8,
Fig. 12.58).
The prefilling barrel (9, fig. 12.57) and (5, fig. 12.58) of the feed screw is fitted with
cooling channels for coolant supply.
The pressure transducer (6, fig. 12.58) in the elbow (7) between the feed screw
and the injection barrel regulates the stuffing pressure of the AF.
The sensor (11, fig. 12.57)/(2, fig. 12.58) at the filling shaft is used to monitor the
material filling level.
The hopper is filled and cleaned via the feed cover (1, fig. 12.58). The feed cover
closure is monitored by a limit switch (see section 12.11.1, page 12-893).
The AF is controlled and supplied with power via the control system of the
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.3 Information on mold masses
12.11.3.1 Storage of mold masses

As mold masses made of duroplastic resins can be toughened via heat, cool
storage facilities should be used wherever possible.
The storage temperature requirements depend on the type of melt.
Phenolic and amino plastics should be stored at room temperature if possible.
Phenolic plastics on a novolak/hexa basis can then be stored for several years.
The shelf life of phenolic plastics on a resol basis and amino plastics is shorter.
In addition to the temperature, the relative humidity in the storage facilities
influences the shelf life of phenolic and amino plastics. These materials become
hard as a result of polycondensation under the cleavage of water.
A relative humidity of approx. 50 to 60 %, as is typical in inhabited rooms, is
therefore recommended. In this case, it must be noted that the relative humidity
also changes in the event of a change in temperature.
In the storage facilities, containers must not be heated or cooled on one side, e.g.
due to heaters, heating pipes, solar radiation or storage directly on cold stone
floors.
Containers which are heated or cooled on one side may reveal defective
processing characteristics, as moisture diffuses from the warmer to the colder
side of the container.
W
Important
Containers which are brought into a warm processing area from a cool storage
facility require approximately one day to stabilize their temperature. The
containers must remain sealed in this case.
If this requirement is not met, the melt may "sweat", leading to processing
defects as a result of uncontrollable moisture absorption.
When using phenolic and amino plastics, which are packed into simple paper
sacks making them adapt rapidly to the moisture level of their environment, a
specific change in humidity can influence the flow/hardening behaviour
(conditioning).
A good overview of these processes in the warehouse can be obtained by
MX_MC6_V1.9_07.09.15_ENG
precisely determining weight. In an environment with high relative humidity, the

©KM
weight of a conventional 25 kg sack may increase very rapidly by approx. 0.5 to

1 kg. However, the moisture which has been absorbed is also released again with
equal rapidity on storage in dry facilities.

12.11.3.2 Mold mass delivery forms

• sheet metal containers with polyethylene inserts,
• styrene-impermeable film sacks,
• containers whose dimensions match those of the injection molding machines'
feeder size, e.g. film sacks,
• extruded form for simple, manual metering, also specifically for the transfer
press process,
• pre-compacted and pre-ventilated injection molding BMC.
12.11.4 Notes on processing BMC
12.11.4.1 Injection melt hardening
W
Important
The cooling of the injection barrel and the prefilling barrel must be kept
continuous operation during an interruption to production.
Non-compliance leads to hardening of the injection melt in the barrel.
When processing duroplast, a purging control system must be installed to

evacuate the molten injection melt in the event of an interruption in production.
When processing polyester, cooled nozzles or a cold runner distribution system
can be used to prevent the injection melt hardening in the injection barrel.
I
Note
Suitable temperatures must be selected to prevent solidifying of the plastic in
the sprue.
The correct temperatures have to be carefully determined in each individual
case, and do not depend solely on the mold and the machine data, but also on
the mold mass used.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.4.2 Finding and rectifying faults, BMC
Fault Fault cause Fault rectification

Large blisters/molded part Hardening time too short Increase hardening time, mold or melt
deformed temperature
Molded part not dimensionally Shrinkage excessive Increase melt temperature
accurate Degas melt better
Part removal from mold poor Mold temperature too low Increase mold temperature
Part sticks in the mold Ejector layout, conical form or polish Rectify mold defects
defective Use mold wax
Molded parts crack after Excessive tension in the molded part Apply injection-compression molding if
cooling (especially amino necessary
plastics)
Parts are severely damaged Gates excessively adhered Rectify gate defects
on breaking off from the sprue Wherever possible, use interchangeable
distributor inserts (ferrotic, sintered metal)
Molded parts are deformed Mold heating uneven Optimize heating
Hardening time too short Extend hardening time
Small blisters at intersection of Injection speed or mold temperature too Reduce injection speed or mold
flow fronts high temperature
Mold ventilation inadequate Clean, optimize mold ventilation
Porous, poss. burnt areas Injection speed or injection pressure too Reduce injection speed or injection
(diesel effect) high pressure
Mold ventilation inadequate Optimize mold ventilation
Flow lines on the surface Mold temperature too high or too low Optimize mold temperature
Parts not injected/ Mold temperature too high or too low Optimize mold temperature
flow fronts not fully formed Holding pressure too low Increase holding pressure
Melt cushion missing Set low melt cushion
Metering changed Change metering
Sprue rod is caught Bushing not polished at discharge/ Rectify mold defects
conical form insufficient Increase injection-side mold temperature
to increase shrinkage
Uneven molded part No back-pressure set Set low back-pressure
filling/metering fluctuations Screw speed too high Select a screw speed between 50 and
MX_MC6_V1.9_07.09.15_ENG
120 rpm
©KM
Material hopper not sufficiently filled Fill material hopper sufficiently

Screw has no reverse rotation lock

12.11.5 Commissioning AF
12.11.5.1 AF 50
Fig. 12.59 Installation of AF 50 operator side

1 Load eye 4 Securing plate
2 Spindle height adjustment 5 Flange
3 Transport lock (2x)
1) Switch off master switch of the machine.

2) Attach lifting rope to the load eye (1, fig. 12.59).
3) Lower the material feed unit carefully into fitting position on injection unit.
4) Mount the securing plate (4) of the material feed unit with four securing bolts
MX_MC6_V1.9_07.09.15_ENG
and tighten.
5) Remove two transport locks (3) and store in a safe place.
©KM
6) Lower material feed unit via spindle (2) onto connector.

When doing so, turn the flange (5) so that the screw heads on the connector
face through the bores.
7) Turn the flange and tighten the securing bolts.

1, 2
Fig. 12.60 Installation of AF 50 operator rearside

1 Plug-in connector - T531 3 Plug-in connector - F90
2 Plug-in connector - T540 4 Coolant feed quick-release coupling
8) Connect the electrical lines of the control cabinet to the plug-in connectors
(1, 2 and 3, Fig. 12.60).
9) Connect the pressure transducer with the plug-in connector
10) Install electrical lines to permit any possible swivelling out of the hopper.
11) Connect the coolant supply with two quick-release couplings (4).
12) Connect hydraulic oil lines with quick-release couplings.
13) Unlock material feed unit at the mechanical lock.
14) Switch on master switch of the machine.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.5.2 AF 100
4
9
3
A A-A
9 10 9
1 2
8 7
11 6
A
13 12
5
Fig. 12.61 Installation of the material feed unit AF 100

1 Pressure transducer 8 Securing bolt (4x)
2 Pressure transducer cover 9 Plug-in connection (6x)
3 Lower load eye (2x) 10 Forked bolt with fork head
4 Upper load eye 11 Coolant quick-release coupling
5 Bushing (2x) 12 Securing bolt (4x)
6 Bearing pin (2x) 13 Securing bolt (4x)
7 Bearing plate (2x)

2) Attach lifting ropes to the two lower load eyes (3, fig. 12.61) and the upper
load eye (4).
3) Position bushing (5) on the bearing pins (6) on both sides.
4) Lower the material feed unit into fitting position on injection unit.
5) Install bearing plates (7) on both sides.
MX_MC6_V1.9_07.09.15_ENG
6) Screw in the securing bolts (8) and tighten them.

7) Install fork head (10).
©KM
8) Install and secure forked bolt (10).

10) Connect electrical lead to pressure transducer (1).
11) Connect electrical lines with six plug-in connections (9).
12) Connect coolant feed with two quick-release couplings (11) at the bottom and
at the operator rearside.
13) Install cover for pressure transducer (2).
15) Switch on master switch of the machine.

12.11.6 De-commissioning AF
12.11.6.1 AF 50
Prerequisites
• Hopper emptied
Procedure
1) Switch off the main switch.
2) Carry out the disassembly of the material feed unit in reverse order to
installation.
3) Place material feed unit down and secure.
12.11.6.2 AF 100
Prerequisites
• Hopper emptied
Procedure
2) Disconnect electrical lines from the six plug-in connections (9, fig. 12.61).
3) Unscrew the four securing bolts (13) and remove the pressure transducer
cover (2).
4) Disconnect plug-in connection at pressure transducer -BP531 (1).
5) Unscrew the four securing bolts (12).
6) Disconnect coolant feed at two quick-release couplings (11) at the bottom and
w
D
Caution
Load eyes that become loose can result in injury and damage to the machine.
Check load eyes for firm seating.
7) Attach lifting ropes to the two lower load eyes (3, fig. 12.61) and the upper
load eye (4).
8) Release and remove forked bolts (10).
MX_MC6_V1.9_07.09.15_ENG
9) Unscrew the four securing bolts (8) and remove the bearing plates (7).
10) Carefully raise material feed unit, paying attention bushings (5) and cables
©KM
and lines that become exposed.

11) Place material feed unit down and secure.

12.11.7 Removal of the feed screw
12.11.7.1 AF 50
Prerequisites
• Hopper emptied
• Injection barrel purged
Procedure
1
2
3
Fig. 12.62 Disassembly of the feed screw AF 50

MX_MC6_V1.9_07.09.15_ENG
1 Load eye 3 Securing bolt (4x)

2 Feed screw 4 Bolts
©KM
w
D
Caution
Harmful vapours form in the hopper depending on the injection melt used.
• Only briefly carry out visual inspections.
• Do not inhale vapours.
• Note accident prevention regulations.

2) Press and hold the "Rotate feed screw" button until no bolt (4, fig. 12.62)
points into the feed screw.
If necessary, perform a visual inspection.
4) Attach lifting rope to the load eye (1).
6) Pull the feed screw (2) carefully out of the mounting.
12.11.7.2 AF 100
Prerequisites
• Injection barrel purged
• Material feed unit is swivelled out of the injection area and is emptied
(see section 12.11.12.2, page 12-934).
w
D
Caution
• Only briefly carry out visual inspections.
MX_MC6_V1.9_07.09.15_ENG
©KM

Procedure
1 2 3
Fig. 12.63 Disassembly of the feed screw AF 100

1 Feed screw 4 Half shell (2x)
2 Bolts 5 Stud bolt (2x)
3 Cover 6 Screw nut
2) Press and hold the "Rotate feed screw" button until no bolt (2, fig. 12.63)
points into the feed screw (1).
If necessary, perform a visual inspection.
MX_MC6_V1.9_07.09.15_ENG
4) Remove cover (3) from the bottom of the material feed unit (access to the
©KM
screw coupling).
5) Loosen stud bolts (5) at the screw nut (6).
6) Unscrew screw nut and push back onto the screw shaft.
7) Remove half shells (4) from the screw nut.
8) Remove screw nut from screw shaft.
9) Carefully pull feed screw out from the hopper.

12.11.8 Operating elements, AF
12.11.8.1 AF machine operating buttons
1 2 3 4
Fig. 12.64 AF machine operating buttons

1 Multi-Select options 3 Button "Hopper left"
2 Button "Hopper right" 4 "Rotate feed screw" button
The components of the AF can be run separately in setting mode using machine
operating buttons.
The buttons for operating the material feed unit are integrated in the area of the
machine operating buttons.
I
Note
A movement can only be initiated if the main drive of the machine is switched
on.
The following movements are selected using the machine operating buttons:
• Turn hopper left
MX_MC6_V1.9_07.09.15_ENG
• Turn hopper right

©KM
• Rotate feed screw

12.11.8.2 Hopper right
Prerequisites
• Pump motor running

• Feed cover closed
Sequence
Pressing the button causes the material hopper of the material feed unit in setting
mode to rotate clockwise.
The "Hopper right" function only works as long as the button is pressed.
In all other operating modes, the "Rotate feed screw" function is actuated via the
control system.
12.11.8.3 Hopper left
Prerequisites

Sequence
I
Note
The material hopper's standard direction of rotation is to the left.
Pressing the button causes the material hopper of the material feed unit in setting
mode to rotate anti-clockwise.
The "Hopper left" function only works as long as the button is pressed.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.8.4 Rotate feed screw
Function
Rotate material feed unit feed screw
Prerequisites

Sequence
Pressing the button causes the feed screw of the material feed unit in "setting
mode" to rotate anti-clockwise.
The "Rotate feed screw" function only works as long as the button is pressed.
In all other operating modes, the "Rotate feed screw" function is actuated via the
control system.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.9 Operation of AF
12.11.9.1 Activating automatic feed unit
Fig. 12.65 Injection/holding pressure auxiliary devices 2

1 Selection field "Accumulator charging, only standard" 2 "Deactivating automatic feed unit" selection
Deactivating automatic feed unit (on/off)
AF deactivated
• The AF is always activated in normal operation.
• Deactivation is available so that the machine can also be operated without the
AZ drive, e.g. when the AZ drive has been disassembled. When operating the
MX_MC6_V1.9_07.09.15_ENG
machine with pourable duroplast, the AF is also deactivated.

©KM
• After deactivation, the note "Automatic feed unit deactivated" appears on the
"AF automatic feed unit" screen pages (see fig. 12.67, page 12-913). All
display and input fields and machine operating buttons for the AF are no
longer displayed.
AF activated
• The AF is actuated in manual, semi-automatic and fully automatic mode
during the plasticizing function.
• In setting mode, the AF drive is not cut in during plasticizing.

12.11.9.2 Display/set-up of automatic feed unit
1 2 3
4
5
6
11
10 7
8
Fig. 12.66 AF automatic feed unit 1

1 "Fill level" digital input LED indicator 7 "SC flange temperature" set value
2 "Hopper cover" digital input LED indicator 8 "SC flange temperature" actual value
3 "Screw motor" digital input LED indicator 9 "Stuffing pressure" actual value
4 "Screw motor rotational speed" set value 10 "Hopper motor rotational speed" actual value
5 "Screw motor rotational speed" actual value 11 "Hopper motor rotational speed" set value
6 "Prefilling screw torque" actual value
If the automatic feed unit is activated (see section 12.11.9.1, page 12-911),
calling up the "AF automatic feed unit 1" screen page shows a display of the AF
MX_MC6_V1.9_07.09.15_ENG
with the most important parameters.

©KM

12.11.9.3 AF Automatic feed unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14

1 "Stuffing pressure control" selection 8 "Hopper direction of rotation" selection field
2 "Stuffing pressure +tolerance" set value 9 "Time for AF hopper contra-rotating after plasticizing" selection
3 "Stuffing pressure" set value, actual value field
4 "Delay time for tolerance monitoring for stuffing pressure control" 10 "Time for hopper stop before contra-rotating" set value
set value 11 "Cycle-dependent material monitoring" selection field
5 "Feed screw rotational speed" set value, actual value 12 "Counter for material level empty" set value, actual value
6 "Hopper rotational speed" set value, actual value 13 "Counter for cycle-end alarm" set value, actual value
7 "Delayed stuffing with AF" set value 14 "Material monitoring time after clamping force reached" set value
The "AF automatic feed unit 2" and "AF automatic feed unit 3" screen pages
contain all the parameters relevant for the automatic feed unit.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.9.4 Parameters for stuffing pressure closed-loop control
1
2
3
4
Fig. 12.68 Stuffing pressure closed-loop control

1 "Stuffing pressure control" selection 4 "Delay time for tolerance monitoring for stuffing pressure control"
2 "+Tolerance for stuffing pressure for alarm activation" set value set value
3 "Stuffing pressure" set value, actual value
Stuffing pressure closed-loop control (on)

Stuffing pressure closed-loop control regulates a constant, adjustable pressure at
the plasticizing flange via the speed of the hopper and the feed screw.
Stuffing pressure
Adjustable material pressure present at the plasticizing flange. By switching on
tolerance monitoring, the material pressure available in the cycle is monitored.
Delay time for tolerance monitoring for stuffing pressure control

With the stuffing pressure closed-loop control switched on, the delay time begins
with the start of plasticizing. Tolerance monitoring is carried out only after the
delay time has elapsed. If the stuffing pressure is outside the tolerance, the white-
shaded display alarm A10321 "Stuffing pressure outside the tolerance" is
displayed.
I
Note
If the delay time is set to zero, no stuffing pressure tolerance monitoring is
carried out.
Operation without stuffing pressure closed-loop control (stuffing pressure

MX_MC6_V1.9_07.09.15_ENG
closed-loop control off)

Approach set values for speed of feed screw and hopper.
©KM
When the torque limit is reached, the system slows down automatically.
12.11.9.5 Parameters of the AF
Feed screw rotational speed

Parameter (5, fig. 12.67) used to influence stuffing speed and stuffing pressure.
Hopper RPM
Parameter (6, fig. 12.67) for optimum feed screw filling.

Delayed stuffing with AF

"Begin plasticizing" starts the "Delayed stuffing with AF" (7) time. After this time,
the AF is started and delivers material depending on the plasticizing setting
parameters.
12.11.9.6 Selection of hopper function
Selection "Clockwise/anticlockwise hopper rotation"

With the selection "Clockwise/anticlockwise hopper rotation", the following
parameters are activated:
1
2
Fig. 12.69 Clockwise/anticlockwise hopper rotation

1 Time for AF hopper contra-rotating after plasticizing 2 Time for hopper stop before contra-rotating
The standard direction of rotation of the hopper is anticlockwise.

In this case, the hopper turns to the right as long as the "plasticizing" function is
active. After plasticizing, the hopper is stopped and the time "Hopper stop before
contra-rotating" runs out. When this time has elapsed, the hopper is contra-
rotated for the set time.
Selection "Hopper rotation, oscillating"

With the selection "Oscillating hopper rotation", the following parameters are
activated:
1
2
Fig. 12.70 Oscillating hopper rotation

1 Activation time hopper left 2 Activation time hopper right
MX_MC6_V1.9_07.09.15_ENG
The activation times specify the duration of the hopper's rotational direction.
©KM
During the "Plasticizing" function, the hopper is rotated in the corresponding

direction according to these times.
The longer set time specifies the hopper's starting rotational direction at the start
of feeding.

12.11.9.7 Material monitoring parameters
Cycle-dependent material monitoring (off)

If the filling level sensor continuously detects no material in the hopper (0 signal)
for one second, the white-shaded display alarm A10319 "No material in the AF
hopper" is displayed.
The pump motor is not switched off.
I
Note
If no material monitoring function is desired, cycle-dependent material
monitoring must be switched on and the material monitoring time set to zero.
Cycle-dependent material monitoring (ON)

The hopper material level is checked with the aid of the filling level sensor. The
setting parameters provide prior warning or interrupt the cycle before part quality
problems occur due to a lack of material.
Cycle-dependent material monitoring is only effective in the semi-automatic or
fully automatic modes.
Counter for material level empty

If, in semi-automatic or fully-automatic mode, no material is detected by the filling
level sensor in "Material monitoring time after clamping force made", the "Actual
counter for material level empty" is incremented by 1 per cycle. If this has reached
the set value, the white-shaded display alarm A10319 "No material in the AF
hopper" is displayed.
Counter for cycle-end alarm

If, in semi-automatic or fully-automatic mode, no material is detected by the filling
level sensor in "Material monitoring time after clamping force made", the "Actual
counter for end of cycle alarm" is incremented by 1 per cycle. If this has reached
the set value, the machine is switched off following the end of the cycle with alarm
A10320 "No material in the AF hopper".
Material monitoring time after clamping force made

Period of time during the cycle in which material monitoring is active.
MX_MC6_V1.9_07.09.15_ENG
Actual counter reset

©KM
The counters are reset via the following conditions:

• Deactivation of cycle-dependent material monitoring
• Setting the material monitoring time to zero
• Material detection in the hopper during Material monitoring time after
clamping force made (material detection during the remaining cycle does not
result in a reset of the actual counters)

12.11.9.8 Parameters for torque monitoring
1
2
3

1 "Feed screw torque monitoring" selection 3 "Feed screw torque threshold for interruption alarm" input field
2 "Feed screw torque threshold for cycle end alarm" input field
Feed screw torque monitoring (on/off)
Feed screw torque monitoring activated

For protecting the prefilling screw, e.g. for dried-out material, the following are set:
• Torque threshold for cycle end alarm, feed-screw
• Torque threshold for feed screw interruption alarm
MX_MC6_V1.9_07.09.15_ENG
Feed screw torque monitoring deactivated

If torque monitoring is deactivated, the torque is limited to 90 % of the torque
©KM
threshold for the feed screw interruption alarm.

12.11.9.9 Purging program at end of production
1
2
3
4
5
6
7
8
Fig. 12.72 Purging program at end of production

1 Purging program selection 5 RPM
2 Nozzle lift-off delay time 6 Back-pressure
3 Delay time for purging start 7 Plasticizing time
4 Start plasticizing 8 Number of purging cycles
No purging control
No function
Injection unit movement after production interruption
Prerequisites
MX_MC6_V1.9_07.09.15_ENG
• Semi-automatic or fully automatic mode is active.

©KM
After the production interruption the waiting time for unit lifting is started (step
display: delay time injection unit). When the delay time has elapsed, the injection
unit is retracted completely.

Purging control after production interruption
Prerequisites
• Semi-automatic or fully automatic mode is active.
• Stroke point for plasticizing is set to smaller value than plasticizing stroke.
• Switching function is enabled.
After the production interruption, the waiting time for unit lifting is started.
The P00051 "Delay time injection unit" step is displayed.
When the delay time has elapsed, the injection unit is retracted. Once the injection
unit is completely retracted, the delay time for purging start is started.
After the delay time, the machine is purged until the holding pressure changeover
point is reached.
Afterwards, the delay time is restarted.
After the time has elapsed, plasticizing is executed based on the set parameters
and the machine is purged again until the holding pressure changeover point is
reached.
If 0 has been entered for "Number of purging cycles", the process is repeated
continuously.
1
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 12.73 Settings alarm overview

1 Delay time for pump shutdown during malfunction

Description of the "Settings alarm overview" screen pages (see section 8.17.2,
page 8-674)
W
Important
If purging control should also carried out when a cycle-end alarm triggers
production interruption, the delay time for pump switch-off in the alarm settings
must be set in such a way that the purging control can be carried out.
After purging control has been executed, the pump motor is switched off.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.9.10 Polylift automatic loading system
1
2
3
4
5
6
7
8
9
10
Fig. 12.74 Automatic feed unit 3 - "PolyLift"

1 "Feed screw torque monitoring" selection 6 "Polylift automatic loading system" selection
2 Torque threshold for cycle-end alarm 7 Injection unit reloading position
3 Torque threshold for interruption alarm 8 Reloading position reached
4 Minimum stuffing pressure1) 9 "Reloading AF with material monitoring" selection field
5 Maximum stuffing pressure 1) 10 Number of cycles for reloading AF
1) Only visible in access level 6
Reloading in setting mode
Prerequisites
• Injection unit has been moved into reloading position using the machine
MX_MC6_V1.9_07.09.15_ENG
control button
• "Injection unit in reloading position" input is present
©KM
• Feed cover open
The valves for the feed cover can be activated in setting mode by using the
corresponding machine control buttons. First, the opposite direction is activated
for 0.15 s.
Then, reloading can be started via the PolyLift control system.
If the "External request for filling" signal is present, the "Start loading cycle" output
is set. The signal is not reset until the hopper has traversed the standby position
while retracting.

The loading cycle can be started as many times as desired.
W
Important
Do not overload the hopper.
Reloading in semi/fully automatic mode
Prerequisites
• "Polylift automatic loading system" is selected on the "AF Automatic feed
unit 3" screen (see fig. 12.74, page 12-921).
Reloading with material monitoring
Prerequisites
• Hopper in standby position.
If the set value for "Material level empty" is reached, the injection unit is moved
backwards in the next cycle until it is in reloading position.
The reloading position is set on the "AF Automatic feed unit 3 " screen
(see fig. 12.74, page 12-921). The position of the injection unit, the "Injection unit
in reloading position" sensor and the position of the hopper must be aligned with
each other.
Once the reloading position is reached, the feeder cover is opened and then the
"Start loading cycle" signal is set.
After loading, while traversing the standby position and upon reaching the
injection unit area free position, the signal is reset again. The feeder cover is
closed.
Upon detecting the new material, the material level counter is reset.
Reloading with set number of cycles
Prerequisites
• Hopper in standby position.
If the set number of cycles for reloading is reached, the loading process is
initiated. The sequence does not differ from that of the first version.
After the loading process is completed, the actual counter is reset.
MX_MC6_V1.9_07.09.15_ENG
In semi/fully automatic mode, the loading process can be started during a cycle
©KM
via the external request for loading by pressing the start button of the PolyLift.

