ENG - Hylectric MM v3.02

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

Injection Unit Model: RS22 to RS155
Issue: v 3.02 - March 2003

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.
Copyright  2003, Husky Injection Molding Systems.
All Rights Reserved.
ii v 3.02 - March 2003

Machine Manual
General Information
Equipment Identification
SUPPLY No.1 LOAD V A Hz SYSTEM

6 LARGEST MOTOR A
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

CERTIFICATION
MAX.
1
MODEL WEIGHT
Kg
3 SERIAL# THIS EQUIPMENT OR ITS USE MAY BE
COVERED BY ISSUED OR PENDING
PATENTS. SEE INFORMATION SCREEN
4 DATE 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: 1 800 465 4875
Europe: (352) 52 115 4300
For on-site service, contact the local regional service and sales office.
v 3.02 - March 2003 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 - (61) 2 9898 9911
Aires Luxembourg
5411 4836 1800 00352-52 11 51
Brazil - Jundiai - SP Denmark, Norway, Sweden - China - Beijing
55-11 4589 7200 Hørsholm 86-10-8518-5177
+45-4516 2121
Canada - Toronto Eastern Europe, Russia - China - Hong Kong
1 905 951 5000 Luxembourg 852-2168-5700
00352-52.11.51
Colombia, Costa Rica, France - Lyon China - Shanghai
Ecuador, Panama, Peru, 0033/4-74.46.88.00 86-21-5046-2800
Venezuela - Bogota
57-1-416 5626
Mexico - Mexico City Germany (South), Austria and India - Mubai
5255-5089-1160 Switzerland - Augsburg 2-91-22-2570-6316
0049/821-44489 0
Mexico - Monterrey Germany (North) - Bad Indonesia - Jakarta
5281-8315-0365 Salzuflen 6221-575-0878
0049-5208-91380
USA - Atlanta*, GA Israel - Caeserea Japan - Osaka
1 770 487-6234 972-4-621-8080 81-6-6338-0561
USA - Boston, MA Italy - Rivoli (TO) Japan - Nagoya
1 978 692-0077 0039/011-9565611 81-52-805-5562
USA - Buffalo, NY Luxembourg - Benelux* Japan - Yokohama*
Parts Distribution Center 00352-52.11.51 81-45-923-1001
1 716 630 7300
1 800 828 7842
USA - Chicago, IL Portugal, Spain - Barcelona Korea - Seoul
1 708 535-0092 0034/93432-9800 82-31-399-6422-26
USA - Cincinnati, OH Russia - Moscow Philippines - Makati City
1 513 965-8080 7-095-216-6534 632-757-5130 or 5131
USA - Dallas, TX United Kingdom - Coventry* Singapore
1 817 224 9440 0044/2476-518900 65-276-8616
USA - Detroit, MI Singapore Spare Parts Center
1 248 735-6300 65-6276-2747
Husky Regional Service and Sales Offices iv v 3.02 - March 2003

Machine Manual
Americas Europe/Africa Asia Pacific

USA - Los Angeles*, CA Taiwan - Taipei
1 714 545-8200 886-2-2378-9269
USA - Milton, VT Thailand - Bangkok
1 802 859 8000 662-661-9269 or 9270
USA - Philadelphia, PA
1 215 497-9700
* Technical Center
v 3.02 - March 2003 v Husky Regional Service and Sales Offices

Standard Worldwide Warranty Conditions
Small, Medium, Large Tonnage Machines and Robots for orders placed after August 1,
1997 (Rev. Dec. 1998)
Parts Warranty
Husky Injection Molding Systems warrants its new Machines and Product Handling
Equipment (hereinafter called the "Equipment") to be free of defects in material and
workmanship for a period of up to 37 months on original equipment parts, starting on
the date the equipment is ready to ship ex works, hereinafter called the "Warranty Start
Date".
Service Labor
Field service labor costs for Husky technicians to repair any such defects will be
covered for a period of 13 months from the Warranty Start Date.
Exceptions, warranted for 13 months

• Plasticizing screws and check valves against manufacturing defects; and
• Seals for mold stroke, carriage and shut-off cylinders; pins and bushings for shut-
off linkages; hose assemblies; switches and sensors
Failed Parts
• Failed parts will be replaced with new, or refurbished components of equivalent
quality. Repair or replacement of failed components shall not exceed the warranty
coverage on the Equipment beyond the original expiration date
• Husky will advise customers whether to return or dispose of defective parts that
are under warranty. If Husky requires the return of defective parts, Husky will cover
the cost of returning defective parts that are under warranty, as well as shipping
and handling of replacement parts
• Failure to return and properly identify requested warranty parts may result in the
invoicing of such parts
Limitations
This warranty shall not apply to:
• Filter elements, fuses, bulbs, lubricants, pressure gauges, and gate glass;
• Wear of plasticizing screw and barrel, resulting from the processing of abrasive/
aggressive resins, or the operation at unusually low or high barrel temperatures.
Accelerated wear of the barrel head/ distributor, shut-off plunger, machine nozzle
and nozzle adapter, due to the processing of abrasive/ aggressive resins is also
excluded, unless the equipment was ordered to handle such circumstances
Standard Worldwide Warranty Conditions vi v 3.02 - March 2003

Machine Manual
• Failure, or damage due to noncompliance with maintenance procedures, as speci-

fied in machine manual, abuse, neglect, misuse, use of non-Husky supplied parts,
or the use of lubricants/ fluids other than those recommended in the manual
• Failure, or damage due to non-Husky modifications or other circumstances beyond
our control
• Consequential loss, work stoppages, delays, or slowdowns in production and acci-
dental damages; and
• Noncompliance with codes or bylaws that govern the operation of such Equipment
in a specific region, unless included in the purchase agreement
There are no other expressed or implied warranties on Husky Equipment. This
warranty applies to the original purchase only, and is non-transferable.
Safety and Indemnity

• The Purchaser agrees to maintain and operate the Equipment safely and in accor-
dance with Husky’s recommended guidelines and applicable legal requirements.
• The Purchaser assumes all risks and liabilities for the operation and use of the
Equipment. The Purchaser agrees to defend and save Husky and its employees
harmless from all claims and costs arising from any cause related to Equipment
operation or use, except to the extent caused by Equipment defectively engineered
or manufactured by Husky or serviced by Husky personnel, subject to the further
limitation below.
• Under no circumstances will Husky be responsible for claims or costs associated
with product produced by the Equipment or for any consequential, special or inci-
dental damages associated with its use.
Legal Disclaimer
Failure to comply with any safety requirements or conditions pertaining to injection
molding machines can cause equipment damage, or serious personal injury, including
death.
v 3.02 - March 2003 vii Standard Worldwide Warranty Conditions

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v 3.02 - March 2003

Machine Manual
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Husky Regional Service and Sales Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Standard Worldwide Warranty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xx
Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi
Chapter 1: Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.2 Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.3 Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
1.4 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.5 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.6 Guards And Interlocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.7 Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.7.1 Performing Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1.7.2 Removing Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
1.8 Safety Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.8.1 Mechanical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.8.1.1 Worn Hoses and Safety Restraints . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.8.1.2 Cooling Water Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.8.1.3 Injection and Clamp Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.8.2 High Pressure Leak Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.8.2.1 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.8.2.2 Skin Puncture Injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.8.3 Burn Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.8.3.1 Hot Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.8.3.2 Molten Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.8.4 Explosion Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.8.4.1 High Pressure Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.8.5 Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.8.6 Noise Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
v 3.02 - March 2003 ix

1.8.7 Gas, Vapor, and Dust Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10

1.8.8 Slip, Trip, or Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.8.9 Lifting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.9 Personal Protective Equipment and Safety Equipment. . . . . . . . . . . . . . 1–11
1.9.1 Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . 1–11
1.9.2 Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
1.10 Ancillary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
1.11 Material Safety Data Sheet (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
1.12 Materials, Parts, and Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Chapter 2: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

2.1 Machine Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.2 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.3 Electrical Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.4 Machine Cooling Water Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.4.1 Cooling Water Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.4.2 Cooling Water Treatment Procedure . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.4.3 Typical Cooling Water Analysis Report . . . . . . . . . . . . . . . . . . . . . . 2–10
2.5 Mold Cooling Water Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
2.6 Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
2.7 Oil Capacity Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
2.8 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
2.9 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17
2.9.1 Grease Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17
2.9.2 Gearbox Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17
2.10 Nitrogen Volume for Hydraulic Accumulators . . . . . . . . . . . . . . . . . . . . . 2–18
2.11 Rust Inhibitor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
2.12 Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
2.13 Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23
2.13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23
2.13.1.1 Surface Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
2.13.2 HGT-35 Standard (Screws) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
2.13.5 HGT-SS Standard (Set Screws) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
2.13.6 HGT-EL Standard (Electrical Applications) . . . . . . . . . . . . . . . . . . . 2–30
2.13.7 HGT-FT Standard (Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30
Chapter 3: Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

3.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1.1 Warning Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.1.2 Machine Safety Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
3.1.2.1 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
x v 3.02 - March 2003

Machine Manual
3.1.2.2 Front Operator’s Gate and Rear Guard . . . . . . . . . . . . . . . . . . . . 3–7

3.1.2.3 Mechanical Safety Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
3.1.2.4 CEN Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
3.1.2.4.1 H90 - H225. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
3.1.2.4.2 H300 - H1000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
3.1.2.5 Automatic Dump Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
3.1.2.6 Manual Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
3.1.2.7 Purge Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
Chapter 4: Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

4.1 Installing Leveling Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.2 Aligning Injection and Clamp Units (Split Base Models) . . . . . . . . . . . . . . 4–5
4.3 Unpacking the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.4 Removing Shipping Hardware (H90 to H500) . . . . . . . . . . . . . . . . . . . . . . 4–7
4.5 Removing Shipping Hardware (H650 to H1000) . . . . . . . . . . . . . . . . . . . . 4–9
4.5.1 Installing Column Bell (H90 to H800) . . . . . . . . . . . . . . . . . . . . . . . . 4–11
4.5.2 Installing Column Bell (H1000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11
4.6 Assembling Safety Gates (H650 to H1000) . . . . . . . . . . . . . . . . . . . . . . 4–12
4.6.1 Operator’s gate: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12
4.6.2 Rear gate:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13
4.6.3 Both gates: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13
4.7 Cleaning Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15
4.8 Connecting Hydraulic Hoses (Split Base Models). . . . . . . . . . . . . . . . . . 4–15
4.9 Connecting Electrical Cables (Split Base Models) . . . . . . . . . . . . . . . . . 4–16
4.10 Installing Platform (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19
4.11 Installing Material Feed Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20
4.11.1 Installing Optional Hopper Magnet . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22
4.11.2 Material Feed Equipment Recommendations . . . . . . . . . . . . . . . . . 4–22
4.12 Installing Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24
4.13 Installing Purge Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24
4.14 Installing Drool chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–25
4.15 Checking Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26
4.16 Hooking Up Oil Collection Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27
4.17 Hooking Up Compressed Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27
4.18 Hooking Up Electrical Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28
4.18.1 Machine Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–29
4.19 Hooking Up Machine Cooling Water Supply . . . . . . . . . . . . . . . . . . . . . . 4–31
4.20 Hooking Up Mold Cooling Water Supply (Optional) . . . . . . . . . . . . . . . . 4–32
4.21 Machine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33
4.22 Draining Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33
4.23 Checking Hydraulic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–34
4.24 Attaching Carriage Cylinders (Split Base Models) . . . . . . . . . . . . . . . . . 4–35
4.25 Contact Husky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–35
v 3.02 - March 2003 xi

Chapter 5: Commissioning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

5.1 Checking Pump Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5.1.1 Reversing Pump Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.2 Checking Machine Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.3 Checking Machine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
5.4 Running in the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
Chapter 6: User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

6.1 Human Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.1.1 Machine Cycle Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.1.2 Robot Home Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.1.3 Robot Enable Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.1.4 Pump Motor Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.1.5 Sidebar Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.1.5.1 Sidebar Icons Explained. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
6.1.5.2 Function Keys and Icon Relationships . . . . . . . . . . . . . . . . . . . . . 6–6
6.1.5.3 Process Value Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.1.5.4 User Configurable Sidebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.1.5.5 USER CONFIGURATION Screen . . . . . . . . . . . . . . . . . . . . . . . 6–10
6.1.5.6 Adding or Exchanging Function Icons . . . . . . . . . . . . . . . . . . . . 6–13
6.1.5.7 User Configuration Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
6.1.5.8 Function Icon Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
6.1.5.9 User Configuration Recycle Bin . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
6.1.6 Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
6.1.6.1 Message Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
6.1.6.2 Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
6.1.6.2.1 Screen Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
6.1.7 Administrator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
6.1.7.1 Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
6.1.7.2 OPEN ACCOUNT Pop-up Screen . . . . . . . . . . . . . . . . . . . . . . . 6–18
6.1.7.3 Programming the DataKey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–19
6.1.7.4 Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–19
6.1.7.5 CREATE NEW GROUP Pop-up Screen . . . . . . . . . . . . . . . . . . 6–21
6.1.7.6 ADD/REMOVE USER IN GROUP Pop-Up Screen . . . . . . . . . . 6–22
6.1.7.7 Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–23
6.1.7.8 Others. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24
6.1.8 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26
6.1.9 Machine Function Mode Selector. . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27
6.1.10 HMI Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28
6.1.10.1Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28
6.1.10.2Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–29
6.1.10.3Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–30
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6.1.10.4Shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–31
6.1.10.5Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–32
6.1.10.5.1 Background Printing Configuration Screen . . . . . . . . . . . . 6–33
6.1.10.6Remote. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–34
6.1.10.7Saving and Restoring Machine Backups . . . . . . . . . . . . . . . . . . 6–35
6.1.10.8Others. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–36
6.1.10.8.1 Operator Stop Reason Utility . . . . . . . . . . . . . . . . . . . . . . . 6–37
6.1.10.8.2 Using the OPERATOR STOP REASON Utility . . . . . . . . . 6–37
6.1.10.8.3 Using the Stop Reason Definition Screen . . . . . . . . . . . . . 6–38
6.1.11 User Log On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–40
6.1.12 User Log Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–40
6.1.13 On-Line Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–40
6.1.14 Status Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–41
6.1.15 Screen Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–41
6.1.16 Manual Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–45
6.1.17 Common Screen Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–47
6.1.17.1Field Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–47
6.1.17.2Alphanumeric Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–48
6.1.17.3Numeric Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–48
6.1.17.4Calendar Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–49
6.1.17.5Timeset Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–50
6.1.17.6Color Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–50
6.1.17.7Common Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–51
6.1.18 User Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–52
6.1.18.1Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–53
6.1.18.2Default User Names and Passwords . . . . . . . . . . . . . . . . . . . . . 6–53
6.1.18.3DataKey Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–53
Chapter 7: Starting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

