Huski - MM - H-RS - ENG - 4-11-1 - 200703

S01-101056.
eps
Machine Manual
Hylectric Injection Molding Machine
Clamp Model: H/HL90 to H/HL1000

Injection Unit Model: RS22 to RS155
Issue: v 4.11.1 — March 2007

This document contains information which is the exclusive property of Husky Injection
Molding Systems Ltd. Except for any rights expressly granted by contract, this
document may not be duplicated or disclosed, in whole or in part, without the prior
written permission of Husky Injection Molding Systems Ltd.
Notwithstanding the foregoing, Husky Injection Molding Systems Ltd. grants
permission to its customers to make extracts or reproduce portions of this document
for limited shop use only.
Husky, Hylectric, HyPET, HyPAC, CoolJet, CoolPik, Reflex, Index, Quadloc, HyMET,
Thixosystems, Smartstart, Smartset, Polaris, Mixcel, and Micropitch are trademarks of
Husky Injection Molding Systems Limited.
Beckhoff™ and TwinCAT® are trademarks of Beckhoff Industrial Electronics.
Copyright ©2002-2007, Husky Injection Molding Systems.
All Rights Reserved.
ii v 4.11.1 — March 2007

Machine Manual
General Information
Equipment Identification
6 SUPPLY No.1 LOAD

LARGEST MOTOR
V
A
A Hz SYSTEM
SHORT-CIRCUIT
TOTAL HEAT LOAD A INTERRUPTING CAPACITY KA
SUPPLY No.1 LOAD V A Hz SYSTEM

LARGEST MOTOR A
TOTAL HEAT LOAD A KA
MACHINE TYPE
DIAGRAM Number SERIAL Number
HUSKY INJECTION MOLDING SYSTEMS LTD.

BOLTON, ONTARIO, CANADA L7E 5S5
S01-100720.eps
2 5
MODEL SERIES
MODEL HYD. PRESSURE
WEIGHT
MAX. CERTIFICATION
1
MODEL
3 SERIAL# THIS EQUIPMENT OR ITS USE MAY BE

Kg
COVERED BY ISSUED OR PENDING
4 DATE
PATENTS. SEE INFORMATION SCREEN
AT CONTROL STATION FOR DETAILS.
HUSKY INJECTION MOLDING SYSTEMS LTD.

560 QUEEN STREET SOUTH
BOLTON, ONTARIO, CANADA, L7E 5S5
Nameplate Locations
1. Machine nameplate 2. Model number 3. Serial number 4. Warranty Start Date
5. Certification symbols 6. Electrical nameplate
Telephone Support Numbers

North America: +800-465-4875 (toll free) or 905-951-4875
Europe (EC): +008000-800-4300
Europe (non EC): +352-52-115-4300
Asia (Greater China): +800-820-1667
Asia (Outside Greater China): +800-000-24462 or +0086-21-50484922
For on-site service, contact the local regional service and sales office.
v 4.11.1 — March 2007 iii General Information

Husky Regional Service and Sales Offices

The following is a list of telephone numbers of the various Husky Regional Service and
Sales offices:
Americas Europe/Africa Asia Pacific
Argentina, Bolivia, Chile, Africa, India, Israel, Middle Australia - Sydney

Paraguay, Uruguay - Buenos East, South Africa, Turkey - Tel: +61-2-9898-9911
Aires Luxembourg
Tel: +5411- 4836-1800 Tel: +352-521151
Brazil - Jundiai - SP Denmark, Norway, Sweden - China - Beijing

Tel: +55-11-4589-7200 Hørsholm Tel: +86-10-8518-5177
Tel: +45-32-48-6200
Canada - Toronto Eastern Europe, Russia - China - Hong Kong

Tel: +905-951-5000 Luxembourg Tel: +852-2168-5700
Tel: +352-521151
Colombia, Costa Rica, France - Lyon China - Shanghai

Ecuador, Panama, Peru, Tel: +33-4-74-46-88-00 Parts and Distribution Center
Venezuela - Bogota Technical Center
Tel: +57-1-4165626
Tel: +86-21-5048-4800
Fax: +86-21-5048-4900
Mexico - Mexico City Germany (South), Austria and China - South

Parts Distribution Center Switzerland - Augsburg Tel: +86-755-298-24200
Tel: +5255-5089-1160 Tel: +49-821-444890
Fax: +5255-5089-1161
Mexico - Monterrey Germany (North) - Bielefeld India - Mumbai

Tel: +5281-8315-0365 Tel: +49-521-77-02 87-0 Tel: +91-22-2570-6316
USA - Atlanta, GA Israel - Caesarea Indonesia - Jakarta

Technical Center Tel: +972-4-6218080 Tel: +6221-576-1238
Tel: +770-487-6234
USA - Boston, MA Italy - Rivoli (TO) Japan - Nagoya

Tel: +978-692-0077 Tel: +39-011-9565611 Tel: +81-90-7354-0175
USA - Buffalo, NY Luxembourg - Benelux Japan - Osaka

Parts Distribution Center Technical Center Tel: +81-6-6338-0561
Technical Center Tel: +352-521154300
Toll Free: +800-828-7842 Fax: +352-523040
Tel: +716-630-7300
Fax: +716-630-7320
USA - Chicago, IL Portugal, Spain - Barcelona Japan - Yokohama

Tel: +708-535-0092 Tel: +34-93-5948550 Tel: +81-45-923-1001
General Information iv v 4.11.1 — March 2007

Machine Manual
Americas Europe/Africa Asia Pacific
USA - Cincinnati, OH Russia - Moscow Korea - Seoul

Tel: +513-965-8080 Tel: +7-495-232-94-50 Tel: +82-31-399-6422-6
USA - Dallas, TX United Arab Emirates - Dubai Philippines - Makati City

Tel: +817-224-9440 Tel: +971-4-2997760 Tel: +632-757-5130 or 5131
USA - Detroit, MI United Kingdom - Coventry Singapore - Singapore

Tel: +248-735-6300 Tel: +44-24-76-518900 Tel: +65-6276-8616
USA - Los Angeles, CA Singapore Spare Parts Center

Technical Center Tel: +65-6276-2747
Tel: +714-545-8200
USA - Miami, FL Taiwan - Taipei

Tel: +305-261-3003 Tel: +886-2-2378-9269
USA - Milton, VT Thailand - Bangkok

Tel: +802-859-8000 Tel: +66-2661-9593 or 9596
USA - Philadelphia, PA
Tel: +215-497-9700
* Technical Center
v 4.11.1 — March 2007 v General Information

General Information vi v 4.11.1 — March 2007

Machine Manual
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
Chapter 1: Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.1 Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.2 Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
1.3 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.4 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.5 Guards And Interlocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.6 Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.6.1 Performing Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1.6.2 Removing Locks and Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
1.7 Safety Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.7.1 Mechanical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.7.1.1 Worn Hoses and Safety Restraints . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.7.1.2 Cooling Water Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.7.1.3 Injection and Clamp Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.7.2 High Pressure Leak Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.7.2.1 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.7.2.2 Skin Puncture Injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.7.3 Burn Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.7.3.1 Hot Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.7.3.2 Molten Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.7.4 Explosion Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.7.4.1 High Pressure Explosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.7.5 Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.7.6 Noise Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.7.7 Gas, Vapor, and Dust Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.7.8 Slip, Trip, or Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.7.9 Lifting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.8 Personal Protective Equipment and Safety Equipment. . . . . . . . . . . . . . 1–10
1.8.1 Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.8.2 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
v 4.11.1 — March 2007 vii

1.9 Ancillary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11

1.10 Material Safety Data Sheet (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
1.11 Materials, Parts, and Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
1.12 Warning Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
1.13 Machine Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
1.13.1 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
1.13.2 Front Operator’s Gate and Rear Guard . . . . . . . . . . . . . . . . . . . . . . 1–14
1.13.3 Powered Front/Rear Gates Only - Gate Close Interlock Device . . . 1–14
1.13.4 Powered Front/Rear Gates Only - Security Strip . . . . . . . . . . . . . . . 1–15
1.13.5 Mechanical Safety Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
1.13.6 CEN Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
1.13.7 Automatic Dump Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
1.13.8 Manual Dump Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
1.13.9 Purge Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18
1.13.10Electrical Cabinet Door Interlocks and Override (UL only) . . . . . . . 1–19
Chapter 2: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

2.1 Machine Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.2 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.3 Electrical Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.4 Machine Cooling Water Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4.1 Cooling Water Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4.2 Cooling Water Treatment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.4.3 Typical Cooling Water Analysis Report . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.5 Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6 Oil Capacity Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.7 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
2.7.1 Detailed Hydraulic Fluid Specification . . . . . . . . . . . . . . . . . . . . . . . 2–13
2.7.1.1 Notes About Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–15
2.8 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
2.8.1 Grease Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
2.8.2 Gearbox Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17
2.9 Nitrogen Volume for Hydraulic Accumulators . . . . . . . . . . . . . . . . . . . . . 2–17
2.10 Rust Inhibitor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
2.11 Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
2.12 Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23
2.12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23
2.12.1.1 Torque Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
2.12.1.2 Lubricants and Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
2.12.2 HGT-35 Standard (Screws) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27
2.12.3 HGT-50 Standard (Screws and Threaded Rods). . . . . . . . . . . . . . . 2–28
2.12.4 HGT-80 Standard (Screws and Threaded Rods). . . . . . . . . . . . . . . 2–29
2.12.5 HGT-SS Standard (Set Screws) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30
viii v 4.11.1 — March 2007

Machine Manual
2.12.6 HGT-FT Standard (Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31

2.12.7 HGT-EL Standard (Electrical Applications) . . . . . . . . . . . . . . . . . . . 2–40
2.12.8 Supplier Recommended Torque Specifications . . . . . . . . . . . . . . . . 2–41
2.12.9 Split Flange Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–43
Chapter 3: Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

3.1 Unpacking the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.2 Installing Leveling Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3.3 Aligning Injection and Clamp Units (Split Base Models) . . . . . . . . . . . . . . 3–4
3.4 Removing Shipping Hardware (H90 to H500) . . . . . . . . . . . . . . . . . . . . . . 3–6
3.5 Removing Shipping Hardware (H650 to H1000) . . . . . . . . . . . . . . . . . . . . 3–8
3.5.1 Installing Column Bell (H90 to H800) . . . . . . . . . . . . . . . . . . . . . . . . 3–11
3.5.2 Installing Column Bell (H1000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
3.6 Installing Optional Stack Mold Carrier (90 – 500 Tonnes Clamps) . . . . . 3–12
3.6.1 Installing the Propeller Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
3.6.2 Installing Horizontal Linkages to the Stationary Platen . . . . . . . . . . 3–16
3.6.3 Installing Horizontal Linkages to the Moving Platen. . . . . . . . . . . . . 3–17
3.7 Installing Optional Stack/Tandem Mold Carrier
(650 – 1000 Tonnes Clamps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18
3.8 Assembling Safety Gates (H650 to H1000) . . . . . . . . . . . . . . . . . . . . . . 3–20
3.8.1 Operator’s Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20
3.8.2 Rear Gate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20
3.8.3 Both Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20
3.9 Cleaning Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
3.10 Connecting Hydraulic Hoses (Split Base Models). . . . . . . . . . . . . . . . . . 3–22
3.11 Connecting Electrical Cables (Split Base Models) . . . . . . . . . . . . . . . . . 3–23
3.12 Check Profibus Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24
3.13 Installing Platform (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24
3.14 Installing Material Feed Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
3.14.1 Installing Optional Hopper Magnet . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
3.14.2 Material Feed Equipment Recommendations . . . . . . . . . . . . . . . . . 3–28
3.15 Installing Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30
3.16 Installing Purge Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30
3.17 Installing Drool Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
3.18 Checking Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32
3.19 Filling the Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32
3.20 Priming the System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–34
3.21 Leveling Machine and Adjusting Nozzle Concentricity . . . . . . . . . . . . . . 3–35
3.21.1 Preparation for Machine Leveling - Mono Base . . . . . . . . . . . . . . . . 3–36
3.21.2 Base Leveling - Mono Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
3.21.3 Preparation for Machine Leveling - Split Base . . . . . . . . . . . . . . . . . 3–41
3.21.4 Clamp Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–44
3.21.4.1 H90 - H500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–46
v 4.11.1 — March 2007 ix

3.21.4.2 H650 - H1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–47

3.21.5 Injection Unit Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–48
3.21.6 Parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–50
3.21.7 Checking Nozzle Concentricity - RS22 to RS40 . . . . . . . . . . . . . . . 3–57
3.21.7.1 Vertical Adjustment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–57
3.21.7.2 Horizontal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–58
3.21.8 Checking Nozzle Concentricity - RS45 to RS155 . . . . . . . . . . . . . . 3–60
3.21.8.1 Vertical Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–60
3.21.8.2 Horizontal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–60
3.21.8.2.1 Horizontal Adjustment (Type 1) . . . . . . . . . . . . . . . . . . . . . 3–60
3.21.8.2.2 Horizontal Adjustment (Type 2) . . . . . . . . . . . . . . . . . . . . . 3–62
3.21.9 Leveling the Electrical Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–63
3.21.10Final Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–64
3.22 Hooking Up Oil Collection Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–65
3.23 Hooking Up Compressed Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–65
3.24 Hooking Up Electrical Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–66
3.24.1 Machine Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–67
3.25 Hooking Up Machine Cooling Water Supply . . . . . . . . . . . . . . . . . . . . . . 3–69
3.26 Hooking Up Mold Cooling Water Supply (Optional) . . . . . . . . . . . . . . . . 3–70
3.27 Machine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–71
3.28 Charging the Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–72
3.28.1 Checking Accumulator Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . 3–72
3.28.2 Precharging the Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–74
3.28.3 Discharging Accumulator Precharge . . . . . . . . . . . . . . . . . . . . . . . . 3–76
3.29 Checking Hydraulic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–78
3.30 Attaching Carriage Cylinders (Split Base Models) . . . . . . . . . . . . . . . . . 3–78
3.31 Checking Machine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–79
3.32 Inspect for Installation Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–80
3.33 Contact Husky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–81
3.34 Remove Plastic Shrink Wrap From the Ball Valve . . . . . . . . . . . . . . . . . 3–81
Chapter 4: User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

4.1 Human Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.1 Machine Cycle Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.1.2 Robot Home Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.1.3 Robot Enable Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.1.4 Pump Motor Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.1.5 Sidebar Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.1.5.1 Sidebar Icons Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.1.5.2 Function Keys and Icon Relationships . . . . . . . . . . . . . . . . . . . . 4–6
4.1.5.3 Process Value Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
4.1.5.4 User Configurable Sidebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9
4.1.5.5 USER CONFIGURATION Screen. . . . . . . . . . . . . . . . . . . . . . . 4–10
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4.1.5.6 Adding or Exchanging Function Icons. . . . . . . . . . . . . . . . . . . . 4–12

4.1.5.7 User Configuration Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13
4.1.5.8 Function Icon Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13
4.1.5.9 User Configuration Recycle Bin . . . . . . . . . . . . . . . . . . . . . . . . 4–13
4.1.6 Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–14
4.1.6.1 Message Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15
4.1.6.2 Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15
4.1.6.2.1 Screen Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15
4.1.7 Administrator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16
4.1.7.1 Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16
4.1.7.2 OPEN ACCOUNT Pop-up Screen . . . . . . . . . . . . . . . . . . . . . . 4–18
4.1.7.3 Programming the DataKey . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19
4.1.7.4 Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19
4.1.7.5 CREATE NEW GROUP Pop-up Screen . . . . . . . . . . . . . . . . . . 4–21
4.1.7.6 ADD/REMOVE USER IN GROUP Pop-Up Screen. . . . . . . . . . 4–22
4.1.7.7 Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–23
4.1.7.8 Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24
4.1.8 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26
4.1.9 Machine Function Mode Selector. . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27
4.1.10 HMI Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27
4.1.10.1 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28
4.1.10.2 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–29
4.1.10.3 Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30
4.1.10.4 Shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–31
4.1.10.5 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–32
4.1.10.5.1 Background Printing Configuration Screen . . . . . . . . . . . . 4–33
4.1.10.6 Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–34
4.1.10.7 Saving and Restoring Machine Backups . . . . . . . . . . . . . . . . . 4–35
4.1.10.8 Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–36
4.1.10.8.1 Operator Stop Reason Utility . . . . . . . . . . . . . . . . . . . . . . . 4–36
4.1.10.8.2 Using the OPERATOR STOP REASON Utility . . . . . . . . . 4–37
4.1.10.8.3 Using the Stop Reason Definition Screen . . . . . . . . . . . . . 4–38
4.1.11 User Log On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–39
4.1.12 User Log Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–39
4.1.13 On-Line Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–39
4.1.14 Status Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–40
4.1.15 Screen Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–40
4.1.16 Manual Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–43
4.1.17 Common Screen Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–45
4.1.17.1 Field Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–45
4.1.17.2 Alphanumeric Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–46
4.1.17.3 Numeric Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–46
4.1.17.4 Calendar Touchpad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–47
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4.1.17.5 Timeset Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–48

4.1.17.6 Color Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–48
4.1.17.7 Common Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–49
4.1.18 User Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–50
4.1.18.1 Default Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–51
4.1.18.2 Default User Names and Passwords . . . . . . . . . . . . . . . . . . . . 4–51
4.1.18.3 DataKey Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–51
Chapter 5: Starting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

5.1 Powering Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.2 Logging On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.3 Checking Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.3.1 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.3.2 Front Operator’s Gate and Rear Guard . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.3.3 Mechanical Safety Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.3.4 Automatic Dump Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
5.3.5 Purge Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
5.4 Oil Warming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.5 Checking/Resetting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
5.5.1 Checking Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
5.5.2 Resetting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
5.6 Checking Machine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12
5.7 Checking and Installing Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5.7.1 Checking Suitability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5.7.2 Installing Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5.7.2.1 One Piece Mold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–15
5.7.2.2 Multiple Piece Mold Installation. . . . . . . . . . . . . . . . . . . . . . . . . 5–20
5.7.2.3 Previously Installed Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–28
5.7.3 Installing Molds in Tandem Carriers (H/HL650 – H/HL1000). . . . . . 5–32
5.7.3.1 Single Mold Operation on Machines with Tandem Carrier . . . . 5–33
5.7.4 Stack Mold Installation (H/HL90 – H/HL500) . . . . . . . . . . . . . . . . . . 5–35
5.7.5 Stack Mold Installation (H/HL650 – H/HL1000) . . . . . . . . . . . . . . . . 5–36
5.7.6 Mold Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–38
5.7.6.1 Testing Mold Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–40
5.8 Recalling Machine Setups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–41
5.8.1 Copying Machine Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–43
5.9 Configuring Mold Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–46
5.9.1 Setting Up and Calibrating the Ejector . . . . . . . . . . . . . . . . . . . . . . . 5–46
5.9.1.1 Enabling Auto Function Keys to Run Production . . . . . . . . . . . 5–48
5.10 Checking Robot Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–48
5.11 Checking Mold Function Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–49
5.12 Setting Up/Checking Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–49
5.13 Turning Heats On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–49
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5.13.1 Turning Optional Mold Heats On . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–51

5.13.2 Turning Optional Nozzle Heats On. . . . . . . . . . . . . . . . . . . . . . . . . . 5–52
5.13.3 Machine Heats Self-Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . 5–52
5.14 Opening Process Material Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–56
5.14.1 Opening Process Material Feed Manual Shutoff . . . . . . . . . . . . . . . 5–57
5.14.2 Opening Process Material Feed Auto-shutoff . . . . . . . . . . . . . . . . . 5–58
5.14.3 Opening Magnet Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–58
5.15 Setting Up/Checking Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–59
5.15.1 Setting Up Injection and Hold Parameters . . . . . . . . . . . . . . . . . . . . 5–59
5.15.2 Setting Up Recovery Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . 5–60
5.16 Purging Barrel Before Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–61
5.16.1 Manually Purging the Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–61
5.16.2 Auto Purging the Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–63
5.17 Cleaning Nozzle Tip & Purge Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–65
5.18 Cycling and Fine-tuning Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–66
5.19 Setting Up SPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–66
5.20 Saving Machine Setups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–66
5.21 Starting Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–68
5.22 Logging Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–69
5.22.1 Logging Off Using the Log Off Button . . . . . . . . . . . . . . . . . . . . . . . 5–69
5.22.2 Logging Off Using the Datakey . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–69
Chapter 6: Stopping Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

6.1 Stopping Machine in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.2 Pausing Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
6.3 Stopping Machine in a Controlled Manner . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.3.1 Stopping Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.3.2 Shutting Process Material Feed Off . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.3.3 Purging Barrel After Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
6.3.4 Cleaning Nozzle Tip & Purge Guard . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.3.5 Emptying Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.3.6 Turning Heats Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.3.6.1 Shutting Machine Heats Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.3.6.2 Shutting Mold Heats Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
6.3.6.3 Shutting Nozzle Heats Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
6.3.7 Cleaning Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.3.8 Turning Mold Cooling Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.3.9 Removing Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.3.10 Turning Pumps Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
6.3.11 Turning Air Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
6.3.12 Powering Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
6.4 Unexpected Machine Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
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Chapter 7: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

7.1 Draining Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.2 Cleaning the Machine and HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.3 Checking Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.4 Blow-Down Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
7.5 Y-Strainer Screen Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.6 Inspecting and Cleaning Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.7 Inspecting and Cleaning Optional Magnet Drawer . . . . . . . . . . . . . . . . . . 7–8
7.8 Clearing Feed Throat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
7.9 Checking the Oil Recovery Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10
7.9.1 Cleaning the Oil Recovery Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10
7.10 Checking Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
7.11 Checking Hydraulic Cylinders, Valves and Manifolds . . . . . . . . . . . . . . . 7–11
7.12 Checking Hydraulic Hose Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12
7.12.1 Reading Layline Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
7.13 Replacing Hydraulic Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14
7.13.1 Removing Hydraulic Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . 7–14
7.13.2 Reinstalling Hydraulic Hose Assemblies . . . . . . . . . . . . . . . . . . . . . 7–14
7.14 Checking System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16
7.15 Checking Cooling Water Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16
7.16 Disconnecting Machine Cooling Water Supply . . . . . . . . . . . . . . . . . . . . 7–17
7.16.1 Draining Main Motor and Heat Exchanger . . . . . . . . . . . . . . . . . . . . 7–17
7.16.2 Draining Feed Throat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–19
7.16.3 Draining Gearbox, Cabinet, and Injection Motor . . . . . . . . . . . . . . . 7–19
7.16.4 Flushing System with Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20
7.16.5 Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20
7.17 Checking Pneumatic Valves and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . 7–21
7.17.1 Replacing Pneumatic Valves and Hoses . . . . . . . . . . . . . . . . . . . . . 7–21
7.18 Lubricating Mold Stroke Column Guide Bushings. . . . . . . . . . . . . . . . . . 7–22
7.19 Lubricate Locking Cylinder Rod Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23
7.20 Drive Cooling Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23
7.21 Checking Hydraulic Tank Oil Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–24
7.22 Checking Hydraulic Tank Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–27
7.23 Replacing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–28
7.23.1 Draining Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–28
7.23.2 Filling the Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–29
7.24 Priming the System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–30
7.25 Checking Gearbox Oil Level - Electrical Screw Drive Only . . . . . . . . . . . 7–31
7.26 Replacing Gearbox Oil - Electrical Screw Drive Only . . . . . . . . . . . . . . . 7–31
7.26.1 Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–31
7.26.2 Adding Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–31
7.27 Checking Electric Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32
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7.28 Checking Pump Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33

7.28.1 Reversing Pump Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35
7.29 Checking Mold Stroke Column Guide Bushings . . . . . . . . . . . . . . . . . . . 7–36
7.30 Checking Optional Nozzle Shutoff Bushings and Pins . . . . . . . . . . . . . . 7–37
7.31 Replacing Optional Nozzle Shutoff Bushings and Pins. . . . . . . . . . . . . . 7–37
7.31.1 Rotary Nozzle Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38
7.31.2 Plunger Nozzle Shutoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39
7.31.3 Pin Nozzle Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40
7.31.3.1 Adjusting the Pin Shutoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
7.32 Lubricating Moving Platen Linear Bearings (H90 - H/HL500) . . . . . . . . . 7–42
7.33 Lubricating Optional Stack Mold Carrier Linear Bearings
(H90 - H/HL500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–44
7.34 Lubricating Injection Piston Linear Bearings (RS40 - RS135). . . . . . . . . 7–45
7.35 Lubricating Injection Sled Linear Bearings (RS22 – RS40). . . . . . . . . . . 7–46
7.36 Replacing Oil Filter Element – H90 to H/HL500 (RS70 and smaller) . . . 7–47
7.37 Replacing Oil Filter Element – H/HL650 to H/HL1000 (RS80 and larger) 7–49
7.37.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–49
7.37.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–50
7.37.3 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–51
7.38 Replacing the Pilot Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–51
7.39 Checking Carriage Cylinder Bushings and Pins . . . . . . . . . . . . . . . . . . . 7–55
7.40 Removing Stack Mold Harmonic Linkage (90 - 500 Tonne Clamps) . . . 7–57
7.40.1 Removing the Top Horizontal Linkages . . . . . . . . . . . . . . . . . . . . . . 7–58
7.40.1.1 Operator Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–58
7.40.1.2 Non-Operator Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–59
7.40.2 Removing the Bottom Horizontal Linkages . . . . . . . . . . . . . . . . . . . 7–60
7.40.2.1 Operator Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–60
7.40.2.2 Non-Operator Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–61
7.40.3 Removing the Propeller Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–61
7.40.4 Removal of the Side Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–62
7.40.4.1 Operator Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–62
7.40.5 Non Operator Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–64
7.41 Replacing Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–65
7.42 Replacing Air Regulator Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 7–66
7.43 Lubricating Electric Pump Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . 7–68
7.44 Replacing Water Saver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–71
7.44.1 Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–71
7.44.2 Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–72
7.45 Checking Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–73
7.45.1 Checking Front Operator’s Gate and Rear Guard . . . . . . . . . . . . . . 7–73
7.45.2 Checking Mechanical Safety Device . . . . . . . . . . . . . . . . . . . . . . . . 7–74
7.45.3 Checking CEN Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–75
7.45.3.1 H90 - H225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–75
v 4.11.1 — March 2007 xv

7.45.3.2 H300 - H1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–75

7.46 Replacing Heater Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–76
7.47 Changing the Plasticizing Screw and Check Valve - RS22 to RS115. . . 7–78
7.47.1 Removing Plasticizing Screw - RS22 to RS40. . . . . . . . . . . . . . . . . 7–78
7.47.2 Removing Plasticizing Screw - RS45 to RS115. . . . . . . . . . . . . . . . 7–87
7.47.3 Removing Plasticizing Screw Check Valve . . . . . . . . . . . . . . . . . . . 7–97
7.47.4 Setting Up Plasticizing Screw Check Valve . . . . . . . . . . . . . . . . . . . 7–98
7.47.5 Reassembling the Plasticizing Screw - RS22 to RS40 . . . . . . . . . 7–100
7.47.6 Reassembling the Plasticizing Screw - RS45 to RS115 . . . . . . . . 7–107
7.48 Changing the Plasticizing Screw on RS135 and larger
(H650-H1000 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–112
7.48.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–112
7.48.2 Removing Plasticizing Screw with Powered Barrel Swing . . . . . . . 7–112
7.48.3 Reassembling Plasticizing Screw . . . . . . . . . . . . . . . . . . . . . . . . . 7–123
7.49 Barrel Removal and Installation - RS22 to RS115 . . . . . . . . . . . . . . . . 7–128
7.49.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–128
7.49.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–132
7.50 Barrel Removal and Installation - RS135 and up . . . . . . . . . . . . . . . . . 7–133
7.50.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–133
7.50.1.1 Screw uncoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–133
7.50.1.2 Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–135
7.50.1.3 Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–136
7.50.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–136
7.50.2.1 Screw Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–136
7.50.2.2 Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–136
7.50.2.3 Screw Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–137
7.51 Oil Recovery Unit Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–138
7.52 Running in the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–140
7.53 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–141
7.53.1 When to Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–142
7.53.2 Clamp Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–142
7.53.2.1 Calibrating the Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–143
7.53.3 Injection Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–147
7.53.3.1 Calibrating the Injection Piston . . . . . . . . . . . . . . . . . . . . . . . . 7–147
7.53.4 Carriage Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–148
7.53.4.1 Calibrating the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–149
7.53.5 Cavity Pressure Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–149
7.53.5.1 Calibrating the Cavity Pressure Sensor . . . . . . . . . . . . . . . . . 7–150
Chapter 8: Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

8.1 PC Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
8.1.1 Industrial PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
8.1.1.1 SERCOS Master Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
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8.1.1.2 PROFIBUS Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8

8.1.2 HMI Screen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
8.1.3 Servo Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10
8.1.3.1 SERCOS Drive Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
8.1.4 PROFIBUS Bus Terminal System . . . . . . . . . . . . . . . . . . . . . . . . . . 8–12
8.1.4.1 PROFIBUS Bus Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–12
8.1.4.1.1 Beckhoff BK3150 Bus Coupler. . . . . . . . . . . . . . . . . . . . . . 8–12
8.1.4.2 PROFIBUS Bus Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14
8.1.5 TC-Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14
8.2 Creating Recovery Disk Image/Restoring Hard Disk . . . . . . . . . . . . . . . 8–15
8.2.1 Creating a Recovery Disk Image . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15
8.2.1.1 Creating a Bootable Floppy Diskette. . . . . . . . . . . . . . . . . . . . . 8–15
8.2.1.2 Creating a Recovery Disk Image Using the Built-in CD-RW
Device for the P3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16
8.2.1.3 Creating a Recovery Disk Image Using the Built-in CD-RW
Device for the P4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
8.2.1.4 Scanning the Hard Disk for Errors . . . . . . . . . . . . . . . . . . . . . . 8–18
8.2.1.5 Modifying the Boot-Up Sequence for the P3 IPC . . . . . . . . . . . 8–18
8.2.1.6 Modifying the Boot-Up Sequence for the P4 IPC . . . . . . . . . . . 8–18
8.2.1.7 Restoring a Hard Disk from a Recovery Disk Image for
the P3 IPC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–19
8.2.1.8 Restoring a Hard Disk from a Recovery Disk Image for
the P4 IPC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–20
8.3 Replacing the Uninterruptible Power Supply Battery . . . . . . . . . . . . . . . 8–22
Chapter 9: Statistical Process Control (SPC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

9.1 SPC Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
9.2 SUMMARY Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
9.3 DETAILS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
9.3.1 DISTRIBUTION AND TREND Screen . . . . . . . . . . . . . . . . . . . . . . . . 9–6
9.3.2 XBAR AND R/s Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
9.4 HISTORY Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
9.5 GROUP Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
9.6 SETUP Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14
9.7 CONTROL LIMITS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–19
9.8 SPC Concepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–20
9.8.1 Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–20
9.8.2 SPC Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21
9.8.3 Monitoring Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21
9.8.4 Machine Cycles and Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21
9.8.5 Trend and Distribution Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–22
9.8.6 Process Variability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–22
9.8.7 Specification Limits and Standards . . . . . . . . . . . . . . . . . . . . . . . . . 9–23
v 4.11.1 — March 2007 xvii

9.8.8 Process Quality Factor (Cpk) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–23

9.8.9 Control Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–26
9.8.10 Xbar Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–26
9.8.11 R/s Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–28
9.8.12 SPC Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–30
9.8.13 SPC Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–31
9.8.14 SPC Statistical References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–34
Chapter 10: Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
xviii v 4.11.1 — March 2007

Machine Manual
Preface
Purpose of this Manual
The purpose of the Machine Manual is to assist the Customer to receive, handle,
install, setup, commission, run and maintain the Hylectric Injection Molding Machine.
Safety
First read the Chapter 1,Safety Summary. Make sure that all personnel involved in the
running and maintenance of the machine are thoroughly familiar with all safety issues
and procedures discussed in this manual.
v 4.11.1 — March 2007 xix Purpose of this Manual

Safety xx v 4.11.1 — March 2007

Machine Manual Safety Summary
Chapter 1 Safety Summary
The Safety Summary describes general requirements and conditions for safe
installation, operation, and maintenance of injection molding equipment. Personnel
must read, understand, and follow all safety precautions listed in the equipment
manuals. Personnel must follow applicable industry and regulatory safety
requirements for safe installation, operation, and maintenance of equipment.
1.1 Manuals
Husky manuals aid in the safe and proper use of the machine, robot, and mold. The
manuals provide instructions on installation, operation, and maintenance. A separate
Drawing Package includes parts lists and drawings.
Personnel should review all manuals thoroughly prior to performing any tasks.
Proceed with tasks only if all instructions are understood. Follow applicable workplace
safety requirements.
Keep manuals in a convenient location for future reference.
Signal words are used in the manuals according to the degree of severity, and
classified as: Danger, Warning, or Caution. Signal words alert the user to hazardous
situations that arise during routine installation, operation, and maintenance.
DANGER!
The term DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING!
The term WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION!
The term CAUTION indicates a potentially hazardous situation which, if not
avoided, can result in property damage.
v 4.11.1 — March 2007 1–1 Manuals

1.2 Safety Signs
Safety signs clearly mark potentially hazardous areas in or around equipment. For the
safety of personnel involved in equipment installation, operation, and maintenance,
use the following guidelines.
1. Verify all signs are in the proper locations. Refer to the Drawing Package for
details.
2. Do not alter signs.
3. Keep signs clean and visible.
4. Order replacement signs when necessary. Refer to the Drawing Package for part
numbers.
The table below describes safety symbols appearing on safety signs. Each safety sign
could include a detailed explanation of the potential hazard and associated
consequences.
Safety Symbol General Description of Symbol
General – Warning
This symbol indicates a potential personal injury hazard. It is usually
accompanied by another pictogram or text to describe the hazard.
Danger – Hazardous Voltage

[
Contact with hazardous voltages will cause death or serious injury. Turn
off power and review electrical schematics before servicing equipment.
Electrical cabinet can contain more than one live circuit. Test all circuits
before handling to make sure circuits have been de-energized.
Warning – Molten Material and/or High Pressure Gas

Contact with molten material or high pressure gas can cause death or
severe burns. Wear personal protective equipment while servicing the
feed throat, nozzle, mold areas, and when purging the injection unit.
Warning – Lockout/Tagout
Servicing equipment without disabling all internal and external power
sources can cause death or serious injury. De-energize all internal and
external power sources. Electrical, hydraulic and pneumatic are
examples of energy sources to consider.
Warning – Crushing and/or Impact Points

Contact with moving parts can cause serious crushing injury. Do not
reach over, under, around, or through guards. Always keep fixed and
movable guards in place.
Warning – Crushing and/or Impact Points

Contact with moving parts can cause serious crushing injury. Do not
reach over, under, around, or through guards. Always keep fixed and
movable guards in place.
Safety Signs 1–2 v 4.11.1 — March 2007

Safety Symbol General Description of Symbol
Warning – High Pressure

Overheated water or steam may cause severe burns. Discharge
pressure before disconnecting water lines.
Warning – High Pressure Accumulator

Sudden release of high pressure gas or oil can cause death or serious
injury. Discharge all gas and hydraulic pressure before disconnecting or
disassembling accumulator.
Warning – Hot Surfaces

Contact with exposed hot surfaces will cause serious burn injury. Wear
protective gloves when working near these areas.
Warning – Slip, Trip, or Fall Hazard

Personnel climbing on equipment surfaces may slip, trip, or fall causing
injury. Do not climb on equipment surfaces.
Warning – Crushing Hazard

Contact with the rotating screw can cause serious crushing injury. Do not
insert body parts into the feed throat opening while the machine is
operating. Install a hopper or a direct feed system.
Warning – Read Manual Before Operation

Personnel involved with equipment operation and maintenance should
be properly trained. Personnel should read and understand all
instructions in the manuals before working on equipment.
Warning – Class 2 Laser Beam

Personal injury will result with prolonged exposure to the laser beam. Do
not stare directly into the laser beam and avoid exposure. Unplug the
connector to switch off the laser beam.
Warning – Barrel Cover Grounding Strap

Contact with an energized barrel cover can cause death or serious
injury. The barrel cover can become energized upon removal of
grounding strap(s). Complete Lockout/Tagout before removing the barrel
cover. Make sure grounding strap(s) are connected before applying
power to machine.
v 4.11.1 — March 2007 1–3 Safety Signs

1.3 Qualified Personnel
Only fully trained personnel should be permitted to operate, maintain, and service
equipment. In addition, make sure:
1. Only one qualified person operates the equipment at a time.
2. The area around the equipment is safe at all times.
1.4 Training
Skilled personnel are required to operate and maintain Husky equipment. Contact a
Husky Regional Service and Sales office to arrange training.
1.5 Guards And Interlocks
Guards are provided where hazards exist. There are two types of guards: movable
and fixed. Movable guards are interlocked to stop hazardous motion when the guards
are moved or removed. Fixed guards are not interlocked. Fixed guards must be
installed and completely secured anytime power is applied to the machine.
Before operating the equipment, make sure of the following.
1. Safeguards are in place.
2. Safeguards are not bypassed or modified.
3. Safeguards are tested and inspected regularly for correct operation.
4. Only qualified personnel perform maintenance tasks.
1.6 Lockout/Tagout
The Lockout/Tagout procedure must be performed before maintenance and service

tasks. Lockout/Tagout includes isolation or depletion of stored energy from all
integrated ancillary equipment. For detailed Lockout/Tagout instructions, refer to the
equipment manual and local regulations and codes.
After performing Lockout/Tagout and disconnecting the supply voltage, allow 10
minutes for the extruder servo DC Bus to discharge residual voltage to less than 50
Volts before performing any electrical procedures.
When troubleshooting electronics, Lockout/Tagout may not be possible. In this case,
Service Personnel must secure the work cell by installing a Danger sign at all isolation
points and cordoning off the area around the equipment.
Qualified Personnel 1–4 v 4.11.1 — March 2007

1.6.1 Performing Lockout/Tagout
Special Tool Required
1 Hydraulic pressure gauge suitable to 21 MPa (3000 psi) with quick-disconnect fitting
Perform Lockout/Tagout using the following instructions.
DANGER!
Electrocution hazard – risk of death or serious injury. Install danger sign at all
isolation points and rope off the area around the machine. When live
troubleshooting is required, do not work alone. Have emergency medical
assistance nearby throughout the procedure.
WARNING!
Hazardous voltages, high pressure fluids, crushing or impact hazards – risk of
death or serious injury. Perform Lockout/Tagout procedure in accordance with
local codes. After performing Lockout/Tagout procedure, allow 10 minutes for
residual voltage to discharge to less than 50 Volts before performing any
electrical procedures.
Only qualified personnel should perform Lockout/Tagout procedure.
CAUTION!
Switch off Q1M breaker last when powering down. Failure to do so can result in
unnecessary wear on the components and lead to premature failure.
1. Turn off the power supply to the machine at the main disconnect switches in the
following sequence: Q3M, Q2M (if equipped) and finally, Q1M. Attach a lock and a
tag. Then wait 10 minutes for residual voltage to discharge.
NOTE: The Q2M breaker is found only on machines equipped with mold heats.
2. Verify that all power to the machine is switched off using an voltmeter that has
been tested on a known source.
3. Remove the cap from the gauge port (typically "PP6G"). Refer to your schematic
for specific location. Refer to Figure 1-1. Attach a hydraulic pressure gauge (2) to
the gauge port.
4. Turn the manual dump valve (3) off to ensure that the accumulator is fully
discharged.
5. Check the pressure gauge to verify the accumulator is completely discharged.
v 4.11.1 — March 2007 1–5 Lockout/Tagout

1
2
2 3
Figure 1-1 Manual Dump Valve (2 Configurations Shown)

1. Power manifold assembly 2. Pressure gauge 3. Manual dump valve
4. Accumulator
6. Turn off shutoff lever (5) on the air regulator (6) to turn off the air supply to the
machine – refer to Figure 1-2. Attach a lock (7) and a tag (8) on the air regulator.
8
S01-101037.eps
Figure 1-2 Air Regulator (Typical)

5. Shutoff lever 6. Air regulator 7. Lock 8. Tag
Lockout/Tagout 1–6 v 4.11.1 — March 2007

1.6.2 Removing Locks and Tags

Remove locks and tags using the following instructions.
WARNING!
Hazardous voltages – risk of death or serious injury. Perform Lockout/Tagout
removal procedure in accordance with local codes.
Only qualified personnel should be permitted to perform Lockout/Tagout

procedure.
1. Check all power cables are properly connected.

2. Verify the danger zone around the machine is clear of all personnel before
attempting to remove the lock and tag at the main disconnect switch.
3. The lock and tag should only be removed by the person who installed them.
If the person is unable to personally remove the lock and tag, verbal instructions
can be given to remove the lock and tag. The instructions must also include any
specific measures required to return the machine to safe operating condition.
If the person cannot be contacted, then a supervisor and a qualified technician
who has a thorough understanding of the machine should perform the following
checks.
a. Check all isolation points to make sure that hoses, wires, and/ or systems are
set to a safe condition.
b. Verify that the danger zone around the machine is clear of all personnel.
c. Remove the lock and tag only when both the supervisor and the technician
agree that all systems are in order, and there is no potential for injury.
CAUTION!
Switch on Q1M breaker first when powering up. Failure to do so can result in
4. Turn on the power supply to the machine at the main disconnect switches in the
following sequence: Q1M, Q2M (if equipped) and finally, Q3M.
5. Turn the manual dump valve to close the hydraulic circuit.
6. Remove the pressure gauge from the hydraulic power pack. Refer to Figure 1-1.
Cap the gauge port.
7. Remove the lock and tag on the air regulator. Use the shutoff lever on the air
regulator to turn on the air supply to the machine. Refer to Figure 1-2.
v 4.11.1 — March 2007 1–7 Lockout/Tagout

1.7 Safety Hazards
Some common safety hazards associated with injection molding equipment are:
1. Mechanical (pinching, shearing, crushing)
2. High Pressure Leak
3. Burn
4. Explosion
5. Electrical
6. Noise
7. Gas, Vapor, and Dust Emissions
8. Slip, Trip, or Fall
9. Lifting
1.7.1 Mechanical Hazards
1.7.1.1 Worn Hoses and Safety Restraints

Regularly inspect and replace all flexible hose assemblies and restraints.
1.7.1.2 Cooling Water Hoses

Cooling water hoses degrade over time and need to be replaced on a yearly basis.
Cooling water hoses routed in the vicinity of the barrel are exposed to high
temperatures that shorten their useful life and can require more frequent replacement.
Degraded hoses become brittle and can break or separate from the fitting when
manipulated. To minimize the risk of failure, inspect the hoses regularly and replace as
required.
Make sure to wait until the machine has cooled down before servicing cooling water
hoses.
1.7.1.3 Injection and Clamp Units

Hydraulic circuits in Injection and Clamp Units contain high pressure accumulators.
Before servicing hydraulic systems, perform the Lockout/Tagout procedure to
discharge all stored energy. When servicing hydraulic systems, read equipment
manuals and refer to hydraulic schematics for additional details.
Safety Hazards 1–8 v 4.11.1 — March 2007

1.7.2 High Pressure Leak Hazards
1.7.2.1 Hydraulic System

Flexible hose connections and piping in hydraulic systems must be properly tightened
to prevent the release of fluids or gases under pressure. Hoses must be inspected
periodically for signs of sweating and/or blistering. Steel tubes should be tested using
dye penetrant.
1.7.2.2 Skin Puncture Injuries

High pressure hydraulic spray can penetrate human tissue and cause severe bodily
injury. Seek immediate medical help in any event of skin puncture by fluid spray.
1.7.3 Burn Hazards
1.7.3.1 Hot Surfaces

The mold area, ancillary mold equipment, and injection unit heating elements have
numerous high temperature surfaces. At normal operating temperatures, contact with
these surfaces will cause severe skin burns. These areas are clearly marked with
safety signs. Wear personal protective equipment (PPE) when working in these areas.
1.7.3.2 Molten Material

Never touch process material purged or otherwise flowing from the nozzle, mold, or
material in the feed throat area. Molten material can appear cool on the surface, but
remain very hot on the inside. Wear personal protective equipment when handling
purged material.
1.7.4 Explosion Hazards
1.7.4.1 High Pressure Explosion

Pressure can build up in a nozzle or feed throat area and cause some process
material to explode. In some cases, molten material can be ejected unintentionally due
to insufficient pre-drying or degradation of process materials. These areas are clearly
marked with safety signs. Be aware of these areas. Wear appropriate personal
protective equipment when accessing these areas.
v 4.11.1 — March 2007 1–9 Safety Hazards

1.7.5 Electrical Hazards

Molding equipment draws high power. The electrical requirements are indicated on the
electrical nameplate on the electrical cabinet, and in the electrical schematics.
Connect equipment to a suitable power supply as specified in the electrical schematics
and in compliance with all applicable local regulations.
1.7.6 Noise Hazards

Noise emissions from a single Husky Injection Molding Machine is not hazardous
under normal operating conditions. However, prolonged exposure to excessive noise
levels can cause hearing loss. Make sure noise levels are in compliance with all
applicable local regulations. Wear hearing protection when operating equipment.
1.7.7 Gas, Vapor, and Dust Emissions

Certain processed materials release harmful gas, vapors, or dust. Install an exhaust
system according to local codes.
1.7.8 Slip, Trip, or Fall Hazards

Do not walk, stand, climb, or sit on machine surfaces.
Use an approved platform or walkway around equipment to reach areas that are not
accessible from the floor.
1.7.9 Lifting Hazards

When lifting the machine or machine components, use suitable lifting equipment,
proper balancing techniques, and designated lifting points. Refer to the installation
details for handling and lifting instructions. Do not exceed the rated capacity of the
lifting equipment.
1.8 Personal Protective Equipment and Safety Equipment
1.8.1 Personal Protective Equipment (PPE)

Wear appropriate personal protective equipment when working on or near equipment.
Standard personal protective equipment includes: safety glasses, face shield, heat
resistant gloves, hearing protection, and safety shoes.
Personal Protective Equipment and Safety Equipment 1–10 v 4.11.1 — March 2007
1.8.2 Safety Equipment

Use appropriate safety equipment when working on or near equipment. Standard
safety equipment for clearing frozen resin includes: telescopic mirrors, brass
hammers, and brass rods.
1.9 Ancillary Equipment
Husky is only responsible for the interaction of the machine with ancillary equipment
when Husky is the system integrator. If ancillary equipment is removed, proper
safeguards must be installed. For information about integrating non-Husky ancillary
equipment, contact a Husky Regional Service and Sales office.
1.10 Material Safety Data Sheet (MSDS)
The Material Safety Data Sheet (MSDS) is a technical document which indicates the
potential health effects of a hazardous product, and contains safety guidelines to
protect personnel. Before handling a product, refer to the MSDS. These sheets identify
hazards related to use, storage, and handling of the product, including emergency
procedures. Contact the material supplier to obtain a copy of the MSDS sheet.
1.11 Materials, Parts, and Processing
To prevent personal injury or damage to the equipment, make sure of the following.
1. The equipment is only used for its intended purpose, as described in the manuals.
2. The operating temperatures do not exceed the specified permissible maximum
value.
3. The maximum temperature setpoint is set below the ignition point of the material
being processed.
4. Lubricants, oils, process materials, and tools used on equipment meet Husky
specifications.
5. Only authentic Husky parts are used.
v 4.11.1 — March 2007 1–11 Ancillary Equipment

1.12 Warning Device
REMINDER: If your machine is equipped with a special warning device, refer to

Customer Specials – Chapter 10—Additional Information.
The machine is equipped with a red warning light (3) that lights up when the machine
stops due to an alarm condition – refer to Figure 1-3. An optional audible horn (1) also
sounds to indicate the alarm condition. A blue warning light combined with a different
audible alarm indicates a pending warning on the software alarm screen.This feature
gives an early warning to the operator that a cycle interruption will occur if not
addressed.
On machines equipped with the Statistical Process Control (SPC) option, the amber
light (2) lights up to indicate a SPC-related alarm.
1
2
3
S01-101059.eps
Figure 1-3 Warning Device (Typical)

1. Horn 2. Amber light 3. Red light
Warning Device 1–12 v 4.11.1 — March 2007

1.13 Machine Safety Devices
The machine is equipped with a number of safety devices designed to ensure the
safety of the operator. The safety devices are: Emergency Stop button, Front
Operator’s Gate, Rear Guard, Mechanical Safety Device, CEN Valve, Automatic
Dump Valve, Manual Dump Valve and Purge Guard.
1.13.1 Emergency Stop Button

The Emergency Stop button (1) is used to stop the machine in the event of an
emergency. It is located on the panel below the HMI – refer to Figure 1-4.
Figure 1-4 EMERGENCY STOP Button (Typical)

1. Emergency Stop button
Push the <EMERGENCY STOP> button to de-energize all control circuits, and stop
the machine. Pull the button to reset it.
v 4.11.1 — March 2007 1–13 Machine Safety Devices

1.13.2 Front Operator’s Gate and Rear Guard

The machine is equipped with an operator’s gate (1), and rear guard (2) to prevent
access to the mold and clamp areas – refer to Figure 1-5. The clear Plexiglas panel in
the guards allow a clear view of the area behind the guards.
Each guard is monitored by four limit switches (3). Limit switches S7LS, S8LS, S12LS
and SL13LS monitor the guards, and trigger an alarm when either guard is opened.
S01-101113.eps
Figure 1-5 Operator’s Gate and Rear Guard (Typical)

1. Operator’s gate 2. Rear guard 3. Limit switch (Typical)
1.13.3 Powered Front/Rear Gates Only - Gate Close Interlock Device

An interlock device prevents an unintentional return of the gate to the closed position.
Before the gate can be closed the piston must be lifted up by pushing the “Front/Rear
Gate interlock Reset” button.
Machine Safety Devices 1–14 v 4.11.1 — March 2007

1.13.4 Powered Front/Rear Gates Only - Security Strip

On the “hot” side of the gate, a security strip (item 1, Figure 1-6) is installed, to prevent
catching a person during forward moving of the gate.
When the gate closes and the security strip is touched, the gate immediately stops. To
decrease the stop-time, the motor will be electrically decelerated. In reversing the
gate, it is possible to remove the squeeze.
Figure 1-6 Powered Gate Squeeze Interlock

1. Security strip

1.13.5 Mechanical Safety Device

The mechanical safety device consists of a mechanical pin (1) that prevents unsafe
movement of the clamp stroke column (2) when the operator’s gate is opened – refer
to Figure 1-7. Limit switches S352LS and S353LS monitor the guards, and activate the
mechanical safety device when either guard is opened.
The mechanical safety device is typically installed on all machines shipped to
Customers in North America and Australia.
Y195SV
S4PX
2
S01-101044.eps
Figure 1-7 Mechanical Safety Device (Typical)

1. Mechanical pin 2. Mold stroke column
1.13.6 CEN Valve

Please refer to the hydraulic schematic for details specific to your machine.
H90 - H225
The CEN valve prevents system hydraulic pressure from reaching the clamp, stroke,
injection and ejection cylinders when either the front or rear operator gate is opened.
Limit switches S333LS and S334LS monitor the position of the moveable guards, and
activate the CEN valve when either guard is opened.
H300 - H1000
The CEN valve prevents system hydraulic pressure from reaching the stroke cylinder
when either the front or rear operator gate is opened. Limit switches S333LS and
S334LS monitor the position of the moveable guards, and activate the CEN valve
when either guard is opened.

1.13.7 Automatic Dump Valve

The automatic dump valve discharges all system pressure from the accumulator when
the <PUMP MOTOR OFF> key is pressed. This ensures that there is no stored
hydraulic pressure in the system when the machine is shut down.
1.13.8 Manual Dump Valve

The manual dump valve (1) is a backup safety device to ensure that all system
pressure is discharged from the accumulator – refer to Figure 1-8. Before servicing the
hydraulic system, open the manual dump valve and wait for all pressure to discharge.
Figure 1-8 Manual Dump Valve (Typical)

1. CEN valve 2. Manual dump valve

1.13.9 Purge Guard

The purge guard (1) protects the operator from molten spray that can be discharged
from the injection nozzle – refer to Figure 1-9. Limit switch S1LS monitors the purge
guard, and triggers an alarm when the purge guard is opened.
RS45–RS155
1
S01-100769a
RS22–RS40
Figure 1-9 Purge Guards (Typical)

1. Purge guards

1.13.10Electrical Cabinet Door Interlocks and Override (UL only)

Interlocks on every electrical cabinet doors cut power to the electrical components
whenever a cabinet door is opened – refer to Figure 1-10.
Figure 1-10 Electrical Cabinet Door Interlock Switch
A door interlock override key switch provides a method for opening the electrical
cabinet without power loss, when required for troubleshooting electrical components.
An indicator push-button lights up to show the cabinet interlocks are OFF.
• Turning the key switch to the OFF position disables the electrical cabinet inter-
locks.
• Pressing in the push-button tests the interlock override indicator light.
NOTE: Replace any burned out bulb immediately.
2 3
Figure 1-11 Electrical Cabinet Door Interlock Override

1. Electrical cabinet 2. Door Interlock OFF Indicator push-button 3. Door Interlock
override key switch


Machine Manual Specifications
Chapter 2 Specifications
This chapter lists machine technical specifications, environmental requirements,

services, supplies, and torque specifications.
Husky reserves the right to change specifications without prior notice.
2.1 Machine Weights
IMPORTANT!
5 The clamp and injection unit weights listed in Table 2-1 through to Table 2-11 are
approximate and are given to assist in planning lifting requirements. Actual weight
varies according to machine configuration.
Table 2-1 Machine Weights - H90 Models (Calculated)
Weight
Machine lb (kg)
Model
RS22 RS28 RS35 RS40 RS45
H90 15000 (6800) 15653 (7100) 16094 (7300) 16755 (7600) 19841 (9000)
Table 2-2 Machine Weights - H/HL120 Models (Calculated)
Weight
Machine lb (kg)
Model
RS22 RS28 RS35 RS40 RS45 RS55
15000 15653 16094 16755 17200 19841

H120
(6800) (7100) (7300) (7600) (7800) (9000)
16534 17196 17636 18077 18298 20800

HL/120
(7500) (7800) (8000) (8200) (8300) (9500)
v 4.11.1 — March 2007 2–1 Machine Weights

Table 2-3 Machine Weights - H/HL160 Models (Calculated)
Weight
lb (kg)
Machine Model
RS35 RS40 RS45 RS55
H160 19000 (8600) 17636 (8000) 20000 (9071) 19841 (9000)
HL160 18518 (8400) 19841 (9000) 21164 (9600) 19000 (10000)
Table 2-4 Clamp and Injection Unit Weights - H/HL225 Models (Calculated)
H225 HL225
Clamp +Clamp Base lb (kg) lb (kg)
17200 (7800) 19800 (9880)
Injection Unit Injection Weighta Total Machine Weight Total Machine Weight
lb (kg) lb (kg) lb (kg)
RS45 10400 (4700) 27600 (12500) 30200 (14580)
RS55 12600 (5700) 29800 (13500) 32400 (15580)
RS65 15400 (7000) 32600 (14800) 35200 (16880)
RS80 21000 (9500) 38200 (17300) 40800 (19380)
a. Weight includes injection unit, injection base, electrical cabinet, and hydraulic power pack.
H300 HL300
Clamp + Clamp Base lb (kg) lb (kg)
25400 (11500) 26400 (12000)
RS45 10400 (4700) 35800 (16200) 36800 (16700)
RS55 12600 (5700) 38000 (17200) 39000 (17700)
RS65 15400 (7000) 40800 (18500) 41800 (19000)
RS80 21000 (9500) 46400 (21000) 47400 (21500)
RS95 23700 (10800) 49100 (22300) 50100 (22800)
Machine Weights 2–2 v 4.11.1 — March 2007

Table 2-6 Machine and Injection Unit Weights - H/HL400 Models (Calculated)
H400 HL400
39900 (18100) 42500 (19300)
RS55 12600 (5700) 52500 (23800) 55100 (23800)
RS65 15400 (7000) 55300 (25100) 57900 (26300)
RS80 21000 (9500) 60900 (27600) 63500 (28800)
RS95 23700 (10800) 63600 (28900) 66200 (30100)
RS115 29300 (13300) 69200 (31400) 71800 (32600)
H500 HL500
46200 (21000) 49700 (22600)
RS65 15400 (7000) 61600 (28000) 65100 (29600)
RS80 21000 (9500) 67200 (30500) 70700 (32100)
RS95 23700 (10800) 69900 (31800) 73400 (33400)
RS115 29300 (13300) 75500 (34300) 79000 (35900)
H600 HL600
50490 (22900) 54015 (24500)
RS95 23700 (10800) 74190 (33700) 77715 (35300)
RS115 29300 (13300) 79790 (36200) 83315 (37800)
v 4.11.1 — March 2007 2–3 Machine Weights

H650 HL650
63000 (28600) 65500 (29800)
Injection Unit RS Unit Weighta Total Machine Weight Total Machine Weight
RS80 21000 (9500) 84000 (38100) 86500 (39300)
RS95 23700 (10800) 86700 (39400) 89200 (40600)
RS115 29300 (13300) 92300 (41900) 94800 (43100)
RS135 42000 (19100) 105000 (47700) 107500 (48900)
a. Weight includes power pack, electrical cabinet, and injection base.
H800 HL800
88200 (40100) 97000 (44100)
RS80 21000 (9500) 109200 (49600) 118000 (53600)
RS95 23700 (10800) 111900 (50900) 120700 (54900)
RS115 29300 (13300) 117500 (53400) 126300 (57400)
RS135 42000 (19100) 130200 (59200) 139000 (63200)
RS155 45900 (20900) 134100 (61000) 142900 (65000)
Machine Weights 2–4 v 4.11.1 — March 2007

H1000 HL1000
116844 (53000) 121253 (55000)
RS95 23700 (10800) 140544 (63800) 144953 (65800)
RS115 29300 (13300) 146144 (66300) 150553 (68300)
RS135 42000 (19100) 158844 (72100) 163253 (74100)
RS155 45900 (20900) 162744 (73900) 167153 (75900)
2.2 Environmental Requirements
The production room ambient room temperature and ventilation system must meet
requirements in Table 2-12.
Table 2-12 Environmental Requirements
Requirement
Ambient Room Temperature 0°C to 40°C (32°F to 104°F)

without the Tropical Cooling Option
Ambient Room Temperature with 0°C to 48°C (32°F to 118°F)

the Tropical Cooling Option
Ventilation Suitable ventilation system to remove all harmful

gases, vapors or dust released when processing
certain plastic resins.
2.3 Electrical Power Specifications
The machine and mold (optional) electrical power supplies must conform to
specifications in the System Information drawing located in Chapter 5 in the Site
Preparation Manual. The specifications are also listed on the electrical nameplate and
the electrical schematics.
All power cables must be rated accordingly.
v 4.11.1 — March 2007 2–5 Environmental Requirements

Voltage of supply to equipment may vary up to ±10% (of the value on the electrical
cabinet nameplate, and electrical schematic).
The supply to the electric drives on the machine must come from a solidly grounded
wye (star) source. If a solidly grounded wye source is not used to supply the machine,
then an isolation transformer must be installed to create the solidly grounded wye
source for the drive system. Husky can provide additional details for the specific
machine if required.
Frequency of supply to equipment may vary by up to ±1% continuously (of the value
on the electrical cabinet nameplate, and electrical schematic).
The prospective short circuit fault level at the main equipment terminals shall be no
more than 10,000 A RMS symmetrical.
2.4 Machine Cooling Water Specifications
2.4.1 Cooling Water Guidelines
CAUTION!
Failure to abide by these guidelines for tower and chilled water quality could
result in damages to the injection molding system, and may void the warranty.
Cooling water treatment is required to protect,

• molds,
• injection molding machines,
• chillers,
• cooling towers,
• piping, and
other water cooled equipment from corrosion and deposit fouling inside the cooling
channels. Corrosion can lead to water leaks and failure of mold/machine components.
Deposits in the cooling channels reduce heat transfer resulting in:
• reduced efficiencies,
• longer molding cycles,
• reduced part quality,
• increased maintenance,
• increased costs.
Since local water supplies vary widely in quality, Husky recommends that you work
with reputable water treatment company in your area to establish a water treatment
program that is best suited for your needs. A good water treatment program must be
developed specifically for each facility, taking into account the;
• municipal water conditions,
• cooling system design,
• water usage patterns.
Machine Cooling Water Specifications 2–6 v 4.11.1 — March 2007

2.4.2 Cooling Water Treatment Procedure

The first step of a water treatment program is to have a qualified laboratory perform an
analysis of the following.
• Municipal water supply.
• Chilled water system.
• Tower water system.
For a sample report showing the typical criteria of the analysis, see Section 2.4.3,
together with Husky’s recommended values.
Once this analysis is completed, a water treatment specialist can recommend the
appropriate water treatment. This analysis and treatment of the cooling water should
be performed on a regular basis.
2.4.3 Typical Cooling Water Analysis Report
Sample Locations
Constituents Units
Closed Loop Chiller Tower Water
pH pH units 7.2 - 9.5 7.2 - 9.0
Conductivity µmhos/cm < 3,000 1000 - 2000
Total Hardness [as CaCO3] mg/L or ppm < 10 60 - 800
Calcium Hardness [as CaCO3] mg/L or ppm < 10 60 - 800
“M” Alkalinity (Total) [as CaCO3] mg/L or ppm NA < 500
Cations
Total Iron [as Fe] mg/L or ppm < 0.5 < 1.0
Copper [as Cu] mg/L or ppm < 0.05 < 0.1
Aluminum [as AI] mg/L or ppm < 0.1 < 0.1
Anions
Free Chlorine [as CI2] mg/L or ppm <0 < 1.0
Chloride (as CI) mg/L or ppm < 400 < 400
Sulfate [as SO4] mg/L or ppm < 300 < 300
Silica as [Si02] mg/L or ppm < 150 < 150
Microbiological Activity
Sulfate Reducing Bacteria Col./mI <1 <1
Total Aerobic Bacteria Col./mI < 10,000 < 10,000
v 4.11.1 — March 2007 2–7 Machine Cooling Water Specifications

Sample Locations
Constituents Units
Closed Loop Chiller Tower Water
Solids
Suspended Solids mg/L or ppm < 10 < 10
Solid Size (< 5 µm side stream filters recommended) µm <5 <5
Maximum Corrosion Rate (of 90 day test specimens, if used)
Mild Steel µm Per Year < 25.4 < 76.2
Copper µm Per Year < 12.7 < 12.7
Aluminium µm Per Year < 12.7 < 12.7
NOTE: The values specified in the above table are typical recommended values that
may be achievable in most cooling systems. Deviations from these values
may be necessary, but should be reviewed with your water treatment
company.
NOTE: The recommended values above represent conditions under which most
problems associated with poor water quality can be controlled using normal
water treatment additives - THEY DO NOT REPRESENT WATER WHICH
CAN BE USED UNTREATED. Meeting the recommended values does not in
itself guarantee that cooling water will not be corrosive. It is important that all
the metals in the cooling system (steel, stainless steel, cast iron, aluminum,
copper, zinc, nickel plating, etc.) be protected using suitable corrosion
inhibitors.
Table 2-13 Machine Cooling Water Specifications
Description Value
Inlet temperature range 10 to 34°C (50 to 93°F) - Non -condensing*a
Inlet pressure (minimum to maximum) 0.45 to 0.6 MPa (60 to 90 psi)
Pressure drop (minimum) 0.2 MPa (30 psi)
a. The temperature of the water supply must be above the temperature at which condensation will occur.
Table 2-14 Machine Cooling Water Flow Rates

Electric Motor Water Flow
HP kW m3/hr USG/min
30 22 2.5 11.0
50 37 3.9 17.2
60 45 4.9 21.7
75 56 6.1 26.9
Machine Cooling Water Specifications 2–8 v 4.11.1 — March 2007

Table 2-14 Machine Cooling Water Flow Rates

Electric Motor Water Flow
HP kW m3/hr USG/min
100 75 7.0 30.8
125 93 9.1 40.1
150 112 8.5 37.4
200 149 11.8 52.0
250 187 15.8 69.6
300 224 17.0 74.9
350 261 24.4 107.4
2.5 Compressed Air Supply
Compressed air supply must meet specifications in Table 2-15.
Table 2-15 Compressed Air Supply Specifications
Description Value
Compressed air supply 56 l/min (2 scfm)
Inlet pressure (minimum to maximum) 0.6 to 1.03 MPa (90 to 150 psi)
NOTE: Refer to the Manufacturer’s Robot Manual for compressed air requirements
for the robot.
Table 2-16 Compressed Air Flow Specificationsa
Compressed Air Consumer Machine Size Valve Series Port Size Cv Rating
Air Function (Standard) H90 - H600 2012 3/8" 1.8
Air Function (Standard) H650 - H1000 ISO 2 1/2" 2.9
Air Function (High Flow) H300 - H600 ISO 2 1/2" 2.9
Air Function (High Flow) H650 - H1000 ISO 3 3/4" 5.3
Pneumatic core H90 - H600 2012 3/8" 1.2
Pneumatic core H650 - H1000 ISO 2 1/2" 2.9
Pneumatic valve gate control H90 - H1000 2012 3/8" 1.2
a. Compressed air flow specifications depends on consumer layout and cycle conditions.
v 4.11.1 — March 2007 2–9 Compressed Air Supply

2.6 Oil Capacity Data
The hydraulic oil volumes listed in Table 2-17 through Table 2-26 are hydraulic
reservoir capacity only. For initial hydraulic system fill capacities, which include hoses,
motors, cylinders, and manifolds, refer to Table 2-27.
Table 2-17 H90 - H/HL120 Oil Capacity Data (Reservoir Only)

RS Injection Unit
Units
RS22 RS28 RS35 RS40 RS45 RS55
Hydraulic Oil Volume l 580 580 580 580 580 580
US gal 153 153 153 153 153 153
Gearbox Oil Volume l 6.5 12 12 12 12 17
US gal 1.7 3.2 3.2 3.2 3.2 3.2
Table 2-18 H/HL160 Oil Capacity Data (Reservoir Only)

RS Injection Unit
Units
RS35 RS40 RS45 RS55
Hydraulic Oil Volume l 580 580 580 580
US gal 153 153 153 153
Gearbox Oil Volume l 6.5 12 12 17
US gal 1.7 3.2 3.2 3.2
Table 2-19 H/HL225Oil Capacity Data (Reservoir Only)

RS Injection Unit
Units
RS45 RS55 RS65 RS80
US gal 193 135 159 217
Gearbox Oil Volume l 12 17 17 28
US gal 3.2 4.5 4.5 7.4

RS Injection Unit
Units
Hydraulic Oil Volume l 730 510 600 820 820
US gal 193 135 159 217 217
Gearbox Oil Volume l 12 17 17 28 28
US gal 3.2 4.5 4.5 7.4 7.4
Oil Capacity Data 2–10 v 4.11.1 — March 2007