12.11.9.11 Duroplast conveyor
Reloading in setting mode
Prerequisites
• Injection unit has been moved into reloading position using the machine
control button
• "Injection unit in reloading position" input is present
• Feed cover open
The valves for the feed cover can be activated in setting mode using the
corresponding machine control buttons. First, the opposite direction is activated
for 0.15 s.
Then, reloading can be started via the duroplast conveyor control system. The
loading cycle can be started as many times as desired.
W
Important
Do not overload the hopper.
After loading is completed, close the feed cover using the machine control
buttons.
Reloading in semi/fully automatic mode
Prerequisites
• "Polylift automatic loading system" is selected on the "AF Automatic feed
unit 3" screen (see fig. 12.74, page 12-921).
Reloading with material monitoring

MX_MC6_V1.9_07.09.15_ENG
Prerequisites
©KM
• Container in standby position

If the set value for "Material level empty" is reached, the injection unit is moved
backwards after plasticizing and unit lifting in the next cycle until the "Injection unit
in reloading position" signal is present.
Once the reloading position is reached, the feeder cover is opened and then the
"Start loading cycle" signal is set.
After loading, while traversing the standby position and upon reaching the
"Injection unit area free" position, the signal is reset again. The feeder cover is
closed. The material level counter is then reset again.

12.11.9.12 AF alarm messages
Feed cover open

If the AF feed cover is not closed, the hopper and the feed screw are unable to
move.
Plasticizing is additionally blocked in manual, semi-automatic and fully automatic
mode.
The message P00131 "Feed cover open" appears in the step display.
Screw drive fault

If a fault occurs in the screw drive, alarm A00318 "AF feed screw converter fault"
is displayed.
Classification: switching-off alarm shaded red.
Hopper drive fault

If a fault occurs in the hopper drive, alarm A00317 "AF hopper converter fault" is
displayed.
Feed screw drive communication error

If there is an interruption in the communication with the feed screw drive
converter, alarm A10324 "Feed screw drive communication error" is displayed.
Hopper drive communication error

If there is an interruption in the communication with the hopper drive converter,
alarm A10326 "Hopper drive communication error" is displayed.
Hardware enable error at feed screw converter

If there is no hardware enable signal at the feed screw converter (24 V level at the
fast stop and pulse block inputs), the alarm A10325 "Feed screw drive not ready
to be switched on" is displayed.
Hardware enable error at hopper converter

If there is no hardware enable signal at the hopper converter (24 V level at the
fast stop and pulse block inputs), the alarm A10327 "Hopper drive not ready to be
MX_MC6_V1.9_07.09.15_ENG
switched on" is displayed.

©KM
PolyLift fault
If a signal is no longer present at input -X901/28 (PolyLift fault), the
A10476 "Polylift fault" alarm is output.
If a signal is no longer present at input -XY901/26 (injection unit area free),
injection unit movements are no longer possible and the P10135 "Injection unit
area not free" step is output.

12.11.9.13 Heat-balancing of AF
1
6
5
4 3
2
Fig. 12.76 View from operator side, AF 100

1 Securing bolts for pressure transducer cover (4x) 4 Screw bearing
2 Elbow securing bolts (4x) 5 Securing nut
3 Prefilling barrel 6 Locknut
The AF is equipped with two cooling circuits. The cooling connections for the
screw bearing (4, fig. 12.76) are usually located on the SC flange in this case.
During prefilling barrel cooling (3), bridging the AF barrel's water outlet with the
plasticizing barrel inlet is advisable, so that both barrels form one cooling circuit.
12.11.9.14 Starting the AF

1) Check heat-balancing connections and mold temperature controllers.
2) Check hopper level and fill with material.
3) Carry out basic settings.
4) Start the plasticizing procedure in manual mode.
5) Check pressure build-up and plasticizing progress.
6) Inject melt out in order to check its homogeneity.
7) Repeat work steps 4 to 6 several times.
MX_MC6_V1.9_07.09.15_ENG
W
©KM
Important
Ensure that there is sufficient pause time between the plasticizing procedures
to prevent heating of the locking ring.
Failure to observe this instruction may result in damage to the return-flow lock.

12.11.9.15 Production interruption
Long-term interruption
In the case of a long period of interruption to production, the material feed unit
must be emptied (see section 12.11.12, page 12-933) and cleaned
(see section 12.11.13, page 12-936).
Short-term interruption
1) Run material hopper empty.
2) Move the feeder screw to the front limit position and then retract
approx. 30 mm.
3) In order to prevent the material from drying out, check whether the feed cover
was closed when the material level was last checked.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.9.16 Calibration of the pressure transducer BP531
5 2
3
Fig. 12.77 Calibration of the pressure transducer BP531

1 Activation of "Pressure⁄force transducer calibration" 4 Activate calibration of "Stuffing pressure"
2 Input of 80% stuffing pressure in bar 5 Input the zero signal 0 bar
3 "Stuffing pressure" actual values
If the Calibration function of a pressure sensor is activated, the current voltage

value from the Actual column is automatically transferred into the plotting point
column when a pressure value is entered into the Min. or Max. plotting point
column.
Procedure
MX_MC6_V1.9_07.09.15_ENG

©KM

3) Activate "Calibration of pressure⁄force transducer" (1, fig. 12.77).
4) Activate calibration of "Stuffing pressure" (4).
5) Enter the 0-signal (5) of the unloaded pressure transducer under
"PlottPt.min".
6) Enter 80% of the maximum stuffing pressure (50 bar) under "Sett. pts.
max" (2).

12.11.9.17 Setting the material level display
Fig. 12.78 Material level display

1 Ultrasonic sensor
The AF is equipped with an ultrasonic sensor (1, fig. 12.78) at the filling shaft for
recording the material level. The detection range to be recorded can be adjusted
by a potentiometer.
I
Note
For further information, refer to the catalogue of the manufacturer Balluff:
"Bus ultrasonic sensors"
Sensor designation: BUS M18KO-PSXEP-150-EP00.3-GS92
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.10 AF fault rectification
Fault Fault rectification

AF does not start • Close feeder cover, check limit switch
• See: pressure transducer does not function correctly
• Standalone version: check plug connector for machine control system
• Overload error at frequency converter; remedy: switch off machine briefly and then
on again
Plasticizing time is exceeded • Stuffing pressure is not built up; remedy: increase stuffing pressure
• Material solidified in elbow; remedy: clean elbow
• Check return-flow lock (no solidified material)
Pressure transducer does not • Pressure transducer indicates max. pressure in unloaded state; remedy: check
function correctly connector and connect correctly if necessary. Check pressure transducer. If the
connector is correctly connected, replace pressure transducer.
• If, when not loaded, the pressure transducer displays pressure which deviates from
0 (which exceeds the set target stuffing pressure), the transducer must be cleaned.
If this does not rectify the problem: recalibrate pressure transducer
(see section 12.11.9.16, page 12-927)
• If necessary, work without pressure regulation
Stuffing pressure is not built up • Refill material
or is built up inadequately • If necessary, work without pressure regulation and with increased feed screw speed
• Reduce plasticizing screw speed
Stuffing pressure curve • Refill material
fluctuates severely • Activate pressure regulation
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.11 Maintenance AF
w
D
Warning!
During maintenance work, it is essential that the drive cannot be switched on
and that no exposed parts can be accidentally energized by voltage.
When the maintenance tasks have been completed, reinstall the protective and
safety devices on the drive.
12.11.11.1 Materials used in operation
Oil specifications, gear unit
W
Important
Do not mix lubricating greases with lubricating greases that have a different
soap base.
Characteristic data Unit Mobilgear 600 XP 220 Test procedure

Labelling as per DIN CLP ISO VG 220
Soap base Polyglycol
Viscosity index 97 ASTM D 2270 101
Base oil viscosity DIN 51366
• at 40 °C [mm2⁄s] 220 ISO-VG 220
• at 100 °C [mm2⁄s] 19
Flash point [°C] 240 ASTM D 92
Pourpoint [°C] -9 ASTM D 97
Density at 15.6 °C [kg/l] 0.89 ASTM D 4052
Rolling element wear [mg] 2 DIN 51819-3, D7
Lubricant specifications, material feed unit AF 100
Characteristic data Unit Aralub HLP2 Aralub LFZ1 Test procedure

(track system) (toothing)
Ignition point [°C] > 300 > 300 DIN 51794
MX_MC6_V1.9_07.09.15_ENG
Risk of explosion only with thermal load and/or atomization

Explosion limits (UEG/OEG) Vol % 0.6 - 6.5 approx. 0.6 - 6.5
©KM
Density at 15.0 °C [g/cm3] 0.85 - 0.95 0.85 - 0.95 DIN 51757

Solubility in water at 20 °C insoluble insoluble
pH value not applicable not applicable
Viscosity (kinem.) at 40 °C [mm2⁄s] 50 - 300 50 - 900 DIN 51562
Flash point [°C] > 500 > 150 ISO 2592
Pourpoint [°C] not applicable not applicable ISO 3016
Drip point [°C] > 180 > 180 ISO 2176

12.11.11.2 Changing oil

Carry out oil change every 6 months.
Material feed unit AF 50
1 2
5
6
Fig. 12.79 Maintenance devices, AF 50

1 Oil filler screw 4 Barrel fork head
2 Inspection glass 5 Lower barrel mount (2x)
3 Oil drain plug 6 Profiled rail guide
MX_MC6_V1.9_07.09.15_ENG
1) Position a suitable oil collecting tank for collecting oil at the screw drive gear.
2) Unscrew oil filler screw (1, fig. 12.79) on the top of the gear.
©KM

4) Drain the oil completely.
5) Screw oil drain plug (3) in with a new seal ring and tighten.
6) Pour in 7.0 l oil.
The oil level must reach the middle of the inspection glass.
7) Check oil level at inspection glass (2).
8) Screw oil filler screw (1) in with a new seal ring and tighten.

Material feed unit AF 100
Fig. 12.80 Maintenance devices, AF 100

1 Track system (2x) 3 Oil drain plug
2 Bleed screw 4 Toothing (4x)
1) Position a suitable oil collecting tank for collecting oil at the screw drive gear.
2) Unscrew bleed screw (2, fig. 12.80) on the top of the gear unit.
4) Drain the oil completely.
5) Screw oil drain plug (3) in with a new seal ring and tighten.
6) Pour in 5.3 l oil.
7) Insert bleed screw (2).
8) Open the ventilation by turning anticlockwise.
12.11.11.3 Inspecting oil level

Check the oil fill level at the inspection glass of the screw drive gear unit.
The oil level must reach/fill 2/3 of the inspection glass (2, fig. 12.79).
12.11.11.4 Lubrication of material feed unit
AF 50
MX_MC6_V1.9_07.09.15_ENG
Lubricate profiled rail beneath the hopper at the profiled rail guide (6, fig. 12.79).
©KM
Lubricate barrel fork head (4). Lubricate lower barrel mount (5) at two lubricating
nipples.
AF 100
Lubricate track system (1, fig. 12.80) at two lubricating nipples. Lubricate the
toothing (4) at four lubricating nipples on the lower side of the hopper.

12.11.12 Draining
12.11.12.1 Emptying of AF 50
Fig. 12.81 Emptying of AF 50

1 Flange 3 Securing bolt (4x)
2 Coolant feed quick-release coupling 4 Spindle height adjustment
1) Ensure that the injection barrel is empty.

2) Disconnect coolant feed from two quick-release couplings (2, fig. 12.81) at
the operator rearside.
MX_MC6_V1.9_07.09.15_ENG
3) Loosen the four securing bolts (3) and turn the flange (1) until the screw heads
©KM
show through the bores.

4) Move the material feed unit with the spindle height adjustment (4) upwards as
far as the stop.
5) Mechanically lock material feed unit in the uppermost position.
6) Place a suitable container beneath the material feed unit.

w
D
Caution
• Only briefly carry out a visual inspection of the material level in the hopper.
8) Press the "Hopper left" and "Rotate feed screw" buttons until no further
injection melt emerges.
If necessary, carry out a visual inspection of the material level in the hopper.
9) Switch the machine master switch off and secure against unintentional
reactivation.
10) Clean hopper with suitable agent.
12.11.12.2 Emptying of AF 100
3
1 2
9 8 7 6 5
Fig. 12.82 Emptying of AF 100

MX_MC6_V1.9_07.09.15_ENG
1 Pressure transducer cover 6 Securing bolt (3x)

2 Elbow 7 Securing bolt (4x)
©KM
3 Locknut 8 Pressure transducer -BP531

4 Securing nut 9 Securing bolt (4x)
5 Coolant quick-release coupling
1) Ensure that the injection barrel is empty.

2) Place a suitable container beneath the material feed unit.
3) Unscrew the four securing screws (9, fig. 12.82) and remove the pressure
transducer cover (1).

4) Disconnect the plug-in connection at pressure transducer BP531

(8, fig. 12.82).
5) Disconnect coolant feed at two quick-release couplings (5) at the bottom and
7) Loosen lock nut (3) and screw back.
8) Screw fastening nut (4) up as far as possible until AF has pivoted out of the
injection barrel area
9) Unscrew three securing bolts (6).
10) Remove elbow (2) and clean with suitable agent.
w
D
Caution
• Only briefly carry out a visual inspection of the material level in the hopper.
12) Press the "Hopper left" and "Rotate feed screw" buttons until no further
injection melt emerges.
If necessary, carry out a visual inspection of the material level in the hopper.
13) Switch the machine master switch off and secure against unintentional
reactivation.
14) Clean hopper with suitable agent.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.13 Cleaning of AF 50/100
I
Note
The agent to be used for cleaning depends on the injection melt used. You can
obtain information on this from the manufacturer of the injection melt.
The material feed unit must be cleaned during production interruptions and
material changes.
In the case of production interruption, the time of cleaning depends on the
injection melt used and on the processing and environmental conditions.
Important information in this regard is provided by the manufacturer.
12.11.13.1 Cleaning with non-reactive material

When processing duroplasts, non-reactive material can be used for cleaning to
prevent hardening of the injection melt in the plasticizing unit. This material can
remain in the injection unit until production resumes.
1) Ensure that the hopper of the material feed unit is emptied.

2) Ensure that the plasticizing unit is purged.
3) Fill non-reactive material into the hopper of the material feed unit.
5) Move the injection unit with "Injection unit back" button into the front limit
position.
6) Press the "Plasticizing" button until material emerges from the nozzle.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.14 AF vacuum pump
12.11.14.1 Overview
7
1
2 8
Fig. 12.83 Vacuum pump with styrene separator

1 Intake filter 5 Oil level inspection glass
2 Pump motor 6 Styrene separator
3 Vent screen 7 Clean gas outlet
4 Oil filler screw 8 Fluid drain
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.14.2 Installation
W
Important
The distance to the adjacent walls (1, fig. 12.84) must be at least 100 mm.
1
1
Fig. 12.84 Installation location of vacuum pump

1 Distance to the adjacent walls > 100 mm
Ambient temperature:
• > 5 °C
• < 40 °C
Air specifications:
• Air humidity: relative humidity max. 90%
• Altitude: Up to 800 m above MSL (mean sea level)
MX_MC6_V1.9_07.09.15_ENG
©KM

Preparatory measures
Consumable material
• CASTROL AIRCOL PD 100
Oil quantity cup U 4.29: 0.5 l
Oil specifications, vacuum pump, automatic feed unit (ZE)

Compressor oil (VDL) on mineral oil basis CASTROL AIRCOL PD 100
Part number: 0750324
W
Important
• In principle, mixing of 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.
• Only certain grades of oil may be intermixed for disposal.
• Enquire at manufacturer/supplier regarding the requirements for disposing
of the oil used.
Characteristic data Unit Characteristic value Test procedure

CASTROL AIRCOL
PD 100
Density at 15 °C [kg⁄m3] 885 DIN 51757
Viscosity DIN 51562
• at 40 °C [mm2⁄s] 100
• at 100 °C [mm2⁄s] 11.4
Viscosity index (VIE) 100 ISO 2909
Flash point [°C] 243 DIN ISO 2592
Pourpoint [°C] - 12 DIN ISO 3016
SAE class 30
MX_MC6_V1.9_07.09.15_ENG
©KM

Oil filling
MAX
OIL
MIN
2
Fig. 12.85 Oil filling, vacuum pump

1 Oil filler screw 3 Oil level inspection glass
2 MAX/MIN oil fill level
1) Unscrew oil filler plug (1, fig. 12.85).

2) Fill oil and check oil fill level at inspection glass (3).
3) Screw in oil filler plug (1).
Intake nozzle shut-off

1) Remove sealing cap from intake nozzle (3, fig. 12.87).
Blow-out opening
W
Important
The blow-out opening (4, fig. 12.87) must be open.
No pressure must be applied to the opening.
Electrical connection
W
Important
MX_MC6_V1.9_07.09.15_ENG
• The power feed must be de-energized and secured against reactivation.

• Observe the specifications of the relevant energy supply company as well
©KM
as any applicable national standards and regulations regarding such a

connection.
• Do not switch on the pump motor until oil has been poured in.

A 1 2
3
9 8 7 6
10
Fig. 12.86 Electrical connection

1 Cover 6 Nut (4x)
2 Bolt (4x) 7 L3
3 Cable feedthrough 8 L2
4 Socket 9 L1
MX_MC6_V1.9_07.09.15_ENG
5 Contact rings (4x) 10 Earthing

©KM
1) Unscrew bolts (2, fig. 12.86).

2) Remove the cover (1).
3) Push cable through cable feedthrough (3).
4) Insert contact rings (5) in respective connection.
5) Secure connections by screwing on nuts (6).
6) Close cover (1).
7) Insert screws (2) and tighten.

Checking direction of rotation of pump
Testing/measuring equipment:
• Direction of rotation measuring device
Prerequisites
• Filled with oil (see "Oil filling", page 12-940).
• Electrical connection for pump set up (see "Electrical connection",
page 12-940).
Procedure
W
"
Important
If the pump motor runs for a lengthy period of time in the wrong direction of
rotation, the pump will be damaged.
1) Checking direction of rotation with direction of rotation measuring device.

The direction of rotation must match the direction of rotation arrow on the fan
housing.
D
e
d
Hazard from electrical voltage exists in the socket (4, fig. 12.86).
Steps 2 to 4 must only be carried out by a properly qualified electrician.
W
Important
Only perform steps 2 to 4 if the direction of rotation of the pump motor does not
match the direction of rotation arrow on the fan housing.
2) Disconnect the power supply.

3) Switch around the two phases (wires) of the connection cable.
4) Restore the power supply.
5) Perform work step 1 and ensure that the direction of rotation of the pump
motor matches the direction of rotation arrow on the housing.
MX_MC6_V1.9_07.09.15_ENG
©KM

Connection of vacuum tube
W
Important
The threaded coupling (2, fig. 12.87) must not come into contact with grease
and/or oil.
Prerequisites
• Sealing cap removed from intake nozzle (3, fig. 12.87).
• Observe correct length of tube:
– Tube diameter 1/2": tube length < 2 m
– Tube diameter 3/4": tube length > 2 m … 10 m
Procedure
4
MX_MC6_V1.9_07.09.15_ENG
Fig. 12.87 Tube connection

©KM
1 Tube 3 Intake nozzle

2 Threaded coupling 4 Blow-out opening
1) Screw in tube (1, fig. 12.87) with threaded coupling (2) into intake nozzle (3)
and tighten.

12.11.14.3 Commissioning
Prerequisites
• Filled with oil
• All connections established
• Blow-out opening free
Procedure
W
Important
Due to high oil viscosity, cold starts below 5 °C can result in damage to pumps
and hydraulic motors.
The ambient temperature and pump temperature must always be > 5 °C during
connection.
The vacuum pump starts running when the master switch of the injection molding
machine is switched on.
12.11.14.4 Maintenance
D
w
Warning!
Prior to all maintenance work on the vacuum pump, switch the machine master
switch off and secure against unintentional reactivation.
W
Important
Does seal the exhaust air connection (6, fig. 12.89) in normal operation. If the
air flow is obstructed, this can result in damage to the vacuum pump.
Function/maintenance of the styrene separator

In the styrene separator, the liquefied styrene extracted from the mold is
separated and directed through a manual fluid drain (8, fig. 12.83).
This prevents styrene from getting into the pump and damaging it in the long run.
MX_MC6_V1.9_07.09.15_ENG
Maintenance
©KM
Check bolt connections once a year with a torque wrench.

Checking oil level, vacuum pump

Contaminated intake filters or obstructed air de-oiling elements reduce the suction
power of the vacuum pump.
Insufficient oil shortens the service life and can result in total failure of the vacuum
pump.
Check the oil level with the pump switched off. The oil level must reach the middle
of the inspection glass (5, fig. 12.83).
W
Important
When processing injection melts containing styrene, this can lead to an
increase in the oil volume.
Cleaning intake filter
G
B
Eye protectors
Always wear eye protectors when cleaning the vacuum pump.
Dirt particles can result in severe eye injury or even in the loss of eyesight.
1) Remove filter cover from intake filter (1, fig. 12.83).

2) Remove filter element and replace if badly contaminated.
3) If only slightly contaminated, blow out with compressed air, working from the
inside to the outside.
4) Suck out the inside of the intake filter.
5) Install filter element.
Clean vent screen

Blow out vent screen (3, fig. 12.83) on vacuum pump motor with compressed air.
MX_MC6_V1.9_07.09.15_ENG
©KM

Vacuum pump oil change
Consumable material
• CASTROL AIRCOL PD 100
Specifications (see "Preparatory measures", page 12-939)
Procedure
H
d
D
There is a risk of burns due to hot surfaces on the vacuum pump.
Carry out an oil change after 100 working hours and at least every 6 months.
MAX
OIL
MIN
2
3 4
Fig. 12.88 Vacuum pump oil change

1 Oil filler screw 3 Oil level inspection glass
2 MAX/MIN oil fill level 4 Oil drain plug
W
Important
MX_MC6_V1.9_07.09.15_ENG
Drain oil change only when the oil is warm.

©KM

2) Unscrew oil filler plug (1, fig. 12.88).
3) Unscrew oil drain plug (4) and drain oil completely.

Fig. 12.89 Vacuum pump maintenance

1 Cover 4 Air de-oiling element
2 Bolt (3x) 5 Strainer
3 Seal 6 Exhaust air connection
4) Unscrew screws (2, fig. 12.89), remove cover (1) and gasket (3).
5) Remove air de-oiling element (4), clean it and replace it after 2000 h.
6) Remove strainer (5) and clean it.
7) Install strainer.
8) Install air de-oiler element.
9) Secure cover with gasket.
10) Insert oil drain plug (4, fig. 12.88) in with a new seal ring and tighten.
11) Fill oil (approx. 0.5 l) and check oil fill level at inspection glass (3, fig. 12.88).
12) Insert oil filler plug (1, fig. 12.88) with new seal ring.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.11.14.5 Removal
Prerequisites
• Oil collecting tank provided.
Procedure
w
D
Warning!
The power feed must be de-energized and secured against reactivation.