7.1 Powering Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
7.2 Logging On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.3 Checking Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
7.3.1 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
7.3.2 Front Operator’s Gate and Rear Guard . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.3.3 Mechanical Safety Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.3.4 Automatic Dump Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
7.3.5 Purge Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
7.4 Oil Warming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
7.5 Checking/Resetting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
7.5.1 Checking Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
7.5.2 Resetting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12
7.6 Checking Machine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
7.7 Checking and Installing Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14
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7.7.1 Checking Suitability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14

7.7.2 Installing Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14
7.7.2.1 One Piece Mold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16
7.7.2.2 Multiple Piece Mold Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7–22
7.7.2.3 Previously Installed Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–29
7.8 Recalling Machine Setups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33
7.8.1 Copying Machine Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36
7.9 Configuring Mold Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38
7.9.1 Setting Up and Calibrating the Ejector . . . . . . . . . . . . . . . . . . . . . . . 7–38
7.9.1.1 Enabling Auto Function Keys to Run Production . . . . . . . . . . . . 7–40
7.10 Checking Robot Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
7.11 Checking Mold Function Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
7.12 Setting Up/Checking Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
7.13 Turning Heats On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
7.13.1 Turning Optional Mold Heats On . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–43
7.13.2 Turning Optional Nozzle Heats On . . . . . . . . . . . . . . . . . . . . . . . . . 7–45
7.14 Opening Process Material Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–46
7.14.1 Opening Process Material Feed Manual Shutoff . . . . . . . . . . . . . . . 7–47
7.14.2 Opening Process Material Feed Auto-shutoff . . . . . . . . . . . . . . . . . 7–47
7.14.3 Opening Magnet Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–48
7.15 Setting Up/Checking Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–49
7.15.1 Setting Up Injection and Hold Parameters . . . . . . . . . . . . . . . . . . . . 7–49
7.15.2 Setting Up Recovery Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . 7–50
7.16 Purging Barrel Before Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–51
7.16.1 Manually Purging the Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–51
7.16.2 Auto Purging the Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–54
7.17 Cleaning Nozzle Tip & Purge Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–56
7.18 Cycling and Fine-tuning Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–57
7.19 Setting Up SPC (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–58
7.20 Saving Machine Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–58
7.21 Starting Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–60
7.22 Logging Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–60
7.22.1 Logging Off Using the Log Off Button . . . . . . . . . . . . . . . . . . . . . . . 7–60
7.22.2 Logging Off Using the Datakey . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–60
Chapter 8: Stopping Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

8.1 Stopping Machine in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
8.2 Pausing Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
8.3 Stopping Machine in a Controlled Manner . . . . . . . . . . . . . . . . . . . . . . . . 8–5
8.3.1 Stopping Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
8.3.2 Shutting Process Material Feed Off . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
8.3.3 Purging Barrel After Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7
8.3.4 Cleaning Nozzle Tip & Purge Guard . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
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8.3.5 Emptying Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9

8.3.6 Turning Heats Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
8.3.6.1 Shutting Machine Heats Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
8.3.6.2 Shutting Mold Heats Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
8.3.6.3 Shutting Nozzle Heats Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–12
8.3.7 Cleaning Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–13
8.3.8 Turning Mold Cooling Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–13
8.3.9 Removing Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14
8.3.10 Turning Pumps Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16
8.3.11 Turning Air Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16
8.3.12 Powering Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
8.4 Unexpected Machine Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
Chapter 9: Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

9.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
9.2 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
9.2.1 Draining Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
9.2.2 Cleaning the Machine and HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
9.2.3 Checking Accumulator Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
9.2.4 Precharging the Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
9.2.5 Discharging Accumulator Precharge . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
9.2.6 Checking Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11
9.2.7 Inspecting and Cleaning Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
9.2.8 Inspecting and Cleaning Optional Magnet Drawer. . . . . . . . . . . . . . 9–13
9.2.9 Clearing Feed Throat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14
9.2.10 Checking the Oil Recovery Pocket. . . . . . . . . . . . . . . . . . . . . . . . . . 9–15
9.2.10.1Cleaning the Oil Recovery Pocket . . . . . . . . . . . . . . . . . . . . . . . 9–15
9.2.11 Checking Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–16
9.2.12 Checking Hydraulic Cylinders, Valves and Manifolds . . . . . . . . . . . 9–16
9.2.13 Checking Hydraulic Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . 9–17
9.2.13.0.1 Reading Layline Information . . . . . . . . . . . . . . . . . . . . . . . 9–18
9.2.14 Replacing Hydraulic Hose Assemblies. . . . . . . . . . . . . . . . . . . . . . . 9–19
9.2.14.1Removing Hydraulic Hose Assemblies . . . . . . . . . . . . . . . . . . . 9–19
9.2.14.2Reinstalling Hydraulic Hose Assemblies . . . . . . . . . . . . . . . . . . 9–19
9.2.15 Checking System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–20
9.2.16 Checking Cooling Water Components . . . . . . . . . . . . . . . . . . . . . . . 9–20
9.2.17 Checking Pneumatic Valves and Hoses . . . . . . . . . . . . . . . . . . . . . 9–21
9.2.17.1Replacing Pneumatic Valves and Hoses . . . . . . . . . . . . . . . . . . 9–21
9.2.18 Lubricating Mold Stroke Column Guide Bushings . . . . . . . . . . . . . . 9–21
9.2.19 Lubricate Locking Cylinder Rod Ends . . . . . . . . . . . . . . . . . . . . . . . 9–22
9.2.20 Checking Hydraulic Tank Oil Quality . . . . . . . . . . . . . . . . . . . . . . . . 9–23
9.2.21 Checking Hydraulic Tank Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . 9–25
9.2.22 Replacing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–26
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9.2.22.1Draining Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–26

9.2.22.2Filling the Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–27
9.2.23 Priming the System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–28
9.2.24 Checking Gearbox Oil Level - Electrical Screw Drive Only . . . . . . . 9–29
9.2.25 Replacing Gearbox Oil - Electrical Screw Drive Only . . . . . . . . . . . 9–29
9.2.25.1Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–29
9.2.25.2Adding Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–30
9.2.26 Checking Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–31
9.2.27 Checking Mold Stroke Column Guide Bushings . . . . . . . . . . . . . . . 9–31
9.2.28 Checking Optional Nozzle Shutoff Bushings and Pins. . . . . . . . . . . 9–32
9.2.29 Replacing Optional Nozzle Shutoff Bushings and Pins . . . . . . . . . . 9–33
9.2.30 Lubricating Moving Platen Linear Bearings (H/HL90 - H/HL500). . . 9–33
9.2.31 Lubricating Optional Stack Mold Carrier Linear Bearings (H/HL90 - H/
HL500)9–35
9.2.32 Lubricating Injection Piston Linear Bearings (RS80 - RS115) . . . . . 9–36
9.2.33 Replacing Oil Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–37
9.2.34 Checking Carriage Cylinder Bushings and Pins . . . . . . . . . . . . . . . 9–39
9.2.35 Leveling Machine and Adjusting Nozzle Concentricity. . . . . . . . . . . 9–40
9.2.35.1Leveling the Clamp Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–40
9.2.35.2Leveling the Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–44
9.2.35.3Checking Nozzle Concentricity. . . . . . . . . . . . . . . . . . . . . . . . . . 9–46
9.2.35.4Leveling the Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–48
9.2.35.5Leveling the Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 9–49
9.2.35.6Leveling Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–50
9.2.35.7Final Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–51
9.2.36 Replacing Breather Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–52
9.2.37 Replacing Air Regulator Filter Element . . . . . . . . . . . . . . . . . . . . . . 9–53
9.2.38 Lubricating Electric Pump Motor Bearings . . . . . . . . . . . . . . . . . . . . 9–54
9.2.39 Replacing ITT Water Saver Valve Diaphragm . . . . . . . . . . . . . . . . . 9–57
9.2.40 Checking Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–58
9.2.40.1Checking Front Operator’s Gate and Rear Guard . . . . . . . . . . . 9–58
9.2.40.2Checking Mechanical Safety Device . . . . . . . . . . . . . . . . . . . . . 9–59
9.2.40.3Checking CEN Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–60
9.2.40.3.1 H90 - H225. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–60
9.2.40.3.2 H300 - H1000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–60
9.2.41 Replacing Heater Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–60
9.2.42 Changing the Plasticizing Screw and Check Valve . . . . . . . . . . . . . 9–62
9.2.42.1Removing Plasticizing Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–62
9.2.42.2Removing Plasticizing Screw Check Valve . . . . . . . . . . . . . . . . 9–69
9.2.42.3Setting Up Plasticizing Screw Check Valve . . . . . . . . . . . . . . . . 9–70
9.2.42.4Reassembling Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–71
9.2.43 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–77
9.2.43.1When to Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–77
2–xvi v 3.02 - March 2003

Machine Manual
9.2.43.2Clamp Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–78

9.2.43.2.1 Calibrating the Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–78
9.2.43.3Injection Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–82
9.2.43.3.1 Calibrating the Injection Piston. . . . . . . . . . . . . . . . . . . . . . 9–82
9.2.43.4Carriage Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–83
9.2.43.4.1 Calibrating the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–83
9.2.43.5Cavity Pressure Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–84
9.2.43.5.1 Calibrating the Cavity Pressure Sensor . . . . . . . . . . . . . . . 9–84
Chapter 10: Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

10.1 PC Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
10.1.1 Industrial PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3
10.1.1.1SERCOS Master Interface Card . . . . . . . . . . . . . . . . . . . . . . . . 10–6
10.1.1.2PROFIBUS Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–8
10.1.2 HMI Screen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–9
10.1.3 Servo Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–10
10.1.3.1SERCOS Drive Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . 10–11
10.1.4 PROFIBUS Bus Terminal System . . . . . . . . . . . . . . . . . . . . . . . . . 10–12
10.1.4.1PROFIBUS Bus Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–13
10.1.4.1.1 Beckhoff BK3100, BK3110 Bus Couplers . . . . . . . . . . . . 10–13
10.1.4.2PROFIBUS Bus Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–14
10.1.5 TC-Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–15
10.2 Creating Recovery Disk Image/Restoring Hard Disk on IPC Type 10, 11 10–
16
10.2.1 Creating a Recovery Disk Image . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17
10.2.1.1Creating a Bootable Floppy Diskette . . . . . . . . . . . . . . . . . . . . 10–17
10.2.1.2Creating a Recovery Disk Image Using the Built-in CD-RW Device .
10–17
10.2.1.3Scanning the Hard Disk for Errors . . . . . . . . . . . . . . . . . . . . . . 10–18
10.2.1.4Modifying the Boot-Up Sequence. . . . . . . . . . . . . . . . . . . . . . . 10–18
10.2.1.5Restoring a Hard Disk from a Recovery Disk Image . . . . . . . . 10–19
10.3 Creating Recovery Disk Image/Restoring Hard Disk on IPC Type 1, 2, 3, 4 .
10–21
10.3.1 Creating a Recovery Disk Image . . . . . . . . . . . . . . . . . . . . . . . . . . 10–22
10.3.1.1Laptop Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–22
10.3.1.1.1 Laptop Setup Procedure For Windows NT . . . . . . . . . . . 10–22
10.3.1.1.2 Laptop Setup Procedure For Windows 95 . . . . . . . . . . . . 10–23
10.3.1.1.3 Laptop Setup Procedure For Windows 2000 . . . . . . . . . . 10–25
10.3.1.2Machine Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–27
10.3.1.3Creating An Image File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–28
10.3.1.4Creating A Recovery Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–29
10.3.2 Restoring a Hard Disk from a Recovery Disk Image . . . . . . . . . . . 10–30
A.1 SPC Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
v 3.02 - March 2003 2–xvii

A.2 SUMMARY Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3

A.3 DETAILS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–5
A.3.1 DISTRIBUTION AND TREND Screen . . . . . . . . . . . . . . . . . . . . . . . . A–7
A.3.2 XBAR AND R/s Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–10
A.4 HISTORY Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–11
A.5 GROUP Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–14
A.6 SETUP Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–16
A.7 CONTROL LIMITS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–22
A.8 SPC Concepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–24
A.8.1 Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–24
A.8.2 SPC Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–24
A.8.3 Monitoring Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–24
A.8.4 Machine Cycles and Sampling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–25
A.8.5 Trend and Distribution Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–25
A.8.6 Process Variability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–26
A.8.7 Specification Limits and Standards . . . . . . . . . . . . . . . . . . . . . . . . . A–26
A.8.8 Process Quality Factor (Cpk) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–27
A.8.9 Control Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–31
A.8.10 Xbar Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–31
A.8.11 R/s Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–33
A.8.12 SPC Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–35
A.8.13 SPC Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–36
A.8.14 SPC Statistical References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–39
2–xviii v 3.02 - March 2003

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 “Safety Summary”. Ensure 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 3.02 - March 2003 xix Purpose of this Manual

Contents of this Manual
The following table summarizes the contents of the various chapters in this manual:
Chapter Discusses
1 General safety relating to the installation and use of the machine.
2 Technical specifications, environmental requirements, services, supplies,

machine and torque specifications.
3 General overview of the machine, identifies various components of the

machine, and safety features of the machine.
4 Installing the machine, hooking up services and setting up the machine.
5 Commissioning the machine.
6 User interface, and how to navigate through the HMI.
7 Setting up the machine for production.
8 Stopping the machine.
9 Maintenance schedule, and maintenance procedures.
10 PC control, and electrical components.
Appendix A SPC and how to use it (optional).
Appendix B Customer specials.
- User Feedback
After using this manual, please fill out the questionnaire at the back of this manual, and
fax it back to Husky at the number indicated on the top of the questionnaire.
Contents of this Manual xx v 3.02 - March 2003

Machine Manual
Conventions Used in this Manual
This manual uses hazard warnings in the form of Danger, Warning and Caution notes.
These hazard warning notes appear in bold font. An example of a hazard warning note
is shown below.
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.
This manual also uses the following conventions:

• Membrane keys on the HMI, as well as Emergency Stop button on the machine are
capitalized and enclosed in angle brackets. For example, <SCREW ROTATE> key,
<EMERGENCY STOP> button
• HMI screen or tab names are capitalized. For example, PRODUCTION SETUP
screen
• Button names on the HMI have initial capitals
• User inputs such as radio buttons, checkboxes, drop down boxes, data fields, etc.,
on the HMI screen have initial capitals. For example, select Machine Heats Enable
checkbox
• Machine function names have initial capitals. For example, check the machine is in
Mold Set mode
• Machine alarms are indicated in quotes. For example, "Oil Temperature Low"
• Reminder notes are indicated in the form shown below.
REMINDER: The plasticizing screw has a left-hand thread.
• Supplementary notes are indicated in the form shown below.