RS Injection Unit
Units
US gal 135 159 217 217 317
Gearbox Oil Volume l 17 17 28 28 58
US gal 4.5 4.5 7.4 7.4 15.3

RS injection Unit
Units
RS65 RS80 RS95 RS115
US gal 159 217 217 317
Gearbox Oil Volume l 17 28 28 58
US gal 4.5 7.4 7.4 15.3

RS injection Unit
Units
RS80 RS95 RS115
Hydraulic Oil Volume l 1080 1080 1375
US gal 285 285 363
Gearbox Oil Volume l 28 28 58
US gal 7.4 7.4 15.3

RS Injection Unit
Units
RS80 RS95 RS115 RS135 RS155
US gal 271 271 469 601 704
Gearbox Oil Volume l 28 28 58 58 N/A
US gal 7.4 7.4 15.3 15.3 N/A
v 4.11.1 — March 2007 2–11 Oil Capacity Data


RS Injection Unit
Units
RS80 RS95 RS115 RS135 RS155
US gal 271 271 469 601 704
Gearbox Oil Volume l 28 28 58 58 N/A
US gal 7.4 7.4 15.3 15.3 N/A

RS Injection Unit
Units
RS95 RS115 RS135 RS155
US gal 271 469 601 704
Gearbox Oil Volume l 28 58 58 N/A
US gal 7.4 15.3 15.3 N/A
Table 2-27 Oil Capacity Data - Initial System Fill in liters
RS Size RS22 RS28 RS35 RS40 RS45 RS55 RS65 RS80 RS95 RS115 RS135 RS155
H90 650 650 650 675 675 675
H/HL120 650 650 650 675 675 675
H/HL160 650 675 675 675
H/HL225 850 630 720 970
H/HL300 900 680 720 1005 1025
H/HL400 680 720 1020 1035 1475
H/HL500 720 1020 1035 1475
H/HL600 1280 1295 1650
H/HL650 1350 1350 2125 2850 3310
H/HL800 1350 1350 2125 2870 3330
H/HL1000 1375 2125 2890 3350
Oil Capacity Data 2–12 v 4.11.1 — March 2007

Table 2-28 Oil Capacity Data - Initial System Fill in US Gallons
RS Size RS22 RS28 RS35 RS40 RS45 RS55 RS65 RS80 RS95 RS115 RS135 RS155
H90 172 172 172 178 178 178
H/HL120 172 172 172 178 178 178
H/HL160 172 178 178 178
H/HL225 225 166 190 256
H/HL300 238 180 190 266 271
H/HL400 180 190 269 273 390
H/HL500 190 269 273 390
H/HL600 338 342 436
H/HL650 357 357 561 753 875
H/HL800 357 357 561 758 880
H/HL1000 363 561 764 885
2.7 Hydraulic Oil Specifications
Hydraulic fluid must comply with the hydraulic fluid specification in Section 2.7.1.
Husky guarantees compliance of recommended and equivalent fluids listed in
Table 2-29.
IMPORTANT! It is customer’s responsibility to ensure hydraulic fluid compliance

5 should they decide to use a fluid that is not listed under recommended or equivalent
fluids. The test apparatus and test data confirming compliance of such fluids must be
available upon Husky’s request.
CAUTION!
Avoid mixing different brands or grades of lubricants or greases. Mixing
lubricants or greases can cause premature breakdown of the lubricant or grease
which will result in machine damage.
2.7.1 Detailed Hydraulic Fluid Specification

• Viscosity grade classification, ISO 3448: 1992 Industrial liquid lubricants - ISO vis-
cosity classification: VG46 with a viscosity of 46 cSt ± 10% at 40°C.
• Specific mass of 840 to 900 kg/m3@ 15°C.
v 4.11.1 — March 2007 2–13 Hydraulic Oil Specifications

• Additives classification ISO 6743-4:1999 Lubricants, industrial oils and related

products (class L) - Classification - Part 4: Family H (Hydraulic systems) HM
hydraulic fluids. (Hydraulic Oil DIN 51 524 - HLP 46)
• Approved by Denison HF-0 hydraulic fluid performance evaluation on vane pumps
and piston pumps at 25 MPa (3625 psi), 1700 rpm, high temperature, with and
without presence of water.
• A current listing of all HF-0 approved oils can be obtained from:
Parker (Denison Hydraulics Division)
14249 Industrial Parkway
Marysville, Ohio, 43040
USA
Tel: 937 644 3915
Fax: 937 642 3738
www.parker.com
• Base stock identification: Group “I and II”, base stock (API category 1 and 2)
• Upper limit of cleanliness level, ISO 4406: 17/14/11 (4μm/6μm/14μm).
• Pressure/Temperature, ISO 6743-4:1999; HM hydraulic fluids, general hydraulic
systems which included highly loaded components, operating temperatures -20°C
to 90°C. Operating pressure 20 MPa.
• Additives shall remain uniformly distributed throughout the oil at all temperatures
from the pour point up to 90°C. The oil shall retain the homogeneity once is cooled
below its pour point.
• Service life based on ISO 4263-1/ASTM D943 TOST of minimum 2500 hours. (Oil
life expectancy goal: 8000 hours)
• Worldwide availability, quality and consistency in composition.
• Compatibility:
• Residual oil. (Traces of Shell Tellus 46/Shell Tellus S 46 will be present in new
machines from test and assembly)
• Elastomer/Paint compatibility
• Nitrile of Buna-N NBR (O-Rings)
• Fluorocarbon FKM, FPM rubber (Viton) (O-Rings)
• Turcon®-Polytetrafluoroethylene [PTFE] (Glyd-Rings)
http://www.busakind.com/html/products_turcomglydring.htm
• Luytex®-Polyester based (Wear-Rings)
http://www.busakshamban.com/ADMIN/ASSETS/files/dl_slydring.pdf
• Neoprene (Hose material)
The machine is equipped with the hydraulic hoses supplied by Manuli
Rubber Industries. Check the “Fluid Compatibility” section on Manuli
website for compatibility with preferred fluid:
http://www.manuli-hydraulics.com
The following hose types are to be checked: Wire Spiral (Rockmaster,
Shieldmaster), Wire Braid (Tractor, Rockmaster and Shieldmaster), Textile
Braid (Astro)
Only the fluids with “Good” and “Excellent” compatibility are to be used.
Hydraulic Oil Specifications 2–14 v 4.11.1 — March 2007

If preferred oil is not listed please contact:

Manuli Rubber Industries S.p.A
Piazza della Republicca, 14/16
20124 Milano, Italy
Tel: +39 02 627 13.1
• Any concerns regarding the reservoir paint contact Husky Technical
Support.
• Minimum failure load stage requirement of 10 in the FZG gear test rig. (DIN 51 354
part of DIN 51 524 part 2, requirement)
NOTE: All Husky machines are tested with Shell Tellus S 46 hydraulic oil. To ensure
maximum machine performance, only use one of the oils listed below. Check
with local supplier that the oil is compatible with the existing Shell Tellus S 46
oil in the machine. Only use new oil in the machine.
Table 2-29 Approved Hydraulic Oils List
Details
Recommended oil Shell Tellus S 46
Other approved oils Chevron AW 46 Shell Tellus Premium 46

Petro-Canada Hydrex AW46 Texaco Rando HD 46
Shell Tellus 46 TotalFinaElf Azolla ZS 46
2.7.1.1 Notes About Oil

1. Hydraulic oils with a high zinc content as part of the anti-wear additive package
(>400 ppm Zn), will most likely experience a corresponding increase in the copper
content as noted in the oil sample over time. While this copper (in solution with the
oil) poses no threat as particulate contamination, it is known that it can increase
the rate of oxidation of the fluid and thus an extremely high content (>100 ppm Cu)
is undesirable.
2. Zinc-free (ashless) oils are gaining popularity in industry. Their alternative anti-
wear additive packages contain no heavy metals. This results in the oils being
considered more environmentally-friendly at time of disposal and as such are
preferred by Husky as a hydraulic fluid. Care must be taken to assure compatibility
when mixing zinc-based fluids with zinc-free alternatives. Contact your oil supplier
for availability of suitable fluids.
3. Group II hydraulic fluids are those which have been formulated to resist the
processes of oxidation and additive depletion. Although being slightly more
expensive, these oils may be preferred by customers who would like to extend the
interval of fluid replacement. Customers should contact their oil supplier for
availability of suitable fluids.
4. Group III (semi-synthetic) and Group IV (synthetic) fluids have been emerging as
preferred upper-tier fluid alternatives for customers who wish to attain maximum
life out of their oil. Customers should contact their oil supplier for availability of
suitable fluids.
v 4.11.1 — March 2007 2–15 Hydraulic Oil Specifications

5. Husky does not endorse the usage of fire resistant or higher flashpoint hydraulic
oils due to a possible incompatibility with seals and excess wear on hydraulic
components.
2.8 Lubricant Specifications
CAUTION!
Do not mix different brands or grades of lubricants or greases. Mixing lubricants
or greases can cause premature breakdown of the lubricant or grease which will
result in machine damage.
2.8.1 Grease Specifications

Greases used in the machine must meet specifications in Table 2-30.
Table 2-30 Lubricant Specifications
Specification/Type Trade Name Where Used
NLGI Grade 1 Lubriplate FGL-1 Moving platen linear bearings,

Food-grade grease stack mold carrier linear bearings,
piston support linear bearings,
mold stroke column guide
bushings
NLGI Grade 2 Lubriplate 3000 Clamp lock cylinder linkages

Extreme pressure moly grease
NLGI Grade 2 Staburags NBU 8- Electric motor bearings

Lithium-based grease EP
or Shell Alvania EP2
Static Application Grease Dow Corning Anti-corrosion compound for

ZEPF FE12 Paste application to non-moving
components
Lubricant Specifications 2–16 v 4.11.1 — March 2007

2.8.2 Gearbox Oil Specifications

Gearbox oil must meet specifications in Table 2-31.
Table 2-31 Gearbox Oil Specifications
Details
Type Heavy-duty industrial gear lubricant
Trade names Mobilgear 630 (recommended), Amogear EP 220, Energear EP 220,

Compound EP 220, Spartan EP 220, Omala 220, Meropa 220.
NOTE: Do not mix oil brands in the gearbox.
2.9 Nitrogen Volume for Hydraulic Accumulators
Nitrogen volume supply specifications are dependant upon the machine configuration.
Refer to Table 2-32 for nitrogen volumes and accumulator sizes.
WARNING!
Explosion hazard – risk of death or serious injury. To prevent an explosion, use
pure nitrogen gas to precharge the accumulator. Nitrogen gas must be at least
99.995% pure.
Table 2-32 Nitrogen and Accumulator Specifications
Machine Injection Clamp Injection High Speed

Model Unit Accumulator Accumulator Accumulator
H90-H120 RS22 N/A 1 x 10 l 1 x 10 l

(1 x 2.64 US gal) (1 x 2.64 US gal)
RS28 N/A 1 x 10 l 1 x 10 l
(1 x 2.64 US gal) (1 x 2.64 US gal)
RS35 N/A 1 x 32 l 1 x 32 l
(1 x 8.45 US gal) (1 x 8.45 US gal)
RS40 N/A 1 x 32 l 2 x 20 l
(1 x 8.45 US gal) (2 x 5.26 US gal)
RS45 N/A 1 x 32 l 2 x 20 l
(1 x 8.45 US gal) (2 x 5.26 US gal)
RS55 N/A 1 x 50 l 2 x 32 l
(1 x 13.20 US gal) (2 x 8.45 US gal)
v 4.11.1 — March 2007 2–17 Nitrogen Volume for Hydraulic Accumulators


HL120 RS22 N/A 1 x 20 l 1 x 20 l

(1 x 5.26 US gal) (1 x 5.26 US gal)
RS28 N/A 1 x 20 l 1 x 20 l
(1 x 5.26 US gal) (1 x 5.26 US gal)
RS35 N/A 1 x 32 l 1 x 32 l
(1 x 8.45 US gal) (1 x 8.45 US gal)
RS40 N/A 1 x 32 l 2 x 20 l
(1 x 8.45 US gal) (2 x 5.26 US gal)
RS45 N/A 1 x 32 l 2 x 20 l
(1 x 8.45 US gal) (2 x 5.26 US gal)
RS55 N/A 1 x 50 l 2 x 32 l
(1 x 13.20 US gal) (2 x 8.45 US gal)
H160 RS35 N/A 1 x 32 l 1 x 32 l

(1 x 8.45 US gal) (1 x 8.45 US gal)
RS40 N/A 1 x 32 l 2 x 20 l
(1 x 8.45 US gal) (2 x 5.26 US gal)
RS45 N/A 1 x 32 l 2 x 20 l
(1 x 8.45 US gal) (2 x 5.26 US gal)
RS55 N/A 1 x 50 l 2 x 32 l
(1 x 13.20 US gal) (2 x 8.45 US gal)
HL160 RS35 N/A 1 x 32 l 1 x 32 l

(1 x 8.45 US gal) (1 x 8.45 US gal)
RS40 N/A 1 x 32 l 2 x 20 l
(1 x 8.45 US gal) (2 x 5.26 US gal)
RS45 N/A 1 x 50 l 2 x 32 l
(1 x 13.20 US gal) (2 x 8.45 US gal)
RS55 N/A 2 x 32 l 2 x 32 l
(2 x 8.45 US gal) (2 x 8.45 US gal)
H225 RS45 N/A 1 x 50 l 2 x 32 l

(1 x 13.20 US gal) (2 x 8.45 US gal)
RS55 N/A 2 x 32 l 2 x 32 l
(2 x 8.45 US gal) (2 x 8.45 US gal)
RS65 N/A 2 x 32 l 2 x 32 l
(2 x 8.45 US gal) (2 x 8.45 US gal)
RS80 N/A 3 x 32 l NA
(3 x 13.20 US gal)
Nitrogen Volume for Hydraulic Accumulators 2–18 v 4.11.1 — March 2007


HL225 RS45 N/A 2 x 32 l 2 x 32 l

(2 x 8.45 US gal) (2 x 8.45 US gal)
RS55 N/A 2 x 32 l 2 x 32 l
(2 x 8.45 US gal) (2 x 8.45 US gal)
RS65 N/A 2 x 50 l 2 x 50 l
(2 x 13.20 US gal) (2 x 13.20 US gal)
RS80 N/A 3 x 50 l NA
(3 x 13.20 US gal)
H300 RS45 1 x 20 l 1 x 20 l 2 x 10 l
(1 x 5.25 US gal) (2 x 5.25 US gal) (2 x 2.64 US gal)
RS55 1 x 20 l 1 x 32 l 2 x 20 l
RS65 1 x 20 l 1 x 50 l 2 x 32 l
RS80 1 x 20 l 2 x 32 l 6 x 20 l
RS95 1 x 20 l 3 x 50 l 6 x 32 l
HL300 RS45 1 x 32 l 1 x 20 l 2 x 10 l
RS55 1 x 32 l 1 x 32 l 2 x 20 l
RS65 1 x 32 l 1 x 50 l 2 x 32 l
RS80 1 x 32 l 2 x 32 l 6 x 20 l
RS95 1 x 32 l 3 x 50 l 6 x 32 l


H400 RS55 1 x 20 l 1 x 32 l 2 x 20 l
RS65 1 x 20 l 1 x 50 l 2 x 32 l
RS80 1 x 20 l 2 x 32 l 6 x 20 l
RS95 1 x 20 l 3 x 50 l 6 x 32 l
RS115 1 x 20 l 4 x 50 l 6 x 32 l
HL400 RS55 2 x 50 l 1 x 32 l 2 x 20 l
RS65 2 x 50 l 1 x 50 l 2 x 32 l
RS80 2 x 50 l 2 x 32 l 6 x 20 l
RS95 2 x 50 l 3 x 50 l 6 x 32 l
RS115 1 x 20 l 4 x 50 l 6 x 32 l
H500 RS65 1 x 50 l 1 x 50 l 2 x 32 l
RS80 1 x 20 l 2 x 32 l 6 x 20 l
RS95 1 x 20 l 3 x 50 l 6 x 32 l
RS115 1 x 20 l 4 x 50 l 6 x 32 l
HL500 RS65 2 x 50 l 1 x 50 l 2 x 32 l
RS80 1 x 50 l 2 x 32 l 6 x 20 l
(1 x 13.20 US gal)) (2 x 8.45 US gal) (6 x 5.26 US gal)
RS95 1 x 50 l 3 x 50 l 6 x 32 l
RS115 1 x 50 l 4 x 50 l 6 x 32 l
Nitrogen Volume for Hydraulic Accumulators 2–20 v 4.11.1 — March 2007


H600 RS95 2 x 50 l 3 x 50 l 6 x 32 l
RS115 2 x 50 l 3 x 50 l 6 x 32 l
HL600 RS95 2 x 50 l 3 x 50 l 6 x 32 l
RS115 2 x 50 l 3 x 50 l 6 x 32 l
H/HL650 RS80 2 x 32 l N/A 6 x 20 l

(2 x 8.45 US gal) (6 x 5.26 US gal)
RS95 2 x 32 l N/A 6 x 32 l
(2 x 8.45 US gal) (6 x 8.45 US gal)
RS115 2 x 32 l 4 x 50 l 6 x 32 l
RS135 2 x 32 l 8 x 50 l 8 x 50 l
H/HL800 RS80 2 x 50 l N/A 6 x 20 l

(2 x 13.20 US gal) (6 x 5.26 US gal)
RS95 2 x 50 l N/A 6 x 32 l
(2 x 13.20 US gal) (6 x 8.45 US gal)
RS115 2 x 50 l 4 x 50 l 6 x 32 l
RS135 2 x 50 l 8 x 50 l 8 x 50 l
RS155 2 x 50 l 10 x 50 l 10 x 50 l
H/HL1000 RS95 2 x 50 l N/A 6 x 32 l

(2 x 13.20 US gal) (6 x 8.45 US gal)
RS115 2 x 50 l 4 x 50 l 6 x 32 l
RS135 2 x 50 l 8 x 50 l 8 x 50 l
RS155 2 x 50 l 10 x 50 l 10 x 50 l

2.10 Rust Inhibitor Specifications
Rust inhibitor used on the machine must meet specifications in Table 2-33.
Table 2-33 Rust Inhibitor Specifications
Details
Type Water-borne corrosion resistant non-hardening film
Trade name Cortec Corp. VCI-389
2.11 Machine Data
Table 2-34, Table 2-35, and Table 2-36 list the various machine settings or limits.
Table 2-34 Hydraulic System Settings
Description All but H/HL600 H/HL600
Hydraulic oil filtration ß3 ≥ 1000
Hydraulic oil operating temperature – minimum/ 47/53°C (117/127°F)

maximum
Hydraulic system operating pressure 18 MPa (2610 psi) 21 MPa (3045 psi)
Accumulator precharge pressure at operating 14 Mpa (2030 psi) 17 Mpa (2465 psi)
temperature
Table 2-35 Pneumatic Settings
Air Regulator Setting Value
Inlet pressure 0.6 MPa (90 psi)
Table 2-36 Injection Temperature Limit.
Injection Temperature Value
Maximum permissible temperature for plasticizing 415°C (779°F)
Rust Inhibitor Specifications 2–22 v 4.11.1 — March 2007

2.12 Standard Torque Specifications
2.12.1 General
The following torque specification standards shown in Table 2-37 apply to all threaded
connections, unless specified on the assembly drawing.
CAUTION!
Use of improper torque can result in equipment damage. Consult assembly
drawings for torque specifications before using torque charts in this section.
Table 2-37 Torque Standards
Torque Specification
Application Hardware
Standard
Mechanical connections Screws DIN 912–12.9 (SHCS) HGT-35

and DURLOK–12.9–UNB HGT-50
threaded DIN 912–10.9 (HHCS) HGT-80a
rods DIN 976-12 & 10.9
ASTM A574
Setscrews ISO 898/ 5 - 45H HGT-SS

ASTM F912
Hydraulic, lubrication, Fittings & O-ring Face Seal HGT-FT

pneumatic, and water plugs JIC (37° Flared)
connections NPT, BSPP, Ferrule (Bite)
SAE Straight Thread
Electrical connections Screws Steel, AL & Cu, Brass HGT-EL
a. The maximum allowable torque for 10.9 SHCS, HHCS, and threaded rods is HGT-50.
Table 2-38 HGT Torque Standards
Preload Class
HGT–35 Recommended for all aluminum casting and wrought aluminum alloy applications
HGT–50 Recommended for parts manufactured from ductile iron castings or mild carbon
steel. Standard torque for most Husky Machine and Mold applications.
HGT–80 Recommended for the majority of Hot Runner products in high strength and/or
high fatigue applications using grade 12.9 bolts that will not crush, gall, warp or
fracture the joint material under preload (e.g. high-strength alloy steel).
v 4.11.1 — March 2007 2–23 Standard Torque Specifications

2.12.1.1 Torque Tolerances

The more accurate the method of controlling tightness the more of the strength of the
fastener can be utilized. The tolerance values specified in this standard pertain to the
tool’s accuracy and not the induced fastener’s load that is affected by other variables
such as lubrication, clamped materials, temperature, etc.
For example, assembly torque wrenches should be calibrated to stay within ± 4%
when applying HGT-50, 80 or 35 and the fastener’s induced load accuracy can be
expected to range from ± 10-20%.
2.12.1.2 Lubricants and Adhesives

Apply the correct lubricant to all threads and contacting surfaces before installation.
Table 2-39 Lubricants for General Applications
Lubricant
Application
Food Grade Non Food Grade
Mechanical (Fastener Threads) - FGL-1 Shell Tellus 46, LUB 3000,

Low Temperature (<150°C) Molykote G (MoS2) or
Equivalent
Mechanical (Fastener Threads) - Not Available Optimoly Paste TA or

High Temperature (>150°C) Equivalent
Electrical (Fastener Threads) – High

Temperature e.g. Heater Bands
Generic Hydraulic Oil Refer to Section 2.7
Roller and Ball Bearing (Open Cage) FGL-1 or FGL-2 LUB 3000
Linear Bearing FGL-1 LUB 730-1
Gear Box SFG0 Ultra 220 PG220 FUCHS
Dynamic Joints (Rod Ends, Plain FGL-1 (Automatic LUB 3000

Bearing, Linkages, Tie Bar Shoe, Greasing) or FGL-2
etc.)
Seals (before and after installation) SFG0 Ultra 46 Shell Tellus 46, Fiske
AW46, etc.
Standard Torque Specifications 2–24 v 4.11.1 — March 2007

Table 2-40 Adhesives for Soft Joint Mechanical Applicationsa
Connection Product Name
Fasteners M5 and Removable with Low -55 to Loctite 222

smaller hand tools Strength 150°C (purple)
Fasteners M6 to Medium -54 to Loctite 242 (blue)

M20 Strength 149°C
Fasteners M10 to Removable with High -54 to Loctite 271 (red)

M25 (or greater) heat and hand Strength 150°C
tools
a. Example of soft joint application: rigid clamping systems for hoses and pipes
Table 2-41 Lubricants List (From Light to Extreme Pressure)
Mineral Oil Synthetic Oil Grease Paste
Shell Tellus 46 SFG0 Ultra 46 (H1)a FGL-1 Molykote G

Gulf Harmony 46 AW FGL-2 (MoS2)
SFG0 Ultra 220 (H1)
Mobil DTE 25 PG220 FUCHS LUB 3000 (NLGI-2)
Texaco Rando HDZ46 (Alpha gearboxes) LUB 730-1
Sunoco Sunvis 821 WR
Conoco Hydroclear AW46
Chevron AW46
a. H1 = non-toxic and edible

Table 2-42 Lubricants for Fittings
Application Connection Food Grade Non Food Grade
Hydraulic Steel SAE, ORFS, FGL-2 (surface of Shell Tellus 46 or

BSPP contact of o-ring) Equivalent (threads)
Lubrication Steel SAE, ORFS,

BSPP
NPT Not Available Loctite 592
Air Steel, NPT (0 to 1 inch)

Aluminum
and Brass NPT (1 inch and Teflon Tape (White) Teflon Tape (White)
higher)
JIC Not Available Shell Tellus 46 or

Equivalent
Steel SAE, BSPP
Brass SAE, BSPP No Lubrication
Water Steel NPT Teflon Tape Loctite 592

and (Orange)
Brass
SAE, BSPP, JIC Not Available Shell Tellus 46 or
Equivalent
Aluminum NPT Teflon Tape Loctite 592

(Orange)
Stainless NPT
Steel
JIC, SAE Not Available Kleen-Flo Anti-
(SAE plugs Seize Compound
included)

2.12.2 HGT-35 Standard (Screws)

The torque values shown in Table 2-43 must be applied to screws in order to produce
35% Preload.
Table 2-43 Torque Values for Metric and Imperial Screws
Grade 12.9 and 10.9 Fasteners ASTM A574 Fasteners

• Socket Head Cap Screws • Imperial Socket Head Cap Screw
• Hex Head Cap Screw
• Flat Head Cap Screw
• Button Head Cap Screw
Torque (± 4%) Induced Torque (± 4%) Induced

Size Screw Size Screw
Nm lb-ft Load (N) Nm lb-ft Load (N)
M4 2.1 1.5 2980 #8 1 1 2670
M5 4 3 4800 #10 3 2 3100
M6 9 7 7800 1/4 7 5 5800
M8 19 14 14200 5/16 14 10 9800
M10 37 27 22000 3/8 23 17 14200
M12 50 37 24500 7/16 38 28 20000
M16 125 90 49000 1/2 58 42 26700
M20 250 185 79000 5/8 110 81 41000
M24 440 325 115000 3/4 180 135 60000
M30 875 650 182000 7/8 300 220 83000
M36 1530 1130 265000 1 450 330 111000
1 1/8 620 460 138000

NOTE: 1 Nm = 0.737 lb-ft; 1 lb-ft = 1.356 Nm 1 1/4 890 660 175000
1 3/8 1170 860 208000
1 1/2 1550 1140 254000
1 3/4 2450 1790 342000

2.12.3 HGT-50 Standard (Screws and Threaded Rods)

50% Preload.
Grade 12.9 and 10.9 Fasteners ASTM A574 Fasteners

• Durlok Hex Head Cap Screw
• Threaded Rod (DIN 976)

M4 3 2.2 4250 #8 3 2 4360
M5 6.2 4.6 8900 #10 4 3 5450
M6 10 7 9800 1/4 11 8 9900
M8 25 18 17800 5/16 22 16 16300
M10 53 40 31500 3/8 40 30 24000
M12 95 70 47000 7/16 60 45 33000
M14 130 95 56000 1/2 95 70 44000
M16 220 160 85000 5/8 180 135 68000
M18 270 200 93000 3/4 310 230 100000
M20 390 290 124000 7/8 490 360 139000
M24 660 490 171000 1 750 550 182000
M30 1300 960 272000 1 1/8 1040 770 230000
M36 2300 1700 396000 1 1/4 1480 1090 291000
M42 3700 2700 544000 1 3/8 1940 1430 347000
M48 5500 4000 714000 1 1/2 2580 1900 423000
1 3/4 4050 2990 570000
NOTE: 1 Nm = 0.737 lb-ft; 1 lb-ft = 1.356 Nm

2.12.4 HGT-80 Standard (Screws and Threaded Rods)

80% Preload.
Grade 12.9 Fasteners ASTM A574 Fasteners

• Durlok Hex Head Cap Screw
• Threaded Rod (DIN 976)

M4 4.6 3.4 6800 #8 5 4 7000
M5 9.5 7.1 11000 #10 7 5 8700
M6 16 12 15600 1/4 16 12 15800
M8 39 29 28400 5/16 35 25 26100
M10 77 57 45000 3/8 60 45 38000
M12 135 100 65000 7/16 95 70 53000
M14 215 160 90000 1/2 150 110 71000
M16 330 245 122000 5/8 290 210 108000
M20 650 480 190000 3/4 500 360 160000
M24 1100 810 273000 7/8 790 580 222000
M30 2250 1660 435000 1 1180 865 291000
M36 3850 2840 634000 1 1/8 1680 1240 367000
M42 6270 4630 870000 1 1/4 2400 1750 466000
M48 8560 6320 1140000 1 3/8 3100 2300 555000
1 1/2 4100 3040 676000
1 3/4 6500 4800 911000
NOTE: 1 Nm = 0.737 lb-ft; 1 lb-ft = 1.356 Nm

2.12.5 HGT-SS Standard (Set Screws)

The following torque values in Table 2-46 must be applied to set screws.
Table 2-46 Torque Values for Setscrews
Metric Setscrews Imperial Setscrews
Torque (± 4%) Torque (± 4%)

Size Size
Nm lb-ft Nm lb-ft
M3 0.9 0.66 #5 1.1 0.8
M4 2.2 1.6 #6 1.1 0.8
M5 4 3 #8 2.7 2
M6 7.2 5.3 #10 4 3
M8 17 12.6 1/4 9.5 7
M10 33 24 5/16 19 14
M12 54 40 3/8 33 24
M16 134 99 1/2 70 52
M20 237 175 9/16 70 52
M24 440 325 5/8 150 110
3/4 270 200
7/8 410 300
1 570 420

2.12.6 HGT-FT Standard (Fittings)

The following tables provide the recommended torque values required for the safe and
effective operation of the fittings using a torque wrench or other methods such as
"Turn From Finger Tight", "Flats From Finger Tight" or "Flats from Wrench
Resistance". For TFFT or FFFT, the joint should be hand tightened snugly and then
tightened with a wrench by the number of flats or turns indicated by the table. For
"FFWR", the joint should be tightened snugly with a wrench and then tightened again
with the same wrench by the number of flats indicated by the table.
Note: The torque method of assembly is the preferred method of assembly. It reduces
the risk of human error during assembly that is more prevalent in the "FFWR" method.
To ensure the most accurate assembly of the fitting, it is strongly recommended that
the torque method be utilized.
Table 2-47 Torque Values for O-ring Face Seal Fittings, Tube Ends
O-Ring Face Seal Tube Ends
Tube Side FFWR

SAE Thread Size Torque FFWRa Swivel & Hose
Dash Size in (+10% –0) Tube Nuts Ends
Nm (lb-ft) (min - max) (min - max)
-4 9/16 - 18 25 (18) 1/4 - 1/2 1/2 - 3/4
-6 11/16 - 16 40 (30) 1/4 - 1/2 1/2 - 3/4
-8 13/16 - 16 55 (40) 1/4 - 1/2 1/2 - 3/4
-10 1 - 14 80 (60) 1/4 - 1/2 1/2 - 3/4
-12 1-3/16 - 12 115 (85) 1/4 - 1/2 1/3 - 1/2
-16 1-7/16 - 12 150 (110) 1/4 - 1/2 1/3 - 1/2
-20 1-11/16 - 12 190 (140) 1/4 - 1/2 1/3 - 1/2
-24 2 - 12 245 (180) 1/4 - 1/2 1/3 - 1/2
a. FFWR - Flats From Wrench Resistance

Table 2-48 HGT-FT ORFS Hose Ends (Manuli Hose Fittings)
O-ring Face Seal
SAE Dash Hose Thread Tooling FFFT

Recommended Torque Values
Size ID Size mm/in Hose Ends
-4 1/4" 9/16"-18 14-16 10-12 19 1/2
-6 3/8" 11/16"-16 24-26 18-20 22 1/2
-8 1/2" 13/16"-16 43-47 31-35 24 1
-12 3/4" 1 3/16"-12 91-95 65-69 36 1/4
-16 1" 1 7/16"-12 125-135 92-100 41 1/4
-20 1 1/4" 1 11/16"-12 170-190 125-139 50 1/4
-24 1 1/2" 2"-12 200-230 150-164 2 3/8” 1/2

Table 2-49 Torque Values for Fittings with SAE or BSPP Straight Thread Ends
Adjustable and Non-Adjustable SAE and BSPP Ends (Plugs excluded)
Torque (+10% –0)
JIC, Ferrule JIC, Ferrule &

Face Seal Fittings
Fittings Pipe Fittings
Adjustable Adjustable &

Straight Straight
SAE
Thread Size
Dash Size
in Nm (lb-ft) Nm (lb-ft) Nm (lb-ft)
-4 7/16 - 20 20 (15) 29 (15) 20 (15)
-6 9/16 - 18 40 (30) 40 (30) 46 (35)
-8 3/4 - 16 70 (52) 70 (52) 80 (60)
-10 7/8 - 14 115 (85) 115 (85) 135 (100)
-12 1-1/16 - 12 183 (135) 183 (135) 185 (135)
-14 1-3/16 - 12 237 (175) 237 (175) 235 (175)
-16 1-5/16 - 12 271 (200) 271 (200) 270 (200)
-20 1-5/8 - 12 339 (250) 339 (250) 340 (250)
-24 1-7/8 - 12 414 (305) 414 (305) 415 (305)

Table 2-50 HGT-FT JIC Ends
JIC (37° Flared Tube) Ends
Assembly Hose End of

SAE Size Tube End
Torque (+10% –0) Swivel Nut
Dash Size in FFFTa
Nm (lb-ft) FFFTa
-4 7/16 - 20 16 (12) 2 2
-6 9/16 - 18 29 (22) 1.5 1.25
-8 3/4 - 16 63 (46) 1.5 1
-10 7/8 - 14 75 (55) 1.5 1
-12 1-1/16 - 12 115 (85) 1.25 1
-14 1-3/16 - 12 140 (103) 1 1
-16 1-5/16 - 12 165 (122) 1 1
-20 1-5/8 - 12 230 (170) 1 1
-24 1-7/8 - 12 270 (200) 1 1
-32 2-1/2 - 12 365 (270) 1 1
a. FFFT - Flats From Finger Tight

Table 2-51 HGT-FT NPT and BSP Plugs and Fittings
NPT and BSPT Fittings and Plugs
NPT
NPTF BSPT
in in TFFTa
(min-max)
1/8 - 27 1/8 - 28 2-3
1/4 - 18 1/4 - 19 2-3
3/8 - 18 3/8 - 19 2-3
1/2 - 14 1/2 - 14 2-3
3/4 - 14 3/4 - 14 2-3
1 - 11-1/2 1 - 11 1.5 - 2.5
1-1/4 - 11-1/2 1-1/4 - 11 1.5 - 2.5
1-1/2 - 11-1/2 1-1/2 - 11 1.5 - 2.5
2 - 11-1/2 2 - 11 1.5 - 2.5
a. TFFT - Turns From Finger Tight

Table 2-52 HGT-FT Flareless Tube Ends
Ferrule (Bite) Fittings
Nut
Size
SAE Dash Size
in FFFTa
(min-max)
4 7/16 - 20 1/3 - 1/2
6 9/16 - 18 1/3 - 1/2
8 3/4 - 16 1/3 - 1/2
10 7/8 - 14 1/3 - 1/2
12 1-1/16 - 12 1/3 - 1/2
14 1-3/16 - 12 1/3 - 1/2
16 1-5/16 - 12 1/3 - 1/2
20 1-5/8 - 12 1/3 - 1/2
24 1-7/8 - 12 1/3 - 1/2
32 2-1/2 - 12 1/3 - 1/2
a. FFFT - Flats From Finger Tight

Table 2-53 HGT-FT SAE Plugs
SAE Straight Thread Plugs
Torque (+10% –0)
Hollow Hex Plug Hex Plug
Thread Size
SAE
Dash Size
in Nm (lb-ft) Nm (lb-ft)
-2 5/16 - 24 3.5 (2.6) 10 (7.4)
-4 7/16 - 20 13. 5 (10) 29 (21)
-6 9/16 - 18 46 (34) 40 (30)
-8 3/4 - 16 80 (60) 70 (52)
-10 7/8 - 14 135 (100) 115 (85)
-12 1-1/16 - 12 185 (135) 183 (135)
-14 1-3/16 - 12 235 (175) 237 (175)
-16 1-5/16 - 12 270 (200) 271 (200)
-20 1-5/8 - 12 340 (250) 339 (250)
-24 1-7/8 - 12 415 (305) 414 (305)
-32 2-1/2 - 12 510 (375) 509 (375)

Table 2-54 HGT-FT Bulkhead Locknuts
Bulkhead Locknuts
Torque (+ 10% –0)
O-ring Face Seal Ends JIC or Ferrule Ends
SAE
Nm (lb-ft) Nm (lb-ft)
4 20 (15) 20 (15)
6 34 (25) 40 (30)
8 75 (55) 70 (50)
10 100 (75) 115 (85)
12 170 (125) 183 (135)
14 230 (170) 237 (175)
16 270 (200) 271 (200)
20 330 (240) 339 (250)
24 365 (270) 414 (305)

Table 2-55 Torque Values for BSPP and Metric Plugs
BSPP Plugs Metric Plugs
Thread Size Torque (+10% –0) Thread Size Torque (+10% –0)
Inch Nm (lb-ft) Metric Nm (lb-ft)
1/8 - 28 15 (11) M42 400 (295)
1/4 - 19 30 (22) M48 500 (370)
3/8 - 19 60 (44) M52 600 (440)
1/2 - 14 90 (66) M60 800 (590)
3/4 - 14 135 (100) M64 850 (630)
1 - 11 210 (155) M68 1000 (740)
1-1/4 - 11 360 (265) M70 1100 (810)
1-1/2 - 11 450 (330) M75 1300 (960)
M80 1550 (1150)
M85 1800 (1330)
M90 2000 (1480)

REMINDER:
• Torque values shown are for steel components lubricated as described in
Table 2-39.
• For brass fittings (NPT excluded), use approximately 65% of the torque values
shown.
• For stainless steel fittings (NPT excluded), use 110% of the torque values shown.
• For NPT elbows, never back-off to achieve alignment.
• For ferrule (bite) fittings, manually screw the nut on the fitting body until finger
tight. Continue to tighten the joint with a wrench by the number of flats indicated in
the table. If the fitting body is used for ferrule pre-set, the nut must be re-tightened
to the same fitting body used in pre-set.
• Assembled parts (nut and adapter) must have identical plating.
• Fittings displayed in tables are for reference only.
• Torque values shown in the tables apply to the referenced end of the displayed
fittings, as indicated by arrows.
2.12.7 HGT-EL Standard (Electrical Applications)

The torque values shown apply to screws used in electrical connections.
Table 2-56 Torque Values for Screws (Electrical)
Metric and Imperial Screws
Torque (+ 10% –0)
Size Steel Aluminum and Copper Brass
Nm lb-ft Nm lb-ft Nm lb-ft
M3 #4 0.7 0.5 0.3 0.2 0.6 0.4
M3,5 #6 1 0.7 0.5 0.4 0.8 0.6
M4 #8 1.3 1 0.7 0.5 1.2 0.9
M5 #10 1.9 1.4 1 0.7 1.7 1.2
M6 1/4 6 4 3 2 5 3
M8 5/16 8 6 4 3 5 4
M10 3/8 10 7 5 4 8 6

2.12.8 Supplier Recommended Torque Specifications

The following torque values are recommended by suppliers and are also specified on
the assembly drawings.
Table 2-57 Torque Values for Hydraulic Manifold Valves Mounting Bolts
Torque Nm (lb-ft) min. – max.
Bosch Rexroth Moog/Hydrolux

Hyd. Option
Bolt Size Segment
Prop Direct Prop Direct Prop Direct Manifold
Cartridges Cartridges Cartridges
Valves Valves Valves Valves Valves Valves
6-8 6-8 6.2-8.9 6.2-8.9 5.8-7.8 7.2-8 8.9-9.8

M5
(4.4-5.9) (4.4-5.9) (4.6-6.6) (4.6-6.6) (4.2-5.7) (5.3-5.9) (6.6-7.2)
11-14 11-14 11-15.5 11-15.5 9.4-12.6 11.7-13 15.5-17

M6
(8.1-10.3) (8.1-10.3) (8.1-11.4) (8.1-11.4) (6.9-9.3) (8.6-9.6) (11.5-12.6)
26-31 23-32 27-30 32-35

M8
(19-23) (17-23) (20-22) (23-26)
40-50 50-60 53-75 53-75 46-62 50-55 75-83

M10
(30-37) (37-44) (39-55) (39-55) (34-45) (37-40) (55-61)
90-120 85-100 90-105 91-130 91-130 77-110 80-108 90-100 90-100 110-121
M12
(66-88) (63-73) (66-77) (67-96) (67-96) (57-81) (59-80) (66-74) (66-74) (81-89)
240-260 189-270 270-300 270-297

M16
(178-192) (139-199) (199-221) (200-219)
450-560 450-500 301-430 301-430 364-520 391-529 495-550 495-550 520-572

M20
(332-410) (332-369) (222-317) (222-317) (268-383) (288-390) (365-406) (365-405) (385-422)
630-900 810-900 900-990

M24
(464-664) (598-664) (665-730)
1260-1800 1620-1800 1800-1980

M30
(929-1327) (1195-1328) (1330-1460)
Lubricant Hydraulic Oil Grease
Table 2-58 Torque Values for Orifices on Hydraulic Manifolds
Torque (± 4%)
Bolt Size
Nm lb-ft
M5 4 3
M6 6 4.5
M8 13.5 10
M10 27 20
Lubricant Grease

Table 2-59 Torque Values for Hose/Pipe Clamps Mounting Bolts
Torque in Nm (lb-ft) (± 4%) with Clamping

Material
Bolt Clamp
Clamp Type Lubricant
Size Size
Aluminum Polypropylene Polyamid
(AL) (PP) (PA)
Single clamp M6 0 to 6 12 (9) 8 (5.9) 10 (7.4)

Light series
1
M10 30 (22) 12 (9) 20 (15)
2
3 35 (26) 15 (11) 25 (18)

Single clamp
Heavy series M12 4 55 (40) 30 (22) 40 (30)
Loctite
M16 5 120 (90) 45 (33) 55 (40)
M20 6 220 (160) 80 (60) 150 (110)
M24 7 250 (180) 110 (80) 250 (180)
M6 1 N/A 5 (3.7) 6 (4.4)
2 N/A
Twin clamp 12 (8.9) 12 (8.9)
3 N/A
M8
4 N/A
5 N/A 8 (5.9) 8 (5.9)
Table 2-60 Torque for Hydraulic Motor Mounting Bolts
Torque Nm (lb-ft) ± Tolerance Value
Bolt Size Hagglungs Hydraulic Motors
M16 280 ±15 (205 ± 11)
M20 540 ± 20 (400 ± 15)
M24 900 ± 30 (665 ± 22)
Lubricant Hydraulic Oil
Table 2-61 Torque for AMPCO 18 Mounting Screws
Maximum Tightening Torque Maximum Tightening Torque

(+ 0 / - 10%) (+ 0 / - 10%)
Size Size
Nm lb-ft Nm lb-ft
M4 2 1.5 M16 69 51
M5 3 2.2 M18 92 68

Table 2-61 Torque for AMPCO 18 Mounting Screws
Maximum Tightening Torque Maximum Tightening Torque

(+ 0 / - 10%) (+ 0 / - 10%)
Size Size
Nm lb-ft Nm lb-ft
M6 5 3.7 M20 131 97
M8 11 8 M22 178 131
M10 22 16 M24 240 177
M12 26 19 M27 296 218
M14 44 32 M30 456 336
2.12.9 Split Flange Assemblies
CAUTION!
Lightly torque all screws before applying the final recommended torque values
to avoid breaking the flange halves during installation.
Table 2-62 Split Flange Assemblies (ISO 6162:1994)
4 Bolt Split Flange Assemblies 4 Bolt Split Flange Assemblies

Code 61 (25 bar to 350 bar series) Code 62 (400 bar series)
Torquea (+25% –0) Torquea (+25% –0)

Bolt Size Bolt Size
Nm lb-ft Nm lb-ft
M8 25 18 M8 25 18
M10 53 40 M10 53 40
M12 95 70 M12 95 70
M16 220 160 M14 150 110
– – – M16 220 160
– – – M20 390 290
Lubricant Lubriplate FGL-1 or Molykote G – rapid plus with MoS2
a. The recommended torque values are consistent with the HGT-50 general standard with the exception of
M14 bolts (refer to the assembly drawing). The recommended torque values may be increased by 25%
when flange head type 12.9 screws are used with Unbrako Durlok-12.9 screws.


Machine Manual Installing
Chapter 3 Installing
This chapter describes how to prepare the machine, install and level it, hook up
services, set up the machine, and commission the machine. Make a photocopy of the
checklist below and perform all procedures in the order they are presented.
Table 3-1 Machine Installation and Setup Checklist
Item Task Reference Check
1 Unpacking the Machine 3.1
2 Installing Leveling Mounts 3.2
3 Aligning Injection and Clamp Units (Split Base Models) 3.3
4 Removing Shipping Hardware 3.4 and 3.5
5 Check the electrical cabinet is seated on its mounts and 3.4 and 3.5
not suspended on the injection base.
6 Installing Optional Stack Mold Carrier (90 – 500 Tonnes 3.6

Clamps)
7 Installing Optional Stack/Tandem Mold Carrier (650 – 3.7

1000 Tonnes Clamps)
8 Assembling Safety Gates (H650 to H1000) 3.8
9 Cleaning Machine 3.9
10 Connecting Hydraulic Hoses (Split Base Models) 3.10
11 Connecting Electrical Cables (Split Base Models) 3.11
12 Check the Profibus Cable Routing 3.12
13 Installing Platform (Optional) 3.13
14 Installing Material Feed Equipment 3.14
15 Installing Warning Light 3.15
16 Installing Purge Tray 3.16
17 Installing Drool Chute 3.17
18 Checking Electrical Connectors 3.18
19 Filling the Hydraulic Tank 3.19
20 Priming the System Pump 3.20
21 Leveling Machine and Adjusting Nozzle Concentricity 3.21
22 Hooking Up Oil Collection Line 3.22
v 4.11.1 — March 2007 3–1

Table 3-1 Machine Installation and Setup Checklist
Item Task Reference Check
23 Hooking Up Compressed Air Lines 3.23
24 Hooking Up Electrical Power Supply 3.24
25 Hooking Up Machine Cooling Water Supply 3.25
26 Hooking Up Mold Cooling Water Supply (Optional) 3.26
27 Machine Lubrication 3.27
28 Precharge the Accumulators 3.28
29 Checking Hydraulic Connections 3.29
30 Attaching Carriage Cylinders (Split Base Models) 3.30
31 Inspect for installation damage 3.32
32 Contact Husky 3.33
33 Remove plastic shrink wrap from the ball valve 3.34
3.1 Unpacking the Machine
WARNING!
Crushing hazard – risk of serious injury or damage to the machine. Do not
remove the special shipping bolts, or the wooden braces between the platens
until the leveling mounts have been installed. Removing the special shipping
bolts or the wooden braces can cause machine components to shift during
installation.
WARNING!
Crushing hazard – risk of serious injury or damage to the machine. Do not
remove the tie wraps that fasten the operator’s gate and rear guard. Removing
the tie wraps from the operator’s gate and rear guard can cause the guards to
move freely during installation.
Unpack and inspect the machine using the following instructions.

1. Remove all protective wrapping from the machine.
2. Make sure tamper proof seals are intact on the ball valve, hatch covers, breather
cap and vent.
NOTE: If tamper proof seals are not intact, contact Husky immediately.
3. Inspect the machine for any signs of damage. Report any damage to the Husky
Regional Service and Sales office.
Unpacking the Machine 3–2 v 4.11.1 — March 2007

3.2 Installing Leveling Mounts
Install leveling mounts on the injection unit (if not already installed) and clamp unit
using the following instructions. Refer to the Site Preparation Manual for guidelines on
floor preparation and instructions on how to lift the machine.
IMPORTANT!
5 Husky recommends lifting the machine from above with an overhead crane. Do not
exceed the rated capacity of the lifting equipment.
1. If installed, remove the shipping beams that are under the clamp base.
NOTE: On some machines the leveling mounts and the column bell are located in
a box between the stationary and the moving platen.
2. Refer to the installation drawing for the number and location of leveling mounts for
each unit. Note the different types and sizes of leveling mounts.
NOTE: Before installing leveling mounts on the machine, verify that the mounts
are properly threaded by fully inserting the bolt into the mount.
3. Position the unit so that there is approximately 100 mm (4 in) between the floor
and the base (1) – refer to Figure 3-1.
WARNING!
Crushing hazard – risk of death or serious injury. Do not work under suspended
load. To prevent injury, install safety blocks.
4. Position safety blocks and lower the machine onto the safety blocks.
5. Clean the underside of the base where it would make contact with the leveling
mount (2 and 4).
6. Apply grease to the threads of the leveling mount and the bolt (5). For lubricant
specifications, refer to Section 2.8.
7. Attach the locknut (4), lock washer (5) and washer (6) to the bolt, and thread the
bolt into the leveling mount, as shown.
NOTE: Check the leveling mounts are oriented, as shown, in the direction of
movement of the mold stroke column so the dampener can work properly.
8. Spin the leveling mount until the bolt bottoms out.
9. Fasten the locknut (8) so the leveling mount is snug against the base. Do not
tighten the locknut at this stage.
10. Repeat step 5 - step 9 to attach the remaining injection and clamp leveling mounts.
11. Similarly, install leveling mounts under the electrical cabinet.
NOTE: The leveling mounts under the electrical cabinet are smaller in size than
the ones under the injection base.
12. Apply grease to the threads of the leveling mounts and the bolts (5).
13. Assemble the leveling mounts to the mounting brackets on the injection unit (1)
and the clamp unit (3) using the bolts (5), washers (7) and locknuts (8), as shown.
v 4.11.1 — March 2007 3–3 Installing Leveling Mounts

14. Apply grease to the threads of the bolts (5).

15. Attach the mounting brackets to the captive nuts in the base of the electrical
cabinet using the bolts (5) and flat washers (7).
16. Carefully lower the unit to the floor.
2 4
6
7
2 8
4
Figure 3-1 Installing Leveling Mounts

1. Injection unit 2. Injection unit leveling mount (IM-81) 3. Clamp unit 4. Clamp unit
leveling mount (IM-71) 5. Bolt 6. Locknut 7. Lock washer 8. Locknut
3.3 Aligning Injection and Clamp Units (Split Base Models)
Align and fasten the clamp unit to the injection unit using the following instructions.
1. Check that the purge guard is in the fully open position.
Aligning Injection and Clamp Units (Split Base Models) 3–4 v 4.11.1 — March 2007
WARNING!
Crushing hazard – risk of death or serious injury.
• Improperly balanced loads can make lifting unmanageable. Always use
designated lifting points to lift the machine.
• Use suitable lifting equipment to lift the machine. Exceeding the rated
capacity of lifting equipment can cause injury or death.
• Exercise care when working beside the suspended machine. To prevent
injury, keep hands and fingers out of the way.
2. Position the clamp unit such that the mounting pads (1) are aligned with the flange
(2) on the injection unit. Refer to Figure 3-2.
S01-101006.eps
2
4
3
Figure 3-2 Aligning Injection and Clamp Units (Typical)

1. Mounting pad 2. Flange 3. Bolt 4. Washer
3. Lower the clamp unit and check that the mounting pads are fully seated against the
flange.
v 4.11.1 — March 2007 3–5 Aligning Injection and Clamp Units (Split Base Models)
CAUTION!
Risk of damage to the machine. Failure to align the two units properly can
damage the nozzle tip and carriage cylinder.
4. Place a square against the machined surface of the injection rail, and the
machined surface on the injection side of the stationary platen. Check that the
injection unit is perpendicular to the stationary platen. Adjust the clamp unit as
necessary.
5. Attach the mounting bolts (3) and washers (4). Do not fasten the bolts at this time –
they will be fastened once the machine is leveled.
IMPORTANT!
5 Under the static load, the rubber molecules of the leveling mounts gradually change
from a round to an elongated shape, initially in the first 12 hours and finally at about
72 hours. Recheck level and torques to ensure accuracy.
6. Check leveling alignment and torque values at 12 and 72 hours.

7. Slightly raise the stationary platen end of the clamp unit to relieve stress off the
mounting pads. Lower the clamp unit to the floor, and remove lifting slings
3.4 Removing Shipping Hardware (H90 to H500)
WARNING!
Crushing hazard – risk of death or serious injury. Centre of gravity of the
machine can shift and unbalance the load. Do not remove the shipping
hardware until after the leveling mounts are installed, and the machine is
lowered to the floor.
CAUTION!
Sliding or shifting parts – risk of damage to the machine. Once the shipping
hardware is removed, do not lift or move the machine. To prevent damage to the
machine, install the shipping hardware before lifting or moving the machine.
CAUTION!
Risk of serious damage to the machine. Starting up the machine without
removing the shipping hardware can damage the clamp block and injection
carriage. Remove the shipping hardware before using the machine.
Remove the shipping bolts using the following instructions.

1. Remove the tie wraps that hold the operator’s gate and rear guard in place.
2. Open the operator’s gate and rear guard. Remove the shipping bolts (1) located on
both sides of the clamp casting (2) – refer to Figure 3-3.
Removing Shipping Hardware (H90 to H500) 3–6 v 4.11.1 — March 2007

3. Remove the shipping plates (4) located under the injection carriage.
CAUTION!
Risk of damage to equipment. Make sure all shipping hardware has been
removed from the cabinet, and that the electrical cabinet is detached from the
machine base before running the machine.
4. Support the electrical cabinet (5) and remove the shipping bolt (3) from the rear of
the cabinet. Attach the supplied restraining cable (Figure 3-4, item 2) to the
machine electrical cabinet.
Repeat for the remaining electrical cabinet shipping bolts.
NOTE: Make sure the electrical cabinet sits firmly on its leveling mounts.
5. Cut the tie wraps and remove the two wooden braces between the platens.
6. Remove the exterior packaging and protective wrapping from the hoses, the
hopper assembly, the warning light, and the carriage cylinders.
7. Label and store all shipping hardware in a safe place for use at a later date when
relocating the machine.
2
1
Figure 3-3 Shipping Hardware (Typical)

1. Bolt 2. Clamp 3. Bolts 4. Injection plate 5. Electrical cabinet
v 4.11.1 — March 2007 3–7 Removing Shipping Hardware (H90 to H500)

3.5 Removing Shipping Hardware (H650 to H1000)
WARNING!
Crushing hazard – risk of death or serious injury. Centre of gravity of the
machine can shift and unbalance the load. Do not remove the shipping
hardware until after the leveling mounts are installed, and the machine is
lowered to the floor.
CAUTION!
Sliding or shifting parts – risk of damage to the machine. Once the shipping
hardware is removed, do not lift or move the machine. To prevent damage to the
machine, install the shipping hardware before lifting or moving the machine.
CAUTION!
Risk of serious damage to the machine. Starting up the machine without
removing the shipping hardware can damage the clamp block and injection
carriage. Remove the shipping hardware before using the machine.
Remove the shipping bolts using the following instructions.

1. Remove the shipping bolts (Figure 3-5, item 1) located on both sides of the clamp
platen.
2. Remove the tie-down strap that holds down the column (2).
3. Remove the column blocking plate (3). Keep the nut, screws, and retainer plate for
the bell assembly.
4. Remove the shims under the cam followers of the moving platen (4).
5. Remove the box located between the stationary and the moving platen. It contains
the column bell.
6. Remove the shipping plate (6) from the injection carriage (5).
CAUTION!
machine base before running the machine.
7. Remove the shipping blocks (Figure 3-4, item 1) from the electrical cabinet, attach
the retaining cable (2) to prevent the electrical cabinet (3) from tipping over.

Figure 3-4 Electrical Cabinet Retaining Cable

1. Shipping blocks 2. Retaining cable 3. Electrical cabinet
8. Label and store all shipping hardware in a safe place for use at a later date when
relocating the machine.

L-2433
L-2436
L-2432
1 2
L-2437
5 6
Figure 3-5 Removing Clamp Unit Shipping Hardware

1. Clamp platen shipping bolt 2. Column tie-down strap 3. Column blocking plate
4. Cam follower shim 5. Injection carriage 6. Shipping plate

3.5.1 Installing Column Bell (H90 to H800)

1. Level the clamp in accordance with Section 3.21.
2. Push the moving platen to the maximum mold open position.
3. Make sure the stroke cylinder rod is fully back inside the column.
4. Insert the stroke cylinder rod end into the end of the bell and attach the bell to the
clamp platen.
5. Assemble the split ring to sit into the groove of the stroke cylinder rod without
clearance. Torque the bolts to Husky specifications – refer to Section 2.12. Make
sure there is an equal gap between the two halves.
3.5.2 Installing Column Bell (H1000)

1. Level the clamp in accordance with the Machine Manual, Section 3.21.
2. Push the moving platen to the maximum mold open position.
3. Make sure the stroke cylinder rod is fully back inside the column.
4. Insert the stroke cylinder rod end into the end of the bell and attach the bell to the
clamp platen.
5. Tighten the nut until the inner face of the nut touches the shoulder of the rod end.
6. Make sure the nut touches the end face of the bell uniformly around the
circumference to prevent rod bending when the nut is loaded against the bell.
7. Install the cylinder retainer. Torque the bolts to Husky specifications – refer to
Section 2.12.
8. Make sure the cylinder retainer (Figure 3-3, item 1) is parallel to the bell
(Figure 3-3, item 2).
1
2
L-2437
Figure 3-6 Column Bell

1. Column bell 2. Cylinder retainer

3.6 Installing Optional Stack Mold Carrier (90 – 500 Tonnes Clamps)
REMINDER: Only qualified people should perform the following procedure.
WARNING!
Inadequate lifting equipment can fail and cause injury or death. Make sure the
lifting eye bolts, chains/slings and lifting device are rated for the load and in
safe operating condition.
1. Use a crane of sufficient lifting capacity while performing the following procedures.
Table 3-2 Lifting Weight Specifications
H90-
H160 H225 H300 H400 H500
H120
Side Carrier (kg) 42 78 130 174 130 310
Horizontal Link Arm (kg) 8 16 18 35 46 70
Propeller Arm (kg) (Carrier link arm) 28 51 70 120 180 215
Mold Carrier Water Manifold (kg) _ 25 25 25 79 79
WARNING!
Crushing hazard - risk of death or serious injury. Do not work under suspended
loads. To prevent injury, install safety blocks.
2. Lower the non-operator side carrier into the machine.

3. Attach a second sling around the carrier long enough to pass through the gate on
the same side. (Refer to Figure 3-7, item A). Guide the carrier into position
between the tiebars.
CAUTION!
Care must be taken not to damage the tiebars when installing the carrier.
Installing Optional Stack Mold Carrier (90 – 500 Tonnes Clamps)3–12 v 4.11.1 — March 2007
Crane
Figure 3-7 Side Carrier Support
4. Install the SHCS securing the carrier to the linear bearing block. Torque to
specified requirements. (refer to the torque chart in Section 2.12.)
Figure 3-8 Carrier Mounting

1. Carrier mounting screws
v 4.11.1 — March 2007 3–13Installing Optional Stack Mold Carrier (90 – 500 Tonnes Clamps)
5. Attach lifting chains/slings to the water manifold. Lift the manifold into position.
6. Install the SHCS securing the water manifold to the carrier, Figure 3-9. Torque to
specified requirements, refer to the torque chart in Section 2.12.
Figure 3-9 Water Manifold

1. Side carrier 2. Water manifold mounting 3. Screws 4. Underside of water
manifold
7. Remove the lifting chains/slings.

8. Repeat step 2 through step 7, on the operator side of the machine.
3.6.1 Installing the Propeller Bar
5
4
3
2
Figure 3-10 Propeller Bar Assembly

1. Thrust washer 2. Large retaining plate 3. SHCS 4. Carrier pin 5. Duralon
bearing 6. Propeller bar
WARNING!
WARNING!
2. Lower the propeller bar into position.

3. Install propeller bar assembly. Refer to Figure 3-10.
4. Install the SHCS item 4, securing the propeller bar to the side carrier. Torque to
required specifications, refer to the torque chart in Section 2.12.
5. Install the retaining plate cover, item 2. Torque SHCS to required specifications,
refer to the torque chart in Section 2.12.
WARNING!
Crushing hazard - risk of death or serious injury. Propeller bar can rotate. To
prevent injury, secure propeller bar to side carrier.
6. Use straps to secure the propeller bar to the side carrier preventing rotation.
7. Remove the lifting chain/slings.
8. Repeat step 2 through step 7 on the opposite side.
3.6.2 Installing Horizontal Linkages to the Stationary Platen
7
6
5
1
2
3
4
Figure 3-11 Horizontal Arm Assembly

1. Bushing 2. Thrust washer 3. Link pin boss 4. Link pin boss SHCS 5. Retaining
plate SHCS 6. Retaining plate 7. SHCS 8. Platen pin
WARNING!
WARNING!
2. Lower linkage into position.

3. Install the link pin and assembly into the propeller bar.
4. Install the stationary platen side linkage assembly (refer to Figure 3-11). Torque
SHCS, item 7, to required specifications (refer to the torque chart in Section 2.12).
5. Install the retaining plate on the stationary platen side of the linkage, refer to
Figure 3-11. Torque SHCS to required specifications (refer to the torque chart in
Section 2.12).
6. Remove the straps used to secure the propeller bar to the side carrier.
8. Repeat step 2 through step 7, on the opposite side.
3.6.3 Installing Horizontal Linkages to the Moving Platen

1. Allow sufficient clearance between the moving platen and the clamp door opening.
WARNING!
WARNING!
3. Lower linkage into position.

4. Install link pin and assembly to the propeller bar, refer to Figure 3-11.
5. Install the moving platen side of linkage arm assembly (refer to Figure 3-11).
Torque SHCS to required specifications (refer to the torque chart in Section 2.12).
6. Install the retaining plate, refer to Figure 3-11. Torque SHCS to required
specifications (refer to the torque chart in Section 2.12).
7. Remove the straps used to secure the propeller bar to the side carrier.
9. Repeat step 3 through step 8, on the opposite side.
3.7 Installing Optional Stack/Tandem Mold Carrier (650 – 1000

Tonnes Clamps)
REMINDER: Only qualified people should execute the following procedure.
1. Check that all mounting surfaces for the carrier linkage system on the stationary
and moving platens are clean and covered with a light film of grease.
NOTE: Check that the platen pins are present on the stationary and moving
platens. If they are missing, contact your Husky Service representative.
2. Refer to the assembly drawing and make sure to use the correct fastener type and
torque where specified.
3. Hook-up the pre-assembled mold carrier, with the main linkage arm (2), to a crane
using the lifting eye bolt (3) supplied with the carrier.
WARNING!
4. Lift the carrier and rotate the main linkage arm to a horizontal position to clear the
tiebars during installation.
5. Move the carrier into the mold area and place it, from the inside, with the cam
followers onto the top of the machine base rail.
6. Move the carrier into position at equal distance between the two platens so that the
linkage bars (1) can be installed.
NOTE: In the case of adjustable linkage bars, determine the right location in
relation to the actual linkage bar length.
7. Install anti-tip brackets (6).
8. Install the carrier retaining brackets (4) and the limit switch bracket (5) and tighten
bolts to specified torque.
9. Remove the lifting eye bolt.
10. Rotate the main linkage arm in the position to match with the linkage bar length.
11. Lift the linkage bars using a crane and slings.
12. Slide the linkage bars over the platen pins at the stationary and moving platen
edges, and connect them to the main linkage arms. Be sure to install thrust
bearings, as shown on the assembly drawing.
REMINDER: In cases where only two of the linkage bars are adjustable, install them
both on the same platen side. (e.g. adjustable connection of the carrier with the
moving platen)
Installing Optional Stack/Tandem Mold Carrier (650 – 1000 Tonnes Clamps)3–18 v 4.11.1 — March 2007
NOTE: You may have to displace the carrier slightly in order to have the correct
distance between the linkage arm bore and the platen pin on the moving
platen.
13. Attach the covers to the pins and verify the torque on all bolts.
14. Repeat step 3 to step 13 to install the carrier on the opposite side of the machine.
CAUTION!
Make sure the stack mold, or center plate on multi-mold applications, is
attached to the carriers before dry-cycling the machine. Failure to do so may
cause cocking of the carriers and damage to the linkage bearings.
NOTE: The carriers may be moved under reduced clamp speed, without a mold,
only when they need to be aligned for stack mold installation purposes.
3
1
1 2
6
4
Figure 3-12 Stack Mold Carrier

1. Linkage bars 2. Main linkage arm 3. Lifting eye bolt 4. Carrier retaining bracket
5. Limit switch bracket 6. Anti-tip block
v 4.11.1 — March 2007 3–19 Installing Optional Stack/Tandem Mold Carrier (650 – 1000
3.8 Assembling Safety Gates (H650 to H1000)
3.8.1 Operator’s Gate

Take the gate from the shipping frame. Use the eye bolts (Figure 3-13, item 1 and 2).
CAUTION!
The slings must be parallel while lifting the safety gates. The gates can be
damaged if there are lifted otherwise.
Fasten the bottom rail to the clamp base (Figure 3-14, item 1).
Attach the connection arm (2) to the stationary platen.
1
2
Figure 3-13 Lifting Safety Gates

1. Lifting point - clamp platen side 2. Lifting point - stationary platen side
3.8.2 Rear Gate

Take the gate from the shipping frame. Use also the eye bolts.
Assemble the gate to both consoles (Figure 3-14, item 3).
Fasten the gate connection arm (4) to the stationary platen.
3.8.3 Both Gates

Connect the gates with the bars (Figure 3-14, item 5).
Check that the safety gates are vertical. They can be adjusted by using the clearance
of the fixation holes of the connecting arms (2 and 4) and two bumpers on the clamp
end panels.
Check that the closed gates are parallel to the frame. The parallelism might be
adjusted by using the eccentric of the wheels.
Route the electrical cables to the connectors. All the electrical connectors are labelled.
Make the male and female connectors match each other.
Assembling Safety Gates (H650 to H1000) 3–20 v 4.11.1 — March 2007

2
1
Figure 3-14 Assembling Safety Gates

1. Clamp base - Operator side 2. Connection arm of the operator’s gate 3. Consoles of
the rear gate 4. Connection arm of the rear gate 5. Connecting bars
v 4.11.1 — March 2007 3–21 Assembling Safety Gates (H650 to H1000)

3.9 Cleaning Machine
WARNING!
Flying debris – risk of serious injury. Using compressed air to clean the
machine can cause flying debris and serious injury. Clean the machine surfaces
with a lint-free cloth.
Before the machine leaves the factory, all exposed or unpainted metallic surfaces are
sprayed with a rust inhibitor. Before starting up the machine, use soap, warm water,
and a lint-free cloth to remove the rust inhibitor from all exposed or unpainted machine
surfaces.
3.10 Connecting Hydraulic Hoses (Split Base Models)
Connect all hydraulic lines between the injection unit and clamp unit in accordance
with the hydraulic schematic.
NOTE: The hydraulic ports and hydraulic lines are identified with color coded tie-
wraps.
1. Connect the return line (1) to the flanged connection on the hydraulic tank – refer
to Figure 3-15. Torque the bolts to Husky specifications – refer to Section 2.12.
2. Connect the pressure line (2) and the pilot line (3) to the bulkhead in the power
pack.
3. Connect the manifold drain line (4) to the port on the hydraulic tank.
Cleaning Machine 3–22 v 4.11.1 — March 2007

S01-101008a.eps
1
Figure 3-15 Connecting Hydraulic Lines (Typical)

1. Return line 2. Pressure line 3. Pilot line 4. Drain line
3.11 Connecting Electrical Cables (Split Base Models)
Connect all electrical cables between the injection unit and clamp unit in accordance
with the electrical schematic – refer to Figure 3-16.
NOTE: The cables and plugs are labelled for easy identification.
v 4.11.1 — March 2007 3–23 Connecting Electrical Cables (Split Base Models)
Figure 3-16 Electrical Cables Connections at Clamp and Injection Interface (Typical)
3.12 Check Profibus Cable Routing
1. Profibus cable is 100 mm away from power cables.