2) Disconnect electrical connection.
3) Drain oil and dispose of in an environmentally proper manner.
4) If necessary, remove filter and dispose of in an environmentally compatible
manner.
5) For further measures (see chapter 13 Taking machine out of service/Placing
into storage/Disposal).
MX_MC6_V1.9_07.09.15_ENG
©KM

12.12 Bar-pulling device

The bar-pulling device can be used to move a bar of the clamping unit out or in
hydraulically for installing and removing the mold. The bar is locked in the moved-
in position hydraulically.
12.12.1 Variants of the bar-pulling device

The type of bar-pulling device depends on the size of the injection unit. There are
three variants:
• Support in front (centre)
• Support in rear
• Without support, self-support.
The bar-pulling device can be installed on the operator side or operator rearside.
2
4
1
3
Fig. 12.90 Bar-pulling device with support in rear, operator side

1 Traverse cylinder 4 Clamping unit
2 Support in rear 5 Bar-pulling carrier
3 Injection unit
MX_MC6_V1.9_07.09.15_ENG
©KM

1 2
4
3
Fig. 12.91 Bar-pulling device with support in front (centre), operator rearside
1 Bar-pulling carrier 3 Work platform
2 Support, front (centre) 4 Injection unit
1 2 3 2
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 12.92 Bar-pulling device, self-supporting (without support), operator side

1 Bar (operator side) 3 FP
2 Bar-pulling device, self-supporting

12.12.1.1 Bar-pulling device with support, rear
1 2 3 4
9 8 7 6
11 10
12
Fig. 12.93 Bar-pulling device with support, rear

1 A = distance between front surface of bar (moved out) and working 7 Mechanical stop
plate FP (approx. 5 mm) 8 Driver
2 Hydraulic control, bar-pulling (bar-pulling block) 9 Column head (bar)
3 Linear unit 10 Limit switch -B141 "Bar moved in"
4 Bar-pulling carrier 11 Limit switch -B135/-B145 "Bar clamping element
5 Support released/clamped"
6 Limit switch -B131 "Bar pulled/moved out" 12 Fixed mold clamping platen (FP)
MX_MC6_V1.9_07.09.15_ENG
©KM

12.12.1.2 Bar-pulling device, self-supporting (without support)
1 2 3 4 1 7 3 8
5
5 5 11 10 14 9
11 12 13
1 7 3 14 5
Fig. 12.94 Bar-pulling device, self-supporting (without support)

1 Bar-pulling device (installation position, operator side) 9 Column head (bar)
2 Hydraulic control, clamping elements (clamping block) 10 Warning sign "Danger of crushing"
3 Fixed mold clamping platen (FP) 11 Movable mold platen (MP)
4 Bar-pulling device (installation position, operator rearside) 12 Limit switch -B135/-B145 "Bar clamping element
5 Driver released/clamped"
6 Bar clamping elements 13 Proximity switch -B131 "Bar pulled/moved out"
7 Bar 14 Proximity switch -B141 "Bar moved in"
8 Hydraulic control, bar-pulling (bar-pulling block)
MX_MC6_V1.9_07.09.15_ENG
©KM

1 3 4 5 6 3
2
9 7
Fig. 12.95 Bar-pulling device, self-supporting (bar-pulling device moved out)

1 Movable mold platen (MP) 6 Hydraulic control, bar-pulling (bar-pulling block)
2 Maximum clearance 7 Rated stroke
3 Bar (pulled/moved out) 8 Hydraulic control, clamping elements (clamping block)
4 Fixed mold clamping platen (FP) 9 Maximum opening width
5 Bar-pulling device (moved out)
With the self-supporting bar-pulling device, the bar cannot be pulled behind the
clamping surface of the FP (see fig. 12.95, page 12-953).
The bar is pulled completely when the rated stroke (7, fig. 12.95) has been
reached.
The size of the rated stroke depends on the machine size and can be obtained
from the technical data in the corresponding drawing (see chapter 15 Parts
lists/drawings).
The maximum clearance (2) for mold change is based on the distance between
MP and completely pulled bar at maximum opening width (9). The maximum
clearance is slightly larger than the maximum mold installation height. The
maximum mold installation height can be obtained from the machine data
I
Note
The bar-pulling device in the self-support variant is already installed on delivery
MX_MC6_V1.9_07.09.15_ENG
of machines up to KM 1600 MX.

On machines of sizes KM 2000 MX to KM 4000 MX, the clamping unit is
©KM
transported in assemblies and the self-supporting bar-pulling device is installed

by KraussMaffei Service.
If necessary, obtain information on installation from our KM Service.

12.12.2 Operating/display elements

1 Mold change/clamping assembly module 3 Button "Move bar in/clamp"
2 "Activation of mold change/clamping assembly 4 Button "Release/move out bar"
module" button
Move bar in/clamp

• Press the button to move the bar in.
• The bar moves in the direction of MP until the limit position is reached.
• The bar clamping elements are clamped.
Release/move bar out

• Press the button to release the bar clamping elements and the bar is moved
out.
• The bar moves in the direction of the FP until the limit position is reached.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.12.3 Moving bar out/in
12.12.3.1 Prerequisites
D
w
Warning!
Ensure that the transport locks are attached to the mold and that the lifting
ropes are attached.
Persons can be injured, mold and injection molding machine can be damaged.
W
Important
Bar-pulling operation must only be performed by at least two persons.
• One person makes the inputs at the operating/display panel
(see fig. 12.96, page 12-954).
• A second person monitors the "Bar-pulling" safety area.
I
Note
Bar movements are only possible:
• in setting mode / mold change mode
• with safety gates for the mold area closed and
• with step-on safety grid not actuated.
In bar-pulling operation, the bar-pulling speeds are limited to a maximum
of 30 mm⁄s.
In subsections where there is no danger to operating personnel, 60 mm/s is
also permissible.
• The "bar-pull" safety zone is not changed and cannot be walked through.
• The installation of the bar-pulling device has been carried out
(see section 12.12.1.1, page 12-951).
• The injection unit is in its rear end position.
• All electrical plug connections, cooling water connections and hydraulic
connections are separated between mold and machine and equipped with the
corresponding covers/sealing plugs.
MX_MC6_V1.9_07.09.15_ENG
• Safety gates closed.

©KM
• Pump motor running.

• Password entered.
• "Setting mode" button actuated.
• "Move back pressure plungers" button actuated.

Pressure pistons moved back and clamping pressure released.
Step P00084 "Main ram in rear position" is displayed.

W
Important
When the button "Activation of mold change/clamping assembly module"
(2, fig. 12.96) is pressed, the buttons for the clamping assembly and bar-
pulling function are displayed.
• Press the "Activation of mold change/clamping assembly module" button

(see fig. 12.96, page 12-954).
I
Note
With mold change activated, the
• bar can be moved out into any MP position
• the MP can be moved up in setting mode up to the max. possible opening
position.
• If, with the bar pulled, the distance between MP and FP is insufficient to install
a mold, the MP can be moved away from the FP using the "Mold opening"
function. This is also permitted with three installed columns.
I
Note
With the bar pulled, the "Close mold/sliding table/turning board" function can
generally not be executed. This is only permitted with the bar moved in and
clamped.
• With the bar removed, the speed of opening mold/sliding table/turning board
is limited automatically by the control system to 100 mm/s if the setting or
adjustment speed for Mold opening is set higher than 100 mm/s. Opening
speeds lower than 100 mm/s are retained.
12.12.3.2 Moving bar out
I
Note
With mold change activated, the bar can already be moved out if the mold is
MX_MC6_V1.9_07.09.15_ENG
still closed.
©KM
1) Select the mold change/clamping assembly module on the operating/display

panel (1, fig. 12.96) and activate via the button "Activation of mold
change/clamping assembly module" (2).

W
Important
In bar-pulling operation, the bar-pulling speeds are limited to a maximum
of 30 mm⁄s.
2) Press the "Release/move out bar" button.

• Step P00852 "Releasing bar clamping element" is displayed.
• If the bar clamping element is moved out, step P00853 "Bar clamping
element released" is displayed.
3) Press the "Release/move out bar" button once again.
• Step P00856 "Move out/pull bar" is displayed.
• The bar is moved out of the movable mold clamping platen until the limit
position is reached.
• Step P00857 "Bar is moved out/pulled" is displayed.
12.12.3.3 Moving bar in

2) Press the "Move bar in/clamp" button.
• Step P00858 "Moving bar in" is displayed.
• The bar is moved into the movable mold clamping platen until the limit
position is reached.
• Step P00859 "Bar moved in" is displayed.
3) Press the "Move bar in/clamp" button once again.
• Step P00854 "Clamping bar clamping element" is displayed.
• The bar clamping element moves in.
• If the bar clamping element is moved in, step P00855 "Bar clamping
element clamped" is displayed.
4) Exit bar-pulling operation. To do this, deactivated the button "Activation of
mold change/clamping assembly module" (2).
I
Note
If the bar is not completely moved in, alarm A00209 "Bar-pulling device not
clamped" alarm is triggered (see section 12.12.4, page 12-958).
MX_MC6_V1.9_07.09.15_ENG
©KM
5) If necessary, acknowledge the alarm and switch the pump motor on.

12.12.4 Alarms, bar-pulling
W
Important
There is no possibility of alarm bypass in setting mode (see section 8.4.1,
page 8-381).
A00209 "Bar-pulling device not clamped"

• Bar not moved in (limit/proximity switch -B141 "Bar moved in") or not clamped
(limit switch -B145 "Bar clamping element clamped").
The bar must be moved in completely outside of bar-pulling operation and the bar
clamping element must be clamped.
If this is not the case, alarm A00209 "Bar-pulling device not clamped" is triggered
and the pump motor is switched off.
In bar-pulling operation, no machine movement is possible until the bar is not
completely moved in or the bar clamping element is not clamped.
A00210 "Bar limit switch monitoring"

• Limit switch for bar moved in (limit/proximity switch -B141 "Bar moved in") and
bar moved out (limit/proximity switch -B131 "Bar pulled") actuated.
If both limit/proximity switches of the bar are reached simultaneously, alarm

A00210 "Bar limit switch monitoring" is triggered and the pump motor is switched
off.
I
Note
The limit/proximity switch -B131 has a 1-signal as long as the bar is not moved
out.
Once the bar is completely moved out/pulled, the signal drops out.
A00211 "Bar clamping element limit switch"

• Limit switches for bar clamping element clamped (limit switch -B145 "Bar
clamping element clamped") and released (limit switch -B135 "Releasing bar
clamping element") activated.
MX_MC6_V1.9_07.09.15_ENG
©KM
If both limit switches of the bar clamping element are reached simultaneously,
alarm A00211 "Bar clamping element limit switch" is triggered and the pump
motor is switched off.

12.12.5 Bar-pulling for mold change
W
Important
• In bar-pulling operation, the bar-pulling speeds are limited to a maximum
of 30 mm⁄s. In subsections where there is no danger to operating
personnel, 60 mm/s is also permissible.
• With the bar pulled, move the MP slowly at max. speed of 100 mm/s.
1) Ensure that the installation of the bar-pulling device has been carried out
(see section 12.12.1.1, page 12-951).
2) Ensure that all electrical plug connections, cooling water connections and
hydraulic connections between the mold and machine are disconnected and
equipped with the corresponding covers/sealing plugs.
4) Enter the password.

6) Press the "Mold closing" button.

Mold is closed.
8) Attach transport locks to the mold.

9) Attach the lifting ropes to the mold.
10) Remove mold fixings (magnetic clamping system/clamping assembly or other
fixing) on the movable mold clamping platen (MP).
12) Bar-pulling (see section 12.12.3.2, page 12-956).

13) Press the "Mold opening" button until the movable mold clamping platen is
moved back to the necessary opening width.
MX_MC6_V1.9_07.09.15_ENG

©KM
15) Remove mold fixings (magnetic clamping system/clamping assembly or other

fixing) on the fixed mold platen.
16) Lift mold out.

I
Note
If, with the bar pulled, the distance between MP and FP is insufficient to install
a mold, the MP can be moved away from the FP using the "Mold opening"
function.
17) Bring the new mold into the installation position on the fixed mold clamping
platen.
18) Attach the mold to the fixed mold clamping platen (see section 7.16,
page 7-348).
20) Moving bar IN (see section 12.12.3.3, page 12-957).
21) Switch to screen page "Machine calibration" (see section 7.17.2, page 7-352)
and set selection "Set stroke encoder zero points" (1, fig. 7.32) to "manual".
22) Press the "Mold closing" button until the movable mold clamping platen butts
against the mold.
23) Set zero points of the position transducers manually (see section 7.17.2,
page 7-352)/(see section 8.14.1, page 8-628).
24) Press the button "Move pressure piston forward" and build up clamping force
until step P00020 "Clamping force reached" is displayed.
26) Attach the mold to the movable mold platen.

27) Remove the lifting ropes and transport locks on the mold.
28) Establish the electrical plug connections, cooling water connections and
hydraulic connections between the mold and machine.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.12.6 Venting the bar-pulling device

Prerequisites
Procedure
Fig. 12.97 Minimess connections, bar-pulling device, self-supporting

1 Minimess connections X131 and X141 2 Minimess connections X135 and X145
1) Connect bleed hoses with the Minimess connections for the self-supporting
bar-pulling device:
• X131, X141 at traverse cylinder of bar-pulling device (1, fig. 12.97)
• X135, X145 at clamping elements of bar-pulling device (2, fig. 12.97)
• X1310, X1311 at connecting lines to bar-pulling block and clamping block
of bar-pulling device with support
MX_MC6_V1.9_07.09.15_ENG

3) Then use the buttons "Release/move out bar" and "Move in/clamp bar" to
©KM
move the traverse cylinder of the bar-pulling device.

4) Bleeding is completed as soon as hydraulic oil flows out free of bubbles at all
bleed hoses into the oil reservoir.
5) Remove the bleed hoses while hydraulic fluid emerges and seal the Minimess
connections.

12.12.7 Servicing the bar-pulling device
Fig. 12.98 Lubrication points for bar-pulling device (with support)

1 Guide slide, lubrication point 3 Bar clamping element, lubricating point
2 Bar-pulling spindle
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 12.99 Lubrication points for bar-pulling device, self-supporting (without support)
1 Bar clamping elements, lubrication points

Prerequisites
• Suitable climbing aid available (e.g work platform; 3, Fig. 12.91).
12.12.7.1 Lubricating
Lubricant
Grease: Tribol 3020/1000-2 (see section 3.4.3.2, page 3-159).
Bar-pulling device (with support)

Grease lubricating points (1 and 3, Fig. 12.98) and entire bar-pulling spindle (2)
before commissioning and as necessary.
Bar-pulling device, self-supporting (without support)

Grease the lubrication points on bar clamping elements (1, fig. 12.99) before
initial operation and as required.
12.12.7.2 Cleaning
Bar-pulling device (with support)

Clean entire bar-pulling spindle (2, fig. 12.98) as necessary using a brush or
suitable tool.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.13 Self-sufficient gas/water systems (EUROMAP 62)

• The internal gas pressure systems are covered by enhanced safety
requirements.
• Only appropriate trained personnel may operate such systems.
• Observe the operating manuals of the manufacturers of such systems.
• Carry out the maintenance and upkeep of such systems in accordance with
the manufacturer's recommendations.
• It is essential to observe accident prevention regulations and the occupational
safety directive.
• Pressure vessels require to be inspected regularly by an approved inspection
authority.
• The setting of pressure and safety valves with anti-tamper seals must not be
altered.
• Inspect the safety devices each time before the system is started.
• Depressurize the system before commencing servicing and repair work.
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 12.100 Gas/water systems, self-sufficient 1
It is possible to make settings and check the signals from external gas/water
system on the screen, e.g. for fluid injector systems (ZE 42.65).

Station is switched off

The input signals are ignored; output signals are not issued.
Start time-delayed from start of injection

The entered delay time is started at the start of injection. If it elapses during
injection or holding pressure, the start signal is issued. After the end of holding
pressure, no more start signal is issued.
Start screw stroke-dependent

The start signal is issued if the entered screw stroke is reached during injection
or holding pressure.
Start time-delayed from beginning of holding pressure

The delay time starts with the start of holding pressure. It must have elapsed
during holding pressure in order to issue a start signal. After the end of holding
pressure, no more start signal is issued.
Start time-delayed from end of holding pressure

The delay time starts with the end of holding pressure. The start signal is issued
after holding pressure has elapsed if clamping force is still applied to the mold.
From the start of clamping force release, the start signal is no longer issued.
12.13.1 Input and output signals, gas/water system

All signals from or to the gas/water system are only processed with the selection
function activated. If it is deactivated, the input signals are ignored by the machine
and the output signals are not issued.
The software interface signals are displayed on the screen. The "Safety gates
shut" signal (Pin 7-8) cannot be displayed directly because it is a combination of
software and hardware signals (see section "Output K911 (Pin 7-8)",
page 12-966).
12.13.1.1 Inputs
Input Function
-FIS/EN_MO Enabling mold opening (Pin 25)
-FIS/EN_MC Enabling mold closing (Pin 26)
-FIS/RE Reject (Pin 27)
MX_MC6_V1.9_07.09.15_ENG
-FIS/FA Fault in gas/water system, no fault (Pin 28)

©KM
Input FIS/EN_MO (Pin 25)

The input is a necessary enable signal for Mold opening in all mode of operation.
With a 0-signal, step P00930 "Gas/water system blocks mold opening" is
displayed. In this case, it is not possible to open the mold.

Input FIS/EN_MC (Pin 26)

The input enables closing of the mold in semi-/fully automatic mode with a
1-signal. With a 0-signal, step P00929 "Gas/water system blocks Mold closing" is
displayed. In this case, it is not possible to close the mold.
Input FIS/RE (Pin 27)

The input is connected with reject processing in semi- and fully automatic mode.
With a 1-signal, the reject pieces counter is increased and the part is treated as a
bad part.
Input FIS/FA (Pin 28)

If the selection function "Gas/water system, self-sufficient" is activated, the input
is queried in all operating modes. With a 0-signal, the machine shuts down and
alarm A01116 "Fault in self-sufficient gas/water system" is issued.
12.13.1.2 Outputs
Output Function
-K911 Safety gates shut (Pin 7-8)
-K916 Mold closed (Pin 9)
-K913 Start gas/water supply (Pin 10)
-K917 Mold open (Pin 11)
-K918 Machine fault (Pin 12)
-K919 Automatic (semi- or fully automatic mode, Pin 13)
Output K911 (Pin 7-8)

The output is issued with closed mold cavity safety gates and closed nozzle
protection. It is taken over by a hardware-related safety circuit, which closes the
switching contact Pin 7-8 when output K911 is issued provided that the
emergency stop and the step-on safety grid (if installed) are not actuated.
Output K916 (Pin 9)

The output is issued with closed mold and clamping force built up.
Output K913 (Pin 10)

The output is set when the starting conditions in semi- and fully automatic mode
MX_MC6_V1.9_07.09.15_ENG
have been met for 0.5 seconds. The starting conditions are specified by the
selection program.
©KM

The output is set with mold completely open.

The output is set as soon as an alarm is issued that shuts down the machine.


The output is set in semi- and fully automatic mode of the machine.
I
Note
Pins 14, 15 and 16 are not defined by EUROMAP 62. They can be assigned
with signals from the KraussMaffei GID system to guarantee compatibility with
the old system.
The exact assignment is described in the hardware documentation.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.14 Magnetic clamping system (ZE 45.695x, 89.57x)
12.14.1 Safety instructions
w
D
Warning!
Nonobservance of the following information can result in potentially fatal injury
and damage to property:
• Check preconditions for the mold installation at the magnetic clamping

system and operation of the magnetic clamping system.
• In case of doubt or problems, contact the manufacturer of the magnetic
clamping system.
• Prior to mold change, secure the mold against falling down (crane) and
only release it after successful installation.
• Carry out a mold change according to the operating instructions of the
manufacturer.
• Do not change the configuration of the magnetic clamping system.
• Only use the magnetic clamping system for the purposes and material
intended by the manufacturer.
• Only trained and qualified personnel may operate the magnetic clamping
system.
q
d
D
Danger of crushing
Due to the powerful force of the magnetic field, there is a danger of crushing at
the clamping surface of the magnetic clamping system.
• Only magnetize when the mold is butting against the magnetic clamping
surfaces.
• Take note of core-pulling units or other moving mold parts.
L
p
R
Prohibited for persons with medical devices
Pacemakers, hearing aids or other medical devices can be damaged or
impaired by the magnetic clamping system.
MX_MC6_V1.9_07.09.15_ENG
Persons using these kinds of medical devices must not be present in the
©KM
vicinity of the magnetic clamping system.
a
B
Instructions on the operation and maintenance of the magnetic clamping
system are enclosed. All persons assigned to working on the machine must
have read and understood the operating manual before installing the machine
and performing the work.

Customer installation
• The magnetic clamping system must not be rearranged, reinstalled or
installed in another machine without prior consultation with the manufacturer
of the machine.
• Diagrams for installation and connection work are provided for customer
installations.
• The magnetic clamping system must be switched off along with the machine.
12.14.1.1 Safety devices
Temperature monitoring
Magnetic clamping plates are equipped with a temperature sensor that trips a
fault message when the maximum service temperature is reached.
Repeat magnetization
If the air gap between mold and magnetic clamping plate is too wide, the
magnetization is repeated automatically depending on the magnetic clamping
system:
1) The machine executes an EMERGENCY STOP immediately.
2) A magnetization cycle for clamping the mold starts up.
3) The air gap between the magnetic clamping plate and the mold is reduced.
The mold has been reclamped.
EMERGENCY STOP
If the machine is stopped by an EMERGENCY STOP, the magnetic clamping
system switches off if:
• Magnetizing or demagnetizing is not stopped.
• Magnetizing or demagnetizing was stopped but the magnetic clamping plates
are in undefined status.
12.14.1.2 Safety displays

Observe the operating Instructions of the magnetic clamping system, particularly
in the case of non-integrated magnetic clamping systems (ZE 45.4951,
ZE 89.57).
Magnetic clamping system with holding force display (ZE 89.573)

• Status messages and alarms on the "Mold change" screen (see fig. 12.103,
MX_MC6_V1.9_07.09.15_ENG
page 12-974)/(see fig. 12.104, page 12-975).

©KM
Control panel (ZE 89.571)

• Displays on the control panel (see fig. 12.111, page 12-985):
– PROXIMITY
– UCS
– FCS
• LEDs on the pc board in the control cabinet of the magnetic clamping system
(see fig. 12.112, page 12-987). The control cabinet must only be opened by
an electrician or Service technician.

12.14.1.3 Notes
Magnetic clamping plate

The magnetic clamping system can consist of two or several magnetic clamping
plates.
• The plates must be mounted in a defined manner on the FP and MP.
• Securing bores must be available on the MP and FP.
• Plates that belong together are marked. Example: M1 to M4 = MP, F1 to
F4 = FP. Observe identification plates on FP and MP!
Interface EUROMAP 70.0/70.1
W
Important
• Observe the circuit diagrams.
• Do not bundle the cable for the magnetic clamping system with other
cables.
• For divided machines, the cables for the platen connections are routed via
interfaces on the FP.
• The EUROMAP 70.x interface defines the signal exchange between machine
and magnetic clamping system.
Non-integrated interface EUROMAP 70.0

• ZE 89.57, 45.6951, 45.69511
• Control of non-integrated magnetic clamping systems is carried out at the
magnetic clamping system itself. Signals for clamping/releasing and feedback
signals "clamped/released" are not supported.
Partially integrated interface EUROMAP 70.1

• ZE 89.571, 89.573, 45.6952
• Control of partially integrated magnetic clamping systems is via the
operating/display panel or the control panel at the injection molding machine.
Signals for clamping/releasing and feedback signals are supported.
Control cabinet for magnetic system
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MX_MC6_V1.9_07.09.15_ENG
Low-voltage power fuses are provided and easily accessible in the control
©KM
cabinet of the magnetic clamping system.

The control cabinet must only be opened by an electrician or Service
technician.
• Circuit diagrams and information on the magnetic clamping system can be

found in the control cabinet of the system.
• The control cabinet can also contain LED displays for function monitoring.

12.14.2 Commissioning
Take note of the installation, operating and maintenance instructions (see chapter
18 Supplier Documentation).
12.14.3 Mold change with holding force display (ZE 89.573)
a
B
Note
In case of doubt or problems, especially with status messages/fault messages,
make use of the operating instructions of the magnetic clamping system or
contact the manufacturer of the magnetic clamping system.
12.14.3.1 Mold change interface
1
6
7
8
9
2 10
3 11
4 12
5 13
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 12.101 Mold change interface

1 Selection menu "Clamping geometry" 1) 8 Input field "Dimension Y1" 3)
2 Mold parameter MP 2) 9 "Save data" button
3 Tickbox "Mold with centring ring MP" 10 Mold parameter FP 2)
4 Holding force of magnetic clamping plate MP 11 Tickbox "Mold with centring ring FP"
5 Temperature of magnetic clamping plate MP 12 Holding force of magnetic clamping plate FP
6 Input field "Mold" 13 Temperature of magnetic clamping plate FP
7 Input field "Dimension X1" 3)
1) (see fig. 12.102, page 12-973)
2) (see section 12.14.3.2, page 12-973), work step 3
3)
(see section 12.14.3.2, page 12-973), work step 4

On the "Mold change interface" screen, the parameters for mold and clamping are
entered prior to the mold change.
The calculated holding force of the magnetic clamping plates and, in addition,
their current temperatures, are displayed as the result.
Holding force of magnetic clamping plate MP

The molding force of the magnetic clamping plate MP (4, fig. 12.101) is the
magnetic force with which the mold half fitted on the MP is held on the MP. If the
tear-open force / mold opening force is greater, the mold is released from the MP:
• The tear-open force of the machine must not be greater than the holding force
of the magnetic clamping plate at the MP.
• The ejector force that can force the mold from the MP, must not be greater
than the holding force of the magnetic clamping plate at the MP.
• The tear-open force of machine with an F-injection unit must not be greater
than the holding force of the magnetic clamping plate at the MP minus the
nozzle contact force after clamping force release.
Holding force of magnetic clamping plate FP

The molding force of the magnetic clamping plate FP (12, fig. 12.101) is the
magnetic force with which the mold half fitted on the FP is held on the FP. If the
tear-open force / mold opening force is greater, the mold is released from the FP:
• The tear-open force of the machine plus the nozzle contact force after
clamping force release must not be greater than the holding force of the
magnetic clamping plate at the FP.
Temperature of magnetic clamping plate MP / FP

The maximum contact temperature of the mold with the magnetic clamping plate
is described in the Technical data of the magnetic clamping system.
MX_MC6_V1.9_07.09.15_ENG
©KM

12.14.3.2 Determining holding force of the magnetic clamping system
W
Important
As long as the parameters of the clamping geometry (6 to 8, Fig. 12.101) are
not saved, no holding force is displayed.
1) On the "Mold change interface", select the clamping geometry

(1, fig. 12.101):
• Rectangular mold, concentric
• Rectangular mold, eccentric
• Round mold
• Special mold (special geometry)
2) In the "Mold" (6) input field, enter the name of the mold.
3) Entering mold parameters for MP/FP (2, 10):
• Mold height
• Mold weight
• Percentage share of holes (based on the clamping surface)
• Mold with centring ring
(Activate the tickbox (3, 11) for mold halves with centring ring.)
4) Measure parameter according to the selected clamping geometry and enter
in input fields (7, 8).
Clamping Rectangular mold, Rectangular mold, Round mold Special mold (special
geometry concentric eccentric geometry)
Displayed
graphic X2
(Fig. 12.101)
Y1 Y2 d
Y1
X1
X1
Parameters to Dimension X1: width Dimension X1/X2: Diameter d: diameter of Request the parameters
be entered distance to platen centre clamping surface from the manufacturer
(7, 8, (width) of the magnetic
Fig. 12.101) Dimension Y1: height Dimension Y1/Y2: clamping system.
MX_MC6_V1.9_07.09.15_ENG
distance to platen centre

(height)
©KM
Fig. 12.102 Entering clamping geometry
5) Press the "Save data" button (9, fig. 12.101).