NOTE: Sidebar icons will vary from machine to machine, depending on the machine’s
configuration and installed options.
For the remainder of this manual:
• The term “Machine” refers to the Hylectric Injection Molding Machine.
• The term "Mono Base" refers to machines with a single clamp and injection base.
• The term "Split Base" refers to machines with a separate clamp base and injection
base.
• The term “Husky” refers to Husky Injection Molding Systems Ltd.
v 3.02 - March 2003 xxi Conventions Used in this Manual

v 3.02 - March 2003

Machine Manual Safety Summary
Chapter 1 Safety Summary
1.1 General
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.
1.2 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 3.02 - March 2003 1–1 General

1.3 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 3.02 - March 2003

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 3.02 - March 2003 1–3 Safety Signs

1.4 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.
1.5 Training
Skilled personnel are required to operate and maintain Husky equipment. Contact a
Husky Regional Service and Sales office to arrange training.
1.6 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:
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.
1.7 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 3.02 - March 2003

1.7.1 Performing Lockout/Tagout
Special Tool Required
1 Hydraulic pressure gauge suitable to 210 bar (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.
1. Turn off the power supply to the machine at the main disconnect switches, Q1M
and Q3M. If your machine is equipped with a Q2M mold heat switch, turn off the
power. Attach a lock and a tag. Then wait 10 minutes for residual voltage to
discharge.
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 on the gauge port marked "PP6G" in the power manifold
assembly (1) – 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 3.02 - March 2003 1–5 Lockout/Tagout

S01-101036A.eps
2
2 3
Figure 1-1 Manual Dump Valve (2 configurations shown).

1. Power manifold assembly 2. Pressure gauge 3. Manual dump valve
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.
Lockout/Tagout 1–6 v 3.02 - March 2003

S01-101037.eps
Figure 1-2 Air Regulator (Typical).

4. Shutoff lever 5. Air regulator 6. Lock 7. Tag
1.7.2 Removing Lockout/Tagout

Remove Lockout/Tagout 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.
v 3.02 - March 2003 1–7 Lockout/Tagout

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.
d. Turn on the power supply to the machine at the main disconnect switches.
e. Turn the manual dump valve to close the hydraulic circuit.
f. Remove the pressure gauge from the hydraulic power pack. Refer to
Figure 1-1. Cap the gauge port.
g. 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.
1.8 Safety Hazards
Some common safety hazards associated with injection molding equipment are:
1. Mechanical (pinching, shearing, crushing)
2. High Pressure Leak
3. Thermal
4. Spray
5. Electrical
6. Noise
7. Gas, Vapor, and Dust Emissions
8. Slipping, Tripping, or Falling
9. Lifting.
1.8.1 Mechanical Hazards
1.8.1.1 Worn Hoses and Safety Restraints

Regularly inspect and replace all flexible hose assemblies and restraints.
1.8.1.2 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.
Safety Hazards 1–8 v 3.02 - March 2003

Make sure to wait until the machine has cooled down before servicing cooling water
hoses.
1.8.1.3 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.
1.8.2 High Pressure Leak Hazards
1.8.2.1 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.
1.8.2.2 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.
1.8.3 Burn Hazards
1.8.3.1 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.
1.8.3.2 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.
v 3.02 - March 2003 1–9 Safety Hazards

1.8.4 Explosion Hazards
1.8.4.1 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.
1.8.5 Electrical Hazards

Molding equipment draws high amperage current at high voltage. The electrical power
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.
1.8.6 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.
1.8.7 Gas, Vapor, and Dust Emissions

Certain processed materials release harmful gas, vapors, or dust. Install an exhaust
system according to local codes.
1.8.8 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.
1.8.9 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.
Safety Hazards 1–10 v 3.02 - March 2003

1.9 Personal Protective Equipment and Safety Equipment
1.9.1 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.
1.9.2 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.
1.10 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.
1.11 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.
1.12 Materials, Parts, and Processing
To prevent personal injury or damage to the equipment, make sure:

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.
v 3.02 - March 2003 1–11 Personal Protective Equipment and Safety Equipment
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.
Materials, Parts, and Processing 1–12 v 3.02 - March 2003

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
Table 2-1 Machine Weights - H90 Models (Calculated).
Weight
Machine Model
lb (kg)
H90 -RS35/32 12000 (5445)
H90 -RS35/28 12500 (5670)
H90 -RS40/35 13000 (5900)
H90 -RS45/42 13000 (5900)
Table 2-2 Machine Weights - H160 Models (Calculated).
Weight
Machine Model
lb (kg)
H160-RS28/25 16000 (7260)
H160-RS40/35 17000 (7710)
H160-RS55/45 19000 (8620)
H160-RS55/50 19000 (8620)
HL160-RS55/50 19200 (8710)
v 3.02 - March 2003 2–1 Machine Weights

Table 2-3 Clamp and Injection Unit Weights - H225 Models (Calculated).
H225 H225 SPLIT HL225 HL225 SPLIT

lb lb lb lb
(kg) (kg) (kg) (kg)
Clamp +Clamp 17232 18888

Base (7820) (8570)
Power Pack + 14687 14687

Elec Cabinet + (6660) (6660)
Injection Base
Total (without 28765 31919 30683 33575

RS inj. unit) (13000) (14500) (13900) (15200)
Total Machine Total Machine Total Machine Total Machine

Injection Only
Weight Weight Weight Weight
RS Unit lb
lb lb lb lb
kg
(kg) kg kg kg
RS22 620 29385 31303

(281) (13300) (14200)
RS28 655 29420 31338

(297) (13300) (14200)
RS35 700 29465 31383

(318) (13400) (14200)
RS40 855 29620 31538

(388) (13400) (14300)
RS45 1235 30000 31918

(560) (13600) (14500)
RS55 1800 30565 32483

(816) (13900) (14700)
RS65 2815 31580 33498

(1280) (14300) (15200)
RS80 4725 36644 38300

(2140) (16600) (17400)
RS95 7425 39344 41000

(3370) (17800) (18600)
Machine Weights 2–2 v 3.02 - March 2003

H300 H300 SPLIT HL300 HL300 SPLIT

lb lb lb lb
(kg) (kg) (kg) (kg)
Clamp + Clamp 29432 32577

Base (13400) (14800)
Power Pack + 14687 14687

Elec Cabinet + (6660) (6660)
Injection Base
Total (without 35185 44119 38140 47264

RS inj. unit) (16000) (20000) (17300) (21400)
Total Machine Total Machine Total Machine Total Machine

Injection Only
Weight Weight Weight Weight
RS Unit lb
lb lb lb lb
(kg)
(kg) (kg) (kg) (kg)
RS22 620 35805 38760

(281) (16200) (17600)
RS28 655 35840 38795

(297) (16300) (17600)
RS35 700 35885 38840

(318) (16300) (17600)
RS40 855 36040 38995

(388) (16300) (17700)
RS45 1235 36420 39375

(560) (16500) (17900)
RS55 1800 36985 39940

(816) (16800) (18100)
RS65 2815 38000 40955

(1280) (17200) (18600)
RS80 4725 48844 51989

(2140) (22200) (23600)
RS95 7425 51544 54689

(3370) (23400) (24800)

Table 2-5 Machine and Injection Unit Weights - H400 Models (Calculated).
H400 HL400
lb lb
(kg) (kg)
Machine Only 17907 17907

(8120) (8120)
39085 39485
Clamp + Clamp Base
(17700) (17900)
Power Pack + Elec 14687 14687

Cabinet +Injection Base (6660) (6660)
Total (without RS inj. 53772 54172

unit) (24400) (24600)
Injection Only Total Machine Weight Total Machine Weight

RS Unit lb lb lb
(kg) (kg) (kg)
RS22 620
(281)
RS28 655
(297)
RS35 700
(318)
RS40 855
(388)
RS45 1235
(560)
RS55 1800 55572 55972

(816) (25200) (25400)
RS65 2815 56587 56987

(1280) (25700) (25800)
RS80 4725 58497 58897

(2140) (26500) (26700)
RS95 7425 61197 61597

(3370) (27800) (27900)
RS135 68215 68615

(30900) (31100)

H500 HL500
lb lb
(kg) (kg)
Machine Only
51834 52534
Clamp + Clamp Base
(23500) (23830)
Power Pack + Elec 14687 14687

Cabinet +Injection Base (6660) (6660)
Total (without RS inj. 66521 67221

unit) (30200) (30490)
Injection Only Total Machine Weight Total Machine Weight

RS Unit lb lb lb
(kg) (kg) (kg)
RS22 620
(281)
RS28 655
(297)
RS35 700
(318)
RS40 855
(388)
RS45 1235
(560)
RS55 1800 68321 69021

(816) (31000) (31300)
RS65 2815 69336 70036

(1280) (31500) (31800)
RS80 4725 71246 71946

(2140) (32300) (32600)
RS95 7425 73946 74646

(3370) (33500) (33900)
RS135 80964 81664

(36700) (37000)

H650 HL650
lb lb
(kg) (kg)
68345 72750
Clamp + Clamp Base
(31000) (33000)
RS Unit Weight (incl.

Power Pack + Elec Total Machine Weight Total Machine Weight
RS Unit Cabinet + Injection Base) lb lb
lb (kg) (kg)
(kg)
RS80 14990 83335 87740

(6800) (37800) (39800)
RS95 19400 87745 92150

(8800) (39800) (41800)
RS115 32190 100535 104940

(14600) (45600) (47600)
RS135 43650 111995 116400

(19800) (50800) (52800)
RS155 45855 114200 118605

(20800) (51800) (53800)

H800 HL800
lb lb
(kg) (kg)
88185 97000
Clamp + Clamp Base
(40000) (44000)

lb (kg) (kg)
(kg)
RS80 14990 103175 111990

(6800) (46800) (50800)
RS95 19400 107585 116400

(8800) (48800) (52800)
RS115 32190 120375 129190

(14600) (54600) (58600)
RS135 43650 131835 140650

(19800) (59800) (63800)
RS155 45855 134040 142855

(20800) (60800) (64800)

H1000 HL1000
lb lb
(kg) (kg)
114640 119050
Clamp + Clamp Base
(52000) (54000)

lb (kg) (kg)
(kg)
RS80 14990 129630 134040

(6800) (58800) (60800)
RS95 19400 134040 138450

(8800) (60800) (62800)
RS115 32190 146830 151240

(14600) (66600) (68600)
RS135 43650 158290 162700

(19800) (71800) (73800)
RS155 45855 160495 164905

(20800) (72800) (74800)
2.2 Environmental Requirements
The production room ambient room temperature and ventilation system must meet
requirements in Table 2-10.
Table 2-10 Environmental Requirements.
Requirement
Ambient Room Temperature without the 0 οC to 40 oC (32 oF to 104 oF)

Tropical Cooling Option
Ambient Room Temperature with the 0 oC to 48 oC (32 oF to 118 oF)

Tropical Cooling Option
Ventilation Suitable ventilation system to remove all

harmful gases, vapors or dust released
when processing certain plastic resins.
Environmental Requirements 2–8 v 3.02 - March 2003

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.
Voltage of supply to equipment may vary up to ±10% (of the value on the electrical
cabinet nameplate, and electrical schematic).
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;
v 3.02 - March 2003 2–9 Electrical Power Specifications

• municipal water conditions,

• cooling system design,
• water usage patterns.
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:
• 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
Machine Cooling Water Specifications 2–10 v 3.02 - March 2003

Sample Locations
Constituents Units
Closed Loop Chiller Tower Water
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
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 2-11 Machine Cooling Water Specifications.
Description Units Value
Inlet temperature range °C 10 to 34

°F 50 to 93
Inlet pressure bar 4.5 to 6

(minimum to maximum) psi 65 to 87
Pressure drop (minimum) bar 2

psi 30
v 3.02 - March 2003 2–11 Machine Cooling Water Specifications

Table 2-12 Machine Cooling Water Flow Rates.

Water Flow (USG/
Electric Motor (HP) Electric Motor (KW) Water Flow (m3/hr)
min)
25 19 2.0 8.8
30 22 2.5 11.0
40 30 3.1 13.7
50 37 3.9 17.2
75 56 6.1 26.9
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 Mold Cooling Water Specifications
Mold cooling water supply specifications are dependent upon the mold. Refer to the
Manufacturer’s Mold Manual for details.
2.6 Compressed Air Supply
Compressed air supply must meet specifications in Table 2-13.
Table 2-13 Compressed Air Supply Specifications.
Compressed air supply l/min 56

scfm 2
Inlet pressure bar 4.7 to 10.3

(minimum to maximum) psi 70 to 150
NOTE: Refer to the Manufacturer’s Robot Manual for compressed air requirements
for the robot.
Mold Cooling Water Specifications 2–12 v 3.02 - March 2003

Table 2-14 Compressed Air Flow Specificationsa.
Compressed Air Consumer Level Peak Flow
Air Function 1/2" ISO 2 2200 NI/min
Air Function 3/4" ISO 3 4316 NI/min
Air Service n/a n/a
Robot n/a n/a
Pneumatic valve gate ISO 1 1300 NI/min

control
Pneumatic core pull ISO 2 2200 NI/min
a. Compressed air flow specifications depends on consumer layout and cycle conditions.
2.7 Oil Capacity Data
Table 2-15 H/HL90 Oil Capacity Data.
RS Injection Unit
Units
RS22 RS28 RS35 RS40 RS45
Hydraulic Oil Volume l 360 360 360 360 360
US gal 95 95 95 95 95
Gearbox Oil Volume l 6.5 6.5 6.5 12 12
US gal 1.7 1.7 1.7 3.2 3.2
RS Injection Unit
Units
RS35 RS40 RS45 RS55
Hydraulic Oil Volume l 400 400 400 400
US gal 106 106 106 106
Gearbox Oil Volume l 6.5 12 12 17
US gal 1.7 3.2 3.2 3.2
v 3.02 - March 2003 2–13 Oil Capacity Data

Table 2-17 H/HL225Oil Capacity Data.
RS Injection Unit
Units
US gal 177 177 177 177 290.5
Gearbox Oil Volume l 12 12 17 17 28
US gal 3.2 3.2 4.5 4.5 7.4
RS Injection Unit
Units
US gal 177 177 177 290.5 290.5
Gearbox Oil Volume l 12 17 17 28 28
US gal 3.2 4.5 4.5 7.4 7.4
RS Injection Unit
Units
US gal 290.5 290.5 290.5 290.5 290.5
Gearbox Oil Volume l 17 17 28 28 N/A
US gal 4.5 4.5 7.4 7.4 N/A
RS injection Unit
Units
RS65 RS80 RS95 RS115
Hydraulic Oil Volume l 1100 1100 1100 1100
US gal 290.5 290.5 290.5 290.5
Gearbox Oil Volume l 17 28 28 N/A
US gal 4.5 7.4 7.4 N/A
Oil Capacity Data 2–14 v 3.02 - March 2003