2. The cable has a bend radius of 120mm minimum.
3. The cable crosses power cables at 90°.
4. All connectors are tight.
5. The cable is protected from sharp edges.
3.13 Installing Platform (Optional)
Install the optional platform and railings using the following instructions.
1. Support the platform (1) with a lifting device and position it against the machine
base.
WARNING!
Crushing hazard – risk of death or serious injury. Exercise care when working
beside the suspended platform. To prevent injury, do not stand under the
suspended platform more than absolutely required.
Check Profibus Cable Routing 3–24 v 4.11.1 — March 2007

2. With the platform still supported by the lifting device, install supplied bolts and
washers on each end of the platform to secure it to the injection base. Refer to
Figure 3-17.
3. Attach remaining bolts and washers under the platform.
4. Attach the ladder (2) and the railings (3) to the platform with the supplied hardware.
S01-101004.eps
1
Figure 3-17 Installing Optional Platform

1. Platform 2. Ladder 3. Railings
3.14 Installing Material Feed Equipment
For recommendations to install additional process material feed equipment such as

dryers and mixers see Section 3.14.2.
Install the hopper or direct feed tube, magnet drawer and shutoff assemblies using the
following instructions:
1. Remove the tape covering the feed throat (1).
2. Attach the manual shutoff assembly (2) to the feed throat using four M10 bolts (3).
3. If the machine is equipped with an auto-shutoff assembly (4), continue on.
Otherwise, skip to step 6.
4. Locate the auto-shutoff assembly on the four studs (5) in the manual shutoff
assembly.
v 4.11.1 — March 2007 3–25 Installing Material Feed Equipment

5. Connect the pneumatic hose (6) and the two electrical connectors (7) to the
solenoid valve (8).
6. If the machine is equipped with a magnet drawer (9), continue on. Otherwise, skip
to step 9.
7. Attach the magnet drawer to the four studs, and fasten using four M10 flanged nuts
(10). If no stud is available, use M10 bolts (11).
8. Attach the hopper (12) or direct feed tube (13) to the magnet drawer using four
M10 bolts (11).
9. If the machine is equipped with a hopper (12), attach it using four bolts (11).
Otherwise, attach the direct feed tube (13) using four flanged nuts (10) or bolts
(11).
10. If the machine is equipped with Feed Throat Temperature Monitoring (PET style)
option, attach the thermocouple (14) to the flange in the direct feed tube.
Attach the process material supply tube to the direct feed tube.
Installing Material Feed Equipment 3–26 v 4.11.1 — March 2007

12
11 11
10 13 10
14
9
11
10
6
3
7
4
1
5
2
S01-101012.eps
Figure 3-18 Material Feed Equipment Configuration (Typical)

1. Feed throat 2. Manual shutoff assembly 3. Bolt 4. Auto-shutoff assembly
5. Stud 6. Pneumatic hose 7. Electrical connector 8. Solenoid valve 9. Magnet
drawer 10. Flanged nut 11. Bolt 12. Hopper 13. Direct feed tube
14. Thermocouple

3.14.1 Installing Optional Hopper Magnet

Install the optional hopper magnet using the following instructions:
1. Remove the lid on the hopper (1), and place the hopper magnet (2) in the hopper –
refer to Figure 3-19.
2. Install the lid.
1
S01-101013.eps
Figure 3-19 Hopper and Hopper Magnet (Typical)

1. Hopper Lid 2. Optional hopper magnet
3.14.2 Material Feed Equipment Recommendations
WARNING!
Operating a machine equipped with material handling equipment whose inertia
exceeds maximum permissible values can cause injury and damage. To
minimize the risk of failure, make sure the loads are within the indicated values.
Any additional equipment such as dryers or mixers attached to the process material
feed equipment must satisfy the following requirements (refer to Figure 3-20).
1. The total mass of all equipment attached to the mounting flange (1) should not
exceed the values in Table 3-3.
2. The total moment generated by all equipment above the mounting flange should
not exceed the values in Table 3-3.
Installing Material Feed Equipment 3–28 v 4.11.1 — March 2007

Table 3-3 Allowable Hopper Weights
Hopper
Allowable Allowable
Height of Center of Assembly Injection Unit
Weight Moment
Gravity Mounting Size
kg (lbs) Nm (ft-lb)
Method
On Feedthroat RS22 to RS65 80 (175) 1,020 (750)

Maximum 1300 mm RS80 to RS115 150 (330) 1,900 (1,400)
(51 in.) above
feedthroat mounting On Slide RS22 to RS65 80 (175) 1,020 (750)
face Assembly
RS80 to RS115 150 (330) 1,900 (1,400)
RS135 to RS155 250 (550) 3,200 (2,360)
The moment, in Newton-meters (Nm) can be calculated using the following formula.
Moment = Weight (kg) x Centre of Gravity location (m) x 9.81 m/s2,
where Center of Gravity location is the distance from the mounting flange to the center
of gravity of all process material equipment above the flange.
For example, a mass of 200 kg stacked above the mounting flange, with the centre of
gravity located 1 m above the flange produces a moment of 1962 Nm (200 kg x 1 m x
9.81 m/s2).
3
1
S01-100459A.eps
Figure 3-20 Process Material Feed Equipment Recommendations

1. Mounting flange 2. Hopper 3. Magnet drawer

3.15 Installing Warning Light
Install the warning light using the following instructions.

1. Remove the lower nut (Figure 3-21, item 2), washer (item 1) and feed the light
assembly through the clearance hole in the corner bracket (item 3).
2. Slip the washer on the light pole and then fasten using the nut (2). Apply a torque
of 125 Nm or 90 ft lbs.
3
2
1
Figure 3-21 Installing Warning Light

1. Washer 2. Nut 3. Mounting bracket 4. Light assembly
3.16 Installing Purge Tray
On machines equipped with a purge tray, install as follows:

1. Slacken the screws (1) and attach the purge tray (2), as shown in Figure 3-22.
2. Tighten the screws.
Installing Warning Light 3–30 v 4.11.1 — March 2007

42
S01-101016.eps
1
Figure 3-22 Installing Purge Tray (Typical)

1. Screw 2. Purge tray
3.17 Installing Drool Chute
On machines equipped with a drool chute assembly, install as shown in Figure 3-22.
L-2453
Figure 3-23 Installing Drool Chute

1. Drool chute cover 2. Drool chute
v 4.11.1 — March 2007 3–31 Installing Drool Chute

3.18 Checking Electrical Connectors
WARNING!
Fire hazard - risk of damage to the machine. To prevent any fires, retighten all
electrical connectors.
Any electrical components that may have shaken loose during shipping pose a fire
hazard. Connect and recheck all electrical connectors using the following instructions.
1. Check and retighten all connectors on the motor terminal board. The motor
terminal board is located in the terminal box on the pump motor.
If the machine has been in extended storage, check the resistance of the motor
winding before starting the motor. For details, contact Husky.
2. Check and retighten all connectors on the motor terminal board on the servo
motor.
3. Check and retighten all power, control, and communications connections
throughout the machine.
3.19 Filling the Hydraulic Tank
Fill the hydraulic tank using the following instructions:

1. Perform Lockout/Tagout procedure. Refer to Section 1.6.1.
NOTE: Portable fluid transfer carts are often used to fill reservoirs from barrels,
holding tanks and trucks. These units should be fitted with filters no
coarser than 10 micron with efficiency ß10 > 1000. Customers must fill
through the designated fill port upstream of the filter assembly.
2. Connect the supply hose (1) from the transfer pump to the supplied female quick-
disconnect coupling (2). Refer to Figure 3-24.
NOTE: The female quick-disconnect fitting takes a ¾ in. NPT hose-end fitting.
CAUTION!
Risk of damage to the machine. Unfiltered oil in the hydraulic tank will damage
hydraulic components in the machine. Always fill the tank through the filter, and
not through the drain port.
3. Connect the supply hose to the male quick-disconnect fitting (3) on the filter (4).
Checking Electrical Connectors 3–32 v 4.11.1 — March 2007

4
1
2
3
Figure 3-24 Filling Hydraulic Tank (Typical)

1 Supply hose 2 Female quick-disconnect coupling 3 Male quick-disconnect coupling
4 Filter
CAUTION!
Risk of damage to the machine. To prevent damage to hydraulic components,
do not overfill the hydraulic tank.
4. Fill the hydraulic tank to between one-half to three-quarter full in the sight glass
(Refer to Figure 3-25). This is the “High Level” mark.
v 4.11.1 — March 2007 3–33 Filling the Hydraulic Tank

Figure 3-25 Oil Level

1 Sight glass (typical location)
5. Disconnect the female quick-disconnect coupling from the filter.

6. Prime the system and extruder pumps after refilling the tank. Refer to Section 3.20.
NOTE: The system pump does not require priming when adding additional oil to
the hydraulic tank.
7. Start up and cycle the system.
Check the oil level on the sight glass. Top up as necessary to maintain correct level.
3.20 Priming the System Pump
CAUTION!
Risk of damage to the system pump. To prevent damage to the system pump, do
not restart the pump until it is primed.
1. Perform Lockout/Tagout. Refer to Section 1.6.1.

2. Remove the drain hose (1) at the drain port on the system pump (2) – refer to
Figure 3-26. Keep the hose end elevated to prevent the hydraulic tank from
draining.
Priming the System Pump 3–34 v 4.11.1 — March 2007

3. Fill the pump case with clean hydraulic oil through the drain port. Refer to
Section 2.6 for hydraulic oil specifications.
4. Reconnect the drain hose. Check for any oil leaks.
5. Remove locks and tags – refer to Section 1.6.2.
6. Run in the machine – refer to Section 7.52.
Figure 3-26 Priming System Pump (Typical)

1 Drain hose 2 System pump
3.21 Leveling Machine and Adjusting Nozzle Concentricity
1. Perform Lockout/Tagout procedure – refer to Section 1.6.1.
WARNING!
Complete the Lockout/Tagout procedure in accordance with applicable local
codes before performing maintenance activities. Failure to do so can result in
injury or death.
CAUTION!
Risk of damage to the machine. The clamp unit must be level to within the
tolerance of 0.15 mm/m (0.0015"/10"). The injection unit must be level to within
the tolerance of 0.8 mm/m (0.008"/10"). Failure to level the machine to the
specified tolerances can impair machine performance and increase component
wear.
v 4.11.1 — March 2007 3–35 Leveling Machine and Adjusting Nozzle Concentricity
IMPORTANT!
5 For proper leveling, the hydraulic tank must be filled before starting this procedure. If
the procedure is completed with the hydraulic tank empty all leveling values must be
rechecked and adjusted as necessary once the hydraulic tank is filled.
NOTE: Please record all required leveling and parallelism measurements in the
Leveling and Parallelism Checklist provided in Table 3-11.
NOTE: If upon completion of the procedure level and parallelism cannot be
achieved, attach the Leveling and Parallelism Checklist to a Baan Service
Module Incident Report.
2. For the Hylectric mono base level procedure, proceed to Section 3.21.1.
3. For the Hylectric split base level procedure, proceed to Section 3.21.3.
IMPORTANT!
5 The support foot on the accumulator bank (certain machines only) must NOT be used
when leveling the machine. Adjust it AFTER leveling, otherwise damage to the
machine could result.
Figure 3-27 Accumulator Bank Leveling Pad

1 Leveling pad
3.21.1 Preparation for Machine Leveling - Mono Base

NOTE: Check the area, where the leveling mounts are positioned, for cleanliness.
Clean all oil, grease, and wax buildup that is found. Heavily coated areas
should be scraped or sanded back to bare concrete.
1. Make sure that the leveling pads are properly oriented.
NOTE: Leveling pads that are properly oriented have the labels facing outwards
and the pads are in the direction of the mold stroke column movement.
Leveling Machine and Adjusting Nozzle Concentricity 3–36 v 4.11.1 — March 2007
Figure 3-28 Leveling Pad

1 Locknuts 2 3 mm minimum protrusion 3 Shim location
2. Loosen the locknuts.

3. Preload all of the leveling pads.
NOTE: The leveling mount pads should protrude a minimum of 3mm (0.125 in)
from the bottom of the mount housing. Due to floor irregularities, this
condition must be set at the highest floor level. The IM-series mounts have
a height adjustment range of 35 mm. For uneven floors add shims as
required between the leveling mount and the bottom of the base leg to
avoid exceeding the adjustment range.
4. Position the moving platen to maximum shutheight. Table 3-4 shows the maximum
shutheight.
Table 3-4 Maximum Shutheight Table - Monobase Machines
Maximum Shutheight Chart
Machine Size Max. Shutheight Machine Size Max. Shutheight
H90 500mm HL90 700mm
H120 550mm HL120 750mm
H160 550mm HL160 750mm
3.21.2 Base Leveling - Mono Base
CAUTION!
Make sure the precision level is accurate and calibrated. Failure to do so will
result in incorrect readings. For accuracy of level measurements use the same
level for all measurements.
1. Place the precision level on the rail surface. Turn the precision level 180 degrees.
Make sure the level measurement is the same when checked in both orientations.
If the measurement is not the same, do not use the level.
2. Refer to Figure 3-29 and Figure 3-30 for measurement locations. Take preliminary
level measurements at the following locations.
Description
L1 Rail between moving and stationary platen (OPS and NON OPS)
L2 Rail between moving platen and clamp casting (OPS and NON OPS)
L3 Across rails @ stationary platen
L4 Across rails @ clamp casting
L5 Box level measurement on stationary platen (OPS and NON OPS)
L6 Box level measurement on moving platen (OPS and NON OPS)
L7 Box level measurement on clamp casting (OPS)
L8 Injection leveling pad or machined guide rail
NOTE: Make sure L1 and L2 precision levels are not positioned over base
supports. Position the precision levels between the base supports, halfway
between the moving and stationary platen.
Figure 3-29 Measurement Locations 2

1 Across rails at stationary platen (L3) 2 Across rails at the clamp casting (L4)
1
2
Figure 3-30 Measurement Locations

1 Rail between moving and stationary platen (L1) 2 Rail between moving platen and
clamp casting (L2) 3 Injection leveling pad (L8)
3. Adjust one side of the base, along its length, from the clamp end to the injection
end.
4. Adjust the level of the machine at the end where the precision level indicates the
maximum deviation.
5. If required, turn the bolt of the pads to raise or lower the machine.
NOTE: Heavily loaded leveling mount positions may require the use of a pancake
jack to take the pressure off the leveling screw to enable it to be turned
more easily.
6. Check the level of the machine and make sure that the level is within tolerance.
0.15mm / meter (0.0015” / 10") at the clamp end and 0.8mm / meter (0.008" / 10")
at the injection end.
7. Level the other side of the base, check the level again and re-adjust the first side.
NOTE: To determine the location of maximum deviation, check the level
crossways while leveling the machine lengthways.
8. Use Vee- blocks and a precision parallel bar to measure the level at these
locations.
• Across the base at the stationary platen (50 mm from the platen).
• Across the base at the clamp casting.
NOTE: The location of the Vee-blocks depend upon the space between:
1) The stationary platen and the rails.
2) The clamp casting and the rails.
Figure 3-31 Precision Level on Straight Edge
9. Check the level on the straight edge at the stationary platen with a precision level.
maximum deviation.
11. Adjust all pads on one side evenly to achieve the proper level within a tolerance of
0.15mm / meter (0.0015”/10").
12. Repeat step 8 through step 11 at the clamp casting.
more easily.
13. Recheck the level lengthways and adjust as required.
NOTE: The level lengthways and crossways must be within limits before leveling
is considered achieved.
14. Check the nozzle concentricity as per either Section 3.21.7 or Section 3.21.8.
Remove the mold from the stationary platen if required using a suitable lifting
device and properly rated slings. If required, make adjustments to the nozzle
concentricity as per Machine Manual.
Figure 3-32 Pads

1 Locknut
15. Once the level and concentricity are achieved, tighten all locknuts.
16. Recheck the nozzle concentricity.
17. Reinstall the mold on the stationary platen.
18. Place the precision level at the required locations (L1, L2, L3, L4, L8) to determine
if the level is still within tolerance. If it is not, make adjustments as required. Record
all final values in the checklist on Table 3-11.
19. Once completed, proceed to Section 3.21.6.
3.21.3 Preparation for Machine Leveling - Split Base

1. Loosen the SHCS that attach the injection base to the clamp base.
2. Use a feeler gauge to measure the gap between the injection base and the clamp
base on the operator side and non operator side at the top and bottom of the
interface bar.
3. If the gap is not equal, proceed to step 4. If the gap is equal, proceed to step 9.
CAUTION!
Do not force bases together using interface SHCS. Forcing the bases together
using the interface SHCS can result in machine misalignment.
4. Torque the SHCS that attach the injection base to the clamp base.
5. Position the moving platen at maximum daylight and position the injection unit fully
back to reduce the load at the stationary platen end of the clamp.
6. Lift the clamp at the stationary platen end with a suitable crane and lifting slings (if
the crane capacity allows).
7. Lower the machine and loosen the SHCS.
Figure 3-33 Gap
8. Measure the gap between the injection base and the clamp base (Figure 3-33). If
the gaps are not equal, repeat step 4 through step 8.
CAUTION!
The difference between the operator and non operator side (top and bottom of
interface bar) should not be greater than 0.05 mm. Failure to make sure the gaps
are equal can result in machine misalignment.
9. Record final gap measurements in the checklist on Table 3-11.

NOTE: Check the area where the leveling mounts are positioned for cleanliness.
Clean all oil, grease, and wax buildup that is found. Heavily coated areas
should be scraped or sanded back to bare concrete.
10. Make sure that the leveling pads are properly oriented.
NOTE: Leveling pads that are properly oriented have the labels facing outwards
and the pads are in the direction of the mold stroke column movement.
Figure 3-34 Leveling Pad

1 Locknuts 2 3mm minimum protrusion 3 Shim location
11. Loosen the locknuts.

12. Preload all of the leveling pads.
NOTE: The leveling mount pads should protrude 3mm (0.125 in) from the bottom
of the mounts housing. Due to floor irregularities, this condition must only
be set at the highest floor level. The IM-series mounts have a height
adjustment range of 35 mm. For uneven floors add shims as required
between leveling mount and the bottom of base leg to avoid exceeding the
adjustment range.
13. Position the moving platen to maximum shutheight. Table 3-5 shows the maximum
shutheight.
Table 3-5 Maximum Shutheight Table - Split Base machines
Maximum Shutheight Chart
Machine Size Max. Shutheight Machine Size Max. Shutheight
H225 660mm HL225 900mm
H300 750mm HL300 1000mm
H400 850mm HL400 1100mm
H500 950mm HL500 1200mm
H650 1100mm HL650 1400mm
H800 1200mm HL800 1500mm
H1000 1300mm HL1000 1600mm
3.21.4 Clamp Leveling
CAUTION!
Make sure the precision level is accurate and calibrated. Failure to do so will
result in incorrect readings. For accuracy of level measurements use the same
level for all measurements.
1. Place the precision level on the rail surface. Turn the precision level 180 degrees.
Make sure the level measurement is the same when checked in both orientations.
If the measurement is not the same, do not use the level.
2. Refer to Figure 3-35, Figure 3-36 and Figure 3-40 for measurement locations.
Take preliminary level measurements at the following locations.
Description
L1 Rail between moving and stationary platen (OPS and NON OPS)
L2 Rail between moving platen and clamp casting (OPS and NON OPS)
L3 Across rails @ stationary platen
L4 Across rails @ clamp casting
L5 Box level measurement on stationary platen (OPS and NON OPS)
L6 Box level measurement on moving platen (OPS and NON OPS)
L7 Box level measurement on clamp casting (OPS)
L8 Injection unit lenghtways (OPS and NON OPS)
L9 Injection unit crossways
NOTE: Make sure L1 and L2 precision levels are positioned over the base
supports. Position the precision levels between the base supports, halfway
between the moving and stationary platens.
Figure 3-35 Measurement Location

1 Across rails at the clamp casting (L4)
1 2
Figure 3-36 Measurement Location

1 Rail between moving and stationary platen (L1) 2 Rail between moving platen and
clamp casting (L2) 3 Across rails at stationary platen (L3)
NOTE: During the clamp leveling procedure, check that the interface SHCS that
attach the injection base to the clamp base are able to move freely and the
gaps are within specification (0.05 mm difference).
3. Adjust one side of the base, along its length, from clamp end to the stationary end.
maximum deviation.
NOTE: Heavily loaded leveling mount positions may require the use of a pancake jack
to take the pressure off the leveling screw to enable it to be turned more
easily.
6. Check the level of the machine and make sure that the level is within a tolerance of
0.15mm / meter (0.0015” / 10").
7. Level the other side and check and readjust the first side.
NOTE: To determine the location of maximum deviation, check the level crossways
while leveling lengthways.
3.21.4.1 H90 - H500
Figure 3-37 Precision Level on Straight Edge (L3)
1. Use the Vee- blocks and precision parallel bar to measure the level at the following
locations.
• Across the base at the stationary platen (50 mm from the platen).
• Across the base at the clamp casting.
NOTE: The location of the Vee-blocks depends upon the space between:
1) The stationary platen and the rails.
2) The clamp casting and the rails.
2. Check the level at the stationary platen using a straight edge and a precision level.
maximum deviation.
0.15mm / meter (0.0015” / 10").
5. Repeat step 1 through step 4 at the clamp casting.

7. Make sure that the bolts that attach the injection base to the clamp base are able
to move freely and the gaps are within specification (0.05 mm difference).
3.21.4.2 H650 - H1000

1. Install leveling plate as shown in Figure 3-38 and Figure 3-39 using SHCS.
Figure 3-38 Leveling Plate
Figure 3-39 Leveling Plate Installed on Stationary Platen
2. Use the leveling plate to measure the level across the base at the stationary
platen.
3. Check the level at the stationary platen with a precision level on the leveling plate.
4. Adjust all pads evenly to achieve the proper level within a tolerance of 0.15mm/
meter (0.0015"/10").

6. Make sure that the bolts that attach the injection base to the clamp base are able
to move freely and the gaps are within specification (0.05 mm difference).
3.21.5 Injection Unit Leveling

NOTE: During the injection unit leveling procedure, check that the interface SHCS
that attach the injection base to the clamp base are able to move freely and
the gaps are within specification (0.05 mm difference).
1. Check the level on the operator and non-operator side of the rails of the injection
unit.
NOTE: Make sure that the levels are positioned midway between the leveling
mounts.
Figure 3-40 Precision Levels

1 Precision level on rails (L8) 2 Large precision level across rails (L9)
2. Adjust one side of the injection base, along its length, from the gearbox / extruder
motor end to the stationary platen end.
maximum deviation.
more easily.
5. Check the level of the machine and make sure that the level is within a tolerance of
0.8mm / meter (0.008in/ 10").
6. Level the other side and check and readjust the first side if necessary.
NOTE: Make sure that both sides are level before leveling crossways.
7. Check the reading on the precision level across the rails. Use a precision parallel
bar if required to span the injection rails.
maximum deviation.
0.8mm / meter (0.008in / 10").
NOTE: Both lengthways and crossways must be level before leveling is
considered achieved.
NOTE: Upon completion of leveling make sure that the connection bolts are able
to move freely.
11. Check the nozzle concentricity as per either Section 3.21.7 or Section 3.21.8.
Remove the mold from the stationary platen if required using a suitable lifting
device and properly rated slings. Make adjustments to the nozzle concentricity if
required.
12. Make sure the SHCS that attach the injection base to the clamp base are as close
to the center of the slot as possible and the gaps are within specification (0.05
mm).
13. Once the level and concentricity is achieved, tighten all leveling mount locknuts.
14. Tighten the SHCS that attach the injection base to the clamp base. Torque as per
Section 2.12.
Figure 3-41 Leveling
15. Place the precision level at required locations (L1, L2, L3, L4 L8, L9) to determine
if the level is still within tolerance. If not, make adjustments as required. Record all
final values in the checklist (Table 3-11).
16. Recheck the nozzle concentricity.
17. Reinstall the mold on the stationary platen.
3.21.6 Parallelism
NOTE: A mold or test blocks should be installed prior to taking parallelism
measurements.
1. Make sure that the gap between the tiebar nuts and the retaining plates are
correctly set at the clamp end. Table 3-6 shows the gap dimensions.
1 1
Figure 3-42 Tiebar Nuts

1 Gap
2. Position the moving platen to maximum shutheight. Table 3-4 and Table 3-5 show
the maximum shutheight.
Table 3-6 Tiebar Nut Gap Dimension
Machine size Gap Dimension
H/HL90 - H/HL/225 2mm
H/HL/300 - H/HL/50 3mm
H650 - H1000 5mm
NOTE: The following step 3 to step 5 are for H90 - H500 only.
3. Insert the spacer blocks between the clamp and the dowel pins on both sides.
4. Verify that the clamp spacer blocks (HPN2521393) are able to move freely and a
0.1mm (0.004") feeler gauge cannot be inserted between the spacer block and the
dowel pin.
5. Record the distance between the dowel and the clamp casting in Table 3-11
(section E).
6. Make sure the clamp casting is centered on the base by comparing gaps between
the clamp casting wear pad shoulder and the clamp base. Refer to Figure 3-43
item 2.
1
2
Figure 3-43 Clamp

1 Spacer block 2 Clamp casting / base interface
7. If the clamp casting is not centered on the base, position the moving platen in the
minimum shutheight position to reduce the load on the clamp casting end of the
machine. Table 3-7 shows the minimum shutheight.
Table 3-7 Minimum Shutheight Chart
Machine Size Min. Shutheight Machine Size Min. Shutheight
H90 220mm HL90 370mm
H120 220mm HL120 370mm
H160 250mm HL160 400mm
H225 280mm HL225 450mm
H300 300mm HL300 480mm
H400 320mm HL400 520mm
H500 350mm HL500 550mm
H650 400mm HL650 600mm
H800 500mm HL800 700mm
H1000 600mm HL1000 800mm
8. Reinstall the clamp casting shipping bolts and torque to specifications. Refer to
Section 2.12.
9. Lift the back end of the machine at the clamp casting with a suitable lifting device
and properly rated slings.
10. Lower the machine and remove the shipping bolts. Recheck after the machine has
cycled under tonnage.
11. Recheck the machine level and adjust as necessary.
CAUTION!
Make sure the precision box level is accurate and calibrated. Failure to do so
will result in incorrect readings. For accuracy of level measurements use the
same level for all measurements.
12. Position the box level against the stationary platen as shown in Figure 3-44. Make
sure the level measurement is the same when checked in both orientations. If the
measurement is not the same, do not use the level.
Figure 3-44 Box Level Measurement on Stationary Platen (L5)
13. Place the box level on the operator and non-operator side of the stationary platen
to verify that the stationary platen is perpendicular to the base on the operator and
non-operator’s sides.
Table 3-8 Stationary Platen Tilt
Platen Tilt Without Mold With Mold
Toward Moving Platen 0.1 mm/m (0.001"/10") 0.15 mm/m (0.0015"/10")
Away from Moving Platen 0.2 mm/m (0.002"/10") 0.15 mm/m (0.0015"/10")
14. Place the box level on the operator and non-operator side of the moving platen to
verify that the moving platen is perpendicular to the base on the operator and non-
operator sides.
Figure 3-45 Box Level Measurement on Moving Platen (L6)
Table 3-9 Moving Platen Tilt
Platen Tilt Without Mold With Mold
Toward Stationary Platen 0.1 mm/m (0.001"/10") 0.15 mm/m (0.0015"/10")
Away from Stationary Platen 0.15 mm/m (0.0015"/10") 0.15 mm/m (0.0015"/10")
15. Place the box level on the clamp cylinder to verify that the clamp cylinder is
perpendicular to the base.
NOTE: The tolerance must be within +/- 0.15 mm / meter (0.0015” / 10") relative to
the precision level on the base.
Figure 3-46 Box Level Measurement on Clamp Casting (L7)
16. Place the precision level at required locations (L5 to L7). Record all final values in
the checklist on Table 3-11.
NOTE: Platen parallelism cannot exceed Table 3-10.

17. Using an inside micrometer, take measurements from the four corners between
the stationary and the moving platen’s mold faces.
Figure 3-47 Box Level Measurement on Clamp Casting (L7)
18. Take the measurements from just above and below the tiebars. Zero the
micrometer at one location prior to recording measurements.
19. Check that the maximum difference between each of the four measurements is
within the tolerances listed in Table 3-10.
20. Record parallelism values in the checklist on Table 3-11.
Table 3-10 Parallelism Tolerances
Machine Size Tolerance Machine Size Tolerance
H/HL90 0.12mm H/HL400 0.20mm
H/HL120 0.13mm H/H500 0.23mm
H/HL160 0.13mm H650 0.25mm
H/HL225 0.15mm H800 0.28mm
H/HL300 0.17mm H1000 0.30mm
21. Position the moving platen to maximum day light, less the stroke required for
access to the clamp column bushings.
22. Use a 0.05 mm (0.002 in) feeler gauge to check for a gap between the column
guide bushings and the column.
Figure 3-48 Clamp Column Bushings

1 Bushing
23. Record gaps in the checklist in Table 3-11.

NOTE: If unable to insert the feeler gauge, recheck the level and parallelism of the
machine.
24. If after completing this procedure the leveling and parallelism tolerances cannot be
met, contact CSG.
25. After the machine has cycled under tonnage perform the following final leveling
checks.
a. Verify the longitudinal and lateral level of the clamp unit.
b. Verify the longitudinal and lateral level of the injection unit.
c. Verify the parallelism.
26. Under static load, the rubber molecules of new leveling mounts gradually change
from a round to an elongated shape, initially in the first 12 hours and finally at 72
hours. The machine level and parallelism values should be rechecked at this time
and adjusted if necessary.
27. Check the nozzle concentricity using the following procedure (Refer to
Figure 3-51).
Table 3-11 Leveling and Parallelism Checklist

Customer: Serial Number:
Machine Type: Date: Done By:
A: Levelling Values B: Parallelism Values (between moving and stationary
platen)
Unit OPS NOPS Tolerance Unit OPS NOPS
L1 mm/m +/- 0.15 mm/m* top mm
L2 mm/m +/- 0.15 mm/m* bottom mm
*(- clamp side high, + stationary platen side high)
Unit Across Tolerance C: Clearance between Column and Wear Pads
L3 mm/m +/- 0.15 mm/m** Unit OPS NOPS
L4 mm/m +/- 0.15 mm/m** mm
**(- non ops side high, + ops side high)
L5 mm/m +/- 0.15 mm/m† D: Clearance between clamp base and injection base at
interface bar
L6 mm/m +/- 0.15 mm/m† Unit OPS NOPS
L7 mm/m +/- 0.15 mm/m† top mm
†(- leaning in (towards molding area), + leaning out (away bottom mm
from molding area))
L8 mm/m +/- 0.8 mm/m‡
‡(- clamp side high, + screw drive side high) E: Clamp casting side to side (between clamp casting and
base dowel)
L9 mm/m +/- 0.8 mm/m§ Unit OPS NOPS
§(- non ops side high, + ops side high) mm
/ / /
/ /
$
1236 236 236 1236
/ /
6F
3.21.7 Checking Nozzle Concentricity - RS22 to RS40
WARNING!
Burn hazard – risk of serious injury. If nozzle concentricity is not within
specification, molten process material at high pressure can escape and cause
severe burns. To prevent leakage between the nozzle tip and the mold, nozzle
concentricity should be within tolerance.
WARNING!
Burn hazard – risk of serious injury. During production the injection barrel is hot
and can cause severe burns. Lockout/tagout the machine and allow the barrel to
cool to room temperature before checking and adjusting concentricity.
1 Inside vernier caliper capable of measuring up to 200 mm.
Check and adjust the nozzle concentricity using the following instructions.
A 3 1
Figure 3-49 Checking Nozzle Concentricity

1 Nozzle tip 2 Stationary platen mounting surface 3 Locating ring
3.21.7.1 Vertical Adjustment:

1. Check that the nozzle tip (1) is flush with the mounting surface of the stationary
platen (2) – refer to Figure 3-49.
2. Using a vernier caliper, measure the vertical distances (C and D) between the
nozzle tip and the locating ring (3).
3. Check that the difference between the two vertical measurements does not exceed
1 mm (0.04 in).
4. If adjustment is necessary, proceed as follows – refer to Figure 3-50.

a. Loosen the fixing screws (1) at the rear of the injection sled (2)
b. Slacken the fixing screws at the front of the injection sled.
c. Turn the jacking screws (3) to raise or lower the front of the injection sled.
d. Repeat step 1 and step 2 until the vertical concentricity is within tolerances.
e. Tighten all the fixing screws in the sled.
3.21.7.2 Horizontal Adjustment

1. Check that the nozzle tip is flush with the mounting surface of the stationary platen
– refer to Figure 3-49.
2. Using vernier caliper, measure the horizontal distances (A and B) between the
nozzle tip and the locating ring.
3. Check that the difference between the two horizontal measurements does not
exceed 0.5 mm (0.02 in).
4. If adjustment is necessary, proceed as follows – refer to Figure 3-50.
a. Slacken the locking bolts (4) on either side of the injection swivel bed (5).
b. Loosen the locknut (6).
c. Turn the setscrew (7) to shift the nozzle horizontally.
d. Repeat step 2 and step 3 until the horizontal concentricity is within tolerances.
e. Tighten the locknut.
f. Tighten the locking bolts in the swivel bed.
6
1 4 7
3
2
Figure 3-50 Adjusting Nozzle Concentricity

1 Fixing screws 2 Injection sled 3 Jacking screw 4 Locking bolt 5 Swivel bed
6 Locknut 7 Setscrew
3.21.8 Checking Nozzle Concentricity - RS45 to RS155
WARNING!
Burn hazard – risk of serious injury. If nozzle concentricity is not within
specification, molten process material at high pressure can escape and cause
severe burns. To prevent leakage between the nozzle tip and the mold, nozzle
concentricity should be within tolerance.
Check the nozzle concentricity using the following instructions.
3.21.8.1 Vertical Adjustment

1. Measure the vertical distances (C and D) between the nozzle tip and the locating
ring. Refer to Figure 3-51.
2. Check that the difference between the two vertical measurements do not exceed 1
mm (0.04 in).
WARNING!
CAUTION!
Risk of damage to the machine. Do not use the jam nut on the barrel support to
adjust vertical concentricity as this can cause misalignment of the screw and
barrel. To prevent damage to the screw and barrel, use the levelling mounts for
vertical adjustment.
For leveling adjustment refer to Section 3.21.5.
3.21.8.2 Horizontal Adjustment

NOTE: For horizontal adjustment determine the type of support used, refer to
Figure 3-51 and Figure 3-52, then refer to the accompanying instructions.
3.21.8.2.1 Horizontal Adjustment (Type 1)

1. Press and hold the <CARRIAGE FORWARD> key or the <CARRIAGE BACK> key
until the nozzle tip (1) is flush with the surface of the stationary platen (2) – refer to
Figure 3-51.
2. Use a vernier caliper to measure the horizontal distances (A and B) between the
inside edge of the nozzle tip and the locating ring (3).
3. Check that the difference between the two horizontal measurements do not
4. If necessary, slacken the cap screws (4) and adjust the barrel assembly (5)
horizontally, as discussed below.
5. Insert a 6 mm diameter rod into the hole in the side of the eccentric ring (6). Turn
the eccentric ring clockwise to move the barrel assembly to the non-operator side,
and vice versa.
6. Repeat step 2 and step 3.
A 3 1
5
B
S01-101046.eps
6
4
Figure 3-51 Checking and Adjusting Nozzle Concentricity. (Barrel Support Type 1)
1 Nozzle tip 2 Stationary platen mounting surface 3 Locating ring 4 Cap screw
5 Barrel assembly 6 Eccentric ring
3.21.8.2.2 Horizontal Adjustment (Type 2)

1. Press and hold the <CARRIAGE FORWARD> key or the <CARRIAGE BACK> key
until the nozzle tip (1) is flush with the surface of the stationary platen (2) – refer to
Figure 3-52.
2. Use a vernier caliper to measure the horizontal distances (A and B) between the
inside edge of the nozzle tip and the locating ring (3).
3. Check that the difference between the two horizontal measurements do not
4. If horizontal adjustment is required:
a. Release the locking nut (4).
b. Tighten the adjustment screws (5) on the side of the barrel mounting assembly,
as required.
5. Repeat step 2 and step 3.
6. Secure the locking nut to Husky required torque specifications.
A 3 1
Figure 3-52 Checking and Adjusting Nozzle Concentricity (Barrel Support Type 2)
1 Nozzle tip 2 Stationary platen mounting surface 3 Locating ring 4 Locking nut
5 Adjustment screw
3.21.9 Leveling the Electrical Cabinet

Level the electrical cabinet using the following instructions.
CAUTION!
machine base.
1. Place a level (1) on the top surface of the electrical cabinet (2) – refer to
Figure 3-53.
2. Slacken the locknut (3) and turn the bolt (4) to raise or lower the electrical cabinet.
Tighten the locknut.
S01-101022.eps
2 1
Figure 3-53 Leveling Electrical Cabinet (Typical)

1 Level 2 Electrical cabinet 3 Locknut 4 Bolt
3.21.10Final Check
Once power is supplied to the machine, check the platen faces for parallelism:
1. Move the mold sections together, not closed, but just before the mold leader pins
engage.
2. Using an inside micrometer, measure the perpendicular distance between the
stationary and moving platens, as close as possible to the four tiebars.
NOTE: The specifications listed in Table 3-12 are maximum tolerances. Husky
recommends targeting tighter values to maximize machine efficiency.
3. Verify the maximum difference between any of the measurements and compare
with the specification listed in Table 3-12. If the difference between any of the
measurements is larger than the specification, contact the Husky Regional Area
Service Department for assistance.
Table 3-12 Parallelism Specification
Clamp Size Parallelism Specification
H90-H120 0.12 mm (0.005 in)
H160 0.13 mm (0.005 in)
H225 0.15 mm (0.006 in)
H300 0.17 mm (0.007 in)
H400 0.20 mm (0.008 in)
H500 0.23 mm (0.009 in)
H650 0.25 mm (0.01 in)
H800 0.28 mm (0.01 in)
H1000 0.32 mm (0.01 in)
After the machine has completed a few cycles, perform final leveling and concentricity
checks:
1. Check the longitudinal and lateral level of the clamp unit.
2. Check the longitudinal and lateral level of the injection unit.
3. Check the nozzle concentricity.
4. Verify all measurements are within tolerance. If necessary, loosen the mounting
bolts between the two units and adjust the leveling mounts as required.
5. Once all adjustments are made, tighten the mounting bolts. Be sure sufficient
torque is applied while tightening the bolts.
NOTE: Whenever items such as a mold or product handling equipment are
installed, re-check the level of the machine and the nozzle concentricity.
3.22 Hooking Up Oil Collection Line
Hook up the oil collection line using the following instructions.

1. Connect the oil collection line to the fitting (1) on the inside of the clamp base
below the stationary platen – refer to Figure 3-54.
6
5
7
S01-101009.eps
2
3
Figure 3-54 Hooking Up Oil Collection Line & Compressed Air Lines (Typical)
1. Fitting 2. Air line 3. Air line 4. Fitting 5. Shutoff lever 6. Regulator knob 7. Air
pressure gauge
3.23 Hooking Up Compressed Air Lines
Refer to Section 2.5 for compressed air specifications.

Hook up compressed air lines to the machine using the following instructions.
1. Connect the air lines (2), (3) to the tee fittings on the inside of the clamp base
below the stationary platen – refer to Figure 3-54.
2. Connect the supply line to the fitting (4) on the air regulator.
3. Open the air supply to the machine.
4. Turn on the air supply to the machine using the shutoff lever (5). Adjust the
regulator knob (6) so the air pressure gauge (7) reads 6 bar (90 psi).
5. Listen for any leaks in the air lines.
6. Shut off the air supply. Check that the pressure gauge registers zero pressure.
7. Turn on the air supply again.
v 4.11.1 — March 2007 3–65 Hooking Up Oil Collection Line

3.24 Hooking Up Electrical Power Supply
DANGER!
Electrocution and/or burn hazard – risk of death or serious injury, and a
potential for fire.
• Ensure that the prospective short circuit fault level does not exceed 10,000 A
RMS.
• Only qualified personnel should connect the electrical power supply. All
work must conform to local electrical codes.
WARNING!
Electrocution hazard – risk of death or serious injury.
• High voltages present in the electrical cabinet after the power supply is
connected.
• Only connect the bonding strip where local codes require the neutral bar to
be bonded to the enclosure.
• When connecting the PE-to-N bonding strip, follow manufacturer’s
instructions. Failure to use the proper mounting bolt will result in an
incorrect bonding circuit.
• Properly ground all ancillary equipment.
WARNING!
Crushing hazard – risk of death or serious injury. Interlock all hazardous motion
from non-Husky ancillary equipment to the machine Emergency Stop circuit.
Refer to the electrical schematics.
CAUTION!
Risk of damage to the machine.
• Do not modify the electrical cabinet.
• The main electrical power cable must be rated to handle machine power
requirements, in compliance with local codes.
• Do not operate the machine until pump motor rotation is verified – see
Section 7.28
Hooking Up Electrical Power Supply 3–66 v 4.11.1 — March 2007

3.24.1 Machine Power Supply

Refer to the electrical nameplate or the electrical schematics for machine power
supply specifications.
Hook up the machine electrical power supply using the following instructions:
NOTE: On machines shipped to Europe with integrated mold heats option, the Q1M
breaker controls both machine and mold heats power.
NOTE: In some cases, the Q1M breaker will be larger than the Q3M. In these cases,
connect to Q1M. Please refer to your schematic for details
WARNING!
Electrocution hazard – risk of death or serious injury. Perform Lockout/Tagout
procedure in accordance with local codes. Only qualified personnel should
perform Lockout/Tagout procedure.
1. Switch off the power supply from the plant to the machine at the main disconnect
switch. Use Lockout/Tagout – see Section 1.6.
2. Check and confirm the main breakers, Q1M (1) and Q3M (2) on the electrical
cabinet (3) are turned off. Check and confirm the main mold heat breaker Q2M (4)
is turned off, if applicable – refer to Figure 3-55.
3. Cut holes in the blanking plate (5) to provide access for the electrical cables.
Conform to local guidelines for correct cable strain reliefs.
4. Run the power supply cable (6) into the electrical cabinet through the hole cut in
the blanking plate.
5. Connect the three-phase wires to the bottom of the Q3M breaker, and the mold
heat breaker Q2M, if applicable.
NOTE: There are already jumpers between the Q1M and Q3M breakers to supply
the Q1M circuit.
v 4.11.1 — March 2007 3–67 Hooking Up Electrical Power Supply

S01-101111A.eps
2 8
4
1
7
3
5
6 9
10
11
Figure 3-55 Hooking Up Machine Power Supply (Typical)

1. Main breaker Q1M 2. Main breaker Q3M 3. Electrical cabinet 4. Mold heat breaker
Q2M (optional) 5. Blanking plate 6. Machine power supply cable 7. Ground (Potential
Earth) 8. Neutral bar 9. Mold heat power supply cable (optional) 10. Flange mount
type breaker (Ref.) 11. Rotary handle type breaker (Ref.)
6. Connect the ground (Potential Earth) wire to the ground strip (7).
7. Connect the neutral wire, where available, to the neutral bar (8).
8. Remove locks and tags – refer to Section 1.6.2. Switch on the power supply at the
production facility’s main disconnect switches.
Hooking Up Electrical Power Supply 3–68 v 4.11.1 — March 2007

3.25 Hooking Up Machine Cooling Water Supply
Refer to Section 2.4 for machine cooling water specifications.
CAUTION!
Risk of machine damage due to overheating. Consult the base water assembly
drawing for the correct position of the valves. Avoid plugging the drain port.
Hook up machine cooling water supply using the following instructions.

1. Refer to the installation drawing for machine cooling water inlet and outlet sizes,
and to the base water assembly drawing for the correct cooling lines configuration.
2. Remove the cap from the cooling water inlet fitting (1), and attach the cooling water
supply line. Refer to Figure 3-56.
3. Remove the cap from the cooling water outlet fitting (2), and attach the return line.
4. Turn the handles on the water inlet and drain port valves to the working positions –
Refer to Figure 3-57.
5. Open the water supply and drain cock on return line to bleed any trapped air from
the lines.
2 1
S01-101026b.eps
Figure 3-56 Hooking Up Machine Cooling Water Supply (Typical)

1. Inlet 2. Outlet
v 4.11.1 — March 2007 3–69 Hooking Up Machine Cooling Water Supply

Units smaller RS80 and up

than RS80 Water Inlet
Valve
-90°
°
90°
° -90°

90°

1 2
90°
°
B 180°
°
Water Drain
Port Valve
Figure 3-57 Cooling Water Circuit (Typical)

1. Water inlet valve handle (working position) 2. Drain port valve handle (working
position)
3.26 Hooking Up Mold Cooling Water Supply (Optional)
Refer to Section 2.4 for mold cooling water specifications.

If the machine is ordered with Mold Cooling option, hook up the mold cooling water
supply using the following instructions.
1. Refer to the installation drawing for mold cooling water inlet and outlet sizes.
Hooking Up Mold Cooling Water Supply (Optional) 3–70 v 4.11.1 — March 2007
2. Remove the cap from the mold cooling water inlet fitting (1), and attach the supply
line – refer to Figure 3-58.
3. Remove the cap from the mold cooling water outlet fitting (2), and attach the return
line.
4. Open the cooling water supply and bleed any trapped air from the lines.
S01-101027.eps
Figure 3-58 Hooking Up Mold Cooling Water Supply (Typical)
1. Mold cooling water inlet 2. Mold cooling water outlet
3.27 Machine Lubrication
If the machine arrives directly from the factory, skip this section. However, if a machine
has been in storage, it must be fully lubricated before use. For lubricant specifications
refer to Section 2.8.
Lubricate the machine using the following instructions.
1. Lubricate mold stroke column guide bushings. Refer to Section 7.18.
2. Lubricate clamp lock cylinder rod ends. Refer to Section 7.19.
3. Lubricate moving platen linear bearings, if installed. Refer to Section 7.32.
4. Lubricate optional stack mold carrier linear bushings. Refer to Section 7.33.
5. Lubricate injection piston linear bearings if installed. Refer to Section 7.34.
6. Lubricate electric pump motor bearings. Refer to Section 7.43.
v 4.11.1 — March 2007 3–71 Machine Lubrication

3.28 Charging the Accumulators
3.28.1 Checking Accumulator Precharge
Special Tools Required
1 Accumulator charging kit (Part number 732452)
Refer to Section 2.11 for accumulator capacity and precharge pressure.

Operating temperature has an effect on gas pressure. To account for temperature and
pressure differential, charge the accumulator to the pressure indicated on the
hydraulic schematic and then operate the machine until the temperature of the
hydraulic fluid stabilizes. Recheck the pressure and, if necessary, charge or deplete
the nitrogen supply.
At intervals specified in the Maintenance Schedule, check the accumulator precharge
using the following instructions.
WARNING!
Suffocation hazard – risk of death or serious injury. High pressure nitrogen gas
can deplete the oxygen in the air and cause rapid suffocation. Read the Material
Safety Data Sheet (MSDS) before checking the precharge.
WARNING!
High pressure hazard – risk of death or serious injury. Do not remove the entire
gas valve assembly or the drain fitting. A loosened gas valve assembly or drain
fitting under pressure can become a high velocity projectile.

2. Review the hydraulic schematic to determine the required pressure and capacity of
the gas side of the accumulator.
3. Remove the valve protection cap (1), and the valve seal cap (2) – refer to
Figure 3-59.
4. Turn the T-handle (5) fully to retract the plunger in the charge/gauge unit (6).
5. Turn the manual bleed valve (8) to shut off bleed.
6. Attach the charge/gauge unit to the valve stem. Tighten the nut (7).
CAUTION!
Risk of damage to the machine. To prevent damage to the accumulator valve,
turn the T-handle just to the point where the pressure gauge starts to register
pressure or to a maximum of three full revolutions.
7. Turn the T-handle clockwise to open the accumulator valve, until the pressure
gauge (9) just begins to register the pressure or to a maximum of three full
revolutions.
Charging the Accumulators 3–72 v 4.11.1 — March 2007

8. Note the accumulator precharge pressure.

9. If necessary, adjust the precharge pressure – refer to Section 3.28.2. Otherwise,
go to the next step.
10. Turn the T-handle fully to close the accumulator valve.
11. Turn the manual bleed valve to bleed trapped pressure. Then shut off the bleed.
12. Inspect the accumulator valve for any leakage.
5
1
9
8
2
6
3
7
4
S01-101035.eps
Figure 3-59 Checking Accumulator Precharge (Typical)

1 Valve protection cap 2 Valve seal cap 3 O-ring 4 Valve stem 5 T-handle
6 Charge/Gauge unit 7 Nut 8 Manual bleed valve 9 Pressure gauge
v 4.11.1 — March 2007 3–73 Charging the Accumulators

3.28.2 Precharging the Accumulators
Special Tools/ Materials Required
2 Nitrogen gas (at least 99.995% pure)
Precharge or increase the precharge pressure of the accumulator as follows:

NOTE: Refer to Section 2.11 for accumulator capacity and precharge pressure.
Figure 3-60.
5
8
5 11
1 6 7
2 12
3
4
14
13
S01-101034.eps
10
Figure 3-60 Precharging Accumulator (Typical)

6 Charge/Gauge unit 7 Nut 8 Manual bleed valve 9 Pressure gauge 10 Charging
hose 11 Check valve 12 Shutoff valve 13 Nitrogen tank 14 Accumulator nut
5. Turn the manual bleed valve (8) to shut off bleed.

CAUTION!
To prevent damage to the accumulator valve, turn the T-handle just to the point
where the pressure gauge starts to register pressure or to a maximum of three
full revolutions.
7. Turn the T-handle to open the accumulator valve, until the pressure gauge (9) just
begins to register the pressure, or to a maximum of 3 full revolutions.
8. Note the accumulator precharge pressure.
.
WARNING!
Explosion hazard – risk of death or serious injury. To prevent an explosion, use
pure nitrogen gas to precharge the accumulator. Nitrogen gas must be at least
99.995% pure.
WARNING!
can deplete the oxygen in the air and cause rapid suffocation. Read the Material
Safety Data Sheet (MSDS) before using nitrogen. Use under well ventilated
conditions.
WARNING!
High pressure gas stored in cylinder – risk of death or serious injury. Use
equipment rated to handle the cylinder pressure. Turn the supply valve off after
each use, and when the cylinder is empty.
NOTE: In order to complete the connections, it may be necessary to install

adaptor fittings onto components with either incompatible valve
arrangements or end couplings. Be sure these adaptors are available from
the gas supplier and install them as required while executing the
instructions.
10. Connect the charging hose (10) to the check valve (11) in the charge/gauge unit.
11. Connect the charging hose to the nitrogen tank using the adaptor in the charging
kit, if necessary.
CAUTION!
Charge the accumulator by slowly opening the shut-off valve of the nitrogen
cylinder. The accumulator can be damaged if the valve is opened quickly.
12. Listen carefully while slowly opening the valve of the charging cylinder. Stop
opening the valve once the gas begins to audibly enter the accumulator. Allow the
pressure to reach 100 psi.
13. Once the pressure gauge indicates 100 psi, increase the flow rate incrementally by
slowly opening the charge valve in 10 second intervals for the next minute.
14. Charge the accumulator to the pressure specified on the schematic.

15. Allow the bladder to settle for 30 seconds, then reopen the accumulator valve and
charge to the proper precharge pressure.
REMINDER: When the shutoff valve in the nitrogen tank is open, the accumulator
pressure gauge indicates the pressure in the charging hose. To determine the correct
accumulator precharge pressure, close the shutoff valve.
16. Close the shutoff valve in the nitrogen tank.

18. Turn the manual bleed valve to bleed trapped pressure. Then shut off the bleed.
19. Wait 20 to 30 minutes for the gas pressure to stabilize.
NOTE: On subsequent charging, allow 5 to 10 minutes for the gas pressure to
stabilize before checking the pressure.
20. Turn the T-handle (maximum 3 revolutions) to open the accumulator valve.
21. Check the precharge pressure on the gauge at the accumulator.
22. If necessary, repeat step 12 through step 20 to increase the precharge pressure,
or decrease the precharge pressure in accordance with Section 3.28.3.
23. On new or rebuilt accumulators, make sure the accumulator nut (14) remains
torqued to 80 Nm (59 ft. lbs) after precharging to prevent leakage.
3.28.3 Discharging Accumulator Precharge
Discharge the accumulator precharge using the following instructions.

Figure 3-61.
5. Turn the manual bleed valve (8) fully to shut off bleed.
CAUTION!
Risk of damage to the machine. To prevent damage to the accumulator valve,
turn the T-handle just to the point where the pressure gauge starts to register
pressure or to a maximum of three revolutions.
7. Turn the T-handle to open the accumulator valve until the pressure gauge (9)
begins to register the pressure or to a maximum of 3 revolutions.

5
1
9
8
3
7
4
S01-101035.eps
Figure 3-61 Discharging Accumulator Precharge (Typical)

6 Charge/Gauge unit 7 Nut 8 Manual bleed valve 9 Pressure gauge
WARNING!
can deplete the oxygen in the air and cause rapid suffocation. Read the MSDS
before discharging nitrogen gas from the accumulator. Perform this procedure
in a well ventilated area.
WARNING!
Noise hazard – risk of hearing loss. High pressure nitrogen gas can create high
pitched noises as it escapes the accumulator. Wear hearing protection before
discharging the accumulator.
8. Turn the manual bleed valve to slowly discharge the nitrogen gas precharge in the
accumulator.
9. Check the pressure gauge to ensure that all the nitrogen gas has been discharged.
10. Turn the manual bleed valve to bleed any trapped pressure.
11. Remove the charge/gauge unit from the gas valve of the accumulator.
12. Reinstall the valve seal cap. Install the valve protection cap and hand-tighten.

3.29 Checking Hydraulic Connections
WARNING!
High pressure spray hazard – risk of death or serious injury. Loose connections
can cause high pressure. High pressure hydraulic oil spray that can penetrate
human tissue causing serious injury or death. Check all hoses for damage, and
tighten all hydraulic connections before starting up the machine.
WARNING!
Fire hazard – risk of death or personal injury, and property damage. Hydraulic
oil can spray onto hot machine surfaces and cause a fire. Check all hoses for
damage, and tighten all hydraulic connections before starting up the machine.
Perform the following checks.

1. Check and retighten all connections at the inlet and outlet side of the pumps. Refer
to Section 2.12 for torque specifications.
2. Check and retighten all connections at the manifolds.
3. Check and retighten all remaining hydraulic connections throughout the machine.
3.30 Attaching Carriage Cylinders (Split Base Models)
Attach the carriage cylinders using the following instructions.

1. Remove any carriage cylinder supports and tie wraps.
2. Disconnect the hydraulic hoses to the carriage cylinders, and place the ends in a
receptacle to catch leaking oil.
3. Pull the piston rod (1) of the carriage cylinder by hand, and attach the clevis blocks
(2) to the stationary platen (3) using the bolts (4) – refer to Figure 3-62. Torque the
bolts to Husky specifications HGT-50 – refer to Section 2.12.3.
4. Reattach the hydraulic hoses, and wipe up any oil spill.
Checking Hydraulic Connections 3–78 v 4.11.1 — March 2007

2
1
Figure 3-62 Installing Carriage Cylinders

1. Piston rod 2. Clevis block 3. Stationary platen 4. Bolt
3.31 Checking Machine Functions
NOTE: This procedure is peformed by the Husky Field Service Representative upon
initial installation.
Check all machine functions using the following instructions.
1. Press the <PUMP MOTOR ON> key.
2. Press the <MANUAL> mode key to manually step through the machine cycle.
3. From the toolbar, press the Machine Function Mode selector button, and select the
Mold Set button.
4. Press the <CLAMP> key and select the SETUP tab – refer to Figure 3-63.
v 4.11.1 — March 2007 3–79 Checking Machine Functions

Figure 3-63 (Clamp) SETUP Screen
5. Select the field that represents the maximum Opened Position profile. Enter a
suitable value.
6. Enter a value in the corresponding Speed field.
7. Press and hold the <MOLD OPEN> key to retract the mold stroke column.
8. Press and hold the <MOLD CLOSE> key to extend the mold stroke column.
9. Press and hold the <CARRIAGE FORWARD> key to move the injection carriage
forward.
10. Press and hold the <CARRIAGE BACK> key to move the injection carriage back.
11. Check for any leaks in the hydraulic hoses, cylinders or manifolds.
3.32 Inspect for Installation Damage
1. Make sure tamper proof seals are intact on the ball valve, hatch covers, breather
cap and vent.
NOTE: If tamper proof seals are not intact, contact Husky immediately.
2. Inspect the machine for any signs of damage. Report any damage to the Husky
Regional Service and Sales office.
Inspect for Installation Damage 3–80 v 4.11.1 — March 2007

3.33 Contact Husky
Contact Husky to assist with commissioning the machine.
3.34 Remove Plastic Shrink Wrap From the Ball Valve
Remove the plastic shrink wrap from the ball valve.
Figure 3-1 Plastic Shrink Wrapped Ball Valve
v 4.11.1 — March 2007 3–81 Contact Husky

Remove Plastic Shrink Wrap From the Ball Valve 3–82 v 4.11.1 — March 2007
Machine Manual User Interface
Chapter 4 User Interface
This chapter discusses the Human Machine Interface (HMI) through which the
operator interacts with the machine. It describes the basic features and functions of
the HMI, and how to navigate through the HMI.
4.1 Human Machine Interface (HMI)
The operator interacts with the machine through the HMI. The HMI allows the operator
to monitor the operation of the machine, and modify certain operating parameters.
The HMI has a display screen in the center of the control panel, and a number of
control/function keys positioned around the screen’s perimeter. (Refer to Figure 4-1.)
Each of the screen elements shown in the following illustration is covered in detail later
in this chapter.
v 4.11.1 — March 2007 4–1 Human Machine Interface (HMI)

1 2 3 4
5 5
S01-100856a.eps
6 7 8
Figure 4-1 Human Machine Interface (HMI)

1. Cycle Mode keys 2. <ROBOT HOME> key 3. <ROBOT ENABLE> key 4. Pump Motor keys
5. Sidebar function keys 6. Main screen 7. Screen keys 8. Manual function keys
NOTE: The HMI control panel background and border in the above illustration were
removed intentionally to aid clarity.
Human Machine Interface (HMI) 4–2 v 4.11.1 — March 2007

4.1.1 Machine Cycle Modes

There are three machine cycle mode keys that allow the operator to select how the
machine runs, and a <CYCLE START> key that actually starts the cycle. The cycle
modes can be selected by pressing the machine cycle keys located at the top left of
the HMI panel. Table 4-1 describes the machine cycle mode keys.
NOTE: Each key has a LED indicator. When the LED is lit, it indicates the function or
mode is active. A flashing LED (except for the <CYCLE START> key)
indicates that an alarm has been triggered and must be cleared before the
machine can run. A flashing LED on the <CYCLE START> key indicates that
the machine (and chosen cycle mode) is ready to start.
Table 4-1 Machine Cycle Modes
Machine Cycle Function
Press the <CYCLE START> key to run the machine in either

Auto or Semi-auto cycle mode, after the mode is selected.
NOTE: Manual mode does not require use of this key.
Press the <AUTO> key to make the machine run continuously.
Press the <SEMI> key to make the machine run one complete
machine cycle.
Press the <MANUAL> key to make the machine run one machine
function at a time.
4.1.2 Robot Home Key

The <ROBOT HOME> key is used to reset the robot to the home position. The key is
described in Table 4-2.
Table 4-2 Robot Home
Key Function
Press the <ROBOT HOME> key to return the robot to the home
position.

4.1.3 Robot Enable Key

If the machine is equipped with a materials handling robot the <ROBOT ENABLE> key
activates the robot. The key is described in Table 4-3. For complete details on robot
operation, see the Robot manual.
Table 4-3 Robot Enable
Key Function
Press the <ROBOT ENABLE> key to run the robot during

machine operation.
4.1.4 Pump Motor Keys

There are two pump motor keys located at the top right of the HMI panel. Each key has
a LED indicator, which lights up when the key is selected. The keys are described in
Table 4-4.
Table 4-4 Pump Motor Keys
Key Function
Press the <PUMP MOTOR ON> key to start the hydraulic pump
motor.
Press the <PUMP MOTOR OFF> key to shut off the hydraulic
pump motor.
4.1.5 Sidebar Function Keys

The sidebar function keys allow the operator to access a wide range of machine
functions and process values. Each function or process value is represented by its
own icon on the sidebar. This can include the following,
• Preset automatic and manual functions.
• Process values.
• Optional automatic and manual functions, depending on how the machine is con-
figured.
• User configured function keys.
Refer to Figure 4-2 and Figure 4-3 for more information on the sidebar keys.

1 1
2 3 2
Figure 4-2 Sidebar Function Keys

1. Function group selectors 2. Function keys 3. Sidebar function icons
Press a function group

key to select a specific
range of functions.
Press a function key to

select a function group
or specific function.
Figure 4-3 Sidebar Function Selectors

4.1.5.1 Sidebar Icons Explained

Depending on how a machine is configured it may have numerous icons on the
sidebars. Each icon can represent a specific function, a function group, or some other
machine information. However, the sidebar icons have many common features. Refer
to Table 4-5 for a description of these features.
Table 4-5 Sidebar Icon Features
Icon Description
Function Group Selector

When this icon appears,
• It is always displayed at the top of the sidebar.
• It only appears if the operator presses the sidebar function
group selector key or when the machine starts.
• The icons displayed below always represent the various
function groups.
Function Group
1 2 This icon represents a group of related functions. When it
appears, it can
• Display below the function group selector on the sidebar to
indicate the function group can be selected.
• Display at the top of the sidebar to indicate the icons below
are all part of the same function group.
3 1 – Folder symbol indicates this is a function group.
4
2 – Type of function group (in this case, mold).
3 – Type of function (in this case, mold).
4 – Function group range of numbers.
Function
1 2
This icon represents a specific function within a function group (in
this case, mold functions). It can appear anywhere within one of
eight positions below the top one on the sidebar.
1 – LED symbol indicates function on or off.
2 – type of function group (in this case, mold).
3
4 3 – type of function (in this case, auto air).
4 – function number.
NOTE: Some function icons may display more or fewer graphic
elements than shown here.
4.1.5.2 Function Keys and Icon Relationships

The relationship between the sidebar function keys and the sidebar icons is easy to
understand if you think of the function group selector key as a doorway into a large
building with many rooms – each room representing a function group. Each function
group icon is a doorway into a single room that contains all of the functions in that

group. And each function icon represents a single function, or in some cases, machine
process information. The sidebar icons change depending on what function menu is
selected.
The following example (refer to Figure 4-4) describes how to access the manual mold
functions group and set the machine air to automatic.
1 Operator presses function group selector key

to display function groups.
2 Operator presses mold group function key

to display mold functions.
3 Operator presses auto air key to

set mold air on automatic.
5 LED in top left corner of

icon turns green to
indicate function is now
active.
4 Auto air icon background

turns yellow while
operator keeps key
pressed.
Figure 4-4 Sidebar Example
NOTE: Sidebar icons vary from machine to machine, depending on the machine’s
configuration and installed options. The only sidebar icons that remain
consistent from machine to machine are the process value and user
configurable sidebar icons, described below.

4.1.5.3 Process Value Icons

Unlike the other icons on the sidebar which allow the operator to start or stop a
machine function, the process value sidebar icons only display real-time machine
process values. When a process value icon is activated, it displays at the top of the
selected sidebar.
The examples below illustrate the clamp and injector process value icons. Refer to
Table 4-6 for details.
NOTE: Depending on how your machine is configured, the sidebars may display more
process value icons than those shown here.
Table 4-6 Process Value Icons
Icons Description
These icons display the real-time process values for the clamp
function while in run mode.
1 1 – Clamp position
2 – Clamp speed
3 – Clamp pressure
2 4 – Clamp tonnage.
These icons display the real-time process values for the injector
function while in run mode.
1 1 – Injector position
2 – Injector speed
3 – Injector pressure
2 4 – Injector rpm.

4.1.5.4 User Configurable Sidebars

The User Configuration function allows the operator to customize two sidebars (one on
each side of the screen) so that the operator can quickly access frequently used
functions.
For example, the operator might choose to set up machine air functions using the left
sidebar for auto functions and the right sidebar for manual functions. Each operator
has the ability to set up his or her own configurable sidebars.
Press the User Configuration button (as shown above) to display the current user
configuration for the user currently logged onto the machine. Refer to Figure 4-5 for
more information.
NOTE: The following illustrations use a large number of robot functions. These are
representative examples only. Your machine may have a completely different
set of functions to choose from.
1 1
2
2
3
3
Figure 4-5 User Configurable Sidebars

1. User configurable group 2. Function keys already configured by the operator
3. Blank function keys available to the operator 4. Access key for user configuration
screen

4.1.5.5 USER CONFIGURATION Screen

Press the User Configuration button to access the USER CONFIGURATION screen.
The screen is used to add, exchange and remove function icons from the user
configurable sidebars.
NOTE: The USER CONFIGURATION screen can only be accessed after selecting
the User (2) Configuration button.
Refer to Figure 4-6 for details.
5
4
2 3 7 8
6
Figure 4-6 USER CONFIGURATION Screen

1. Function groups appear in rows 2. Sidebar icons already assigned 3. Scroll bar
displays additional function groups, if required 4. Greyed out icons indicate functions are
assigned to user configurable sidebar 5. Colored icons indicate function is available for
assignment to a sidebar button 6. Help button 7. Information button 8. Recycle bin
The following table describes each of the icons on the user configurable screen.