The entered parameters (6 bis 8) are transferred to the magnetic clamping
system and the holding force (4, 12) is displayed.
6) Set the machine forces (tear-open force, ejector force, nozzle contact force)

12.14.3.3 Status messages during mold change
1 2
Fig. 12.103 Mold change (1/2)

1 Status messages from magnetic clamping system MP 2 Status messages from magnetic clamping system FP
There are two "Mold change" tabs. (Do not mix up with the "Mold change" screen,
see Fig. 12.108.)
The status messages are visualized in the first "Mold change" (see fig. 12.103,
page 12-974) tab with LEDs.
Status messages
Status messages indicate the operating status of the magnetic clamping plates
MX_MC6_V1.9_07.09.15_ENG
(MP or FP), e.g. magnetized or demagnetized.

©KM
Extended status messages

Extended status messages indicate faults in the magnetic clamping plates (MP or
FP).
Extended status messages, general

Extended general status messages indicate faults in the safety circuit, hardware
faults or missing readiness to start the machine cycle.

12.14.3.4 Alarm messages during mold change
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Warning!
The display of the holding force under "Warnings" is an information item that
does not intervene in the machine functions and limit the machine forces. It is
the responsibility of the setter to set the machine forces correctly.
1 2
Fig. 12.104 Mold change (2/2)

1 Status messages from magnetic clamping system MP 2 Status messages from magnetic clamping system FP
The alarms and warnings are visualized in the second "Mold change"
MX_MC6_V1.9_07.09.15_ENG
(see fig. 12.104, page 12-975) tab with LEDs.

©KM
Alarms / Warnings
The Alarms / Warnings indicate parameter violations. They must be eliminated
before the mold change or machine cycles can be continued.
Info field in the operating/display panel

In case of faults in the magnetic clamping system, group alarm A12161 "Fault
integrated magnetic clamping system" is displayed.

12.14.4 Setting machine forces
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Warning against tear open
Machine forces that are set too high (tear-open force, ejector force, nozzle
contact force) result in tearing opening of the mold and can lead to potentially
fatal injuries and damage to property.
• The control system does not indicate alarms if the set machine forces
exceed the holding force of the magnetic clamping system.
• The displayed holding force (4, 12, Fig. 12.101) and all warnings related to
holding force (Fig. 12.105) are for information purposes and do not limit the
machine forces.
• Observe special features of the mold (geometry, material, increased tear-
open force through over-injection).
• If not all magnetic poles are covered by the mold, make allowance for
holding force reduction in accordance with the manufacturer's
documentation.
W
Important
Set the machine forces as low as possible.
MP
• The tear-open force must be lower than the holding force of the magnetic
clamping plate MP (4).
• The ejector force must be lower than the holding force of the magnetic
clamping plate MP.
• On machines with F-injection unit: the sum of nozzle contact force after
clamping force release plus tear-open force must be lower than the holding
force of the magnetic clamping plate MP.
FP
• The sum of nozzle contact force after clamping force release plus tear-
open force must be lower than the holding force of the magnetic clamping
plate FP (12, fig. 12.101).
MX_MC6_V1.9_07.09.15_ENG
Procedure
1) Determine the holding force of the magnetic clamping system
©KM
(see section 12.14.3.2, page 12-973) or refer to the manufacturer's

documentation.
2) Set the tear-open force on the screen "Mold opening" (see fig. 12.105,
page 12-977).
3) Set the ejector force on the screen "Ejector" (see section 8.7.3.1,
page 8-435).
4) Set the nozzle contact force on the screen "Injection unit movement"

5) Clear all warnings on holding force that appear in the second tab "Mold
change" (see fig. 12.104, page 12-975) or at the control panel.
Reducing tear-open force
Fig. 12.105 Mold opening

1 Input field "Tear-open force"
For machines with magnetic clamping system, the maximum tear-open force is
entered on the "Mold opening" screen (1, fig. 12.105).
Tear open/tear-open force

• The tear-open force is required to move the mold halves apart.
• The maximum tear-open force is built up during the cycle operation. The
MX_MC6_V1.9_07.09.15_ENG
maximum value is reached with an over-injected mold or at a very high mold

©KM
opening speed (in the first opening stage).

• The tear-open force cannot be checked by opening a newly installed mold
because the mold opens without the maximum tear-open force having to be
built up.

12.14.5 Operation / mold change
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Warning!
• Secure the mold against falling down (crane).
• With ZE 89.571, the LED displays are located in the control cabinet. The
control cabinet must only be opened by an electrician or Service
technician.
a
B
Note
• In case of doubt or problems, refer to the operating instructions of the
magnetic clamping system or contact the manufacturer of the magnetic
clamping system.
• Read the instructions on mold installation (see section 7.16, page 7-348)
and zero-point calibration (see section 7.17, page 7-351) before the mold
change.
12.14.5.1 Magnetizing per operating/display panel (ZE 89.571, 89.573)
2 3 4 5 6 7

1 Mold change/clamping assembly module 4 Button "Demagnetize MP"
2 "Activation of mold change/clamping assembly 5 Button "Magnetize MP"
module" button 6 Button "Demagnetize FP"
3 "Pressure release" display 7 Button "Magnetize FP"
MX_MC6_V1.9_07.09.15_ENG
©KM

Keyswitch for approval

The keyswitch has to be actuated for magnetizing and demagnetizing (two-hand
operation).
Fig. 12.107 Keyswitch for approval
Prerequisites
• Mold attached plane-parallel
• "Setting stroke encoder zero points" (1, fig. 7.32) "manual" selected
(calibration mode active)
• Clamp. unit is moved up to maximum opening stroke
• Ejector in mechanical limit position

• Injection unit in mechanical limit position
Procedure
• The button "Activation of mold change/clamping assembly module" (2)
and the "Pressure release" (3) display light up.
• The automatic pressure release relieves the hydraulic area core-pulling at
the FP/MP and the cascade control area.
2) Check that the mold is secured to the crane. Confirm safety prompt "Enable
clamping system - mold secured?".
MX_MC6_V1.9_07.09.15_ENG
3) Align the mold with the centring ring of the FP.

©KM
• ZE 89.571: PROXIMITY flashes at the control panel (2, fig. 12.111).

• ZE 89.573: the LED "Mold present FP" (2, fig. 12.103) lights up.
4) Carefully close the clamping unit until the MP is touching the mold and the
mold is fitted into the centring ring of the MP.
The mold is touching the magnetic clamping plates on both sides.
• ZE 89.571: PROXIMITY goes out at the control panel.
• ZE 89.573: the LED "Mold present MP" (1, fig. 12.103) lights up.
5) Set clamping unit zero point (see section 7.17.2.2, page 7-353).

6) Close clamping unit until calibration clamping force (see section 8.7.1.6,
page 8-425) is built up.
7) Turn the keyswitch to "1" and hold it.

8) To magnetize the FP, press the "Magnetize FP" button until step P00456
"Fixed mold platen clamped" is displayed.
9) Release the keyswitch.
• ZE 89.571: in the control cabinet, the green LED 9 (9, fig. 12.112) lights
up.
• ZE 89.573: the LED "Mold magnetized FP" (2, fig. 12.103) lights up.
11) To magnetize the MP, press the "Magnetize MP" button until step P00457
"Movable mold platen clamped" is displayed.
• ZE 89.571: in the control cabinet, the green LED 12 (12, fig. 12.112) lights
up.
• ZE 89.573: the LED "Mold magnetized MP" (1, fig. 12.103) lights up.
Both mold halves are magnetically clamped.
13) Check: after magnetizing, no alarms, warnings or faults must be displayed.
14) The mold can be opened.
15) Carry out further steps as described under "Mold installation"
(see section 7.16, page 7-348) and "Zero-point calibration" (see section 7.17,
page 7-351).
12.14.5.2 Magnetizing per operating/display panel (ZE 89.571, 89.573)
Prerequisites
• Mold secured against falling down (crane)
• Clamping unit closed, clamping force is built up

• "Setting stroke encoder zero points" (1, fig. 7.32) "manual" selected
(calibration mode active)
• Ejector in mechanical limit position
MX_MC6_V1.9_07.09.15_ENG
• Injection unit in mechanical limit position

©KM

Procedure
• The button "Activation of mold change/clamping assembly module" (2)
and the "Pressure release" (3) display light up.
• ZE 89.571: PROXIMITY (2, fig. 12.111) is dark at the control panel.
• ZE 89.573: the LEDs "Mold present MP/FP" (1, 2, Fig. 12.103) light up.
4) To magnetize the FP, press the "Demagnetize FP" button until step P00454
"Fixed mold platen released" is displayed.
• ZE 89.571: in the control cabinet, the red LED 10 (10, fig. 12.112) lights
up.
• ZE 89.573: the LED "Mold demagnetized FP" (2, fig. 12.103) lights up.
7) To demagnetize the MP, press the "Demagnetize MP" button until
step P00455 "Fixed mold platen released" is displayed.
• ZE 89.571: in the control cabinet, the red LED 11 (11, fig. 12.112) lights
up.
• ZE 89.573: the LED "Mold demagnetized MP" (1, fig. 12.103) lights up.
9) After the demagnetizing process is completed without errors, open the
clamping unit to the maximum opening stroke.
The mold can be removed from the machine.
• ZE 89.571: at the control panel, FCS (1, fig. 12.111) and PROXIMITY (2)
light up.
• ZE 89.573: the LEDs "Mold present MP/FP" (1, 2, Fig. 12.103) light up.
MX_MC6_V1.9_07.09.15_ENG
©KM

Option: removing mold halves individually
Fig. 12.108 Mold change

1 Tickbox "Mold removal without clamping force monitoring"
Prerequisites
On the "Mold change" screen, the option "Mold removal without clamping force
monitoring" (1, fig. 12.105) must be activated by KraussMaffei. (Do not mix up
with the "Mold change" tabs, see Fig. 12.103/12.104.)
Procedure
1) Ensure prerequisites are met, as described under "Prerequisite"
(see section 12.14.5.2, page 12-980).
2) Secure both mold halves against falling down (crane).
MX_MC6_V1.9_07.09.15_ENG
3) On the "Mold change" screen, activate the tickbox "Mold removal without
©KM
clamping force monitoring".

The condition "Mold under clamping force" is deactivated.
4) Open the clamping unit to maximum opening stroke.
5) Demagnetize both mold halves independently of one another and remove as
described in "Procedure" (see section 12.14.5.2, page 12-980).

12.14.5.3 Magnetizing/demagnetizing at the magnetic clamping system (ZE 89.57)
I
Note
This option is used when the magnetic clamping system is not controlled by the
machine.
4 1

1 Mold change/clamping assembly module 3 "Pressure release" display
2 "Activation of mold change/clamping assembly 4 Button "Magnetic clamping system connection"
module" button
Procedure
1) Prerequisites
• Magnetizing: (see section 12.14.5.1, page 12-978)
• Demagnetizing: (see section 12.14.5.2, page 12-980)
• The button "Activation of mold change/clamping assembly module" (2),
"Pressure release" (3) display and the button "Magnetic clamping system
connection" (4) light up.
4) Press button "Magnetic clamping system connection".
MX_MC6_V1.9_07.09.15_ENG
The machine checks the safety and sends the enable signal to the magnetic
clamping system.
©KM
With the enable issued, the yellow border of the button "Magnetic clamping
system connection" turns green and is now completely green.
5) Carry out magnetizing/demagnetizing in accordance with the operating
instructions for the magnetic system.
6) Carry out further steps as described under "Mold installation"
(see section 7.16, page 7-348) and "Zero-point calibration" (see section 7.17,
page 7-351).

12.14.6 Control panel (example ZE 89.571)
a
B
Note
In case of doubt or problems, or with the use of another control panel, refer to
the operating instructions for the magnetic clamping system or contact the
manufacturer of the magnetic clamping system.
12.14.6.1 Magnetic clamping plate
9
8
7 2
6
3
4
5
Fig. 12.110 Magnetic clamping plate (example)

1 Pole 6 Centring ring
2 Flux control system (FCS) 7 Proximity switch
3 Housing 8 Junction box
4 Epoxy resin 9 Cable connection
5 Fastening bores
MX_MC6_V1.9_07.09.15_ENG
©KM

12.14.6.2 Control panel of magnetic clamping system
1 2
4 3
Fig. 12.111 Control panel for magnetic clamping system (ZE 89.571)
1 Illuminated pushbutton FCS (yellow) 3 UCS lamp (red)
2 PROXIMITY lamp (yellow) 4 RESTART/ENABLE switch
Illuminated pushbutton FCS (yellow)
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Warning against tear open
When the FCS illuminated button is flashing, the magnetic clamping force is
insufficient. This can lead to potentially fatal injuries and damage to property.
• Do not operate the magnetic clamping system when the FCS illuminated
button is flashing.
• Follow the instructions in the operating instructions for the magnetic
clamping system or contact the manufacturer of the magnetic clamping
system.
• Ensure that the red FCS sensor in the measuring poles are covered by the
mold.
• Do not deactivate the flashing of the FCS illuminated button:
– Flashing can be deactivated by pushing a button and machine
operation can thus be forced. The flashing has simply been switched
off. The danger of insufficient magnetic clamping force remains.
– Deactivate the flashing only on your personal responsibility and while
observing all safety measures!
MX_MC6_V1.9_07.09.15_ENG
The FCS illuminated button switches the Flux Control System (FCS) on and off.
©KM
The system checks whether the magnetic flux has reached the calibrated value.
The red FCS sensors are located in special measuring poles on the magnetic
clamping plate.
Lights up FP and MP switched off simultaneously

Flashes Magnetic force insufficient
Total value for clamping not reached
Magnetic pole with red dot not sufficiently covered
Off Magnetic force sufficient

PROXIMITY lamp (yellow)

The PROXIMITY lamp indicates when the two proximity switches SQ1/SQ2
(7, fig. 12.110) have detected the following statuses:
• Incorrect mold position during clamping
• Imminent loosening of the mold in cycle operation
The proximity switches interrupt the mold movement when the air gap width is
increased.
Lights up Both mold halves missing

No proximity switch assigned
Flashes One of the two mold halves incorrectly positioned
Only one proximity switch assigned
Off Both mold halves centred
Both proximity switches assigned
UCS lamp (red)

The UCS lamp always lights up if an alarm is pending.
Functions:
• Check of the current supply to the magnetic clamping plates during
magnetizing/demagnetizing
• Check for impermissible current flow in the magnetic clamping system in cycle
operation (except for magnetizing/demagnetizing)
• Indicates that a mold has become loose in connection with
magnetizing/demagnetizing of a plate.
Lights up in case of Problems with the power supply, and thus no proper magnetizing or
alarm demagnetizing
Unexpected current pulse
One of the proximity switches signals that the mold has become loose
RESTART/ENABLE switch
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Caution
MX_MC6_V1.9_07.09.15_ENG
The RESTART/ENABLE switch must not be activated during magnetizing and

©KM
demagnetizing.
Do not continuously press and hold the switch.
Functions:
• Resetting the control system
• Bridging the safety devices

12.14.6.3 LEDs in the control cabinet for the magnetic clamping system
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Low-voltage power fuses are provided and easily accessible in the control
cabinet of the magnetic clamping system.
The control cabinet must only be opened by an electrician or Service
technician.
12 9
11 10
8 7
13 14
2 1
15 3
16 4
Fig. 12.112 LEDs on the pc board PR06 (ZE 89.571)

1 Yellow - FP proximity switch 9 Green - FP magnetized
2 Yellow - MP proximity switch 10 Red - FP demagnetized
3 Red - Mold change IMM 11 Red - MP demagnetized
4 Red - cycle 12 Green - MP magnetized
(lights up during magnetizing/demagnetizing) 13 Yellow - MP FCS Alarm
5 1) 14 Yellow - FP FCS alarm
6 1) 15 Green - FCS deactivated
7 Red - FP alarm 16 Yellow - magnetic clamping system faultless
8 Red - MP alarm
1) LEDs 5 /6 not available
MX_MC6_V1.9_07.09.15_ENG
The LEDs indicate the functions of the magnetic clamping system and must be
©KM
checked during commissioning. In the event of a fault, they must be checked by

an electrician or Service technician.

12.14.7 Fault rectification

Eliminate faults in accordance with the specifications
(see chapter 18 Supplier Documentation)
12.14.8 Maintenance
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• Disconnect the power supply.
• Take safety precautions.
• Wear protective clothing.
Carry out maintenance tasks according to the specifications.

12.14.9 Taking machine out of service

For decommissioning, storage and disposal,
MX_MC6_V1.9_07.09.15_ENG
©KM

12.15 Mold heating KraussMaffei/PSG (ZE)
12.15.1 General
This chapter describes the functions of the KraussMaffei/PSG mold heating (PSG
= Plastic Service Group). Functions that are not listed explicitly are identical to the
mold heating described in chapter 8.11.
The display is split into up to 3 screens. The parameters for setting and displaying
the mold temperatures are shown on these screens.
12.15.2 Automatic ramp

The different dimensions of the control zones in a hotrunner result in different
temperature levels. During heating up, for example, the set temperatures of the
nozzles are reached significantly faster than in the distributor zones. This results
in temperature-dependent variations in the expansion of the steel, which causes
undesirable mechanical stress.
If the heating circuit is implemented via an automatic ramp, all control zones are
heated evenly as far as possible. All zones are oriented automatically to the
respective slowest control zone. Its actual value is used as a reference for the set
values of the remaining zones.
This measures ensures during the heating up phase that all zones remain
automatically at the same temperature level. The hotrunner is relieved and
conserved. This can reduce damage and extend maintenance intervals.
W
Important
A zone is removed from the automatic ramp group if one of the following
occurs:
• Sensor in the zone is faulty.
• The zone is in OD setter mode.
• The manual temperature ramp is active.
• The zone is switched off.
MX_MC6_V1.9_07.09.15_ENG
©KM

3
4
5
6
Fig. 12.113 Mold-temperatures start-up/lowering

1 "Start-up switching" selection menu 4 "Boost time" input field
2 Selector switch "Drying out program On/Off" 5 "Start Boost" button
3 "Boost temperature" input field 6 "Stop boost" button
The selection program "Heating circuit via automatic ramp"

is set on the screen "Mold temperatures start-up/lowering" via the selection menu
"Start-up circuit (1, fig. 12.113)".
MX_MC6_V1.9_07.09.15_ENG
12.15.3 Prioritized heating

©KM
The "Prioritized heating" function (2, fig. 8.100) is included in the

KraussMaffei/PSG mold heating in the function "Heating circuit via automatic
ramp". This does not require separate setting parameters.

12.15.4 Drying out program (Heat‘n‘Dry)

If molds are stored for long periods, the insulation material on the electric heating
elements can attract moisture. With rapid heating-up operations (without drying
out program Heat‘n‘Dry), this moisture can result in steam pressure inside the
cartridge heater and can damage it. Furthermore, the moisture can cause
leakage current if protective conductors are connected. Leakage current trips a
fault-current circuit breaker and thus prevents heating up.
The function "Drying out program" (PSG term: Heat‘n‘Dry) offers a gentle heating-
up procedure with a power supply that increases step-by-step. The leakage
current is checked continuously. The moisture is completely dried at a set value
of 110 °C.
Heating up to the final set value only takes place if there is a guarantee that
• the fault current is below the limit value of 60 mA
• there is no more moisture in the heating elements.
The drying out program starts if the following starting conditions are met:
• Actual value < 90 °C
• Set value > 110 °C
• Drying out program (2, fig. 12.113) switched on.
MX_MC6_V1.9_07.09.15_ENG
©KM

Fig. 12.114 Mold temperatures graphic 1 - "Drying out program" mode

1 Diagrammatic display of the actual and set values 3 Display of "Drying out program active" status
2 Selector switch "Drying" 4 "Edit" button 1)
The settings for the mold temperature zones are made on the screen "Mold
temperatures graphic 1" (see fig. 12.114, page 12-992). Via the selector switch
"Drying" (2, fig. 12.114), the control zones of the mold heating are selected for the
drying out program.
During the heating-up phase of the zones with active drying out program, the
zones in which drying is not active are also regulated to 110 °C. After the zones
with active drying out program have been controlled to 110 °C, all zones are
MX_MC6_V1.9_07.09.15_ENG
regulated to the set value (see fig. 12.114, page 12-992).

©KM
I
Note
No current measurement is carried out while the drying out program is running.
As long as the drying out program is active, this is indicated at the respective zone
in the status display by the symbol "Drying out program is active" (3, fig. 12.114).

Symbol legend for status message

Drying out program is active
Symbol legend for temperature status and fault messages (see section 8.11.1.1,
page 8-557)
12.15.5 Boost
In boost mode, the set values are raised, e.g. to heat nozzles briefly after
downtimes and to guarantee a smooth production start.
Boost mode can be used in two situations:

• Boost mode is started during operation with the Start button (5, fig. 12.113).
The set values of the control zones are increased by an adjustable
temperature value (3). After a predefined time (4), Boost mode is ended
automatically. Otherwise Boost mode is ended with the Stop button (6).
• Alternatively, the function can be controlled by an internal signal. In this case,
Boost mode follows heating up. The control zones are increased for an
adjustable time (4) by an adjustable temperature value (3). This process
support the user during automated heating-up procedures because manual
intervention is no longer required.
A special control system is required for the function via an external system.
MX_MC6_V1.9_07.09.15_ENG
©KM

Fig. 12.115 Mold temperatures graphic 1 - "Boost" mode

1 Diagrammatic display of the actual and set values 3 Display of "Boost" status
2 "Boost" selector switch 4 "Edit" button 1)
On the "Mold temperatures graphic 1" screen (see fig. 12.115, page 12-994), the
control zones for mold heating for "Boost" mode are selected via the "Boost"
(2, fig. 12.115) selector switch.
If "Boost" mode is activated (5, fig. 12.113), the set values in the selected control
zones are increased by the set temperature value (3). As long as Boost mode is
active, this is indicated in the screen "Mold temperatures graphic 1" at the
respective zone in the status display with the symbol "Boost is active"
(3, fig. 12.115).
MX_MC6_V1.9_07.09.15_ENG
When "Boost" mode is deactivated (6, fig. 12.113) or after the set time (4) has
©KM
elapsed, all zones are regulated to the respective set value.

Boost is active
Symbol explanations for temperature status and fault messages


12.15.6 Guide zone mode

In the event of a sensor defect, a zone does not necessarily have to be shut down
or immediate repair carried out.
There are two alternative functions for solving this case:
• OD setter mode (see "OD setter", page 8-555)
• Guide zone mode.
Fig. 12.116 Mold temperatures graphic 1 - "Guide zone"

1 Diagrammatic display of the actual and set values 3 "Guide zone" input fields
2 Display of "Guide zone mode is active" status 4 "Edit" button 1)
MX_MC6_V1.9_07.09.15_ENG
Guide zone mode provides the option of regulating the zone with a sensor defect
from a similar type of zone with a functioning sensor. For this purpose, the zone
©KM
with defective sensor must be informed of the zone number of the guiding zone.
This ensures that the zone with faulty sensor is also regulated.
Guide zone mode guarantees operational reliability and prevents production
downtimes.
The number of the guiding temperature zone can be set via the "Guide zone"
(3, fig. 12.116) input fields. The guide zone mode is switched off if the value = 0
is set.

As long as guide zone mode is active, this is indicated at the respective zone in
the status display with the symbol "Guide zone mode is active" (2, fig. 12.116).