RS Injection Unit
Units
RS80 RS95 RS115 RS135 RS155
US gal 491 491 602 713 845
US gal 7.4 7.4 15.3 15.3 N/A
RS Injection Unit
Units
RS80 RS95 RS115 RS135 RS155
US gal 491 491 602 713 845
US gal 7.4 7.4 15.3 15.3 N/A
RS Injection Unit
Units
RS80 RS95 RS115 RS135 RS155
US gal 491 491 602 713 845
US gal 7.4 7.4 15.3 15.3 N/A
v 3.02 - March 2003 2–15 Oil Capacity Data

2.8 Hydraulic Oil Specifications
Hydraulic oil used in the machine must conform to the approved list in Table 2-24.
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.
NOTE: All Husky machines are tested with Shell Tellus 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 46 oil
in the machine. Only use new oil in the machine.
Table 2-24 Approved Hydraulic Oils List.
Details
Recommended oil Shell Tellus 46
Other approved oils Esso Nuto H46

Gulf Harmony 46 AW
Mobil DTE 25
Texaco Rando HDZ46
Sunoco Sunvis 821 WR
Conoco Hydroclear AW46
Chevron AW46
Hydraulic Oil Specifications 2–16 v 3.02 - March 2003

2.9 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.
2.9.1 Grease Specifications

Greases used in the machine must meet specifications in Table 2-25.
Table 2-25 Lubricant Specifications.
Grease Specification Type Trade Name Where Used
NLGI Grade 1 Food-grade grease Lubriplate FGL-1 Moving platen linear

bearings, stack
mold carrier linear
bearings, mold
stroke column guide
bushings
NLGI Grade 2 Extreme pressure Lubriplate 3000 Clamp lock cylinder

moly grease linkages
NLGI Grade 2 Lithium-based Staburags NBU 8- Electric motor

grease EP, or Shell Alvania bearings
EP2
2.9.2 Gearbox Oil Specifications

Gearbox oil must meet specifications in Table 2-26.
Table 2-26 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.
v 3.02 - March 2003 2–17 Lubricant Specifications

2.10 Nitrogen Volume for Hydraulic Accumulators
Nitrogen volume supply specifications are dependant upon the machine configuration.
Refer to Table 2-27 for nitrogen volumes and accumulator sizes.
WARNING!
99.995% pure.
Table 2-27 Nitrogen and Accumulator Specifications.
Machine Model Injection Unit Clamp Accumulator Injection Accumulator
H90 RS22 1 x 10 l NA
(1 x 2.64 US gal)
RS28 1 x 10 l NA
(1 x 2.64 US gal)
RS35 2 x 10 l NA
(2 x 2.64 US gal)
RS40 2 x 10 l NA
(2 x 2.64 US gal)
RS45 2 x 10 l NA
(2 x 2.64 US gal)
H/HL160 RS28 2 x 10 l NA
(2 x 2.64 US gal)
RS35 2 x 10 l NA
(2 x 2.64 US gal)
RS40 2 x 10 l NA
(2 x 2.64 US gal)
RS45 2 x 20 l NA
(2 x 5.28 US gal)
RS55 2 x 32 l NA
(2 x 8.45 US gal)
Nitrogen Volume for Hydraulic Accumulators 2–18 v 3.02 - March 2003

H/HL225 RS40 2 x 10 l NA
(2 x 2.64 US gal)
RS45 2 x 20 l NA
(2 x 5.28 US gal
RS55 2 x 32 l NA
(2 x 8.45 US gal)
RS65 3 x 32 l NA
(3 x 8.45 US gal)
RS80 3 x 50 l NA
(3 x 13.20 US gal)
H/HL300 RS45 1 x 20 l 2 x 20 l
(1 x 5.25 US gal) (2 x 5.25 US gal)
RS55 1 x 20 l 2 x 20 l
(1 x 5.25 US gal) (2 x 5.25 US gal)
RS65 1 x 20 l 3 x 20 l
(1 x 5.25 US gal) (3 x 5.25 US gal)
RS80 1 x 20 l 3 x 20 l
(1 x 5.25 US gal) (3 x 5.25 US gal)
RS95 1 x 20 l 4 x 32 l
(1 x 5.25 US gal) (4 x 8.45 US gal)
H/HL400 RS55 1 x 32 l 2 x 10 l
(1 x 8.45 US gal) (2 x 2.64 US gal)
RS65 1 x 32 l 3 x 20 l
(1 x 8.45 US gal) (3 x 5.25 US gal)
RS80 1 x 32 l 3 x 32 l
(1 x 8.45 US gal) (3 x 8.45 US gal)
RS95 1 x 32 l 4x 32 l
(1 x 8.45 US gal) (4 x 8.45 US gal)
RS115 1 x 32 l 4 x 50 l
(1 x 8.45 US gal) (4 x 13.20 US gal)
v 3.02 - March 2003 2–19 Nitrogen Volume for Hydraulic Accumulators

H/HL500 RS65 1 x 50 l 3 x 20 l
(1 x 13.20 US gal) (3 x 5.25 US gal)
RS80 1 x 50 l 3 x 32 l
(1 x 13.20 US gal) (3 x 8.45 US gal)
RS95 1 x 50 l 4 x 32 l
(1 x 13.20 US gal) (4 x 8.45 US gal)
RS115 1 x 50 l 4 x 50 l
(1 x 13.20 US gal) (4 x 13.20 US gal)
H/HL650 RS80 2 x 50 l 3 x 32 l
(2 x 13.20 US gal) (3 x 8.45 US gal)
RS95 2 x 50 l 4 x 32 l
(2 x 13.20 US gal) (4 x 8.45 US gal)
RS115 2 x 50 l 4 x 50 l
(2 x 13.20 US gal) (4 x 13.20 US gal)
RS135 2 x 50 l 6 x 50 l
(2 x 13.20 US gal) (6 x 13.20 US gal)
H/HL800 RS80 2 x 50 l 3 x 32 l
(2 x 13.20 US gal) (3 x 8.45 US gal)
RS95 2 x 50 l 4 x 32 l
(2 x 13.20 US gal) (4 x 8.45 US gal)
RS115 2 x 50 l 4 x 50 l
(2 x 13.20 US gal) (4 x 13.20 US gal)
RS135 2 x 50 l 6 x 50 l
(2 x 13.20 US gal) (6 x 13.20 US gal)
RS155 2 x 50 l 8 x 50 l
(2 x 13.20 US gal) (8 x 13.20 US gal)
H/HL1000 RS95 2 x 50 l 4 x 32 l
(2 x 13.20 US gal) (4 x 8.45 US gal)
RS115 2 x 50 l 4 x 50 l
(2 x 13.20 US gal) (4 x 13.20 US gal)
RS135 2 x 50 l 6 x 50 l
(2 x 13.20 US gal) (6 x 13.20 US gal)
RS155 2 x 50 l 8 x 50 l
(2 x 13.20 US gal) (8 x 13.20 US gal)
Nitrogen Volume for Hydraulic Accumulators 2–20 v 3.02 - March 2003

2.11 Rust Inhibitor Specifications
Rust inhibitor used on the machine must meet specifications in Table 2-28.
Table 2-28 Rust Inhibitor Specifications.
Details
Type Water-borne corrosion resistant non-hardening film
Trade name Cortec Corp. VCI-389
2.12 Machine Data
Table 2-29, Table 2-30, Table 2-31 and Table 2-32 list the various machine settings or
limits.
Table 2-29 Hydraulic System Settings.
Hydraulic oil filtration micron 3
Hydraulic oil operating temperature – o

C 47/53
minimum/ maximum oF 117/127
Hydraulic system operating pressure bar 180

psi 2610
Accumulator precharge pressure at operating temperature bar 140

psi 2030
Table 2-30 Pneumatic Settings.
Air Regulator Setting Units Value
Inlet pressure bar 6

psi 90
v 3.02 - March 2003 2–21 Rust Inhibitor Specifications

Table 2-31 Injection Temperature Limit.
Injection Temperature Units Value
Maximum permissible temperature for plasticizing oC 415

o
F 779
Table 2-32 Machine Level/Nozzle Concentricity Specification.
Maximum Tolerance
Machine Level 0.05 mm per m

(0.002 in per ft)
Nozzle Concentricity 1 mm
(0.04 in)
Machine Data 2–22 v 3.02 - March 2003

2.13 Standard Torque Specifications
2.13.1 General
The following torque specification standards shown in Table 2-33 .apply to all threaded
connections, unless specified on the assembly drawing.
Table 2-33 Torque Standards.
Torque Specification
Application Hardware
Standard
Mechanical, Screws DIN 912 - 12.9 and 10.9 HGT-80

hydraulic DURLOK HGT-50
connections
ASTM A574 HGT-35
Mechanical Setscrews ISO 898/ 5 - 45H HGT-SS

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

lubrication, Plugs JIC (37° Flared)
pneumatic, water
NPT, BSPP, Ferrule (Bite)
connections
SAE Straight Thread
Electrical Screws Steel, AL & Cu, Brass HGT-EL

connections
Table 2-34 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
HGT - 80 Recommended if the highest torque is required
v 3.02 - March 2003 2–23 Standard Torque Specifications

2.13.1.1 Surface Lubrication

All contact surfaces and threads must be lubricated as described in Table 2-35 and
Table 2-36
REMINDER:
• O-rings must be inserted dry into the groove.
• On hydraulic fittings that use O-rings, lubricate the contact surface of the O-ring
with Lubriplate FGL - 2 (534967) or Molykote G with MOS2 (2658271).
• Apply tape on NPT fittings only.
• Do not apply thread sealant or tape on the first 2 threads of NPT fittings
Table 2-35 Lubrication for Screws.
Application Connection Lubricant Part Number
Mechanical and Low temperature Lubriplate FGL - 2 534967

hydraulic (<150°C) Molykote G with MOS2 2658271
High Temperature Optimoly Paste TA 644751

(>150°C)
Electrical Low Temperature No Lubrication -

(<150°C)
High Temperature Optimoly Paste TA 644751

(>150°C). For example,
heater bands.
Standard Torque Specifications 2–24 v 3.02 - March 2003

Table 2-36 Lubrication for Fittings and Plugs.
Part
Application Connection Lubricant
Number
Hydraulic Steel SAE, ORFS, Shell Tellus 46 or equivalent 2172702

BSPP
Lubrication N/A N/A Lubriplate FGL - 0 656247
Pneumatic Steel and NPT < 3/8 in Loctite 592 Thread Sealant 2172705
Brass
≥ 3/8 in White Teflon Tape 10364
JIC No Lubrication -
Steel SAE, BSPP Shell Tellus 46 or equivalent 2172702
Brass SAE, BSPP No Lubrication -
Water Steel and NPT < 3/4 in Pink Teflon Tape 732439
Brass
≥ 3/4 in Pink Teflon Tape, Loctite 732439
Aviation Form A Gasket 2172710
SAE, BSPP, No Lubrication -

JIC
Stainless NPT < 3/4 in Pink Teflon Tape 732439

Steel
≥ 3/4 in Pink Teflon Tape, Loctite 732439
Aviation Form A Gasket 2172710
JIC, SAE Kleen-Flo Anti-Seize 2172715

(SAE plugs Compound
included)

2.13.2 HGT-35 Standard (Screws)

The torque values shown in Table 2-37 apply to screws used in mechanical and
hydraulic connections with 35% Preload.
Table 2-37 Torque Values for Metric and Imperial Screws.
Metric Screws
Metric Screws Grade 10.9
Grade 12.9 Fasteners Fasteners Imperial Screws
ASTM A574 Fasteners
Socket Head Cap Screws Hex Head Screw
Imperial Socket Head Cap Screw
Durlock Hex Head Cap Screw Flat Head Cap Screw
Button Head Cap Screw
Torque Torque
Size Size
Nm lb ft Nm lb ft Nm lb ft
M4 2.1 1.5 #8 1 1
M5 4 3 #10 3 2
M6 9 7 5 4 1/4 7 5
M8 19 14 12 9 5/16 14 10
M10 37 27 25 18 3/8 23 17
M12 50 37 43 32 7/16 38 28
M16 125 90 100 75 1/2 58 42
M20 250 185 195 145 5/8 110 81
M24 440 325 340 250 3/4 180 135
M30 875 670 670 490 7/8 300 220
M36 1530 1130 1170 860 1 450 330
M42 1880 1390 1 1/8 620 460
M48 2820 2080 1 1/4 890 660
1 3/8 1170 860
1 1/2 1550 1140
1 3/4 2450 1790
NOTE: 1 Nm = 0.737 lb ft; 1 lb ft = 1.356 Nm


Metric Screws
ASTM A574 Fasteners
Torque Torque
Size Size
M4 3 2.2 #8 3 2
M5 6.2 4.6 #10 4 3
M6 10 7 9 7 1/4 11 8
M8 25 18 20 15 5/16 22 16
M10 53 40 40 30 3/8 40 30
M12 95 70 70 50 7/16 60 45
M14 130 95 1/2 95 70
M16 220 160 170 125 5/8 180 135
M18 270 200 3/4 310 230
M20 390 290 325 240 7/8 490 360
M24 660 490 560 410 1 750 550
M30 1300 960 1120 830 1 1/8 1040 770
M36 2300 1700 1950 1440 1 1/4 1480 1090
M42 3700 2700 3130 2300 1 3/8 1940 1430
M48 5500 4000 4700 3500 1 1/2 2580 1900
1 3/4 4050 2990


Metric Screws
ASTM A574 Fasteners
Torque Torque
Size Size
M4 4.6 3.4 #8 3 4
M5 9.5 7.1 #10 7 5
M6 16 12 14 10 1/4 16 12
M8 39 29 33 24 5/16 35 25
M10 77 57 65 48 3/8 60 45
M12 135 100 112 80 7/16 95 70
M14 215 160 1/2 150 110
M16 330 245 270 200 5/8 290 210
M20 650 480 520 380 3/4 500 360
M24 1100 810 900 660 7/8 790 580
M30 2250 1660 1790 1320 1 1180 865
M36 3850 2840 3120 2300 1 1/8 1680 1240
M42 6270 4630 5000 3700 1 1/4 2400 1750
M48 8560 6320 4700 5500 1 3/8 1940 2300
1 1/2 4100 3040
1 3/4 6500 4800

2.13.5 HGT-SS Standard (Set Screws)

The torque values shown in Table 2-40 apply to set screws used in mechanical
connections.
Table 2-40 Torque Values for Setscrews.
Metric Setscrews Imperial Setscrews
Torque Torque
Size Size
Nm lb ft Nm lb ft
M3 0.92 0.68 #5 1.1 0.8
M4 2.2 1.6 #6 1.1 0.8
M5 4 3 #8 2.7 2
M6 7 5 #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

2.13.6 HGT-EL Standard (Electrical Applications)

The torque values shown in Table 2-41 apply to screws used in electrical connections.
Table 2-41 Torque Values for Screws (electrical).
Metric and Imperial Screws
Size Torque
Aluminum and
Steel Brass
Copper
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
2.13.7 HGT-FT Standard (Fittings)

Torque Specification Standard HGT-FT applies to torque values for pneumatic and
hydraulic fittings and plugs.
Table 2-42, Table 2-43, Table 2-44, Table 2-45, Table 2-46, and Table 2-47 provide the
recommended torque values for safe use of pneumatic and hydraulic fittings and
plugs.
Torque values are measured using a torque wrench, or other methods such as "Turn
From Finger Tight” (TFFT) and “Flats From Finger Tight” (FFFT). For TFFT or FFFT,
the joint should first be hand tightened snugly, and then tightened with a wrench by the
number of flats or turns indicated in Table 2-45,Table 2-46 and Table 2-47.