Table 4-7 User Configurable Sidebar Buttons
Sidebar Function Group

Sidebar Sub-function Button Button Name
Button
Machine Function Group Ejector Auto
Clamp Monitoring Stroke Position
Stroke Speed
Stroke Pressure
Clamp Tonnage
Injection Monitoring Injection Position
Injection Speed
Injection Pressure
Screw RPM
Air Auto Air Auto
Air Auto
Air Auto
Air Auto

Table 4-7 User Configurable Sidebar Buttons
Sidebar Function Group

Sidebar Sub-function Button Button Name
Button
Air Manual On Air Manual On
Air Manual On
Air Manual On
Air Manual On
Screw Change Group Screw Release
Screw Engage
Injection Jog Forward
Injection Jog Back
4.1.5.6 Adding or Exchanging Function Icons

User configurable function icons can be added to or exchanged on the sidebars very
easily. Each operator can define eight function icons on the left sidebar and seven
function icons on the right sidebar.
To add a function icon, simply press a left or right function key where you want to place
the icon. The icon button’s blank background changes to yellow to indicate it is active
and ready to be configured. Press the desired icon that appears in the icon array in the
USER CONFIGURATION screen. The icon for that function immediately appears on
the sidebar button and its image in the icon array is greyed out to indicate it is
assigned.
To exchange an icon for another, simply press the function key where you want to
exchange an existing icon. The background changes to yellow to indicate it is active
and ready to be configured. Press the desired function icon in the array and it
immediately replaces the former function. Its image in the icon array is then greyed out
to indicate it is assigned. The replaced function returns to its original color in the array
to indicate it is available for reassignment.

Press the Exit button when the configuration is complete. A pop-up screen appears
asking you to confirm the changes.
NOTE: The pop-up confirmation screen will change if the operator is logged in using a
regular screen log on, or a datakey access log on. The example shown below
is for an operator using datakey access.
Figure 4-7 USER CONFIGURATION Confirmation Screen
4.1.5.7 User Configuration Help

Press the User Configuration Help button to display brief instructions on how to add,
exchange and delete functions from the user configurable sidebars.
4.1.5.8 Function Icon Information

Press the Information button to access a brief description of each function icon that
appears on the USER CONFIGURATION screen. When the operator presses the
information button the icon’s background turns yellow to indicate it is active. All greyed
out icons display their original colors while the information icon is active.
To display information about an icon simply press the icon and a pop-up screen
appears containing a brief description of the icon.
To return to the USER CONFIGURATION screen, press the Information icon. The
Information icon’s background returns to its original color and all assigned icons return
to a greyed out state.
4.1.5.9 User Configuration Recycle Bin

Select the Recycle Bin button to remove a function icon from the user configurable
sidebars. Select the sidebar icon you want to remove. Its background turns yellow.
Press the Recycle button. The function icon returns to its original color in the icon array
in the center of the screen. The function icon is now available for reassignment to any
sidebar button.

4.1.6 Main Screen

The operator uses the main screen to monitor the function of the machine and modify
any operating parameters.
The main screen is divided into six part.
• A message bar displayed across the top (1) – refer to Figure 4-8.
• A toolbar (2) – refer to Figure 4-8 and Figure 4-9.
• Main machine function screen (3).
• Screen tabs (4).
• A status bar displayed across the bottom (5).
• Sidebar function icons displayed down each side of the HMI screen (6) – refer to
Section 4.1.5 for details.
1 2 3 4
6 5 6
Figure 4-8 HMI Screen Parts

1. Message bar 2. Toolbar 3. Machine function screen 4. Tabs 5. Status bar
6. Sidebar function icons
The HMI features numerous function keys that border the screen. The screen itself is
touch-sensitive. Instead of a mouse or cursor keys the operator moves the cursor
arrow around the screen simply by light finger pressure on the screen. The operator
touches the screen to do the following.
• Open a tab from a main screen.
• Return to a main screen from a tab.
• Activate a field for input.
• Regular alphanumeric or numeric input fields automatically open either an
alphanumeric touchpad or a numeric touchpad.
• Drop-down boxes with preset values open with the list of selections.
• Start an action associated with an on-screen button.

NOTE: Each of these navigation actions is discussed in greater detail later in this
chapter.
4.1.6.1 Message Bar

The most current alarm message appears in the message bar. The operator uses the
ALARM screens and tabs to view a complete list of alarm messages, active cycle
information and related data.
4.1.6.2 Toolbar
The toolbar displays across the top of the screen just below the message bar. It allows
the operator to access many of the machine’s common administrative and control
functions. Some of these functions are described in greater detail in the following
topics. Refer to Figure 4-9.
1 2 3 4 5 6 7 8 9 10
Figure 4-9 Toolbar

1. Current screen group 2. Screen capture 3. Administrator 4. Calibration selector
5. Machine mode selector 6. Alarm horn off 7. HMI configuration 8. User log on / log
off 9. (Not activated in this version) 10. (Not activated in this version)
4.1.6.2.1 Screen Capture

The screen capture utility allows the operator to capture the current screen, then print
it or save it to a file.
Press the screen capture button to capture the screen. Each capture is identified at the
bottom of the captured screen with the machine’s serial number, model number, and a
description of the action being performed at the time of the capture.
Save Capture to File

Press the Save Capture to File button to save an image of the file. This is a useful
utility operators and administrators can use to help in preparing reports and auditing
machine performance. The HMI displays a dialog that allows the operator to:
• Select the directory where the image is stored.
• Define a name for the saved image
• Select the graphic format (i.e., jpeg, tiff, bmp) for the saved file.
Print Captured Image

Press the Print Captured Image button to print an image of the captured screen. The
HMI displays a print request screen that allows the operator to select a printer and
print the captured image.

4.1.7 Administrator Access

The HMI Administrator functions are used to manage the various users, user groups,
assigned rights and passwords needed to allow access to the machine. If the
administrator successfully logs in, the button shown below appears on the toolbar.
4.1.7.1 Users
The USERS tab allows the administrator to manage the various users and the groups
to which they are assigned within the HMI.
Press the Administrator button on the toolbar to display the ADMINISTRATOR
ACCESS screen at the USERS tab. Refer to Figure 4-10.
Figure 4-10 ADMINISTRATOR ACCESS – USERS Screen
Table 4-8 describes each screen element shown in Figure 4-10.
Table 4-8 ADMINISTRATOR ACCESS – USERS Screen Descriptions
Field Description
User Name Displays the user name selected in the User Name list box.
Full Name Displays the actual user name of the user selected in the User
Name list box.
(List Box) Displays all users in the HMI user Database.
HMI Users
Press this button to display all HMI users in the list box.
Press this button to create a new user account. Refer to

Section 4.1.7.2.

Table 4-8 ADMINISTRATOR ACCESS – USERS Screen Descriptions
Field Description
Press this button to change the full name of a current user.

NOTE: Click on the name of the user whose full name you want
to change or type the user’s name into the User Name
field. Make the change to the full name, then press the
Set Name button.
Press this button to remove a user from the HMI User database.
NOTE: The administrator must click on the name of the user to
be removed, or type the user’s name in the User Name
field before pressing the Remove button.
Member Of
Press this button to list all the HMI groups of which the selected
user is a member.
Press this button to remove the selected user from a selected

group.
NOTE: To use this function, the administrator must first choose
the user, list the groups the user is a member of, select a
group from the groups list, then press the Remove
button.
NT Users
Press this button to display all registered users in the local NT

User Management and Security database.
Press this button to add a user defined in the NT system to the

HMI system.

4.1.7.2 OPEN ACCOUNT Pop-up Screen

The OPEN ACCOUNT pop-up screen allows the administrator to create a new HMI
user account.
Press the Create button on the USERS tab of the ADMINISTRATOR ACCESS screen
to display this screen. Refer to Figure 4-11.
Figure 4-11 OPEN ACCOUNT Pop-Up Screen
Table 4-9 OPEN ACCOUNT Pop-Up Screen Descriptions
Field Description
User Name Enter the user name as it will appear on the HMI.
Full Name Enter the actual user’s name.
Password Enter the password the new user will need to log on to the
machine.
Confirm Password Re-enter the new user’s password.
Domain Enter the domain name defined for the machine if you connect
over a network.
NOTE: Local machine users should leave this field blank.
Save To DataKey Select this check box to save the new user name and password
information to the datakey.
NOTE: DataKey fields are activated only when a datakey is used
to access the machine. Refer to Section 4.1.7.3.
Load DataKey Press this button to load current user name and password
information from the datakey.

4.1.7.3 Programming the DataKey

To program an operator’s datakey, follow these instructions.
1. Log on as administrator.
2. Press the Administrator button on the toolbar to display the ADMINISTRATOR
ACCESS screen.
3. Select the USERS tab.
4. Remove the Administrator datakey from the machine.
5. Insert the operator’s datakey that needs to be programmed into the machine.
6. Program the datakey as required.
7. Remove the operator’s datakey.
8. Re-insert the administrator datakey.
9. Log off.
4.1.7.4 Groups
The GROUPS tab allows the administrator to manage the various groups, group
members and group rights defined within the HMI.
ACCESS screen, then select the GROUPS tab. Refer to Figure 4-12.
Figure 4-12 ADMINISTRATOR ACCESS – GROUPS Screen

Table 4-10 ADMINISTRATOR ACCESS – GROUPS Screen Descriptions
Field Description
Group Info
Group Name Displays the name of the currently selected group.
Comments Displays any comments assigned to the currently selected group.
HMI Groups
Press this button to display all HMI groups in the list box.
Press this button to create a new group account. Refer to

Section 4.1.7.5.
Press this button to change the comments defined for the

selected group.
NOTE: Select the group whose comment information you want
to change or type the group name into the Group Name
field. Make the change to the comment information, then
press the SetComm button.
Press this button to remove a group from the system.

NOTE: The administrator must select the name of the group to
be removed, or type the group name in the Group Name
field before pressing the Remove button.
Group Members
Press this button to list all users in the selected HMI group.
Press this button to add or remove users in the selected group.

For details, refer to Section 4.1.7.6.
NT Group Rights
Press this button to display all rights currently assigned to the

group displayed in the NT GroupName field.
Press this button to remove rights from a selected group.

4.1.7.5 CREATE NEW GROUP Pop-up Screen

The CREATE NEW GROUP pop-up screen allows the administrator to create a new
HMI group.
Press the Create button on the GROUPS tab of the ADMINISTRATOR ACCESS
screen to display this screen. Refer to Figure 4-13.
Figure 4-13 CREATE NEW GROUP Pop-Up Screen
Table 4-11 CREATE NEW GROUP Pop-Up Screen Descriptions
Field Description
New Group
Group Name Enter the group name as it will appear on the HMI.
Description Enter a comment or description to identify the group.
Members
(List Box) Lists all the members (users) assigned to the group.
Press this button to add a user to the selected HMI group. For
details, refer to Section 4.1.7.6.
Press this button to remove a user from the selected group.

NOTE: To use this function, the administrator must first choose
the user from the user list then press the Remove button.

4.1.7.6 ADD/REMOVE USER IN GROUP Pop-Up Screen

The ADD & REMOVE USER IN GROUP pop-up screen allows the administrator to
view and manage users in each defined HMI group account.
To access this screen, press the Add button on the CREATE NEW GROUPS screen.
Figure 4-14 ADD/REMOVE USER IN GROUP Pop-Up Screen
Table 4-12 ADD/REMOVE USER IN GROUP Pop-Up Screen Descriptions
Field Description
Users In Group Displays the name of the selected group.
(List Box) Lists all current members of the group.
Users
(List Box) Displays the user names and full names of all users not currently
assigned to the selected group.
Press this button to add a selected user to the group.
Press this button to remove a selected user from the group.

4.1.7.7 Rights
The RIGHTS tab allows the administrator to assign rights to users and groups and to
remove rights from users and groups.
NOTE: Only those rights currently defined in the HMI can be assigned or removed.
Rights cannot be created or deleted using this screen.
ACCESS screen, then select the RIGHTS tab. Refer to Figure 4-15.
Figure 4-15 ADMINISTRATOR ACCESS – RIGHTS Screen
Table 4-13 ADMINISTRATOR ACCESS – RIGHTS Screen Descriptions
Field Description
Right Info
Right Name Displays the name of the right currently highlighted in the Rights List
drop down box.
Comments Displays any comment or description associated with the right currently
highlighted in the Rights List drop down box.
Rights List Press the Rights List button to list all rights currently defined for the
HMI.

Table 4-13 ADMINISTRATOR ACCESS – RIGHTS Screen Descriptions
Field Description
User Rights
(User Rights drop Use this drop down list to select a user currently defined within the HMI.
down list)
User Rights List Press this button to display all rights currently assigned to the user
selected in the User Rights drop down box.
Assign User Press this button to assign additional rights to the user selected in the
Privilege User Rights drop down box.
Deny User Press this button to remove specific rights from the user currently
Privilege selected in the User Rights drop down box.
Group Rights
(Group Rights Use this drop down list to select a group currently defined within the
drop down list) HMI.
Group Right List Press this button to display all rights currently assigned to the group
selected in the Group Rights drop down box.
Assign Group Press this button to assign a new right to the group selected in the
Right Group Rights drop down box.
NOTE: Use the GROUPS tab to remove rights from a specific group.
4.1.7.8 Others
The OTHERS tab allows the administrator to change the password of the user
displayed in the User Name field.
NOTE: This screen enables the administrator to change a user’s password without
having to know the user’s current password. This function can be used to
permit access to users who have forgotten their passwords, or to "lock out" a
user to prevent machine access.
ACCESS screen, then select the OTHERS tab. Refer to Figure 4-16.

Figure 4-16 ADMINISTRATOR ACCESS – OTHERS Screen
Table 4-14 ADMINISTRATOR ACCESS – OTHERS Screen Descriptions
Field Description
Change Password
User Name Enter the user’s name currently recognized by the HMI.
Password Enter the new password for the user.
Domain Enter the domain only if you are connecting over a network.
NOTE: Local machine users should leave this field blank.
Press this button to change the password for the selected user.
Press this button to cancel the change in password for the

selected user.
Update DataKey Select the check box to save the new user name and password
information to the datakey.
NOTE: DataKey fields are activated only when a datakey is used
to access the machine. Refer to Section 4.1.7.3.

4.1.8 Calibration
The calibration utility allows the user to calibrate machine components. This includes
calibration for clamp, ejector, injection, and carriage.
To open the main calibration screen, press the Calibration button on the toolbar, then
press the required calibration button to display the specific calibration sub-screen.
Refer to Figure 4-17 for more details.
NOTE: Some of the above calibration items are optional and may not be installed on
the machine.
1 2 3 4
Figure 4-17 Main Calibration Screen

1. Clamp calibration 2. Ejector calibration 3. Injection calibration 4. Carriage
calibration 5. Cavity pressure calibration
NOTE: Some components may not be capable of calibration. If so, the button is
displayed with a large "X" as shown in the illustration. This could occur if the
component is already calibrated, if the component is calibrated automatically,
or if the machine is in a particular mode or cycle that prevents the component
from being calibrated.
For details on calibration, refer to Chapter 7—Maintenance.

4.1.9 Machine Function Mode Selector

There are six machine function modes that allow the operator to select the type of
machine operation. The machine function modes can be selected by pressing the
appropriate button on the Machine Function Mode selector menu on the toolbar.
Table 4-15 describes the various machine function modes.
Table 4-15 Machine Function Modes
Function
Button Function
Mode
Normal Machine must be in Normal mode to run production.

When this function mode is selected, the <SEMI>,
<AUTO>, and <MANUAL> cycle keys are functional.
Dry Cycle Use the Dry Cycle mode to cycle the clamp regardless of
machine temperature. Injection is disabled. When this
function mode is selected, the <SEMI>, <AUTO>, and
<MANUAL> cycle keys are functional.
Auto Purge Use the Auto Purge to automatically purge the barrel.
Clamp is disabled. When this function mode is selected,
the <SEMI>, <AUTO>, and <MANUAL> cycle keys are
functional.
Mold Set Use the Mold Set mode to operate the machine at
reduced speed and pressure during mold installation.
When this function mode is selected, only the
<MANUAL> cycle key is functional.
Unload All Use the Unload All Pumps mode to redirect the flow from
Pumps the hydraulic pumps back to the tank, at low pressure.
When this function mode is selected, none of the cycle
keys are functional.
Screw Use the Screw Change mode to operate the extruder

Change motor at reduced speed during plasticizing screw
replacement. When this function mode is selected, only
the <MANUAL> cycle key is functional.
4.1.10 HMI Configuration

The HMI Configuration button opens a multi-tabbed screen the operator can use to
control a range of machine setup and configuration information. This includes the
following.
• Define a new password.
• Select display units.
• Select a language.
• Define shift start times.
• Set the time and date.
• Control remote monitoring and alarm messaging.

4.1.10.1 Password
Press the HMI Configuration button to display the HMI CONFIGURATION screen at
the PASSWORD tab. Refer to Figure 4-18.
Figure 4-18 PASSWORD Tab
Table 4-16 HMI Configuration – PASSWORD TAB Field Descriptions
Field Description
User Name Enter the user name.
Old Password Enter the old password.
New Password Enter the new password.
Confirm Password Enter the new password again.
Press to save the new user name and password information to the
datakey.
NOTE: DataKey fields are activated only when a datakey is used to
access the machine.
Save to DataKey Select this checkbox to enable the Save to DataKey button shown
above.
Load Datakey Press this button to load current user name and password information
from the datakey.

4.1.10.2 Units
Press the HMI Configuration button to display the HMI CONFIGURATION screen then
press the UNITS tab. Refer to Figure 4-19.
Figure 4-19 UNITS Tab
Table 4-17 HMI Configuration – UNITS TAB Field Descriptions
Field Description
Unit System Selection
SI–System Select this option button to use metric (System International) units
exclusively. Note that the fields in the UNITS area are greyed out when this
button is active.
Imperial– Select this option button to use Imperial units exclusively. Note that the fields
System in the UNITS area are greyed out when this button is active.
Custom– Select this option button to select a custom assortment of measurement units
System from the UNITS area of the tab.
Special Unit Settings
Process Select this check box to display all process type variables as process values
(e.g., mm, cubic cm, etc.)
Units
Distance Select the type of unit for distance displays (Metric or Imperial).
Pressure Select the type of unit for pressure displays (Metric or Imperial).
Temperature Select the type of unit for temperature displays (Metric or Imperial).

Table 4-17 HMI Configuration – UNITS TAB Field Descriptions
Field Description
Tonnage Select the type of unit for tonnage displays (Metric Tonnes, US tons, or
Imperial).
Update Press this button to update the current unit data on the datakey.
Datakey NOTE: DataKey fields are activated only when a datakey is used to access
the machine.
4.1.10.3 Language
press the LANGUAGE tab. Refer to Figure 4-20.
Figure 4-20 LANGUAGE Tab
Table 4-18 HMI Configuration – LANGUAGE TAB Field Descriptions
Field Description
Language Select the appropriate language input to change all screen displays to
the selected language.
Update Datakey Press this button to update the current language data on the datakey.
NOTE: DataKey fields are activated only when a datakey is used to
access the machine.

4.1.10.4 Shifts
press the SHIFTS tab. Refer to Figure 4-21.
Figure 4-21 SHIFTS Tab
Table 4-19 HMI Configuration – SHIFTS TAB Field Descriptions
Field Description
2 Shifts Select this option button to display only fields for two shifts.
3 Shifts Select this option button to display fields for three shifts.
1st Enter the start time for the first operator shift. Enter time in 24 hour format.
Example, 14:30 for 2:30 PM.
2nd Enter the start time for the second operator shift. Enter time in 24 hour
format.
3rd Enter the start time for the third operator shift. Enter time in 24 hour format.

4.1.10.5 Printer
press the PRINTER tab. Refer to Figure 4-24.
Figure 4-22 PRINTER Tab
Table 4-20 HMI Configuration – PRINTER TAB Field Descriptions
Field Description
Add Printer Double-click on this icon to add a new printer.
No Connection Window Select this box to enable/disable the Windows printer wizard.
When Add Printer
Show Print Dialog Box Select this checkbox to show the printer dialog box.
When Printing
Delete Printer Click this button to delete the selected printer.
Set Default Printer Click this button to set the selected printer as the default printer.
Default Printer The default printer is displayed in this field.
Background Printing
Click this button to save all screens to floppy disk or removal USB
storage drive (if equipped).
Click this button to print all screens to the default printer.
Click this button to configure your printer settings. Refer to

Section 4.1.10.5.1 for details.

4.1.10.5.1 Background Printing Configuration Screen

The BACKGROUND PRINTING CONFIGURATION screen allows the administrator to
select files for printing in the background. Refer to Figure 4-23.
Figure 4-23 BACKGROUND PRINTING CONFIGURATION Screen
Table 4-21 describes each element shown in Figure 4-23.
Table 4-21 BACKGROUND PRINTING CONFIGURATION Screen Descriptions
Field Description
Screen Print Select this check box if you would like to print the whole screen, including
the toolbar and sidebars, in the background.
NOTE: You can double-click the Print All label to view a drop-down list of
all HMI screens. You can then select the screens you wish to print
in the background.
Print All Select this check box if you would like to print all the HMI screens, without
the toolbar and sidebars, in the background.
NOTE: You can also double-click the Print All label to view a drop-down
list of all HMI screens, then select only those screens you wish to
print in the background.

4.1.10.6 Remote
press the REMOTE tab. Refer to Figure 4-24.
Figure 4-24 REMOTE Tab
Table 4-22 HMI Configuration – REMOTE TAB Field Descriptions
Field Description
Remote Connection
Enable Select this option button to enable remote connection.

NOTE: Select ConnectionType option button prior to selecting this
field.
Disable Select this option button to disable remote connection.

NOTE: Select Connection Type option button prior to selecting this
field.
Connection Type
Modem Select this option button to communicate with Husky by modem.

NOTE: Connect the modem to the COM port, communication line and
power source prior to selecting this button.
TCP/IP Select this option button to communicate with Husky by TCP/IP.
Computer Information
Computer Name Displays the computer name.
TCP/IP Address Displays the TCP/IP address.

4.1.10.7 Saving and Restoring Machine Backups

press the BACKUP tab. Refer to Figure 4-25. If the HMI is unable to start up, double-
click the icon Shortcut to Restore.exe on the desktop to begin the restore procedure.
NOTE: You must have access rights to backup and restore machine data.
Figure 4-25 BACKUP Screen
Table 4-23 HMI Configuration – BACKUP TAB Field Descriptions
Field Description
Backup Destination Enter a backup file destination folder name. The backup function will
Folder automatically create an additional folder using the machine serial
number as the folder name and create a backup file in the folder.
NOTE: The destination location can be either a network location or
floppy disk.
Restore Source File Enter an existing backup file destination and name.
NOTE: The existing backup file must be a backup file from the same
machine with the same software version.
Backup Schedule Select the check box to determine the backup day of the week. Then
enter the start time.
Number of Backups Set the number of backups from 1-10.

NOTE: The default is 5.
Backup Press this button to backup machine data.
Restore Press this button to restore machine data.

NOTE: The machine must be calibrated after restoring machine data
from backup.

4.1.10.8 Others
press the OTHERS tab. Refer to Figure 4-26.
Figure 4-26 OTHERS Tab
Table 4-24 HMI Configuration – OTHERS TAB Field Descriptions
Field Description
Settings
Show Title Bar NOTE: Select this checkbox to display the Windows NT title bar at
the top of the screen.
Stop Reason NOTE: Press this button to display the OPERATOR STOP
Configuration REASONS screen. This utility allows the administrator to
define various user groups and reasons within those groups
as to why a machine has been stopped. Refer to "Operator
Stop Reason Utility" on Section 4.1.10.8.1.
Clear Active Alarms Press this button to clear all inactive alarms.
Time
Time NOTE: Displays the current time in HH:MM:SS format. Only the
administrator can change these values.
Date Displays the current date in YY:MM:DD format. Only the administrator
can change these values.
4.1.10.8.1 Operator Stop Reason Utility

The Operator Stop Reason utility allows the administrator to define various user
groups and reasons within those groups as to why a machine has been stopped (i.e.,
lunch, maintenance down time, mold change, etc.).
The utility consists of the following two screens.
• The main OPERATOR STOP REASON screen.

• The individual reasons definition screen within each group.

You can define up to 12 stop reasons groups and up to 12 stop reasons definitions
within each group. The individual stop reasons definitions are nested below the
defined reason group, so you need to open the group before you can edit or add a
definition to the group.
4.1.10.8.2 Using the OPERATOR STOP REASON Utility

Press the Stop Reason Configuration button on the OTHERS tab of the HMI
CONFIGURATION screen. The HMI displays the OPERATOR STOP REASONS
screen – refer to Figure 4-27.
Figure 4-27 OPERATOR STOP REASON Screen
Table 4-25 OPERATOR STOP REASONS Screen Descriptions
Field Description
(1) Reason This part of the screen displays the currently defined Reason Groups. Up to
Groups 12 groups can be defined on this screen.
Press this button (the button background turns yellow to indicate it is active)
then select a group button to edit the name of the group.
Press this button to add a new reason group to the screen. Refer to
Section 4.1.10.8.3.
Press this button (the button background turns yellow to indicate it is active)
then select the button of a group that you want to delete. The group button is
immediately removed from the screen.
NOTE: Removing a group button also removes all reasons associated with
the group.

4.1.10.8.3 Using the Stop Reason Definition Screen

With the OPERATOR STOP REASON screen displayed, press the button for the
particular group you want to edit. The HMI displays the individual reasons screen for
that specific group. Refer to Figure 4-28.
Figure 4-28 STOP REASON DEFINITONS Screen
Table 4-26 OPERATOR STOP REASON Screen Descriptions
Field Description
(1) Stop This part of the screen displays the currently defined stop reasons for the
Reasons selected Group. Up to 12 reasons can be defined for a group.
Press this button (the button background turns yellow to indicate it is

active) then select a reason button to edit the name of the reason.
Press this button to add a new reason to the group.
Press this button (the button background turns yellow to indicate it is

active) then select the button of a reason that you want to delete. The
reason button is immediately removed from the screen.
Press this button to close the screen and return to the OPERATOR
STOP REASONS screen.

4.1.11 User Log On

The User Log On button opens a pop-up screen the operator can use to sign on to the
machine’s control system. Refer to Figure 4-29.
Figure 4-29 USER LOG ON Screen
Table 4-27 USER LOG ON Field Descriptions
Field Description
User Name Enter the user name or ID.
Password Enter the password.
Domain Enter the domain name only if connecting over a network.
Press the Submit User Log On button to start the log on when all information is
entered into the screen fields.
4.1.12 User Log Off

The User Log Off button appears on the toolbar once the user is logged on. Press the
button to log off the HMI.
4.1.13 On-Line Manual

The On-Line Manual is not operational in this version.

4.1.14 Status Bar

The status bar displays across the bottom of the screen and shows the operator the
machine’s status information at a glance. Refer to Figure 4-30.
2 3 4 5 6
Figure 4-30 Status Bar

1. Cycle Mode indicator 2. Machine cycle time 3. Oil temperature (see note below)
4. Current user name 5. Current date 6. Current time
NOTE: The thermometer in the Oil Temperature area is color coded as follows:
• Blue = Low
• Green = Normal
• Red = High
4.1.15 Screen Keys

There are nine main screen groups accessed using the screen keys. Refer to
Figure 4-31. The keys named F10 to F12 are reserved for future functions. Each
screen group has several screens (also referred to as "tabs" throughout this manual).
Figure 4-31 Screen Keys
Use the appropriate screen key to select a screen group, then press the tab on the
touch-sensitive panel to display the appropriate screen. Table 4-28 describes the
screen groups and tabs. Screen groups and tabs shown in brackets are optional items.

Table 4-28 Machine Screens
Screen Screen
Screen/Tab Name To View the Screen
Key Group
ALARMS Press <ALARMS> key to display the

ALARMS screen.
EVENTS Press <ALARMS> key and select the tab to

Alarms HISTORY display the EVENTS HISTORY screen.
REPORTS Press <ALARMS> key and select the tab to

SELECTION display the REPORTS SELECTION screen.
REPORT VIEW Press <ALARMS> key and select the tab to

display the REPORT VIEW screen.
LOG TRANSFER Press <ALARMS> key and select the tab to

display the LOG TRANSFER screen.
MACHINE Press <MACHINE> key to display the

SPECIFICATIONS MACHINE SPECIFICATIONS screen.
CYCLE TIME Press <MACHINE> key and select the tab to

Machine BREAKDOWN display the CYCLE TIME BREAKDOWN
screen.
GRAPH Press <MACHINE> key and select the tab to

display the GRAPH screen.
PRODUCTION Press <PRODUCTION> key to display the

SETUP PRODUCTION SETUP screen.
MOLD SETUP Press <PRODUCTION> key and select the

Production tab to display the MOLD SETUP screen.
MOLD Press <PRODUCTION> key and select the

INSTALLATION tab to display the MOLD INSTALLATION
screen.
OVERVIEW Press <CLAMP> key to display the

OVERVIEW screen.
Clamp SETUP Press <CLAMP> key and select the tab to
display the SETUP screen.
GRAPH Press <CLAMP> key and select the tab to

display the GRAPH screen.
VALVES STATUS Press <CLAMP> key and select the tab to

display the VALVES STATUS screen.

Screen Screen
Key Group
EJECTOR/CORE Press <MOLD FUNCTIONS> key to display

the EJECTOR/CORE screen.
EJECTOR SETUP Press <MOLD FUNCTIONS> key and select

the tab to display the EJECTOR SETUP
Mold screen.
Functions AIR Press <MOLD FUNCTIONS> key and select
the tab to display the AIR screen.
VALVE GATES Press <MOLD FUNCTIONS> key and select

the tab to display the VALVE GATES
screen.
OVERVIEW Press <INJECTION> key to display the

INJECTION screen.
INJECTION Press <INJECTION> key and select the tab

to display the INJECTION screen.
Injection INJECTION Press <INJECTION> key and select the tab
GRAPH to display the INJECTION GRAPH screen.
RECOVERY Press <INJECTION> key and select the tab

to display the RECOVERY screen.
RECOVERY Press <INJECTION> key and select the tab

GRAPH to display the RECOVERY GRAPH screen.
VALVES STATUS Press <INJECTION> key and select the tab

to display the VALVES STATUS screen.
BARREL Press <HEATS> key to display the BARREL

screen.
(MOLD) Press <HEATS> key and select the tab to

display the optional MOLD screen.
Heats (NOZZLE TIPS) Press <HEATS> key and select the tab to
display the optional NOZZLE TIPS screen.
(THERMOLATOR) Press <HEATS> key and select the tab to

display the optional THERMOLATOR
screen.
(Product – –
Handling)

Screen Screen
Key Group
(SUMMARY) Press <SPC> key to display the optional

SUMMARY screen.
(DETAILS) Press <SPC> key and select the tab to

display the optional DETAILS screen.
(HISTORY) Press <SPC> key and select the tab to

display the optional HISTORY screen.
(SPC)
(GROUP) Press <SPC> key and select the tab to
display the optional GROUP screen.
(SETUP) Press <SPC> key and select the tab to

display the optional SETUP screen.
(CTRL LIMITS) Press <SPC> key and select the tab to

display the optional CTRL LIMITS screen.
4.1.16 Manual Function Keys
Figure 4-32 Manual Function Keys
The manual function keys permit individual machine functions when the machine is in
Manual cycle mode. In Manual mode, all function keys only operate as long as the
keys are held down. Some manual function keys can be latched to run in Semi or Auto
cycle modes. Each manual function key has a LED indicator which lights up when the
function is enabled. A flashing LED indicates that the function has been completed.
Table 4-29 describes the manual function keys.
Table 4-29 Manual Function Keys
Key Function
Press the <MOLD OPEN> key to open the mold. Mold travels only while
button is pushed
Green light on - Mold is moving and at fully open position.
Press the <MOLD CLOSE> key to close the mold. Mold travels only while
button is pushed.
Green light on - Mold is moving and at fully closed position.

Table 4-29 Manual Function Keys
Key Function
Press the <UNCLAMP> key to retract the clamp piston and disengage the
shutter. Clamp travels only while button is pushed
Green light on - Clamp is moving and at clamp home position.
Press the <CLAMP UP> key to engage the shutter. Clamp travels only while
button is pushed
NOTE: Ensure the mold is in the closed position prior to clamping up.
Green light on - Clamp is moving and at fully closed position with tonnage
applied.
Press the <EJECTOR BACK> key to retract the mechanical ejector in

Manual mode. Ejector moves only while button is pushed.
Green light on - while moving and when at back position.
NOTE: Enable for Auto mode.
Press the <EJECTOR FORWARD> key to extend the mechanical ejector in

Manual mode. Ejector moves only while button is pushed.
Green light on - while moving and when at forward position.
Press the optional <MOLD COOLING> key to open and close the mold
cooling water valve.
Green light on - water flow to mold for cooling.
Press the optional <VALVE GATE OPEN> key to open the mold valve gate.
Momentary push of button moves valve to open position. Momentary push
of button moves valve to closed position.
Green light on - valve gate open.
Press the <INJECT> key to move the injection piston and screw forward.
Green light on - only while moving.
NOTE: The optional nozzle shutoff valve opens if it is selected.
Press the <SCREW ROTATE> key to rotate the screw and plasticize.
Push of button starts the screw rotating.
Release of button stops the screw rotating.
Green light on - only while pressing push button.
Press the <CARRIAGE FORWARD> key to move the injection carriage

forward.
Carriage moves only while button is pushed.
Green light on - only while carriage is moving.
Press the <CARRIAGE BACK> key to move the injection carriage back.
Carriage moves only while button is pushed or when gate is opened.
Green light on - only while carriage is moving if selected.

4.1.17 Common Screen Elements

Many HMI screens and tabs use similar fields and screen control elements throughout
the interface. The topics from here to the end of the chapter describe these common
fields and elements.
4.1.17.1 Field Types

There are several types of fields that can appear on the screens and tabs. Table 4-30
summarizes the different field types and their features.
Table 4-30 Field Type Descriptions
Entry type/ Background

Field Type Features
display Color
Input Alphanumeric White The operator uses either a pop-up numeric

or numeric or alphanumeric touchpad to enter a value.
The system checks the input value for invalid
characters and range. If the operator does
not have sufficient access privileges, the
input field is greyed out.
Input Drop-down box White The input value can be selected from a pre-
determined value within a set range.
Input Slider White stripe The slider allows the operator with limited
down the access rights to modify certain setpoint
middle of the values. Press the Up or Down arrow to
slider when it increase or decrease the setpoint value. The
is active slider has a range of 20 steps – 10 up and 10
down.
Calendar Pop-up n/a
Timeset Select n/a
Process Alphanumeric Light Grey A process field displays the value from the
current cycle.
Log Alphanumeric Dark Grey A log field displays a value from the previous
cycle.

4.1.17.2 Alphanumeric Touchpad

When the operator touches an alphanumeric input field, an alphanumeric touchpad
opens on screen. The operator touches each character and numeral in sequence as
required and then presses the Enter key to complete the entry. The touchpad then
closes automatically. Refer to Figure 4-33 for details.
10
3
9
7 8
6
Figure 4-33 Alphanumeric Touchpad

1. Field name 2. Alphanumeric display 3. Touch sensitive keys 4. Shift key
5. Reserved for future use 6. Reserved for future use 7. Reserved for future use
8. Space bar 9. Enter key 10. Backspace key
4.1.17.3 Numeric Touchpad

When the operator touches a numeric input field, a numeric touchpad opens on
screen. The operator touches each numeral in sequence as required and then presses
the Enter key to complete the entry. The touchpad then closes automatically. Refer to
Figure 4-34 for details.
NOTE: The background color for the numeric input field turns yellow on the screen to
indicate it is the field being edited.

1
2 9
3
6
10
4
5
Figure 4-34 Numeric Touchpad

1. Field name 2. Numeric display 3. Touch sensitive keys 4. Toggle between positive
and negative integer 5. Enter key 6. Field value spin buttons 7. Minimum field value
8. Maximum field value 9. Clear 10. Exit to Previous Screen
NOTE: The spin buttons in the above illustration allow the operator to press once to
increase or decrease the field value by one, or to press down and hold to
rapidly increase or decrease the displayed field value.
4.1.17.4 Calendar Touchpad

When the operator touches a drop down calendar field, a calendar touchpad opens on
screen. The operator touches the desired date to set it and the touchpad then closes
automatically. Refer to Figure 4-35 for details.
1 3
Figure 4-35 Calendar Touchpad

1. Previous month 2. Current machine date setting 3. Following month 4. Selected
HMI date (i.e., machine process/function date) 5. Current calendar date

4.1.17.5 Timeset Touchpad

Many screens utilize timeset fields the operator can use to set the time for a particular
action or machine event. The operator touches different areas of the timeset field to
modify the current time value. Refer to Figure 4-36 for details.
3 5
4 6
Figure 4-36 Timeset Touchpad

1. Spin buttons 2. Time format 3. Select hours 4. Select minutes 5. Select
seconds 6. Select a.m. or p.m.
NOTE: The spin buttons in the above illustration allow the operator to press once to
increase or decrease the field value by one, or to press down and hold to
rapidly increase or decrease the displayed field value.
4.1.17.6 Color Adjustment

The COLOR screen allows the operator to modify background and foreground colors
and other screen display elements – especially in machine function graph screens.
Refer to Figure 4-37 for details.
Select a color from the basic palette, or define a custom color. Press OK to close the
screen and return to the HMI.
Figure 4-37 COLOR Screen

1. Basic color palette 2. Custom color setup 3. Custom color storage

4.1.17.7 Common Buttons

Many HMI screens and tabs contain the same type of button which can be used to
perform a specific action. Table 4-31 summarizes the common buttons and their
features.
Table 4-31 Common Button Descriptions
Button Function
Press Exit button to close the active screen or pop-up and return to the
previous screen.
Press Information button to display additional information about a

particular function or screen element.
Press Expand View button to zoom in for a larger view of a machine

function or operation. This larger view often includes additional
controllers and machine information.
Press Recycle button to send the selected item to the trash.
Press Stop button to end a machine process or calibration function.
Press Help button to display the online help system.

NOTE: The online help system may not be fully integrated with the
machine you are currently running.
Press Reset button to return all screen settings and values to the original
(default) values.
Press Accept button to confirm a change to machine information.
Press Cancel button to cancel a change to the machine information.

4.1.18 User Access

User access to machine operation is restricted to one of two methods.
• Log on via user name and password. Refer to Section 4.1.11.
• Log on via datakey. Refer to Section 4.1.18.3.
Access to various machine functions is further restricted through the use of "user
rights". When a user is logged on, a right defines the permission a user has to execute
a specific machine function or access a particular machine resource.
NOTE: The administrator can assign a user one or more rights depending on the
user’s access requirements.
The rights categories are summarized below in Table 4-32.
Table 4-32 User Rights Summary
Operator Level
Operator Level
Administrator
Maintenance
View Only
Processor
Rights Level – Description
2
View operator screens 9 9 9 9 9 9
Adjust sliders, plus limited access to certain 9 9 9 9 9
machine functions
Change operator setpoints 9 9

Change process setpoints 9
Calibrate machine 9
Switch languages and units 9 9 9 9 9
Manage machine users and rights 9
Recall mold setup parameters 9
Change machine 9 9
Change date and time formats 9 9 9
Set shifts 9 9
Install molds 9 9
To operate the machine each user must have a user account on the machine with
sufficient access rights. A system administrator should be able to set up user
accounts. Refer to Section 4.1.10 for details.
NOTE: If you do not have sufficient access rights, some fields and buttons on the HMI
screen will disappear, or will be greyed out.

4.1.18.1 Default Settings

Each machine ships from Husky with all rights activated. It is the responsibility of the
administrator to set up the appropriate rights levels for all personnel who will operate
and manage the machine.
4.1.18.2 Default User Names and Passwords

Each machine ships from Husky with the following default user names and passwords
– refer to Table 4-33. It is the responsibility of the administrator to set up the
appropriate user names and passwords for all personnel who will operate and manage
the machine.
Table 4-33 Default User Names and Passwords
User Default User Name Default Password
Administrator hmiadministrator hmiadmnhmi
Operator operator 123
NOTE: All user names and passwords are lower case.
4.1.18.3 DataKey Access

Each machine ships from Husky with two datakeys – an administrator key and an
operator key.
Each datakey can be programmed to remember a user’s name, password, language
and other customized machine information (e.g., sidebar setup, material process
information, user rights assigned by the administrator, etc.). The datakey is slipped
upward into the special slot at the bottom right hand side of the control panel. This logs
in the user and resets the machine to the parameters defined on the datakey. Refer to
Figure 4-38.
NOTE: Only datakeys originally programmed by Husky can be reprogrammed by the
customer.
NOTE: The datakey must remain in the machine during operation. Removing the key
will prevent the user from making any changes to the machine and will only
allow the user to view machine screens.

Figure 4-38 Control Panel

1. Datakey
Additional datakeys can be ordered from Husky as required.

Machine Manual Starting Machine
Chapter 5 Starting Machine
5.1 Powering Up
Power up the machine using the following instructions.
CAUTION!
following sequence: Q1M (1), Q2M (3, if equipped) and finally, Q3M (2). Refer to
Figure 5-1.
2
3
1
S01-101110.eps
Figure 5-1 Powering Up (Typical)

1. Main machine breaker Q1M 2. Main machine breaker Q3M 3. Mold heats breaker
Q2M
NOTE: On machines shipped to Europe with integrated mold heats, the main
breaker controls both the machine and mold heats power.
v 4.11.1 — March 2007 5–1 Powering Up

2. After the PC boots up, the automation software starts up, and the PATENT screen
is displayed. A progress indicator on the PATENT screen updates as the system
initializes. When initialization is complete, press the button (1) on the screen to
continue. Refer to Figure 5-2.
Figure 5-2 Patent Screen

1. Continue button
3. Check the air supply is turned on. If necessary, turn the shutoff lever (1) to turn on
the air supply. Refer to Figure 5-3.
Check air pressure is approximately 0.6 MPa (90 psi).
1
S01-101075.eps

1. Shutoff lever
Powering Up 5–2 v 4.11.1 — March 2007

5.2 Logging On
Access to machine functions is restricted through user name and password, or

datakey. To log on to the machine using a user name and password refer to step 1. To
log on to the machine using a datakey refer to step 2.
NOTE: You must have sufficient access rights to perform the procedures described in
this chapter.
1. If you have a user name and password, press the User Log On button on the
Toolbar to display a pop-up screen. Refer to Figure 5-4.
Enter the user name and password. If the machine is connected to a network,
enter the NT network account in the Domain field; otherwise leave the field blank.
Then press the Submit button (1).
Figure 5-4 User Log On Screen

1. Submit button
2. If you have a datakey (1), insert it into the slot (2) at the bottom of the HMI to log
on. Refer to Figure 5-5.
NOTE: The datakey must remain in the slot to access machine functions.
After logging on to the machine, refer to Section 5.3.
Figure 5-5 Datakey

1. Datakey 2. Datakey slot
v 4.11.1 — March 2007 5–3 Logging On

5.3 Checking Safety Devices
The machine is equipped with a number of safety devices designed to ensure the
safety of the operator. The safety devices are: emergency stop button, front operator’s
gate and rear guard, mechanical safety device, automatic dump valve, manual dump
valve and purge guard.
Check all safety devices using the following instructions.
5.3.1 Emergency Stop Button

Check the Emergency Stop using the following instructions.
1. Press the <PUMP MOTOR ON> key to restart the pump.
2. Push the <EMERGENCY STOP> button to activate the Emergency Stop – refer to
Figure 5-6.
S01-101089.eps
S01-101063.eps
1 2
Figure 5-6 Emergency Stop Button (Typical)

1. Pushing the Emergency Stop button 2. Resetting the Emergency Stop button
3. Check that the pump motor stops, and all machine motion stops.
4. Check that the ALARMS screen displays the Emergency Stop alarm in red.
5. Pull the to button to reset the Emergency Stop (Figure 5-6).
6. Check that the Emergency Stop alarm is disabled. The alarm message on the
screen will change color from red to white when the alarm is disabled.
Checking Safety Devices 5–4 v 4.11.1 — March 2007

5.3.2 Front Operator’s Gate and Rear Guard

Check the front operator’s gate and rear guard using the following instructions:
1. Open the front operator’s gate and rear guard – refer to Figure 5-7.
2. Check the ALARMS screen displays the messages "Gate Open" and "Guard
Open".
NOTE: The limit switches must be tripped before the alarm can be reset.
3. Close the front operator’s gate and rear guard and check that alarms are inactive.
S01-101113.eps
Figure 5-7 Front Operator’s Gate and Rear Guard (Typical)
5.3.3 Mechanical Safety Device

Check the gates using the following instructions.
1. Open the front operator safety gate.
2. Check the mechanical safety device (drop bar) is extended – refer to Figure 5-8.
3. Check the indicator lights on the solenoid valve and proximity switch are switched
off.
4. Close the front operator safety gate Check that the mechanical safety device is
retracted.
v 4.11.1 — March 2007 5–5 Checking Safety Devices

Y195SV
S4PX
S01-101044.eps
Figure 5-8 Mechanical Safety Device
5.3.4 Automatic Dump Valve

The automatic dump valve discharges all system pressure from the accumulator when
the <PUMP MOTOR OFF> key is pressed.
1 Hydraulic pressure gauge suitable to 210 bar (3000 psi) with quick-disconnect
Check the automatic dump valve using the following instructions.

for specific location (1). Attach a hydraulic pressure gauge (2) to the gauge port –
3. Allow the pumps to run for a minute or so to build up system pressure.
4. Press the <PUMP MOTOR OFF> key.
5. Check the gauge to verify that the accumulator is fully discharged.
6. Leave the gauge in place for the next check.

S01-101036c.eps
2
Figure 5-9 Power Manifold (Typical)

1. Power manifold assembly 2. Pressure gauge 3. Manual dump valve
5.3.5 Purge Guard

The purge guard protects the operator from molten spray discharged from the injection
nozzle. A limit switch monitors the purge guard, and triggers an alarm when the purge
guard is opened.
Check the purge guard using the following instructions.
1. Open the purge guard (1) – refer to Figure 5-10. Check the ALARMS screen
displays the message “Purge Guard Open”.
2. Close the purge guard, and check the “Purge Guard Open” alarm is disabled.
NOTE: The limit switch must be tripped before the alarm can be reset.

S01-100769a
S01-101045a.eps
RS22–RS40
RS45–RS155
Figure 5-10 Purge Guard (Typical)

1. Purge guard
After checking safety devices, refer to Section 5.4.
5.4 Oil Warming
Warm up the hydraulic oil in the machine using the following instructions.
1. Press the <MANUAL> cycle key.
2. Press the Machine Function Mode Selector on the toolbar, and select the Mold Set
button.
3. Press <PUMP MOTOR ON> key to start the hydraulic pumps.
The hydraulic pumps are unloaded until oil temperature is above 45.5°C (114°F).
NOTE: The operator safety gates must be closed for the pumps to run.
4. Check the oil temperature (1) on the status bar – refer to Figure 5-11. Table 5-1
outlines oil temperature screen messages and required actions.
Figure 5-11 Status Bar

1. Oil Temperature
Oil Warming 5–8 v 4.11.1 — March 2007

Table 5-1 Oil Temperature Summary
Temperature
Screen Message Action
°C °F
> 60 > 140 Oil Temperature Too High for Finish cycle or 5 minutes -
Operation – Pump Off whichever comes first. Stop
pump load. Stop pump.
58 - 60 136 - 140 Oil Temperature Too High for 5 minute timer. Finish cycle
Auto Cycle – Auto Cycle Will when timer expires.
Be Disabled in 5 minutes
Oil Temperature Too High for Pumps remain running. Manual

Auto Cycle motion permitted.
55 - 58 130 - 136 Oil temperature Too High for 30 minute timer. Finish cycle
Auto Cycle – Auto Cycle Will when timer expires.
Be Disabled in 30 Minutes
Oil Temperature Too High for Pumps remain running. Manual

Auto Cycle motion allowed.
53 - 55 127 - 130 High Oil Temperature No action. Screen message

appears to alert of potential
problem.
47 - 53 116 - 127 None Acceptable Operating Range
45 - 47 113 - 116 Oil Temperature Low Oil warming in Manual mode.
5 - 45 41 - 113 Oil Temperature Too Low – in Manual and Auto Cycle not
Oil Warming permitted. Oil warming in
progress.
<5 < 40 Oil Temperature Too Low to Pump motor will not start.
Start Pump Motor
After warming oil, refer to Section 5.5.
v 4.11.1 — March 2007 5–9 Oil Warming

5.5 Checking/Resetting Alarms
5.5.1 Checking Alarms

All machine alarms are displayed on the ALARMS screen (1). Active alarms are red in
color, and inactive alarms are grey. Refer to Figure 5-12.
1. Press the <ALARMS> key to view machine alarms.
NOTE: Details of mold function alarms can be checked visually on the EJECTOR/
CORE screen (2). When there is a mold function alarm, the borders of the
affected button turns red.
2. Press the Clear Inactive Alarms button (3) on the ALARMS screen to clear inactive
alarms.
1
3
Figure 5-12 Alarm Screens

1. ALARMS screen 2. EJECTOR/CORE screen 3. Clear inactive Alarms button
Checking/Resetting Alarms 5–10 v 4.11.1 — March 2007

5.5.2 Resetting Alarms

There are two types of alarms: those that clear automatically as the machine starts up,
and those that prevent machine operation.
The following alarms reset automatically as the machine starts up.
• “Machine Heats Off” – deactivates after the machine heats are enabled. (Refer to
Section 5.13 for additional information.)
• “Machine Heats Low Temperature Deviation” – deactivates after the machine
heats are enabled, and temperatures reach setpoint values
• “Oil Temperature Low” – deactivates after oil temperature rises above 47°C
(117°F)
• “Accumulator Charging in Progress” – deactivates a few seconds after pressing
<PUMP MOTOR ON> key when the accumulator is charged up.
Refer to Table 5-2 for a list of typical alarms that prevent machine operation.
NOTE: The list in Table 5-2 is not meant to be comprehensive.
Table 5-2 Alarms that Prevent Machine Operation
Alarm Resolution
Hydraulic Pump Press the <PUMP MOTOR ON> key to resolve the alarm.
Motor Off
Front Gate Open Open and close the front operator’s gate to resolve the alarm.
NOTE: The limit switch must tripped before the alarm can be reset.
Rear Gate Open Open and close the rear guard to resolve the alarm.
Purge Guard Open Close the purge guard to resolve the alarm.
Front Gate Opening Open and close the front operator’s gate to resolve the alarm.
Check Required NOTE: The limit switch must be tripped before the alarm can be reset.
Rear Gate Opening Open and close the rear guard to resolve the alarm.
Check Required NOTE: The limit switch must be tripped before the alarm can be reset.
Drop Bar Failure To resolve the alarm, open and close the front operator’s gate, and
check the air supply is turned on.
Injection Positions Recalibrate the injection piston and carriage positions. Refer to
Not Calibrated Section 7.53.3, and Section 7.53.4 respectively to resolve the alarm.
Core Setup Mode Press the <MOLD FUNCTIONS> key to display the EJECTOR/CORE
Error screen. The borders of the affected mold function button are red in
color.
After checking and resetting alarms, refer to Section 5.6.
v 4.11.1 — March 2007 5–11 Checking/Resetting Alarms

5.6 Checking Machine Functions
Check clamp and injection functions using the following instructions.

1. Check the pumps are running.
2. Check the <MANUAL> cycle key is enabled.
3. Check the Machine Function Mode Selector on the toolbar displays the Mold Set
button.
4. Press and hold the <MOLD OPEN> key to retract the mold stroke column.
5. Press and hold the <MOLD CLOSE> key to extend the mold stroke column.
NOTE: If the mold will not close, check and reset all mold function alarms.
6. Press and hold the <CARRIAGE FORWARD> key to move the injection carriage
forward.
7. Press and hold the <CARRIAGE BACK> key to move the injection carriage back.
NOTE: If the injection carriage is out of calibration, it may not be possible to move
the carriage. If necessary, refer to Section 7.53.3.
8. Check for any leaks in the hydraulic hoses, cylinders and manifolds throughout the
machine.
After checking machine functions refer to Section 5.7. If mold is already installed on
the machine and calibrated, refer to Section 5.8.
Checking Machine Functions 5–12 v 4.11.1 — March 2007

5.7 Checking and Installing Mold
5.7.1 Checking Suitability

Before installing the mold, use the following checklist to verify that the mold can be
installed and run on the machine.
1. Check suitability of mold to run on the machine by determining the following
requirements.
• Shot size.
• Plasticizing capacity.
• Maximum barrel residence time.
• Clamping force.
• Cooling water flow.
2. Check that the mold will fit between the tiebars, and that there is adequate
shutheight to install and run the mold.
3. Check the ejector type (push/pull), length, diameter, stroke and pattern. Check that
the ejector rods are straight, and free of scratches. If there are multiple ejector
rods, check that they are of the same length.
4. Check the locating ring diameter will not cause interference with the stationary
platen.
5. Check that the radius and orifice size of the nozzle tip are compatible for the mold.
6. Check that the nozzle tip can actually make full contact with the mold sprue.
7. Check the nozzle adapter will not interfere with the mold locating ring.
8. Check that the machine is capable of accommodating the required core sequence.
9. If the mold requires a hot sprue bushing or a hot runner, check that integrated mold
heats or a suitable external mold heat controller is available.
10. Check that the mounting holes in the mold will allow the safe use of clamps.
11. Check that the mold can accommodate safety latches and lifting eye bolt.
NOTE: For specific mold installation guidelines refer to the Manufacturers Mold
Manual.
5.7.2 Installing Mold

After verifying the mold can be installed and run on the machine, use the following
instructions to install the mold.
1. Check the pumps are running.
3. Check the Machine Function Mode Selector on the toolbar displays the Mold Set
button.
4. Press and hold the <MOLD OPEN> key to retract the mold stroke column, so that
there is enough space between the platens to install the mold.
v 4.11.1 — March 2007 5–13 Checking and Installing Mold

5. Press and hold the <CARRIAGE BACK> key to fully retract the injection carriage
cylinder.
WARNING!
Crushing hazard - risk of death or serious injury. Perform Lockout/Tagout
procedure in accordance with local codes.

7. Open the operator’s gate and clean the platens. Clean all mold surfaces.
8. Place the ejector rods (1) loosely into the machine ejector plate and moving platen
using the appropriate ejector hole pattern. Refer to Figure 5-13.
S01-100581.eps
Figure 5-13 Ejector Rods (Typical)

1. Ejector rods
WARNING!
safe operating conditions.
9. Install safety latches (1), and a lifting eye bolt (2) on the mold. Attach a lifting sling
(3) to the eye bolt. Refer to Figure 5-18.
10. Refer to the following Installations.
• Section 5.7.2.1 – One Piece Mold Installation
• Section 5.7.2.2 – Multiple Piece Mold Installation
• Section 5.7.2.3 – Previously Installed Mold
Checking and Installing Mold 5–14 v 4.11.1 — March 2007

5.7.2.1 One Piece Mold Installation

Complete the following procedures for full mold installation.
1. Check values in data entry fields are suitable for mold installation (2). Refer to
Figure 5-14.
2. Press the Start button on the Mold Installation screen. Refer to Figure 5-14.
Figure 5-14 Mold Installation

1. Start button 2. Data entry fields
3. Refer to Instructions on screen and press the Accept button to confirm. Refer to
Figure 5-15.
Figure 5-15 Mold Setup

1. Accept button

4. The HMI displays the carriage jump back screen. Refer to Figure 5-16.
a. Select Yes or No depending on mold application (1).
b. Press the Accept button (2).
Figure 5-16 Jump Back Screen

1. Option button 2. Accept button
5. The HMI displays the mold installation option screen. Refer to Figure 5-17.
a. Select one piece installation (1).
Figure 5-17 Type of Installation

1. One piece installation 2. Accept button
6. Carefully hoist the mold into the space between the two platens.
7. Locate the mold on the stationary platen with the aid of the mold locating ring.

3
2
00582.eps
Figure 5-18 Lifting the Mold
1. Safety latch 2. Lifting eye bolt 3. Lifting sling
WARNING!
Crushing hazard – risk of death or serious injury. Secure mold to platen to
prevent it from falling.
8. Level the mold, and fasten it to the stationary platen. Tighten the bolts.
CAUTION!
Risk of damage to the ejector. Check that the ejector rods will not interfere with
the ejector plate.
9. If the mold has a push-pull type of mechanical ejection system, fasten the ejector
rods to the mold.
10. Check that all gates are closed.
11. Remove locks and tags. Refer to Section 1.6.2.
12. Review instructions on HMI screen. Refer to Figure 5-19.
Close the mold.
Figure 5-19 Instruction Screen

13. Review instructions on HMI screen. Refer to Figure 5-20.

Press the Accept button.

1. Accept button
14. HMI Calibrating Mold screen displays. Refer to Figure 5-21.
Figure 5-21 Calibration Screen

15. HMI Clamp-up screen displays. Refer to Figure 5-22.

a. Follow instructions on screen.
b. Press the Accept button.
Figure 5-22 Clamp-up and Unclamp

1. Accept button
16. HMI displays for ejector core option. Refer to Figure 5-37.
Depending on the mold,
a. Select the Auto Sequence (1).
Press the Accept button (2).
or
b. Leave Auto Sequence unselected.
Figure 5-23 Ejector Core

1. Auto sequence 2. Accept button

17. HMI Installation Complete displays with message.

• "Auto sequence in Manual not selected..." Refer to Figure 5-24.
• "Auto sequence in Manual is selected..." Refer to Figure 5-38.
Figure 5-24 Installation Complete
5.7.2.2 Multiple Piece Mold Installation

Complete the following procedures for separate mold plate installation. Refer to the
Manufacturers Mold Manual for specific installation procedures.
Figure 5-25.
2. Press the Start button on the Mold Installation screen. Refer to Figure 5-25.
Figure 5-25 Mold Installation

1. Start button 2. Data entry fields

3. Refer to Instructions on screen. Refer to Figure 5-26.

Press the Accept button.
Figure 5-26 Mold Setup

1. Accept button
4. The HMI displays the carriage jump back screen. Refer to Figure 5-27.
a. Select Yes or No depending on mold application (1).
Figure 5-27 Jump Back Screen

1. Option button 2. Accept button

5. The HMI mold installation option screen displays. Refer to Figure 5-28.
a. Select multiple pieces (1).
b. Press the Accept Button (2).
Figure 5-28 Type of Installation

1. Multiple piece installation 2. Accept button
WARNING!
WARNING!
7. Carefully hoist the mold halves into the space between the two platens. Refer to
Manufacturers Mold Manual for installation procedures.

S01-100790a.eps
Figure 5-29 Lifting the Mold
1. Lifting sling 2. Lifting eye bolt
8. Depending on mold, reset the HMI screen to display the options for programmed
sequence. Refer to Figure 5-30.
a. Select "Follow programmed sequence..." (1).
or
b. Select "Ignore programmed sequence..." (2).
Press the Accept button (3), go to step 11.
Figure 5-30 Program Option

1. Follow sequence 2. Ignore sequence 3. Accept button

9. Follow instructions on screen. Refer to Figure 5-31.

a. Check mold shutheight and enter measurement (1).
b. Press the Accept button.
Figure 5-31 Shutheight

1. Shutheight measurement 2. Accept button
10. HMI displays the ejector core option. Refer to Figure 5-32.
a. Select Auto sequence (1).
or
b. Leave Auto sequence unselected.

1. Auto Sequence 2. Accept button

11. New screen displays. Follow instructions on screen. Refer to Figure 5-33.
Figure 5-33 Mold Close Instructions
12. Confirm mold is closed on the HMI screen and press the Accept button (1). Refer
to Figure 5-34.
Figure 5-34 Confirm Mold Closed

1. Accept button

13. HMI screens displays for calibrating mold. Refer to Figure 5-35.
Figure 5-35 Calibration Screen
14. HMI Clamp-up screen displays. Refer to Figure 5-36.

a. Follow instructions on screen.
b. Press the Accept button
Figure 5-36 Clamp-up and Unclamp

1. Accept button

15. If Auto Sequence was previously chosen the HMI screen displays with ejector core
option. Refer to Figure 5-37.
or


• "Auto Sequence in Manual selected..." Refer to Figure 5-38.
• "Auto Sequence in Manual not selected..." Refer to Figure 5-46.

1. Auto sequence

5.7.2.3 Previously Installed Mold

The following procedures can be used on molds already installed in the machine.
Figure 5-39.
2. Select, Calibrate Previously Installed Mold (2). Refer to Figure 5-39.
3 2
Figure 5-39 Start Calibration

1. Data entry fields 2. Calibrate button 3. Accept button
3. HMI Programmed Sequence screen displays. Refer to Figure 5-40.

a. Select "Ignore programmed sequence..." (2).
Press the Accept button (2) to follow this procedure.
or
b. Select "Follow programmed sequence..." (1).
Press the Accept button (2). Refer to step 9 & step 10 on Page 5-24, then
proceed to step 5 on Page 5-30.

Figure 5-40 Programmed Sequence

1. Follow sequence 2. Ignore sequence 3. Accept button
4. HMI instructional screen displays. Refer to Figure 5-41.

a. Read instructions.

1. Accept button

5. HMI message displays. Refer to Figure 5-42.
Figure 5-42 Ready to Calibrate
6. HMI message displays. Refer to Figure 5-43.

a. Read message and perform procedure.
Figure 5-43 Check Mold

1. Accept button

7. HMI Calibration screen displays. Refer to Figure 5-44.
Figure 5-44 Calibrating Screen
8. On completion of calibration, the Auto/Manual Sequence screen displays. Refer to

Figure 5-45.
or
Figure 5-45 Auto/Manual Sequence Screen



• "Auto sequence in Manual not selected..." Refer to Figure 5-46.
• "Auto sequence in Manual is selected..." Refer to Figure 5-38.
5.7.3 Installing Molds in Tandem Carriers (H/HL650 – H/HL1000)

The following procedure applies to the installation of two individual standard molds –
stack mold installation is described separately in Section 5.7.4.
NOTE: Automatic services hook-up provisions on the molds may require positioning
the locating ring at the opposite side of the sprue bushing, which affects the
installation procedure. In such cases, first attach the molds to the two platens,
then verify locating ring concentricity during platen closing.
1. Open moving platen to maximum daylight position.
WARNING!
2. Perform Lockout/Tagout procedure – refer to Section 1.6.

3. Verify that sprue bushings are clean and in good condition and that the hot runner
nozzle protrusion matches with the sprue bushing position.
WARNING!

5. Install mold A on the center plate towards the moving platen side with mold halves
locked.
6. Install mold B on the center plate towards the stationary platen side with mold
halves locked.
7. Loosen the clamping bolts on both adjustable linkage bars.
8. Remove locks and tags. Refer to Section 1.6.
9. Close clamp completely.
CAUTION!
Ensure before platen closing that the difference in mold shutheight does not
exceed the linkage bar adjusting range. Failure to do so may result in damage to
the linkage bars.
10. Clamp-up to the required mold close force.

11. Fasten both molds to the moving and stationary platen faces and unlock mold
halves.
12. Tighten all bolts on both adjustable linkage bars and torque as specified on
nameplate.
13. Connect mold services.
14. Complete the mold installation following directions:
• For a first time installation, refer to Section 5.7.2.1, step 12 through step 17.
• For a previously installed mold, refer to Section 5.7.2.3.
5.7.3.1 Single Mold Operation on Machines with Tandem Carrier

There are two ways to operate the clamp with a single mold on a tandem carrier. The
first method can accommodate single molds of the same size as the tandem molds,
while the second method is designed to fit larger single molds.
Method One
1. Install a dummy block of adequate shutheight to meet the linkage bar adjustment
range.
2. Exchange the respective nozzle for an adapter part that closes the melt channel
and takes the reaction forces to ensure that the first nozzle contact is made
correctly.

Method Two
CAUTION!
The following method requires the removal of carriers and linkage system from
the machine. Failure to do so may result in damage to either the carriers or
linkage mechanism.
1. Remove the hot runner. This allows sliding the centerplate (1) past the upper
tiebars.
2. Remove the centerplate from the carrier and attach it to the stationary platen
face (2).
3. Exchange the nozzle for an adapter part that closes the melt channel on the
unused face and takes the reaction forces to ensure that the first nozzle contact is
made correctly.
4. Exchange the front part of the sprue bar for an adaptor to hold the sprue bushing
5. Install a block (3) on the stationary platen face to resist the injection nozzle force
acting on the hot runner.
Figure 5-47 Single Mold Installation on Tandem Carrier

1. Mold carrier centerplate 2. Stationary platen 3. Sprue adaptor block

5.7.4 Stack Mold Installation (H/HL90 – H/HL500)

1. Position moving platen at maximum daylight position.
CAUTION!
Do not dry cycle the machine without having the stack mold attached to the
carriers. This may cause cocking of the carriers and damage to the linkage
bearings.
WARNING!

3. Measure the distance from the mold center, at the keyway slot, to the end of the
sprue bar, and make sure it is below the distance from the stationary platen face to
the carrier centerline (keys).
NOTE: In the event the distance is greater, remove the pins in the main linkage
arm to allow carrier displacement further away from the stationary platen
during mold installation.
WARNING!
Pinching risk – Secure the free ends of linkage bars, or remove the bars
completely. Failure to do so can result in injury to an operator.
4. Secure or remove disconnected linkage bars.
WARNING!
6. Lift the mold with the crane ensuring that the keyways in the mold center plate are
vertical to allow easy assembly with the carriers.
7. Loosen the bolts on the linear bearings on the operator’s side.
8. Install mold by sliding the mold center plate over the keys in the carrier until the
movement bottoms out on the top keys.
9. Torque the bolts on the linear bearings to Husky specifications – refer to
Section 2.12.
10. Connect the mold to the carrier using bolts in all the accessible locations and hand
tighten.