Guide zone mode is active
Symbol legend for temperature status and fault messages (see section 8.11.1.1,
page 8-557)
MX_MC6_V1.9_07.09.15_ENG
©KM

12.15.7 Hotrunner leak monitoring

The hotrunner leak monitoring is an important module for operational reliability. It
is used to monitor the status of the hotrunner with regard to leaks. If used
correctly, unnecessary downtimes for cleaning the hotrunner to remove over-
injected plastic are avoided.
Evaluation of the process parameters allows the hotrunner leak monitoring
system to detect a pending leak quickly and reliably.
1
5
6
2
3
4

1 Heating zones for mold heating 4 Button for "Acknowledge alarms of hotrunner leak monitoring"
2 Display of "Alarm hotrunner leak monitoring" status 5 Temperature actual and set values of heating zones
3 "Hotrunner leak monitoring" selection 6 Display of "Hotrunner leak monitoring active" status
MX_MC6_V1.9_07.09.15_ENG
After the heating is switched on, the hotrunner leak monitoring automatically
©KM
determines in a learning phase the characteristic values (working point, tolerance

range) which are used to monitor the status of the control zone in the hotrunner.
As long as the learning phase is active, this is indicated at the respective zone in
the "Status" display by the symbol "Learning phase, hotrunner leak monitoring is
active".
With hotrunner leak monitoring active, in the respective zone in the "Status"
display a green symbol "Hotrunner leak monitoring is active" (6, fig. 12.117) is
displayed.


Learning phase, hotrunner leak monitoring is active
Hotrunner leak monitoring is active
Alarm hotrunner leak monitoring
Alarm with hotrunner leak monitoring

If the hotrunner leak monitoring function is running, in the event of a fault, i.e. if a
tolerance limit is exceeded, alarm A00729 "Mold heating: zone xxx hotrunner leak
monitoring" is generated and the machine stops at the end of the current cycle. In
addition, a red symbol "Alarm hotrunner leak monitoring" (2, fig. 12.117) is shown
in the respective zone in the status display.
I
Note
An alarm from the hotrunner leak monitoring is generated until it is permanently
acknowledged after repair or after a mold change.
If a hotrunner leak was repaired or a mold change was carried out, the alarms can
be acknowledged permanently. The acknowledgement is carried out by actuating
the button "Acknowledge alarms of hotrunner leak monitoring" (4, fig. 12.117).
Acknowledgement is only possible in setting mode and is protected by a safety
prompt (see fig. 12.118, page 12-998).
MX_MC6_V1.9_07.09.15_ENG
©KM
Fig. 12.118 Safety prompt
W
Important
If hotrunner leak monitoring alarms are acknowledged without repair of the
leak, incorrect characteristic values will be learnt the next time the mold heating
system is switched on. Any leaks that then occur will no longer be detected.

12.15.8 Sensor type/compensation

1 "Sensor" display 2 "Compensation" display
The "Mold temperatures control parameters 1" screen (see fig. 12.119,
page 12-999) displays the sensor type and compensation. Both values are
specified in the electrical diagram and cannot be changed.
Sensor type
• J: sensor type J (iron, copper, nickel), DIN IEC 584
• L: sensor type L (iron, copper, nickel), DIN 43710
MX_MC6_V1.9_07.09.15_ENG
• K: sensor type K (nickel, chrome, nickel), DIN IEC 584

©KM
Compensation
• 0: Internal compensation on module rack
• 1: External compensation 1
• 2: External compensation 2

Symbol legend for status and error messages
Error during optimization

Drift error
If a drift error occurs during optimization, this will be displayed in addition to the
optimization status display.
Sensor fault
Sensor break
In the case of a sensor break, there is an interruption at an undefined point in the
sensor circuit between the sensor and controller. After the fault is detected, a fault
message is issued immediately and the heating for the corresponding zone is
switched off.
Sensor short-circuit
• The sensor cable is crushed at some point between sensor and controller,
which causes a short-circuit.
• The sensor is not in its designated position (removed, or interchanged with
another sensor).
Sensor reverse polarity

In case of sensor reverse polarity, the thermocouple is connected with the wrong
polarity to the controller. The incorrect wiring means that the controller measures
an incorrect actual value.
Potential fault at sensor input

An excessively high voltage was detected at the sensor input. For protection
purposes, all zones (incl. zones on the other power controller cards) are de-
energized (relay on power controller card off) because voltage can come from
every zone.
Other faults
Safety shutdown (actual value too high)
If no load is detected when the heating is switched on, the heating circuit is de-
energized (relay on power controller card off) and a fault message is issued.
Hardware error
MX_MC6_V1.9_07.09.15_ENG
• Defective controller module

©KM
• Defect on a VARAN component

• VARAN communication error

Phase/fuse error
The hotrunner controller checks the status of the phases and fuses in the heating
circuits and issues a fault message if there is a defect.
Heat sink temperature alarm

The temperature in the module rack of the KraussMaffei/PSG mold heating is too
high or the fan in the module rack is defective.
Symbol legend for temperature status and fault messages (see fig. 8.112,
page 8-557)
MX_MC6_V1.9_07.09.15_ENG
©KM

12.15.9 Heating circuit monitoring

The heating current measurement and heating current monitoring have the
following goals:
• Heating currents are determined by means of measurement
• Measured Value are compared with the set value and tolerance
• A plausibility check is carried out.
1
2
3
4
5
6
7
Fig. 12.120 Mold heat. circuit monit.

1 "Current" set values 5 "Accepting actual values as set values" pushbutton
2 "Current" actual values 6 "Tolerance" input field
3 "Leak current" actual values 7 Activation of "Fault heating circuit monitoring blocks cycle"
4 "Status" display
MX_MC6_V1.9_07.09.15_ENG
The display and setting of the parameters for Mold heating circuit monitoring
©KM
takes place on the screen "Mold heat. circuit monit.".

The heating currents are measured in a fixed pattern. Apart from the display of
the currently flows heating currents, the heating current measurement provides
information on the status of the heater (total failure or partial failure with parallel
connections of heaters) and monitors the current value (2, fig. 12.120), while
making allowance for a tolerance range (6).
Explanation of parameters (see section 8.11.4.1, page 8-568)
Explanation of the status symbols (see page 12-1003)

The heating current measurement monitors the status of the power controllers
and signals an alarm with continuously activated heating controllers, which can
be damaged due to overheating at the heater.
The heating current measurement supports a large number of controller

functions. Incorrect adaptations of the control parameters, for example, can be
avoided because the automatic parameter determination (optimization) is only
started if a corresponding heat current of the control zone is detected. Only then
can you guarantee that the zone is ready for heating. Otherwise, the optimization
function is delayed until a heating current is detected.
In addition, any fault current that is present is displayed. This provides important
information on the status of the heaters in the hotrunner and signals damage in
good time.
The heating current measurement is carried out via current transformers.
Symbol legend for heating circuit monitoring status and error messages
Fuse faulty
The hotrunner controller checks the status of the fuses in the heating circuits and
issues a fault message if there is a defect.
Heating circuit interruption

If there is an interruption in the heating circuit or no load is connected, the fault
message "Heating circuit interruption" is displayed.
Short-circuit fault (Thyristor)

A Thyristor short-circuit fault indicates a defect in a module in the hotrunner
controller.
The hotrunner controller measures the heating currents to check whether heating
in the hotrunner controller is uncontrolled due to a defective power controller
(Thyristors). As this is a critical error, which can result in damage to the heating
circuit due to overheating, the heating circuit is de-energized immediately (relay
on power controller card off).
Leakage current fault

The leakage current limit of 60 mA was exceeded and the heaters were de-
MX_MC6_V1.9_07.09.15_ENG
energized (relay on power controller card off).

©KM
Current limit fault

When the control zone is switched on, the heating current is checked. If it exceeds
the limit of 16 A, there is either a short-circuit in the heating circuit or the load is
too high. The heating circuit is de-energized (relay on power controller card).

Current tolerance error

A current tolerance error (+/- tolerance error) indicates that a heating current was
measured that is outside the tolerance range of the comparison value (current set
value) defined for the temperature zone.
The hotrunner controller continuously measures the currents through the heater
and compares them with reference values - the current set values. This can be
specified manually or automatically by pressing the button "Accepting actual
values as set values" (5, fig. 12.120). A current tolerance error indicates either a
partial failure of a heater or that the current set values have not yet been set
following a change of the hotrunner connected to the controller.
A current tolerance error provides the operator with a concrete reference to a fault
in the hotrunner or an incorrect setting and offers an option for fast correction of
the fault.
Symbol legend for heating circuit monitoring status and fault messages
(see fig. 8.118, page 8-570)
12.15.10 Diagnosis mold hotrunner system - MoldCheck

During the diagnosis of the mold hotrunner system, a complete check of the
electric state of the hotrunner system (PSG term: MoldCheck) and the associated
peripherals is carried out.
Apart from the complete wiring check, the diagnosis also includes a performance
test of heaters and sensors.
The diagnosis is carried out for all zones in which "Measuring" mode is set. The
mode setting is carried out on the screen page "Mold temperatures graphic 1"
(see fig. 12.114, page 12-992).
W
Important
The diagnosis must only be carried out when the machine is not producing. The
mold heating must be switched on.
MX_MC6_V1.9_07.09.15_ENG
©KM

1
2
3
4
5
6
7
Fig. 12.121 Diagnosis mold hotrunner system (1/4)

1 "Status" display 5 Actual values "Leakage current"
2 "Error" button 6 Button for "Start diagnosis mold hotrunner system"
3 "Outflow" actual values 7 Button for "Cancel diagnosis mold hotrunner system"
4 "Inflow" actual values 8 Information window
The diagnosis is tripped on the screen "Diagnosis mold hotrunner system"

(see fig. 12.121, page 12-1005) by pressing the button "Start diagnosis mold
hotrunner system" (6, fig. 12.121).
The diagnosis must only be carried out when the machine is not producing. For
this reason, the buttons "Start diagnosis mold hotrunner system" (6) and "Cancel
diagnosis mold hotrunner system" (7) are only active in setting mode.
MX_MC6_V1.9_07.09.15_ENG
The mold heating must be switched on.

©KM

Status
The LED colour displays the current diagnosis status of a zone:
LED colour Diagnosis status
Diagnosis is not yet being executed
Diagnosis is currently being executed
Diagnosis carried out with error
Diagnosis carried out without error
"Error" button
This button becomes active for faulty zones at the end of the diagnosis. When the
button is pressed, a window with the faults that occurred is displayed.
Outflow
Current at heater off, e.g. with shorted TRIAC
Inflow
Current flow with switched on heater
Leakage current
Current flow connected to earth
Button for "Start diagnosis mold hotrunner system"

Starts the diagnosis (can only be operated in setting mode)
Button for "Cancel diagnosis mold hotrunner system"

Cancels the diagnosis (can only be operated in setting mode)
12.15.10.1 Procedure
Prerequisites
MX_MC6_V1.9_07.09.15_ENG
• Machine is not in production

• Mold heating switched on
©KM
Procedure
1) On the "Diagnosis mold hotrunner system" screen (see fig. 12.121,
page 12-1005), press the button "Start diagnosis mold hotrunner system"
(6, fig. 12.121).

1
2
3
4
5
6
7

1 "Status" display 5 Actual values "Leakage current"
2 "Error" button 6 Button for "Start diagnosis mold hotrunner system"
3 "Outflow" actual values 7 Button for "Cancel diagnosis mold hotrunner system"
4 "Inflow" actual values 8 Information window
2) Switch to the screen "Diagnosis mold hotrunner system" (see fig. 12.122,
page 12-1007). The yellow information window displays "Diagnosis started"
(8, fig. 12.122).
MX_MC6_V1.9_07.09.15_ENG
©KM


1 "Status" display 2 Information window
3) The diagnosis of the individual heating zones is carried out in steps. The
currently active zone is highlighted yellow in the "Status" (1, fig. 12.123)
display. The yellow information window (2) displays the number of the
currently active zone.
3
MX_MC6_V1.9_07.09.15_ENG

©KM
1 "Status" display 3 Information window

2 "Error" button
4) When the diagnosis is complete, "Diagnosis ended" is displayed in the yellow

information window. Faulty heating zones are highlighted in red in the "Status"
(1, fig. 12.124) display and correct heating zones are marked green. For
faulty zones, the "Error" (2) button can be used to open a pop-up window
showing the faults (see fig. 12.125, page 12-1009) that occurred.

Fig. 12.125 Diagnosis zone
5) When the "Error" (2, fig. 12.124) button is pressed, a "Diagnosis zone"
(see fig. 12.125, page 12-1009) pop-up window appears with information on
the faults that occurred in the affected heating zone. The
"Error" (2, fig. 12.124) is only active if there are faulty zones.
12.15.10.2 Faults
During the diagnosis of the mold hotrunner channel system, the following faults
can be analysed:
• Diagnosis sensor assignment and sensor polarity
– Sensor break
– Sensor polarity
– No temperature increase
– Temperature increase in zone xxx
MX_MC6_V1.9_07.09.15_ENG
– Temperature increase despite shut-down heating

©KM
• Switch-on diagnosis
– Phase/fuse error
– Leakage current fault
– Potential fault at sensor input
– Short-circuit fault a heating output

• Outflow
– Current measured although heating is off
• Inflow
– No current measured
• Leakage current
– Leakage current present
I
Note
If it was not possible to measure a test point, "Test not carried out" is displayed
in the yellow information window (3, fig. 12.124).
MX_MC6_V1.9_07.09.15_ENG
©KM

12.16 Robot
See separate operating instructions:
• Linear robot LRX
• Industrial robot
MX_MC6_V1.9_07.09.15_ENG
©KM

MX_MC6_V1.9_07.09.15_ENG
©KM

13 Taking machine out of service/Placing into

storage/Disposal
This chapter provides you with information regarding taking the machine out of
service and reliable storage and disposal of the machine in conformity with
environmental regulations.
13.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . 1014

the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1014
13.3 Shutting down the machine . . . . . . . . . . . . . . . . . . . 1015
13.4 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 1016
13.5 Taking machine out of service . . . . . . . . . . . . . . . . . 1016
13.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1017

MX_MC6_V1.9_07.09.15_ENG
©KM
Taking machine out of service/Placing into storage/Disposal 13-1013

13.1 Safety regulations

Pay attention to the general accident prevention regulations relating to taking the
robot out of service and placing it in storage.
H
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D
Contact with hot surfaces on the machine may result in severe harmful effects,
Allow the machine to cool down before taking the machine out of service,
placing it into storage or disposing of it.
h
d
D
Severe injury may occur from detached lines that perform a whip-like action,
and from service products that flow out.
Depressurize the hydraulic and pneumatic supply before taking the machine
out of service, putting it in storage or disposing of it.
r
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Risk of slipping
When taking the machine out of service, placing it in storage or disposing of it,
service products, such as hydraulic oil, may flow out and pollute the floor area.
For this reason, ensure that suitable devices are available for catching such
fluids and keep the floor area around the machine clean.
e
d
D

MX_MC6_V1.9_07.09.15_ENG

©KM
13-1014 Taking machine out of service/Placing into storage/Disposal

13.3 Shutting down the machine

1) Ensure that all screw barrels are purged.
2) Ensure that no part remains in the mold.
3) Carry out preservation of the machine as follows:
a) Preserve mold as specified in instructions of mold manufacturer.
b) Switch off cooling water supply and disconnect.
c) Separate all cooling water hoses between barrel flange cooling and oil
cooler and collect water which flows out.
d) Blow through all cooling water hose connections between barrel flange
cooling and oil cooler, as well as connections at barrel flange and oil
cooler with compressed air, and dry.
e) Fit together all separated cooling water hose connections again.
f) Clean all sliding surfaces and machined metallic surfaces on clamping
unit and injection unit and treat with corrosion protection agent
CORREX 36 or an equivalent commercially available product.
4) Ensure that the installed mold is closed but that there is no clamping pressure.
5) Ensure that all safety gates are closed.
6) Ensure that the shut-off valves at the cooling water supply connection for the
feed and return flow are closed.
7) Switch off the pump motor, mold heating, mold temperature control and barrel
heating.
I
Note
Carry out the step described below only if the machine is equipped with a
pressure accumulator.
8) Ensure that the shut-off cock S5800 on the pressure accumulator block is
opened fully.
MX_MC6_V1.9_07.09.15_ENG
©KM

13.4 Storage conditions
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D
Warning!
Fluids that leak out can produce hazardous situations.
Prior to placing the machine in store, drain all the fluids (hydraulics, cooling
system).
Store the machine in such a way that it does not represent a hazard for the
environment.
In doing so, be absolutely certain to pay attention in this connection to the water
hazard classes of the materials and substances used and carry out any steps
in conformity with the valid environmental protection regulations and directives.
Note Specifications
Type of storage Store in a dry place, protected from dew.
Protect from direct rays of the sun.
Storage period Maximum storage period: 2 years
Space required (see chapter 3 Specifications)
Physical conditions Store in a dry, darkened room
13.5 Taking machine out of service
W
Important
Use only the cleaning products specified in the "Maintenance" chapter.
Activity Brief description

Shutting down machine Switch machine off.
Disconnect the energy and service product lines.
Drain all fluid reservoirs.
Cleaning Clean machine before placing into storage.
Observe valid safety regulations for machine parts in
which chemical products are used.
MX_MC6_V1.9_07.09.15_ENG
Attaching transportation guard (see chapter 4 Transport/Packaging)

Marking Affix storage and safety marking on the machine and on
©KM
the packaging.

13.6 Disposal
W
Important
Only authorized KraussMaffei personnel are permitted to dispose of the MX
machine.
13.6.1 Information regarding disposal procedure
Component Procedure
Packaging In the case of plastic packaging, pay attention to the
disposal regulations of the country concerned.
Operating materials Remove all service products from the machine.
(Hydraulic fluids from lines and tanks, oils and greases from
all drive motors and bearings)
Base unit Disassemble the base unit into the following groups:
plastics,
non-ferrous metals,
components which contain chemicals,
motors,
control components,
steel, sheets.
13.6.2 Disassembly
• Keep to the order specified for disassembly.
• Allow machine to cool down.
• Interrupt the mains supply.
• Stop the supply flow of service products.
• Drain the medium (see section 13.3, page 13-1015).
• Remove operating material connections and extraction.
• Disassembly in accordance with the specifications for the series.
W
Important
The method described below can also be used for relocating/preparing for
MX_MC6_V1.9_07.09.15_ENG
transportation.
©KM
2) Fit on transport lock.
3) Remove retaining pin from piston rod of injection unit traversing cylinder in
bearing bracket.
4) In setting mode, continue operating "Injection unit forward" button until the
piston rod of the injection unit traversing cylinder is fully retracted.

r
d
D
Risk of slipping
5) Remove the remaining granulate from the material conveyor.

6) Dismantle the material conveyor.
7) Remove mold.
8) Install clamping unit transport locks
e
d
D
The following step must only be performed by a properly qualified electrician.
Hazard from electrical voltage in the control cabinet.

10) Remove pre-fuses and disconnect power supply.
11) Take off parts removal unit if fitted.
W
Important
Collect hydraulic oil pumped out in a suitable vessel and dispose of in
conformity with regulations.
12) Drain hydraulic oil tank.

a) Close tank return-flow shut-off valve if fitted.
b) Ensure that the drain cock S5800 is opened fully.
13) Switch off cooling water supply and disconnect.
a) Separate all cooling water hoses between mold cooling, barrel flange
cooling and oil cooler and collect water which flows out.
b) Blow through connections at barrel flange cooling and oil cooler with
compressed air and dry.
c) Fit plugs to all connections and attach loose connections.
14) Switch off compressed air supply and disconnect. Fit plugs to all connections
MX_MC6_V1.9_07.09.15_ENG
and attach loose connections.

©KM
W
Important
Perform next step only in order to disassemble machine.
15) Remove central lubrication pump if fitted.

16) Remove the nozzle safety gate.

i
t
Environmental note
Collect hydraulic oil pumped out in a suitable vessel and dispose of in
conformity with regulations.
17) Separate all hydraulic hose and pipe connections at the operator rearside. Fit
plugs to all connections and attach loose connections.
W
Important
Perform next step only in order to disassemble machine.
w
D
Caution
Prior to disassembly or repair, relieve the oil pressure in the pressure
accumulator system.
When conducting repairs at the pressure vessel, the prefill pressure must also
be drained.
18) Remove pressure accumulator.

19) In control cabinet field 5, separate all the plug-in connectors which transmit
signals to the clamping unit.
a) Fit dummy covers to all the plug-in connectors.
b) Run all the plug-in connectors which transmit signals to the clamping unit,
out of the control cabinet, place down in the clamping unit and attach.
20) Remove securing bolts and side adjustment bolts.
21) Remove securing nuts from all wedge shoes / suspension elements.
13.6.3 Disposal points
Activity Short description

Return to manufacturer Return to manufacturer, also of replacement assemblies
or service products, where specified by legislation or
MX_MC6_V1.9_07.09.15_ENG
manufacturer and written agreement exists with

manufacturer.
©KM
Advice to manufacturer For statistical data purposes, inform the manufacturer if

the machine is taken out of service and disposed of.

MX_MC6_V1.9_07.09.15_ENG
©KM

14 Index
Numbers Rotate feed screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-910
2K-injection molding technology . . . . . . . . . . . . . . . . . . . . . . 2-124 AF vacuum pump
3-zone screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113 Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-946
7-day timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-639 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-944
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-942
A Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 12-937, 12-944
A_ _ _ _ _ Alarm numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-401 Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-940
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-44 Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-945
Names of plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116 Oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-939
Access authorization Styrene separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-944
Access rights to screens . . . . . . . . . . . . . . . . . . . . . . . . . 8-372 Air specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151
Input authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-360 Alarm number information. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-401
Password input . . . . . . . . . . . . . . . . . . . . . . . . . . 7-302, 8-360 Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-401, 8-672
Acknowledgement A_ _ _ _ _ Alarm numbers . . . . . . . . . . . . . . . . . . . . . . . 8-401
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-79, 6-253, 8-672 Acknowledge . . . . . . . . . . . . . . . . . 1-79, 6-253, 8-672, 8-673
Core-pulling input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-254 AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-924
Acknowledgement button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-82 Alarm bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-382
Acoustic fault signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83, 1-84 Alarm functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-253
Action button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240 Alarm hardkey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-253
Activation of core-pulling setting . . . . . . . . . . . . . . . . . . . . . . 6-254 Alarm information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-401
Actual values Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-79
Actual-value column . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-234 Alarm overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-672
Actual-value fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-239 Alarm overview, settings . . . . . . . . . . . . . . . . . . . . . . . . 8-674
Exporting/printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-588 Alarm types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-649
Actual-value cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-584 Bar-pulling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-958
Adaptive process control . . . . . . . . . . . . . . . . . . . . . . 8-520, 8-525 Events log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-675
Additional modules External alarm inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-648
Core-pulling module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-292 Machine doors, overview . . . . . . . . . . . . . . . . . . . . . . . . 8-679
Function buttons for additional components . . . . . . . . . . 6-291 Mold safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-416
Mold change/clamping assembly module . . . . . . . . . . . . 6-294 Occurrence of an alarm . . . . . . . . . . . . . . . . . . . . . . . . . 8-673
Addresses Priority of the alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-673
Sea transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-194 Pump shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-674
Training department . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-31 Quality alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-618
AF Show description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-673
Calibrating pressure transducer . . . . . . . . . . . . . . . . . . 12-927 Tolerance has been exceeded. . . . . . . . . 8-545, 8-562, 8-582
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-936 Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . 12-901, 12-925 Inspect alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-323
Draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-933 Alphanumeric keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-248
Fault rectification . . . . . . . . . . . . . . . . . . . . . . . 12-924, 12-929 Ambient conditions for the electrical equipment . . . . . . . . . . 3-151
Functions and parameters . . . . . . . . . . . . . . . 12-914–12-923 Assignment of hard keys/soft keys . . . . . . . . . . . . . . . . . . . . 6-236
Information on fault elimination BMC . . . . . . . . . . . . . . 12-899 Asynchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-310
Information on mold masses. . . . . . . . . . . . . . . . . . . . . 12-898 Automatic feed unit (AF) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-893
Machine operating buttons . . . . . . . . . . . . . . . . . . . . . . 12-908 Automatic oil preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-269
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-930
MX_MC6_V1.9_07.09.15_ENG
Automatic plasticizing before start of cycle . . . . . . . . . . . . . . 8-619

Material level display. . . . . . . . . . . . . . . . . . . . . . . . . . . 12-928 Auxiliary devices
Oil specifications, gear unit . . . . . . . . . . . . . . . . . . . . . . 12-930
©KM
Automatic feed unit (AF) . . . . . . . . . . . . . . . . . . . . . . . 12-893

Oil specifications, vacuum pump. . . . . . . . . . . . . . . . . . 12-939 Bar-pulling device, hydraulic . . . . . . . . . . . . . . . . . . . . 12-949
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-911 Bypass flow filter (from SP 24500). . . . . . . . . . . . . . . . 12-880
PolyLift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-921 Bypass flow filter, external . . . . . . . . . . . . . . . . . . . . . . 12-878
Production interruption . . . . . . . . . . . . . . . . . . . . . . . . . 12-926 Chip card reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-825
Removing feed screw . . . . . . . . . . . . . . . . . . . . . . . . . . 12-905 Display core-pulling, ejector and mold clamping
Stuffing pressure closed-loop control . . . . . . . . . . . . . . 12-914 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-890
Taking machine out of service . . . . . . . . . . . . . . . . . . . 12-904 Foot switch, keyswitch -S016. . . . . . . . . . . . . . . . . . . . 12-882
Vacuum pump, see AF vacuum pump Gas/water systems, self-sufficient . . . . . . . . . . . . . . . . 12-964
AF buttons Injection unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-505
Hopper left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-909 Injection/holding pressure . . . . . . . . . . . . . . . . . . . . . . . 8-490
Hopper right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-909 Magnetic clamping system. . . . . . . . . . . . . . . . . . . . . . 12-968
Index 14-1021
Auxiliary devices Bleeding the positioning cylinders . . . . . . . . . . . . . . . . . . . . . 7-314