REMINDER:
• Torque values shown are for steel components lubricated as described in Table 2-36.
• 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.
• Torque values given for NPT fittings are for reference only. Required torque values for a
reliable joint may differ.
• 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.
• Displayed fittings are for reference only. Torque values also apply to other fittings.
• Torque values shown in the tables apply to the top end of the displayed fittings.
Table 2-42 Torque Values for O-ring Face Seal Fittings.
Hose Connection & Tube Nut
SAE Tube Side

Thread Size
Dash Size in
Assembly Torque
Nm (lb ft)
-4 9/16 - 18 25 (18)
-6 11/16 - 16 40 (30)
-8 13/16 - 16 55 (40)
-10 1 - 14 80 (60)
-12 1-3/16 - 12 115 (85)
-16 1-7/16 - 12 150 (110)
-20 1-11/16 - 12 190 (140)
-24 2 - 12 245 (180)

Table 2-43 Torque Values for Fittings with SAE or BSPP Straight Thread Ends.
JIC and Ferrule (Bite) Fittings Face Seal
Adjustable Straight Adjustable &

Straight
Thread Size
SAE
Dash Size
in Nm (lb ft) Nm (lb ft) Nm (lb ft)
-5 1/2 - 20 28 (21) 28 (21) -
-6 9/16 - 18 34 (25) 34 (25) 46 (35)
-8 3/4 - 16 55 (40) 60 (45) 80 (60)
-10 7/8 - 14 80 (60) 115 (85) 135 (100)
-12 1-1/16 - 12 100 (75) 140 (105) 185 (135)
-14 1-3/16 - 12 135 (100) 190 (140) 235 (175)
-16 1-5/16 - 12 150 (110) 210 (155) 270 (200)
-20 1-5/8 - 12 290 (215) 290 (215) 340 (250)
-24 1-7/8 - 12 325 (240) 325 (240) 415 (305)

Table 2-44 Torque Values for SAE Straight Thread Plugs.
Hollow Hex Plug Hex Plug
Thread Size
SAE
Dash Size
in Nm (lb ft) Nm (lb ft)
-5 1/2 - 20 19 (14) 28 (21)
-6 9/16 - 18 23 (17) 34 (25)
-8 3/4 - 16 60 (45) 60 (45)
-10 7/8 - 14 95 (70) 115 (85)
-12 1-1/16 - 12 110 (80) 140 (105)
-14 1-3/16 - 12 170 (125) 190 (140)
-16 1-5/16 - 12 175 (130) 210 (155)
-20 1-5/8 - 12 290 (215) 290 (215)
-24 1-7/8 - 12 325 (240) 325 (240)
-32 2-1/2 - 12 420 (310) 420 (310)

Table 2-45 Torque Values for JIC (37° Flared) Fittings.
Hose Connection & Tube or Swivel Nut
Hose End of
SAE Size Assembly Tube End
Swivel Nut
Dash Size in Nm (lb ft) FFFT
FFFT
-4 7/16 - 20 16 (12) 2 2
-5 1/2 - 20 21 (15) 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
FFFT - Flats From Finger Tight

Table 2-46 Torque Values for NPT Pipe Thread.
Fittings and Plugs
Thread Size NPT

in TFFT
1/8 - 27 3
1/4 - 18 3
3/8 - 18 3
1/2 - 14 3
3/4 - 14 3
1 - 11-1/2 2.5
1-1/4 - 11-1/2 2.5
1-1/2 - 11-1/2 2.5
2 - 11-1/2 2.5
TFFT - Turns From Finger Tight

Table 2-47 Torque Values for Ferrule (Bite) Fittings.
Size Nut
SAE Dash Size
in FFFT
-4 7/16 - 20 3
-5 1/2 - 20 3
-6 9/16 - 18 3
-8 3/4 - 16 3
-10 7/8 - 14 3
-12 1-1/16 - 12 3
-14 1-3/16 - 12 3
-16 1-5/16 - 12 3
-20 1-5/8 - 12 3
-24 1-7/8 - 12 3
-32 2-1/2 - 12 3

Machine Manual Overview
Chapter 3 Overview
This chapter provides a brief functional description of the machine, and the various
machine components. It also discusses the safety features of the machine.
3.1 General Description
The Hylectric injection molding machine consists of a reciprocating screw injection unit
(1), and a hydro-mechanical clamp unit (2) – refer to Figure 3-1. Process material
pellets (3) are fed into a heated extruder barrel (4) in the injection unit, where an
electrically-driven plasticizing screw (5) rotates and turns them into a molten mass.
2
7 6 3
9
4
S01-100613.eps
5
10 8
Figure 3-1 H-Machine Injection Molding Concept (Typical).

1. Injection Unit 2. Clamp unit 3. Process material 4. Extruder barrel 5. Plasticizing screw
6. Stationary platen 7. Moving platen, 8. Frame 9. Mold halves 10. Ejector
v 3.02 - March 2003 3–1 General Description

The two halves of a mold are attached to the stationary platen (6) and the moving
platen (7). The stationary platen is pinned to the frame (8), and the moving platen is
attached to the clamp unit. The clamp unit closes the mold halves (9) to create a mold
cavity into which molten material can be injected. Additional clamping force is then
applied to keep the mold halves from separating during the injection stage.
A preset amount of plasticized material is then injected at very high pressure into the
mold cavity. This allows the molten material to fill and pack the mold cavity. Pressure is
maintained until the molded part has a chance to cool.
Pressure is then removed, and the plasticizing screw rotates again to prepare more
molten material for the next injection. At the same time, clamping force is removed
from the two platens, and as the two mold halves begin to separate an ejector (10)
pushes the molded part off the mold. This is called simultaneous operation.
The whole process can be controlled from the Human Machine Interface (HMI) by an
operator. Once the process is fine tuned, the machine can produce a batch of parts
unattended. A warning device on the machine alerts the operator when a machine
stoppage occurs. The warning device is discussed in Section 3.1.1.
Basic features and navigation of the HMI are discussed in Chapter 6—User Interface.
All functions of the machine are controlled by an industrial PC located in the electrical
cabinet. PC controls is discussed in Chapter 10—Electrical.
A number of safety features have been built into the design of the machine to ensure
the safety of the operator. These safety devices are discussed in Section 3.1.2.
Refer to Figure 3-2 and Figure 3-3 to become familiar with the various components of
the machine. These components will be referred to in other chapters of this manual.
General Description 3–2 v 3.02 - March 2003

15
16
Non-operator side
S01-101109.eps
17
18
19
14
12
13
Front Right View

11
9 7
10 8 6
1 5
3 4
2
23
20
21
22 Operator side
24
25
Front Left View 26
Figure 3-2 Front View of Hylectric Injection Molding Machine (Typical).

1. Clamp unit 2. Tie bar 3. Extruder barrel 4. Carriage cylinder 5. Injection
carriage 6. Servo motor 7. Gearbox 8. Electrical cabinet 9. Mold breaker Q2M
(optional) 10. Machine breaker Q1M 11. Platform and railings (optional) 12. Purge
guard 13. Platen guide rail 14. Locking cylinder 15. Warning light 16. Top panel
17. Hopper 18. Accumulator 19. Injection unit 20. Machine breaker Q3M
21. Carriage guide rail 22. HMI 23. Stationary platen 24. Air regulator 25. Moving
platen 26. Front operator’s gate

S01-101001.eps
Operator side
27 33
28
30 29
Rear Right View

32
34
35
36
Non-operator side
37
31
Rear Left View
Figure 3-3 Rear View of Hylectric Injection Molding Machine (Typical).

27. Power pack 28. Power manifold assembly 29. Pump motor 30. Hydraulic filter
31. Tower cooling water connections 32. Rear guard 33. Mold stroke cylinder
housing 34. Clamp block 35. Mold stroke column 36. Mold cooling water
connections 37. Heat exchanger

3.1.1 Warning Device
If your machine is equipped with a special warning device, refer to Customer Specials –
Appendix B.
The machine is equipped with a red warning light (1) that lights up when the machine
stops due to an alarm condition – refer to Figure 3-4. An optional audible horn (2) also
sounds to indicate the alarm condition. On machines equipped with the Statistical
Process Control (SPC) option, the amber light (3) lights up to indicate a SPC-related
alarm.
2
1
3
S01-101059.eps
Figure 3-4 Warning Device (Typical).

1. Red light 2. Horn 3. Amber light

3.1.2 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.
3.1.2.1 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 3-5.
S01-101042.eps
Figure 3-5 EMERGENCY STOP Button (Typical).

1. Emergency Stop button
Push the <EMERGENCY STOP> button to de-energize all control circuits, and stop
the machine. Turn the button clockwise to reset it.

3.1.2.2 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 3-6. 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 3-6 Operator’s Gate and Rear Guard (Typical).

1. Operator’s gate 2. Rear guard 3. Limit switch (typical)

3.1.2.3 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 3-7. 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
S01-101044.eps
2
Figure 3-7 Mechanical Safety Device (Typical).

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

Please refer to the hydraulic schematic for details specific to your machine.
3.1.2.4.1 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.
3.1.2.4.2 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
when either guard is opened.

3.1.2.5 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.
3.1.2.6 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 3-8. Before servicing the
hydraulic system, open the manual dump valve and wait for all pressure to discharge.
S01-101060.eps
Figure 3-8 Manual Dump Valve (Typical).

3.1.2.7 Purge Guard

The purge guard (1) protects the operator from molten spray that can be discharged
from the injection nozzle – refer to Figure 3-9. Limit switch S1LS monitors the purge
guard, and triggers an alarm when the purge guard is opened.
S01-101045a.eps
Figure 3-9 Purge Guard (Typical).
1. Purge guard

Machine Manual Installing
Chapter 4 Installing
This chapter describes how to prepare the machine, install and level it, hook up
services and set up the machine, in preparation for commissioning the machine.
The machine is shipped from the factory in two pieces – the clamp unit, and the
injection unit. Other accessories are shipped separately on pallets. Oil in the hydraulic
tank is drained before the machine is shipped. If the machine is shipped by sea or air,
nitrogen gas is also discharged from the accumulators prior to shipping.
All the red parts are shipping hardware. They must be removed during the installation
procedure.
Make a photocopy of this checklist and perform all procedures in the order they are
presented.
Table 4-1 Machine Installation and Setup Checklist.
Check
Item Description Reference
“X”
1 Check all injection unit leveling mounts are installed Section 4.1
correctly.
2 Check all clamp unit leveling mounts are installed Section 4.1
correctly.
3 Check the clamp unit and injection unit are aligned. Section 4.2
4 Unpack the machine and inspect for any damages. Section 4.3
5 Check the shipping hardware is removed. Section 4.4
6 Check the electrical cabinet and power pack are seated Section 4.1 and
on their mounts and not suspended on the injection Section 4.4
base.
7 Check that all machine surfaces are free of rust Section 4.7
inhibitor.
8 Check the hydraulic hoses between the injection and Section 4.8
clamp units are connected.
9 Check the electrical cables between the injection and Section 4.9
clamp units are connected.
10 Check the optional platform is installed. Section 4.10
11 Check the material feed equipment installation. Section 4.11
12 Check the warning light. Section 4.12
13 Check the purge tray is installed. Section 4.13
v 3.02 - March 2003 4–1

Table 4-1 Machine Installation and Setup Checklist.
Check
Item Description Reference
“X”
14 Check all electrical connections. Section 4.14
15 Check the hydraulic tank is full. Section 9.2.22.2
16 Check the system pump is primed. Section 9.2.23
17 Check the machine is level. Section 9.2.35
18 Check the oil collection line hook up. Section 4.16
19 Check the compressed air hook-up. Section 4.17
20 Check the electrical power supply hook-up. Section 4.18
21 Check the machine cooling water hook-up. Section 4.19
22 Check the mold cooling water hook-up. Section 4.20
23 If the machine has been in storage, check the machine Section 4.21
is lubricated.
24 Check the gearbox oil level is drained. Section 4.22
25 Check the accumulator precharge. Section 9.2.3
26 Check all hydraulic connections. Section 4.23
27 Check the carriage cylinders are installed. Section 4.24
28 Contact Husky to assist with commissioning the Chapter 5

machine.
4–2 v 3.02 - March 2003

4.1 Installing Leveling Mounts
Install leveling mounts on the injection unit (if not already installed), clamp unit and
power pack using the following instructions. Refer to the Site Preparation Manual,
Section 4.2 for instructions to lift the machine.
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 4-1.
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).
6. Apply grease to the threads of the leveling mount and the bolt (3). For lubricant
specifications, refer to Section 2.13.1.1.
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 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 base leveling mounts.
11. Similarly, install leveling mounts (7) under the power pack.
NOTE: The leveling mounts under the power pack are smaller in size than the
ones under the injection base.
v 3.02 - March 2003 4–3 Installing Leveling Mounts

S01-101003A.eps
3
4 3
5
6 4
5
6
1
1
2
2
9
8
11
10
13
7
12
Figure 4-1 Installing Leveling Mounts.