11. Release the mold from the crane.

WARNING!
Possible linkage damage. With adjustable linkage bars, the bolts on the two adjustable
bars must be released slightly to allow individual mold shutheight adjustment without
overloading the linkage bar bushings.
Perform this operation at minimum speed.
The adjustable bars get compressed during platen closing until the first mold touches
the mating platen face, and then expands again until the second mold touches it’s
platen face.
13. Close the moving platen while verifying that the sprue bar fits correctly into the
locating bushing at the stationary platen.
14. Apply clamp tonnage.
16. Install bolts in the remaining locations from step 10.
17. Torque all bolts to Husky specifications – refer to Section 2.12.
NOTE: It is necessary at mold removal to release the bolts that are not accessible
on the carriers when the moving platen is at maximum daylight position.
18. Attach the mold back plates to the stationary and moving platens.
19. With adjustable linkage bars, tighten all the bolts on the two adjustable bars to the
torque specified on the nameplate.
5.7.5 Stack Mold Installation (H/HL650 – H/HL1000)

1. Position moving platen at maximum daylight position.
CAUTION!
Do not dry cycle the machine without having the stack mold attached to the
carriers. This may cause cocking of the carriers and damage to the linkage
bearings.
WARNING!


3. Measure the distance from the mold center, at the keyway slot, to the end of the
sprue bar, and make sure it is below the distance from the stationary platen face to
the carrier centerline (keys).
NOTE: In the event the distance is greater, remove the pins in the main linkage
arm to allow carrier displacement further away from the stationary platen
during mold installation.
WARNING!
Pinching risk – Secure the free ends of linkage bars, or remove the bars
completely. Failure to do so can result in injury to an operator.
4. Secure or remove disconnected linkage bars.
WARNING!
6. Lift the mold with the crane ensuring that the keyways in the mold center plate are
vertical to allow easy assembly with the carriers.
7. Install mold by sliding the mold center plate over the keys in the carrier until the
movement bottoms out on the top keys.
8. Connect the mold to the carrier using bolts in all the accessible locations and hand
tighten.
9. Release the mold from the crane.
WARNING!
Possible linkage damage. With adjustable linkage bars, the bolts on the two adjustable
bars must be released slightly to allow individual mold shutheight adjustment without
overloading the linkage bar bushings.
Perform this operation at minimum speed.
The adjustable bars get compressed during platen closing until the first mold touches
the mating platen face, and then expands again until the second mold touches it’s
platen face.
11. Close the moving platen while verifying that the sprue bar fits correctly into the
locating bushing at the stationary platen.
12. Apply clamp tonnage.
14. Install bolts in the remaining locations from step 10.

15. Torque all bolts to Husky specifications – refer to Section 2.12.

NOTE: It is necessary at mold removal to release the bolts that are not accessible
on the carriers when the moving platen is at maximum daylight position.
16. Attach the mold back plates to the stationary and moving platens.
17. With adjustable linkage bars, tighten all the bolts on the two adjustable bars to the
torque specified on the nameplate.
5.7.6 Mold Protection

Mold Protection, incorporating hydraulic and electronic controls, is designed to
minimize the potential for damage of the mold surfaces caused by closing on foreign
objects.
Five input fields on the Clamp Setup Screen are key to achieving optimal mold running
conditions. These input fields include three mold protection and two mold approach
parameters.
• Low Pressure Start (distance).
• Low Pressure (hydraulic pressure).
• Mold Close Deceleration (deceleration).
• Mold Close Final Speed (velocity).
• Part Interference (distance).
Mold protection fields dictate at what position mold protection starts, and how sensitive
its setting is. Mold approach fields dictate how smoothly mold faces come together.
Refer to Table 5-3 for details on mold protection fields.
These operator - entered parameters are based on the following.
• Molded part design.
• Physical mold size.
• Weight.

Figure 5-48 Clamp Setup Screen

1. Mold protection fields
Table 5-3 Mold Protection Fields
Field Description
Low Pressure This setpoint establishes the point in the closing stroke where the normal
Start closing pressure is reduced to a lower "mold protection" pressure.
In Semi and fully Automatic modes, once this setpoint is made, the
moving platen has a preset amount of time to reach the mold close
setpoint. If not, the machine automatically opens back up and a machine
alarm signals a part interference.
• Higher value in this field may cost cycle time.
• Lower value could compromise the effectiveness of mold protection.
Low Pressure This adjusts the mold stroke pressure that is available for mold closing
after the low pressure start setpoint is reached.
• Lower value may cost cycle time or prevent the stroke cylinder from
overcoming normal forces, such as leader pins or cam actions.
• Higher value may compromise the effectiveness of mold protection
and allow the mold to clamp up on obstructions and damage the
mold.
NOTE: Given that later model Husky machines are equipped with ultra
low friction linear bearings on the moving platen, it may still be
possible to close the mold at the minimum mold protection
pressure as long as no obstructions exist. Older systems may
stall out due to the friction of the tie bar bushings and moving
platen support bushings.

Table 5-3 Mold Protection Fields
Field Description
Mold Close This is the deceleration rate of the moving platen during mold close.
Deceleration
Mold Close Final This is the speed of the moving platen at mold close.
Speed
Part This changes the maximum distance between the mold halves for part
Interference interference.
CAUTION!
If Part Interference is set too high, smaller parts may not be
detected resulting in possible damage to the mold.
The mold halves are brought together under Low Pressure until the
distance between them is less than this value before the clamp builds
tonnage.
NOTE: If the mold faces are below this limit and the clamp lock has
clearance to engage, the machine will clamp up.
• Setting this to a higher value will the cause the mold protection to be
less sensitive and clamp up on obstructions.
• Setting this value too low may cause the machine to be over sensitive
and to trip a part interference fault when no obstruction exists.
5.7.6.1 Testing Mold Protection
CAUTION!
The correct setup of the mold protection system greatly reduces the potential
for damage to the mold surfaces due to obstructions between the mold faces.
The mold protection system controls the forces created by the mold stroke cylinder.
The operator should be aware that there are also forces present from mechanical
inertia as a result of the momentum of the moving components.
These forces vary with the mass of the mold and the closing velocities. Be sure to test
the mold protection at the speeds that you plan to run the machine to make sure that
these additional forces do not override the ability of the circuit to protect the mold.
CAUTION!
Use a suitable test material that will not cause damage to the mold or machine
when under tonnage or velocity. Contact your local Husky service
representative or the Central Service Group (CSG) in Bolton if you have any
questions.
1. Place or tape a piece of test material (Husky recommends cardboard or flexible

magnetic strips) on the mold face.
2. For the initial trial,
a. Set all mold close speeds to 30% of maximum.

b. Set the velocity set-points for every 100mm.

c. Set "Low Pressure Start" to 150mm if possible (if a setting that high is not
allowed on the machine, set it to the maximum allowed on that control).
d. Set the mold protection pressure to its minimum value.
3. Place the machine in Dry Cycle mode.
4. Start the pump.
5. Check that the safety gates are closed.
6. Select Semi Automatic mode.
7. Press mold close to extend the stroke cylinder.
The cylinder should stall out and stop when a part interference is detected. After a
three second delay, it should open, and the screen should display a "part
interference" alarm.
8. If the test material shows no signs of contact or compression.
a. Repeatedly close and open the mold while increasing both the close velocity
and mold protection pressure set-points in 5% increments.
b. When the test material shows signs of contact or compression, decrease both
set-points by 5%.
9. Reduce the mold protection "start" setpoint in increments of 5mm until the test
material again shows signs of contact or compression, then increase the setpoint
by 5mm.
10. If the machine stops on a part interference trip and there is no evidence of part
interference:
a. Check for galling of the mold leader pins and bushings.
b. Check for an overheated mold condition that has caused the pins to jam in their
bushings.
5.8 Recalling Machine Setups
Machine setups contain clamp, mold, ejector, pneumatic function, core, standard and
custom mold function, injection, hold, recovery, machine heats, mold heats, nozzle tip
temperature, nozzle shutoff, SPC, and product handling (robot) setups.
If machine setups from previous production runs on the machine do not exist, skip this
section and refer to Section 5.9.
By default, machine setups are always saved from the RAM in the PC to the local hard
disk. When a machine setup is recalled, it is always loaded from the local hard disk
into the RAM in the PC, where it is referred to as the active setup. Any changes to the
active setup are saved internally in the computer, and only written to the machine
setup and robot program files on the local hard disk when the Save Setup function is
used – refer to Section 5.20.
v 4.11.1 — March 2007 5–41 Recalling Machine Setups

REMINDER:
• You cannot recall machine setups if you do not have suitable user access rights.
• The machine must be idle to recall the machine setup.
• Machine setups are always recalled from the local hard disk to the RAM in the PC.
You can recall both the machine setup and robot program files from the hard disk
at the same time, or recall them separately.
Figure 5-49 MOLD SETUP Screen

1. Recall setup button 2. Save setup button 3. Delete setup button 4. Copy setup
button
Recall the machine setup using the following instructions (refer to Figure 5-49).
1. Press <PRODUCTION> key, then touch the MOLD SETUP tab to display the
MOLD SETUP screen.
2. Select the appropriate machine setup file and robot program file (as applicable)
from the list boxes on the MOLD SETUP screen. The selected files are highlighted.
If the required machine setup is saved anywhere but on the local hard disk, such
as on a floppy disk or network drive, it must first be copied to the local hard disk.
For instructions on copying machine setups refer to Section 5.8.1.
NOTE: All machine setup files and robot program files available on the local hard
disk are displayed in the list boxes.
NOTE: Selecting a machine setup with a linked robot program will automatically
select the robot program linked to it. You cannot deselect the linked robot
program to select another robot program unless you first clear the link –
refer to Clearing Link to Robot Program.
CAUTION!
Unsaved active setup will be overwritten. Save it first to the hard disk, if
necessary, before recalling another mold setup.
3. Touch the Recall Setup button (1) to recall the mold setup.
Recalling Machine Setups 5–42 v 4.11.1 — March 2007

4. If a machine setup file is selected for recall, a warning message is displayed

prompting you to confirm the overwrite. Touch the Yes button to overwrite the
active machine setup, or the No button to cancel the recall.
If a robot program file is selected for recall and the active robot program has been
modified, a warning message is displayed prompting you to confirm the overwrite.
Touch the Yes button to overwrite the active robot program, or the No button to
cancel the recall.
5. If a machine setup file is selected for recall, the machine sizes are checked for
compatibility. If machine sizes are not compatible, file recall is aborted.
6. If machine sizes are compatible, the machine serial numbers are then checked. If
the machine serial numbers are different, a warning message is displayed
prompting you to confirm if you wish to continue. Touch the Yes button to continue,
or the No button to cancel the file recall.
NOTE: If a robot program file is selected for recall, no size check or serial number
check is performed.
7. If a robot program file is selected for recall, a file integrity check is performed. If the
test is successful, the file is downloaded to the machine if the following conditions
are satisfied – configured "Home" position, work spaces, "Move" position values in
the Main Sequence, Home Sequence and EOAT Sequence are all within the
stroke limits of the robot.
When the file is downloaded successfully, the newly recalled robot program is
displayed in the robot ACTIVE PROGRAM screen.
If file integrity check fails, or the robot conditions are not satisfied, or download is
not completed successfully the previous active robot program is reloaded into the
RAM in the computer.
8. If a machine setup file is selected for recall, a file integrity check is performed. If the
test is successful, the machine setpoints and SPC settings are downloaded to the
machine.
9. When mold setup is recalled successfully, the Machine Setup and Robot Program
text boxes on the MOLD SETUP screen are updated (as applicable) to display the
new file names.
NOTE: When a machine setup is recalled successfully, the mold stroke must be
calibrated before you can run the machine.
5.8.1 Copying Machine Setups

Depending on your configuration, either Insert a diskette (1) into the floppy drive in the
PC or install a removable USB device into the USB port. Open the panel (1) on the
electrical cabinet (2) to access the floppy drive. Refer to Figure 5-50.
NOTE: If equipped with a removable USB storage device, use of the internal floppy
drive is restricted to maintenance functions only.
CAUTION!
Risk of damage to software and PC hardware. Scan diskette for viruses before
using in machine.

Figure 5-50 Accessing the Floppy Drive / Removable USB Storage

1. Panel 2. Electrical cabinet 3. USB
REMINDER:
• You cannot copy machine setups if you do not have suitable user access rights.
• You cannot copy the active setup from the RAM in the computer – use the Save
Setup function instead to save the active setup to the local hard disk.
• Machine setups are always copied from a permanent storage device such as the
local hard disk, or floppy diskette, or a network drive (if available) to another per-
manent storage device such as the local hard disk or a floppy diskette or a net-
work drive (if available).
Copy a mold setup from one storage device to the same storage device under a
different name, or to another storage device using the following instructions. You can
also use the same procedure to make a copy of the robot template.
MOLD SETUP screen (refer to Figure 5-49, item 1).
2. Touch the Copy Setup button (refer to Figure 5-49, item 4) to display the COPY
MOLD SETUP pop-up window – refer to Figure 5-51.
3. Select the source icon (1) – local hard disk, floppy diskette, network drive (if
available), or host computer (visible only if Husky Host Interface option is enabled).
The list boxes display the machine setup files (2), robot programs and robot
template available in the selected storage device. The upper (Machine) list box
also displays the file name of the linked robot program (if available).
4. Select as many machine setup files and robot program file as required. All selected
files are marked with a check mark (9).
If a machine setup has a linked robot program, selecting the machine setup file will
automatically select the linked robot program file.
NOTE: If you deselect the linked robot program, a warning message is displayed
prompting you to confirm that the link will be deleted on the destination
device. Touch the Yes button to delete the link, or the No button to cancel
the file copy.
Recalling Machine Setups 5–44 v 4.11.1 — March 2007

Figure 5-51 COPY MOLD SETUP Pop-up Window

1. Source icons 2. Machine setup files 3. Destination icons
5. Select the destination icon (3) – local hard disk, floppy diskette, or network drive (if
available), or host computer (visible only if Husky Host Interface option is enabled).
NOTE: You can only browse the contents of the network drive (if available).
6. If the local hard disk or floppy diskette is selected, two additional fields appear on
the screen. Enter a new file name.
CAUTION!
If the same file name exists on the destination drive, the file on the destination
drive may be overwritten. Enter a new file name if necessary.
7. Touch the Copy button to copy the file, or the Cancel button to abort the file copy.
If the file names already exist on the destination device a warning message is
displayed prompting you to confirm the file overwrite. Touch the Yes button to
overwrite the file(s), or the No button to cancel the file copy.
After recalling setups, refer to Section 5.9.

5.9 Configuring Mold Functions
Configuring specific mold functions is beyond the scope of the manual, as the
procedure will vary from process to process. In general, configure mold functions
using the following outline.
• Set up and calibrate the ejector.
• Set up mold functions using the EJECTOR/CORE screen, if necessary.
• Set up air blowing using the AIR screen, if necessary.
• Set up the valve gates using the VALVE GATES screen, if necessary.
5.9.1 Setting Up and Calibrating the Ejector

Set up and calibrate the ejector using the following procedure.
1. Press the <MOLD FUNCTIONS> key, and select the EJECTOR SETUP tab (1).
1
2
3
4 5
Figure 5-52 EJECTOR SETUP Tab

1. EJECTOR SETUP tab 2. Number of Strokes field 3. Forward Dwell field 4. Ejector
Profile Forward field 5. Ejector Back Profile field
2. Check the Number of Strokes (2), and Forward Dwell (3) fields have suitable
values.
3. Check that the Ejector Forward Profile (4) and Ejector Back Profile (5) fields have
suitable values.
4. Press the Calibration button on the toolbar to display the CALIBRATION screen.
5. Press the Ejector button.
Configuring Mold Functions 5–46 v 4.11.1 — March 2007

6. Press the Start button on the EJECTOR CALIBRATION screen. Refer to

Figure 5-53.
Figure 5-53 EJECTOR CALIBRATION Screen

1. Start button 2. Measured Ejector Position field 3. OK button
7. The HMI prompts for the distance between the ejector plate and the face of the
mold stroke column. Measure the distance, and enter the value in the Measured
Ejector Position field (2). Select the OK button (3).
When calibration is complete, the field beside the Start button displays
"Calibrated".
8. Select the EJECTOR/CORE tab (1). Refer to Figure 5-54. Assign mold functions, if
necessary.
9. Select the AIR tab (2). Set up air blowing, if necessary.
10. Select the VALVE GATES tab (3). Set up valve gates, if necessary.
v 4.11.1 — March 2007 5–47 Configuring Mold Functions

Figure 5-54 Setting Up Mold Functions, Air and Valve Gates

1. EJECTOR/CORE tab 2. AIR tab 3. VALVE GATES tab
5.9.1.1 Enabling Auto Function Keys to Run Production

Enable the following manual function keys, as required.
Press the <EJECTOR BACK> key. Press the optional <CORE SET>, <AIR AUTO>,
and <PLATE AUTO> buttons which can be accessed through the sidebar function
keys. Check the LED on the keys/buttons light up as they are enabled.
After configuring mold functions, refer to Section 5.10.
5.10 Checking Robot Functions
If the machine is equipped with a robot, refer to the Robot Manual for checking robot
functions.
After checking robot functions refer to Section 5.11.
Checking Robot Functions 5–48 v 4.11.1 — March 2007

5.11 Checking Mold Function Keys
Some manual function keys related to mold functions must be enabled to allow the
machine to run in Semi or Auto cycle modes.
Check the manual function keys using the following instructions.
1. Check the required manual function keys are enabled.
2. Check that the <EJECTOR BACK> key, the optional <CORE SET>, <AIR AUTO>,
and <PLATE AUTO> buttons are enabled.
3. If necessary, enable the required functions. Check the LED on the keys/buttons
light up as they are enabled.
After checking mold function keys, refer to Section 5.12.
5.12 Setting Up/Checking Clamp
Dry Cycle the clamp, and adjust the clamp, custom mold functions, and robot settings
using the following instructions.
1. Press the Machine Function Mode Selector on the toolbar, and select the Dry
Cycle button.
2. Press the <SEMI> key, then the <CYCLE START> key to cycle the machine.
3. Adjust the clamp, custom mold functions, and robot settings as required.
After setting up and checking clamp, refer to Section 5.13.
5.13 Turning Heats On
Turn on extruder barrel heaters, optional mold and nozzle extension heaters, and
change setpoints using the instructions below.
NOTE: Turn on the heats, and allow sufficient barrel soaking time.
1. Press the <HEATS> key to display the BARREL screen (1). Refer to Figure 5-55.
2. Select the Machine Heats Enable check box (2).
3. Check that the Standby check box (3) is deselected.
4. Select the input field (4) beside the Standby check box, and enter a suitable value
for standby temperature.
5. Select each setpoint field (5), and enter/modify the setpoint temperature using the
pop-up screen.
v 4.11.1 — March 2007 5–49 Checking Mold Function Keys

1
5
Figure 5-55 BARREL Screen

1. BARREL screen 2. Machine Heats Enable check box 3. Standby check box
4. Standby temperature input field 5. Setpoint field
6. If necessary, select each Zone Setup box, and enter/modify the setpoint
temperature using the pop-up screen. Refer to Figure 5-56.
NOTE: You must have access rights to use the Zone Setup screens.
1
2
3
5
4
6
Figure 5-56 SETUP MACHINE HEATS Pop-up Window

1. High Alarm field 2. Low Alarm field 3. Auto option button 4. Manual option
button 5. Auto Tune Enable check box 6. Thermocouple Enable check box
7. Enter suitable values in the High Alarm (1) and Low Alarm (2) fields.
8. Select Auto (3) or Manual (4) option button, Auto Tune Enable (5) and
Thermocouple Enable (6) check boxes, if applicable.
Turning Heats On 5–50 v 4.11.1 — March 2007

5.13.1 Turning Optional Mold Heats On

Turn on optional mold heats using the instructions below.
CAUTION!
Risk of damage to the mold. Turn mold cooling on before turning on mold heats.
1. On machines with optional mold heats, first press the <MOLD COOLING> key to
start mold cooling.
2. Press the MOLD tab (1), and select the Mold Heats Enable check box (2). Refer to
Figure 5-57.
2 4
Figure 5-57 MOLD HEATS Screen

1. MOLD tab 2. Mold Heats Enable check box 3. Standby check box 4. Standby
Temperature input field
5. Select each Zone Setup box, and enter/modify the setpoint temperature. Refer to
Figure 5-56.
NOTE: You must have access rights to use the Zone Setup screens.
6. Enter suitable values in the High Alarm (1) and Low Alarm (2) fields.
7. Select Auto (3) or Manual (4) option button, Auto Tune Enable (5), Thermocouple
Enable (6), and Enable (7) check boxes, as required.
v 4.11.1 — March 2007 5–51 Turning Heats On

5.13.2 Turning Optional Nozzle Heats On

Turn on optional nozzle heats using the instructions below.
1. Press the Nozzle Tips tab (1), and select the Nozzle Heats Enable check box (2).
4
2
Figure 5-58 NOZZLE HEATS Screen

1. Nozzle tips tab 2. Nozzle heats enable check box 3. Standby check box
4. Standby temperature input field
After turning heats on, refer to Section 5.14.
5.13.3 Machine Heats Self-Tuning Procedure

Self tuning can be used to optimize temperature control for the machine, mold, or
nozzle tip heaters. Self tuning allows for greater thermal stability and faster machine
warm up from room temperatures.
Self tuning should be performed when:
• Unsure if the machine has been started before
• The machine is started for the first time (new machine)
• Whenever a heat zone has been modified
• Whenever a mold is replaced or installed
• Self tuning is performed at the factory before the machine is shipped.
Typically, heat zones that are physically adjacent to one another should be tuned
together.
1. Turn OFF mold heats main breaker.

2. Confirm mold type on Heats Setup screen (see Figure 5-59). Disable any zones
that are not required.
1
2
Figure 5-59 Main Heat Setup Screen

1. Enable Mold Heats 2. Enable Self Tune
3. Allow all enabled mold heat zones to cool down to ambient temperature
(Figure 5-60).
Figure 5-60 Mold Heats Screen

1. Mold tab 2. Heat zone setup box 3. Heater Output
4. Make sure that the temperature of all zones is stable; i.e. the temperature of any
zone does not change in five minutes.
5. Turn ON mold cooling.
NOTE: Before starting the self tune procedure, all enabled zones must be
functioning properly. Any zones that do not function properly will cause
faulty parameters for self tune.
6. Turn ON mold heats main breaker and confirm voltages.
7. Confirm that breakers to the individual mold heats zones are ON.

8. Clear any alarms related to the mold heats and mold cooling circuits.
9. Set the temperature set points for all heat zones that need to be tuned to
processing temperature values.
NOTE: Make sure there is a temperature difference of at least 160°C (320°F)
between actual temperature and set point values.
10. Touch the Heat Zone Setup box (Figure 5-60, item 2), to display the pop-up
window.
2
3
Figure 5-61 Pop-up Window for Heat Zone

1. Control Option - Auto 2. Auto Tune Enable 3. Enable
11. Check that the Control option - Auto (Figure 5-61, item 1), as well as the Auto Tune
Enable (item 2) and Enable (item 3) check boxes are selected.
12. Close the pop-up window.
13. Repeat steps 10 through 12 above for each zone.
14. On the main heat setup screen (Figure 5-59), in the mold heat section:
a. Enable Mold Heats (item 1)
b. Enable Self Tune (item 2)
NOTE: Select the Mold Heats Enable checkbox (item 1) and then select the Self Tune
checkbox (item 2) immediately thereafter. This will result in 100% output to all
selected zones.
NOTE: HyPET Setup screen is shown in Figure 5-59. Other product lines use
different screens.
15. Monitor the alarm screen (Figure 5-62) for any alarms related to the mold heats
and mold cooling circuits.

Figure 5-62 Alarm Screen
16. The Self Tune procedure is complete when the check mark from the Self Tune field
disappears (Figure 5-59, item 2).
NOTE: There is no information on the alarm output screen indicating that the mold
heats Self Tune procedure is in progress, or that the mold heats Self Tune
procedure is complete.
17. During the Self Tune procedure, monitor the outputs to the manifold heaters (which
should be greater than zero - Figure 5-60, item 3), and verify that the manifold
temperature is rising and that there are no related mold heats and mold cooling
alarms (Figure 5-62).
18. If for any reason during the Self Tune procedure there is a faulty zone or a related
alarm (mold heats or mold cooling, power off, breaker tripped alarms), restart the
Self Tune procedure from step 1.
19. If the quality of temperature control is unacceptable (during processing), repeat the
procedure.
NOTE: If after repeating the self tuning procedure the temperature control continues
to be unacceptable, default parameters may be used.
NOTE: To use the default parameters:
a. Start the mold heat Self Tune procedure.
b. Deselect the Mold Heats Enable checkbox (Figure 5-59, item 1) and the Self
Tune checkbox (item 2) while the self tuning procedure is running.
c. Power down. Power up and restart the system.
NOTE: For software releases V6.002 and up (Figure 5-63, item 2), the "Mold Heats
Self Tuning Selected But Not Enabled" alarm will be displayed if the self tune
procedure did not initiate successfully. Manually clear the Self Tune check box
and repeat the self tuning procedure.

Figure 5-63 Check Software Version, Refer to Notes (at right)

1. Machine Specifications screen 2. Software version
NOTE: Altering any setting while the self tune procedure is in progress will terminate
self tuning.
5.14 Opening Process Material Feed
Load the hopper, and open material feed to the machine using the following
instructions.
WARNING!
Slip, trip or fall hazard – risk of serious injury. Do not climb on machine surfaces
to fill hopper – use a safe platform to access the hopper.
1. Fill the hopper (1), or connect feed lines securely. Refer to Figure 5-64.
2. If the machine is equipped with a direct feed system (2), open the feed lines to the
machine.
Opening Process Material Feed 5–56 v 4.11.1 — March 2007

S01-100032
1 2
Figure 5-64 Opening Process Material Feed

1. Hopper 2. Direct feed system
WARNING!
Burn hazard – risk of serious injury. Machine surfaces can be hot. Wear
Personal Protective Equipment (PPE).
5.14.1 Opening Process Material Feed Manual Shutoff

If the machine is equipped with a material feed manual-shutoff, load the hopper, and
open material feed to the machine using the following instructions.
1. Loosen the knob (1) in the manual shutoff, and push the slider (2) toward the feed
throat opening. Refer to Figure 5-65.
2. Push the slider until the detent pin in the knob locks.
3. Tighten the knob.
1 2
-100133.eps
Figure 5-65 Process Material Feed Manual Shutoff

1. Manual shutoff knob 2. Slider
v 4.11.1 — March 2007 5–57 Opening Process Material Feed

5.14.2 Opening Process Material Feed Auto-shutoff

If the machine is equipped with an optional feed auto-shutoff, load the hopper, and
open material feed to the machine using the following instructions.
1. Select the <INJECTION> key, then select the RECOVERY tab (1). Refer to
Figure 5-66.
2. Select the Hopper Open check box (2).
Figure 5-66 Process Material Feed Auto Shutoff

1. RECOVERY tab 2. Hopper open check box
5.14.3 Opening Magnet Drawer

If the machine is equipped with an optional magnet drawer, push the handle (1) all the
way in to open material feed. Refer to Figure 5-67.
1
S01-100033
Figure 5-67 Opening Magnet Drawer

1. Magnet drawer handle
After opening process material feed, refer to Section 5.15.
Opening Process Material Feed 5–58 v 4.11.1 — March 2007

5.15 Setting Up/Checking Injection
Set up injection, hold and recovery parameters using the instructions below.
5.15.1 Setting Up Injection and Hold Parameters

Set up injection and hold parameters using the instructions below.
1. Press <INJECTION> key, and select the INJECTION tab (1). Refer to Figure 5-68.
2. Select the Speed Profile (2) and Position Profile (3) fields, and enter suitable
values using a Profile Control screen.
NOTE: The value in the Position field represents the Shot Size.
3. Select the Pressure Profile (4) and Time Profiles (5) fields, and enter suitable
values.
4. Select the appropriate transition check boxes – Position (6), Hydraulic Pressure
(7), or Fill Time (8). Then enter a suitable value in the field adjacent to each
selected check box.
5. Select the Cooling Time (9), and Fill Pressure Limit (10) fields and enter suitable
values, as required.
6. If required, select the Fill Time Limit (11) field, and enter a suitable value.
2
4
3
5
7
10
8 11
9
Figure 5-68 INJECTION Tab

1. INJECTION tab 2. Speed profile field 3. Position profile field 4. Pressure profile
field 5. Time profiles field 6. Position option button 7. Hydraulic pressure option
button 8. Fill time option button 9. Cooling time field 10. Fill pressure limit field
11. Fill time limit field
v 4.11.1 — March 2007 5–59 Setting Up/Checking Injection

5.15.2 Setting Up Recovery Parameters

Set up recovery parameters using the instructions below.
1. Select the RECOVERY tab (1). Refer to Figure 5-69.
2. Select the Speed (2), Position (3), and Back Pressure (4) Profile fields and enter
suitable values.
3. Enter Pullback Before (5) and Pullback After (6) values, as required.
4. Select the Nozzle Shutoff Enable check box (7), if applicable.
5. Select the Maintain Carriage Forward check box (8), as required.
6. If sprue break is required, enter suitable values in the Sprue Break (9) and Screw
Rotation Delay (10) fields.
7. Enter suitable values in the Forward (11) and Too Far Forward (12) fields.
5
6
2
3
8
4
11
12
10 7
Figure 5-69 RECOVERY Tab

1. RECOVERY tab 2. Speed field 3. Position field 4. Back Pressure field
5. Pullback Before field 6. Pullback After field 7. Nozzle Shutoff Enable check box
8. Maintain Carriage Forward check box 9. Sprue Break field 10. Screw Rotation Delay
field 11. Forward 12. Too Far Forward
After setting up/checking injection, refer to Section 5.16.
Setting Up/Checking Injection 5–60 v 4.11.1 — March 2007

5.16 Purging Barrel Before Production
Purge the barrel before production using one of the following two methods:
• Manual purging.
• Auto purging.
5.16.1 Manually Purging the Barrel

Plasticize and purge material from the barrel manually using the instructions below.
1. Check the Machine Function Mode Selector on the toolbar displays the Normal
button.
4. Check that the barrel is up to temperature.
5. Check that there is adequate supply of process material in the hopper for purging
the barrel.

1. BARREL screen
WARNING!
Explosion hazard - risk of serious injury. Molten material at high pressure can
be present. Wear PPE. Clear the area of all non-essential personnel. Never
purge the barrel when the nozzle tip is outside the purge guard.
6. Press and hold the <CARRIAGE FORWARD> key until the carriage is in the purge
zone.
v 4.11.1 — March 2007 5–61 Purging Barrel Before Production

NOTE: The carriage is in the purge zone when the purge guard overlaps the
barrel cover by 10 mm (0.4 in).
7. Press <INJECTION> key and select the INJECTION tab (1). Refer to Figure 5-71.
Figure 5-71 INJECTION Tab

1. INJECTION tab 2. Injection position value
8. Press the <INJECT> key to purge process material from the barrel.
NOTE: If the nozzle tip is not in the Purge zone, the HMI will display a warning,
and prevent purging. If that occurs, press the <CARRIAGE FORWARD>
key until the carriage stops, and try again.
9. When the “Injection Position” value (2) is equal to zero, release the <INJECT> key.

1. RECOVERY tab
Purging Barrel Before Production 5–62 v 4.11.1 — March 2007

11. Press and hold the <SCREW ROTATE> key to retract the screw and plasticize
process material.
12. When the screw stops rotating, release the <SCREW ROTATE> key.
13. Repeat step 7 to step 12 above, until the quality of plasticized material is
acceptable.
WARNING!
Burn hazard – risk of serious injury. Wear PPE when handling purged material.
14. After purging is completed and has cooled, empty the purged material in the tray
into a suitable metal container for disposal.
5.16.2 Auto Purging the Barrel

Plasticize and purge material from the barrel automatically using the following
instructions.
1. Press the Machine Function Mode Selector on the toolbar and select the Auto
Purge button.
NOTE: The carriage will automatically move into the Purge zone after selecting
Auto Purge.
3. Check that the barrel is up to temperature (2).
4. Check that there is adequate supply of process material in the hopper for purging
the barrel.
1 2
Figure 5-73 Auto Purging the Barrel

1. BARREL screen 2. Barrel temperature field
v 4.11.1 — March 2007 5–63 Purging Barrel Before Production

3 2

1. RECOVERY tab 2. Auto purge cycles field 3. Hopper open check box
6. Select the Auto Purge Cycles field (2) and enter a suitable value.
7. Check that the Hopper Open check box (3) is enabled.
8. Press the <AUTO> cycle key, then the <CYCLE START> key to start auto purging.
Auto purging will stop after the specified number of purge cycles.
WARNING!
Burn hazard – risk of serious injury. Wear PPE when handling purged material.
9. After purging is completed, empty the purged material in the tray into a suitable
metal container for disposal.
Purging Barrel Before Production 5–64 v 4.11.1 — March 2007

5.17 Cleaning Nozzle Tip & Purge Guard
Clean the nozzle tip and purge guard using the instructions below.
WARNING!
Explosion hazard – risk of serious injury. Molten material at high pressure can
be present. Wear PPE, and use a mirror to look in the nozzle opening.
WARNING!
Burn hazard – risk of serious injury. Machine surfaces can be hot. Molten
process material can be hot. Wear PPE.
CAUTION!
Risk of damage to nozzle tip. Use brass tools to remove any process material
build-up.
1. Open the purge guard (1), and use a brass tool to carefully remove all molten
material (2) from the nozzle tip. Refer to Figure 5-75.
2. Remove all molten material from the stationary platen.
3. Use the brass tool to remove any solidified process material inside the purge
guard. Close the purge guard.
4. Press and hold the <CARRIAGE FORWARD> key until the nozzle tip is firmly
seated against the mold sprue.
WARNING!
Burn hazard – risk of serious injury. Wear PPE when handling molten process
material.
5. After cleaning, dispose the cooled molten process material into a suitable metal
container.
1
S01-100988.eps
Figure 5-75 Cleaning Nozzle Tip and Purge Guard

1. Purge guard (sliding type) 2. Molten material
After cleaning the nozzle tip and purge guard, refer to Section 5.18.
v 4.11.1 — March 2007 5–65 Cleaning Nozzle Tip & Purge Guard
5.18 Cycling and Fine-tuning Machine
Before starting production fine-tune all machine functions using the following
instructions.
button.
3. Check the mold is closed. If necessary, press the <MOLD CLOSE> key.
4. Press the <CARRIAGE FORWARD> key and check that the nozzle tip is firmly
seated against the mold sprue.
5. Press the <SEMI> key, then the <CYCLE START> key to cycle the machine.
6. Adjust all machine functions, as required.
After fine-tuning machine functions, refer to Section 5.19.
5.19 Setting Up SPC
Set up SPC after the process has stabilized. Refer to Chapter 9 to set up and run SPC
quickly.
After setting up optional SPC, refer to Section 5.20.
5.20 Saving Machine Setups
Save all current machine setups to Machine Memory using the instructions below.
Machine setups should also be saved to Portable Memory as a back up.
NOTE: You cannot save mold setups if you do not have suitable user access rights.
NOTE: Active setups are always saved from the RAM in the PC to the local hard disk.
To save to removable media, refer to Section 5.8.1.
You can save both the active machine setup and the active robot program together, or
save them separately to the local hard disk. Save the active setup using the following
instructions:
MOLD SETUP screen.
Cycling and Fine-tuning Machine 5–66 v 4.11.1 — March 2007

Figure 5-76 MOLD SETUP Screen

1. Recall setup button 2. Save setup button 3. Delete setup button 4. Copy setup
button
2. If you wish to overwrite an existing machine setup file or robot program file on the
local hard disk, select the appropriate machine setup and robot program files (as
applicable) from the list boxes on the MOLD SETUP screen.
Otherwise, leave them unselected.
3. Touch the Save Setup button (Figure 5-76, item 2) to display the SAVE MOLD
SETUP pop-up window – refer to Figure 5-77.
4. Touch the Machine Setup check box to save only the machine setup file, or the
Robot Program check box to save only the robot program file, or select both check
boxes to save both files.
NOTE: If both Machine Setup and Robot Program check boxes are selected, a
link is automatically established between the two files when the active
setup is saved to the local hard disk.
CAUTION!
Risk of overwriting existing machine setup and robot program files with the
same name on the local hard disk. If you do not wish to overwrite the existing
files, enter a name that is not already used.
Figure 5-77 SAVE MOLD SETUP Pop-up Window
v 4.11.1 — March 2007 5–67 Saving Machine Setups

5. Enter a suitable name in the text boxes for the machine setup file and robot
program file, as applicable, or leave them as displayed. If a check box is selected,
it must be assigned a file name.
The file names can be up to 32 characters long, and cannot contain the word
"Template".
6. Touch the Save button to write the active setup to the local hard disk, or touch the
Cancel button to cancel the save.
If a machine setup file or robot program file with the same file names exist on the
local hard disk, a warning message is displayed prompting you to confirm the
overwrite. Touch the Yes button to overwrite the file, or the No button to cancel the
save.
If a robot program file is to be overwritten, a list of all available machine setups files
linked to that particular robot program file will be displayed. You will be prompted to
select one of the following options – keep the existing links, break the existing
links, or cancel the save.
The robot program file (if applicable) is saved to the local hard disk first. If the file is
saved successfully, then the machine setup file is saved to the local hard disk.
Otherwise, the machine setup file is not written to the hard disk.
If the machine setup and robot program files are saved successfully to the hard
disk, the Machine Setup and Robot Program text boxes and list boxes on the
MOLD SETUP screen are updated to display the new file names. The Machine list
box also displays the file name of the linked robot program (if applicable).
5.21 Starting Production
Start production using the following instructions.

button.
2. Press the <AUTO> cycle key.
3. Then press the <CYCLE START> key to start production.
Starting Production 5–68 v 4.11.1 — March 2007

5.22 Logging Off
Once the machine has been set up, the operator can log off the machine, and the
machine will run unattended. Section 5.22.1, and Section 5.22.2.
5.22.1 Logging Off Using the Log Off Button

Use the following instructions to log off using the Log Off button.
1. Press the Log Off button on the toolbar. Refer to Figure 5-78.
The HMI displays the message “Are you sure you want to log off?”
2. Press the Yes button to log off the machine.
Figure 5-78 Log Off Button

1. Log Off button
5.22.2 Logging Off Using the Datakey

If a datakey is used to log on to the machine, remove it from the bottom of the HMI to
log off the machine. Refer to Figure 5-79.
Figure 5-79 Datakey

1. Datakey
v 4.11.1 — March 2007 5–69 Logging Off

Logging Off 5–70 v 4.11.1 — March 2007

Machine Manual Stopping Machine
Chapter 6 Stopping Machine
The machine is considered stopped when all motions stop, and all stored energy in the
machine is discharged.
NOTE: When the operator safety gate is opened, the machine motions stop.
However, the pumps keep running, and the hydraulic system remains fully
energized. In this condition, the machine is not considered stopped.
This chapter discusses three different ways to stop the machine.
• Stopping Machine in an Emergency
• Pausing Machine
• Stopping Machine in a Controlled Manner
In addition, it also discusses:
• Unexpected Machine Stoppage
6.1 Stopping Machine in an Emergency
The <EMERGENCY STOP> button allows the operator to stop the machine during an
emergency. All machine motions stop, all pumps stop, and the hydraulic system
pressure is discharged.
The <EMERGENCY STOP> button should not be used to stop the machine in non-
emergency situations. Use Controlled Stop instead.
1. Push the <EMERGENCY STOP> button to stop the machine during an emergency
(1). Refer to Figure 6-1.
2. After clearing any problems, pull the button to reset the Emergency Stop (2).
3. Restart the machine as usual. Refer to Chapter 5—Starting Machine.
v 4.11.1 — March 2007 6–1 Stopping Machine in an Emergency

S01-101089.eps
S01-101063.eps
1 2
Figure 6-1 Emergency Stop Button (Typical)

1. Pushing the Emergency Stop button 2. Resetting the Emergency Stop button
6.2 Pausing Machine
Pause the machine for short periods using the following instructions.
WARNING!
Explosion hazard – risk of death or serious injury. Pressure can build up in a
nozzle or feed throat area and cause some process material to explode. To
prevent pressure build up, purge the barrel if the machine will be paused for
longer than 90 seconds – refer to Section 6.3.3.
1. Press the <SEMI> cycle key to take the machine off Auto cycle mode. The
machine completes one cycle, then stops.
2. Press the <HEATS> key to display the BARREL tab (1). Refer to Figure 6-2.
3. Select the Standby check box (2) to reduce machine heats.
Pausing Machine 6–2 v 4.11.1 — March 2007

Figure 6-2 BARREL Tab

1. BARREL tab 2. Standby check box
4. If the machine is equipped with mold heats, select the MOLD tab (1). Refer to
Figure 6-3.
5. Select the Standby check box (2) to reduce mold heats.
Figure 6-3 MOLD Tab

1. MOLD tab 2. Standby check box
6. If the machine is equipped with nozzle heats, select the NOZZLE TIPS tab. Refer
to Figure 6-4.
7. Select the Standby check box to reduce nozzle heats.
NOTE: If heat control is set to "manual", selecting the check box will not reduce
nozzle heats.
v 4.11.1 — March 2007 6–3 Pausing Machine

Figure 6-4 NOZZLE TIPS Tab

1. NOZZLE TIPS Tab 2. Standby check box
When ready to start production, restart the machine as usual. Refer to Chapter 5—
Starting Machine.
6.3 Stopping Machine in a Controlled Manner
Stop the machine for an extended period of time, or at the end of production in the
order shown below.
1. Stopping Production – refer to Section 6.3.1
2. Shut Off Process Material – refer to Section 6.3.2
3. Purging Barrel After Production – refer to Section 6.3.3
4. Cleaning Nozzle Tip and Purge Guard – refer to Section 6.3.4
5. Emptying Hopper (optional) – Section 6.3.5
6. Turning Heats Off – refer to Section 6.3.6
7. Cleaning Mold – refer to Section 6.3.7
8. Turning Mold Cooling Off (optional) – refer to Section 6.3.8
9. Removing Mold (optional) – refer to Section 6.3.9
10. Turning Pumps Off – Section 6.3.10
11. Turning Air Off (optional) – Section 6.3.11
12. Powering Down (optional) – refer to Section 6.3.12
Stopping Machine in a Controlled Manner 6–4 v 4.11.1 — March 2007

6.3.1 Stopping Production

Stop production using the following instructions.
1. Press the <SEMI> cycle key to take the machine off Auto cycle mode. The
machine completes one cycle, then stops.
6.3.2 Shutting Process Material Feed Off

Shut off process material feed using the following instructions.
1. If the machine is equipped with an optional magnet drawer, pull the handle (1) out
all the way to shut off material feed. Refer to Figure 6-5.
2. Shut off external process material supply to the hopper or direct feed tube.
S01-100135.eps
Figure 6-5 Magnet Drawer (Typical)
3. If the machine is equipped with an optional feed auto-shutoff, press the

<INJECTION> key, then select the RECOVERY tab (1). Refer to Figure 6-6.
4. Deselect the Hopper Open check box (2).
v 4.11.1 — March 2007 6–5 Stopping Machine in a Controlled Manner


1. RECOVERY tab 2. Hopper Open check box
WARNING!
Burn hazard – risk of serious injury. Machine surfaces can be hot. Wear PPE.
5. Loosen the knob in the manual shutoff (1). Refer to Figure 6-7.
6. Pull the slider until the detent pin in the knob locks it in the first position after the
feed throat. Tighten the knob.
1
S01-100126.eps
Figure 6-7 Manual Shutoff Knob (Typical)

1. Manual shutoff
6.3.3 Purging Barrel After Production

Purge the barrel after production using one of the following two methods.
• Manual Purging – refer to Section 5.16.1.
• Auto Purging – refer to Section 5.16.2.

CAUTION!
Risk of damage to the plasticizing screw. The plasticizing screw can seize up in
the barrel. Never leave the injection piston fully retracted.
1. Press the <SCREW ROTATE> key or <INJECT> key until the injection piston is
located a distance approximately twice the diameter of the plasticizing screw back
from the zero position (1).
2. Leave the carriage in the purge position. Check that the nozzle tip does NOT make
contact with the mold sprue.
Figure 6-8 Purging Barrel

1. Injection Position field
6.3.4 Cleaning Nozzle Tip & Purge Guard

Clean the nozzle tip and purge guard after purging the barrel – refer to Section 5.17.
6.3.5 Emptying Hopper

Empty the hopper or direct feed tube, when necessary, using the following
instructions. Otherwise, refer to Section 6.3.6.
1. Check that all external process material supply to the hopper or direct feed tube is
switched off.
WARNING!
2. Place a container under the drain tube to catch all process material from the
hopper or direct feed tube.

3. Loosen the knob in the manual shutoff, and pull the slider all the way until the
detent pin in the knob locks it at the discharge tube. Empty all process material
from the discharge pipe. Refer to Figure 6-9.
S01-100127.eps
Figure 6-9 Manual Shutoff Knob (Typical)

1. Manual shutoff knob
4. If the machine is equipped with an optional feed auto-shutoff, press the

<INJECTION> key, then select the RECOVERY tab (1). Refer to Figure 6-10.
5. Select the Hopper Open check box (2).

1. RECOVERY tab 2. Hopper Open check box
6. If the machine is equipped with an optional magnet drawer, push the handle (1) all
the way in to open material feed. Refer to Figure 6-11.

S01-100033
7. After emptying all process material, push the slider until the detent pin in the knob
locks it in the first position before the feed throat. Check that the feed throat
opening is covered. Tighten the knob.
8. Pull the handle in the magnet drawer to shut off feed.
9. Deselect the Hopper Open check box on the INJECTION screen.
6.3.6 Turning Heats Off

Turn off machine heats, mold heats, and nozzle tip heats using the following
instructions.
6.3.6.1 Shutting Machine Heats Off

Shut off machine heats using the following instructions.
2. Deselect the Machine Heats Enable check box (2) to shut off machine heats.


1. BARREL screen 2. Machine heats enable check box
6.3.6.2 Shutting Mold Heats Off

Shut off mold heats using the following instructions.
1. If the machine is equipped with mold heats, select the MOLD tab (1). Refer to
Figure 6-13.
CAUTION!
Risk of damage to the mold. Leave mold cooling on until mold cools to 37°C
(100°F).
2. Deselect the Mold Heats Enable check box (2) to shut off mold heats.

Figure 6-13 MOLD Tab.

1. MOLD tab 2. Mold Heats Enable check box
6.3.6.3 Shutting Nozzle Heats Off

Shut off nozzle heats using the following instructions.
1. If the machine is equipped with nozzle heats, select the NOZZLE TIPS tab (1).
2. Deselect the Nozzle Heats Enable check box (2) to shut off nozzle heats.
Figure 6-14 NOZZLE TIPS Tab.

1. NOZZLE TIPS tab 2. Nozzle Heats Enable check box

6.3.7 Cleaning Mold
WARNING!
Burn hazard – risk of serious injury. Mold can be hot. Wear PPE.
Refer to the mold manual for instructions to clean the mold.

1. After cleaning the mold, check that the <MANUAL> cycle key is enabled.
2. Check that the Machine Function Mode Selector on the toolbar displays the Mold
Set button.
3. Press and hold the <MOLD CLOSE> key until there is a gap of approximately 5
mm (0.25 in) between the mold halves.
6.3.8 Turning Mold Cooling Off

On machines equipped with optional mold cooling, turn off cooling water using the
instructions below.
CAUTION!
(100°F).
1. After the mold has cooled off, press the <MOLD COOLING> key to shut off
cooling.
6.3.9 Removing Mold

If it is necessary to remove the mold, use the following instructions. Otherwise, refer to
Section 6.3.10.
button.
CAUTION!
(100°F).
3. After the mold has cooled off, press the <MOLD COOLING> key to shut off
cooling.
WARNING!
Burn hazard – risk of serious injury. The mold can be hot. Wait for the mold to
cool down to 37°C (100°F) before removing it.

4. Disconnect heater cables, cooling water hoses, and any mechanical, pneumatic,
or hydraulic ejector functions. Purge cooling water from the mold with compressed
air.
5. Press and hold the <MOLD CLOSE> key to close the mold.
WARNING!
Crushing hazard – risk of death or serious injury. Attach safety latches and a
lifting eye bolt with a shoulder or a swivel lifting bolt, before hoisting the mold. If
using a lifting eyebolt with a shoulder, ensure the shoulder is in contact with the
area around the tapped hole. Use suitable lifting equipment, and ensure that the
mold is level and balanced as it is hoisted.
6. Install safety latches (1) and lifting eye bolt (2). Refer to Figure 6-15.
7. Attach a lifting hook (3) to the eye bolt, and take up the slack in the lifting slings (4).
3
4
5
S01-100584.eps
S01-100585.eps
1
6
Figure 6-15 Safety Latches and Lifting Eye Bolt (Typical)

1. Safety latches 2. Lifting eye bolt 3. Lifting hook 4. Lifting slings 5. Moving platen
bolts 6. Stationary platen bolts
8. Remove the bolts (5) holding the mold to the moving platen.
9. Press the <MOLD OPEN> key and move the moving platen out of the way.
10. Remove the bolts (6) holding the mold to the stationary platen.
11. Hoist the mold out of the machine and set it on a clean working surface. Refer to
the mold manual for storage instructions.
6.3.10 Turning Pumps Off

Turn off the pumps using the following instructions.
1. Press the <PUMP MOTOR OFF> key to shut off all pumps.

6.3.11 Turning Air Off

Turn air off using the following instructions.
1. Turn the shutoff lever (1) clockwise to turn off the air supply. Refer to Figure 6-16.
S01-101075.eps
Figure 6-16 Turning Air Off

1. Shutoff lever
6.3.12 Powering Down

Power down the machine using the following instructions.
CAUTION!
following sequence: Q3M, Q2M (if equipped) and finally, Q1M. Refer to
Figure 6-17.

2
3
S01-101110.eps
1
Figure 6-17 Powering Down (Typical)

1. Main machine breaker Q1M 2. Main machine breaker Q3M 3. Mold heats breaker
Q2M
At the end of production, perform daily maintenance procedures. Refer to Chapter 7—

Maintenance, Table 7-1.
6.4 Unexpected Machine Stoppage
The machine can also stop unexpectedly when certain alarms occur, or if there is a
power failure.
If there is an alarm, follow instructions in the alarm message, and restart the machine
as usual.
If there is a power failure, power up the machine and go through the start-up
procedures. Refer to Chapter 5—Starting Machine.
v 4.11.1 — March 2007 6–15 Unexpected Machine Stoppage

Unexpected Machine Stoppage 6–16 v 4.11.1 — March 2007

Machine Manual Maintenance
Chapter 7 Maintenance
This chapter contains a maintenance schedule, and maintenance procedures for all
preventative and corrective maintenance tasks.
Table 7-1 shows the daily, weekly, monthly, quarterly, semi-annual and annual
maintenance schedule.
Table 7-1 Maintenance Schedule – Hylectric Machines

Item Frequency Task Description Reference
1 Daily Drain water in air regulator Section 7.1
2 Daily Clean nozzle tip, stationary platen, and purge guard Section 5.17
3 Daily Check machine safety devices Section 5.3
4 Daily Clean the machine and HMI Section 7.2
5 Weekly Check accumulator prechargea Section 3.28.1
b
6 Weekly Check hydraulic tank oil quality Section 7.21
7 Weekly Checking oil filter Section 7.3
8 Weekly Inspect and clean magnet drawer Section 7.7
9 Weekly Inspect and clean hopper, optional hopper magnet Section 7.7
10 Weekly Check oil recovery pocket Section 7.9
11 Monthly Check electrical components Section 7.10
12 Monthly Check all hydraulic cylinders, valves, and manifolds Section 7.11
13 Monthly Check all hydraulic hose assemblies and fittings Section 7.12
14 Monthly Check system pressure Section 7.14
15 Monthly Check all cooling water components Section 7.15
16 Monthly Check all pneumatic valves and hoses Section 7.17
17 Monthly Lubricate mold stroke column guide bushings Section 7.18
18 Monthly Lubricate locking cylinder rod ends Section 7.19
19 Monthly Check drive cooling air filter Section 7.20
a
20 Quarterly Check accumulator precharge Section 3.28
21 Quarterly Check oil level in the hydraulic tank Section 7.22
22 Quarterly Check gearbox oil level Section 7.25
23 Quarterly Check electric motor Section 7.27
24 Quarterly Check mold stroke column guide bushings Section 7.29
25 Quarterly Check optional nozzle shutoff bushings and pins Section 7.30
v 4.11.1 — March 2007 7–1

Table 7-1 Maintenance Schedule – Hylectric Machines

Item Frequency Task Description Reference
26 Quarterly Replacing the pilot oil filters Section 7.38
27 Semi-annual Check oil quality in the hydraulic tankc Section 7.21
28 Semi-annual Lubricate linear bearings – moving platen (H/HL225 - H/ Section 7.32
HL500)
29 Semi-annual Lubricate linear bearings – optional stack mold carrier Section 7.33
30 Semi-annual Lubricate linear bearings – injection piston Section 7.34
31 Semi-annual Replace oil filter element Section 7.36
32 Semi-annual Replacing the blow-down filter Section 7.4
33 Semi-annual Cleaning the Y-strainer screens Section 7.5
34 Semi-annual Check carriage cylinder bushings and pins Section 7.39
35 Annual Level machine and adjust nozzle concentricity Section 3.21
36 Annual Replace breather cap filter element Section 7.41
37 Annual Replace air filter element Section 7.42
38 Annual Lubricate pump motor bearings Section 7.43
39 Annual Replace gearbox oil Section 7.26
40 As required Draining the cooling water system Section 7.16
41 As required Replace hydraulic oil Section 7.23
42 As required Check safety devicesd Section 7.45
43 As required Replace heater band Section 7.46
44 As required Change the plasticizing screw and check valve - RS22 to Section 7.47
RS115
45 As required Change the plasticizing screw and check valve - RS135 Section 7.48
and higher
46 As required Barrel removal and installation - RS22 to RS115 Section 7.49
47 As required Barrel removal and installation - RS135 and up Section 7.50
48 As required Oil recovery unit functional check Section 7.51
49 As required Calibrate the machine Section 7.53
a. This check needs to be performed once at the end of the first week after charging the accumulator.
b. This check needs to be performed once at the end of the first week after filling the hydraulic tank.
c. Semi-annually or every 4000 Machine Hours.
d. This check needs to be performed after upgrading software or performing maintenance on an interlock
component.
7–2 v 4.11.1 — March 2007

7.1 Draining Air Regulator
CAUTION!
Water condensation in the air regulator can cause rust damage to pneumatic
components. Drain water regularly from the sight glass in the regulator.
1. Place a container beneath the air regulator (1) – refer to Figure 7-1.
2. Open the bleed screws (2) to drain water from the cup. Tighten the bleed screws
after draining the water.
1
S01-101037.eps

1 Air regulator 2 Bleed screw
7.2 Cleaning the Machine and HMI
Cleaning Materials
1 Cleaning solution made up of 70% denatured alcohol and 30% water
1. Clean up any oil, dirt, grease or process material in and around the machine.
2. Clean the surface of the HMI screen and the membrane keys using a clean cloth
and the cleaning solution indicated above.
NOTE: Do not use solvents or abrasive materials to clean the machine and HMI.
Solvents and abrasive materials may cause corrosion or damage to the
machine and HMI surfaces.
v 4.11.1 — March 2007 7–3 Draining Air Regulator

7.3 Checking Oil Filter
At intervals specified in the Maintenance Schedule, check the oil filter using the
following instructions:
1. Press the <PUMP MOTOR ON> key to start the hydraulic pumps. Allow the oil to
come up to operating temperature. Check that the low oil temperature alarm on the
ALARMS screen is cleared.
NOTE: The ALARMS screen will also display "Dirty Oil Filter" message when the
element is clogged. The machine can run with a clogged filter for a two
hour period, after which the machine will shut down.
2. Check the LED (1) on the top of the filter (2) is green – refer to Figure 7-2. When
the filter is dirty, the LED is red in color.
If necessary, replace the dirty filter element – refer to Section 7.36.
Figure 7-2 Hydraulic Filter

1 LED 2 Oil filter
Checking Oil Filter 7–4 v 4.11.1 — March 2007

7.4 Blow-Down Filter Change
The Blow-Down filter element (Figure 7-3, item 1) should be changed every 6 months
or if there is a Blow Down alarm on the HMI.
NOTE: If the blow-down filter is being replaced it would be prudent to clean the Y-
strainer screens at the same time. Contamination in the blow-down filter could
also be found in the Y-strainer screens. See Section 7.5.
2. Open the power pack cover and locate the blow-down filter mounted on the right
side of the hydraulic tank.
3. Disconnect the hose from the bottom of the filter body, (Figure 7-3, item 2). Have a
small bucket available to catch leaking fluid.
NOTE: A check valve inside the tank will prevent hydraulic fluid inside the tank
from pouring out of the blow-down filter once disconnected.
Figure 7-3 Blow-Down Filter

1 Blow-Down filter 2 Filter bowl
4. Turn the filter bowl and remove the filter element.

5. Install the new filter inside the filter body (item 2).
6. Reinstall the filter bowl onto the blow-down filter (item 1).
7. Reconnect the hose on the bottom of the filter body. Torque to specification (See
Section 2.12).
v 4.11.1 — March 2007 7–5 Blow-Down Filter Change

7.5 Y-Strainer Screen Cleaning
The Y-strainer screens (Figure 7-4, item 3) should be removed and cleaned every 6
months or when no vacuum is able to be generated.
2. Open the power pack cover and locate the four bronze Y-strainers (Figure 7-4,
mounted on the inside left of the power pack).
1
2 3
2
Figure 7-4 Bronze Y-strainers

1. Strainer retaining nut 2. Filter inlet tubing 3. Screens
3. With a wrench, remove the strainer retaining nuts (item 1).

4. Remove the screens (item 3) from the Y-strainers and clean.
5. Reinstall the screens (item 3).
6. Reinstall the strainer retaining nuts and torque to specification. (See Section 2.12).
7.6 Inspecting and Cleaning Hopper
1. Remove the lid, and clean the inside of the hopper (1) with a clean cloth – refer to
Figure 7-5.
2. If the hopper is equipped with an optional hopper magnet (2), remove any metal
objects from the magnet, and wipe it with a clean cloth.
3. Replace the hopper magnet, and install the lid.
Y-Strainer Screen Cleaning 7–6 v 4.11.1 — March 2007

1
S01-101013.eps
Figure 7-5 Hopper and Optional Hopper Magnet (Typical)

1 Hopper 2 Optional hopper magnet
v 4.11.1 — March 2007 7–7 Inspecting and Cleaning Hopper

7.7 Inspecting and Cleaning Optional Magnet Drawer
1. Pull the handle (1) to shut off process material feed into the magnet drawer (2) –
2. Empty all process material from the magnet drawer. Refer to Section 6.3.5.
4
S01-101084.eps

1 Handle 2 Magnet drawer 3 Knob 4 Magnet
3. Loosen the knobs (3) and swivel it to the side.

4. Remove the magnet assembly using the handle.
5. Wipe the magnets (4) with a clean cloth.
6. Replace the magnet assembly and fasten it.
Inspecting and Cleaning Optional Magnet Drawer 7–8 v 4.11.1 — March 2007
7.8 Clearing Feed Throat
Clear feed throat using the following instructions.

1. Perform Lockout/Tagout – refer to Section 1.6.1.
WARNING!
Burn or explosion hazard – risk of death or serious injury. Molten process
material at high pressure can be present. Wear PPE, and keep face and body
away from the feed throat area.
2. Loosen the knob (1), and carefully move the slider (2) to expose the feed throat
opening (3) – refer to Figure 7-7.
3. Keep face away from the feed throat area, and vacuum out any process material
pellets in the feed throat. If the screw is not clearly visible through the feed throat
opening, process material may have solidified in the feed throat.
CAUTION!
Risk of damage to the machine. Use only brass tools to dislodge solidified
process material.
4. Exercise extreme caution when removing solidified material from the feed throat.
Keep face away from the feed throat, and carefully remove solidified material using
a brass chisel and a hammer.
5. Vacuum out all pieces of process material from the feed throat.
3 1 2
S01-100126.eps
Figure 7-7 Cleaning Feed Throat (Typical)

1 Knob 2 Slider 3 Feed throat opening
v 4.11.1 — March 2007 7–9 Clearing Feed Throat

7.9 Checking the Oil Recovery Pocket
1. In manual mode, press the <INJECT> key until the injection piston is fully forward.
2. Perform a visual check of the oil recovery pocket for oil, grease or process
material.
3. Clean the oil recovery pocket, if needed – refer to Section 7.9.1.
7.9.1 Cleaning the Oil Recovery Pocket
Cleaning Materials
1 Cleaning solution made up of 70% denatured alcohol and 30% water

2. Remove the Plexiglas panel (1) – refer to Figure 7-8.
3. Clean up any oil, grease, or process material in and around the oil recovery pocket
(2) or (3).
4. Replace the Plexiglas panel.
2 3
S01-101106.eps
Figure 7-8 Cleaning Oil Recovery Pocket (Typical)

1 Plexiglass panel 2 Oil recovery pocket 3 Oil recovery pocket
Checking the Oil Recovery Pocket 7–10 v 4.11.1 — March 2007

7.10 Checking Electrical Components
WARNING!
procedure according to local codes before opening electrical cabinet. Only
qualified persons who are knowledgeable with machine and hazards should
perform this procedure. After performing Lockout/Tagout procedure, allow 10
minutes for residual voltage to discharge to less than 50 Volts.
1. Perform Lockout/Tagout procedure – refer to Section 1.6.1, then wait 10 minutes

for residual voltage to discharge.
2. Make sure the electrical cabinet sits firmly on its leveling mounts.
3. Wipe the heat sink with a clean cloth.
4. Open the electrical cabinet doors, and check for cracked, burnt, or corroded
components.
5. Check and retighten all power and control connectors in the electrical cabinet.
Check the DC power supply, control circuit breakers, optional mold heat circuit
breakers, and machine heat circuit breakers.
6. Check the cooling fan is clean, and the air flow path is free of obstructions.
7.11 Checking Hydraulic Cylinders, Valves and Manifolds
Check the seals in the cylinders, valves and manifolds at intervals specified in the
Maintenance Schedule. Also check for any signs of oil leaks, or wear, or damage.
v 4.11.1 — March 2007 7–11 Checking Electrical Components

7.12 Checking Hydraulic Hose Assemblies
WARNING!
High pressure spray hazard – risk of death or serious injury. Loose connections
can cause high pressure hydraulic oil spray that can penetrate human tissue
causing death or serious injury. To locate the origin of a leak, use a piece of
sheet metal.
WARNING!
Fire hazard – risk of death or personal injury, and property damage. Loose
connections can cause hydraulic oil to spray onto hot machine surfaces and
start a fire. Regular inspection of hoses and connections, and regular
replacement of hoses will minimize such fire hazards.
WARNING!
Burn hazard – risk of serious injury. Hydraulic oil can be very hot. Wear PPE,
and avoid any contact with hot oil.
CAUTION!
Hoses must be replaced every three years, or when regular inspection identifies
problems. The recommended storage life of a hose is seven years.
High pressure hydraulic oil spray from damaged or worn hoses, or loose connections
can penetrate human tissue causing death or serious injury. Regular inspection of
hoses and connections, and regular replacement of hoses will prevent such hazards.
Hydraulic oil spray or mist from damaged hoses or loose connections will ignite when it
contacts hot surfaces at temperatures equal to or above the oil’s flash point. Regular
inspection and replacement of hoses will minimize such a fire hazard.
1. Turn the pump motor off.
2. Check all hydraulic hoses for any signs of blisters (1), wear (2), radial cracks (3), or
oil leaks from the ends of crimped fittings – refer to Figure 7-9. Replace all
damaged hoses.
3. Check the hydraulic suction hoses are not collapsed or damaged. Replace all
damaged suction hoses.
4. Check for any loose hose fittings. Tighten all hose connections to Husky
specifications – refer to Section 2.12.
Checking Hydraulic Hose Assemblies 7–12 v 4.11.1 — March 2007

3
S01-101079.eps
Figure 7-9 Inspecting Hose Assemblies

1 Blister 2 Wear 3 Radial crack
7.12.1 Reading Layline Information

Hoses are marked with layline information to indicate hose specifications. The
following is an example of two typical laylines with an explanation of each section.
HUSKY 4SH 40 DIN20023 290 BAR WP 1Q01 053

HUSKY: Machine manufacturer.
4SH: The hose type relating to the DIN specification.
40: Nominal size in millimeters.
DIN20023: The DIN specification of the hose.
290 BAR WP: 290 bar working pressure.
1Q01: The hose was manufactured in the first quarter of the year 2001.
053: The lot number in the calendar year. The hose was manufactured in the 53rd lot of 2001.
GATES GLOBAL 5M4K 5/16" (7.9mm) 4000 PSI (28.0MPa) MAX WP FLAME RESISTANT
USMSHA 2G-11C >NBR/NBR-PVC< MADE IN BELGIUM BL 03 1500
GATES GLOBAL: Company name.
5: Hose size in 1/16 inches.
4000 PSI (28.0MPa) MAX WP FLAME RESISTANT: Maximum working pressure.
USMSHA United States Mine Safety & Health Administration.
2G-11C: USMSHA release number.
>NBR/NBR-PVC< Recyclability code (VDA 260).
MADE IN BELGIUM: Country of manufacturing.
BL: Manufacturing plant.
03: Month of manufacture.
1500: Day and year of manufacture.
v 4.11.1 — March 2007 7–13 Checking Hydraulic Hose Assemblies

7.13 Replacing Hydraulic Hose Assemblies
7.13.1 Removing Hydraulic Hose Assemblies

Remove hydraulic hose assemblies using the following instructions.
WARNING!
High pressure spray hazard – risk of death or serious injury. High pressure
hydraulic oil spray can penetrate human tissue causing death or serious injury.
Perform Lockout/Tagout before removing any hose.
WARNING!
Burn hazard – risk of serious injury. Hydraulic oil can be very hot. Wear PPE,
and avoid any contact with hot oil.
IMPORTANT!
Drain the hydraulic reservoir when:
5 •
•
Removing a clamp hydraulic component which is below the fluid level of the injec-
tion unit tank.
Disconnecting a reservoir hydraulic line.
For directions on draining the reservoir, proceed to Section 7.23.1.
CAUTION!
Failure to drain the hydraulic reservoir before removing hydraulic hoses or
components located below the level of the reservoir will cause a massive oil
leak.
2. If a reservoir hydraulic line on the injection unit will be disconnected during

maintenance activities, de-pressurize the reservoir by lifting and then lowering the
over-pressure relief poppet. It is located on the injection base beside the filter/
breather.
3. Disconnect the hydraulic hose, and drain it into a suitable container.
4. Cap the fitting to prevent oil contamination.
5. Carry out maintenance procedure.
7.13.2 Reinstalling Hydraulic Hose Assemblies

Reinstall hydraulic hose assemblies using the following instructions.
1. Remove the cap from the fitting.
If the hose assembly has a flanged fitting, carefully inspect the O-ring for damage.
Replace the O-ring, if necessary.
Replacing Hydraulic Hose Assemblies 7–14 v 4.11.1 — March 2007

2. Reinstall the hose assembly, and torque all connections to Husky specifications –
3. Remove locks and tags – see Section 1.6.2.
WARNING!
Fire Hazard – risk of personal injury and property damage. After reinstalling
hydraulic hoses, test the connections under pressure before turning on the
barrel heats.
4. Press the <PUMP MOTOR ON> key to start the hydraulic pumps.
button.
6. Press the <MANUAL> cycle key, and cycle the machine a few times.
7. Check for any leaks.
If the connection leaks, press the <PUMP MOTOR OFF> key immediately.
Remove and reinstall the hydraulic hose assembly.
v 4.11.1 — March 2007 7–15 Replacing Hydraulic Hose Assemblies

7.14 Checking System Pressure
1. Press the <PUMP MOTOR OFF> key to stop the motor.

for specific location.
3. Attach a hydraulic pressure gauge suitable to 21 MPa (3000 psi) with a quick-
disconnect fitting to the gauge port.
4. Press the <PUMP MOTOR ON> key to start the motor.
5. Allow the system pressure to build up. Check the system pressure is set according
to the value in Section 2.11.
7. Remove the pressure gauge and cap the gauge port.
7.15 Checking Cooling Water Components
WARNING!
High pressure hazard – risk of death or serious injury. High pressure steam or
boiling water can be trapped in the cooling water components. Wear heat
resistant gloves and slowly release the pressure from the cooling system
through the drain cocks before working on any cooling water component.
WARNING!
Check for loose fittings and cooling water leaks in the:

• Optional stationary platen cooling water manifold
• Optional moving platen cooling water manifold
• Mold cooling water connections
• Feed throat
• Machine cooling water connections
Check for cooling water leaks on the machine and inside the power pack. Check for
any wear or damage to hoses and components.
Checking System Pressure 7–16 v 4.11.1 — March 2007

7.16 Disconnecting Machine Cooling Water Supply
When storing the machine, or leaving it idle, for an extended period of time, Husky
recommends disconnecting the machine cooling water supply and draining all water
cooled components.
CAUTION!
Risk of damage to the machine. Any water trapped in the machine can freeze
and cause damage. Flush out any trapped water using compressed air.
Disconnect the machine water cooling system using the instructions below:
1. Shut off cooling water supply to the machine.
2. Remove the supply line at the inlet (1), and the return line at the outlet (2) – refer to
Figure 7-10.
2 1
S01-101026b.eps
Figure 7-10 Machine Cooling Water Supply (Typical)

1 Inlet 2 Outlet
7.16.1 Draining Main Motor and Heat Exchanger

1. Plug the water in and water out lines – see Figure 7-10.
2. Make sure the drain port is open – see Figure 7-11, item 6.
3. Connect air pressure hose to the air inlet (1) on the water inlet valve – see
Figure 7-11.
v 4.11.1 — March 2007 7–17 Disconnecting Machine Cooling Water Supply

4. Energize solenoid “A”.

5. Turn water inlet valve handle (2) counterclockwise 90°, as shown in Figure 7-11.
RS80 and up Water Inlet

Units smaller Valve
than RS80
1 Units smaller
1 than RS80 4
3 3
A
-90°
°
90°
° -90°

90°

2
RS80 and up
4
B
7
Water Outlet
Valve
90°
°
Water Drain
Port Valve
180°
° 6
Figure 7-11 Cooling Water Circuit (Typical)

1 Air inlet 2 Water inlet valve handle (working position) 3 Water inlet
4 Water outlet 5 Drain port valve handle (working position) 6 Drain port 7 Heat
exchanger drain port (hidden)
6. Turn water drain port valve (5) 180°.