Master computer, interface EUROMAP 63/SPI . . . . . . 12-852 Block change, barrel/mold temperatures . . . . . . . . . . . . . . . . 6-252
Material hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-820 Block pump unit
Medium monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-888 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-308
Mold closing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-419 BluePower
Mold heating KM/PSG . . . . . . . . . . . . . . . . . . . . . . . . . 12-989 Energy balance - individual evaluation . . . . . . . . . . . . . . 8-612
Mold opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-430 Energy balance - reference . . . . . . . . . . . . . . . . . . . . . . 8-613
Plasticizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-500 Bolt-On
Quality statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-835 Locking bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88
Water manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-886 Bolts
Barrel head, tightening torques. . . . . . . . . . . . . . . . . . . . 3-163
B Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240
Back-pressure. . . . . . . . . . . . . . . . . . . . . . . . . 2-120, 8-496, 8-513 Buttons
Reduced back-pressure. . . . . . . . . . . . . . . . . . . . . . . . . 8-499 "x" button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-247, 6-249
Ball return-flow lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-771 Acknowledge the alarm . . . . . . . . . . . . . . . . . . . . . . . . . 6-253
Central ball - return-flow lock . . . . . . . . . . . . . . . . . . . . 10-772 Action button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240
Bar-pulling Activating/acknowledging core-pulling setting . . . . . . . . 6-254
Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-295 Additional components, function buttons . . . . . . . . . . . . 6-291
Bar-pulling device Alarm hardkey. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-253
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-958 Bar-pulling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-295, 12-954
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-949 Core-pulling module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-292
Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-963 Date/Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-232
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-962 Delete all core steps, Process designer . . . . . . . . . . . . . 8-405
Moving bar out/in hydraulically . . . . . . . . . . . . . . . . . . 12-955 Delete cycle/core step, process designer . . . . . . . . . . . . 8-405
Operating/display elements . . . . . . . . . . . . . . . . . . . . . 12-954 Editing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-250
Barrel flange cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-743 Editing mode, process designer . . . . . . . . . . . . . . . . . . . 8-404
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-744 Hard copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-383
Barrel head Hard copy for pop-up window. . . . . . . . . . . . . . . . . . . . . 8-387
Installing/removing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-766 Hardkeys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236
Nozzle and barrel head . . . . . . . . . . . . . . . . . . . . . . . . 10-764 Help menu ("?") . . . . . . . . . . . . . . . . . . . . . . . . . 6-233, 8-397
Screws, tightening torques . . . . . . . . . . . . . . . . . . . . . . 3-163 I/O button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-253, 8-381
Barrel head connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-766 Inserting/deleting profile stages . . . . . . . . . . . . . . . . . . . 6-251
Barrel temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-531 Keylock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-255
Barrel heating optimization . . . . . . . . . . . . . . . . . . . . . . 8-548 Machine function module . . . . . . . . . . . . . . . . . . . . . . . . 6-268
Barrel heating zones . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-532 Magnetic clamping system . . . . . . . . . . . . . . . . . . . . . . . 6-294
Block change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-252 Main navigation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-534 Menu functions . . . . . . . . . . . . . . . . . . . . . . . . . . 6-232, 8-380
Control parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-546 Mold change/clamping assembly module. . . . . . . . . . . . 6-294
Default settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-538 Navigation on the screen . . . . . . . . . . . . . . . . . . . . . . . . 6-241
Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-534 Open detail view, process designer . . . . . . . . . . . . . . . . 8-405
Flange temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-533 Paging screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-233
Heating circuit monitoring . . . . . . . . . . . . . . . . . . . . . . . 8-550 Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-387
Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-534 Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240
Melt temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-537 Scrollbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-241
OD setter (switch-on duration) . . . . . . . . . . . . . . . . . . . . 8-534 Show core interruptions, process designer. . . . . . . . . . . 8-404
Oil temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-533 Softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236
Prioritized heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-544 Split-screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-258
MX_MC6_V1.9_07.09.15_ENG
Priority switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-535 Starting machine cycle . . . . . . . . . . . . . . . . . . . . . . . . . . 6-286

Remaining warmup time . . . . . . . . . . . . . . . . . . . . . . . . 8-535 Stop button (zero operating mode) . . . . . . . . . . . 6-271, 8-619
©KM
Start-up/lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-542 Stopping machine cycle . . . . . . . . . . . . . . . . . . . . . . . . . 6-287

Symbol explanations for temperature status/error Switch functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-268
messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-547 Symbol explanation . . . . . . . . . . . . . . . . . . . . . . 6-233, 8-400
System tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-545 User login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-232, 8-360
Basic functions in the screen border. . . . . . . . . . . . . . . . . . . 6-231 Bypass flow filter
Actual-value column . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-234 Replace filter element. . . . . . . . . . . . . . . . . . . . . . . . . . 10-739
Favourites column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-235 Replacing filter element (as of SP 24500) . . . . . . . . . . 12-880
Header bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-231 Bypass flow filter, external . . . . . . . . . . . . . . . . . . . . . . . . . . 12-878
Main navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236 Bypassing alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-382
Batch change control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-520
14-1022 Index
C Machine operating buttons. . . . . . . . . . . . . . . . . . . . . . . 6-267

Calibration Operating mode buttons . . . . . . . . . . . . . . . . . . . . . . . . 6-266
Clamping unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-353 Status displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-266
Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-353, 8-443 Comma, format setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-379
Injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-354, 8-507 Commissioning
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-494 AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-901, 12-925
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-659 AF vacuum pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-944
Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-425 Cleaning of machine prior to commissioning . . . . . . . . . 7-299
Mold venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-354 Compound injection molding. . . . . . . . . . . . . . . . . . . . . . . . . 2-126
Zero point calibration . . . . . . . . . . . . . . . . . . . . . 7-351, 8-628 Compressed air oiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-747
Camera Compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-746
Display screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-651 Maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-746
Cascade control Compression molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-451
Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-517 Condensate
Description of interface . . . . . . . . . . . . . . . . . . . . . . . . . 11-806 Draining condensate from maintenance unit . . . . . . . . 10-747
Functions and parameters . . . . . . . . . . . . . . . . . . . . . . . 8-518 Configuration/Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-654
Holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-516 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-659
Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-515 Cascade control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-517
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-519 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-658
CASTROL TRIBOL® 3020/1000-2 . . . . . . . . . . . . . . . . . . . . 3-159 Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-667
CASTROL TRIBOL® 4020/220-2 . . . . . . . . . . . . . . . . . . . . . 3-158 Diagnosis, injection molding machine . . . . . . . . . . . . . . 8-660
Central ball - return-flow lock . . . . . . . . . . . . . . . . . . . . . . . . 10-772 Ejector configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-442
Central lubrication system . . . . . . . . . . . . . . . . . . . . 7-300, 10-709 Electric screw drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-670
Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-429 Inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-655
Lubricant specification . . . . . . . . . . . . . . . . . . . . . . . . . . 3-159 KM Service (KraussMaffei Service) . . . . . . . . . . . . . . . . 8-654
Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1057 Mold opening configuration . . . . . . . . . . . . . . . . . . . . . . 8-434
Chain lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-325 Plasticizing configuration . . . . . . . . . . . . . . . . . . . . . . . . 8-499
Changes in the cycle sequence . . . . . . . . . . . . . . . . . . . . . . . 8-404 Robot diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-665
Changing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-779 Servo pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-667
Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-708 Step display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-666
AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-931 System pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-671
AF vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-946 Connection dimensions
Changing the backup battery . . . . . . . . . . . . . . . . . . . . . . . . 10-779 Mold connection dimensions . . . . . . . . . . . . . . . . . . . 15-1043
Chip card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-825 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-778
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-828 Interfaces, control cabinet PC . . . . . . . . . . . . . . . . . . . 11-811
User login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-826 Control parameters
CIMI, production signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-646 Barrel temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-546
Clamp safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 Mold temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-563
Clamping assembly module. . . . . . . . . . . . . . . . . . . . . . . . . . 6-294 Control system
Clamping block Terminal assignment, MC6 control system . . . . . . . . . 11-808
Safety gate (service gate) . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 Converter, diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-667
Clamping pressure Conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-431
Build up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-278 Cooling water
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-278 Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-214
Clamping unit Cooling water system. . . . . . . . . . . . . . . . . . . . . . . . . . 10-743
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-353 Mold cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-433
Structure and function. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112 Core monitoring . . . . . . . . . . . . . . . . . . . . . . . 8-458, 8-462, 8-470
MX_MC6_V1.9_07.09.15_ENG
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-314 Core-pulling

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-299 Activating the cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-453
©KM
AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-936 Activating/acknowledging input . . . . . . . . . . . . . . . . . . . 6-254

Closing the mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-413 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-465
CMG gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-719 Core enabling via operating panel without
Coding sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-460
Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-629 Core monitoring . . . . . . . . . . . . . . . . . . . . 8-458, 8-462, 8-470
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-631 Core-pulling expert mode. . . . . . . . . . . . . . . . . . . . . . . . 8-462
Cold-slug ejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-506 Core-pulling module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-292
Colour scheme Core-step programming . . . . . . . . . . . . . . . . . . . . . . . . . 8-475
Cycle steps/nodes in the process designer. . . . . . . . . . . 6-265 Cycle example (process designer). . . . . . . . . . . . . . . . . 8-412
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-265 Default settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-461
Machine function buttons . . . . . . . . . . . . . . . . . . . . . . . . 6-266 Display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-890
Index 14-1023
Core-pulling DEE021, energy logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-615

Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-459 Delay times/actual value displays . . . . . . . . . . . . . . . . . . . . . 8-600
Inserting/deleting core step . . . . . . . . . . . . . . . . . . . . . . 8-472 Delay times/Actual-value displays . . . . . . . . . . . . . . . . . . . . . 8-600
Interruptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-455, 8-469 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-183
Moving cores at Mold closing/opening. . . . . . . . . . . . . . 8-478 Detail view in the process designer . . . . . . . . . . . . . . . . . . . . 8-405
On in setting mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-464 Diagnosis
Operating panel . . . . . . . . . . . . . . . . . . . . . . . . . . 8-460, 8-461 (see configuration/diagnosis) . . . . . . . . . . . . . . . . . . . . . 8-654
Programmed core interruptions . . . . . . . . . . . . . . . . . . . 8-471 Diagnostic files, copying onto USB stick. . . . . . . . . . . . . 8-392
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-467 Injection molding machine . . . . . . . . . . . . . . . . . . . . . . . 8-660
Safety gate (service gate) . . . . . . . . . . . . . . . . . . . . . . . . 1-88 Mold hotrunner system (MoldCheck) . . . . . . . . . . . . . 12-1004
Show core interruptions for cycle step. . . . . . . . . . . . . . 8-404 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-665
Symbols for core step programming . . . . . . . . . . . . . . . 8-479 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-170
Coupling the screw . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-335, 7-342 Mold connection dimensions . . . . . . . . . . . . . . . . . . . 15-1043
Cover wedge support (screw barrel). . . . . . . . . . . . . . 7-330, 7-333 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1017
CTMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-663 Discharge monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-430
Curve computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-591 Discharge/Sprue sorting chute . . . . . . . . . . . . . . . . . . . . . . . 8-431
Curve configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-596 Display panel
Curve selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-599 Operating/display panel . . . . . . . . . . . . . . . . . . . . . . . . . 6-227
Functions and parameters of the curve screens . . . . . . 8-592 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1017
Tolerance monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-593 Disposal points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1019
CWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-662 Documentation of MC6 software . . . . . . . . . . . . . . . . . . . . . . . 0-32
Cycle Door stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-89
(see also overview cycle/times) . . . . . . . . . . . . . . . . . . . 8-600 Download MC6 software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-32
Changes in the cycle sequence. . . . . . . . . . . . . . . . . . . 8-404 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1035
Cycle example (process designer) . . . . . . . . . . . . . . . . 8-412 Drives
Cycle monitoring time . . . . . . . . . . . . . . . . . . . . . . . . . . 8-430 Energy logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-616
Cycle steps/nodes in the process designer . . . . . . . . . . 8-402 Duty cycle
Cycle time, optimization. . . . . . . . . . . . . . . . . . . . . . . . . 8-600 OD setter barrel temperatures . . . . . . . . . . . . . . . . . . . . 8-534
Show core interruptions . . . . . . . . . . . . . . . . . . . . . . . . . 8-404 OD setter mold temperatures . . . . . . . . . . . . . . . . . . . . . 8-555
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-286
Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-287 E
Cycle/Times overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-600 EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . 19-1057
Actual-value displays . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-600 Eco assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-620
Cycle time, optimization. . . . . . . . . . . . . . . . . . . . . . . . . 8-600 Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-250
Cycle, settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-618 Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-435
Delay times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-600 Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-275
Eco assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-620 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-353
Energy analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-610 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-442
Energy balance - individual evaluation . . . . . . . . . . . . . 8-612 Discharge/Sprue sorting chute . . . . . . . . . . . . . . . . . . . . 8-431
Energy balance - reference . . . . . . . . . . . . . . . . . . . . . . 8-613 Display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-890
Energy logging DEE021 . . . . . . . . . . . . . . . . . . . . . . . . 8-615 Ejector area protective panelling (ejector gate) . . . . . . . . 1-87
Energy logging, drives . . . . . . . . . . . . . . . . . . . . . . . . . . 8-616 Ejector compression molding . . . . . . . . . . . . . . . . . . . . . 8-444
Energy logging, peripherals and heaters . . . . . . . . . . . . 8-617 Ejector controlled by core-pulling program . . . . . . . . . . . 8-440
Machine/production status. . . . . . . . . . . . . . . . . . . . . . . 8-626 Ejector gate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87
Machine-overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-604 Ejector time-limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-438
Overview of times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-600 Ejector with robot synchronization . . . . . . . . . . . . . . . . 11-795
Pieces counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-605 End position monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 8-442
MX_MC6_V1.9_07.09.15_ENG
Shift counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-607 Ending semi/fully automatic mode without ejector . . . . . 8-441
Cyclic generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-650 Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-275
©KM
Hold ejector at front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-439

D Mold set-up/calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 8-443
Data Monitoring stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-442
Data record loading/saving . . . . . . . . . . . . . . . . . . . . . . 8-388 Operating panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-462
User data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-362 Retain ejector at rear . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-442
Date Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-437, 8-440
Date format, setting . . . . . . . . . . . . . . . . . . . . . . . 8-378, 8-379 Sprue compression and removal with ejector. . . . . . . . . 8-444
Displaying/entering date/time . . . . . . . . . . . . . . . . . . . . 6-232 Start by mold position . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-438
Deactivate fully automatic mode. . . . . . . . . . . . . . . . . . . . . . 8-618 Electric screw drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-718
Decimal point, format setting . . . . . . . . . . . . . . . . . . . . . . . . 8-379 Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-721
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . 19-1057 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-299
14-1024 Index
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-670 Foot switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-882

Lubricant specification . . . . . . . . . . . . . . . . . . . . . . . . . . 3-160 Foundation drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1041
Electrical equipment, ambient conditions. . . . . . . . . . . . . . . . 3-151 FP
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1051 Mold change/clamping assembly module . . . . . . . . . . . 6-295
Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . 0-26 Mold wall temperatures . . . . . . . . . . . . . . . . . . . . . . . . . 8-558
EMERGENCY STOP Water manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-572
Check of EMERGENCY STOP circuit. . . . . . . . . . . . . . . . 1-93 Freely programmable input, wait category . . . . . . . . . . . . . . 8-411
EMERGENCY STOP button . . . . . . . . . . . . . . . . . . 1-81, 1-82 Fully automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-271
Inspection of EMERGENCY STOP buttons . . . . . . . . . . . 1-93 Function buttons for additional components . . . . . . . . . . . . . 6-291
Enable
Core enabling via operating panel without G
sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-460 Gas/water systems, self-sufficient . . . . . . . . . . . . . . . . . . . 12-964
Energy Gear oil
Energy analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-610 CLP 114 (220) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-160
Energy balance (BluePower) - individual Generation, cyclic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-650
evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-612 H
Energy balance (BluePower) - reference . . . . . . . . . . . . 8-613 Hard copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-383
Energy logging DEE021 . . . . . . . . . . . . . . . . . . . . . . . . . 8-615 Hard copy for pop-up window . . . . . . . . . . . . . . . . . . . . 8-387
Energy logging, drives . . . . . . . . . . . . . . . . . . . . . . . . . . 8-616 Printer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-385
Energy logging, peripherals and heaters . . . . . . . . . . . . 8-617 Screen output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-386
Energy-efficient operation . . . . . . . . . . . . . . . . . . . . . . . . 2-122 System settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-384
Equip. ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1049 Hardkeys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236
Equipment-specific ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1049 Alarm hardkey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-253
Euromap 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-800 Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236
Euromap 62, self-sufficient gas/water systems . . . . . . . . . . 12-964 Heating
Euromap 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-608, 11-813 Energy logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-617
Euromap 63/SPI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-852 Overview of heaters . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1045
Euromap 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-647 Heating bands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-776
Euromap 70.0/70.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-970 Heating circuit monitoring
Euromap 73 Barrel temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-550
Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-796 Mold temperatures . . . . . . . . . . . . . . . . . . . . . . 8-568, 12-1002
Interface for lateral removal . . . . . . . . . . . . . . . . . . . . . 11-799 Heating time, screw barrel . . . . . . . . . . . . . . . . . . . . . . . . . . 8-535
Interface, housing door . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91 Heating zones
Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-672 Barrel heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-532
Events log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-675 Mold heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-554
Exporting/printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-678 Mold wall temperatures . . . . . . . . . . . . . . . . . . . . . . . . . 8-558
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-677 Nozzle heating zones. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-532
External heat-balancing units. . . . . . . . . . . . . . . . . . . . . . . . . 8-577 Shut-off heating zone. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-532
Extrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-501 Height compensation, ladder . . . . . . . . . . . . . . . . . . . . . . . 12-823
Extrusion time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-501 Help menu ("?"). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-233, 8-397
F Holding pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120, 8-485
Fault message signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-649 Cascade control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-516
Fault signal lamp . . . . . . . . . . . . . . . . . . . . . . . . 1-79, 1-83, 8-649 Cooling time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-488
Extended fault signal lamp (three colours) . . . . . . . . . . . . 1-84 Holding pressure through melt pressure . . . . . . . . . . . . 8-487
Fault signal lamp (monocolour). . . . . . . . . . . . . . . . . . . . . 1-83 Holding pressure through mold cavity pressure. . . . . . . 8-488
Favourites column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-235 Profile interpolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-489
MX_MC6_V1.9_07.09.15_ENG
Filter Sprue compression and removal with ejector . . . . . . . . 8-444

Changing filter element of fine filter. . . . . . . . . . . . . . . . 10-735 Horizontal stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-206
©KM
Changing filter element of return-flow filter . . . . . . . . . . 10-737 Hotrunner system

Cleaning/replacing the filter mats in the fan . . . . . . . . . 10-778 Description of interface . . . . . . . . . . . . . . . . . . . . . . . . 11-800
Filter element of internal bypass filter, Hydraulic components
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-739 Tightening torques of securing bolts . . . . . . . . . . . . . . . 3-161
Screen, filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . 6-241 Hydraulic oil
Fine filter Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-724
Replacing the filter cartridge . . . . . . . . . . . . . . . . . . . . . 10-735 Clean hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . 10-724
Flange temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-533 Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-743
Flat rack container, securing the load . . . . . . . . . . . . . . . . . . 4-191 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-217
Fluid injector systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-964 Inspect oil level of hydraulic oil tank. . . . . . . . . . . . . . . 10-727
Folding joint, ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-824 Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
Index 14-1025
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-154 Injector set-up/calibration . . . . . . . . . . . . . . . . . . . . . . . . 8-494

Hydraulic pressure Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-509
Injection pressure, unit of measurement . . . . . . . . . . . . 8-379 Lubricant specification for sliding surfaces . . . . . . . . . . . 3-158
System pressures, hydraulic pressure transducer. . . . . 8-671 Lubricate injection plunger guides . . . . . . . . . . . . . . . . 10-712
Hydraulic pumps Lubricate the profile rail guides. . . . . . . . . . . . . . . . . . . 10-715
Asynchronous motor, bleeding . . . . . . . . . . . . . . . . . . . 7-310 Lubricating points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-711
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . 10-723, 17-1053 Mold nozzles. . . . . . . . . . . . . . . . . . . . . . . 8-492, 8-493, 8-518
Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-106 Monitoring time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-483
Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-306 Nozzle contact force . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-504
Nozzle shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-490
I Plasticizing, auxiliary devices . . . . . . . . . . . . . . . . . . . . . 8-500
Industrial robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1011 Purging control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-512
Information box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-239 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-509
Information field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-235 Structure and function. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
Information signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-76 Injection unit D
AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-893 Locking bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88
Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-282, 8-481 Injection unit, plasticizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-495
Cascade control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-515 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-499
Cleaning injection area . . . . . . . . . . . . . . . . . . . . . . . . 10-753 Unit of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-379
Injection pressures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120 With/without purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-512
Test cycle without injection . . . . . . . . . . . . . . . . . . . . . . 8-382 Injection-compression molding . . . . . . . . . . . . . . . . . . . . . . . 8-451
Injection barrel Input
Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-319 Text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-248
Injection molding Values/parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-246
Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 Input authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-302, 8-360
Sequence of the injection molding process . . . . . . . . . . 2-118 Inputs
Injection molding cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119 External alarm inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-648
Injection molding machine Freely programmable inputs . . . . . . . . . . . . . . . . . . . . . . 8-643
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-660 Inserting/deleting profile stages . . . . . . . . . . . . . . . . . . . . . . . 6-251
Main navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236 Insertion depth for the nozzle . . . . . . . . . . . . . . . . . . . . . . . . 7-347
Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110 Inspection
Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-301 Barrel flange cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-744
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-301 Clamp safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101
Injection plunger guides . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-712 Clamp safety circuit, dynamic . . . . . . . . . . . . . . . . . . . . . 1-102
Injection pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120 Ejector area safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . 1-99
Unit of measurement, conversion . . . . . . . . . . . . . . . . . 8-379 EMERGENCY STOP button. . . . . . . . . . . . . . . . . . . . . . . 1-93
Injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-481 EMERGENCY STOP circuit . . . . . . . . . . . . . . . . . . . . . . . 1-93
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-484 Fixed protective panelling. . . . . . . . . . . . . . . . . . . . . . . . 1-103
Back. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-281 Locking-bolt monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96
Back-pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-496, 8-513 Mold area safety gates . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-354 Pump operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-321
Cascade control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-514 Robot safety gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-103
Cold-slug ejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-506 Safety gate, nozzle area. . . . . . . . . . . . . . . . . . . . . . . . . . 1-98
Delay time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-505 Safety strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96
Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130 Safety test/safety instruction. . . . . . . . . . . . . . . . . . . . . . 1-107
Enabling stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-483 Service gate (core-pulling and clamping block) . . . . . . . . 1-97
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-280 Step-on safety grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-100
MX_MC6_V1.9_07.09.15_ENG
Holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-485 Inspection glass

Holding pressure through melt pressure . . . . . . . . . . . . 8-487 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-720, 10-727
©KM
Holding pressure through mold cavity pressure . . . . . . 8-488 Inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-655
Holding pressure, cooling time . . . . . . . . . . . . . . . . . . . 8-488 Installation
Holding pressure, profile interpolated . . . . . . . . . . . . . . 8-489 Material hopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-820
Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-481 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1037
Injection pressure, unit of measurement . . . . . . . . . . . . 8-379 Installation location
Injection unit auxiliary devices . . . . . . . . . . . . . . . . . . . . 8-505 Air specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151
Injection unit movement. . . . . . . . . . . . . . . . . . . . . . . . . 8-502 Ambient conditions for the electrical equipment . . . . . . . 3-151
Injection unit set-up/calibration . . . . . . . . . . . . . . . . . . . 8-507 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151
Injection unit stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-504 Installing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200
Injection, units of measurement. . . . . . . . . . . . . . . . . . . 8-379 Intake area venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-311
Injection/holding pressure auxiliary devices . . . . . . . . . 8-490
14-1026 Index
Intake filter Injection unit SP 33000 to SP 55000 . . . . . . . . . . . . . . . 4-179