1. Machine base 2. Leveling mount 3. Bolt 4. Locknut 5. Lock washer 6. Leveling
mount 7. Leveling mount 8. Bolt 9. Mounting bracket 10. Washer 11. Locknut
12. Bolt 13. Flat washer
12. Apply grease to the threads of the leveling mounts and the bolts (8).
13. Assemble the leveling mounts to the mounting brackets (9) using the bolts,
washers (10) and locknuts (11), as shown.
14. Apply grease to the threads of the bolts (12).
15. Attach the mounting brackets to the captive nuts in the base of the electrical
cabinet using the bolts and flat washers (13).
16. Repeat Step 12 - Step 13 to attach the electrical cabinet leveling mounts.
17. Carefully lower the unit to the floor.
Installing Leveling Mounts 4–4 v 3.02 - March 2003

4.2 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.
WARNING!
Crushing hazard – risk of death or serious injury. 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 4-2.
S01-101006.eps
2
4
3
Figure 4-2 Aligning Injection and Clamp Units.

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 3.02 - March 2003 4–5 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.
6. 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.
4.3 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. Inspect the machine for any signs of damage. Report any damage to the Husky
Regional Service and Sales office.
Unpacking the Machine 4–6 v 3.02 - March 2003

4.4 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 block (2) – refer to Figure 4-3.
3. Remove the shipping bolts (3) located under the injection carriage (4).
4. Support the power pack base (5), and remove the mounting bolts (6). Lower the
power pack base to the floor.
5. Support the electrical cabinet, and remove the shipping bolt (7) from the rear of the
cabinet. Replace with the supplied shoulder bolt.
Repeat for the remaining electrical cabinet shipping bolts.
6. Cut the tie wraps and remove the two wooden braces between the platens.
7. Remove the exterior packaging and protective wrapping from the hoses, the
hopper assembly, the warning light, and the carriage cylinders.
8. Label and store all shipping hardware in a safe place for use at a later date when
relocating the machine.
v 3.02 - March 2003 4–7 Removing Shipping Hardware (H90 to H500)

2
1
4
3
7
S01-101092.eps
5
Figure 4-3 Removing Shipping Bolts (Typical).

1. Bolt 2. Clamp block 3. Bolt 4. Injection carriage 5. Power pack base 6. Bolt
7. Shipping bolt
Removing Shipping Hardware (H90 to H500) 4–8 v 3.02 - March 2003

4.5 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 (1 on Figure 4-4) 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. For RS80 to RS95, remove the shipping bolts (3) located under the injection
carriage (4) (refer to Figure 4-3).
7. For RS115 and up (6), remove the shipping plate (7) (refer to Figure 4-4).
8. Support the power pack base (item 8, Figure 4-4), and remove the mounting bolts
(9, 10). Lower the power pack base to the floor.
9. Support the electrical cabinet, and remove the shipping bolt (7) from the rear of the
cabinet. Replace with the supplied shoulder bolt (refer to Figure 4-3).
Repeat for the remaining electrical cabinet shipping bolts.
10. 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 L-2438
6 7 8 9 10
Figure 4-4 Removing Clamp Unit Shipping Hardware.

1. Clamp platen shipping bolt 2. Column tie-down strap 3. Column blocking plate
4. Cam follower shim 5. Clamp base shipping beam 6. Injection carriage 7. Shipping
plate 8. Power pack 9. Mounting Bolt 10. Shipping washers
Removing Shipping Hardware (H650 to H1000) 4–10 v 3.02 - March 2003

4.5.1 Installing Column Bell (H90 to H800)

Instructions:
1. Level the clamp in accordance with Section 9.2.35.1.
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 2.13. Make
sure there is an equal gap between the two halves.
4.5.2 Installing Column Bell (H1000)

Instructions:
1. Level the clamp in accordance with the Machine Manual, Section 9.2.35.1.
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 2.13.
8. Make sure the cylinder retainer (1 on Figure 4-3) is parallel to the bell (2 on
Figure 4-3).

L-2437
Figure 4-5 Column Bell

1. Column bell 2. Cylinder retainer
4.6 Assembling Safety Gates (H650 to H1000)
4.6.1 Operator’s gate:

Take the gate from the shipping frame. Use the eye bolts (1 and 2 on Figure 4-6).
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 (1 on Figure 4-7).

Attach the connection arm (2) to the stationary platen.
Assembling Safety Gates (H650 to H1000) 4–12 v 3.02 - March 2003

1
2
Figure 4-6 Lifting Safety Gates.

1. Lifting point - Clamp platen side 2. Lifting point - Stationary platen side
4.6.2 Rear gate:

Take the gate from the shipping frame. Use also the eye bolts.
Assemble the gate to both consoles (3 on Figure 4-7).
Fasten the gate connection arm (4) to the stationary platen.
4.6.3 Both gates:

Connect the gates with the bars (5 on Figure 4-7).
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.
v 3.02 - March 2003 4–13 Assembling Safety Gates (H650 to H1000)

Figure 4-7 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
Assembling Safety Gates (H650 to H1000) 4–14 v 3.02 - March 2003

4.7 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.
4.8 Connecting Hydraulic Hoses (Split Base Models)
Connect all hydraulic lines between the injection unit and clamp unit in accordance
with the hydraulic schematic.
1. Connect the return line (1) to the flanged connection on the hydraulic tank – refer
to Figure 4-8. Torque the bolts to Husky specifications – refer to Section 2.13.
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.
v 3.02 - March 2003 4–15 Cleaning Machine

3
S01-101008.eps
Figure 4-8 Connecting Hydraulic Lines (Typical).

1. Return line 2. Pressure line 3. Pilot line 4. Drain line
4.9 Connecting Electrical Cables (Split Base Models)
Connect all electrical cables between the injection unit and clamp unit in accordance
with the electrical schematic.
1. Route the PROFIBUS cable (1) (B11DT) from the injection unit through the clamp
base to the displacement transducer (2) – refer to Figure 4-9. Connect the cable to
the transducer. Fasten the cable using tie wraps.
Connecting Electrical Cables (Split Base Models) 4–16 v 3.02 - March 2003
5 4
2
1
S01-101108.eps
Figure 4-9 Connecting Electrical Cables in Clamp Unit (Typical).

1. PROFIBUS cable 2. Displacement transducer 3. Mold heater connector base
4. Communication cable 5. HMI
2. H300 to H1000 machines only: Route the electrical cables (Y103SV, Y116SV,
Y117SV, S241FS, S246FS, S247FS, S248FS) from the injection unit to the mold
cooling connection (3). Connect the cables to the matching connectors. Fasten the
cables using tie wraps.
3. Route the optional mold heater cables (W40, W41, W42) with the attached
connector bases (3) from the injection unit through the clamp base. Fasten the
connector bases to the inside of the guards using the supplied screws. Attach the
mold heater connectors to the matching connector bases.
4. Route the communication cables (4) from the injection unit to the back of the HMI
(5). Attach the cables to the connectors on the back of the HMI. Fasten the cables
using tie wraps.
5. H300 to H1000 machines only: Route the electrical cable (S24PS) from the
injection unit to the air regulator. Attach the cable to the connector (7) on the air
regulator. Fasten the cable using tie wraps.
6. Open the electrical cabinet doors beside the PC. Remove the cover (6) – refer to
Figure 4-10.
v 3.02 - March 2003 4–17 Connecting Electrical Cables (Split Base Models)
8 9
7 6
S01-101023.eps
11
10
Figure 4-10 Connecting Electrical Cables in Electrical Cabinet.

6. Cover 7. Shipping panel 8. Sub plate 9. Sub plate 10. Terminal base
11. Mounting rail
7. Remove the nuts holding the shipping panels (7) on the back of the cabinet. Label
and store the shipping panels in a safe place for use at a later date when relocating
the machine.
NOTE: Do not remove the plates that have plastic caps on the nuts.
8. Route the cables with the sub plates (8), (9) from the clamp unit through the
injection unit to the back of the electrical cabinet. Run the terminal bases (10)
through the opening in the back of the cabinet, and attach the sub plates using the
nuts from the previous step.
9. Run the terminal bases with the attached cables under the mounting rail (11), and
attach it to the mounting rail. Connect the terminals with the matching terminal
bases.
10. Reattach the cover over the terminals, and close the electrical cabinet.
Connecting Electrical Cables (Split Base Models) 4–18 v 3.02 - March 2003
4.10 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.
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 4-11.
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
Figure 4-11 Installing Optional Platform.

1. Platform 2. Ladder 3. Railings
v 3.02 - March 2003 4–19 Installing Platform (Optional)

4.11 Installing Material Feed Equipment
For recommendations to install additional process material feed equipment such as

dryers and mixers see Section 4.11.2.
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.
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 4–20 v 3.02 - March 2003

12
11 11
10 13 10
14
9
11
10
6
3
7
4
1
5
2
S01-101012.eps
Figure 4-12 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
v 3.02 - March 2003 4–21 Installing Material Feed Equipment

4.11.1 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 4-13.
2. Install the lid.
1
S01-101013.eps
Figure 4-13 Hopper and Hopper Magnet (Typical).

1. Hopper Lid 2. Optional hopper magnet
4.11.2 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 4-14):
1. The total mass of all equipment attached to the mounting flange (1) should not
exceed the values in Table 4-2.
2. The total moment generated by all equipment above the mounting flange should
not exceed the values in Table 4-2.
Installing Material Feed Equipment 4–22 v 3.02 - March 2003

Table 4-2 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
RS80 to RS115 150 (330) 1,900 (1,400)
1300 mm (51 in.)
above feedthroat On Slide RS22 to RS65 80 (175) 1,020 (750)
mounting 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 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 4-14 Process Material Feed Equipment Recommendations.

1. Mounting flange 2. Hopper 3. Magnet drawer
v 3.02 - March 2003 4–23 Installing Material Feed Equipment

4.12 Installing Warning Light
Install the warning light using the following instructions:

1. Align the holes in the mounting bracket (1) to the holes in the machine frame –
2. Fasten the mounting bracket using the supplied bolts (2).
S01-101014.eps
Figure 4-15 Installing Warning Light.

1. Mounting bracket 2. Bolt
4.13 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 4-16.
2. Tighten the screws.
Installing Warning Light 4–24 v 3.02 - March 2003

42
S01-101016.eps
1
Figure 4-16 Installing Purge Tray (Typical).

1. Screw 2. Purge tray
4.14 Installing Drool chute
On machines equipped with a drool chute assembly, install as shown in Figure 4-16.
42
L-2453
Figure 4-17 Installing Drool chute

1. Drool chute cover 2. Drool chute
v 3.02 - March 2003 4–25 Installing Drool chute

4.15 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.
Checking Electrical Connectors 4–26 v 3.02 - March 2003

4.16 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 4-18.
6
5
7
S01-101009.eps
2
3
Figure 4-18 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
4.17 Hooking Up Compressed Air Lines
Refer to Section 2.6 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 4-18.
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 3.02 - March 2003 4–27 Hooking Up Oil Collection Line

4.18 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.
DANGER!
Electrocution hazard – risk of death or serious injury. 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.
WARNING!
Electrocution hazard – risk of death or serious injury. Only connect the bonding
strip where local codes require the neutral bar to be bonded to the enclosure.
WARNING!
Electrocution hazard – risk of death or serious injury. 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.
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.
WARNING!
Electrocution hazard – risk of death or serious injury. All ancillary equipment
must be properly grounded.
Hooking Up Electrical Power Supply 4–28 v 3.02 - March 2003

CAUTION!
Risk of damage to the machine. Do not modify the electrical cabinet.
CAUTION!
Risk of damage to the machine. The main electrical power cable must be rated to
handle machine power requirements, in compliance with local codes.
CAUTION!
Risk of damage to the machine. Do not operate the machine until pump motor
rotation is verified – Section 5.1
4.18.1 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.
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 1.7.
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 4-19.
v 3.02 - March 2003 4–29 Hooking Up Electrical Power Supply

S01-101111A.eps
2 7
4
1
6
5 8
9
10
Figure 4-19 Hooking Up Machine Power Supply (Typical).

1. Main breaker Q1M 2. Main breaker Q3M 3. Electrical cabinet 4. Mold heat breaker
Q2M (optional) 5. Machine power supply cable 6. Ground (Potential Earth) 7. Neutral
bar 8. Mold heat power supply cable (optional) 9. Flange mount type breaker (Ref.)
10. Rotary handle type breaker (Ref.)
3. Run the power supply cable (5) through the access hole in the electrical cabinet.
4. Connect the three-phase wires to the bottom of the main breakers, Q1M and Q3M,
and the mold heat breaker Q2M, if applicable.
5. Connect the ground (Potential Earth) wire to the ground strip (6).
6. Connect the neutral wire, where available, to the neutral bar (7).
7. Remove Lockout/Tagout – refer to Section 1.7.2. Switch on the power supply at the
main disconnect switches.
Hooking Up Electrical Power Supply 4–30 v 3.02 - March 2003

4.19 Hooking Up Machine Cooling Water Supply
Refer to Section 2.4 for machine cooling water specifications.

Hook up machine cooling water supply using the following instructions:
1. Refer to the installation drawing for machine cooling water inlet and outlet sizes.
2. Remove the cap from the cooling water inlet fitting (1), and attach the cooling water
supply line. Refer to Figure 4-20.
3. Remove the cap from the cooling water outlet fitting (2), and attach the return line.
4. Open the water supply and drain cock on return line to bleed any trapped air from
the lines.
S01-101026.eps
Figure 4-20 Hooking Up Machine Cooling Water Supply (Typical).

1. Inlet 2. Outlet
v 3.02 - March 2003 4–31 Hooking Up Machine Cooling Water Supply

4.20 Hooking Up Mold Cooling Water Supply (Optional)
Refer to the mold manual 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.
2. Remove the cap from the mold cooling water inlet fitting (1), and attach the supply
line – refer to Figure 4-21.
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 4-21 Hooking Up Mold Cooling Water Supply (Typical).