7. Blow compressed air into the air inlet until water stops flowing out of the drain
port (6).
Disconnecting Machine Cooling Water Supply 7–18 v 4.11.1 — March 2007

8. De-energize solenoid “A” and energize solenoid “B”.

port (6).
10. Open heat exchanger drain port (7) and allow remaining water to drain. Close port.
7.16.2 Draining Feed Throat

1. Plug the water in line and open the water out line.
2. Open the feed throat ball valve – see Figure 7-12.
Figure 7-12 Feed Throat Ball Valve (Typical)
Figure 7-11.
4. Turn water inlet valve handle (2) clockwise 90°, as shown in Figure 7-11.
5. Turn water drain port valve (5) 180°.
6. Blow compressed air into the air inlet until water stops flowing out of the water
outlet (4).
7.16.3 Draining Gearbox, Cabinet, and Injection Motor

Figure 7-11.
2. Make sure the drain port is open.
3. Close the feed throat ball valve.
4. Turn water inlet valve handle (2) clockwise 90°, as shown in Figure 7-11.
v 4.11.1 — March 2007 7–19 Disconnecting Machine Cooling Water Supply

5. Turn water drain port valve (5) counterclockwise 90°.

6. Energize solenoid “A”.
port (6).
7.16.4 Flushing System with Antifreeze

Perform the following after completing the water draining procedure outlined in
Section 7.16.1, Section 7.16.2, and Section 7.16.3.
1. Place the handles on the water inlet and outlet valves to the working position (refer
to Figure 7-11).
2. Fill the cooling water system with antifreeze.
3. Repeat the draining procedures in Section 7.16.1, Section 7.16.2, and
Section 7.16.3 for the antifreeze.
4. Open heat exchanger drain port and allow remaining antifreeze to drain. Close
port.
7.16.5 Shipping
Once all the water and antifreeze have been drained from the cooling water circuit,
leave the water inlet valve handle in the clockwise 90° position, and the water drain
port valve in the counterclockwise 90° position.
CAUTION!
Risk of machine damage. Do not plug the air inlet or the drain port.
REMINDER: Return the water inlet and drain port valve handles to the working
position, see Figure 7-11, before putting the machine back in operation.
Disconnecting Machine Cooling Water Supply 7–20 v 4.11.1 — March 2007

7.17 Checking Pneumatic Valves and Hoses
Check the following pneumatic components at intervals specified in the Maintenance

Schedule. Check for any evidence of air leaks or damage.
REMINDER: Hoses should be replaced every three years, or when regular

inspection identifies problems.
1. Check all pneumatic hoses for any signs of blisters, cuts, cracks, hardness or
brittleness. Replace all damaged hoses – refer to Section 7.17.1.
2. Tighten any loose pneumatic hose fittings.
7.17.1 Replacing Pneumatic Valves and Hoses

2. Remove the hose from the fitting and replace with a new hose.
3. Torque all connections to Husky specifications – refer to Section 2.12.
5. Listen for air leaks. If necessary, perform Lockout/Tagout procedure and check the
hose fittings.
v 4.11.1 — March 2007 7–21 Checking Pneumatic Valves and Hoses

7.18 Lubricating Mold Stroke Column Guide Bushings

2. Wipe the grease fittings on the four guide bushings (1) – refer to Figure 7-13.
3. Apply food grade grease indicated on Section 2.8 to the grease fittings. Wipe off
any excess grease.
S01-101028.eps
Figure 7-13 Lubricating Mold Stroke Column Guide Bushings
1 Guide bushing (Typical)
Lubricating Mold Stroke Column Guide Bushings 7–22 v 4.11.1 — March 2007
7.19 Lubricate Locking Cylinder Rod Ends

2. Wipe the grease fittings on the locking cylinder (1) – refer to Figure 7-14.
S01-101029.eps
1
Figure 7-14 Lubricating Locking Cylinder Rod Ends

1 Locking cylinder (Typical)
3. Apply extreme pressure moly grease indicated on Section 2.8 to the two grease
fittings. Wipe off any excess grease.
7.20 Drive Cooling Air Filter
Once a month (more or less frequently depending on experience that you gain at your
plant) remove the cooling filter.
2. Inspect the air filter. If there is an accumulation of dirt on the filter, replace the filter.
3. Remove locks and tags - refer to Section 1.6.2.
v 4.11.1 — March 2007 7–23 Lubricate Locking Cylinder Rod Ends

7.21 Checking Hydraulic Tank Oil Quality
1 Hydraulic fluid sampling kit (Part number 661218)
2 Oil Sample Acquisition tool (Part Number 739193)
High quality hydraulic oil is essential for optimum machine performance and
dependability. Failure to comply with the recommended guidelines for oil replacement
can result in warranty limitation in the event of hydraulic component failure.
WARNING!
High pressure spray hazard - risk of death or serious injury. High pressure
hydraulic spray can penetrate human tissue causing death or serious injury.
NOTE: Semi-annual oil samples (or every 4000 machine hours) are strongly
recommended to allow for proper trending to be carried out and to monitor and
confirm the health of the oil in the reservoir. Alternatively, we suggest the
annual replacement of the reservoir's fluid.
NOTE: Prior to performing this procedure, the machine must be run for a minimum of
30 minutes to evenly distribute particles within the oil, and must be operating
at normal system temperature.
IMPORTANT!
5 It is extremely important to baseline a sample of the oil when it is new. All

comparisons of the quality of the oil from that point onward will be compared to the
new sample.
1. Clean the outside of port PP1G (1) on the power manifold and connect the
sampling valve (2) – refer to Figure 7-15.
NOTE: The location of port PP1G on the manifold varies depending on machine
type and size. Check your hydraulic schematics for the location of the port.
Checking Hydraulic Tank Oil Quality 7–24 v 4.11.1 — March 2007

Figure 7-15 Oil Quality (Typical)

1 Port PP1G 2 Sampling valve 3 Sampling hose
2. Place the hose end (3) of the sampling valve over a clean container, and turn the
handle on the sampling valve to fully open the valve. Release approximately 1 L
(0.25 gallon) of oil into the container.
NOTE: Do not touch the valve while taking the sample. Touching the valve may
cause particles to loosen and contaminate the sample.
3. Fill a sample bottle with oil, cap it and rinse the sample bottle with the oil. Dump the
oil into the waste container. Do this twice before taking the final sample. Fill the
sample bottle to within 1 cm (.5 in) of the top.
4. Immediately cap the vial containing the sample to prevent the possibility of external
contaminants.
5. Turn the handle on the sampling valve to fully close the valve. Remove the
sampling valve.
6. Attach a label containing the machine serial number, total hours the oil has been
operating, and oil set up temperature to the vial.
7. Place the completed sample into the pre-addressed shipping container and
forward immediately to a Husky recommended fluid analysis service, such as
Wear Check International or Hydac.
NOTE: Maintaining a high quality hydraulic fluid is essential for optimum machine
performance and dependability. If, after detailed failure analysis has been
performed, component failures can be directly linked to degraded oil,
Husky may, at its discretion, choose to revoke warranty of any affected
component.
NOTE: If sourcing your own fluid analysis service, Husky recommends sending
samples to an independent laboratory that does not hold interests in
hydraulic oil sales. Refer to Table 7-2 for hydraulic oil parameters and
particle count.
v 4.11.1 — March 2007 7–25 Checking Hydraulic Tank Oil Quality

CAUTION!
Equipment damage - re-additizing the oil does not provide enough protection to
equipment. Customers found to be doing this can expect warranty limitations or
cancellation in the event of hydraulic component failure.
Table 7-2 Hydraulic Fluid Recommended Monitoring Levels
CAUTION!
The oil is considered to be at the end of its useful life when any of the warning
limits have been reached.
Characteristic Test Standard Warning Limit Comments
Appearance Visual Hazy/Cloudy May indicate presence of

water
Viscosity @ 40°C ISO 3104 46 ± 10% May indicate contamination

mm2/s (ASTM D445) and/or oxidation
Total Acid Number ASTM D446 1.5 Indicates oil is severely

mgKOH/g oxidized and no longer fit for
use
Elemental, ppm Additive 50% of new Indicates additive

oil level consumption
Zn
Ca ASTM D5185
Wear/Contamination May indicate unacceptable

wear or contamination
Fe 15 ppm
Cu 20 to 30 ppm
Si 10 ppm
Cleanliness ISO 4406 Warning Limit Excessive particulate

17/14/11 contamination or ongoing
corrosion and wear.
Water content ISO 12937 150 ppm Condensation, leakage

(ASTM D1744)
Checking Hydraulic Tank Oil Quality 7–26 v 4.11.1 — March 2007

7.22 Checking Hydraulic Tank Oil Level
1. While the hydraulic pumps are running, check the oil level in the sight glass (1) is
between the one-half and three-quarter level – refer to Figure 7-16.
If necessary, top up the oil level – refer to Section 7.23.2.
Figure 7-16 Oil Level

1 Sight glass (typical location)
v 4.11.1 — March 2007 7–27 Checking Hydraulic Tank Oil Level

7.23 Replacing Hydraulic Oil
Refer to Section 2.6 for hydraulic tank capacity and hydraulic oil specifications.
7.23.1 Draining Hydraulic Tank

Drain the hydraulic tank using the following instructions.
NOTE: Replace the oil filter element prior to performing this procedure – refer to
Section 7.36.
2. Connect the supply hose to the ball valve (2) – refer to Figure 7-17.
NOTE: A female quick-disconnect fitting is needed on the end of the transfer
hose. The Husky part number for the female quick-disconnect fitting is
745475 (Parker part number H6-62-T12).
3. Open the valve and drain the hydraulic tank.
4. Disconnect the hose.
Figure 7-17 Draining Hydraulic Tank (Typical)

1 Male quick-disconnect fitting
Replacing Hydraulic Oil 7–28 v 4.11.1 — March 2007

7.23.2 Filling the Hydraulic Tank

Fill the hydraulic tank using the following instructions:
NOTE: Portable fluid transfer carts are required to fill reservoirs from barrels,
holding tanks and trucks. These units must be fitted with filters with an
efficiency of ß10 ≥ 1000 or better. Customers must fill through the
designated fill port upstream of the filter assembly.
2. Connect the supply hose (1) from the transfer pump to the supplied female quick-
disconnect coupling (2). Refer to Figure 7-18.
NOTE: The female quick-disconnect fitting takes a ¾ in. NPT hose-end fitting.
CAUTION!
Risk of damage to the machine. Unfiltered oil in the hydraulic tank will damage
hydraulic components in the machine. Always fill the tank through the filter, and
not through the drain port.
3. Connect the supply hose to the male quick-disconnect fitting (3) on the filter (4).
S01-101017a.eps
4
1
2
3
Figure 7-18 Filling Hydraulic Tank (Typical)

1 Supply hose 2 Female quick-disconnect coupling 3 Male quick-disconnect coupling
4 Filter
CAUTION!
Risk of damage to the machine. To prevent damage to hydraulic components,
do not overfill the hydraulic tank.
4. Fill the hydraulic tank to between one-half to three-quarter full in the sight glass
(Refer to Figure 7-16). This is the “High Level” mark.
5. Disconnect the female quick-disconnect coupling from the filter.
v 4.11.1 — March 2007 7–29 Replacing Hydraulic Oil

6. Prime the system and extruder pumps after refilling the tank. Refer to Section 7.24.
NOTE: The system pump does not require priming when adding additional oil to
the hydraulic tank.
7. Start up and cycle the system.
Check the oil level on the sight glass. Top up as necessary to maintain correct level.
7.24 Priming the System Pump
CAUTION!
Risk of damage to the system pump. To prevent damage to the system pump, do
not restart the pump until it is primed.

2. Remove the drain hose (1) at the drain port on the system pump (2) – refer to
Figure 7-19. Keep the hose end elevated to prevent the hydraulic tank from
draining.
3. Fill the pump case with clean hydraulic oil through the drain port. Refer to
Section 2.6 for hydraulic oil specifications.
4. Reconnect the drain hose. Check for any oil leaks.
6. Run in the machine – refer to Section 7.52.
Figure 7-19 Priming System Pump (Typical)

1 Drain hose 2 System pump
Priming the System Pump 7–30 v 4.11.1 — March 2007

7.25 Checking Gearbox Oil Level - Electrical Screw Drive Only
1. Check the oil level is up to the top of the sight glass (1) in the gearbox (2) – refer to
Figure 7-20.
If necessary, add oil until the oil level reaches the top of the sight glass. Refer to
Section 2.8.2 for gearbox oil specifications.
7.26 Replacing Gearbox Oil - Electrical Screw Drive Only
7.26.1 Draining Oil

Drain oil in the gearbox using the following instructions.
2. Remove the breather cap (3), and the overflow plug (4) on the gearbox – refer to
Figure 7-20.
3. Place a 30 L (7.4 US gallon) drain pan under the gearbox, and remove the drain
plug (5).
CAUTION!
Failure to drain oil to the level of the sight glass will damage the seals in the
gearbox.
4. Drain oil from the gearbox until the oil level is to the top of the sight glass (1).
5. Install the drain plug, overflow plug and breather cap. Wipe all surfaces clean.
CAUTION!
To prevent corrosion damage to the inside of the gearbox, always refill the
gearbox after draining the oil. When the machine is not in use for an extended
period of time the oil level must be up to the level of the breather cap.
7.26.2 Adding Oil

Refer to Section 2.6 for gearbox tank capacity, and Section 2.8.2 for gearbox oil
specifications.
Add oil to the gearbox using the following instructions.
1. Remove the breather cap (3), and overflow plug (4) in the gearbox – refer to
Figure 7-20.
2. Add oil through the breather cap port until it starts to flow out through the overflow
port.
3. Install the overflow plug, and the breather cap.
v 4.11.1 — March 2007 7–31 Checking Gearbox Oil Level - Electrical Screw Drive Only
4. Wipe all surfaces clean.
S01-101114.eps
2
Figure 7-20 Lubricating Gearbox (Typical)

1 Sight glass 2 Gearbox 3 Breather cap 4 Overflow plug 5 Drain plug
7.27 Checking Electric Pump Motor

2. Remove the cover over the hydraulic power pack.
3. Remove the bell housing cover.
4. Check for play in the coupling between the motor and the pump assembly.
5. Check for any sign of oil leaks from the front bearing seal in the pump.
6. Replace the bell housing cover, and install the cover over the power pack.
Checking Electric Pump Motor 7–32 v 4.11.1 — March 2007

7.28 Checking Pump Motor Rotation
Contact Husky and arrange for a Husky Field Service Representative to assist with
this procedure.
DANGER!
Electrocution hazard – risk of death or serious injury. This procedure should
only be performed by a Husky Field Service Representative.
REMINDER: Two persons are needed to perform this task.
Check the pump motor rotation using the following instructions.
CAUTION!
following sequence: Q3M, Q2M (if equipped) and finally, Q1M. Attach a lock and a
tag. Then wait 10 minutes for residual voltage to discharge.
WARNING!
Electrocution hazard - risk of death or serious injury. Perform Lockout/Tagout
procedure in accordance with local codes. Only fully qualified personnel should
perform this procedure. After performing Lockout/Tagout procedure, allow 10
minutes for residual voltage to discharge to less than 50 Volts.
2. Perform Lockout/Tagout procedure – refer to Section 1.6.1, then wait 10 minutes

for residual voltage to discharge.
3. Lift up the hydraulic power pack cover (1) to reveal the pump motor (2) – refer to
Figure 7-21. Remove the cover on the bell housing (3), to reveal the coupling (4).
Observe the direction of the arrow on the adapter.
4. Pull the main breaker up to turn the power supply on.
5. Position the Husky Field Service Representative near the pump motor to prepare
to inspect the rotation when the motor is turned on.
6. As the machine starts up, the HMI displays a series of messages on the screen. At
the end of the start-up process, it displays the PATENTS screen. Press the button
on the screen to continue.
7. Log on the machine – refer to Section 5.2.
v 4.11.1 — March 2007 7–33 Checking Pump Motor Rotation

8. Press the <ALARMS> key to display the ALARMS screen. Press the Clear Inactive
Alarms button to clear any inactive alarms.
Unload All Pumps button.
2 3
Figure 7-21 Checking Pump Motor Rotation (Typical)

1. Power pack cover 2. Pump motor 3. Bell housing 4. Coupling
CAUTION!
Risk of damage to the motor. When the machine is initially started up, the
hydraulic pumps may emit high pitched noises for a few seconds as the air is
purged out of the lines. If the pumps continue to make noise after approximately
10 seconds, shut down the pump motor immediately to prevent damage to the
hydraulic pumps.
CAUTION!
Risk of damage to the pumps. If the pump motor is rotating in the wrong
direction, stop the pump motor immediately.
10. Press the <PUMP MOTOR ON> key momentarily to start the motor, then
immediately press the <PUMP MOTOR OFF> key to stop the motor. Observe the
direction of rotation of the motor.
11. Check that the coupling turns in the direction of the arrow. If the direction of
rotation is incorrect, refer to Section 7.28.1.
Checking Pump Motor Rotation 7–34 v 4.11.1 — March 2007

7.28.1 Reversing Pump Motor Rotation

Reverse the pump motor rotation using the following instructions.
WARNING!
procedure in accordance with all applicable local codes. Only a qualified
electrician should perform this procedure. After performing Lockout/Tagout
procedure, allow 10 minutes for residual voltage to discharge to less than 50
Volts.
1. Perform Lockout/Tagout procedure - refer to Section 1.6, then wait 10 minutes for
residual voltage to discharge.
2. Open the electrical cabinet (1) and disconnect any two phases of the supply to
pump motor. This can be done at the servo drive A197.
3. Reverse the two phases and reconnect the cables. Close the electrical cabinet.
4. Remove locks and tags, and switch on the power supply to the machine.
CAUTION!
following sequence: Q1M, Q2M (if equipped) and finally, Q3M.
6. Verify the pump motor rotation – refer to Section 7.28.
S01-101110.eps
Figure 7-22 Reversing Pump Motor Rotation

1. Electrical cabinet
v 4.11.1 — March 2007 7–35 Checking Pump Motor Rotation

7.29 Checking Mold Stroke Column Guide Bushings
WARNING!
Crushing hazard – risk of death or serious injury. Perform Lockout/Tagout
procedure according to local codes before working in the clamp area of the
machine.

2. Remove the screws (1) holding the guide bushing (2) – refer to Figure 7-23.
3. Remove the guide bushing, and measure the thickness “A” of the bushing, as
shown. Check the measurement does not exceed the maximum allowable wear
shown in Table 7-3.
4. If the bushing wear is within maximum wear allowances, reinsert the bushing using
two screws.
If the bushing wear exceeds the maximum allowable wear, replace with a new
bushing.
5. Repeat on remaining bushings.
Table 7-3 Guide Bushing Wear
Minimum Dimension "A" Minimum Dimension "A"

Machine
(mm) (in.)
H90 to H/HL160 15.15 minimum 0.596 minimum
H/HL225 to /HL300 15.10 minimum 0.594 minimum
H/HL400 to /HL500 15.0 minimum 0.591 minimum
H/HL650 to H/HL1000 19.60 minimum 0.772 minimum
Checking Mold Stroke Column Guide Bushings 7–36 v 4.11.1 — March 2007
S01-101081.eps
1
Figure 7-23 Guide Bushing (Typical)

1 Screw 2 Bushing
7.30 Checking Optional Nozzle Shutoff Bushings and Pins
At intervals specified in the Maintenance Schedule, check the optional nozzle shutoff
bushings and pins using the following instructions.
1. Check for excessive drool from the nozzle tips.
If necessary, replace the bushings and pins – refer to Section 7.31.
7.31 Replacing Optional Nozzle Shutoff Bushings and Pins
There are three types of optional nozzle shutoffs. Choose the following maintenance
procedures according to the type installed on your machine:
• for the Rotary Nozzle Shutoff go to Section 7.31.1,
• for the Plunger Nozzle Shutoff go to Section 7.31.2, and
• for the Pin Nozzle Shutoff go to Section 7.31.3.
v 4.11.1 — March 2007 7–37 Checking Optional Nozzle Shutoff Bushings and Pins
7.31.1 Rotary Nozzle Shutoff

Replace the rotary nozzle shutoff assembly bushings and pins using the following
instructions:
WARNING!
material at high pressure may be present. Purge the barrel to minimize the
potential for any pressure build-up. Wear personal protective equipment (PPE)
while purging the barrel.
1. Purge the barrel – refer to Section 5.16 in the Machine Manual.

2. Turn the main breaker switch counterclockwise to switch off the power supply.
Perform Lockout/Tagout procedure – refer to Section 1.6 in the Machine Manual.
WARNING!
Burn hazard – risk of serious injury. Machine surfaces may be hot. Wear
personal protective equipment (PPE).
3. Lift the purge guard up.

4. Remove the four bolts (1) securing brackets (2) and replace the two bushings (3) –
5. Remove pin (4) and replace the bushing (5).
6. Reassemble the nozzle shutoff mechanism, and lower the purge guard.
7. Remove locks and tags – refer to Section 1.6.2 in the Machine Manual.
2 3
2
5 1
4
S01-100836a
Figure 7-24 Rotary Nozzle Shutoff (Typical)

1 Bolts 2 Bracket 3 Bushings 4 Pin 5 Bushing
Replacing Optional Nozzle Shutoff Bushings and Pins 7–38 v 4.11.1 — March 2007
7.31.2 Plunger Nozzle Shutoff

Replace the plunger nozzle shutoff assembly bushings and pins using the following
instructions:
IMPORTANT!
5 Before proceeding with these instructions, make sure the engineering drawing of the
shut-off assembly is available. Alignment instructions required for proper installation
are detailed on this drawing.
WARNING!
material at high pressure can be present. Purge the barrel to minimize the
1. Purge the barrel – refer to Section 5.16.

WARNING!
3. Open the purge guard.

4. Remove the pins, and replace the bushings – refer to Figure 7-25.
5. Reassemble the nozzle shutoff mechanism.
6. Align the shutoff linkage, refer to engineering drawing.
7. Lower the purge guard.
1
1
1 2 2
Figure 7-25 Plunger Nozzle Shutoff (Typical)

1 Pins 2 Bushings
v 4.11.1 — March 2007 7–39 Replacing Optional Nozzle Shutoff Bushings and Pins
7.31.3 Pin Nozzle Shutoff

Replace the pin nozzle shutoff assembly bushings and pins using the following
instructions, refer to Figure 7-26:
WARNING!
material at high pressure can be present. Purge the barrel to minimize the
1. Purge the barrel – refer to Section 5.16.

WARNING!
3. Open the purge guard.

4. Disconnect the band and cable heaters, items 1 and 2, and thermocouples, item 3.
5. Loosen the screws, item 4.
6. Carefully slide the adapter assembly, item 5, over the shutoff pin, item 6.
7. Remove one of the lowermost shutoff head screws, item 7.
8. Remove the pivot pin, item 8, along with spacers, item 9.
9. Drop the lever, item 10, out of the shutoff head, and replace the bushing, item 11.
3
3
6
1
2
4
5 7
8
9
9
10
11
Figure 7-26 Pin Shutoff assembly cross section

1 Band heater 2 Cable heater 3 Thermocouple 4 Screw 5 Nozzle adapter
6 Shutoff pin 7 Screw 8 Pivot pin 9 Spacer 10 Lever 11 Bushing
Replacing Optional Nozzle Shutoff Bushings and Pins 7–40 v 4.11.1 — March 2007
10. Insert the lever into of the shutoff head.

11. Insert the pivot pin along with spacers.
12. Replace the lowermost shutoff head screw.
13. Carefully slide the adapter assembly over the shutoff pin.
14. Tighten the screws.
15. Reconnect the band and cable heaters and thermocouples.
16. Close the purge guard.
18. Proceed with Adjusting the Pin Shutoff—Section 7.31.3.1.
7.31.3.1 Adjusting the Pin Shutoff

1. Heat up the barrel and shutoff assembly to operating temperatures to expand the
components to their working dimensions.
2. Verify the air supply pressure for the pin shutoff, refer to Figure 7-27.
NOTE: Pin shutoff uses a separate regulator/gauge that is factory set at 65 psi.
The location of the regulator varies depending on the size of the injection
unit.
Figure 7-27 Nozzle Shutoff Air Regulator

1 Gauge
3. Thread the rod extension, item 7-28 - item 4 onto the cylinder rod, item 2, leaving a
3 ± 1 mm gap between the jam nut, item 3, and flat face of the cylinder rod.
4. With the shutoff cylinder retracted, slide the proximity sensor, item 1, from the
piston end of cylinder towards the rod end (left to right), to find the location where
the signal is received, then move the sensor another 2 ± 0.5 mm towards the
cylinder rod end.
v 4.11.1 — March 2007 7–41 Replacing Optional Nozzle Shutoff Bushings and Pins
3 ± 1 mm
1 4
2
3
Figure 7-28 Pin Shutoff Nozzle Proxy and Rod Extension Adjustment
1 Proximity sensor 2 Cylinder rod 3 Jam nut 4 Rod extension
7.32 Lubricating Moving Platen Linear Bearings (H90 - H/HL500)

2. Wipe the grease fittings on the moving platen linear bearings (1), (2), (3), (4) –
CAUTION!
Risk of damage to the bearings. Do not over-lubricate the bearings. Use
lubricant quantities specified. Also, do not mix different types of lubricants.
3. Use food grade grease indicated on Section 2.8. Apply the quantity shown in
Table 7-4 to each grease fitting. Do not over-lubricate.
4. Wipe off any excess grease.
Lubricating Moving Platen Linear Bearings (H90 - H/HL500) 7–42 v 4.11.1 — March 2007
S01-101030.eps
2
1
4
3
Figure 7-29 Lubricating Moving Platen Linear Bearings (Typical)

1 Linear bearing 2 Linear bearing 3 Linear bearing 4 Linear bearing
Table 7-4 Grease Quantity for Linear Bearings
Number of Strokesa b
Machine
16 oz grease gun 24 oz grease gun 0.5 L grease gun
H90-H/HL120 7 5 6
H/HL160 7 5 6
H/HL225 12 8 11
H/HL300 25 17 21
H/HL400 18 12 15
H/HL500 18 12 15
a. A standard 10000 psi 16 ounce grease gun delivers approximately 0.04 oz of grease with each stroke of
the hand pump. A 24 oz grease gun delivers approximately 0.06 oz.
b. A standard 40 MPa 0.5 L grease gun delivers approximately 1.4 cm3 of grease with each stroke of the
hand pump.
v 4.11.1 — March 2007 7–43 Lubricating Moving Platen Linear Bearings (H90 - H/HL500)
7.33 Lubricating Optional Stack Mold Carrier Linear Bearings (H90 -

H/HL500)

2. On machines equipped with stack mold carrier, wipe the grease fittings on the
linear bearings (1) in the carrier (2) – refer to Figure 7-30.
CAUTION!
3. Use food grade grease indicated on Section 2.8. Apply the quantity shown in
Table 7-4 to each grease fitting. Do not over-lubricate. Wipe off any excess grease.
1 S01-101031.eps
Figure 7-30 Lubricating Optional Stack Mold Carrier Linear Bearings (Typical)
1 Linear bearing 2 Carrier
Lubricating Optional Stack Mold Carrier Linear Bearings (H90 - H/HL500)7–44 v 4.11.1 — March 2007
7.34 Lubricating Injection Piston Linear Bearings (RS40 - RS135)

2. Remove the Plexiglas panel (1) on both sides of the injection casting – refer to
Figure 7-31.
S01-101011.eps
Figure 7-31 Lubricating Injection Piston Linear Bearings (Typical)

1 Plexiglass panel 2 Linear bearing
3. Wipe the two grease fittings on the linear bearings (2).

4. Use food grade grease, and apply the quantity shown in Table 7-5 to each grease
fitting. Do not over lubricate. Wipe off any excess grease.
5. Install the Plexiglas panels.
Table 7-5 Grease Quantity for Injection Piston Linear Bearings
Number of Strokes a b
Injection Model
16 oz grease gun 24 oz grease gun 0.5 L grease gun
RS40 - RS135 3 2 3
b. A standard 400 bar 0.5 L grease gun delivers approximately 1.4 cm3 of grease with each stroke of the
hand pump.
v 4.11.1 — March 2007 7–45 Lubricating Injection Piston Linear Bearings (RS40 - RS135)
7.35 Lubricating Injection Sled Linear Bearings (RS22 – RS40)
Every six months, lubricate the injection sled linear bearings using the following
instructions. For lubricant specifications refer to the Specifications chapter of the
Maintenance Manual.
1. Wipe the grease fittings on the injection sled linear bearings (1) – refer to
Figure 7-32.
CAUTION!
2. Use food grade grease indicated in the Specifications chapter. Apply the quantity
shown in Table 7-4 to each grease fitting. Do not over-lubricate.
3. Wipe off any excess grease.
2
1
Figure 7-32 Lubricating Moving Platen Linear Bearings

1 Linear bearing 2 Grease fitting
Lubricating Injection Sled Linear Bearings (RS22 – RS40) 7–46 v 4.11.1 — March 2007
7.36 Replacing Oil Filter Element – H90 to H/HL500 (RS70 and

smaller)
Materials Required
1 Spare oil filter element
Replace the oil filter element at intervals specified in the Maintenance Schedule, or
when the “Dirty Oil Filter” message is displayed on the ALARMS screen after the
machine is at operating temperature.
NOTE: The pump motor will continue to run for up to 2 hours after displaying the
message, after which time the pump motor will stop.
Replace the oil filter element using the following instructions.
WARNING!
High pressure spray hazard – risk of death or serious injury. High pressure
hydraulic oil spray can penetrate human tissue causing extensive damage.
Perform Lockout/Tagout before replacing the oil filter element.
WARNING!
Burn hazard – risk of serious injury. Hydraulic oil can be very hot if the machine
has been running for a while. Wear personal protective equipment (PPE), and
avoid any contact with hot oil.
CAUTION!
Risk of damage to the machine. Debris around the machine can contaminate the
oil. Clean the whole area around the filter before removing the filter element.
2. Remove the electrical connector (1) from the top of the oil filter – refer to
Figure 7-33.
3. Turn the filter cap handle (2), and remove the filter cap (3).
4. Use the handle (4) to lift the used filter element (5) out of the housing (6). Discard
the used filter element.
5. Wipe a few drops of clean hydraulic oil on the O-ring (7) in the new filter element.
6. Use the handle to lower the new element into the housing.
v 4.11.1 — March 2007 7–47Replacing Oil Filter Element – H90 to H/HL500 (RS70 and smaller)
CAUTION!
Risk of damage to the machine. To prevent damage to the filter, hand-tighten the
oil filter cap – DO NOT over-tighten.
7. Install the oil filter cap, and turn it by hand to engage a few threads. Turn the cap
until the bleed screw (8) faces out. Then turn the filter cap handle until it is snug.
Check that the bleed screw is not covered by the handle. If necessary, adjust the
filter cap and handle again.
8. Install the electrical connector.
9. Wipe the outside of the oil filter, and clean up any oil spills.
11. Press the <PUMP MOTOR ON> key to start the hydraulic pumps.
12. Use the bleed screw to bleed any trapped air in the oil filter housing. Tighten the
bleed screw.
1
7
2
3
6
S01-101107.eps
Figure 7-33 Replacing Hydraulic Oil Filter Element (Typical)

1 Electrical connector 2 Filter cap handle 3 Filter cap 4 Handle 5 Filter element
6 Filter housing 7 O-ring 8 Bleed screw
Replacing Oil Filter Element – H90 to H/HL500 (RS70 and smaller)7–48 v 4.11.1 — March 2007
7.37 Replacing Oil Filter Element – H/HL650 to H/HL1000 (RS80 and

larger)
1 Hook wrench insert – Diameter 155-230 mm (HPN 2721244)
7.37.1 Removal
WARNING!
Be sure to complete the lockout/tagout procedure in accordance with applicable
local codes before performing maintenance activities. Failure to do so may
result in serious injury or death.
1. Execute the Lockout/Tagout Procedure.

2. De-pressurize the reservoir by lifting and then lowering the over-pressure relief
poppet. It is located on the injection base beside the filter/breather.
3. Place an oil pan below the quick disconnect, refer to Figure 7-34.
4. Remove the quick disconnect from filter housing.
5. Remove the oil filter vent plug.
6. Drain approximately 10 liters (3 US gals) of oil.
7. Install and tighten the quick disconnect. Apply a torque of 25 Nm (18 ft. lb.).
8. Remove the cap at the top of the oil filter housing.
CAUTION!
Avoid turning the filter housing along with the cap. If the housing turns with the
cap, tighten the housing lock nut. Failure to do so could damage the housing
seals and lead to oil leaks.
9. If the cap turn freely, go to step 10, otherwise perform the following.
a. Turn the cap back to its original position.
b. Using the hook wrench insert and a torque wrench, tighten the housing lock nut
to 150 Nm (110 ft. lb.).
c. Remove the filter housing cap.
10. Remove the oil filter from the housing.
v 4.11.1 — March 2007 7–49 Replacing Oil Filter Element – H/HL650 to H/HL1000 (RS80 and
7.37.2 Replacement
1. Install the new oil filter.
CAUTION!
Tightening the filter cap housing too much can result in damage to the filter
housing seals. Hand tighten the cap only.
2. Install and hand tighten the cap of the filter housing. Once the cap is hand tight,
back off 1/4 turn.
3. Install and tighten the oil filter vent plug.
4. Clean the area of spilled hydraulic fluid.
5. Check the fluid level in the sight glass. If the level is below the top of the glass, add
fluid in accordance with Section 7.22.
2
L-2413
Figure 7-34 Oil Filter

1 Quick disconnect filling point 2 Oil filter vent plug 3 Filter housing cap 4 Filter
housing 5 Filter housing lock nut
Replacing Oil Filter Element – H/HL650 to H/HL1000 (RS80 and larger)7–50 v 4.11.1 — March 2007
7.37.3 Check
1. Remove the locks and tags from the machine (refer to Section 1.6.2).
2. Loosen the vent plug from 1 to 1-1/2 turns.
NOTE: Once the hydraulic fluid circulates, air in the system will escape from the
bleed port. After all of the air has escaped, the hydraulic fluid will exit from
the port. At this point, the air in the system is purged and the port can be
closed.
3. Operate the pumps.
4. Observe air bubbles escape from the vent port.
5. Once the air is purged and hydraulic oil emerges from the port, tighten the bleed
plug. Apply a torque of 25 Nm (18 ft. lb.). Clean the oil from the filter housing.
6. Make sure the Low Oil Level Alarm at the HMI is absent.
7. Return the machine to its Normal function mode.
7.38 Replacing the Pilot Oil Filters
The pilot oil filters are integrated into the injection and clamp manifold. Replace them
on every six months or sooner, or at signs of servo valve malfunction, after major
hydraulic component failure, such as pump, hydraulic motor, heat exchanger etc or, as
indicated by oil quality tests.
Even after the hydraulic system has been depressurized and any energy source
locked/tagged out, always use a pressure gauge to verify all pressure has been
removed prior to servicing a hydraulic circuit. It is strongly recommended that the oil
sampling kit be connected to the gauge port of the affected hydraulic manifold and a
small amount of oil be drained from the circuit. The draining happens in a controlled
way due to an installed orifice in the kit.
WARNING!
Be sure to complete the lockout/tagout procedure in accordance with applicable
local codes before performing maintenance activities. Failure to do so may
result in serious injury or death.

To avoid consequential damage, absolute cleanliness must prevail when opening
the hydraulic circuit. Any time hydraulic hoses or valves are removed/replaced,
hose ends and valve ports must be capped to prevent debris from entering.
Thoroughly examine all components removed from the machine for damage or
missing pieces before replacing such components and reassembling the machine.
Any evidence of missing material poses a risk of contamination of the hydraulic
system and requires a full draining and examination of the hydraulic reservoir and
all related components.
v 4.11.1 — March 2007 7–51 Replacing the Pilot Oil Filters

Figure 1 Typical Manifold Locations, H machines, Non-Operator Side

1. Clamp manifold, behind gate on clamp casting 2. Mold stroke manifold, behind gate on
clamp column 3. Injection manifold
2. Clean each manifold and/or servo valve thoroughly before commencing work.
3. Locate the hollow hex O-ring plug on each manifold (item 1).
NOTE: Identify the filter element port on your hydraulic schematic. Note the ID
number and find the matching cavity stamp on the manifold.The filter
cavity on some clamp manifolds is located behind a pilot valve. The pilot
valve must be removed to gain access.
4. If the hollow hex O-ring plug is difficult to remove, place a brass rod on the plug
and hit it with a steel mallet. (Figure 7-35, item 3), Take care not to hit the manifold
as it may cause damage.
Replacing the Pilot Oil Filters 7–52 v 4.11.1 — March 2007

Figure 7-35 Loosening the Hollow Hex O-ring Plug

1 Injection manifold 2 Hollow hex O-ring plug 3 Brass Rod 4 Steel Mallet
NOTE: The servo pilot filter compression spring will drop out of the manifold
(along with hydraulic fluid and possibly debris) when the straight-thread
plug is removed. A catch container should be used to collect all leaking/
discharged debris and fluids.
5. Remove the hollow hex O-ring (Figure 7-35, item 2) using a 3/4 inch hex socket
and a 3/4 inch drive ratchet.
6. Visually inspect the hollow hex O-ring plug and clean as necessary.
7. Remove the servo pilot filter element (Figure 7-36, item 1) from the manifold using
an M4 SHCS in the tapped center hole (item 2).
v 4.11.1 — March 2007 7–53 Replacing the Pilot Oil Filters

Figure 7-36 Removing the Servo Filter

1. Servo pilot filter 2. M4 SHCS
NOTE: In some instances, it may be possible to remove the servo pilot filter from
the manifold by hand.
8. Install the new servo pilot filter element using an M4 SHCS (or by hand).
9. Set the new compression spring (Figure 7-37, item 1) in place on the top of the
hollow hex O-ring plug (item 2). Reinstall the plug and compression spring into the
manifold unit.
Figure 7-37 Reinstalling the Compression Spring and Hollow Hex O-ring Plug
1. Compression spring 2. Hollow hex O-ring plug
Replacing the Pilot Oil Filters 7–54 v 4.11.1 — March 2007

10. Using a torque wrench, the 3/4 inch hex socket (Figure 7-38, item 2) and the 3/4
inch drive ratchet (item 3), torque the hollow hex O-ring plug (item 1) to 250 lb-ft
(340 Nm).
11. Using a clean rag, carefully clean up any discharged debris or hydraulic fluid that
may have accumulated on the machine and hose surfaces.
3
2
Figure 7-38 Tightening the Hollow Hex O-ring Plug

1. Hollow hex O-ring plug 2. 3/4 inch hex socket 3. 3/4 inch drive ratchet
12. Remove all locks and tags before restarting the machine.
NOTE: Some air may be entrained in the hydraulic fluid for a short time after
restarting the machine.
7.39 Checking Carriage Cylinder Bushings and Pins
At intervals specified in the Maintenance Schedule, check the carriage cylinder

bushings and pins using the following instructions:
2. Visually check for signs of brittleness, cracking, or wear in the two bushings (1). If
necessary, replace the bushings and pins (2) – refer to Figure 7-39.
v 4.11.1 — March 2007 7–55 Checking Carriage Cylinder Bushings and Pins
S01-101082.eps
Figure 7-39 Carriage Cylinder Bushings and Pins (Typical)
1 Bushing 2 Pin
Checking Carriage Cylinder Bushings and Pins 7–56 v 4.11.1 — March 2007
7.40 Removing Stack Mold Harmonic Linkage (90 - 500 Tonne

Clamps)
REMINDER: Only qualified people should perform the following procedure.
WARNING!
Crushing hazard – risk of death or serious injury.
• Use suitable lifting equipment to lift the machine. Exceeding the rated
capacity of lifting equipment can cause injury or death.
• Make sure lifting equipment is in good working condition.
• Exercise care when working beside the suspended loads. To prevent injury,
keep hands and fingers out of the way. Install safety blocks.
Table 7-6 Lifting Weight Specifications
H90/
H160 H225 H300 H400 H500
H120
Side Carrier (kg) 42 78 130 174 130 310
Horizontal Link Arm (kg) 8 16 18 35 46 70
Propeller Arm (kg) (Carrier link arm) 28 51 70 120 180 215
Mold Carrier Water Manifold (kg) _ 25 25 25 79 79
2. Remove the mold from the machine. Refer to the mold manual.
v 4.11.1 — March 2007 7–57 Removing Stack Mold Harmonic Linkage (90 - 500 Tonne
1
10
11
9 8
2
4
7 3
5
Figure 7-40 View of Non Operators Side of Stack Mold Carrier (HL 300)
1 Top horizontal link arm 2 Moving platen 3 Propeller bar 4 Bottom horizontal link bar
arm 5 Link pin 6 SHCS 7 Large retaining plate 8 SHCS 9 Retaining plate
10 Stationary platen 11 Side carrier
7.40.1 Removing the Top Horizontal Linkages

7.40.1.1 Operator Side

1. Set the HMI to Mold Set mode.
2. Close the clamp until the linkage arm connected to moving platen clears the clamp
door opening.
WARNING!
serious injury or death.
Removing Stack Mold Harmonic Linkage (90 - 500 Tonne Clamps)7–58 v 4.11.1 — March 2007
3. Perform the Lockout/Tagout procedure in accordance with Section 1.6.1.
WARNING!
WARNING!
5. Attach lifting chains/slings to the linkage arm.

6. Remove the retaining plate located on the stationary platen side of the linkage.
7. Remove the socket head cap screw (SHCS) securing the linkage arm to the
stationary platen.
WARNING!
8. If this is the last linkage arm on this side to be removed, use straps to secure the
propeller bar to the side carrier preventing rotation.
9. Remove the link pin from the propeller bar.
10. Remove the linkage arm to a safe location.
7.40.1.2 Non-Operator Side
WARNING!
WARNING!

3. Remove the retaining plate located on the moving platen side of the linkage.
4. Remove the socket head cap screw (SHCS) securing the linkage arm to the
moving platen.
WARNING!
7.40.2 Removing the Bottom Horizontal Linkages

WARNING!
WARNING!
WARNING!
5. Remove the retaining plate located on the moving platen side of the linkage.
6. Remove the SHCS securing the linkage to the moving platen.
7.40.2.2 Non-Operator Side
WARNING!
WARNING!
WARNING!
5. Remove the retaining plate located on the stationary platen side of the linkage.
6. Remove the SHCS securing the linkage to the stationary platen.
7.40.3 Removing the Propeller Bar

WARNING!
WARNING!
2. Attach lifting chains/slings to the propeller bar.
3. Remove the large retaining plate from the centre of the propeller bar.
4. Remove the SHCS securing the propeller bar to the side carrier.
5. Remove propeller bar to a safe location.
7.40.4 Removal of the Side Carrier

NOTE: Carrier removal procedure to be performed by two qualified technicians.
WARNING!
WARNING!
2. Attach lifting chains/slings to the side carrier.

3. Secure a second strap around the carrier, long enough to pass through the gate on
the same side, refer to Figure 7-41, item A. This will be used to guide the carrier
through the tiebars into the center of the machine.
Crane
Figure 7-41 Side Carrier Support
4. Remove the SHCS securing the carrier to the linear bearing block.
Figure 7-42 Carrier Mounting

1 Carrier mounting screws
5. Slowly lift the carrier from the machine while the second technician guides the
carrier into the center of the machine. Remove the carrier and store in a safe
location, refer to Figure 7-41, item A.
CAUTION!
Care must be taken not to damage the tiebars when removing the Carrier.
7.40.5 Non Operator Side

NOTE: Carrier removal procedure to be performed by two qualified technicians.
WARNING!
WARNING!
2. Attach lifting chains/slings to the water manifold.

3. Remove the SHCS securing the water manifold to the carrier. Refer to Figure 7-43.
4. Remove the manifold and store in a safe location.
5. Attach lifting chains/slings to the side carrier through the center of the machine.
6. Secure a second strap around the carrier, long enough to pass through the gate on
the same side. This will be used to guide the carrier through the tiebars into the
center of the machine.
7. Remove the SHCS securing the carrier to the linear bearing block.
8. Slowly lift the carrier from the machine while the second technician guides the
carrier into the center of the machine, refer to Figure 7-41, item A. Remove the
carrier and store in a safe location.
CAUTION!
Care must be taken not to damage the tiebars when removing the carrier.
NOTE: For installation instructions refer to Section 3.6.
Figure 7-43 Water Manifold

1 Side carrier 2 Water manifold mounting 3 Screws 4 Underside of water manifold
7.41 Replacing Breather Cap
1. Check that the pump motor is turned off.
CAUTION!
Risk of oil contamination. Clean the area around the breather cap before
removing it.
2. Clean the area around the breather cap (1) – refer to Figure 7-44.
3. Turn the breather cap, and remove it.
4. Install a new breather cap and tighten it.
v 4.11.1 — March 2007 7–65 Replacing Breather Cap

Motor End of Injection Base S01-101077a.eps
Figure 7-44 Replacing Breather Cap (Typical)

1 Breather cap
7.42 Replacing Air Regulator Filter Element
At intervals specified in the Maintenance Schedule, replace the filter element in the air
regulator using the following instructions:
WARNING!
High pressure compressed air – risk of death or serious injury. Sudden release
of high pressure air can puncture skin. Shut off air supply, and use Lockout/
Tagout procedure on the air regulator before replacing the filter.
1. Turn the shutoff lever (1) to shut off the air supply – refer to Figure 7-45.
Replacing Air Regulator Filter Element 7–66 v 4.11.1 — March 2007

2
3
8
6
S01-101076.eps
Figure 7-45 Air Regulator - Exploded Detail (Typical)
1 Shutoff lever 2 Lock 3 Tag 4 Nut 5 Cup 6 Filter housing 7 Seal 8 End
cap 9 Filter element
2. Install a lock (2) and tag (3) on the air regulator.

3. Unscrew the nut (4) and remove the cup (5) from the filter housing (6).
4. Remove the seal (7).
5. Turn the end cap (8), and remove it.
6. Remove the used filter element (9) and discard.
CAUTION!
Risk of damage to pneumatic components. Do not clean and reuse the filter
element.
7. Insert a new filter element and attach it using the end cap. Turn the end cap until it
is snug.
8. Install the seal, and reattach the cup to the filter housing. Turn the nut until it is
snug.
9. Remove the lock and tag.
10. Turn the shutoff lever to turn on the air supply. Check for any air leaks.
v 4.11.1 — March 2007 7–67 Replacing Air Regulator Filter Element

7.43 Lubricating Electric Pump Motor Bearings
At intervals specified in the Maintenance Schedule, lubricate the electric motor

bearings using the following instructions. In the event the electric motor has
overheated, re-lubricate the motor bearings using the same procedure. For lubricant
specifications refer to Section 2.8.
CAUTION!
Loss of cooling water can result in overheating of the motor shaft bearings
which causes the bearing grease to degrade. Continued operation of the motor
without re-lubricating the bearings can result in bearing or motor failure.
1. Remove the cover over the hydraulic power pack.

2. Remove the outlet plugs (1) and (2) on both sides of the motor – refer to
Figure 7-46.
NOTE: Some motors come equipped with grease collection chambers, mounted
to the bearing covers, instead of outlet plugs.
3. Press the Machine Function Mode Selector on the toolbar, and select the Unload
All Pumps button.
REMINDER: Expel used grease from the motor bearings, and distribute new grease
uniformly, lubricate the bearings only when the motor is warm.
4. Press <PUMP MOTOR ON> key to start the motor.

5. Allow the motor to run for a few minutes and warm up.
CAUTION!
lubricant quantities specified.
CAUTION!
Risk of damage to the bearings. Do not mix different types of lubricants. Only
use lubricant specified for motor.
7. Wipe the grease fittings (3), (4) on the electric motor.

8. Apply the quantity of grease shown in Table 7-7. Refer to the nameplate (5) on the
motor for frame size.
9. Press the <PUMP MOTOR ON> key to restart the motor.
Run the motor for 20 minutes with the outlet plugs removed to expel excess or
used grease.
Lubricating Electric Pump Motor Bearings 7–68 v 4.11.1 — March 2007

11. Check the expelled grease at the outlet plug for signs of deterioration, such as
hardening, discoloration, or contamination.
a. If the grease appears fine, go to step 12.
b. If the grease shows signs of deterioration, repeat step 7 through step 11 with
half the original amount of grease. If the grease still shows signs of
deterioration, a complete re-greasing of the pump bearing is necessary.
Contact your local Husky Service representative for assistance.
12. Wipe off any grease from the outlet plug areas, and install the outlet plugs.
13. Install the cover over the hydraulic power pack.
14. Press the Machine Function Mode Selector on the toolbar, and select the Normal
button.
2
3
2
Figure 7-46 Lubricating Electrical Motor Bearings (Typical)

1 Plugs 2 Grease fittings 3 Motor nameplate
Table 7-7 Grease Quantity for Motor
Number of Strokesa b – Drive- Number of Strokes – non-Drive-

end Grease Fitting end Grease Fitting
Motor Frame Size
16 oz 24 oz 0.5 L 16 oz 24 oz 0.5 L
gun gun gun gun gun gun
WK 180 L/4-240 16 11 14 12 8 10
WK 180 L/4-290 16 11 14 12 8 10
WK 200 LK/4-250 19 12 16 16 11 14
v 4.11.1 — March 2007 7–69 Lubricating Electric Pump Motor Bearings

Table 7-7 Grease Quantity for Motor
Number of Strokesa b – Drive- Number of Strokes – non-Drive-

end Grease Fitting end Grease Fitting
Motor Frame Size
16 oz 24 oz 0.5 L 16 oz 24 oz 0.5 L
gun gun gun gun gun gun
WK 200 L/4-290 19 12 16 16 11 14
WK 200 L/4-360 19 12 16 16 11 14
WK 250 4-330 24 16 20 19 12 16
WK 280 4-360 27 18 23 27 18 23
WK 280 4-400 27 18 23 27 18 23
WK 315S 4-300AL 19 12 16 19 12 16
WK 315S 4-360AL 19 12 16 19 12 16
WK 315S 4-460 27 18 23 27 18 23
WK 315M 4-550 27 18 23 27 18 23
WK 315M 4-620 27 18 23 27 18 23
WK 315M 4-700 27 18 23 27 18 23
WK 315L 4-800 27 18 23 27 18 23
329TSC 40 25 34 25 15 21
408TSC 35 25 30 35 25 30
449TSC 50 35 43 50 35 43
b. A standard 40 MPa 0.5 L grease gun delivers approximately 1.4 cm3 of grease with each stroke of the
hand pump.
Lubricating Electric Pump Motor Bearings 7–70 v 4.11.1 — March 2007

7.44 Replacing Water Saver Valve
This section describes the procedures for replacing the water saver valve.
7.44.1 Valve Removal
WARNING!
1. Execute the Lockout/Tagout procedure in accordance with Section 1.6.1.

2. Turn off the tower water supply to the machine.
WARNING!
High pressure steam or boiling water may be trapped in the motor cooling water
circuit and could cause severe burns or death. Wear heat resistant gloves and
slowly release the pressure from the cooling circuit through the drain cocks
before working on any part of the motor cooling water circuit.
3. Before servicing any part of the electric motor cooling circuit, slowly open the water
inlet and outlet drain cocks to allow any residual pressure in the system to escape.
4. Disconnect the solenoid cap from the valve.
5. Disconnect the air supply hose from the valve. See Figure 7-47.
Figure 7-47 Valve Air Supply Hose
6. Obtain a large container to drain the water.
v 4.11.1 — March 2007 7–71 Replacing Water Saver Valve

7. Disconnect the 1/2" hydraulic motor cooling return line from the tee fitting, see
Figure 7-48.
8. Disconnect the 1-1/2" main cooling return line from the tee fitting, see Figure 7-48.
9. Unscrew the 1-1/2" union and remove the water saver valve assembly from the
heat exchanger mounting, see Figure 7-48.
Figure 7-48 Burkert Assembly

1 1/2" Hydraulic motor cooling return line 2 1-1/2" main cooling return line 3 Burkert
water saver 4 1-1/2" union to heat exchanger
10. Remove all adapters from the water saver valve.
7.44.2 Valve Replacement

1. Apply teflon tape or paste to the adapters on the water saver valve.
2. The water saver valve has a stroke limiter installed on top of the adapter. Check
that it is set so the stud protrudes from the locknut by approximately 3/8" (10mm).
See Figure 7-49.
3/8" (10mm)
Figure 7-49 Burkert Water Saver Valve
Replacing Water Saver Valve 7–72 v 4.11.1 — March 2007

3. Install the water saver valve assembly to the heat exchanger mounting.
4. Connect the 1-1/2" main cooling return line to the tee fitting, see Figure 7-48.
5. Connect the 1/2" hydraulic cooling return line to the tee fitting, see Figure 7-48.
6. Connect the air supply line to the valve. See Figure 7-47.
7. Connect solenoid cap to the valve.
8. Close any drain valves that were opened during disassembly.
9. Turn on the tower water supply to the machine, (See Figure 7-11, item 2 and
item 5.
NOTE: Setting the stroke limiter ensures that when the water saver valve is open,
there will be sufficient pressure available to feed the other parallel cooling
lines (for the electric motor, feed throat, electric screw motor, gearbox,
etc.)
NOTE: Some minor adjustment of the stroke limiter may be required depending
on the tower water conditions of the plant.
7.45 Checking Safety Devices
After upgrading software or performing maintenance on an interlock component,

check the front operator’s gate and rear guard, mechanical safety device, and CEN
valve using the following instructions.
7.45.1 Checking Front Operator’s Gate and Rear Guard

There are four limit switches on each side of the machine. The limit switches are
activated when the operator’s gate or rear guard is opened or closed.
Limit switches S7LS, S8LS, S12LS and SL13LS monitor the operator’s gate and rear
guard, and trigger an alarm when a gate or guard is opened.
Check the front operator’s gate and rear guard using the following instructions.
1. Open the operator’s gate (1) – refer to Figure 7-50. Check that the ALARMS
screen displays the message “Front Gate Open” in red.
2. Close the front operator’s gate, and check the “Front Gate Open” alarm is inactive.
3. Open the rear guard (2) and check the ALARMS screen displays the message
“Rear Gate Open” in red.
4. Close the rear guard and check that the “Rear Gate Open” alarm is inactive.

S01-101113.eps
1
Figure 7-50 Front Operator Safety Gate and Rear Guard (Typical)
1 Front operator’s gate 2 Rear guard 3 Limit switch (typical)
7.45.2 Checking Mechanical Safety Device

The mechanical safety device consists of a pin that prevents hydraulically activated
clamp motion when the front operator’s gate or rear guard is opened. Limit switches
S352LS and S353LS monitor the guards, and activate the mechanical safety device
The mechanical safety device is typically installed on all machines shipped to
customers in North America and Australia.
If the machine is equipped with a mechanical safety device, use the following
instruction to check that it is fully functional.
1. First check the air supply to the machine is switched on at the air regulator.
3. Open the front operator’s gate.
4. Verify the indicator lights on the solenoid Y195SV (1) and the proximity switch
S4PX (2) are switched off – refer to Figure 7-51.
5. Verify the pin (3) is extended.
6. Close the front operator’s gate, and verify the pin is fully retracted.

Y195SV
S4PX
S01-101044.eps
1
2
Figure 7-51 Mechanical Safety Device (Typical)

1 Solenoid valve 2 Proximity switch 3 Pin
7.45.3 Checking CEN Valve

Please refer to the hydraulic schematic for details specific to your machine.
7.45.3.1 H90 - H225

The CEN valve prevents system hydraulic pressure from reaching the clamp, stroke,
injection and ejection cylinders when either the front or rear operator gate is opened.
Limit switches S333LS and S334LS monitor the position of the moveable guards, and
activate the CEN valve when either guard is opened.
7.45.3.2 H300 - H1000

The CEN valve prevents system hydraulic pressure from reaching the stroke cylinder
when either the front or rear operator gate is opened. Limit switches S333LS and
S334LS monitor the position of the moveable guards, and activate the CEN valve
Check the CEN valve function using the following instructions:
1. Check that the pump is switched on.
Mold Set button.
3. Press and hold the <MOLD OPEN> key to retract the mold stroke column. As the
mold stroke column is retracting, open the front operator’s gate.

4. Verify that all clamp motion stops.

5. Close the front operator’s gate.
7.46 Replacing Heater Band
Replace a faulty heater band using the following instructions.

1. Press the <HEATS> key to display the BARREL screen.
2. Locate the faulty heater band on the BARREL screen.
3. Deselect the Machine Heats Enable checkbox to shut off barrel heaters.
4. Check that the <MANUAL> key is enabled.
button.
6. Press and hold the <CARRIAGE BACK> key until the nozzle tip clears the purge
guard.
7. Perform Lockout/Tagout – refer to Section 1.6.1.
WARNING!
Burn hazard – risk of severe injury. The barrel and heaters are hot. Wear PPE.
8. Disconnect the grounding strap (1), where applicable, and remove the barrel cover
(2). Refer to Figure 7-52.
2
S01-101080.eps
Figure 7-52 Replacing Heater Band (Typical)

1 Grounding strap 2 Barrel cover 3 Heater band 4 Bayonet adaptor 5 Screw
9. Disconnect the thermocouple from the faulty heater band (3) at the bayonet
adaptor (4).
Replacing Heater Band 7–76 v 4.11.1 — March 2007

10. Refer to the electrical schematics, and disconnect the high temperature wire
attached to the heater band from the junction terminal box.
NOTE: The high temperature wire is part of the heater band.
11. Mark the location of the faulty heater band on the barrel. Then remove the screws
(5), and gently remove the heater band.
12. Clean the surface of the barrel where the heater band was attached with soap and
water. Dry the barrel thoroughly.
13. Carefully open the two halves of the replacement heater band, and slide it over the
barrel.
14. Position the new heater band at the location marked in step 11.
15. Apply anti-seize compound to the threads of the heater band screws.
16. Tighten the barrel nuts by tightening the screws.
NOTE: Alternately tighten the screws. Begin with the centre screw, if applicable.
17. Torque all screws to 80 lb ft (9 Nm).
18. Connect the high temperature wire to the junction terminal box. Refer to the
electrical schematics for the connection details.
19. Reconnect the thermocouple.
20. Replace the barrel cover, and reconnect the grounding strap.
22. Start the machine, and display the BARREL screen.
23. Select the Machine Heats Enable checkbox to enable barrel heaters.
24. Observe the temperature of the heat zone in the BARREL screen, and verify that
the new heater band is working properly.
v 4.11.1 — March 2007 7–77 Replacing Heater Band

7.47 Changing the Plasticizing Screw and Check Valve - RS22 to

RS115
7.47.1 Removing Plasticizing Screw - RS22 to RS40
Special Tool and Material
1 Screw wrench
2 High temperature Optimoly Paste TA. Husky part number 644751 (1 kg, 2.2 lb)
Before removing the plasticizing screw, make sure that you have sufficient access
rights on the HMI to do a screw change.
CAUTION!
Risk of damage to the injection piston and plasticizing screw. To prevent
damage, follow instructions below.
REMINDER: Two persons are needed to perform this procedure.
Swing the barrel assembly, and remove the plasticizing screw from the front of the
barrel assembly using the following instructions:
1. Power up the machine, and log on to the machine.
2. If screw change is performed at the end of production, leave the machine heats on,
and go to step 5 below.
3. Press the <HEATS> key to display the BARREL screen. Select "Machine Heats
Enable" checkbox. Do not enable mold heats.
4. Allow the machine to come up to processing temperatures for process material in
the barrel.
5. Shut off process material supply to the feed throat. Drain all material from the feed
system.
WARNING!
material at high pressure may be present. Purge the barrel just prior to
removing the plasticizing screw so as to minimize the potential for any pressure
build-up in the barrel. Wear PPE while purging the barrel.
6. Turn on the pumps, and purge the barrel – refer to Section 5.16.
7. Press the <INJECT> key until the injection piston is fully forward.
Changing the Plasticizing Screw and Check Valve - RS22 to RS1157–78 v 4.11.1 — March 2007
8. Press the Machine Function Mode Selector on the toolbar, and select the Screw
Change button.
The HMI displays a warning message. Read the message and follow instructions.
Select the Yes button to continue.
NOTE: The sidebar shows the function group button related to screw change.
9. Press the <MANUAL> key.
WARNING!
Slip, trip, or fall hazard - risk of serious injury. Use a safe platform to access the
barrel assembly area.
WARNING!
Entanglement hazard – risk of serious injury. Removing finger guard exposes a
hazardous area. Entanglement with the rotating screw can cause serious injury.
Use extreme caution when working in the screw connection area.
10. Remove the finger guard (1) on the injection casting (2) – refer to Figure 7-53.
5
4
3
S01-100846.eps
1
4
Figure 7-53 Inserting Screw Wrench

1 Finger guard 2 Injection casting 3 Plasticizing screw 4 Boss 5 Screw wrench
11. Select the screw change sidebar function key, and jog the <INJECTION BACK>
button. Adjust the position of the plasticizing screw (3) such that the flat surfaces of
the screw are located between the two bosses (4) in the casting.
v 4.11.1 — March 2007 7–79 Changing the Plasticizing Screw and Check Valve - RS22 to
NOTE: Check that the injection piston is not fully forward. Retract the injection
piston, as necessary, so that the flat surfaces are still located between the
two bosses. The injection piston must be retracted to prevent damage to
the plasticizing screw tip as it is disengaged from the piston.
12. Jog the <SCREW ENGAGE> button on the sidebar to turn the plasticizing screw
so that the two flat surfaces on the screw are vertical.
13. Press the <PUMP MOTOR OFF> key to stop the pumps.
WARNING!
Common wrenches or other unapproved tools can slip or break and be
projected if used to disconnect the screw. To minimize the risk of injury, use
only the wrench custom-made for the machine model.
14. Insert the screw wrench (5) between the two bosses in the casting, and grip the flat
surfaces of the plasticizing screw. Check that the wrench is fully seated on the flats
in the screw, and firmly wedged between the two bosses in the casting.
WARNING!
Entanglement hazard – risk of serious injury. Removing the Plexiglas panel
exposes a hazardous area. Entanglement with the rotating screw can cause
serious injury. Use extreme caution when working in the screw connection area.