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-733 Injection unit SP 4300 to SP 12000 . . . . . . . . . . . . . . . . 4-174
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-311 Lateral removal, interface EUROMAP 73 . . . . . . . . . . . . . . 11-799
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-789 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-265
(see also peripherals) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-643 Length match, lifting rope . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-325
Cascade control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-806 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-169
Control cabinet-PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-811 Length match, lifting rope. . . . . . . . . . . . . . . . . . . . . . . . 7-325
Euromap 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-800 Lifting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-170
Euromap 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-813 Clamping unit KM 850 MX to KM 1600 MX, sea
Euromap 63/SPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-852 transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-173
Euromap 70.0/70.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-970 Clamping unit KM 850 MX to KM 1600 MX, road
Euromap 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-796 transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-171
Euromap 73, housing door . . . . . . . . . . . . . . . . . . . . . . . . 1-91 Injection unit SP 6100 to SP 12000 with cabinet . . . . . . 4-176
EUROMAP 73 and lateral removal . . . . . . . . . . . . . . . . 11-799 Injection unit SP 17200 to SP 24500 . . . . . . . . . . . . . . . 4-178
Heating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-800 Injection unit SP 33000 to SP 55000 . . . . . . . . . . . . . . . 4-179
Hotrunner system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-800 Injection unit SP 4300 to SP 12000 . . . . . . . . . . . . . . . . 4-174
Laminar flow box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-815 Limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-74
Mold temperature controllers . . . . . . . . . . . . . 11-802, 11-803 Robot safety gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-103
Parts removal unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-790 Linear robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1011
Production Data Acquisition (BDE) . . . . . . . . . . . . . . . . 11-805 List of users. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-362
Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-801 Locking bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88, 6-285
Internal bypass filter Locking elements
Replace filter element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-739 Bleeding the locking mechanisms . . . . . . . . . . . . . . . . . 7-315
Interpolated profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-489 Move in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-279
Interruptions Move out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-279
Core-pulling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-455, 8-469 Login of the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-232, 8-360
Programmed core interruptions. . . . . . . . . . . . . . . . . . . . 8-471 Lowering
Ixt value (utilization) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-668 Barrel temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-542
Injection unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-509
K Mold temperature controllers . . . . . . . . . . . . . . . . . . . . . 8-581
Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-362 Mold temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-559
Key group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-362 Lubricant specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-157
Creating a new key group . . . . . . . . . . . . . . . . . . . . . . . . 8-368 AF 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-930
Deleting existing key group. . . . . . . . . . . . . . . . . . . . . . . 8-371 Bar-pulling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-963
Editing existing key group . . . . . . . . . . . . . . . . . . . . . . . . 8-371 CASTROL TRIBOL® 3020/1000-2 . . . . . . . . . . . . . . . . 3-159
Keylock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-255 CASTROL TRIBOL® 4020/220-2 . . . . . . . . . . . . . . . . . 3-158
Parameter display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-257 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . 3-159
Keypad Electric screw drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-160
Alphanumeric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-248 Gear oil CLP 114 (220) . . . . . . . . . . . . . . . . . . . . . . . . . 3-160
Numerical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-246 Sliding surfaces, injection unit . . . . . . . . . . . . . . . . . . . . 3-158
Keyswitches Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-708
-S016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-882 AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-932
KM Service (KraussMaffei Service) . . . . . . . . . . . . . . . . . . . . 8-654 Bar-pulling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-963
L Central lubrication system . . . . . . . . . . . . . . . . . . . . . . 10-709
Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-822 Injection unit lubricating points. . . . . . . . . . . . . . . . . . . 10-711
Folding joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-824 M
MX_MC6_V1.9_07.09.15_ENG
Height compensation . . . . . . . . . . . . . . . . . . . . . . . . . . 12-823 Machine

Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-824 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-659
©KM
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-822 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1017

Laminar flow box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-653 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1017
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-815 Production mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-286
Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-649 Shutting down machine . . . . . . . . . . . . . . . . . . . . . . . 13-1015
Language selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-376 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-355
Lashing points Taking machine out of service . . . . . . . . . . . . . . . . . . 13-1016
Clamping unit KM 850 MX to KM 1600 MX, sea Machine base
transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-173 Parallelism to screw barrel. . . . . . . . . . . . . . . . . 7-341, 10-752
Clamping unit KM 850 MX to KM 1600 MX, road Machine calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-351, 8-628
transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-171 Machine configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-658
Injection unit SP 6100 to SP 12000 with cabinet . . . . . . 4-176
Injection unit SP 17200 to SP 24500 . . . . . . . . . . . . . . . 4-178
Index 14-1027
Machine cycle MC6 software

Changes in the cycle sequence. . . . . . . . . . . . . . . . . . . 8-404 Download and documentation . . . . . . . . . . . . . . . . . . . . . 0-32
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-286 Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-654
Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-287 Measuring units, setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-378
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131 Medium monitor function check . . . . . . . . . . . . . . . . . . . . . . 12-888
Machine doors, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-679 Melt cushion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-498
Machine function module . . . . . . . . . . . . . . . . . . . . . . 6-268, 7-303 Melt pressure
Machine number . . . . . . . . . . . . . . . . . 8-604, 8-654, 8-658, 8-659 Holding pressure through melt pressure. . . . . . . . . . . . . 8-487
Machine preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-628 Holding pressure through mold cavity pressure . . . . . . . 8-488
7-day timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-639 Injection pressure, unit of measurement. . . . . . . . . . . . . 8-379
Installation of a coded mold . . . . . . . . . . . . . . . . . . . . . . 8-630 Melt temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-537
Installation of a new mold . . . . . . . . . . . . . . . . . . . . . . . 8-630 Menu functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-232, 8-380
Machine calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-628 Menu functions, header bar button . . . . . . . . . . . . . . 6-232, 8-380
Mold coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-629 Messages
Screw coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-631 Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-79, 6-235, 6-253
Machine type . . . . . . . . . . . . . . . . . . . 8-604, 8-654, 8-658, 8-659 Information field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-235
Machine/production status . . . . . . . . . . . . . . . . . . . . . . . . . . 8-626 Metering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115
Machine-overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-604 Minimess connections
Magnetic clamping system . . . . . . . . . . . . . . . . . . . . . . . . . 12-968 Bleeding the locking mechanisms . . . . . . . . . . . . . . . . . 7-315
Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-294 Bleeding the pressure plunger and positioning
Control panel (ZE 89.571) . . . . . . . . . . . . . . . . . . . . . . 12-984 cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-314
Holding force display (ZE 89.573) . . . . . . . . . . . . . . . . 12-971 MP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-317
Machine forces, reduction . . . . . . . . . . . . . . . . . . . . . . 12-976 Mode
Mold change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-978 Keylock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-255
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-968 Operation of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-227
Main key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236 Process designer editing mode . . . . . . . . . . . . . . . . . . . 8-404
Main navigation Split-screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-258
Injection molding machine . . . . . . . . . . . . . . . . . . . . . . . 6-236 Modifiable displays (multi-select). . . . . . . . . . . . . . . . . . . . . . 6-244
Process designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-263 Modules, diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-661
Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-264 Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-413
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-699 Discharge monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-430
AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-930 Ejector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-435
AF vacuum pump. . . . . . . . . . . . . . . . . . . . . . . 12-937, 12-944 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-348
Bar-pulling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-962 Installation of a coded mold . . . . . . . . . . . . . . . . . . . . . . 8-630
Bypass flow filter, external . . . . . . . . . . . . . . . . . . . . . . 12-878 Installation of a new mold . . . . . . . . . . . . . . . . . . . . . . . . 8-630
Inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-655 Mold cavity pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-423
Magnetic clamping system . . . . . . . . . . . . . . . . . . . . . 12-988 Mold coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-629
Maintenance record . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-707 Mold cooling . . . . . . . . . . . . . . . . . . . . . . . . . . 10-745, 12-886
Maintenance scheme. . . . . . . . . . . . . . . . . . . . . . . . . . 10-704 Mold nozzles. . . . . . . . . . . . . . . . . 8-492, 8-493, 8-514, 8-518
Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-707 Mold safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-413
Medium monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-888 Mold safety, Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-416
Water manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-887 Mold set-up/calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 8-425
Maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-746 Mold vacuum control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-419
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-747 Mold venting calibration . . . . . . . . . . . . . . . . . . . . . . . . . 7-354
Condensate draining . . . . . . . . . . . . . . . . . . . . . . . . . . 10-747 Moving cores at Mold closing/opening . . . . . . . . . . . . . . 8-478
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-747 Pneumatic valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-446
Setting pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-746 Protective panelling, mold area . . . . . . . . . . . . . . . . . . . . 1-86
MX_MC6_V1.9_07.09.15_ENG
Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-271 Mold change

Master computer Magnetic clamping system . . . . . . . . . . . . . . . . . . . . . . 12-978
©KM
Communication, Euromap 63 . . . . . . . . . . . . . . . . . . . 12-867 Mold clamping assembly

Interface EUROMAP 63/SPI . . . . . . . . . . . . . . . . . . . . 12-852 Display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-890
Syntax example, Euromap 63 . . . . . . . . . . . . . . . . . . . 12-873 Mold change module . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-294
Master switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-85 Mold clamping platens
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-215 Mold wall temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . 8-558
Material hopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-820 Mold closing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-277, 8-413
MC6 display, header bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-233 Auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-419
MC6 operating/display panel . . . . . . . . . . . . . . . . . . . . . . . . 6-227 Mold cavity pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-423
Replacing protective film on touchscreen . . . . . . . . . . 10-783 Mold set-up/calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 8-425
Terminal assignment, MC6 control system . . . . . . . . . 11-808 Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-417
Spring-loaded mold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-418
14-1028 Index
Mold connection dimensions . . . . . . . . . . . . . . . . . . . . . . . 15-1043 MP

Mold heating KM/PSG Bleeding the traverse cylinder . . . . . . . . . . . . . . . . . . . . 7-317
Alarm with hotrunner leak monitoring . . . . . . . . . . . . . . 12-998 Mold change/clamping assembly module . . . . . . . . . . . 6-295
Automatic ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-989 Mold wall temperatures . . . . . . . . . . . . . . . . . . . . . . . . . 8-558
Boost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-993 Water manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-572
Diagnosis mold hotrunner system. . . . . . . . . . . . . . . . 12-1004 MP traverse cylinder
Drying out program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-991 Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-317
Guide zone mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-995 Multi-select feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-244
Heating circuit monitoring . . . . . . . . . . . . . . . . . . . . . . 12-1002 Multitouch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-228
Hotrunner leak monitoring. . . . . . . . . . . . . . . . . . . . . . . 12-997 Changing profile stages . . . . . . . . . . . . . . . . . . . . . . . . . 6-251
MoldCheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1004 Core-pulling/ejector display . . . . . . . . . . . . . . . . . . . . . 12-892
Prioritized heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-990 Curve configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-596
Sensor type/compensation . . . . . . . . . . . . . . . . . . . . . . 12-999 Keylock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-255
Mold nozzles . . . . . . . . . . . . . . . . . . . . 8-492, 8-493, 8-514, 8-518 Operating/display panel . . . . . . . . . . . . . . . . . . . . . . . . . 6-227
Open mold nozzle in setting mode . . . . . . . . . . . . . . . . . 6-285 Process designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-402
Mold opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-276, 8-426 RFID chip card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-834
Auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-430 Screen configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-260
Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-434 Slider control SlideX. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-288
Conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-431 Trend graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-589
Mold cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-433
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-428 N
Robot function during mold opening . . . . . . . . . . . . . . . . 8-428 Navigation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-241
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-429 Network settings
Tear-open stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-428 ETHERNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-855
Mold safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-417 Euromap 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-859
Mold temperature controllers Teleservice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-865
External heat-balancing units . . . . . . . . . . . . . . . . . . . . . 8-577 No interruption, wait category . . . . . . . . . . . . . . . . . . . . . . . . 8-408
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-802, 11-803 Node points in the process designer. . . . . . . . . . . . . . . . . . . 8-402
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-581 Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-160
Symbol explanations for temperature status/error Notebook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-681
messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-580 Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-683
Mold temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117, 8-554 Category change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-683
Block change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-252 Create . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-684
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-555 Delete category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-684
Control parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-563 Delete note. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-684
Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-555 Edit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-684
External heat-balancing units . . . . . . . . . . . . . . . . . . . . . 8-577 Edit /display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-682
Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-554 Export. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-684
Heating circuit monitoring . . . . . . . . . . . . . . . . 8-568, 12-1002 Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-682
Heating zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-554 Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-683
Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-555 Note change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-683
Mold heating optimization . . . . . . . . . . . . . . . . . . . . . . . . 8-566 Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-694
Mold temperature controllers lowering . . . . . . . . . . . . . . 8-581 Text operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-690
Mold wall temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . 8-558 Writing operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-691
OD setter (switch-on duration) . . . . . . . . . . . . . . . . . . . . 8-555 Nozzle
Prioritized heating . . . . . . . . . . . . . . . . . . . . . . . 8-561, 12-990 Installing/removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-765
Priority switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-556 Nozzle and barrel head . . . . . . . . . . . . . . . . . . . . . . . . 10-764
MX_MC6_V1.9_07.09.15_ENG
Production data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-638 Nozzle and injection area, cleaning . . . . . . . . . . . . . . . 10-753

Start-up/lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-559 Nozzle centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-343
©KM
Symbol explanations for temperature status/error Nozzle guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87

messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-557, 12-999 Nozzle insertion depth . . . . . . . . . . . . . . . . . . . . . . . . . . 7-347
Symbol legend for heating circuit monitoring Nozzle safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87
status and fault messages . . . . . . . . . . . . . . . 8-570, 12-1003 Overview of nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1047
System tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-562 Protective panelling nozzle area . . . . . . . . . . . . . . . . . . . 1-87
Water batteries FP and MP. . . . . . . . . . . . . . . . . . . . . . . 8-572 Nozzle heating zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-532
Water manifolds, settings . . . . . . . . . . . . . . . . . . . . . . . . 8-576 Nozzle shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-490, 10-774
Mold vacuum valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-419 Pintle catch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-717, 10-774
Mold venting Numbers, comma/decimal point setting . . . . . . . . . . . . . . . . 8-379
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-354 Numeric keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-246
Index 14-1029
O Password
Oil Password input . . . . . . . . . . . . . . . . . . . . . . . . . . 7-302, 8-360
Change oil for electric screw drive. . . . . . . . . . . . . . . . 10-721 PC
Electric screw drive, inspecting oil level. . . . . . . . . . . . . 7-299 Interfaces, control cabinet PC. . . . . . . . . . . . . . . . . . . . 11-811
Gear oil CLP 114 (220) . . . . . . . . . . . . . . . . . . . . . . . . . 3-160 PC 322-K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-811
Oil temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-533 PDF document, importing/displaying. . . . . . . . . . . . . . . . . . . 8-398
Pump motor oil change . . . . . . . . . . . . . . . . . . . . . . . . 10-728 Peripherals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-643, 11-789
Oil cooler Displaying image of a camera . . . . . . . . . . . . . . . . . . . . 8-651
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-730 Energy logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-617
Oil level External alarm inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-648
AF 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-932 Freely programmable inputs . . . . . . . . . . . . . . . . . . . . . . 8-643
AF vacuum pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-945 Freely programmable outputs. . . . . . . . . . . . . . . . . . . . . 8-644
Oil level inspection glass . . . . . . . . . . . . . . 5-220, 10-720, 10-727 Laminar flow box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-653
Oil preheating Production signals BDE . . . . . . . . . . . . . . . . . . . . . . . . . 8-645
Automatic oil preheating . . . . . . . . . . . . . . . . . . . . . . . . 6-269 Production signals CIMI . . . . . . . . . . . . . . . . . . . . . . . . . 8-646
Delay time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-618 Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-652
Oil specification Physical units, format setting . . . . . . . . . . . . . . . . . . . . . . . . . 8-379
AF gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-930 Pieces counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-605
AF vacuum pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-939 Pintle catch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-717, 10-774
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-154 Piston rod bearings
Oil temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-533 Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-714
Opening stroke between the mold clamping platens . . . . . . 7-323 Plasticizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-284
Opens the mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-426 Automatic plasticizing . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-619
Operating hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-604 Auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-500
Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-152 Back-pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-496, 8-513
Operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-270 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-499
Fully automatic mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-271 Injection pressure, unit of measurement. . . . . . . . . . . . . 8-379
Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-271 Injection, units of measurement . . . . . . . . . . . . . . . . . . . 8-379
Operating mode buttons . . . . . . . . . . . . . . . . . . . . . . . . 6-270 Plasticizing delayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-496
Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-286 Plasticizing stroke monitoring . . . . . . . . . . . . . . . . . . . . . 8-619
Robot modes of operation . . . . . . . . . . . . . . . . . . . . . . . 6-272 Purging control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-512
Semi-automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . 6-271 Unit of measurement, conversion . . . . . . . . . . . . . . . . . . 8-379
Setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-270 Plasticizing stroke monitoring . . . . . . . . . . . . . . . . . . . . . . . . 8-619
Zero operating mode (stop button) . . . . . . . . . . . 6-271, 8-619 Plasticizing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-748
Operating mode change via zero operating mode . . . . . . . . 8-619 Dangers on heated plasticizing units . . . . . . . . . . . . . . 10-748
Operating panel Material selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-540
Core enabling via operating panel without Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-460 Screw barrel protective panelling . . . . . . . . . . . . . . . . . . . 1-87
Core-pulling settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-461 Structure and function. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
Operating pen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-226 Temperature range setting . . . . . . . . . . . . . . . . . . . . . . . 8-539
Operating/display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-227 Plastics
Replacing protective film on touchscreen . . . . . . . . . . 10-783 Abbreviations of names of plastics . . . . . . . . . . . . . . . . . 2-116
Terminal assignment, MC6 control system . . . . . . . . . 11-808 Pneumatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1053
Optimization Pneumatic valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-285, 8-446
Barrel heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-548 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-449, 8-450
Eco assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-620 Pop-up menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-244
Length of cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-600 Pop-up window
MX_MC6_V1.9_07.09.15_ENG
Mold heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-566 Pop-up operating elements. . . . . . . . . . . . . . . . . . . . . . . 6-242

Order number . . . . . . . . . . . . . . . . . . . . . . . . . 8-654, 8-658, 8-659 Position transducer
©KM
Outputs Set zero points . . . . . . . . . . . . . . . . . . . . . 7-351, 7-352, 8-628

Freely programmable outputs . . . . . . . . . . . . . . . . . . . . 8-644 Pressure
System pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-671
P Pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . 1-104, 5-221
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-184 Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-784
Page number of an operator side . . . . . . . . . . . . . . . . . . . . . 6-232 Drain the nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-784
Paging back one screen page . . . . . . . . . . . . . . . . . . . . . . . 6-233 Filling with nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-221
Paging forward one screen page . . . . . . . . . . . . . . . . . . . . . 6-233 Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-787
Paging, one screen page back/forward . . . . . . . . . . . . . . . . 6-233 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-787
Parameter display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-257 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-786
Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1035, 15-1039 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-313
14-1030 Index
Pressure cushion Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-728

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-314 Checking running direction . . . . . . . . . . . . . . . . . . . . . . 7-304
Pressure indicator with selector switch . . . . . . . . . . . . . . . . . 7-322 Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-218, 7-309
Pressure pistons Pump unit
Move back. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-278 Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-308
Move forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-278 Pumps
Printing on a USB stick Diagnosis, servo pumps. . . . . . . . . . . . . . . . . . . . . . . . . 8-667
Print hard copy . . . . . . . . . . . . . . . . . . . . . . . . . . 8-386, 8-387 Inspecting pump operation. . . . . . . . . . . . . . . . . . . . . . . 7-321
Printer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-385 Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-309
Prioritized heating Purging control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-512
Barrel heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-544 Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240
Mold heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-561, 12-990
Priority switch Q
Barrel temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-535 Quality
Mold temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-556 Quality alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-618, 8-650
Process designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-263, 8-402 Quality monitoring failure rate . . . . . . . . . . . . . . . . . . . . 8-587
Change sequence of the cycle steps . . . . . . . . . . . . . . . 8-405 Quality monitoring failure rate . . . . . . . . . . . . . . . . . . . . . . . . 8-587
Change settings and parameters of individual Quality statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-835
cycle steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-405 Control chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-844
Changes in the cycle sequence . . . . . . . . . . . . . . . . . . . 8-404 Process capability and stability investigation . . . . . . . . 12-850
Colour scheme of the cycle steps/nodes . . . . . . . . . . . . 6-265 R
Core-pulling programming. . . . . . . . . . . . . . . . . . . . . . . . 8-467 Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1057
Cycle example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-412 Rectifying Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-697
Delete all core steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-405 Reduced back-pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-499
Delete cycle/core step. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-405 Removal
Editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-404 Mold opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-428
Insert a new cycle step . . . . . . . . . . . . . . . . . . . . . . . . . . 8-406 Parts removal unit, description of interface . . . . . . . . . 11-790
Machine cycle/cycle step . . . . . . . . . . . . . . . . . . . . . . . . 8-402 Removal, interface EUROMAP 73 . . . . . . . . . . . . . . . . . . . 11-799
Open detail view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-405 Repeat-stroking counter . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-795
Show core interruptions . . . . . . . . . . . . . . . . . . . . . . . . . 8-404 Replacing protective film on touchscreen . . . . . . . . . . . . . . 10-783
Production data Replacing the filter
Mold temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-638 Bypass flow filter (from SP 24500). . . . . . . . . . . . . . . . 12-880
Production set data . . . . . . . . . . . . . . . . . . . . . . . 8-636, 8-637 Bypass flow filter, external . . . . . . . . . . . . . . . . . . . . . . 12-878
Set-up and production data. . . . . . . . . . . 8-633, 8-634, 8-635 Return-flow filter
Production Data Acquisition Replace filter element . . . . . . . . . . . . . . . . . . . . . . . . . 10-737
Description of interface . . . . . . . . . . . . . . . . . . . . . . . . . 11-805 Return-flow lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-768
Production signals BDE . . . . . . . . . . . . . . . . . . . . . . . . . 8-645 Ball return-flow lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-771
Production mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-286 Central ball - return-flow lock . . . . . . . . . . . . . . . . . . . . 10-772
Production set data . . . . . . . . . . . . . . . . . . . . . . . . . . 8-636, 8-637 RFID chip card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-834
Production signals Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1011
BDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-645 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-665
CIMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-646 Ejector with robot synchronization . . . . . . . . . . . . . . . . 11-795
Production status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-626 Function buttons for additional components . . . . . . . . . 6-291
Profile interpolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-489 Inspecting safety gates . . . . . . . . . . . . . . . . . . . . . . . . . 1-103
Profiled rail guides Operating mode buttons . . . . . . . . . . . . . . . . . . . . . . . . 6-272
Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-715 Operating screens (main navigation) . . . . . . . . . . . . . . . 6-264
Programming the core-pulling . . . . . . . . . . . . . . . . . . . . . . . . 8-467
MX_MC6_V1.9_07.09.15_ENG
Robot function during mold opening . . . . . . . . . . . . . . . 8-428

Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26 Robot signals, wait category . . . . . . . . . . . . . . . . . . . . . . . . . 8-410
Protective housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-207
©KM
Rope lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-325

Protective panelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-86 Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-723
Ejector area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87 RPM for extrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-500, 8-501
Mold area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-86
Nozzle area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87 S
Safety gate core-pulling/clamping block)(service Safety
gate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 Material hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-820
Screw barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87 Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26, 1-72
Service gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-893
Pump control system Limit switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-74
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-312 Magnetic clamping system. . . . . . . . . . . . . . . . . . . . . . 12-968
Pump motor Sequential arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . 1-74
Index 14-1031
Safety gate KM 1600 MX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-173