1. Mold cooling water inlet 2. Mold cooling water outlet
Hooking Up Mold Cooling Water Supply (Optional) 4–32 v 3.02 - March 2003
4.21 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 2.9.
Lubricate the machine using the following instructions:
1. Lubricate mold stroke column guide bushings. Refer to Section 9.2.18.
2. Lubricate clamp lock cylinder rod ends. Refer to Section 9.2.19.
3. Lubricate moving platen linear bearings, if installed. Refer to Section 9.2.30.
4. Lubricate optional stack mold carrier linear bushings. Refer to Section 9.2.31.
5. Lubricate injection piston linear bearings if installed. Refer to Section 9.2.32.
6. Lubricate electric pump motor bearings. Refer to Section 9.2.38.
4.22 Draining Gearbox
Refer to Section 2.7 for gearbox oil capacity, and Section 2.7 for gearbox oil
specifications.
Drain oil in the gearbox to the level of the sight glass using the following instructions:
1. Remove the breather cap (1), and the overflow plug (2) on the gearbox (3) – refer
to Figure 4-22.
CAUTION!
Failure to drain oil to the level of the sight glass will damage seals in the
gearbox.
2. Drain oil from the drain plug (4) in the gearbox until the oil level is to the top of the
sight glass (5).
3. Install the plug, and the breather cap. Wipe all surfaces clean.
v 3.02 - March 2003 4–33 Machine Lubrication

S01-101114.eps
3
2
4
Figure 4-22 Lubricating Gearbox (Typical).

1. Breather cap 2. Overflow plug 3. Gearbox 4. Drain plug 5. Sight glass
4.23 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 for torque specifications.
2. Check and retighten all connections at the manifolds.
3. Check and retighten all remaining hydraulic connections throughout the machine.
Checking Hydraulic Connections 4–34 v 3.02 - March 2003

4.24 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 4-23. Torque the
bolts to Husky specifications HGT-50 – refer to Section 2.13.3.
4. Reattach the hydraulic hoses, and wipe up any oil spill.
S01-101095.eps
2
1
Figure 4-23 Installing Carriage Cylinders.

1. Piston rod 2. Clevis block 3. Stationary platen 4. Bolt
4.25 Contact Husky
Contact Husky to assist with commissioning the machine.
v 3.02 - March 2003 4–35 Attaching Carriage Cylinders (Split Base Models)
v 3.02 - March 2003

Machine Manual Commissioning the Machine
Chapter 5 Commissioning the Machine
This chapter describes the final checks and procedures to commission the machine.
A Husky Field Service Representative must be present to assist with commissioning
the machine.
Make a photocopy of this checklist and perform the procedures in the order that the
information is presented.
Table 5-1 Machine Commissioning Checklist.
Item Description Reference Check “X”
1 Recheck cooling water connections. Section 9.2.16
2 Check pump motor rotation. Section 5.1
3 Check all machine safety devices. Section 5.2
4 Start up the machine and check machine Section 5.3

functions.
5 Check nozzle concentricity. Section 9.2.36
6 Run-in the machine. Section 5.4
7 Replace the factory-installed oil filter element. Section 9.2.33
8 Recheck accumulator precharge. Section 9.2.3
9 Recheck oil level in the hydraulic tank. Section 9.2.21
v 3.02 - March 2003 5–1

5.1 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:

1. Push the main breaker switch down to switch the power supply off. The main
breaker switch is located on the electrical cabinet.
NOTE: On machines shipped to Europe with integrated mold heats, the main
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 1.7.1, then wait 10 minutes

for residual voltage to discharge.
3. Remove the hydraulic power pack cover (1) to reveal the pump motor (2) – refer to
Figure 5-1. Remove the cover (3) on the bell housing (4), to reveal the coupling (5).
Observe the direction of the arrow (6) on the adapter.
4. Pull the main breaker switch 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.
Checking Pump Motor Rotation 5–2 v 3.02 - March 2003

3
1
5
4
S01-101040.eps
6
Figure 5-1 Checking Pump Motor Rotation.

1. Power pack cover 2. Pump motor 3. Cover 4. Bell housing 5. Coupling
6. Arrow
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 7.2.
8. Press the <ALARMS> key to display the ALARMS screen. Press the Clear Inactive
Alarms button to clear any inactive alarms.
9. From the toolbar, press the Machine Function Mode selector button, and select the
Unload All Pumps button.
v 3.02 - March 2003 5–3 Checking Pump Motor Rotation

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 5.1.1.
WARNING!
Electrocution hazard – risk of death or serious injury. Only a qualified electrician
should perform this procedure.
5.1.1 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 1.7, then wait 10 minutes for
residual voltage to discharge.
2. Open the electrical cabinet (1) and disconnect any two phases of the supply to
main breaker.
3. Reverse the two phases and reconnect the cables. Close the electrical cabinet.
4. Remove Lockout/Tagout, and switch on the power supply to the machine.
5. Verify the pump motor rotation – refer to Section 5.1.
Checking Pump Motor Rotation 5–4 v 3.02 - March 2003

S01-101110.eps
1
Figure 5-2 Reversing Pump Motor Rotation.

1. Electrical cabinet
5.2 Checking Machine Safety Devices
safety of the operator. Check the following safety devices:
• "Emergency Stop Button" on page 7–5
• "Automatic Dump Valve" on page 7–7
• "Checking Mechanical Safety Device" on page 9–59
• "Checking CEN Valve" on page 9–60
• "Automatic Dump Valve" on page 7–7
• "Purge Guard" on page 7–9.
v 3.02 - March 2003 5–5 Checking Machine Safety Devices

5.3 Checking Machine Functions
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.
Mold Set button.
4. Press the <CLAMP> key and select the SETUP tab – refer to Figure 5-3.
Figure 5-3 (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.
Checking Machine Functions 5–6 v 3.02 - March 2003

5.4 Running in the Machine
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.
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 9.2.33.
v 3.02 - March 2003 5–7 Running in the Machine

v 3.02 - March 2003

Machine Manual User Interface
Chapter 6 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.
6.1 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 6-1.
Each of the screen elements shown in the following illustration is covered in detail later
in this chapter.
v 3.02 - March 2003 6–1 Human Machine Interface (HMI)

1 2 3 4
5 5
S01-100856a.eps
6 7 8
Figure 6-1 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) 6–2 v 3.02 - March 2003

6.1.1 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 6-1 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 6-1 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.
6.1.2 Robot Home Key

The <ROBOT HOME> key is used to reset the robot to the home position. The key is
described in Table 6-2.
Table 6-2 Robot Home.
Key Function
Press the <ROBOT HOME> key to return the robot to the home
position.

6.1.3 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 6-3. For complete details on robot
operation, see the Robot manual.
Table 6-3 Robot Enable.
Key Function
Press the <ROBOT ENABLE> key to run the robot during

machine operation.
6.1.4 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 6-4.
Table 6-4 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.
6.1.5 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:
• preset automatic and manual functions
• process values
• optional automatic and manual functions, depending on how the machine is config-
ured
• user configured function keys.
Refer to Figure 6-2 and Figure 6-3 for more information on the sidebar keys.

1 1
2 3 2
Figure 6-2 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 6-3 Sidebar Function Selectors.

6.1.5.1 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 6-5 for a description of these features.
Table 6-5 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.
6.1.5.2 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 6-4) 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 6-4 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.

6.1.5.3 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 6-6 for details.
NOTE: Depending on how your machine is configured, the sidebars may display more
process value icons than those shown here.
Table 6-6 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.

6.1.5.4 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 6-5 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 6-5 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

6.1.5.5 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 6-6 for details.
5
4
2 3 7 8
6
Figure 6-6 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 6-7 User Configurable Sidebar Buttons.
Sidebar Function Group

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

Table 6-7 User Configurable Sidebar Buttons.
Sidebar Function Group

Sidebar Sub-function Button Button Name
Button
Air Auto Air Auto
Air Auto
Air Auto
Air Auto
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

6.1.5.6 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.
6.1.5.7 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.
6.1.5.8 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.

6.1.5.9 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.
6.1.6 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 parts:
• a message bar displayed across the top (1) – refer to Figure 6-7
• a toolbar (2) – refer to Figure 6-7 and Figure 6-8
• 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 6.1.5 for details.
1 2 3 4
5
6 6
Figure 6-7 HMI Screen Parts

1. Message bar 2. Toolbar 3. Machine function screen 4. Tabs 5. Status bar 6.
Sidebar function icons (refer to Section 6.1.5)

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:
• 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.
6.1.6.1 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.
6.1.6.2 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 6-8.
1 2 3 4 5 6 7 8 9 10
Figure 6-8 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)
6.1.6.2.1 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.
6.1.7 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.
6.1.7.1 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 6-9.
Figure 6-9 ADMINISTRATOR ACCESS – USERS Screen.
Table 6-8 describes each screen element shown in Figure 6-9.

Table 6-8 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

6.1.7.2.
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.

6.1.7.2 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 6-10.
Figure 6-10 OPEN ACCOUNT Pop-Up Screen.
Table 6-9 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 6.1.7.3.
Load DataKey Press this button to load current user name and password
information from the datakey.

6.1.7.3 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.
6.1.7.4 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 6-11.
Figure 6-11 ADMINISTRATOR ACCESS – GROUPS Screen.

Table 6-10 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 6.1.7.5.
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 6.1.7.6.
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.

6.1.7.5 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 6-12.
Figure 6-12 CREATE NEW GROUP Pop-Up Screen.
Table 6-11 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 6.1.7.6.
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.

6.1.7.6 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.
Refer to Figure 6-13.
Figure 6-13 ADD/REMOVE USER IN GROUP Pop-Up Screen.
Table 6-12 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.

6.1.7.7 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 6-14.
Figure 6-14 ADMINISTRATOR ACCESS – RIGHTS Screen.
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.

Field Description
User Rights
(User Rights drop down Use this drop down list to select a user currently defined within
list) the HMI.
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 Privilege Press this button to assign additional rights to the user selected
in the User Rights drop down box.
Deny User Privilege Press this button to remove specific rights from the user currently
selected in the User Rights drop down box.
Group Rights
(Group Rights drop Use this drop down list to select a group currently defined within
down list) the 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 Right Press this button to assign a new right to the group selected in
the Group Rights drop down box.
NOTE: Use the GROUPS tab to remove rights from a specific
group.
6.1.7.8 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 6-15.

Figure 6-15 ADMINISTRATOR ACCESS – OTHERS Screen.
Table 6-14 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.
used to access the machine. Refer to Section 6.1.7.3.

6.1.8 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 6-16 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 6-16 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 9—Maintenance.

6.1.9 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 6-15 describes the various machine function modes.
Table 6-15 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.

6.1.10 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:
• 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.
6.1.10.1 Password
Press the HMI Configuration button to display the HMI CONFIGURATION screen at
the PASSWORD tab. Refer to Figure 6-17.
Figure 6-17 PASSWORD Tab.
Table 6-16 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.
used to access the machine.

Table 6-16 HMI Configuration – PASSWORD TAB Field Descriptions.
Field Description
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.
6.1.10.2 Units
Press the HMI Configuration button to display the HMI CONFIGURATION screen then
press the UNITS tab. Refer to Figure 6-18.
Figure 6-18 UNITS Tab.
Table 6-17 HMI Configuration – UNITS TAB Field Descriptions.
Field Description
Unit System Selection
SI–System Select this radio 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–System Select this radio button to use Imperial units exclusively.

Note that the fields in the UNITS area are greyed out when
this button is active.
Custom–System Select this radio button to select a custom assortment of

measurement units from the UNITS area of the tab.

Table 6-17 HMI Configuration – UNITS TAB Field Descriptions.
Field Description
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).
Tonnage Select the type of unit for tonnage displays (metric tonnes,
US tons, or Imperial).
Update Datakey Press this button to update the current unit data on the
datakey.
6.1.10.3 Language
press the LANGUAGE tab. Refer to Figure 6-19.
Figure 6-19 LANGUAGE Tab.

Table 6-18 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.
6.1.10.4 Shifts
press the SHIFTS tab. Refer to Figure 6-20.
Figure 6-20 SHIFTS Tab.
Table 6-19 HMI Configuration – SHIFTS TAB Field Descriptions.
Field Description
2 Shifts Select this radio button to display only fields for two shifts.
3 Shifts Select this radio 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.

6.1.10.5 Printer
press the PRINTER tab. Refer to Figure 6-23.
Figure 6-21 PRINTER Tab.
Table 6-20 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

When Add Printer wizard.
Show Print Dialog Box When Select this checkbox to show the printer dialog box.
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.
Click this button to print all screens to the default printer.
Click this button to configure your printer settings. Refer to

Section 6.1.10.5.1 for details.

6.1.10.5.1 Background Printing Configuration Screen

The BACKGROUND PRINTING CONFIGURATION screen allows the administrator to
select files for printing in the background. Refer to Figure 6-22.
Figure 6-22 BACKGROUND PRINTING CONFIGURATION Screen
Table 6-21 describes each element shown in Figure 6-22.
Table 6-21 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.

6.1.10.6 Remote
press the REMOTE tab. Refer to Figure 6-23.
Figure 6-23 REMOTE Tab.
Table 6-22 HMI Configuration – REMOTE TAB Field Descriptions.
Field Description
Remote Connection
Enable Select this radio button to enable remote connection.

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

NOTE: Select Connection Type radio button prior to
selecting this field.
Connection Type
Modem Select this radio 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 radio button to communicate with Husky by TCP/

IP.
Computer Information
Computer Name Displays the computer name.
TCP/IP Address Displays the TCP/IP address.

6.1.10.7 Saving and Restoring Machine Backups

press the BACKUP tab. Refer to Figure 6-24. 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 6-24 BACKUP Screen.
Table 6-23 HMI Configuration – BACKUP TAB Field Descriptions.
Field Description
Backup Destination Folder Enter a backup file destination folder name. The backup
function will 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.

6.1.10.8 Others
press the OTHERS tab. Refer to Figure 6-25.
Figure 6-25 OTHERS Tab.
Table 6-24 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 Configuration NOTE: Press this button to display the OPERATOR STOP
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 6.1.10.8.1.
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.

6.1.10.8.1 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 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.
6.1.10.8.2 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 6-26.
Figure 6-26 OPERATOR STOP REASON Screen.

Table 6-25 OPERATOR STOP REASONS Screen Descriptions.
Field Description
(1) Reason Groups This part of the screen displays the currently defined Reason
Groups. Up to 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 6.1.10.8.3.

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.
6.1.10.8.3 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 6-27.
Figure 6-27 STOP REASON DEFINITONS Screen.

Table 6-26 OPERATOR STOP REASON Screen Descriptions.
Field Description
(1) Stop Reasons This part of the screen displays the currently defined stop
reasons for the selected Group. Up to 12 reasons can be defined
for a group.

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.

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.

6.1.11 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 6-28.
Figure 6-28 USER LOG ON Screen.
Table 6-27 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.
6.1.12 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.
6.1.13 On-Line Manual

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

6.1.14 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 6-29.
2 3 4 5 6
Figure 6-29 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.
6.1.15 Screen Keys

There are nine main screen groups accessed using the screen keys. Refer to
Figure 6-30. 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 6-30 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 6-28 describes the
screen groups and tabs. Screen groups and tabs shown in brackets are optional items.

