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

 Hylectric Injection Molding Machine

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

 Hylectric Injection Molding Machine

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

 Hylectric Injection Molding Machine

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

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 Hylectric Injection Molding Machine

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

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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

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 Hylectric Injection Molding Machine

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

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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

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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

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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.

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 Hylectric Injection Molding Machine

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.

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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.

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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.

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 Hylectric Injection Molding Machine

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.

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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.

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 Hylectric Injection Molding Machine

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

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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
unnecessary wear on the components and lead to premature failure.

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.
NOTE: The Q2M breaker is found only on machines equipped with mold heats.
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.

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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.

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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.

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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.

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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.

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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

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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.

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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.

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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

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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.

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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

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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

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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

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