Closing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-274 Clamping unit lashing points KM 850 MX to KM
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-274 1600 MX, sea transport . . . . . . . . . . . . . . . . . . . . . . . . . 4-173
Safety strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-194
Safety test/safety instruction. . . . . . . . . . . . . . . . . . . . . . . . . 1-107 Securing
Sampling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-156 Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-413, 8-417
Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-652 Securing bolts on hydraulic components, tightening
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-199 torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-161
Screen Securing the load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-181
Displaying image of a camera . . . . . . . . . . . . . . . . . . . . 8-651 Selection elements
Displaying page number of a control page . . . . . . . . . . 6-232 Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240
Displaying/entering date/time . . . . . . . . . . . . . . . . . . . . 6-232 Selection menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240
Paging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-233 Tickbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240
Screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-391 Selector switch
Screen output of hard copy . . . . . . . . . . . . . . . . . . . . . . 8-386 Pressure indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-322
Screen mode Semi-automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-271
Keylock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-255 Sensor
Operation of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 6-227 Acknowledgement button . . . . . . . . . . . . . . . . . . . . . . . . . 1-82
Split-screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-258 EMERGENCY STOP button. . . . . . . . . . . . . . . . . . . . . . . 1-82
Screen, display objects/presentation forms Sensor-actuator box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-806
Actual-value fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-239 Service box, teleservice. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-865
Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240 Service gate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88
Filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-241 Service socket -XJ05 . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93, 5-216
Navigation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-241 Servo pumps, diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-667
Notes fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-239 Set values
Pop-up operating elements . . . . . . . . . . . . . . . . . . . . . . 6-242 Blocked set-value fields . . . . . . . . . . . . . . . . . . . . . . . . . 6-239
Selection elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240 Editable set-value fields . . . . . . . . . . . . . . . . . . . . . . . . . 6-239
Set-value fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-239 Setting
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-762 Ejector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-443
3-zone screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113 Injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-507
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-762, 10-763 Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-494
Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-335, 7-342 Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-425
Injection pressure, unit of measurement . . . . . . . . . . . . 8-379 Setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-270
Injection, units of measurement. . . . . . . . . . . . . . . . . . . 8-379 Set-up and production data . . . . . . . . . . . . . . . 8-633, 8-634, 8-635
Plasticizing, units of measurement . . . . . . . . . . . . . . . . 8-379 Shift counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-607
Screw types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 Shrinking foil packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-189
Screw advance speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115 Shutdown
Screw barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-753 Alarm types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-649
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-760 Shut-off heating zone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-532
Cover wedge support. . . . . . . . . . . . . . . . . . . . . . 7-330, 7-333 Shutting down machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1015
Installing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-324 Signal buzzer . . . . . . . . . . . . . . . . . . . . . . 1-83, 1-84, 8-649, 8-674
Nozzle shut-off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-774 Signals (peripherals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-643
Parallelism to machine base . . . . . . . . . . . . . . . 7-341, 10-752 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-76
Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-754 Skinform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-287
Replacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-755 Slider control SlideX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-288
Support . . . . . . . . . . . . . . . . . . . . . . . . . 7-331, 7-338, 10-749 Slug ejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-506
Support lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-713 Socket
MX_MC6_V1.9_07.09.15_ENG
Screw barrel support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-331 Service socket -XJ05 . . . . . . . . . . . . . . . . . . . . . . 1-93, 5-216

Screw coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-631 Softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236
©KM
Screw coupling Assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236

Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-761 Software version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-654
Screw decompression . . . . . . . . . . . . . . . . . . . . . . . . 6-283, 8-497 Sorting chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-431
Screw drive Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-287
Changing oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-721 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
Checking the oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-299 Split-screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-258
Electric screw drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-718 Spraying on release agent. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-287
Lubricant specification . . . . . . . . . . . . . . . . . . . . . . . . . . 3-160 Spring-loaded mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-418
Screw types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 Sprue
Sea transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-189 Sprue compression and removal with ejector. . . . . . . . . 8-444
Clamping unit attachment points KM 850 MX to Sprue compression and removal with ejector . . . . . . . . . . . . 8-444
14-1032 Index
Spur flat gear unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-718 Tear-open stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-428

Starting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-355 Teleservice
Start-up/lowering Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-865
Barrel temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-542 Temperature
Injection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-509 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-537
Mold temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-559 Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-533
Status displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-268 Test cycle without injection . . . . . . . . . . . . . . . . . . . . . . . . . . 8-382
Colour scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-266 Text input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-248
Header bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-233 Threaded ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-766
Step display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-666 Tickbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-240
Step-on safety grid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-161
Stop button (zero operating mode) . . . . . . . . . . . . . . 6-271, 8-619 Screws on the barrel head . . . . . . . . . . . . . . . . . . . . . . . 3-163
Storage Securing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-165
Storage conditions for decommissioning . . . . . . . . . . 13-1016 Securing bolts on hydraulic components . . . . . . . . . . . . 3-161
Storage for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-192 Tightening torques of securing bolts . . . . . . . . . . . . . . . . . . . 3-165
Stroke monitoring Time
Sprue compression and removal with ejector, 7-day timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-639
enabling mold opening . . . . . . . . . . . . . . . . . . . . . . . . . . 8-444 Displaying/entering date/time. . . . . . . . . . . . . . . . . . . . . 6-232
Supplier Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1055 Times
Support (see overview cycle/times) . . . . . . . . . . . . . . . . . . . . . . . 8-600
Screw barrel . . . . . . . . . . . . . . . . . . . . 7-338, 10-713, 10-749 Tolerance has been exceeded
Support, ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-824 Barrel heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-545
Surface transport Mold heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-562
Clamping unit attachment points KM 850 MX to Mold temperature controllers lowering . . . . . . . . . . . . . . 8-582
KM 1600 MX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-171 Tolerance monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-584
Clamping unit lashing points KM 850 MX to KM Actual-value cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-584
1600 MX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-171 Curve computer . . . . . . . . . . . . . . . . . . . . . . . . . . 8-591, 8-593
Switch functions . . . . . . . . . . . . . . . . . . 6-253, 6-268, 7-303, 8-381 Curve screens, parameters and settings . . . . . . . . . . . . 8-592
Alarm bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-382 Quality monitoring failure rate . . . . . . . . . . . . . . . . . . . . 8-587
Test cycle without injection . . . . . . . . . . . . . . . . . . . . . . . 8-382 Trend graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-589
Switching machine components on/off . . . . . . . . . . . . . . . . . 7-303 Touch functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-230
Symbols Touchscreen operating panel
Cascade control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-519 Operating pen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-226
Core step programming . . . . . . . . . . . . . . . . . . . . . . . . . 8-479 Replacing protective film on touchscreen . . . . . . . . . . 10-783
Core step programming, interruptions. . . . . . . . . . . . . . . 8-457 Terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . 11-808
Eco assistant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-622 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-31
Events log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-677 Transport locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-201
Help menu ("?"). . . . . . . . . . . . . . . . . . . . . . . . . . 6-233, 8-397 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-169
Machine doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-680 Securing the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-181
Mode of water manifolds . . . . . . . . . . . . . . . . . . . . . . . . . 8-574 Trend graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-589
Pneumatic valves . . . . . . . . . . . . . . . . . . . . . . . . 8-449, 8-450 Two-component injection molding technology . . . . . . . . . . . 2-124
Status/fault messages of heating circuit
monitoring system . . . . . . . . . . . . . . . . . . . . . . 8-570, 12-1003 U
Symbol explanation. . . . . . . . . . . . . . . . . . . . . . . 6-233, 8-400 Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-199
Temperature status/fault messages . . . . . . . . . . . . . . . 8-547, Upkeep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-699
8-557, 8-580, 12-999 US format for date, decimal point and physical units . . . . . . 8-379
System pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-671 USB
MX_MC6_V1.9_07.09.15_ENG
System settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-384, 8-395 Hard copy on USB stick . . . . . . . . . . . . . . . . . . . . 8-386, 8-387
Screen saving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-395 USB memory expansion . . . . . . . . . . . . . . . . . . . . . . . 11-813
©KM
System tolerances USB memory expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-813

Barrel heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-545 Use, intended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26
Mold heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-562 User
Creating new user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-364
T Deleting existing user. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-367
Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-243 Editing existing users . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-367
Taking machine out of service . . . . . . . . . . . . . . . . . . . . . . 13-1016 User data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-362
AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-904 User login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-232, 8-360
Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1016 Access rights to screens . . . . . . . . . . . . . . . . . . . . . . . . 8-372
Tank return-flow butterfly valves . . . . . . . . . . . . . . . . . . . . . 10-725 Chip card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-826
Tear-open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-428 Password input / input authorization . . . . . . . . . . 7-302, 8-360
Index 14-1033
Setting of date format and measuring units . . . . . . . . . . 8-378 W

User data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-362 Wait categories, wait function . . . . . . . . . . . . . . . . . . . . . . . . 8-408
Wait category
V
Freely programmable input. . . . . . . . . . . . . . . . . . . . . . . 8-411
Value input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-246
No interruptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-408
Comma/decimal point setting . . . . . . . . . . . . . . . . . . . . 8-379
Robot signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-410
Venting
Wait time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-409
Block pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-308
Wait function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-407
Clamping unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-314
Wait categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-408
Hydraulic pumps with asynchronous motor . . . . . . . . . . 7-310
Wait time, wait category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-409
Hydraulic system, bleed points . . . . . . . . . . . . . . . . . . . 7-306
Water filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-745
Injection barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-319
Water manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-886
Intake filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-311
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-887
Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-315
Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-576
MP traverse cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-317
Water batteries FP and MP . . . . . . . . . . . . . . . . . . . . . . 8-572
Positioning cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-314
Water specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-152
Pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . 7-313
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-170
Pressure pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-314
Pump control system . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-312 Z
Pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-218, 7-309 Zero (zero operating mode), stop button . . . . . . . . . . 6-271, 8-619
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-309 Zero point calibration . . . . . . . . . . . . . . . . . . . . . . . . . 7-351, 8-628
MX_MC6_V1.9_07.09.15_ENG
©KM
14-1034 Index
15 Parts lists/drawings
15.1 Installation instructions . . . . . . . . . . . . . . . . . . . . . . 1037
15.2 Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1039
15.3 Foundation drawing . . . . . . . . . . . . . . . . . . . . . . . . . 1041
15.4 Mold connection dimensions . . . . . . . . . . . . . . . . . . 1043
15.5 Overview of heating . . . . . . . . . . . . . . . . . . . . . . . . . 1045
15.6 Overview of nozzles . . . . . . . . . . . . . . . . . . . . . . . . . 1047
15.7 Equipment-specific ID . . . . . . . . . . . . . . . . . . . . . . . 1049

MX_MC6_V1.9_07.09.15_ENG
©KM
Parts lists/drawings 15-1035

MX_MC6_V1.9_07.09.15_ENG
©KM
15-1036 Parts lists/drawings

15.1 Installation instructions

MX_MC6_V1.9_07.09.15_ENG
©KM

MX_MC6_V1.9_07.09.15_ENG
©KM

15.2 Parts lists

MX_MC6_V1.9_07.09.15_ENG
©KM

MX_MC6_V1.9_07.09.15_ENG
©KM

15.3 Foundation drawing

MX_MC6_V1.9_07.09.15_ENG
©KM

MX_MC6_V1.9_07.09.15_ENG
©KM

15.4 Mold connection dimensions

MX_MC6_V1.9_07.09.15_ENG
©KM

MX_MC6_V1.9_07.09.15_ENG
©KM

15.5 Overview of heating

MX_MC6_V1.9_07.09.15_ENG
©KM

MX_MC6_V1.9_07.09.15_ENG
©KM

15.6 Overview of nozzles

MX_MC6_V1.9_07.09.15_ENG
©KM

MX_MC6_V1.9_07.09.15_ENG
©KM

15.7 Equipment-specific ID
MX_MC6_V1.9_07.09.15_ENG
©KM

MX_MC6_V1.9_07.09.15_ENG
©KM

16 Electrical system
MX_MC6_V1.9_07.09.15_ENG
©KM
Electrical system 16-1051

MX_MC6_V1.9_07.09.15_ENG
©KM
16-1052 Electrical system

17 Hydraulics/Pneumatics
MX_MC6_V1.9_07.09.15_ENG
©KM
Hydraulics/Pneumatics 17-1053
MX_MC6_V1.9_07.09.15_ENG
©KM
17-1054 Hydraulics/Pneumatics
18 Supplier Documentation
MX_MC6_V1.9_07.09.15_ENG
©KM
Supplier Documentation 18-1055

MX_MC6_V1.9_07.09.15_ENG
©KM
18-1056 Supplier Documentation

19 Reports/Certificates
I
Note
The certificate and, if applicable, other order-related documents are located on
the machine.
19.1 EC Declaration of Conformity
I
Note
The signed, order-related EC Declaration of Conformity corresponding to
Machinery Directive 2006/42/EC is stored separately on the machine. The
following figure reflects the content of the EC Declaration of Conformity
(see fig. 19.1, page 19-1058).
MX_MC6_V1.9_07.09.15_ENG
©KM
Reports/Certificates 19-1057
EG-Konformitätserklärung
entsprechend der Maschinenrichtlinie 2006/42/EG
Wir erklären in alleiniger Verantwortung, dass die Spritzgießmaschine
Typenbezeichnung MX
auf Grund ihrer Konzipierung, Bauart und der von uns in Verkehr gebrachten Ausführung folgenden einschlägigen EG-Richtlinien
entspricht:
Maschinenrichtlinie 2006/42/EG Niederspannungsrichtlinie 2006/95/EG EMV-Richtlinie 2004/108/EG
Angewendete harmonisierte Normen, insbesondere
EN201 EN60204-1 EN61000-6-2 EN61000-6-4
Wir erklären, dass die Maschine mit der sicherheitstechnischen Ausführung des geprüften Modells übereinstimmt, das die
EG-Baumusterprüfbescheinigung mit der Nr. HSM 06016 erhalten hat, die von folgender notifizierten Stelle ausgestellt wurde:
HSM 06018
Fachausschuss Maschinenbau, Hebezeuge, Hütten- und Walzwerksanlagen

D-40001 Düsseldorf (Kenn-Nr. 0393)
Bei einer mit uns nicht abgestimmten Änderung verliert diese Erklärung ihre Gültigkeit.
Bevollmächtigter für die Zusammenstellung der technischen Unterlagen: Abt. IR1123 Maschinensicherheit
EC Declaration of Conformity
in accordance with Machine Directive
We accept sole responsibility for declaring that the injection molding machine
Type designation MX
complies with the following relevant EC-directives on the basis of its conception, design and the version put into
circulation by us:
Machine Directive 2006/42/EG Low Voltage Directive 2006/95/EG EMC Directive 2004/108/EG
Harmonized standards applied, in particular
EN201 EN60204-1 EN61000-6-2 EN61000-6-4
We declare that the machine corresponds with the safety version of the tested model which received the
EC prototype test certificate under no. HSM 06016 HSM 06018 which was issued by the following notified
office:
Fachausschuss Maschinenbau, Hebezeuge, Hütten- und Walzwerksanlagen
MX_MC6_V1.9_07.09.15_ENG
D-40001 Düsseldorf (Kenn-Nr. 0393)
In the event of any alterations performed without consulting us first, this declaration loses its validity.
©KM
Representative for the compilation of technical documents: Department IR1123 Machinery Safety
KraussMaffei
Technologies GmbH
Krauss-Maffei-Straße 2
D-80997 München
Fig. 19.1 EC Declaration of Conformity
19-1058 Reports/Certificates
20 Revision Record
Version Date Location of Explanation
modification
Section / Page
V1.1 05.08.13 6.9.1 / 292 Section "Core-pulling module (ZE)": note in section "Symbols for moving
core in/out"
06.09.13 8.4.4 / 391 Section "Screen cleaning" extended by cleaning procedure
8.15.6 / 651 "Image of a camera" added in screen
19.09.13 8.5.1 / 398 Section "Displaying a PDF document": note on USB stick added
09.10.13 3.2 / 131 Table "Machine data" incl. heating capacities updated
11.10.13 6.5.1.3 / 271 Section "Semi-automatic mode" updated
6.5.1.4 / 271 Section "Fully automatic mode" updated
6.5.2 / 272 Section "Mode buttons for robot": figure legend updated, footnote added
6.6.2 / 275, 6.6.3.2 / 277 Sections "Manual mode / semi-automatic mode / fully automatic mode"
updated
6.6.4.1 / 278, Section "Manual mode / semi-automatic mode / fully automatic mode"
6.6.4.2 / 278, 6.6.6 / 280 updated
6.6.3.1 / 276, Section "Semi-automatic mode / fully automatic mode" updated
6.6.6.2 / 281,
6.6.7 / 282, 6.6.9 / 284
6.6.13 / 286 Section "Starting/stopping machine cycle" inserted
6.6.14 / 287 Section "Special functions" inserted
6.8 / 291 Section "Function buttons for additional components" inserted
8.7.3.4 / 441 Section "Ending semi/fully automatic mode without ejector": text and
button updated
08.11.13 8.9.4.1 / 509 Section "Start-up/lowering": text on manual purging updated
13.11.13 8.11.1.2 / 558 Section "Mold wall temperatures" extended
V1.2 05.12.13 12.14 / 968 Section "Magnetic clamping system" - temperature sensor safety
instruction added
18.02.14 1.3 / 71 "Important" note for platforms, ladders and landings added
1.4.2 / 74 Screen "Safety devices", ejector door corrected
05.03.14 All chapters Comparison of software/updating
6.2 / 227 Legend fig. 6.2 updated
6.3.1.5 / 236 Section "Main navigation" revised
6.3.2.8 / 244 Section "Modifiable displays (multi-select feature)" revised
MX_MC6_V1.9_07.09.15_ENG
6.3.2.9 / 244 Section "Pop-up menus" revised

10.14 / 779 Section "Changing the backup battery" revised
©KM
12.15 / 989 Chapter "Mold heating KraussMaffei/PSG (ZE)" added

10.03.14 8.9.6 / 520 Chapter "Adaptive Process Control - injection/holding pressure" added
8.11.5 / 572 Section "Water manifolds (ZE)" expanded
14.03.14 8.10.2 / 542 Heating up automatic ramp described for "Approaching/Lowering barrel
8.11.2 / 559 temperatures" and "Mold-temperatures start-up/lowering"
Revision Record 20-1059


modification
Section / Page
V1.2 14.03.14 8.5.2 / 400 Sections "Symbol explanation" and "Symbol legend for events log" added
8.17.3.1 / 677
02.04.14 7.7.2 / 303 "Screen dimming" deleted
8.3 / 360, 8.4.4 / 391
03.04.14 8.4.2 / 383 Output options for "Create hard copy" changed: "USB stick" to "Bitmap on
USB stick" / "Printer" to "Print file on USB stick"
04.04.14 8.7.5 / 451 "Position point controller becomes active" removed 2x from section
"Compression molding"
11.04.14 8.12.2 / 589 Section "Trend graph (ZE)": "Printer S" / "Printer M" explained
V1.3 12.05.14 8.10.4 / 550 Chapter "Barrel heating circuit monitoring (ZE 89.3801)" updated
8.14.5.1 / 639, Chapter "7-day timer" updated, chapter "Control 7-day timer via start of
8.14.5.2 / 641 production" supplemented
12.4.4.1 / 855, Chapters "Network (network settings)" and "Euromap 63 (network
12.4.4.2 / 859 settings)" added
8 / 357 Chapter revised overall according to specifications
14.05.14 8.7.2.2 / 429 Lubrication settings updated
23.05.14 0.10 / 36 Agency list/addresses updated
26.05.14 4 / 167 Chapter "Transport/Packaging" revised
V1.4 19.06.14 8.4.6 / 393 Chapter "Display calibration" added
25.06.14 8.9.1.3 / 490 Nozzle shut-off type added
21.07.14 3.6.2 / 162 Section "Bolts in high-temperature area, tightening torques" inserted
25.07.14 8.7.1.4 / 419 Chap. "Mold closing auxiliary devices" revised: mold vacuum with 2
selection programs incorporated
25.07.14 8.14.5 / 639 Section "7-day timer" extended by "Oil preheating" function
28.07.14 8.9.6 / 520 Chapter "Adaptive Process Control - injection/holding pressure" updated
V1.5 05.08.14 8.6.3 / 412 "Cycle example" revised
12.08.14 8.9.2.3 / 500 "Plasticizing auxiliary devices": Extrusion-injection added
7.10.1 / 307 Fig. 7.5, "Bleed points of the hydraulic system", legend extended
7.10.5 / 313 Section "Venting the pressure accumulator" updated
7.10.6.1 / 314 Section "Bleeding the pressure plunger and positioning cylinders" updated
7.10.6.2 / 315 Section "Bleeding the locking mechanisms" updated
18.08.14 1.4.9.11 / 88 Section "Robot working range (various safety gate options; ZE)" - Fig. 1.11
MX_MC6_V1.9_07.09.15_ENG
"Robot working range (version 1)" deleted

©KM
1.5.12.1 / 101 Section "Inspecting safety gate limit switches (version 1)" deleted
6 / 225 Sections 6.2 "Operating/display panel MC6 - 19" touchscreen" and 6.24
"Main navigation for robot" updated
8.8.3 / 445 Section "Robot signals for core-pulling" deleted
8.8.5.1 / 461 Section "Core-pulling default settings 1" - Fig. 8.64 "Core-pulling default
settings 1" updated
Section "Core-pulling default settings 1" - "Robot signal for core-pulling"
deleted
20-1060 Revision Record


modification
Section / Page
V1.5 18.08.14 8.8.7.5 / 479 Section "Symbols for core step programming" updated
8.8.9 / 468 Section "Core-pulling programming with robot signal" deleted
12.3 / 835 Chapter "Quality statistics (ZE 89.6705)" added
19.08.14 7.10.5 / 313 Section "Venting the pressure accumulator" updated
25.08.14 6.8 / 291 Section 6.8 "Function buttons for additional components" - Fig. 6.22
"Robot function buttons" deleted
26.08.14 12.11 / 893 Chapter "Automatic feed unit (ZE 12.80, 12.81)" added
V1.6 10.09.14 6 / 225, 8 / 357 Chapter "Operating/display elements", "Operation of Machine" updated
V1.7 27.10.14 2.1.3 / 111, Section "Injection units - combination options" added,
2.6 / 124 chapter "Two-component injection molding technology" revised
11.11.14 1.4.10 / 88 Title "Securing the work area" inserted, rearranged; section "Locking bolt
1.4.10.4 / 88 (as of KM 1000 MX)" revised
8.10.1 / 531 Function "Disable movements at oil temperature below 18 °C" added
V1.8 23.12.14 1.5 / 92 Chapter "Inspection of safety devices": redundant buttons removed;
1.2.2 / 53 section "Obligation on the part of the owner/operator": obligation to co-
operate added
20.01.15 8.10.1 / 531 Section "Barrel temperatures" - Fig. 8.100 "Barrel temperatures" updated
8.10.1.2 / 538 Section "Barrel temperatures pre-settings" added (setting aid for barrel
temperatures)
8.14.3 / 631 Section "Screw coding (ZE)" -
Fig. 8.156 "Screw coding 2" updated
05.02.15 12.14 / 968 Section "Magnetic clamping system (ZE 45.695x, 89.57x)" completely
revised
12.2.4 / 834 Section "RFID chip card" inserted
12.10 / 890 Screen "Display of core-pulling, ejector and cascade" for 24" Multitouch
added
6.2 / 227 Section "Operating/display panel" - extended by 24" Multitouch
6.3.4.2 / 251 Section "Changing profile stages" - extended by 24" Multitouch
6.3.6.1 / 255 Section "Keylock" - extended by 24" Multitouch
6.3.7 / 260 Section "Configuration of screen (24" Multitouch)" - extended by 24"
Multitouch
6.7 / 288 Section "Slider control "SlideX" (24″ Multitouch)" - extended by 24"
Multitouch, note on 24" Multitouch added
8.6 / 402 Section "Process designer" - extended by 24" Multitouch,
MX_MC6_V1.9_07.09.15_ENG
section "Preview window" added

©KM
8.12.2 / 589 Section "Trend graph (ZE)" - extended by 24" Multitouch,

note on 24" Multitouch added
8.12.3.5 / 596 Section "Curve configuration" - extended by 24" Multitouch,
note on 24" Multitouch added
11.02.15 8.6.2 / 407 Section "Wait function" inserted
Revision Record 20-1061


modification
Section / Page
V1.9 23.03.15 8.9.1.3 / 490 Section "Injection/holding pressure auxiliary devices": Function "Open
nozzle early" extended by function "Open nozzle with delay at start of
clamping force build-up"
27.03.15 12.15.10 / 1004, Section "Diagnosis mold hotrunner system - MoldCheck" updated
12.15.10.1 / 1006
12.16 / 1011 Section "Robot" changed and supplemented
15.04.15 8.18 / 681 Chapter "Notebook (ZE)" expanded
11.05.15 8.10.1.2 / 538 Chapter "Barrel temperatures pre-settings" supplemented by fault
message
26.05.15 8.4 / 380 Menu functions, pop-up updated,
8.4.7 / 395 sections "System settings", "Upkeep" added
8.4.8 / 396
8.9.1.2 / 485 Fig. "Holding pressure" updated: "Holding pressure profile interpolated"
button added
8.3 / 360 Fig. "Login: Password" updated: "Login settings" button updated, section
8.3.3 / 374 "Login settings" added
08.06.15 3.4.2 / 154 Section "Hydraulic oil" expanded
10.07.15 6.3.6.1 / 255, Sections "Keylock", "Split-screen": Functional description updated
6.3.6.2 / 258
22.07.15 12.1.2 / 822 Section "Ladder (ZE 12.90)" inserted
23.07.15 7.14 / 343 Add nozzle centre section - "Note" on setting sequence added
27.07.15 10.14 / 779 Chapter "Changing the backup battery" updated
28.08.15 12.12 / 949 Self-supporting bar-pulling device added
01.09.15 10.5 / 704 Section "Maintenance scheme", Note added
MX_MC6_V1.9_07.09.15_ENG
©KM
20-1062 Revision Record

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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