16. Place a horizontal mark on the injection piston (7) with a felt marker. This mark
enables you to determine when the screw has disengaged.
17. Press the <PUMP MOTOR ON> key to restart the pumps.
18. Jog the <SCREW DISENGAGE> button on the sidebar so that the mark on the
piston has rotated approximately 90°.
20. Remove the screw wrench.
22. Press the <INJECTION BACK> button until the piston moves back approximately
three quarters of the way. It is necessary to move the piston back so that the check
valve (8) is away from the barrel head (9).
23. Press the <SCREW DISENGAGE> button on the sidebar until the plasticizing
screw disengages completely from the injection piston.
24. Press the <CARRIAGE BACK> key until the carriage is all the way back.
NOTE: When the <CARRIAGE BACK> key is pressed, the carriage stops at the
purge position. Press the key again to move the carriage back all the way.
26. Release the latch, and swing the HMI (10) out of the way.
27. Lift the purge guard (13) and leave it in the open position.
13
16 17 18
21
20
24
S01-100982.eps
9
15
8
10
19
22
S01-100844a.eps
14
23
11
12
7
6
Figure 7-54 Barrel Assembly Exploded View (Typical)

6 Plexiglas panel 7 Injection piston 8 Check valve 9 Barrel head 10 HMI
11 Bolt 12 Carriage cylinder 13 Purge guard 14 Grounding strap 15 Barrel
cover 16 Nozzle tip 17 Socket-head screw 18 Retaining ring 19 Thermocouple
20 Nozzle adaptor 21 Bolt 22 Heater band 23 Screw 24 Bolt
28. Remove the bolts (11), and disconnect the two carriage cylinders (12) from the
stationary platen.
30. Press the <CARRIAGE FORWARD> key to fully retract the carriage cylinders.
WARNING!
32. Switch off the power supply. Perform Lockout/Tagout procedure – refer to
Section 1.6.1.
REMINDER: After switching off the power, perform the remaining steps in this
procedure without any delay before the barrel cools down.
WARNING!
Burn hazard – risk of serious injury. Machine surfaces may be hot. Wear PPE.
33. Disconnect the grounding strap (14), and remove the barrel cover (15).
NOTE: Some machines with a bolted barrel cover do not have a separate
grounding strap.
CAUTION!
Risk of damage to the injection swivel bed. To prevent damage, follow
instructions below.
28
27
26
25
S01-100836a
Figure 7-55 Disconnecting the Nozzle Shutoff (Rotary Model Shown)

25 Clevis pin 26 Clevis 27 Nozzle shut-off 28 Bolts
34. Disconnect the shut-off cylinder clevis pin (refer to Figure 7-55, item 25) from the
nozzle shut-off assembly.
35. Remove the injection casting locking bolts (29) from each side of the swivel bed
(30) – refer to Figure 7-56.
36. Swing the barrel assembly toward the operator side so as to clear the HMI.
37. While one person maintains tension on the barrel, insert a locking bolt (29) through
the hole on the operator side of the swivel bed (30), and into the tapped hole on
the injection casting.
NOTE: The tension from the hoses will cause the barrel to swing back unless the
locking bolt is in place.
29 31
30
Figure 7-56 Swinging the Barrel

29 Locking bolt (x2) 30 Swivel bed 31 Swivel pin
WARNING!
Burn hazard – risk of serious injury. Hot gases may be trapped behind the
nozzle tip. Wear face shield and protective gloves before removing nozzle tip.
38. Wear a face shield, and carefully remove the nozzle tip (16).
39. Remove the two socket-head screws (17), and the retaining ring (18).
40. On machines equipped with a nozzle shutoff option, continue on. Otherwise, skip
to step 54.
41. Remove the thermocouple (19) from the nozzle adaptor (20).
42. Remove the four bolts (21) using an Allen wrench. Remove the nozzle adaptor,
and place it on a flat surface. DO NOT allow the nozzle adaptor to hang by the
electrical wires. Place it on a protective surface to prevent damage to the machine.
43. Remove the thermocouple from the nozzle shutoff.
44. If it is necessary to reheat the barrel continue on, otherwise skip to step 53.
CAUTION!
Risk of damage to the heaters ahead of the barrel head. To prevent damage to
the heaters, disconnect the power to the heaters at the machine heat connector.
45. Disconnect the machine heat connector (+E-X24) to disable the heaters ahead of
the barrel head.
NOTE: On some machines disconnecting the connector (+E-X24) will disable all
the barrel heaters. In such cases, first turn the power on and log on to the
machine. Then press the <HEATS> key to display the BARREL screen.
Make a note of the temperatures in the heat zones ahead of the barrel
head, and lower the temperatures of those zones to 0 °C. Set the deviation
setpoints, as required, to prevent a High Deviation alarm.
46. Remove locks and tags – refer to Section 1.6. Switch on the power supply, and log
on to the machine.
47. Select the Machine Heats Enable checkbox on the BARREL screen.
WARNING!
48. Perform Lockout/Tagout after the machine comes up to processing temperature

for the process material in the barrel.
REMINDER: After performing Lockout/Tagout, proceed with the remaining steps

without any delay before the barrel cools down.
49. Use an Allen wrench to remove the four bolts (Figure 7-55, item 28). Remove the
nozzle shutoff, and place it on a flat surface. DO NOT allow the nozzle shutoff to
hang by the electrical wires. Place it on a protective surface to prevent damage to
the machine.
50. On machines without a nozzle shutoff option, remove the thermocouple (19) from
the nozzle adaptor (20).
51. Remove the four bolts (21), and the nozzle adaptor.
52. Make a note of the location of the first heater band (22). Loosen the two screws
(23), and gently slide back the heater band until it clears the joint between the
barrel head and the barrel.
CAUTION!
Risk of damage to the heater band. To prevent damage to the heater band,
torque the screws to Husky specifications. Also check that the full length of the
heater band makes contact with the barrel.
53. Fasten the heater band to the barrel. Torque the screws to Husky specifications –
54. Use an Allen wrench to remove the bolts (24), and the barrel head (9).
55. Swing the HMI back in, and then swing the barrel out fully so that the plasticizing
screw can be removed without interfering with the edge of the HMI.
57. Remove locks and tags. Switch on the power, and log on to the machine.
WARNING!


Figure 7-57 Wooden Pry Bar
60. Use a wooden pry bar to force the plasticizing screw out of the barrel – refer to
Figure 7-57.
WARNING!
Burn hazard – risk of serious injury. Machine surfaces are hot. Wear PPE.
61. Carefully grab the plasticizing screw at the nozzle end of the barrel with heat
resistant gloves, and pull it out.
62. To change plasticizing screw check valve, refer to Section 7.47.3.
63. To reassemble the plasticizing screw into the barrel, refer to Section 7.47.6.
7.47.2 Removing Plasticizing Screw - RS45 to RS115
CAUTION!
Risk of machine damage. DO NOT remove the screw from the front for machines
equipped with the High Output Drive option. Follow the directions in
Section 7.49 to remove the barrel and screw from the injection carriage and then
extract the screw from the rear of the barrel.
CAUTION!
1 Screw wrench
and go to step 5 below.
the barrel.
system.
WARNING!
material at high pressure can be present. Purge the barrel just prior to removing
the plasticizing screw so as to minimize the potential for any pressure build-up
in the barrel. Wear PPE while purging the barrel.
Change button.
WARNING!
WARNING!
Use caution when working in the screw connection area.
10. Remove the finger guard (1) on the injection casting (2) – refer to Figure 7-58.
4 5
4
1
S01-101085.eps
Figure 7-58 Inserting Screw Wrench (Typical)

1 Finger guard 2 Injection casting 3 Plasticizing screw 4 Boss 5 Screw wrench
WARNING!
14. Insert the screw wrench (5) between the two bosses in the casting, and grip the flat
surfaces of the plasticizing screw. Check that the wrench is fully seated on the flats
in the screw, and is firmly wedged between the two bosses in the casting.
WARNING!
Entanglement hazard – risk of serious injury. Removing the plexiglass panel
serious injury. Use caution when working in the screw connection area.

16. Place a horizontal mark on the injection piston (7) with a felt marker. This mark
enables you to determine when the screw has disengaged.
18. Jog the <SCREW DISENGAGE> button on the sidebar so that the mark on the
piston has rotated approximately 90°.
20. Remove the screw wrench.
22. Press the <INJECTION BACK> button until the piston moves back approximately
three quarters of the way. It is necessary to move the piston back so that the check
valve (8) is away from the barrel head (9).
26. Release the latch, and swing the HMI out of the way.
12
13
20
24
30 26
31
32
21
22 27
25
8
28
23 33 29
15 36 9
14
34
35
16
17
18
S01-101086.eps
10
7
11
19 6

6 Plexiglass panel 7 Injection piston 8 Check valve 9 Barrel head 10 Bolt
11 Carriage cylinder 12 Purge guard 13 Bolt 14 Grounding strap 15 Barrel
cover 16 Barrel support 17 Screw 18 Side plate 19 Guide rail 20 Nozzle tip
21 Socket-head screw 22 Retaining ring 23 Thermocouple 24 Nozzle adaptor
25 Bolt 26 Pin 27 Clevis 28 Nozzle shutoff 29 Thermocouple 30 Socket-head
screw 31 Retaining ring 32 Bolt 33 Nozzle adaptor 34 Heater band 35 Screw
36 Bolt
NOTE: On some machines it is possible to lift the purge guard and leave it in the
open position to have sufficient room to swing the barrel.
27. If possible, lift the purge guard (12) and leave it in the open position. Go to step 34.
28. If it is not possible to lift the purge guard, attach purge guard (12) to stationary
platen using purge guard screws (37) provided with the kit – refer to Figure 7-60.
37 37
Figure 7-60 Purge Guard Screws

37 Screws
29. Remove screws (13) from purge guard support on both carriage cylinders.
30. Remove clevis pin from carriage cylinders at stationary platen.Press the <PUMP
MOTOR ON> key.
31. Press the <CARRIAGE FORWARD> key to fully retract the carriage cylinders.
33. Remove the purge guard screws, and remove the purge guard – refer to Figure 7-
61.
Figure 7-61 Remove the Purge Guard
WARNING!
Section 1.6.1, then wait 10 minutes for residual voltage to discharge.
WARNING!
35. Disconnect the grounding strap (14), and remove the barrel cover (15).
grounding strap.
36. On machines with a barrel support (16), continue on. Otherwise skip to step 39.
37. Remove the screws (17) and the side plates (18) on the non-operator side.
WARNING!
Off-balance suspended loads can fall and cause injury or death. In order to
prevent injury or death, make sure adequate support is provided.
38. Swing the barrel assembly partially toward the operator side so that the barrel
support clears the carriage guide rail (19). On larger machines, it may be
necessary to lift the barrel in order to swing it. Make sure to support it throughout
the procedure.
NOTE: On some machines, it may be necessary to remove the whole barrel
support if it interferes with the carriage guide rail. In such instances,
unscrew the whole barrel support from the barrel. DO NOT take apart the
barrel support.
39. Swing the barrel assembly toward the operator side so as to clear the HMI.
WARNING!
Burn hazard – risk of serious injury. Hot gases can be trapped behind the nozzle
tip. Wear face shield and protective gloves before removing nozzle tip.
40. Wear a face shield, and carefully remove the nozzle tip (20).
41. Remove the socket-head screws (21), and the retaining ring (22).
Figure 7-62 Swing Barrel Assembly (Typical)
to step 54.
43. Remove the thermocouple (23) from the nozzle adaptor (24).
44. Remove the bolts (25) using an Allen wrench. Remove the nozzle adaptor, and
place it on a flat surface. DO NOT allow the nozzle adaptor to hang by the
45. Remove the pin (26), and disconnect the clevis (27) from the nozzle shutoff (28).
46. Remove the thermocouple (29) from the nozzle shutoff.
47. Remove the socket-head screws (30) and the retaining ring (31).
CAUTION!
the barrel head.
head, and lower the temperatures of those zones to 0°C. Set the deviation
50. Remove locks and tags – refer to Section 1.6.2. Switch on the power supply, and
log on to the machine.
WARNING!


53. Use an Allen wrench to remove the bolts (32). Remove the nozzle shutoff, and
place it on a flat surface. DO NOT allow the nozzle shutoff to hang by the electrical
wires. Place it on a protective surface to prevent damage to the machine.
54. On machines without a nozzle shutoff option, remove the thermocouple (23) from
the nozzle adaptor (33).
55. Remove the bolts (25), and the nozzle adaptor (24).
56. Make a note of the location of the first heater band (34). Loosen the two screws
(35), and gently slide back the heater band until it clears the joint between the
barrel head and the barrel.
CAUTION!
58. Use an Allen wrench to remove the bolts (36), and the barrel head (9).
WARNING!


Figure 7-63 Wooden Pry Bar
64. Use a wooden pry bar to force the plasticizing screw out of the barrel.
WARNING!
65. Grab the plasticizing screw at the nozzle end of the barrel with heat resistant
gloves, and pull it out.
66. To change plasticizing screw check valve, refer to Section 7.47.3.
7.47.3 Removing Plasticizing Screw Check Valve

Remove the plasticizing screw check valve using the following instructions:
1. First remove the plasticizing screw from the barrel – refer to Section 7.47 or
Section 7.48, depending on your barrel size.
CAUTION!
Risk of damage to the check valve. Use brass tools to remove the check valve.
REMINDER: The check valve has a left-hand thread.
2. Use a brass rod and hammer to loosen the check valve, and remove it – refer to
Figure 7-64.
S01-100151.eps
Figure 7-64 Removing Plasticizing Screw Check Valve (Typical)

1 Ring check valve 2 Ball check valve
3. To set up and replace the plasticizing screw check valve, refer to Section 7.47.4.
7.47.4 Setting Up Plasticizing Screw Check Valve

Set a gap of 0.04 mm to 0.07 mm (0.0015 in to 0.0027 in) between the spacer
attached to check valve, and the plasticizing screw.
Set up and replace the ball check valve or ring check valve using the following
instructions.
1. Remove the existing check valve from the plasticizing screw – refer to
Section 7.47.3.
2. For a ring check valve, first check the valve seat (1) makes full contact with the
entire surface of the ring (2) – refer to Figure 7-65.
2 1 6 3
Ring Check
Valve
A
6
4 3 5
4 6
3
S01-100141.eps
A
6
Ball Check
Valve
4
3
5
Figure 7-65 Setting Up Check Valve (Typical)

1 Valve seat 2 Ring 3 Spacer 4 Check valve 5 Screw 6 Plasticizing screw
3. Attach the spacer (3) to the check valve (4) using the screw (5).
4. Attach the check valve to the plasticizing screw (6), and hand-tighten.
5. Use a feeler gauge to measure the gap “A” between the plasticizing screw and the
check valve. Make a note of the measurement.
6. Remove the check valve from the plasticizing screw. Then remove the spacer from
the check valve.
7. Grind the length of the spacer by a measurement equal to the gap in step 5 plus
0.04 mm to 0.07 mm (0.0015 in to 0.0027 in).
8. Reattach the spacer to the check valve using the screw.
9. Apply a high temperature thread compound to the threads of the check valve.
Attach the check valve to the plasticizing screw, and hand-tighten.
10. To reassemble the plasticizing screw into the barrel, refer to Section 7.47.5,
Section 7.47.6, or Section 7.48.3, depending on barrel size.
7.47.5 Reassembling the Plasticizing Screw - RS22 to RS40
REMINDER: When assembling the barrel, use a high temperature thread compound
on all bolts or screws exposed to high temperatures.
Special Materials Required
Reassemble the plasticizing screw through the front end of the barrel assembly using
the following instructions. Torque all bolts to Husky specifications – refer to
Section 2.12.
1. Remove locks and tags, turn the power supply on, and log on to the machine.
NOTE: When the power is switched on, and the barrel is swung out, the HMI
displays the alarm messages "Temposonic fault – invalid number of
magnets" and "Barrel swung out". Ignore these messages.
DANGER!
Electrocution hazard – risk of death or serious injury. The barrel may be live. Do
not touch the barrel once the power is turned on.
2. Press the <HEATS> key to display the BARREL screen. Check that the
temperatures in the heat zones ahead of the barrel head are set to 0°C.
3. Select the Machine Heats Enable checkbox on the BARREL screen. Do not enable
mold heats.
WARNING!
4. Perform Lockout/Tagout procedure after the machine comes up to processing

temperature for the process material in the barrel.
5. Apply a high temperature thread compound on the threads of the plasticizing

screw (1) – refer to Figure 7-66.
17
12
11
8
9
S01-100982.eps
4
15
10
S01-100844a.eps
16
2
14
6
19
20
18
3
13
Figure 7-66 Barrel Assembly Exploded View

1 Plasticizing screw 2 Barrel 3 Injection piston 4 Barrel head 5 Bolt 6 Screw
7 Heater band 8 Bolt 9 Nozzle adaptor 10 Thermocouple 11 Retaining ring
12 Nozzle tip 13 Plexiglas panel 14 Finger guard 15 Barrel cover 16 Grounding
strap 17 Purge guard 18 Carriage cylinder 19 Clevis block 20 Bolt
WARNING!
6. Using heat resistant gloves, carefully insert the plasticizing screw into the front end
of the barrel (2), and push the screw all the way in.
WARNING!
CAUTION!
Risk of damage to the plasticizing screw threads and injection piston. Engage at
least four threads by hand.
7. Using a safe platform to stand on, engage at least four threads of the plasticizing
screw into the injection piston (3) by hand.
8. Swing the HMI out of the way.
9. While one person maintains tension on the barrel, remove the locking bolt, see
Figure 7-67, item 21, from the operator side of the swivel bed.
10. Carefully swing the barrel back into position.
11. Replace the injection housing locking bolts.
12. Tighten the bolts to the recommended torque.
13. Re-attach the shut-off cylinder clevis to the nozzle shut-off and re-insert the clevis
pin (refer to Figure 7-68, item 24).
14. Align the barrel head (4) such that the four inner holes are upright, as shown.
Apply a high temperature thread compound to the threads of the bolts (6), and
reattach the barrel head. Allow the temperature of the barrel head to equalize with
the barrel, then torque the bolts to Husky Specification HGT-50.
CAUTION!
torque the screws to Husky Specifications. Also check that the full length of the
15. Loosen the two screws (6), and slide the heater band (7) to its original position
over the barrel head. Torque the two screws to Husky specifications.
NOTE: Check that the drool hole in the bottom of the barrel head is not covered by
the heater band.
21 23
22
Figure 7-67 Swinging the Barrel

21 Locking bolt (x2) 22 Swivel bed 23 Swivel pin
to step 21.
NOTE: Make sure all contact surfaces of mating parts are free of process material
and other debris before reattaching them.
17. Apply a high temperature thread compound to the threads of the bolts (27), and
reattach the nozzle shutoff (26). Allow the temperature of the nozzle shutoff to
equalize with the barrel, then torque the bolts to Husky Specification HGT-50.
18. Reconnect the nozzle shutoff mechanism using the pin (24).
NOTE: Check that the washers (28) are installed correctly before installing the pin.
19. Reattach the thermocouple to the nozzle shutoff.
27
26
28
25
24
S01-100836a
Figure 7-68 Reconnecting the Nozzle Shutoff

24 Clevis Pin 25 Clevis 26 Nozzle shut-off 27 Bolts 28 Washers
20. Apply a high temperature thread compound to the threads of the four bolts (8), and
reattach the nozzle adaptor (9) to the nozzle shutoff. Allow the temperature of the
nozzle adaptor to equalize with the barrel, then torque the bolts in accordance with
Section 2.12.
21. On machines without a nozzle shutoff option, apply a high temperature thread
compound to the bolts (8), and reattach the nozzle adaptor (9). Allow the
temperature of the nozzle adaptor to equalize with the barrel, then torque the bolts
in accordance with Section 2.12.
22. Reattach the thermocouple (10) to the nozzle adaptor.
23. Reattach the retaining ring (11).
24. Apply a high temperature thread compound to the threads of the nozzle tip (12),
and reattach it to the nozzle adaptor. Tighten the nozzle tip with a hand wrench.
WARNING!
Entanglement hazard – risk of serious injury. The screw connection area is a
hazardous area if left exposed. Install finger guard and Plexiglas panel before
operating the machine.
25. Install the Plexiglas panel (13) and the finger guard (14).
26. Install the barrel cover (15). Connect the grounding strap (16) where available.
27. Lower the purge guard (17).Reconnect the machine heat connector (+E-X24) if it
has been disconnected.
28. Remove locks and tags. Switch on the power supply, and log on to the machine.
29. Press the <HEATS> key to display BARREL screen. Reset the temperatures in the
heat zones ahead of the barrel head back to normal operating temperatures.
30. Select the Enable Machine Heats checkbox. Do not enable mold heats.
Allow the machine to come up to processing temperatures for process material in
the barrel.
32. Check the Machine Function Mode Selector on the toolbar displays the Screw
Change button.
WARNING!
Crushing hazard – risk of serious injury. Keep fingers out of the way when
extending the cylinder.
33. Press the <CARRIAGE BACK> key to extend the carriage cylinders (18) so that
there is a gap of approximately 5 mm (¼ in) between the mounting surface of the
stationary platen and the clevis block (19).
NOTE: Both carriage cylinders may not move at the same rate, due to internal
friction. Complete installation of one cylinder before attempting the other
cylinder.
34. Align the holes in the clevis block with the holes in the stationary platen, and install
the bolts (20). Torque the bolts to Husky Specification HGT-50.
Similarly, reattach the other carriage cylinder.
position.
CAUTION!
Risk of damage to the machine. Do not use the screw wrench to tighten the
plasticizing screw – the threads will engage fully as the injection piston turns.
36. Press the <SCREW ENGAGE> button on the sidebar until the plasticizing screw is
fully engaged.
37. Press the <INJECTION FORWARD> button on the sidebar until the injection
piston is fully forward.
38. Press the <INJECTION> key, and select the INJECTION tab – Figure 7-69. Verify
that the value in the Injection Position field is approximately zero.
Figure 7-69 INJECTION Screen
CAUTION!
Risk of damage to the machine. Remove all tools from the machine before
switching machine back to Normal mode.
39. Press the Machine Function Mode Selector on the toolbar and select the Normal
button when the machine is ready for production.
7.47.6 Reassembling the Plasticizing Screw - RS45 to RS115
the following instructions. Torque all bolts to Husky specifications – refer to
Section 2.12.
DANGER!
mold heats.
WARNING!


WARNING!
WARNING!
CAUTION!
9. Align the barrel head (4) such that the inner holes are upright, as shown. Apply a
high temperature thread compound to the threads of the bolts (5), and reattach the
barrel head. Allow the temperature of the barrel head to equalize with the barrel,
then torque the bolts to Husky Specification HGT-50.
CAUTION!
10. Loosen the screws (6), and slide the heater band (7) to its original position over the
barrel head. Torque the screws to Husky specifications.
the heater band.
to step 17.
15. Reattach the thermocouple (13) to the nozzle shutoff.
26
27
15
12 11
10
19
8
18 5
14
17 13
16
24
4
25
2
23
6
20
29
21
S01-101086.eps
30
3
28
22

7 Heater band 8 Bolt 9 Nozzle Shutoff 10 Retaining ring 11 Pin 12 Washer
13 Thermocouple 14 Bolt 15 Nozzle adaptor 16 Nozzle adaptor
17 Thermocouple 18 Retaining ring 19 Nozzle tip 20 Barrel support 21 Side
plate 22 Plexiglass panel 23 Finger guard 24 Barrel cover 25 Grounding strap
26 Purge guard 27 Bolt 28 Carriage cylinder 29 Clevis block 30 Bolt
nozzle adaptor to equalize with the barrel, then torque the bolts in accordance with
Section 2.12.
in accordance with Section 2.12.
21. Swing the barrel back into position.
22. On machines with barrel support (20), reattach it to the barrel. Then reattach the
side plates (21) to the barrel support.
25. Close the purge guard, or if removed in step 29, re-install purge guard to stationary
platen using purge guard screws (Refer to Figure 7-70).
26. Start the pumps.
WARNING!
27. Press <CARRIAGE BACK> to extend the carriage cylinders to line up with the
clevis pin.
NOTE: Both carriage cylinders may not move at the same rate, due to internal
friction. Complete installation of one cylinder before attempting the other
cylinder.
28. Turn pumps off.
29. Install clevis pin and retaining rings.
30. Install screws into purge guard mounting support on both sides of purge guard.
31. Disconnect purge guard from stationary platen.
32. Reconnect the machine heat connector (+E-X24) if it has been disconnected.
33. Remove locks and tags (refer to Section 1.6.2). Switch on the power supply, and
log on to the machine.
35. Select the Enable Machine Heats checkbox. Do not enable mold heats. Allow the
machine to come up to processing temperatures for process material in the barrel.
Change button.
position.
CAUTION!
fully engaged.
41. Press the <INJECTION> key, and select the INJECTION tab – refer to Figure 7-71.
Verify that the value in the Injection Position field is approximately zero.
CAUTION!
button when the machine is ready for production.
7.48 Changing the Plasticizing Screw on RS135 and larger (H650-

H1000 Only)
7.48.1 Introduction
There are two ways of replacing the plasticizing screw on injection units RS135 and
larger: powered barrel swing or barrel change.
• Powered barrel swing permits changing the screw without removing the barrel
from the injection unit. It is described in Section 7.48.2.
• Barrel change allows removing both barrel and screw from the injection unit, plac-
ing them on a working surface, and removing the screw from there. It is described
in Section 7.50.
NOTE: Barrel change is the only way to replace the barrel and screw on machines
not equipped with powered barrel swing.
CAUTION!
Risk of machine damage. The barrels on machines RS135 and above cannot be
swung out unless the machine is equipped with powered barrel swing. Use
barrel change to remove the barrel and change the screw on machines without
the barrel swing option.
The following procedures contain many safety issues. Read the following instructions
thoroughly before performing either procedure.
7.48.2 Removing Plasticizing Screw with Powered Barrel Swing
1 Screw wrench
5 IMPORTANT!
A minimum of two persons are needed to perform this procedure.
and go to step 5.
Changing the Plasticizing Screw on RS135 and larger (H650-H1000 Only)7–112 v 4.11.1 — March 2007
the barrel.
system.
WARNING!
material at high pressure can be present. Purge the barrel just prior to removing
the plasticizing screw so as to minimize the potential for any pressure build-up
in the barrel. Wear PPE while purging the barrel.
Change button.
WARNING!
WARNING!
Use caution when working in the screw connection area.
v 4.11.1 — March 2007 7–113 Changing the Plasticizing Screw on RS135 and larger (H650-
WARNING!
13. Insert the screw wrench (Refer to Figure 7-72, item 1) into the wrench way of the
casting (item 2), and grip the flat surfaces of the plasticizing screw. Check that the
wrench is fully seated on the flats in the screw, and is firmly wedged between the
two bosses in the casting.
WARNING!
Entanglement hazard – risk of serious injury. Removing the Plexiglas panel
serious injury. Use caution when working in the screw connection area.
Figure 7-72 Screw Wrench for Uncoupling

1 Screw wrench 2 Wrench way
Check that the Barrel Swing Position indicator is lit on the Barrel Swing screen,
refer to Figure 7-74, item 4.
17. Insert the hinge pin — refer to Figure 7-73 This may require back and forward
movement of the carriage.
NOTE: Once the purge guard is opened the carriage cannot be moved.
Figure 7-73 Hinge Pin

3 Hinge pin
Figure 7-74 Barrel Swing Screen

4 Barrel swing position indicator 5 Injection on position indicator
12
13
20
24
30 26
31
32
21
22 27
25
8
28
23 33 29
15 36 9
14
34
35
16
17
18
S01-101086.eps
10
7
11
19 6

6 Plexiglas panel 7 Injection piston 8 Check valve 9 Barrel head 10 Bolt
11 Carriage cylinder 12 Purge guard 13 Bolt 14 Grounding strap 15 Barrel
cover 16 Barrel support 17 Screw 18 Side plate 19 Guide rail 20 Nozzle tip
21 Socket-head screw 22 Retaining ring 23 Thermocouple 24 Nozzle adaptor
25 Bolt 26 Pin 27 Clevis 28 Nozzle shutoff 29 Thermocouple 30 Socket-head
screw 31 Retaining ring 32 Bolt 33 Nozzle adaptor 34 Heater band 35 Screw
36 Bolt
18. Move the injection piston to the swing position using the screw change sidebar
buttons. Check that the Injection Position indicator is enabled on the Screw
Change screen, refer to Figure 7-74, item 5.

21. Remove the purge guard screws, and remove the purge guard – refer to Figure 7-
76. Go to step 34.
22. Remove clevis pin assembly.
Figure 7-76 Remove the Purge Guard
23. Disconnect the grounding strap(item 14), and remove the barrel cover (item 15)
grounding strap.
24. Remove cooling water lines from feed throat.
25. Remove air supply from hopper.
26. Remove the screws (item 17) and the side plates (item 18).
27. Remove the retaining bolts from the swing arm.
37
Figure 7-77 Remove the swing arm bolts

37 Swing arm bolt
28. Remove the bolts (item 13), and disconnect the operator side carriage cylinder
(item 11) from the stationary platen.
29. Move the ladder to upper position (fully hang up), if installed.
30. Swing out the barrel using the barrel swing switch located below the HMI
31. Swing the barrel assembly partially toward the operator side so that the barrel
support clears the carriage guide rail (item 19). On larger machines, it may be
necessary to lift the barrel in order to swing it.
NOTE: On some machines, it may be necessary to remove the whole barrel
support if it interferes with the carriage guide rail. In such instances,
unscrew the whole barrel support from the barrel. DO NOT take apart the
barrel support.
38
Figure 7-78 Barrel Swing Carriage Cylinder

38 Retaining bolt
32. Stabilize the carriage using the swing securing screw located on the non operator
side rail (refer to Figure 7-78).
33. Support the barrel using a heat resistant sling and an overhead crane.
40
39
Figure 7-79 Barrel in Swung Out Position

39 Hole for Swing Security Screw 40 Injection Carriage
WARNING!
Section 1.6.1, then wait 10 minutes for residual voltage to discharge.
WARNING!
Burn hazard – risk of serious injury. Hot gases can be trapped behind the nozzle
tip. Wear face shield and protective gloves before removing nozzle tip.
35. Wear a face shield, and carefully remove the nozzle tip (item 20).
36. Remove the socket-head screws (item 21), and the retaining ring (item 22).
to step 49.
38. Remove the thermocouple (item 23) from the nozzle adaptor (item 24).
39. Remove the bolts (item 25) using an Allen wrench. Remove the nozzle adaptor,
and place it on a flat surface. DO NOT allow the nozzle adaptor to hang by the
40. Remove the pin (item 26), and disconnect the clevis (item 27) from the nozzle
shutoff (item 28).
41. Remove the thermocouple (item 29) from the nozzle shutoff.
42. Remove the socket-head screws (item 30) and the retaining ring (item 31).
CAUTION!
the barrel head.
head, and lower the temperatures of those zones to 0°C. Set the deviation
45. Remove locks and tags – refer to Machine Manual Safety Summary. Switch on the
power supply, and log on to the machine.
WARNING!

IMPORTANT!
5 After performing Lockout/Tagout, proceed with the remaining steps without any delay
before the barrel cools down.
48. Use an Allen wrench to remove the bolts (item 32). Remove the nozzle shutoff,
and place it on a flat surface. DO NOT allow the nozzle shutoff to hang by the
49. On machines without a nozzle shutoff option, remove the thermocouple (item 23)
from the nozzle adaptor (item 33).
50. Remove the bolts (item 25), and the nozzle adaptor (item 24).
51. Make a note of the location of the first heater band (item 34). Loosen the two
screws (item 35), and gently slide back the heater band until it clears the joint
between the barrel head and the barrel.
CAUTION!
refer to Machine Manual Specifications chapter or your machine drawings.
53. Use an Allen wrench to remove the bolts (item 36), and the barrel head (item 9).
WARNING!


59. Use a hydraulic jack to force the plasticizing screw out of the barrel.
WARNING!
60. Grab the plasticizing screw at the nozzle end of the barrel with heat resistant
gloves, and pull it out. Support the screw with slings as necessary.
61. To change plasticizing screw check valve, refer to Machine Manual.
7.48.3 Reassembling Plasticizing Screw
the following instructions. Torque all bolts to Husky specifications – Machine Manual
Specifications chapter or your machine drawings.
DANGER!
mold heats.

WARNING!
26
27
15
12 11
10
19
8
18 5
14
17 13
16
24
4
25
2
23
7
20
29
21
S01-101086.eps
30
3
28
22

7 Heater band 8 Bolt 9 Nozzle Shutoff 10 Retaining ring 11 Pin 12 Washer
13 Thermocouple 14 Bolt 15 Nozzle adaptor 16 Nozzle adaptor
17 Thermocouple 18 Retaining ring 19 Nozzle tip 20 Barrel support 21 Side
plate 22 Plexiglas panel 23 Finger guard 24 Barrel cover 25 Grounding strap
26 Purge guard 27 Bolt 28 Carriage cylinder 29 Clevis block 30 Bolt
WARNING!
CAUTION!
9. Align the barrel head (4) such that the inner holes are upright, as shown. Apply a
high temperature thread compound to the threads of the bolts (5), and reattach the
barrel head. Allow the temperature of the barrel head to equalize with the barrel,
then torque the bolts to Husky Specification HGT-50.
CAUTION!
10. Loosen the screws (6), and slide the heater band (7) to its original position over the
barrel head. Torque the screws to Husky specifications.
the heater band.
to step 17.
15. Reattach the thermocouple (13) to the nozzle shutoff.
nozzle adaptor to equalize with the barrel, then torque the bolts to Husky
Specification HGT-50.
to Husky Specification HGT-50.

Figure 7-81 Barrel Swing Screen
CAUTION!
Failure to remove the swing securing screw can result in damage to the
injection carriage. Be sure to remove the screw before swinging the barrel back
into position.
21. Remove the swing securing screw (refer to Figure 7-79).

22. Swing In with the switch on the electrical cabinet.
23. On machines with barrel support (20), reattach it to the barrel. Then reattach the
side plates (21) to the barrel support.
WARNING!
Entanglement hazard – risk of serious injury. The screw connection area is a
hazardous area if left exposed. Install finger guard and Plexiglas panel before
operating the machine.
WARNING!
Electrocution hazard – risk of death or serious injury. The barrel cover can
become energized if grounding strap(s) is not connected. Make sure grounding
strap(s) is connected before applying power to machine.
26. Close the purge guard (26) or, if removed, reattach the purge guard using the bolts
(27).
27. Reconnect the machine heat connector (+E-X24) if it has been disconnected.
28. Connect the feed throat cooling lines.
29. Connect the hopper air supply.
30. Install the swing arm retaining bolt.
31. Remove the swing pin.
32. Remove locks and tags. Switch on the power supply, and log on to the machine.
34. Select the Enable Machine Heats checkbox. Do not enable mold heats.
Allow the machine to come up to processing temperatures for process material in
the barrel.
Change button.
WARNING!
37. Press the <CARRIAGE BACK> key to extend the carriage cylinder (28) so that
there is a gap of approximately 5 mm (¼ in) between the mounting surface of the
stationary platen and the clevis block (29).
38. Align the holes in the clevis block with the holes in the stationary platen, and install
the bolts (30). Torque the bolts to Husky Specification HGT-50.
position.
CAUTION!
fully engaged.
Press the <INJECTION> key, and select the INJECTION tab – refer to Figure 7-82.
Verify that the value in the Injection Position field is approximately zero.
CAUTION!
button.
43. Recover and purge out the barrel.
7.49 Barrel Removal and Installation - RS22 to RS115
7.49.1 Removal
1. Refer to Section 7.47.2, Removing the Plasticizing Screw.
2. Ensure injection unite has sufficiently cooled down.
3. Disconnect coolant and purge system, Figure 7-83.
4. Disconnect shut-off cylinder and proxies, Figure 7-83.
5. Disconnect electrical connections, Figure 7-83.
Barrel Removal and Installation - RS22 to RS115 7–128 v 4.11.1 — March 2007
4 3
Figure 7-83 Disconnect Components

1 Coolant hoses 2 Electrical connections 3 Proxies 4 Shut-off cylinder hoses
6. Remove the finger guard from the top of the injection casting, Figure 7-84.
7. Remove the barrel cover. Refer to Section 7.47.2, step 35.
Figure 7-84 Finger Guard
v 4.11.1 — March 2007 7–129 Barrel Removal and Installation - RS22 to RS115
WARNING!
WARNING!
loads.
9. Attach lifting chains/slings to the barrel and take up the slack in the chains/slings.
10. Loosen adjustment screws on barrel support, Figure 7-85.
11. Remove barrel support mounting screws, Figure 7-85.
Figure 7-85 Barrel Support

1 Barrel support mounting screws 2 Adjustment screws
12. Remove screw retaining plate Figure 7-86.
Figure 7-86 Retaining Plate

1 Retaining Plate
13. Release locking screw securing jacking bar Figure 7-87.
Figure 7-87 Jacking Bar

1 Locking screw 2 Jacking bar
14. Turn jacking bars evenly (Figure 7-87) to create a gap between the barrel screw
head and injector casting to allow sufficient clearance when removing the barrel.
15. Backup injector housing to ensure the nozzle clears the purge guard area.
16. Remove the barrel assembly to a safe storage location.
v 4.11.1 — March 2007 7–131 Barrel Removal and Installation - RS22 to RS115
7.49.2 Installation
1. Refer to Section 7.47.6, Reassembling the Plasticizing Screw.
WARNING!
WARNING!
loads.
3. Attach lifting chains/slings to the barrel.

4. Apply optimally paste to contact points in the injection casting.
5. Install barrel assembly into injection unite.
6. Install barrel support screws, Figure 7-88.
Figure 7-88 Barrel Support

1 Barrel support mounting screws 2 Adjustment screws
7. Install the barrel retaining plate, Figure 7-86.

8. Adjust jacking bars (Figure 7-87) evenly until barrel contacts the injection casting,
Figure 7-89.
Figure 7-89 Barrel Head

1 Barrel head 2 Injection casting
9. Check the nozzle concentricity. Refer to Section 3.21.8.

10. Torque barrel cover plate to Husky specifications, Figure 7-86.
11. Install the finger guard to top of the injection casting, Figure 7-84.
7.50 Barrel Removal and Installation - RS135 and up
7.50.1 Removal
7.50.1.1 Screw uncoupling

The following conditions must be met before uncoupling the screw.
• The carriage must be in the back position.
• The barrel must be purged and the heats on.
• The hopper must be closed.
• The shut-off nozzle must be closed (if applicable).
Uncouple the screw as follows.
1. Switch on the hydraulic pump motor.
2. Press the < PURGE > key until the Injection piston is fully forward.
v 4.11.1 — March 2007 7–133 Barrel Removal and Installation - RS135 and up
Change button.
1
Figure 7-90 Toolbar
1 Machine function mode selector in screw change mode
4. The HMI displays a warning message. Read the message and follow instructions.
Figure 7-91 Screw Change Purge Warning Message
5. Select the Screw Change function group on the left Sidebar.
6. Select the Injection Process Values function group on the right Sidebar.
7. Press <INJECTION BACK> until Injection piston stops at the position where the
wrench can be inserted.
8. Insert the wrench (Figure 7-92). Don’t worry if the wrench cannot be fully inserted.
It will slip in as soon as screw is rotating in uncoupling direction.
Figure 7-92 Screw Wrench for Uncoupling

1 Screw wrench 2 Wrench way
Barrel Removal and Installation - RS135 and up 7–134 v 4.11.1 — March 2007
9. Press <SCREW DISENGAGE> on the Sidebar until the position of the injection
piston does not change anymore.
10. Press <INJECTION BACK> on the Sidebar until the thread of the screw is fully
free.
11. Switch off the hydraulic pump motor
12. The screw uncoupling sequence is complete.
7.50.1.2 Barrel Removal
Table 7-8 Barrel Weight
Standard Barrel Long Barrel

Barrel Model
kg lbs kg lbs
RS 135 2 700 6 000 3 000 6 600
RS 155 4 300 9 400 4 600 10 100
1. Unscrew the barrel top plate bolts (Refer to Figure 7-93).
Figure 7-93 Barrel Top Plate

1 Barrel top plate 2 Bolt locations
2. Remove the electrical cables from the junction box.

3. Remove the applicable hydraulic, air and water connections.
4. Empty and remove the hopper bin.
WARNING!
Burn risk. The barrel is hot. Wear personal protective equipment to guard
against burns when working on the barrel. Failure to do so may result in severe
injury.
5. Remove the purge guard.

6. On RS 135 and RS155 injection units, remove the barrel covers.
7. Lift the barrel with an overhead crane.
8. Place the barrel on a safe and stable support. Take care to the heater bands while
lowering down.
7.50.1.3 Screw Removal

1. The barrel can be heated up by using extension cables between the junction box of
the machine to the barrel.
2. Dismount the screw-retaining ring.
3. The screw can be pulled out of the back of the barrel.
7.50.2 Installation
7.50.2.1 Screw Installation

1. If the barrel or the screw does not have a plastic film to provide lubrication, brush
Molycot 111 or compatible on the screw.
2. Insert the screw in the barrel by pushing it from the back.
3. Mount the screw retaining ring and the sealing.
7.50.2.2 Barrel Installation

1. The thread at the end of the screw has to be clean and greased.
2. Install the barrel on the injection unit.
3. Tighten the bolts of the barrel top plate.
4. Connect the electrical cables from the junction box. Connect the applicable
hydraulic, air and water connections. Install the covers, the purge guard and the
hopper.
Barrel Removal and Installation - RS135 and up 7–136 v 4.11.1 — March 2007
7.50.2.3 Screw Coupling
WARNING!
Burn risk. The barrel is hot. Wear personal protective equipment to guard
against burns when working on the barrel. Failure to do so may result in severe
injury.
1. Heat the barrel to operating temperature.

2. Lock the new screw with the wrench
3. Switch on the hydraulic pump motor
4. Press <SCREW COUPLE> on the Sidebar until the position of the injection
cylinder does not change anymore.
5. Visually check that the screw is fully coupled
6. Remove the wrench
7. Press the Machine Function Mode Selector on the toolbar, and select the Normal
Mode button.
Figure 7-94 Toolbar

1 Machine function mode selector in normal mode
8. The HMI displays a warning message. Read the message and follow instructions.
Figure 7-95 Screw Change Mode Exit Warning Message
9. Press <PURGE> until the Injection piston is fully forward.

Verify that the Injection piston position is approximately zero.
7.51 Oil Recovery Unit Functional Check
CAUTION!
Risk of damage to equipment. If leakage is observed from the exhaust silencer
port of the oil recovery unit (Figure 7-96) when the machine’s pump motor is off,
it is possible that the reservoir’s purge check valve (Item 7) is being held open
by contamination. If the contamination cannot be cleared with air pressure, the
check valve must be replaced.
1. Turn off the pump.

2. Loosen the screw on each cap for the four oil inlet solenoids and remove
5
4
6
Figure 7-96 Oil Recovery Unit

1 Oil reservoir 2 Oil inlet solenoids 3 Blow down solenoid 4 Air supply solenoid 5 Oil level float
switch 6 Vacuum / pressure gauge 7 Check Valve 8 Y-strainer
3. Loosen the screw on the cap for the blow down solenoid and remove (item 3).
4. Remove the cap from the oil level float switch (item 5) and go to the alarm page on
the HMI. A warning alarm stating Oil Drain System Sensor Fault should activate.
Oil Recovery Unit Functional Check 7–138 v 4.11.1 — March 2007

5. Reconnect the oil level float switch after verifying the warning alarm. Clear the
alarm by pressing the green cycle start button.
6. Remove one of the oil recovery lines from an inlet port at either the clamp or
injection end of the machine and insert it into a container of oil (Shell Tellus 46 or
approved substitute).
7. Start the pump and go to the oil recovery unit. Check to see that the air supply
solenoid (Figure 7-96, item 4) comes on after 1 minute and air can be heard
blowing out the exhaust silencer port.
8. Verify that the vacuum / pressure gauge (item 6) on the side of the recovery unit is
measuring a vacuum. If there is no vacuum, check the canister (Figure 7-96, item
1) seals for a vacuum leak.
9. Check to see that each of the oil inlet solenoids cap LED’s turn on one after the
other in equal intervals.
10. Determine which of the four ports must be energized so that the oil will be drawn
from the oil container which was placed at the clamp or injection end of the
machine (step 6). Connect one of the energized (light on) oil inlet solenoid caps to
this port solenoid to facilitate filling of the oil recovery reservoir. If one solenoid
times out and becomes de-energized, connect the next one that becomes
energized in the sequence. Continue until reservoir is filled.
NOTE: If the reservoir gauge indicates a vacuum but the unit fails to draw oil
through the selected inlet line, the inlet strainer inside the Y-strainer
(Figure 7-97, item 3) may be plugged and require cleaning. (See
Section 7.5.)
1
2 3
2
Figure 7-97 Bronze Y-strainers

1. Strainer retaining nut 2. Filter inlet tubing 3. Screen
11. To check the strainer, unscrew the strainer retaining nut (item 1) and remove the
strainer. Clean and replace.
12. If this does not clear the problem, there is a possibility the tubing may also be
plugged. To clear the tubing, remove the end from the filter inlet (item 2) and blow
air through it. Make sure the air flows freely out the other end of the tube.
13. If the assembly still fails to draw fluid after carrying out step 11 and step 12, there
may be a defect in the applicable inlet solenoid valve. Switch to another solenoid
valve to confirm this.
v 4.11.1 — March 2007 7–139 Oil Recovery Unit Functional Check

14. When the reservoir is filled and the blow down solenoid LED (Figure 7-96, item 3)
turns on, go to the HMI and wait for the warning alarm to come on for Oil Purge Too
Long. The alarm should appear after 90 seconds. None of the vacuum inlet
solenoids should be on during blow down.
15. Stop then restart the pump and press the green cycle start button. This will clear
the alarm and restart the blow down sequence.
NOTE: Perform next step immediately.
16. Go to the recovery system and reconnect the blow down solenoid (Figure 7-96,
item 3). The blow down should commence. It should finish when the float reaches
the bottom. The vacuum recovery sequence should resume again.
17. If step 15 does not happen within 30 seconds, the blow-down filter (Figure 7-98,
item 1) may be blocked. Unscrew the filter body (item 2) and replace the filter
inside. (See Section 7.4.)
Figure 7-98 Blow-Down Filter

1 Blow-Down filter 2 Filter body
18. Return all the solenoid caps to their correct location and tighten the screws
19. Remove the oil inlet line from the oil container and connect it to its original location.
7.52 Running in the Machine
NOTE: This procedure is peformed by the Husky Field Service Representative upon
initial installation.
Prior to starting up production, the machine needs to be run in for a period of
approximately one hour and twenty minutes. This allows the machine to flush the
hydraulic tank. Run in the machine using the following instructions.
1. Unplug the CEN valve 282DQ. The CEN valve is located on the power pack
manifold on machine model H225, and is located on the stroke manifold on
machine models H/HL300 – H/HL1000.
Running in the Machine 7–140 v 4.11.1 — March 2007

NOTE: Unplugging CEN valve 282DQ will isolate the clamp hydraulic circuits from
the pump.
Unload All Pumps button.
3. Press the <PUMP MOTOR ON> key then quickly press the <PUMP MOTOR
OFF> key to jog the hydraulic pump. Wait 10 seconds and then jog the pump
again. Repeat this step two more times.
4. Check the pump is running at minimum 20 bar. If the pump is running at minimum
20 bar continue to the next step.
If the pump is running at less than 20 bar, run the pump at one minute increments
until the pumps reach 20 bar.
5. Gradually increase the time period the pump runs, and allow the pump to run for
approximately one hour.
6. At the end of the one hour period, press the <PUMP MOTOR OFF> key to stop the
pumps.
7. Plug in the CEN valve 282DQ.
8. Press the <PUMP MOTOR ON> key again to restart the hydraulic pumps.
9. When oil warming is complete, check the pump is running between 180 - 184 bar.
10. Run the pump for 20 minutes, then press the <PUMP MOTOR OFF> key to stop
the machine.
11. Replace the factory-installed oil filter(s) – refer to Section 7.36.
7.53 Calibration
The calibration function is used to calibrate a number of machine components such as

the clamp, ejector, injection piston, carriage, as well as cavity pressure sensor.
NOTE: Ejector and mold shutheight calibrations are done after installing the mold.
Refer to the Machine Manual for details.
Touch the Calibration button on the toolbar to display the CALIBRATION MENU
screen – refer to Figure 7-99. Each button on the CALIBRATION MENU screen allows
you to calibrate an individual machine component.
NOTE: Depending on how the machine is configured, some fields/buttons may not be
displayed on the screen.
When a component is calibrated, the button displays a large green check mark. If it is
not calibrated, the button will display a large red "X". If the component cannot be
calibrated, the button will be greyed out.
v 4.11.1 — March 2007 7–141 Calibration

Figure 7-99 CALIBRATION MENU Screen
Select any calibration button to display the individual calibration screen for that
component.
7.53.1 When to Calibrate

The following table describes when to calibrate the different components.
Table 7-9 Calibration Conditions
Component When to Calibrate
Clamp Every time the clamp, stroke position sensor rods, magnet or
mounting brackets are replaced.
Injection Every time the stroke position sensor rod is replaced, or the
plasticizing screw is changed.
Ejector Every time a mold is installed in the machine.
Carriage Every time the stroke position sensor rod is replaced.
Cavity pressure sensor Every time the sensor is replaced.
Error Message Whenever the machine displays an error message informing the
operator to perform a calibration on a component.
7.53.2 Clamp Calibration

Calibrate the clamp every time the clamp, stroke position sensor rods, magnets or
mounting brackets for the magnets are replaced, or when the HMI indicates that the
clamp must be calibrated.
NOTE: All manual clamp functions are allowed even if the clamp is uncalibrated.
Calibration 7–142 v 4.11.1 — March 2007

Touch the Clamp Calibration button to display the CLAMP CALIBRATION pop-up
window – refer to Figure 7-100.
Figure 7-100 CLAMP CALIBRATION Pop-up Window
7.53.2.1 Calibrating the Clamp

Calibrate the clamp using the following instructions.
1. Check that the machine is in Manual cycle mode, and the Mold Set function mode
is selected. Also, check that the pump is running.
2. Touch the Calibration button on the toolbar to display the CALIBRATION MENU
3. Touch the Clamp Calibration button to display the CLAMP CALIBRATION pop-up
window – refer to Figure 7-100.
4. Touch the Start button. The HMI displays the next screen – refer to Figure 7-101.

Figure 7-101 CLAMP CALIBRATION Screen 2
5. If the mold can be opened without any restrictions, select the Automatic Opening
option button and the Confirm button. Then skip to step 6.
Otherwise, touch the Manual Opening option button and the Confirm button. Then
skip to step 10.
NOTE: Calibration can be aborted at any time by pressing the Stop Calibration
button.
NOTE: Calibration will pause under the following circumstances: pump off, safety
gate open, machine switched out of Manual cycle mode or Mold Setup
function mode, or an alarm condition. Calibration will continue when these
conditions are restored.
6. If Automatic Opening option button is selected, the HMI displays a warning
message that cores and ejectors may be damaged if they are not in the correct
positions for mold movement in either direction.
If the cores and ejectors are in the correct positions for the mold to move safely,
touch the OK button to acknowledge the warning and continue calibration;
otherwise touch the Cancel button.
7. If the OK button is touched, the mold opens automatically to the fully open position.
The HMI then prompts you to confirm that the mold is in the fully open position –

Figure 7-102 CLAMP CALIBRATION Screen 3A
8. Check that the mold is in the fully open position, then select the Yes option button
to continue calibration; or the No option button to abort calibration. Touch the
Confirm button.
9. Skip to step 14.
10. If the Manual Opening option button in Figure 7-101 is selected, the HMI displays
the screen below – refer to Figure 7-103.
Figure 7-103 CLAMP CALIBRATION Screen 3B
11. Press the <MOLD OPEN> key on the HMI and open the mold as wide as possible.
Then open the Operator Gate and measure the distance between the faces of the
stationary and moving platens. Close the safety gate.

12. Touch the field Measured Shutheight, and enter the measured value using the
numeric keypad.
NOTE: If the entered value is less than the allowed minimum value shown in the
numeric keypad, some mold components may need to be removed so that
the mold can be opened wider. Then repeat step 11 and step 12 so that
the Measured Shutheight value is between the allowed minimum and
maximum values shown.
CAUTION!
Risk of damage to the mold. DO NOT enter a false value to try and trick the
machine to continue calibration.
13. Touch the Confirm button.

14. The HMI displays another warning message that cores and ejectors may be
damaged if they are not in the correct positions for mold movement in either
direction.
If the cores and ejectors are in the correct positions for the mold to move safely,
touch the OK button to acknowledge the warning and continue calibration;
otherwise touch the Cancel button.
15. If the OK button is touched, calibration continues. It can take an additional 2
minutes to complete calibration.
NOTE: If calibration stops for any reason, touch the Stop Calibration button to
close the CLAMP CALIBRATION pop-up window, and check for any
alarms. After fixing the alarms, restart calibration.
When calibration is completed successfully, the HMI displays a confirmation
message – refer to Figure 7-104.
16. Exit the CLAMP CALIBRATION pop-up window.
Figure 7-104 CLAMP CALIBRATION Screen 4

7.53.3 Injection Calibration

Calibrate the injection piston every time the stroke position sensor rod, or the
plasticizing screw is replaced, or when the HMI indicates that the injection piston must
be calibrated.
Touch the Injection Calibration button to display the INJECTION CALIBRATION
Figure 7-105 INJECTION CALIBRATION Screen
7.53.3.1 Calibrating the Injection Piston

Calibrate the injection piston using the following instructions:
1. Check that the machine is in Manual cycle mode.
3. Touch the (appropriate) Injection Calibration button to display the INJECTION
CALIBRATION screen – refer to Figure 7-105.
4. Touch the Start button. The HMI displays the screen shown below.

Figure 7-106 CALIBRATION Screen
5. Press and hold the <INJECT> key until the injection piston is fully forward.
6. Check that the injection piston is fully forward, and touch the Confirm button. The
machine automatically starts the calibration process.
When calibration is completed, the field beside the Start button displays
"Calibrated".
7.53.4 Carriage Calibration

Calibrate the carriage every time the stroke position sensor rod is replaced, or when
the HMI indicates that the carriage must be calibrated.
Touch the Carriage Calibration button to display the CARRIAGE CALIBRATION
Figure 7-107 CARRIAGE CALIBRATION Setup Screen

7.53.4.1 Calibrating the Carriage

Calibrate the carriage using the following instructions.
3. Touch the (appropriate) Carriage Calibration button to display the CARRIAGE
CALIBRATION screen – refer to Figure 7-107.
Figure 7-108 CARRIAGE CALIBRATION Setup Screen
5. Press and hold the <CARRIAGE BACK> key until the carriage is fully retracted.
6. Check that the carriage is fully retracted, and touch the Confirm button. The
machine automatically starts the calibration process.
When calibration is completed, the field beside the Start button displays
"Calibrated".
7.53.5 Cavity Pressure Calibration

Calibrate the cavity pressure sensor every time the sensor is replaced, or when the
HMI indicates that the cavity pressure sensor must be calibrated.
Touch the appropriate Cavity Pressure Calibration button to display the CAVITY
SENSOR CALIBRATION screen – refer to Figure 7-109.

Figure 7-109 CAVITY SENSOR CALIBRATION Screen
7.53.5.1 Calibrating the Cavity Pressure Sensor

Calibration of cavity pressure sensor is the process of establishing the scaling factor
used to convert sensor signals into pressure in engineering units. The calibration
process depends on the type of sensor, as well as the type of signal amplifier used. All
cavity pressure sensors must be calibrated for the machine to run.
NOTE: If cavity pressure sensors are no longer connected to the machine, the
sensors must still be calibrated using dummy values. Enter any suitable value
in each of the fields. Failure to calibrate the sensors will prevent the machine
from running.
Calibrate the cavity pressure sensor using the following instructions.
3. Touch the appropriate Cavity Pressure Calibration button to display the CAVITY
SENSOR CALIBRATION screen – refer to Figure 7-109.

Figure 7-110 CAVITY SENSOR CALIBRATION Setup Screen
5. Verify that the mold is open and that there are no parts in it.
6. Check that the mold is open and that there are no parts in it, and touch the Confirm
button.
7. The HMI displays the CAVITY SENSOR CALIBRATION screen shown in
Figure 7-111.
NOTE: Depending on the amplifier type and sensor type selected, there are a
number of different fields that appear on the CAVITY SENSOR
CALIBRATION screen.
8. Select the type of amplifier used – "Kistler", "0-10 V", "0-20 mA", or "4-20 mA".
9. Then select the type of sensor used – "pressure", or "force".
10. Enter calibration parameters as indicated below.
Pressure Sensor With Kistler Amplifier: Enter Pressure Sensitivity factor and
Range values. Pressure Sensitivity factor can be read from the label on the
sensor. Select a suitable Range, and enter the Range value. Range can be read
from the label on the amplifier.
Force Sensor With Kistler Amplifier: Enter Force Sensitivity factor, Range values,
and pin diameter. Force Sensitivity factor can be read from the label on the sensor.
Select a suitable Range, and enter the Range value. Range can be read from the
label on the amplifier. Measure and enter the pin diameter.
Pressure Sensor With 0-10 V Amplifier: Enter the Pressure Span, Minimum and
Maximum voltage values. Pressure Span, as well as the Minimum and Maximum
voltage values can be read from the label on the sensor.

Force Sensor With 0-10 V Amplifier: Enter the Force Span, Minimum and
Maximum voltage values, and pin diameter. Force Span, as well as the Minimum
and Maximum voltage values can be read from the label on the sensor. Measure
and enter the pin diameter.
Pressure Sensor With 0-20 mA, or 4-20 mA Amplifier: Enter the Pressure Span,
Minimum and Maximum voltage values, and Resistance value. Pressure Span, as
well as the Minimum and Maximum voltage values can be read from the label on
the sensor. Measure and enter the actual Resistance value.
NOTE: A 0-1000 ohm resistor must be used in the electrical circuit to convert the
signal to a voltage signal. A resistor in the 500 ohm range is suggested.
Force Sensor With 0-20 mA, or 4-20 mA Amplifier: Enter the Force Span,
Minimum and Maximum voltage values, Resistance value, and pin diameter. Force
Span, as well as the Minimum and Maximum voltage values can be read from the
label on the sensor. Measure and enter the actual Resistance value, as well as the
pin diameter.
NOTE: A 0-1000 ohm resistor must be used in the electrical circuit to convert the
signal to a voltage signal. A resistor in the 500 ohm range is suggested.
11. Touch the Read Offset button to complete calibration.

Figure 7-111 CAVITY SENSOR CALIBRATION Screen


Machine Manual Controls
Chapter 8 Controls
This chapter discusses PC controls and the various components of the PC controls
system.
8.1 PC Control System
The heart of the PC controls system consists of an IPC, or industrial PC (1), which
runs an automation software called TwinCAT. TwinCAT controls the various devices on
the machine through serial fieldbuses such as SERCOS and PROFIBUS – refer to
Figure 8-1. The user interacts with the machine through the touch screen HMI (2). The
HMI is discussed in Chapter 4—User Interface.
The servo motor (3) which drives the plasticizing screw is controlled by a servo drive
(4) connected to the SERCOS fieldbus. The optional robot is also controlled through
the SERCOS fieldbus. All analog and digital field devices used on the machine are
connected to the PROFIBUS fieldbus through bus terminal systems (5).
Thermocouples are connected to the PROFIBUS fieldbus through TC-Plugs (6), and
displacement transducers (7) are connected directly to the PROFIBUS fieldbus.
Fieldbuses allow rapid data exchange between the PC and the decentralized field
input and output devices. Up to 8 servo drive controllers can be connected to the
SERCOS fieldbus, and 126 PROFIBUS devices can be connected to the PROFIBUS
fieldbus.
The industrial PC can also be connected to a LAN, and accessed remotely. Through a
connection to a WAN the industrial PC can also be accessed through the Internet/
Intranet or by satellite for remote diagnostics.
v 4.11.1 — March 2007 8–1 PC Control System

CAUTION!
Risk of damage to software and PC hardware. Scan all diskettes and network
files (if used) for viruses before using in machine.
SERCOS PROFIBUS
2
6
LAN
Figure 8-1 PC Controls (Typical)

1. Industrial PC 2. HMI 3. Servo motor 4. Servo drive 5. Bus terminal system 6. TC-Plug
7. Displacement transducer 8. Remote PC
PC Control System 8–2 v 4.11.1 — March 2007

8.1.1 Industrial PC
The industrial PC consists of a IBM-compatible PC with seven PCI/ISA slots for
connecting various interface cards. The PC enclosure houses a motherboard, hard
disk, 1.44 Mb floppy drive and a CD-ROM drive. Figure 8-2 shows the various devices
on the PC.
1 2
5 6
16 12 10 (Top view of computer)

14
15 11
13
Figure 8-2 Typical Industrial PC

1. LED (hard disk) 2. LED (power) 3. 1.44 Mb floppy drive 4. CD-RW drive
5. Serial port (COM2) 6. Serial port (COM1) 7. Fuse 8. Mouse port 9. Keyboard
port 10. Printer port (LPT1) 11. Video card 12. Ethernet card 13. Optional Serial
port card (COM3/4) 14. PROFIBUS interface card 15. SERCOS master interface
card 16. CP-Link interface card

The serial port (COM2), printer port (LPT1), keyboard port, and floppy drive on the PC
can be accessed through an access panel located in the front of the electrical cabinet.
– refer to Figure 8-3.
NOTE: These ports are replaced by the USB ports located on the electrical control
cabinet.
Figure 8-3 Accessing the Floppy Drive / Removable USB Storage

1. Panel 2. Electrical cabinet 3. USB ports
CAUTION!
Risk of damage to software and PC hardware. Scan all diskettes and network
files (if used) for viruses before using in machine.
CAUTION!
Risk of damage to the PC. There are no user-serviceable parts in the PC. Do not
remove the cover on the PC.
PC LED Diagnostics: The three LEDs on the face of the PC (refer to Figure 8-2) are
discussed in Table 8-1.
Table 8-1 PC LED Description
LED Description
HDD Lights up to indicate hard disk activity.
Power Lights up to indicate supply voltage to the PC.
Turbo Not used.

PC Fault Diagnostics: Table 8-2 lists common fault diagnostics related to the PC.
Table 8-2 Industrial PC Fault Diagnostics
Fault Causes Remedy
Nothing happens with the No power being supplied to • Check fuse on the PC, or
industrial PC after power is PC the breaker in the cabinet
switched on • Measure voltage at
connection and check
plug wiring
• Call Husky Service
Industrial PC does not boot Floppy disk in drive • Remove floppy disk, and
up completely press any key
Damaged hard disk (caused • Call Husky Service

by powering off while
software still running)
Other cause • Call Husky Service
Computer boots up and Cables from CP-Link • Check cables

software starts, but control interface card to keyboard,
functions do not operate mouse ports may be loose
correctly
Error in software or • Call Husky Service
equipment other than the
industrial PC
Error during floppy disk Faulty floppy disk • Check the disk in another
access PC
Faulty disk drive • Call Husky Service

8.1.1.1 SERCOS Master Interface Card

The SERCOS master interface card (1) is the communication link between the PC and
the SERCOS drive interface card located on the servo drive (2) – refer to Figure 8-4.
S01-100632.eps
RX
TX
3 1
2 2 2
Figure 8-4 SERCOS Fieldbus System (Typical)

1. SERCOS master interface card 2. Drive 3. Fibre optic cable
All communication between the master interface card and the drives occur through
fibre optic cables (3). These fibre optic cables must be connected properly to ensure
error-free communications.
NOTE: Check the transmitter cable (lit end of the fibre optic cable) is connected to the
input on the drive interface card (refer to Section 8.1.3.1).

CAUTION!
remove the cover on the PC except to inspect the status LEDs on the interface
cards.
Figure 8-5 shows the connections and displays on the Sercans SERCOS SCS-P02
interface card.
RESE
AJ12
AJ13
AJ14
AJ15
AJ16
AJ17
AJ18
OPEN S1
1
VS7
X1SP
2
SYNCH
3
BOOT
TM0
TM1
SCB S3 OPEN
RESJ
4
S01-100548.eps
JP2 JP1
RX 5
IRQ 7 DL3 DL4
X3
TX
Figure 8-5 Sercans SERCOS SCS-P02 Interface Card (Typical)

1. RS232 connector 2. 7-Segment display 3. LED (H3 ERR) 4. Fiber optic receiver
5. Fiber optic transmitter

8.1.1.2 PROFIBUS Interface Card

The Beckhoff PROFIBUS interface card links the various PROFIBUS devices.
Figure 8-6 Beckhoff PROFIBUS Interface Card (Typical)

1. LED (Run) 2. LED (BF)
CAUTION!
remove the cover on the PC except to inspect the status LEDs on the interface
cards.
Status LEDs Diagnostics: The Beckhoff PROFIBUS interface card has 2 LEDs – refer
to Figure 8-6. The Run LED (1) lights up when the bus is functioning normally, and the
BF (Bus Failure) LED lights up when there is a bus failure.
The card is self-configuring as it is PnP (Plug-and-Play) capable.

8.1.2 HMI Screen Display
Control Panel Fault Diagnostics: In the event of a control panel failure, consult the
following fault list. The list contains some of the most common, and easy to solve
control panel faults. Refer to Table 8-3.
Table 8-3 Control Panel Fault Diagnostics
Fault Causes Remedy
Control panel display is Control panel link cable is • Insert plug with red
blank when industrial PC not connected or incorrectly marking into socket with
completely started inserted. red dot
• Call Husky Service
No power being supplied to • Check fuse on the PC, or

industrial PC. the breaker in the cabinet
• Measure voltage at
connection, and check
plug wiring
Computer boots and Error in software, or • Call Husky Service

software starts but control equipment other than the
panel does not operate control panel
correctly
Control panel functions Faulty fluorescent bulb in • Replace control panel

incorrectly or intermittently display
(e.g., no picture or dark
picture) even though disk Defective components in • Replace control panel
drive operates when PC control panel
switched on

8.1.3 Servo Drive

The servo drive consists of a V Controller (1) and power supply – refer to Figure 8-7.
The V Controller consists of communication ports, diagnostic LEDs (2), a 7-segment
display (3), and a SERCOS drive interface card (4).
NOTE: Servo drives can vary in size depending upon the application. However, the V
Controller is identical on all servo drives.
S01-100485.eps
BUS 6V
H20
H21
3 H22
2
X23
X26
BUS 6V
H20
1 H21
H22 4
X23
X27
H43
X26
H44
H47
X25
X27
S48
H43
H44
ON
1 2
S49
H47
X25
S48 OUT
X46
ON
1 2
S49
OUT
X24
X46
X24 IN
IN
X45
X45
Figure 8-7 Servo Drive (Typical)

1. V Controller 2. LEDs 3. 7-segment display 4. SERCOS drive interface card
The V Controller has a 7-segment display which indicates the status of the servo drive.
The drive interface card has its own 7-segment display and status LEDs, which are
discussed on Section 8.1.3.1.

8.1.3.1 SERCOS Drive Interface Card

The SERCOS drive interface card communicates with the SERCOS master interface
card on the PC. Communication between the two cards occur through fibre optic
cables. These fibre optic cables must be connected properly to ensure error-free
communications.
The status LEDs (1) provide communication diagnostics – refer to Figure 8-8. The 7-
segment display (2) displays error diagnostics. The address selector (3) is used to set
the SERCOS address for the drive. The data transmission rate selector (4) is used to
select the transmission rate. The fibre optic cables are connected to the output
connection (5) and the input connection (6).
NOTE: Check the transmitter cable (lit end of the fibre optic cable) is connected to the
input connection.
NOTE: Each drive controller has a SERCOS slave interface card, and there can be
several drive controllers on the machine.
S01-100547.eps
BUS 6V
H20
H21
H22
X23
X26
X27
H43
H44
X25 H47
1
S48
H43
ON
1 2
S49
OUT
X46
X24
X45
IN
H44
2
H47
S48
ON
1 2
S49
OUT 3
X46
IN 4
X45
Figure 8-8 SERCOS Slave Interface Card (Typical)

1. Status LEDs 2. 7-segment display 3. Output connection 4. Input connection
Status LEDs: The green LEDs (H43 and H44) light up to indicate that communications
are in Phase 4, and running properly. The red LEDs (H43 and H44) light up when the
SERCOS ring is broken (possibly due to broken connection at the output connection
X46).

8.1.4 PROFIBUS Bus Terminal System

The bus terminal system is the interface between the PROFIBUS fieldbus and the field
devices. A bus terminal system consists of a bus coupler (1), bus terminals (2), and an
end terminal (3) – refer to Figure 8-9. Different bus terminals are available to handle
different types of signals. Power input terminals can be used to subdivide the terminal
row into groups, each with a separate power supply.
1 2 4
S01-100471.eps
PROFIBUS
RUN
BF
DIA 24 V 0 V
I/O RUN + +
I/O ERR
BECKHOFF
- -
PE PE
5 3
Figure 8-9 Bus Terminal System (Typical)

1. Bus coupler 2. Bus terminal 3. Bus end terminal 4. Potential input terminal
5. Potential isolation
The various types of bus couplers, and bus terminals used in Husky machines are
discussed below.
8.1.4.1 PROFIBUS Bus Coupler
8.1.4.1.1 Beckhoff BK3150 Bus Coupler

The BK3150 handles both digital and analog signals.
Power Supply Status LEDs: The green LED (1), and LED (2) indicate the status of the
24 V power supply of the bus coupler, and the supply to the bus terminals via the K-
bus contacts (3) – refer to Figure 8-10.
Terminal Bus Status LEDs: indicate the operating status of the terminal bus (K-bus),
and the connections to the bus terminals. The green I/O RUN LED lights up to indicate
fault-free operation. The red bus terminal I/O ERROR LED flashes to indicate an error.
The red LED uses two different flash rates in a specific sequence to indicate the start
of error code, type of error, and location of error as follows:
Rapid flash (start of error code) > First slow flash (type of error) > Second slow flash
(location of error).

NOTE: The bus coupler will carry on flashing the error code even when the fault has
been cleared. The bus coupler will remain in "Stop" mode, and the only way to
restart it is to switch the power off, and on again.
12
8 LED
5 1
2
11 6
9 3
7
4
10
Figure 8-10 Beckhoff BK3150 Bus Coupler (Typical)

1. Power LED bus coupler 2. Power LED bus contacts 3. K-Bus I/O RUN
4. K-Bus I/O ERROR 5. Fieldbus LED RUN 6. Fieldbus LED BF
7. Fieldbus LED DIA 8. K-bus contacts 9. Power supply to bus coupler
10. Address selector 11. Fieldbus connector 12. Configuration interface
Table 8-4 BK3150 Terminal Bus Status LED
I/O-RUN BF DIA Meaning
on off off Operating state: RUN, Inputs are read and outputs are
set
on on off, 1. Bus activity, but slave is already parameterised

blinking
2. Bus error with reaction to PROFIBUS error:
a) K-Bus outputs become 0 or
b) K-Bus outputs are retained
off off off Data exchange with the master is not started
off on on No bus activity
off on off, Bus error with reaction to PROFIBUS error: K-Bus

blinking cycle is stopped

8.1.4.2 PROFIBUS Bus Terminal

The PROFIBUS bus terminal is the decentralized link between the PC and the field
devices. The field device input/output is connected to the bus terminal, and does not
need to be wired directly to the PC. There are different types of bus terminals to
handle different types of connections – analog, digital, relay and direct sensors.
8.1.5 TC-Plug
The TC-plug is a PROFIBUS slave device to which thermocouples can be connected.
Internally it is a bus terminal system with a bus coupler and a few analog input bus
terminals.
1
2 3
4 5
Figure 8-11 TC-Plug (Typical)

1. LED (RUN) 2. LED (BF) 3. LED (ERR) 4. LED (TC RUN) 5. LED (TC ERR)
Fieldbus Status LEDs: The RUN LED (1) lights up when the fieldbus is functioning
normally – refer to Figure 8-11. The BF (Bus Failure) LED (2) lights up when there is a
fieldbus failure. The ERR (Error) LED flashes to indicate the error diagnostic. The ERR
LED uses two different flash rates in a specific sequence to indicate the start of error
code, type of error, and error code argument as follows:
Rapid flash (start of error code) > First slow flash (type of error) > Second slow flash
(error code argument).
Thermocouple Status LEDs: The green TC RUN LED (4) lights up to indicate fault-free
operation. The red TC ERR LED (5) flashes to indicate a thermocouple input error.
The TC LED uses two different flash rates in a specific sequence to indicate the start
of error code, error code, and error code argument as follows:
Rapid flash (start of error code) > First slow flash (error code) > Second slow flash
(error code argument).
NOTE: In the event of an open circuit (such as a wire break, disconnected wire, an out
of range error, or back voltage error) the error code argument is the error
location.

8.2 Creating Recovery Disk Image/Restoring Hard Disk
Figure 8-12 IPC (Typical)

1. IPC Label 2. CDRW Drive
8.2.1 Creating a Recovery Disk Image

To create a Recovery Disk Image, a bootable floppy disk is required. The following
procedures explain how to first create a bootable floppy diskette, then create a
Recovery Disk Image using the IPC’s built-in CD-RW device.
8.2.1.1 Creating a Bootable Floppy Diskette

NOTE: A bootable floppy diskette is only required for an IPC Type 10 or 11. This
floppy disk can be created using the machine’s IPC. A formatted floppy disk is
required, and the diskette must be writable.
1. Log on to the HMI using the Administrator key or Administrator password.
v 4.11.1 — March 2007 8–15 Creating Recovery Disk Image/Restoring Hard Disk
2. Click on the HMI Configuration button on the toolbar to open the HMI
CONFIGURATION pop-up window.
3. Click the Others tab and select the Show Title Bar check box.
4. Close the HMI (use the Close button in the upper right hand corner of the HMI
screen) to access the desktop.
5. Double-click the “Make Image Boot Disk” shortcut on the desktop.
6. Follow instructions on the screen to create the bootable floppy diskette.
8.2.1.2 Creating a Recovery Disk Image Using the Built-in CD-RW Device for the P3
The following procedure describes how to create a Recovery Disk Image using the
IPCs built-in CD-RW device.
NOTE: Prior to creating the Recovery Disk Image disconnect all network drives and
empty the Recycle Bin. To disconnect the network drives, go to Windows
Explorer, right-click the network drive and select "Disconnect". Select "Yes" to
confirm. To empty the Recycle Bin, go to the desktop and right-click on the
Recycle Bin icon, and select "Empty Recycle Bin".
1. Scan the hard disk for errors - refer to Section 8.2.1.4.
2. Insert the bootable floppy disk into the floppy drive in the IPC.
3. Insert a blank CD-ROM disk into the CD-RW device.
4. Restart the IPC.
5. Check that the machine boots up from A:\ drive (floppy drive). If necessary, modify
the boot-up sequence to start from A:\ - refer to Section Section 8.2.1.5.
6. Follow instructions on the screen.
7. When the PowerQuest Drive Image Pro 4.0 window is displayed, select "Create
Image".
8. In the Select Source Partitions window click "Select All" and "Next".
9. Click "Browse" in the Name Image File window.
10. Select the CD-RW device (\Pqcd0 HL-DT-ST-CD-RW GCE-8240B 1.06 24x40)
from the pull-down list in the New Image File window.
11. Enter "PQER" for File Name, and click "OK".
12. Click "Next" in the Name Image File window.
13. Select "High" in the Compress Image File window, and click "Next".
14. Click "Finish" in the Ready to Create Image File window.
15. When the disk image is created successfully click "OK", and exit PowerQuest
Drive Image Pro 4.0.
16. Remove the CD-ROM from the built-in CD-RW device. Label the CD-ROM -
include date of Recovery Disk Image, machine serial number and model, and
software version (e.g. v5.007-001A).
17. Remove the bootable diskette from the floppy drive.
18. Restart the IPC.
19. Change the boot sequence to C:\ drive (CD-ROM\C:\A:).
Creating Recovery Disk Image/Restoring Hard Disk 8–16 v 4.11.1 — March 2007
8.2.1.3 Creating a Recovery Disk Image Using the Built-in CD-RW Device for the P4
The following procedure describes how to create a Recovery Disk Image using the
IPC’s built-in CD-RW device.
NOTE: Prior to creating the Recovery Disk Image disconnect all network drives and
empty the Recycle Bin. To disconnect the network drives, go to Windows
Explorer, right-click the network drive and select "Disconnect". Select “Yes” to
confirm. To empty the Recycle Bin go to the desktop and right-click on the
Recycle Bin icon, and select “Empty Recycle Bin”.
1. Scan the hard disk for errors – refer to Section 8.2.1.4.
2. Insert the bootable floppy disk into the floppy drive in the IPC.
3. Insert a blank CD-ROM disk into the CD-RW device.
4. Restart the IPC.
5. Check that the machine boots up from A:\ drive (floppy drive). If necessary, modify
the boot-up sequence to start from A:\ – refer to Section 8.2.1.6.
6. Follow instructions on the screen.
7. When the PowerQuest Drive Image Pro 4.0 (Image Center) window is displayed,
select “Create Image”.
8. In the Select Source Partitions window click “Select All” and “Next”.
9. Click “Browse” in the Name Image File window.
from the pull-down list in the New Image File window.
11. Enter “PQER” for File Name, and click “OK”.
12. Click “Next” in the Name Image File window.
13. Select “High” in the Compress Image File window, and click “Next”.
14. Click “Finish” in the Ready to Create Image File window.
15. The system will display a Power Quest Image Center dialog box with the following
prompt:
"Insert new Media 2 for file "\\.\Pqcd0\pqer.002" into drive TEAC-CD-W55E 1.13
52x52"
16. Insert the next CD.
17. Label each CD appropriately (e.g. 1-of-2, 2-of-2).
NOTE: Continue until all CDs have been produced.
18. When the disk image is created successfully click “OK”, and exit PowerQuest Drive
Image Pro 4.0 (Image Center).
19. Remove the CD-ROM from the built-in CD-RW device. Label the CD-ROM –
include date of Recovery Disk Image, machine serial number and model, and
software version (e.g. v5.007-001A).
20. Remove the bootable diskette from the floppy drive.
22. Change the boot sequence to C:\ drive (CD-ROM\A:\C:).
8.2.1.4 Scanning the Hard Disk for Errors

(NT IPCs include the following numbers: 10,11,12,13,20,21,22,23.)
(XP IPCs include the following numbers: 26,27,28,29.)
1. Go to Windows Explorer and right-click on the C:\ drive
2. Select “Properties”.
3. Select tab “Tools”.
4. In the Error-checking frame click the Check Now… button.
5. In the Check Disk dialog box (Windows NT) / Check Disk System dialog box
(Windows XP) select “Automatically fix file system errors” and “Scan for and
attempt recovery of bad sectors”.
6. Click the Start button.
7. In the pop-up message window “The disk check could not be performed
because…” Click “Yes”.
8. Restart the IPC.
9. Click “Yes” and allow scandisk to run autocheck. This will take a few minutes. The
system will display the message: "A disk check has been scheduled. Windows will
now check the disk.
8.2.1.5 Modifying the Boot-Up Sequence for the P3 IPC

(P3 IPCs include the following numbers: 10,11,12,13.)
1. Press the Delete key on the keyboard as the machine boots up until the blue BIOS
screen appears.
2. Use the Up/Down cursor keys on the keyboard to highlight “BIOS FEATURES
SETUP” and press the Enter key.
3. Use the Up/Down cursor keys to highlight the “BOOT SEQUENCE” section.
4. Use the Page Up/ Page Down keys to change the boot-up sequence order. To
boot up from the CD-ROM change the sequence to “CDROM, …”. To boot up from
the A:\ drive change the sequence to “A, …”.
5. Press the Esc key on the keyboard when finished.
6. Press the F10 key to save and exit the BIOS setup.
7. Press the Enter key to confirm the save.
The IPC will then reboot from the CD-ROM or A:\ drive as selected above.
8.2.1.6 Modifying the Boot-Up Sequence for the P4 IPC

(P4 IPCs include the following numbers: 20,21,22,23,26,27,28,29.)
1. Press the Delete key on the keyboard as the machine boots up until the blue BIOS
screen appears.
2. Use the Up/Down cursor keys on the keyboard to highlight “ADVANCED BIOS
Features” and press the Enter key.
3. Use the Up/Down cursor keys to highlight the “Boot Seq and Floppy SetUp" and
press the Enter key.
4. Use the Page Up/ Page Down keys to change the boot-up sequence order. To
boot up from the CD-ROM change the sequence to “CDROM, …”. To boot up from
the A:\ drive change the sequence to “A, …”.
5. Press the Esc key on the keyboard when finished.
6. Press the F10 key to save and exit the BIOS setup.
7. Press the Enter key to confirm the save.
The IPC will then reboot from the CD-ROM or A:\ drive as selected above.
8.2.1.7 Restoring a Hard Disk from a Recovery Disk Image for the P3 IPC
(P3 IPCs include the following numbers: 10,11,12,13.)
The following procedure describes how to check the hard drive for errors then restore
the hard drive on an IPC type 10, 11 from a Recovery Disk Image.
CAUTION!
Restoring a Recovery Disk Image will delete all existing machine data (software,
mold setups and robot programs) from the hard disk on the IPC. The hard disk
will be restored to the state that it was at the time the Recovery Disk Image was
created.
1. Scan the hard disk for errors – refer to Section 8.2.1.4.

2. If the hard drive has no errors then check that the IPC is set to boot up from the
CD-ROM (Verify that the boot sequence is CD-ROM/C:/A:) – refer to
Section 8.2.1.5.
3. Right-click the Network Neighborhood icon. Select Properties.
4. Note the computer name. If the machine is part of a domain, make a note of the
domain name as well.
5. If the machine is connected to a LAN, select the PROTOCOLS tab and double-
click on TCP/IP PROTOCOL. Note the IP address, then close the window.
6. Insert the Recovery Disk Image CD-ROM into the CD-RW device.
7. Restart the IPC. Check that it boots up from the CD-ROM.
8. Click “Browse” in the Select Image File window.
from the pull-down list.
10. Select “PQER” for File Name list, and click “OK”.
11. Click “Next” in the Select Image File window.
12. Click "Select All" and "Next" in the Select Image File Partitions window.
13. Click “Delete Disk Partitions” in the Select Destination Partition Unallocated Space
window.
14. Click “Delete All” in the Delete Partitions window.
15. Click “Yes” to acknowledge warning about destruction of all data.
16. Click "Close" in the Delete Partitions window.

17. Click "Next in the Select Destination Partitions Unallocated Space window.
18. Click "Finish" in the Ready to Restore Image File window.
19. Click "Yes" to acknowledge the warning message that the partition many not be
bootable.
20. Click “No” when prompted to view results of successful image restore.
21. Remove the Recovery Disk Image CD-ROM from the CD-RW device.
24. Confirm the computer name and the IP address are correct. If necessary, correct
the settings and reboot the IPC.
25. Change the boot sequence to C:\ drive. (CD-ROM/C:/A:). Not required if step 2 is
completed.
26. Restore any machine data using the Backup/Restore utility on the HMI
CONFIGURATION screen, as required.
8.2.1.8 Restoring a Hard Disk from a Recovery Disk Image for the P4 IPC
(P4 IPCs include the following numbers: 20,21,22,23,26,27,28,29.)
The following procedure describes how to check the hard drive for errors then restore
the hard drive on an IPC type 10, 11 from a Recovery Disk Image.
1. Scan the hard drive for errors.
2. If the hard drive has no errors then check that the IPC is set to boot up from the
CD-ROM. Verify that the boot sequence is CD-ROM, A:\, C:\.
4. Note the computer name. if the machine is part of a domain, make a note of the
domain name as well.
5. If the machine is connected to a LAN, select the PROTOCOLS tab and double-
click on TCP/IP PROTOCOL. Note the IP address, then close the window.
6. Insert the Recovery Disk Image CD-ROM into the CD-RW device.
7. Restart the IPC. Check that it boots up from the CD-ROM.
8. Click "Browse" in the Select Image File window.
9. Select the CD-RW device from the pull-down list.
10. Select "PQER" for File Name list, and click "OK".
11. The system will display the following Image Center dialog box prompt message:
"Insert the last media of the image into drive TEAC CD-W552E 1.13 52x52". Insert
the last CD of the set. Wait until the CD-RW device indicator stops flashing before
clicking the OK button. The system will display a Restoring an Image dialog box
with the following image file comments:
"NTFS) * System [file size] MB".
12. If the system is not properly reading the CD, the system will continue to display the
"Insert the last CD…" message. Click "Next" in the Select Image File window.
13. Click "Select All" and "Next" in the Select Image File Partitions window.
14. Click "Delete Disk Partitions" in the Select Destination Partition Unallocated Space
window.
15. Click "Delete All" in the Delete Partitions window.
16. Click "Yes" to acknowledge warning about destruction of all data.
17. Click "Close" in the Delete Partitions window.
18. Click "Next" in the Select Destination Partitions Unallocated Space window.
19. The CD-RW device will eject the CD and display the following message: "Reinsert
first media of the image into TEAC CD- [drive description].
20. Insert the CD and click OK.
21. Continue until all disks have been installed.
22. Click "Finish" in the Ready to Restore Image File window.
23. Click "Yes" to acknowledge the warning message that the partition may not be
bootable.
24. Click "No" when prompted to view results of successful image restore.
25. Remove the Recovery Disk Image CD-ROM from the CD-RW device.
26. Restart IPC.
28. Confirm that the computer name and IP address are correct. If necessary, correct
the settings and reboot the IPC.
29. Change the boot sequence to C:\ drive (CD-ROM, A:\, C:\). Not required if step 2 is
completed.
30. Restore any machine data using the Backup/Restore utility on the HMI
CONFIGURATION screen, as required.
NOTE: Recommended media brands/manufacturers for TEAC CD-R devices:
• 4M • Fornet • Maxell • Nan Ya

• CMC • Fujifilm • MBI (India) • Plasmon
• Csita • GAT • Mirage • Postech
• Daxon • Gigastorage • Mitsubishi • Princo
• Delphi • Infodisc • Mitsui • Prodisc
• DST • KingPro • MPO (France) • Ricoh
• E-Top • LeadData • Multimedia masters
8.3 Replacing the Uninterruptible Power Supply Battery
The IPC is equipped with an Uninterruptible Power Supply (UPS). This prevents the
IPC from crashing in the event of a power outage and allows the operator to save
machine settings. It also protects the IPC from momentary power fluctuations.
Beckhoff recommends replacing the UPS battery at least every four years. Proceed as
follows to replace the battery.
WARNING!
Electrocution hazard – risk of death or serious injury. High voltages present in
the electrical cabinet. Perform Lockout/Tagout procedure in accordance with
local codes. Only qualified personnel should perform Lockout/Tagout
procedure.
1. Perform Lockout/Tagout procedure – refer to Section 1.6.1. Wait until all of the
lights on the IPC have gone out. It takes approximately 30 seconds for the IPC to
shut down properly.
2. Open the door on the controls section of the electrical cabinet.
3. The UPS battery is located directly below the IPC – see Figure 8-13. Remove the
wires connected to the UPS battery.
4. Remove the screws holding the UPS battery to the back rail, and remove the
battery.
5. Position the new UPS battery on the rail and affix with the screws.
6. Reconnect the wires to the UPS battery.
7. Close the doors on the electrical cabinet.
8. Remove locks and tags.
9. Return machine to normal operating conditions.
Replacing the Uninterruptible Power Supply Battery 8–22 v 4.11.1 — March 2007
2
1
Figure 8-13 Uninterruptible Power Supply Battery Replacement

1. IPC 2. UPS battery 3. Wires
v 4.11.1 — March 2007 8–23 Replacing the Uninterruptible Power Supply Battery
Replacing the Uninterruptible Power Supply Battery 8–24 v 4.11.1 — March 2007
Machine Manual Statistical Process Control (SPC)
Chapter 9 Statistical Process Control (SPC)
The optional SPC screens are available when the Statistical Process Control (SPC)
option package is purchased. SPC is a tool that applies basic statistical analysis to
monitor processes. It assists to diagnose and pin point quality and productivity
problems.
The SPC program monitors a process and determines when it has deviated from the
process standard. A process is considered to be deviated from the standard when one
or more monitored SPC variables are outside specified operating ranges. An operator
can define a course of action for each variable when it deviates from the process
standard (e.g., turn on the SPC alarm light, stop the machine, or turn on an auxiliary
output).
9.1 SPC Quick Start
Use the following instructions to quickly set up and run SPC. For a detailed description
of all the features of SPC read Section 9.8, and the individual SPC screens.
1. First select SPC variables for monitoring.
Press <SPC> key, then select the SETUP tab. Select the field beside each
variable to select it. You can choose variables from the list of process variables
displayed on the screen. Refer to Section 9.6 for details.
2. Specify Sample Size and Sampling Period.
The default Sample Size and Sampling Period are 5 and 15 respectively. A
Sample Size of 5 means that 5 consecutive machine cycles make up a sample. A
Sampling Period of 15 means that after one sample is collected, there is a 10 cycle
pause before the next sample is collected.
To change the default sample settings, press <SPC> key and select the SETUP
tab. Refer to Section 9.6 for details.
3. Produce "good" parts, and reset all SPC variables so the SPC program can
automatically set specification limits based on "good" parts.
Start up the machine, and adjust the process until part quality is satisfactory.
Press <SPC> key, then select the DETAILS tab. Select the Reset All Variables
button on the DISTRIBUTION AND TREND tab.
4. Sample the process, and allow the process to settle.
v 4.11.1 — March 2007 9–1 SPC Quick Start

Data points will appear on the control charts as samples are collected. When at
least two samples have been collected, control limits will appear on the control
charts as horizontal red lines, and 3σ limits will appear on the Trend chart as
horizontal purple lines. At the default sampling period setting, control limits will
appear about 30 cycles after the machine starts.
NOTE: Initially, the control limits and 3σ limits will not be very accurate. It will take
some time for them to settle (usually within 10 to 25 samples, depending
on the sampling period).
5. Select specification limits to be set automatically.
After the machine produces "good" parts, and the process has settled, select the
Set All Limits button on the DETAILS screen. Before changing limits, the program
displays a prompt. Select Yes to confirm the change.
The specification limits appear as horizontal yellow lines on Trend charts.
6. Configure SPC alarms for each monitored SPC variable.
Press <SPC> key, then select the SETUP tab. Refer to Section 9.6 to enable
specification and control alarms for monitored variables.
At this point you should have a working SPC package. The SUMMARY, DETAILS and
GROUP screens can be used to check monitored SPC variables. The HISTORY
screen can be used to display historical data for all SPC variables.
After setting up the basic SPC package, there are some additional steps that can be
set up.
1. Specify known control limits for monitored SPC variables.
When a set of Xbar and R/s chart control limits is available for a known batch of
good parts, it may be suitable to monitor machine variations against these known
control limits, rather than have the SPC program calculate them automatically.
Press <SPC> key, then select the CTRL LIMITS tab. Refer to Section 9.7 to set
control limits.
2. Enter known upper and lower specification limits for monitored SPC variables.
When a set of Trend specification limits is available for a known batch of good
parts, it may be suitable to monitor machine variations against these known
specification limits, rather than have the SPC program calculate them
automatically.
Refer to Section 9.3 to enter specification limits for any of the monitored variables.
SPC Quick Start 9–2 v 4.11.1 — March 2007

9.2 SUMMARY Screen
The SUMMARY screen allows the operator to monitor, at a glance, the status of 20
monitored SPC variables. The screen displays the alarm state of each SPC variable,
the current reading and limits, the current Cpk, and if the variable is in a state of
statistical control.
Press <SPC> key to display the SUMMARY screen. Refer to Figure 9-1.
Figure 9-1 SUMMARY Screen

NOTE: You cannot select variables or buttons, or modify any of the selectable fields if
you do not have access rights.
v 4.11.1 — March 2007 9–3 SUMMARY Screen

Table 9-1 Summary Screen Descriptions
Field Description
Variables Displays a list of monitored SPC variables.
LSL and USL The Lower Specification Limits (LSL) and Upper Specification
Limits (USL) list the lower and upper specification limits for each
SPC variable. The specification limits are usually set
automatically using the Set Limits or Set All Limits functions on
the DETAIL screen. However, it is also possible to enter LSL
and USL values in the SUMMARY screen by selecting the
individual fields. A numeric touchpad appears when a field is
selected.
If both specification limits are zero, the SPC program assumes
that the limits are not defined and the limit values are greyed
out.
If the value of a SPC variable is greater than its USL, then its
USL value turns red.
If the value of a SPC variable is less than its LSL, then its LSL
value turns red.
Actual Displays the most recent values of monitored SPC variables.

For process variables, the value displayed is the value from the
last machine cycle. For part variables, the value displayed is the
most recently entered value.
Cpk Displays the current Cpk value for each SPC variable. Cpk will
be zero if either the control limits or specification limits are not
defined for a variable. Cpk is recalculated whenever a new
sample is collected.
If the Cpk value of an SPC variable is less than the Cpk
threshold, its Cpk value turns red.
In Ctrl This column displays the status of the listed variables. The
indicators are color coded as follows:
• Dark grey = first two samples have not been collected
• Green = the variable is in statistical control
• Red = the variable is out of statistical control
SPC Alarms status The three indicators at the bottom of the screen show the
current state of the Machine Stop, SPC alarm light, and auxiliary
outputs. One or more of these indicators may be turned on
when a specification alarm occurs. The indicators are color
coded as follows:
• Green = functioning normally
• Red = machine/auxiliary devices stopped, and SPC alarm
light on
Cycle Number Displays the number of the current machine cycle. This number
is used to correlate part data with process data.
Alarm Delay Displays the number of cycles that the SPC program will wait
before taking alarm measures when the machine is in Auto
cycle mode.
SUMMARY Screen 9–4 v 4.11.1 — March 2007

9.3 DETAILS Screen
The DETAILS screen displays in graphical form all SPC information about a single
monitored variable. The screen contains two tabs where data is displayed in a trend
chart, trend distribution histogram, Xbar graph, and R/s chart. It also allows the
operator to set specification limits manually or automatically, and reset variables.
Press <SPC> key, then select the DETAILS tab. Refer to Figure 9-2.
Figure 9-2 DETAILS Screen
Table 9-2 describes the general fields shown on the DETAILS screen in Figure 9-2.
v 4.11.1 — March 2007 9–5 DETAILS Screen

Table 9-2 DETAILS Screen Descriptions
Field Description
(Variable Drop Use the drop down box to select a variable from the list.
Down Box) The distribution and trend data, and the Xbar and R/s data information is
immediately displayed on the screen.
NOTE: The variable only appears on this list if it has been selected on
the SETUP screen.
X-bar Alarms
The four status indicators light up when the Xbar average is out of
control. The colors of the indicators are summarized below:
• Dark grey – indicates sampling in progress. Remains grey while the
first two samples are collected
• Green – indicates the condition is not active
• Red – indicates the condition is active
Limit This indicator lights up when one sample average is outside the Xbar
control limits.
See indicator status summary above.
Run This indicator lights up when nine or more consecutive averages are
above or below the Xbar average.
Trend This indicator lights up when six or more consecutive averages are
trending upward or downward.
Alt. Data This indicator lights up when fourteen or more consecutive alternating
Xbar points have occurred.
9.3.1 DISTRIBUTION AND TREND Screen

The trend chart displays SPC variable values over 400 machine cycles. The horizontal
axis represents machine cycles, and the vertical axis represents range of process
values. New process data is plotted from right to left across the screen. Old process
data is scrolled off the chart at the opposite edge. The time of the most recent cycle is
displayed under the chart at the entry point on the chart.
The two fields located to the left of the chart, at the top and bottom of the vertical axis,
display the current range of the vertical axis.
The variable’s Upper and Lower Specification Limits are displayed graphically as two
yellow horizontal lines. The two input fields with yellow legends to the left of the chart
may be used to change the limits.
The variable’s ±3σ limits are displayed graphically as two purple horizontal lines. The
two fields to the left of the chart display the 3σ values.
DETAILS Screen 9–6 v 4.11.1 — March 2007

The Xbar average value is displayed graphically as a green horizontal line, and the
numeric value is also displayed in the output field to the left of the chart.
For process variables, the Xbar average and 3σ limits are only displayed over a 25
sample data range. This is intended to show that the values of these lines are based
only on the data that the program displays in the Xbar control chart.
The SPC program shows sampled readings in purple, and the remaining readings in
white. If the sampling period is equal to the sampling size, all readings are purple.
The chart displays the most recent variable value and the variable’s Cpk in "Current"
and "Cpk" fields across the top of the trend chart.
The Distribution histogram shows the distribution of data points currently displayed on
the trend chart. The vertical range for the variable’s distribution is the same as the
range for the trend chart.
A number of the SPC calculations assume that the distribution for a variable is bell
shaped, showing a Normal distribution. This assumption is correct in most cases and
can be easily verified by visually checking the shape of the distribution. If a variable
does not have a Normal distribution, the SPC program may be unable to correctly
determine whether or not it is in a state of statistical control.
Table 9-3 describes the remaining screen elements shown in Figure 9-2.
Table 9-3 DISTRIBUTION AND TREND Screen Descriptions
Field Description
Current Displays most recent variable value.
Cpk Displays the most recent Cpk for the variable.
Old Displays the time of the oldest displayed distribution and trend data.
New Displays the time of the newest displayed distribution and trend data.
Trend
1 – Displays the upper display limit of the trend chart.

1 2 – Enter USL value, if you desire to set it manually.
2 3 – Displays the upper 3σ limit.
3 4 – Displays the Xbar value.
4 5 – Displays the lower 3σ limit.
5 6 – Enter the LSL value, if you desire to set it manually.
6 7 – Displays the lower display limit of the trend chart.
7

Table 9-3 DISTRIBUTION AND TREND Screen Descriptions
Field Description
The Distribution histogram shows the distribution of data points

currently displayed on the trend chart.
Settings
Press this button to reset the displayed variable, and restart sampling
of the variable. The Xbar, R/s chart, and any active alarms are
cleared.
The HMI prompts the operator to confirm the action.
Press this button to reset all monitored variables, and restart sampling
of all variables. This is the equivalent of using the Reset button
individually for each variable.
Press this button to automatically determine specification limits for the

current variable based on its current trend, Control Limits and Cpk
multiplier.
Press this button to set limits for all monitored SPC variables.
Press this button to clear all specification limits, and set them to zero.
Use this function after installing a new mold to clear specifications
from previous runs with a different mold.
Scale Trend By
Data Press this option button to scale the trend chart so that all the data and
limits fit within the chart. Scaling can be applied individually to each
variable.
Limits Press this option button to scale the trend chart so that it only displays
the current specification and ±3σ limits. Scaling Trend by Limits allows
the operator to ignore peaks in the data, and see more detail in the
"normal" range. Scaling can be applied individually to each variable.
DETAILS Screen 9–8 v 4.11.1 — March 2007

9.3.2 XBAR AND R/s Screen

The Xbar and R/s control charts are displayed in their own tab on the DETAILS
screen. These charts graphically display the averages, ranges or standard deviations
of the samples, which let the operator determine if a variable is in a state of statistical
control.
The Xbar and R/s screen allows the operator to specify Xbar and R/s chart control limit
values for SPC variables rather than have the SPC program calculate it automatically.
This is useful when a set of control limits is available for a known process. The
machine variations can then be monitored against these known control limits.
Press <SPC> key, select the DETAILS tab, then select the XBAR and R/s tab. Refer to
Figure 9-3.
Figure 9-3 XBAR and R/S Screen
The current variable’s Upper and Lower Control Limits are displayed graphically as
two red horizontal lines, and the Xbar average value is displayed as a green horizontal
line. The numeric values corresponding to these lines are also displayed in the output
fields to the left of the chart.
Below each chart there are two time stamps which display event time in HH:MM:SS
format. The time stamps display the time of the oldest displayed sample, and the most
recent sample. The elapsed time between the most recent sample and the oldest
displayed sample is displayed between the two time stamps.
Although the horizontal axis displays the time spanned by the control chart, the SPC
program does not plot the samples by time. The samples are plotted so that there is
equal space between samples.

9.4 HISTORY Screen
The HISTORY screen allows an operator to select up to three SPC variables for
extended display. These variables can be any of the defined SPC variables, and not
just the monitored variables. However, the variable must still be defined on the SETUP
screen before it can be selected here.
Press <SPC> key, then select the HISTORY tab. Refer to Figure 9-4.
Figure 9-4 HISTORY Screen
The information displayed on this screen is read from the Data and Event Logs. The
Event Log contains the previous 20,000 events. The Data Log contains SPC variable
values for the previous 10,000 cycles. The duration of this data depends on the cycle
time, as indicated in Table 9-4 below.
Table 9-4 Data Log Duration
Cycle Time (seconds) Cycles/Day Log Duration (Days)
60 1440 7
30 2880 3.5
15 5670 1.7
HISTORY Screen 9–10 v 4.11.1 — March 2007

The upper area of the screen is divided into three panels. Each panel can graphically
display one SPC variable. Any configured variable (selected on the SETUP screen)
can be viewed on the HISTORY screen even if it is currently not monitored. Up to 48
hours of data can be viewed at any time. However, if the number of data points
exceeds the available pixels in the panel some data points may not be visible.
Each chart can be a trend, Xbar, or R/s chart. The horizontal axis represents time, and
the vertical axis represent the variable data. The two output fields to the left of each
panel display the range of the vertical axis. The fields just below the charting area
show the time range of the charts. The three charts always cover the same time range.
Each chart displays a horizontal line (at the midpoint) marking the middle of the
vertical range.
Trend data are shown as connected purple lines. If data points are not sufficiently
close together, a gap appears on the chart. Isolated data points appear as purple dots.
Xbar or R/s data appear as purple (bright magenta) dots connected by purple lines.
These data points are always connected, even across substantial gaps in the data.
Recent Xbar and R/s data are synchronized with the Xbar, R/s charts shown on the
DETAIL screen. This synchronization is maintained across machine mode changes,
but not across a machine shutdown.
When a monitored variable is plotted, the current limits of the variable are
superimposed on the data according to the following scheme:
Trend – specification limit
Xbar – current Xbar control limit
R or s – current R or s control limits
NOTE: For the limits to be visible, the variable must be monitored and have
appropriate control limits. The limits are not updated dynamically. They are
redrawn whenever a search is started, or if the operator moves to another
screen and returns back to it.
v 4.11.1 — March 2007 9–11 HISTORY Screen

Table 9-5 HISTORY Screen Descriptions
Field Description
Variable Select a variable from the drop down box associated with each display
panel.
NOTE: The same variable can be viewed in the other remaining
panels. This allows the variable to be viewed simultaneously as
a trend, Xbar, and R/s chart.
(Chart Type) Select the appropriate trend, Xbar or R/s option button at the top of
each panel. The variable displays accordingly in the panel below.
NOTE: The chart type selected is independent of the selection in other
panels.
Old Starting date and time for the search duration.
New Ending date and time for the search duration.
(Selection Period) Use the drop down box to select the display period for the three data
streams. The options are as follows.
• Last 4 Hours
Select to retrieve and display the previous four hours of data starting
from the current system time. The previous 4 hours of data are
retrieved from the log and plotted in the charts.
• Last 12 Hours
Select to retrieve and display the previous 12 hours of data starting
from the current system time. The previous 12 hours of data are
retrieved from the log and plotted in the charts.
• Date
Select to retrieve and display data for the range specified. The data
within the range are retrieved from the log and plotted in the charts.
NOTE: Selecting the Date option displays date and time touchpads.
Search Press this button to start searching the Event and Data Log.
NOTE: Searches may sometimes take a few moments to a few
minutes to complete – depending on the amount of data to be
examined.
Cancel Press this button to cancel the search.
9.5 GROUP Screen
The GROUP screen allows the operator to directly compare 8 monitored SPC
variables and check for any correlations. The screen can display trend, Xbar, R/s
charts depending on the specification on the SETUP screen.
NOTE: Only eight monitored SPC variables can be compared at one time using the
graphs on screen.
GROUP Screen 9–12 v 4.11.1 — March 2007

Press <SPC> key, then select the GROUP tab. Refer to Figure 9-5.
Figure 9-5 GROUP Screen
The charts are updated in real time as new data become available. New data is plotted
from right to left across the screen.
Depending on the "Scale Trend by Data" or the "Scale Trend by Limits" input selected
on the DETAIL screen, each trend chart is scaled and plotted accordingly.
Table 9-6 GROUP Screen Descriptions
Field Description
Trend Press this option button to display statistical information for variable data
by trend.
Xbar Press this option button to display statistical information for variable data
using Xbar patterns.
R/s Press this option button to display statistical information for variable data
using R/s sample range plotting.
(Variable graphs) There are eight variable graphs on the screen to allow simultaneous
display of eight selected variables. Select the drop down box at the top
of a graph to choose the variable to display.
NOTE: A variable must be selected on the SETUP screen in order to
appear in the drop down list.
v 4.11.1 — March 2007 9–13 GROUP Screen

9.6 SETUP Screen
The SETUP screen allows the operator to select variables for monitoring, specify
alarm configuration settings for monitored variables, and other miscellaneous
configuration settings for the SPC program.
Press <SPC> key, then select the SETUP tab. Refer to Figure 9-6.
Figure 9-6 SETUP Screen
Table 9-7 SETUP Screen Descriptions
Field Description
Configure (Cfg) Select the field beside the variable name to enable/disable
monitoring of that variable. A dialog box appears to prompt you
to verify the action. When the variable is enabled a check mark
appears in the field. Otherwise, the field is left blank, and the
specification alarm and Xbar fields are greyed out.
All variables Use this option button to display all SPC variables. Table 9-8
lists all available SPC variables.
Configured variables Use this option button to restrict the display list to those
variables that have been configured.
SETUP Screen 9–14 v 4.11.1 — March 2007

Field Description
Specification Alarms
To enable/disable specification alarms, select the applicable alarm fields corresponding to

each SPC variable. A dialog box appears to prompt you to verify the action. When the alarm
is enabled, a check mark appears in the field; otherwise the field is left blank.
Enable (En) Select this field to enable/disable the specification alarm for the
SPC variable. When the specification alarm is enabled, the
following events can occur.
• The HMI displays the message "SPC variable(s) outside
specification limits" when the variable is outside the limits.
• The HMI displays the message "SPC variable(s) have Cpk
below threshold" when the variable’s Cpk is below the Cpk
threshold.
• The SPC program will take the appropriate alarm action
defined for the variable.
Threshold (Th) Select the field to display a numeric touchpad to enter the value
for the alarm threshold.
The specification alarm threshold specifies how many times in a
row the SPC variable can exceed specification limits before the
alarm is activated.
Light (Lt) Select this field to enable/disable the warning light when the
SPC variable exceeds specification limits.
Stop (St) Select this field to enable/disable the machine stop when the
Auxiliary (Au) Select this field to enable/disable the auxiliary output when the
Xbar
Enable (En) Select this field to enable/disable monitoring of out-of-control

conditions for process averages.
The HMI triggers an alarm when such a condition is
encountered. The HMI displays the message "SPC variable(s)
out of control", and the status indicator on the SUMMARY
screen turns red.
The detected out-of-control condition can be seen above the
Xbar chart on the DETAIL screen when the variable is
displayed.
Specifications
Sample Size Enter a value between 2 and 25 for the number of cycles over
which samples are acquired. All process variables have the
same sample size.
NOTE: Changing the sample size resets any part variables that
are being monitored.
v 4.11.1 — March 2007 9–15 SETUP Screen

Field Description
Sample Period Enter a value between the value of Sample Size and 999
cycles.
NOTE: Changing the sampling period resets any process
variables that are being monitored.
Desired Cpk When Enter a Cpk value in this field. When the Set Limits button on
Learning Limits the DETAILS screen is selected, the specification limits are
calculated so that the resulting Cpk is approximately equal to
this value.
Cpk Warning Threshold Enter a Cpk warning threshold value. If the calculated Cpk for a
monitored variable goes below this threshold value, the
variable’s Cpk indicator on the SUMMARY screen turns red. In
addition, if specification alarms are enabled, an alarm message
will be generated.
Alarm Light On For Enter the minimum time that the alarm light must remain on
after the specification alarm has gone inactive.
Auxiliary On For Enter the minimum time that the auxiliary output can remain on
after the specification alarm has gone inactive.
Delay Spec. Alarm For Enter the number of cycles that the SPC program must wait,
while in Auto mode, before activating the specification alarm.
This delay allows the machine to stabilize before the SPC
program starts to monitor the variables.
Table 9-8 lists SPC process variables and their descriptions.
Table 9-8 Variable Definition List
Name Description
Back Pressure (psi) Pressure measured at 75% of stroke during

Recovery.
Cavity Pressure at Transition (psi) Cavity pressure measured at transition from Fill to
Hold Cavity pressure monitoring is an option.
Cushion [mm] Injection barrel volume at the end of Hold.
Cycle Time (s) Time duration from the Start of Mold Close to the next
Start of Mold Close.
Effective Cooling Time (s) Cooling setpoint (from INJECTION screen) plus
Unclamp time.
Ejector Back Time (s) Time duration between signal to valve to move the
ejector backward, and when ejection backward
position is reached.
Ejector Forward Time (s) Time duration between signal to valve to move the
ejector forward, and when ejection forward position is
reached.

Name Description
Ejector Max. Forward Position (mm) Injector position at maximum forward position.
Extr. Temperature – 1 (°C) Temperature of the first extruder zone when full
tonnage is reached.
Extr. Temperature – 2 (°C) Temperature of the second extruder zone when full
tonnage is reached.
Extr. Temperature – 3 (°C) Temperature of the third extruder zone when full
tonnage is reached.
Feed Throat Temperature (°C) Temperature in feed throat when full tonnage is
reached. Feed throat temperature monitoring is an
option.
Hold Pressure Zone – 1 (psi) Pressure measured at the end of Hold zone 1
Injection Fill Time (s) Time duration from the Start Of Injection to Transition
Injection Pressure at Transition (psi) Injection pressure of transition from fill to hold.
Max. Fill Pres. (psi) Pressure measured in the time period between Start
of Injection to just before transition.
Maximum Cavity Pressure (psi) Cavity pressure measured during the period from
Start of Injection to just before Transition. Cavity
pressure monitoring is an option.
Maximum Injection Pressure Pressure measured in the time duration between Start
of Injection to just before transition.
Mold Closing Time (s) Time duration from the Start of Mold Close to when
clamp tonnage is achieved.
Mold Heats Temperature – 1 (°C) Temperature in zone 1 when full tonnage is reached.
v 4.11.1 — March 2007 9–17 SETUP Screen

Name Description
Mold Open Time (s) Time duration between Mold Open setpoint and signal
to valve to close the mold.
Mold Opening Time (s) Time duration between Start of Unclamp and when
Mold Open position is reached.
Nozzle Adapter Temperature (°C) Temperature in nozzle when full tonnage is reached.
Nozzle Shutoff Temperature (°C) Temperature in nozzle when full tonnage is reached.
Nozzle extension temperature monitoring is an option.
Nozzle Tip Temperature – 1 (°C) Temperature in zone 1 when full tonnage is reached.
Oil Temperature (°C) Oil temperature when full tonnage is achieved.
Resin Temperature (°C) Resin temperature when full tonnage is reached.
Screw Run Time (s) Time duration between Screw Rotation Start and
Screw Rotation Stop.
Screw Speed (rpm) Measured in rpm at 75% of stroke during Recovery.
Shot Length (mm) The difference between Shot Size and Cushion.
Shot Size (mm) Injection barrel volume just before Start Of Injection.
Tonnage (T) Measurement of pressure when full tonnage is

reached.
Transition Pos. (mm) Injection barrel volume at the transition between Fill
and Hold

9.7 CONTROL LIMITS Screen
The CONTROL LIMITS screen displays the values for the currently assigned upper
control limits and lower control limits for Xbar and R/s. It allows the operator to select
or deselect fixed limits for each variable in the list, rather than let the SPC program
calculate it automatically.
Press <SPC> key, then select the CONTROL LIMITS tab. Refer to Figure 9-7.
Figure 9-7 CONTROL LIMITS Screen
v 4.11.1 — March 2007 9–19 CONTROL LIMITS Screen

Table 9-9 CONTROL LIMITS Screen Descriptions
Field Description
Variables Displays the SPC variables selected for monitoring. Variables

are selected on the SETUP screen. Control limits cannot be set
for any variable that is not selected.
Fixed Limits Select the field to enable/disable fixed control limits for the
variable. A dialog box appears to prompt you to verify the action.
When fixed control limits are enabled, a check mark appears in
the field. Otherwise, the field is left blank.
The DETAILS screen charts will be redrawn with the new control
limits after the next sample is collected.
Xbar Chart, R/s Chart
Lower Control (Ctl) Limits Select the field, and enter/modify the Lower Control Limit value
for the SPC variable.
Upper Control (Ctl) Limits Select the field, and enter/modify the Upper Control Limit value
for the SPC variable.
9.8 SPC Concepts
9.8.1 Functional Overview

The SPC program monitors a process and determines when it has deviated from the
process standard. A process is considered to have deviated from the standard when
one or more monitored SPC variables are outside specified operating ranges.
When a process has deviated from the process standard, an operator can define a
course of action, such as turn on the SPC alarm light, stop the machine, or turn on an
auxiliary output.
The SPC allows an operator to do the following.
• Select SPC variables to monitor from a list of process variables.
• View a summary of monitored SPC variables, their process limits, process capabil-
ity (Cpk), and state of statistical control.
• "Learn" the process standard, and monitor machine performance based on a set of
process criteria.
• View a 400-cycle trend for each monitored variable, the process average, the
"spread", the specification limits, and the Cpk.
• View process averages (Xbar chart), process variability (R/s chart), and current
control limits.
• Specify fixed control limits for Xbar and R/s charts for any monitored variable
• Be alerted to changes in the process with Xbar statistical control tests (samples
outside the control limits, trends, runs, alternating data).
SPC Concepts 9–20 v 4.11.1 — March 2007

• Specify for each monitored variable the alarm action to take when the process is
out of control.
• View Trend, Xbar, R/s charts simultaneously for all monitored variables.
• View Trend, Xbar, R/s data along with machine mode and setpoint change infor-
mation for any SPC variable from the previous 10,000 cycles.
• View the historic log of SPC warnings and alarms.
• Archive a Data Log containing process data for off-line analysis.
9.8.2 SPC Variables

The SPC program can provide statistical analysis for process variables.
A process variable tracks machine performance at the end of each machine cycle.
Process variable examples are Cycle Time, Clamp Tonnage, Screw Speed, etc.
9.8.3 Monitoring Variables

The SPC program can contain numerous process variables. By default, data for all
SPC variables are collected and logged to the Data Log.
In order to monitor SPC variables, they must be selected or defined. Process variables
are selected and configured on the SETUP screen.
The SPC program can simultaneously monitor numerous SPC variables. After
variables have been selected or defined, all SPC functions are applied to those
variables. The data are trended, control charts are plotted, and alarms are activated
when a process has deviated from the process standard.
9.8.4 Machine Cycles and Sampling

The SPC program examines process variables at the end of every machine cycle. A
single process variable value is called a Reading. For some calculations, the SPC
program groups Readings into Samples. The operator can configure the size of
samples and how often to take samples.
For example, a Sample Size of 5 means that 5 consecutive machine cycles make up a
sample. A Sampling Period of 15 means that after one sample is collected, there is a
10 cycle pause before the next sample is collected.
As another example, a Sample Size of 5 and a Sampling Period of 5 indicates that 5
consecutive cycles make up a sample, and the next sample is taken immediately
afterwards without any pause.
Each machine cycle is numbered, and this information is used to correlate part
information with process information.
v 4.11.1 — March 2007 9–21 SPC Concepts

9.8.5 Trend and Distribution Charts

Trend charts graphically display SPC variable data for the last 400 machine cycles.
The Trend charts indicate "spread" of the readings by plotting +3σ and -3σ limits. The
spread indicates the statistical upper and lower ranges for the trend. 99.7% of
readings should fall between the two limits. Refer to Figure 9-8.
1800
S01-100152.eps
+3σ
-3σ
400 cycles
1500
Trend Chart Distribution Chart
Figure 9-8 Trend and Distribution Charts
A Distribution chart divides the range of readings into sub-ranges and displays them
graphically. Refer to Figure 9-8. The Distribution chart indicates where most of the
values in the trend fall, and if they are concentrated in a narrow band or distributed
evenly.
For example, consider a set of data that varies between 1500 and 1800 units. A
Distribution chart divides the range of values into 30 sub-ranges each 10 units wide,
and displays the data distribution as shown in Figure 9-8.
A number of SPC calculations assume that the data follows a bell-shaped Normal (or
Gaussian) distribution. This assumption is correct in most cases, and can be easily
verified by visually checking the shape of the distribution.
9.8.6 Process Variability

SPC variable readings vary from machine cycle to machine cycle. Every process
exhibits some degree of variability. Variability is the result of common causes and
assignable causes.
Common causes cannot be changed without altering the manufacturing process.
Measurement methods, and inherent repeatability limitations in mechanical
components such as hydraulic valves are examples of common causes.
An assignable cause may be detected and identified. Changes in material properties,
environmental conditions, and tool wear are some examples of assignable causes.

9.8.7 Specification Limits and Standards

Specification limits define the desired range for a process. When a process variable is
outside the range, the operator can configure the machine to turn on the SPC warning
light, and/or stop the machine, and/or turn on the auxiliary output.
For example, if it is known that transition pressure must be between 1500 and 1800 psi
in order to properly mold a part, then an operator may choose to stop the machine and
check the actual transition pressure.
The SPC program has a "learn specification limits" feature, which simplifies setting of
standards.
If the process varies from the standard, part quality may or may not be affected. The
operator can then determine how the change in process affected the part quality, and if
specification limits should be widened or narrowed.
NOTE: When saving or recalling machine setups, SPC specification limits and
configurations are included in the machine setup data.
9.8.8 Process Quality Factor (Cpk)

The process capability index (Cpk) for a process variable is a measure of the deviation
from the specification limits. The larger the Cpk number, the further away the
specification limits are from the current operating range for the process.
Cpk is defined as the ratio between the distance from the nearest specification limit to
the current process average, and the 3σ limit of the process variable.
USL – X-
Cpk = --------------------
3σˆ
or,
Cpk = X – LSL-
-------------------
3σˆ
Refer to Section 9.8.13 for details.

In the example in Figure 9-9, the process spread is ± 50 psi. The process can deviate
100 psi up or down before the specification limits are exceeded.
Cpk = 1800 – 1650- = 3

-----------------------------
50

Cpk = 3
1800
S01-100153.eps
+3σ
1700
1650
1600 -3σ
1500
Figure 9-9 Process Capability Index, Cpk = 3.
In the example in Figure 9-10, the process spread is ± 50 psi. The process is at the
specification limits, and any further downward shift in the process average will cause
the process to be outside limits.
Cpk = 1550 – 1500- = 1

-----------------------------
50
Cpk = 1
S01-100154.eps
1800
+3σ
1600
1550
1500 -3σ
In the example in Figure 9-11, the process spread is ± 50 psi. The process is partially
outside the specification limits.
Cpk = 1525 – 1500- = 0.5

-----------------------------
50

Cpk = 0.5
1800
S01-100155.eps
1575 +3σ
1525
1500
-3σ
1475
Figure 9-11 Process Capability Index, Cpk = 0.5.
In the example in Figure 9-12, the process is completely outside the specification
limits. The Cpk is 0.
Cpk = 0
1800
S01-100156.eps
1500
1450 +3σ
1400
1350 -3σ
75 psi up or down before the specification limits are exceeded.
Cpk = 1800 – 1650- = 2

-----------------------------
75

S01-100157.eps
Cpk = 2
1800
1725 +3σ
1650
1575 -3σ
1500
Figure 9-13 Process Capability Index, Cpk = 2
80 psi down and 180 psi upward before the specification limits are exceeded.
Cpk = 1600 – 1500- = 5

-----------------------------
20
Cpk = 5
S01-100158.eps
1800
1620 +3σ
1600
-3σ
1580
1500
Figure 9-14 Process Capability Index, Cpk = 5
9.8.9 Control Charts

Control charts display the average and range of process variable samples. The
sample average consists of the sum of the readings in the sample divided by the
number of readings. The sample range is the difference between the lowest and
highest reading.
9.8.10 Xbar Charts

The purpose of Xbar charts is to determine if the process is in a "state of statistical
control". The process is in "control" if all samples behave in a "random" manner, and
therefore the variation in the process is most likely due to inherent process limitations
(common causes).

The SPC program looks for patterns in the Xbar charts that indicate that the variability
in the process is not random, and may be due to problems that can be rectified.
The Upper Control Limit (UCL) and Lower Control Limit (LCL) define the spread of the
sample averages. Refer to Figure 9-15. If the variation in the process is random, in
almost all cases (99.7%) the averages should fall within the control limits.
Xbar Chart
UCL
S01-100159.eps
Average
LCL
Figure 9-15 Xbar Chart
The SPC program looks for the following patterns.

• Limits – one sample average outside the control limits.
• Run – nine or more consecutive averages above or below the Xbar average.
• Trend – six or more consecutive averages trending upward or downward.
• Alternating data – fourteen or more consecutive alternating Xbar points.
Figure 9-16 shows an example of an Xbar chart with one sample average outside the
control limits.
Xbar Chart - Limits

S01-100160.eps
UCL
Average
LCL
Figure 9-16 Xbar Chart - Limits
Figure 9-17 shows an example of an Xbar chart with nine or more consecutive sample
averages above or below the Xbar average.
Xbar Chart - Run

S01-100161.eps
UCL
Average
LCL
Figure 9-17 Xbar Chart – Run

Figure 9-18 shows an example of an Xbar chart with six or more consecutive sample
averages trending upwards or downwards.
Xbar Chart – Trend
S01-100162.eps
UCL
Average
LCL
Figure 9-18 Xbar Chart - Trend
Figure 9-19 shows an example of an Xbar chart with 14 or more consecutive

alternating sample averages.
Xbar Chart – Alternating Data
S01-100163.eps
UCL
Average
LCL
Figure 9-19 Xbar Chart - Alternating Data
9.8.11 R/s Charts

The purpose of the Range (R) or Standard Deviation (s) chart is to display the process
variability by plotting the sample ranges. If the sample size is 10 or less, the program
calculates the range "R" as the measure of sample variability. For sample sizes
greater than 10, the range calculation does not accurately represent the sample
variability. In such cases, the program calculates the standard deviation "s" as a
measure of sample variability.
Figure 9-20 shows an example of an R/s chart.

R/s Chart
S01-100164.eps
UCL
Average
LCL
Figure 9-20 R/s Chart
The range of a sample is defined as the difference between the lowest and highest
readings. For example, the range for a sample of 5 readings 1550, 1599, 1571, 1583
and 1499 is 100.
Sample range, R = largest observation - smallest observation.
The standard deviation of a sample is defined as the square root of the sum of squares
of the difference between readings and the sample average, divided by the number of
readings less 1.
2
s = ∑ ( Xi – X ) ⁄ (n – 1)
If the difference between the low and high sample values varies significantly, the
process variability is changing and may be a problem. The R/s chart samples should
not cross the upper control limit (UCL) on the range chart.
Figure 9-21 shows how changes in the homogeneity of incoming material may show
up as changes in process variability on the R/s chart.
R/s Chart - Process Variability

S01-100165.eps
UCL
Average
LCL
Figure 9-21 R/s Chart - Process Variability

NOTE: The R chart shows the "spread" of the process, and is not affected by changes
in the process average. For example, if the process average of a process that
is in control changes from 1500 psi to 1600 psi, the change will be indicated in
the Trend and Xbar charts, but not in the R chart. However, if the process
average remains the same, but the "spread" changes, the Trend and R chart
will reflect the change, but not the Xbar chart.
The control charts display about 25 sample averages. The program calculates the
chart limits, and checks for patterns whenever a new sample becomes available. The
charts provide a window of 25 samples into the process, and reflect the current state of
the process. In contrast, the specification limits provide a fixed frame of reference
against which the current process "window" may be compared.
9.8.12 SPC Alarms

The SPC program generates up to four machine alarms. The operator can define
which variables should be monitored for alarm conditions, and what the SPC program
should do if there is an alarm.
The operator configures alarms on the SETUP screen. For each of the monitored
variables, the operator can configure the SPC program to turn on the SPC warning
light, and/or stop the machine, and/or turn on an auxiliary output when the
specification limits are exceeded. The SUMMARY screen summarizes the alarm
settings for the SPC variables.
When an alarm occurs, an alarm message is displayed on the ALARMS screen, and a
more specific message is logged to the Event Log. When the alarm is cleared, an
alarm off message is also added to the Event Log.
Table 9-10 lists the different SPC alarm types.
Table 9-10 SPC Alarm Types
Alarm Condition SPC Alarm Message
SPC variable(s) outside "Variable Name" - Point below Specification Limits

specification limits
"Variable Name" - Point above Specification Limits
SPC variable(s) have "Variable Name" - Cpk below Threshold

Cpk below threshold
SPC variable(s) out of "Variable Name" - Outside Xbar Control Limits

statistical control
"Variable Name" - Run
"Variable Name" - Trend
"Variable Name" - Alternating Data
SPC cycle interruption "The machine has been stopped because of a SPC
specification limit or Cpk threshold alarm".

9.8.13 SPC Formulas

The following is a list of formulas used by the SPC program:
1. Sample Average, Xbar
∑ Xi
X = ------------
n
where Xi is the process variable reading, n is the number of readings in the
sample.
2. Xbar chart average, X
∑X
X = ----------
k
where k is the number of samples in the Xbar or R/s chart

3. Xbar chart control limits – see range chart
UCL x – bar = X + A 2 ( R )
LCL x – bar = X – A 2 ( R )
where A2 is a control chart factor – see Table 9-11, R is range chart average
4. Xbar control limits – see standard deviation chart
UCL x – bar = X + A 3 ( s )
LCL x – bar = X – A 3 ( s )
where A3 is a control chart factor – see Table 9-11

5. Range chart (for sample size ≤ 10)
Sample range, R = largest observation minus smallest observation
Range chart average, R
∑R
R = ----------
k
where k is the number of samples in the Xbar or R/s chart

6. Range chart control limits

UCLrange = D4(R)
LCLrange = D3(R)
where D3, D4 are control chart factors – see Table 9-11
7. Sigma (population estimate),
R-
σ̂ = ----
d2
where d2 is a control chart factor – see Table 9-11

8. Standard deviation (s) chart (for sample size >10)
2
s = ∑ ( Xi – X ) ⁄ (n – 1)
where Xi is process variable reading, X is sample average, and n is number of

readings in the sample
9. Standard deviation chart average, s
∑s
s = ---------
k
where k is the number of samples in the S chart

10. Standard deviation chart control limits
UCLs = B4(s)
LCLs = B3(s)
where B3, B4 are control chart factors – see Table 9-11
11. Sigma (population estimate),
s-
σ̂ = ----
c4
where c4 is a control chart factor – see Table 9-11

12. Process Capability (Cpk)
USL – X-
Cpk = --------------------
3σˆ
or
Cpk = X – LSL-
-------------------
3σ̂
use whichever specification limit is closer to X

Table 9-11 Control Chart Factor Table.
n A2 A3 B3 B4 c4 d2 D3 D4
2 1.880 2.659 0 3.267 0.7979 1.128 0 3.267
3 1.023 1.954 0 2.568 0.8862 1.693 0 2.574
4 0.729 1.628 0 2.266 0.9213 2.059 0 2.282
5 0.577 1.427 0 2.089 0.9400 2.326 0 2.114
6 0.483 1.287 0.030 1.970 0.9515 2.534 0 2.004
7 0.419 1.182 0.118 1.882 0.9594 2.704 0.076 1.924
8 0.373 1.099 0.185 1.815 0.9650 2.847 0.136 1.864
9 0.337 1.032 0.239 1.761 0.9693 2.970 0.184 1.816
10 0.308 0.975 0.284 1.716 0.9727 3.078 0.223 1.777
11 0.285 0.927 0.321 1.679 0.9754 3.173 0.256 1.774
12 0.266 0.886 0.354 1.646 0.9776 3.258 0.283 1.717
13 0.249 0.850 0.382 1.618 0.9794 3.336 0.307 1.693
14 0.235 0.817 0.406 1.594 0.9810 3.407 0.328 1.672
15 0.223 0.789 0.428 1.572 0.9823 3.472 0.347 1.653
16 0.212 0.763 0.448 1.552 0.9835 3.532 0.363 1.637
17 0.203 0.739 0.466 1.534 0.9845 3.588 0.378 1.622
18 0.194 0.718 0.482 1.518 0.9854 3.640 0.391 1.608
19 0.817 0.698 0.497 1.503 0.9862 3.689 0.403 1.597
20 0.180 0.680 0.510 1.490 0.9869 3.735 0.415 1.585
21 0.173 0.663 0.523 1.477 0.9876 3.778 0.425 1.575
22 0.167 0.647 .0534 1.466 0.9882 3.819 0.434 1.566
23 0.162 0.633 0.545 1.455 0.9887 3.858 0.443 1.557
24 0.157 0.619 0.555 1.445 0.9892 3.895 0.451 1.548
25 0.153 0.606 0.565 1.435 0.9896 3.931 0.459 1.541

9.8.14 SPC Statistical References

• Griffith, Gary K. Statistical Process Control Methods, USA, ASQC Quality Press,
1989
• American National Standard, Definitions, Symbols, Formulas, and tables for Con-
trol Charts, USA, ASQC Quality Press, 1987
• American National Standard, Guide for Quality Control Charts, Control Chart
Method of Analyzing Data, Control Chart Method of Controlling Quality During Pro-
duction, USA, ASQC Quality Press, 1985
• Burr, John T. SPC Tools for Operators, USA, ASQC Quality Press, 1989.

Machine Manual Additional Information
Chapter 10 Additional Information
This chapter contains any Safety or Service Bulletins pertaining to the Customer’s
machine and issued since the last documentation revision. It can serve as a
convenient location for storing any such bulletins as may be issued after receiving the
equipment.
This chapter may also describe special options ordered by the Customer. In some
instances, the descriptions here replace the corresponding items in the rest of this
manual.
v 4.11.1 — March 2007 10–1

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S01-101056.

Hylectric Injection Molding Machine

Clamp Model: H/HL90 to H/HL1000

Issue: v 4.11.1 — March 2007

ii v 4.11.1 — March 2007

6 SUPPLY No.1 LOAD

SUPPLY No.1 LOAD V A Hz SYSTEM

TOTAL HEAT LOAD A KA

DIAGRAM Number SERIAL Number

HUSKY INJECTION MOLDING SYSTEMS LTD.

MODEL HYD. PRESSURE

3 SERIAL# THIS EQUIPMENT OR ITS USE MAY BE

COVERED BY ISSUED OR PENDING

HUSKY INJECTION MOLDING SYSTEMS LTD.

Telephone Support Numbers

v 4.11.1 — March 2007 iii General Information

Husky Regional Service and Sales Offices

Americas Europe/Africa Asia Pacific

Argentina, Bolivia, Chile, Africa, India, Israel, Middle Australia - Sydney

Brazil - Jundiai - SP Denmark, Norway, Sweden - China - Beijing

Canada - Toronto Eastern Europe, Russia - China - Hong Kong

Colombia, Costa Rica, France - Lyon China - Shanghai

Mexico - Mexico City Germany (South), Austria and China - South

Mexico - Monterrey Germany (North) - Bielefeld India - Mumbai

USA - Atlanta, GA Israel - Caesarea Indonesia - Jakarta

USA - Boston, MA Italy - Rivoli (TO) Japan - Nagoya

USA - Buffalo, NY Luxembourg - Benelux Japan - Osaka

USA - Chicago, IL Portugal, Spain - Barcelona Japan - Yokohama

General Information iv v 4.11.1 — March 2007

Americas Europe/Africa Asia Pacific

USA - Cincinnati, OH Russia - Moscow Korea - Seoul

USA - Dallas, TX United Arab Emirates - Dubai Philippines - Makati City

USA - Detroit, MI United Kingdom - Coventry Singapore - Singapore

USA - Los Angeles, CA Singapore Spare Parts Center

USA - Miami, FL Taiwan - Taipei

USA - Milton, VT Thailand - Bangkok

v 4.11.1 — March 2007 v General Information

General Information vi v 4.11.1 — March 2007

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Chapter 1: Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

v 4.11.1 — March 2007 vii

1.9 Ancillary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11

Chapter 2: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

viii v 4.11.1 — March 2007

2.12.6 HGT-FT Standard (Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31

Chapter 3: Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

v 4.11.1 — March 2007 ix

3.21.4.2 H650 - H1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–47

Chapter 4: User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

x v 4.11.1 — March 2007

4.1.5.6 Adding or Exchanging Function Icons. . . . . . . . . . . . . . . . . . . . 4–12

v 4.11.1 — March 2007 xi

4.1.17.5 Timeset Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–48

Chapter 5: Starting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

xii v 4.11.1 — March 2007

5.13.1 Turning Optional Mold Heats On . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–51

Chapter 6: Stopping Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1