Table 6-28 Machine Screens.
Screen
Screen Group Screen/Tab Name To View the Screen
Key
ALARMS Press <ALARMS> key to display

the ALARMS screen.
EVENTS HISTORY Press <ALARMS> key and

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

SELECTION select the tab to 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

SPECIFICATIONS display the MACHINE
SPECIFICATIONS screen.
Machine CYCLE TIME Press <MACHINE> key and

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

GRAPH screen.
PRODUCTION Press <PRODUCTION> key to

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

MOLD SETUP screen.
MOLD Press <PRODUCTION> key and

INSTALLATION select the tab to display the
MOLD INSTALLATION screen.

Screen
Key
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.
EJECTOR/CORE Press <MOLD FUNCTIONS>

key to display the EJECTOR/
CORE screen.
EJECTOR SETUP Press <MOLD FUNCTIONS>

Mold Functions key and select the tab to display
the EJECTOR SETUP screen.
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

Injection INJECTION screen.
INJECTION GRAPH Press <INJECTION> key and

INJECTION GRAPH screen.
RECOVERY Press <INJECTION> key and

RECOVERY screen.
RECOVERY Press <INJECTION> key and

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

VALVES STATUS screen.

Screen
Key
BARREL Press <HEATS> key to display

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

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

NOZZLE TIPS screen.
(THERMOLATOR) Press <HEATS> key and select

THERMOLATOR screen.
(Product Handling) – –
(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

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

GROUP screen.
(SETUP) Press <SPC> key and select the

SETUP screen.
(CTRL LIMITS) Press <SPC> key and select the

tab to display the optional CTRL
LIMITS screen.

6.1.16 Manual Function Keys
Figure 6-31 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 6-29 describes the manual function keys.
Table 6-29 Manual Function Keys.
Key Function
Press the <MOLD OPEN> key to open the mold.
Press the <MOLD CLOSE> key to close the mold.
Press the <UNCLAMP> key to retract the clamp piston and

disengage the shutter.
Press the <CLAMP UP> key to engage the shutter.

NOTE: Ensure the mold is in the closed position prior to
clamping up.
Press the <EJECTOR BACK> key to retract the mechanical

ejector in Manual mode.
NOTE: Enable for Auto mode.
Press the <EJECTOR FORWARD> key to extend the

mechanical ejector in Manual mode.
Press the optional <MOLD COOLING> key to open and close

the mold cooling water valve.

Table 6-29 Manual Function Keys.
Key Function
Press the optional <VALVE GATE OPEN> key to open the mold
valve gate.
Press the <INJECT> key to move the injection piston and screw
forward.
NOTE: The optional nozzle shutoff valve opens if it is selected.
Press the <SCREW ROTATE> key to rotate the screw and

plasticize.
Press the <CARRIAGE FORWARD> key to move the injection

carriage forward.
Press the <CARRIAGE BACK> key to move the injection

carriage back.

6.1.17 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.
6.1.17.1 Field Types

There are several types of fields that can appear on the screens and tabs. Table 6-30
summarizes the different field types and their features.
Table 6-30 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 White The input value can be selected from a pre-
box 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.

6.1.17.2 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 6-32 for details.
10
3
9
7 8
6
Figure 6-32 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
6.1.17.3 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 6-33 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
4
5
Figure 6-33 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
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.
6.1.17.4 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 6-34 for details.
1 3
Figure 6-34 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

6.1.17.5 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 6-35 for details.
3 5
4 6
Figure 6-35 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.
6.1.17.6 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 6-36 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 6-36 COLOR Screen.

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

6.1.17.7 Common Buttons

Many HMI screens and tabs contain the same type of button which can be used to
perform a specific action. Table 6-31 summarizes the common buttons and their
features.
Table 6-31 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.

6.1.18 User Access

User access to machine operation is restricted to one of two methods:
• Log on via user name and password. Refer to Section 6.1.11.
• Log on via datakey. Refer to Section 6.1.18.3.
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 6-32:
Table 6-32 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 9 9 9 9 9
certain 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 6.1.10 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.

6.1.18.1 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.
6.1.18.2 Default User Names and Passwords

Each machine ships from Husky with the following default user names and passwords
– refer to Table 6-33. 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 6-33 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.
6.1.18.3 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 6-37.
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 6-37 Control Panel.

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

Machine Manual Starting Machine
Chapter 7 Starting Machine
This chapter discusses basic machine start-up procedures.

1. Powering Up – see Section 7.1
2. Logging On – see Section 7.2
3. Checking Safety Devices – see Section 7.3
4. Oil Warming – see Section 7.4
5. Checking/Resetting Alarms – see Section 7.5
6. Checking Machine Functions – see Section 7.6
7. Installing Mold – see Section 7.7
8. Recalling Machine Setups – see Section 7.8
9. Configuring Mold Functions – see Section 7.9
10. Checking Robot Functions – see Section 7.10
11. Checking Mold Function Keys – see Section 7.11
12. Setting Up/Checking Clamp – see Section 7.12
13. Turning Heats On – see Section 7.13
14. Opening Process Material Feed – see Section 7.14
15. Setting Up/Checking Injection – see Section 7.15
16. Purging Barrel Before Production – see Section 7.16
17. Cleaning Nozzle Tip & Purge Guard – see Section 7.17
18. Cycling & Fine-tuning Machine – see Section 7.18
19. Setting Up SPC – see Section 7.19
20. Saving Machine Setups – see Section 7.20
21. Starting Production – see Section 7.21
22. Logging Off – see Section 7.22
v 3.02 - March 2003 7–1

7.1 Powering Up
Power up the machine using the following instructions.

1. Switch the main machine breakers Q1M (1) and Q3M (2) to the ON position to
switch on the power. Refer to Figure 7-1.
2. If the machine is equipped with mold heats, switch the main mold breaker Q2M (3)
to the ON position to switch on the mold power supply.
breaker controls both the machine and mold heats power.
2
3
1
S01-101110.eps
Figure 7-1 Powering Up (Typical).

1. Main machine breaker Q1M 2. Main machine breaker Q3M 3. Mold heats breaker
Q2M
3. 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 7-2.
Powering Up 7–2 v 3.02 - March 2003

Figure 7-2 Patent Screen.

1. Continue button
4. Check the air supply is turned on. If necessary, turn the shutoff lever (1) to turn on
the air supply. Refer to Figure 7-3.
Check air pressure is approximately 0.6 MPa (90 psi).
1
S01-101075.eps

1. Shutoff lever
7.2 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.
v 3.02 - March 2003 7–3 Logging On

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 7-4.
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 7-4 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 7-5.
NOTE: The datakey must remain in the slot to access machine functions.
After logging on to the machine, refer to Section 7.3.
Figure 7-5 Datakey.

1. Datakey 2. Datakey slot
Logging On 7–4 v 3.02 - March 2003

7.3 Checking Safety Devices
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.
7.3.1 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 7-6.
S01-101042.eps
Figure 7-6 Emergency Stop Button (Typical).
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. Turn the button clockwise to reset the Emergency Stop.
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.
v 3.02 - March 2003 7–5 Checking Safety Devices

7.3.2 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 7-7.
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 7-7 Front Operator’s Gate and Rear Guard (Typical).
7.3.3 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 7-8.
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.
Checking Safety Devices 7–6 v 3.02 - March 2003

Y195SV
S4PX
S01-101044.eps
Figure 7-8 Mechanical Safety Device.
7.3.4 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:

1. Remove the cap from the gauge port marked “PP6G” in the power manifold
assembly (1). Attach a hydraulic pressure gauge (2) to the gauge port – refer to
Figure 7-9.
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.
v 3.02 - March 2003 7–7 Checking Safety Devices

S01-101036.eps
2
Figure 7-9 Power Manifold (Typical).

1. Power manifold assembly 2. Pressure gauge 3. Manual dump valve
Checking Safety Devices 7–8 v 3.02 - March 2003

7.3.5 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 7-10. 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.
Figure 7-10 Purge Guard (Typical). S01-101045a.eps
1. Purge guard
After checking safety devices, refer to Section 7.4.
7.4 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 45.5oC (114 oF).
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 7-11. Table 7-1
outlines oil temperature screen messages and required actions.
v 3.02 - March 2003 7–9 Oil Warming

Figure 7-11 Status Bar.

1. Oil Temperature
Table 7-1 Oil Temperature Summary
Temperature Temperature
Screen Message Action
°C °F
Greater than Greater than Oil Temperature Too Finish cycle or 5 minutes -
60 140 High for Operation – whichever comes first. Stop
Pump Off pump load. Stop pump.
58 - 60 136 - 140 Oil Temperature Too 5 minute timer. Finish cycle when
High for Auto Cycle – timer expires.
Auto Cycle Will Be
Disabled in 5 minutes
Oil Temperature Too Pumps remain running. Manual

High for Auto Cycle motion permitted.
55 - 58 130 - 136 Oil temperature Too 30 minute timer. Finish cycle

High for Auto Cycle – when timer expires.
Auto Cycle Will Be
Disabled in 30 Minutes
Oil Temperature Too Pumps remain running. Manual

High for 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 Manual and Auto Cycle not

Low – in Oil Warming permitted. Oil warming in
progress.
Less than 5 Less than 40 Oil Temperature Too Pump motor will not start.
Low to Start Pump
Motor
After warming oil, refer to Section 7.5.
Oil Warming 7–10 v 3.02 - March 2003

7.5 Checking/Resetting Alarms
7.5.1 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 7-12.
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 7-12 Alarm Screens.

1. ALARMS screen 2. EJECTOR/CORE screen 3. Clear inactive Alarms button
v 3.02 - March 2003 7–11 Checking/Resetting Alarms

7.5.2 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 7.13 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 oC (117
o
F)
• “Accumulator Charging in Progress” – deactivates a few seconds after pressing
<PUMP MOTOR ON> key when the accumulator is charged up.
Refer to Section Table 7-2 for a list of alarms that prevent machine operation.
Table 7-2 Alarms
Alarm Resolution
Hydraulic Pump Motor Off Press the <PUMP MOTOR ON> key to resolve the alarm.
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.
NOTE: The limit switch must be tripped before the alarm can
be reset.
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.
NOTE: The limit switch must be tripped before the alarm can
be reset.
Injection Positions Not Recalibrate the injection piston and carriage positions. Refer to
Calibrated Section 9.2.43.3, and Section 9.2.43.4 respectively to resolve
the alarm.
Core Setup Mode Error Press the <MOLD FUNCTIONS> key to display the EJECTOR/
CORE screen. The borders of the affected mold function button
are red in color.
After checking and resetting alarms, refer to Section 7.6.
Checking/Resetting Alarms 7–12 v 3.02 - March 2003

7.6 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.
8. If the injection carriage is out of calibration, it may not be possible to move the
carriage. If necessary, refer to Section 9.2.43.4.
9. Check for any leaks in the hydraulic hoses, cylinders and manifolds throughout the
machine.
After checking machine functions refer toSection 7.7. If mold is already installed on the
machine and calibrated, refer to Section 7.8.
v 3.02 - March 2003 7–13 Checking Machine Functions

7.7 Checking and Installing Mold
7.7.1 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 tie bars, 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.
7.7.2 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.
Checking and Installing Mold 7–14 v 3.02 - March 2003

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.
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.
6. Perform Lockout/Tagout procedure – refer to Section 1.7.1.

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 7-13.
1
S01-100581.eps
Figure 7-13 Ejector Rods (Typical).

1. Ejector rods
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 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 7-18.
10. Refer to the following Installations.
• "One Piece Mold Installation" on page 7–16
• "Multiple Piece Mold Installation" on page 7–22
• "Previously Installed Mold" on page 7–29
v 3.02 - March 2003 7–15 Checking and Installing Mold

7.7.2.1 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 7-14.
2. Press the Start button on the Mold Installation screen. Refer to Figure 7-14.
Figure 7-14 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 7-15.
Figure 7-15 Mold Setup

1. Accept Button

4. The HMI displays the carriage jump back screen. Refer to Figure 7-18.
a. Select Yes or No depending on mold application (1).
b. Press the Accept button (2).
Figure 7-16 Jump Back Screen

1. Radio Button 2. Accept Button
5. The HMI displays the mold installation option screen. Refer to Figure 7-17.
a. Select one piece installation (1).
b. Press the Accept Button (2).
Figure 7-17 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.

S01-100582.eps
Figure 7-18 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 Lockout/Tagout. Refer to Section 1.7.2.

12. Review instructions on HMI screen. Refer to Figure 7-19.

Close the mold.
Figure 7-19 Instruction Screen
13. Review instructions on HMI screen. Refer to Figure 7-19.

Press the Accept button.

1. Accept Button

14. HMI Calibrating Mold screen displays. Refer to Figure 7-21.
Figure 7-21 Calibration Screen
15. HMI Clamp-up screen displays. Refer to Figure 7-22.

a. Follow instructions on screen.
b. Press the Accept button.
Figure 7-22 Clamp-up and Unclamp

1. Accept Button

16. HMI displays for ejector core option. Refer to Figure 7-37.
Depending on the mold:
a. Select the Auto Sequence (1).
Press the Accept button (2).
or
b. Leave Auto Sequence unselected.
Figure 7-23 Ejector Core

1. Auto Sequence 2. Accept button
17. HMI Installation Complete displays with message.

• "Auto sequence in Manual not selected..." Refer to Figure 7-24.
• "Auto sequence in Manual is selected..." Refer to Figure 7-38.
Figure 7-24 Installation Complete

7.7.2.2 Multiple Piece Mold Installation

Complete the following procedures for separate mold plate installation. Refer to the
Manufacturers Mold Manual for specific installation procedures.
Figure 7-25.
2. Press the Start button on the Mold Installation screen. Refer to Figure 7-25.
Figure 7-25 Mold Installation

1. Start Button 2. Data Entry Fields
3. Refer to Instructions on screen. Refer to Figure 7-26.

Press the Accept button.
Figure 7-26 Mold Setup

1. Accept Button

4. The HMI displays the carriage jump back screen. Refer to Figure 7-27.
a. Select Yes or No depending on mold application (1).
Figure 7-27 Jump Back Screen

1. Radio Button 2. Accept Button
5. The HMI mold installation option screen displays. Refer to Figure 7-17.
a. Select multiple pieces (1).
b. Press the Accept Button (2).
Figure 7-28 Type of Installation

1. Multiple Piece Installation 2. Accept Button

WARNING!
Crushing hazard - risk of death or serious injury. Perform Lockout/Tagout
procedure in accordance with local codes.
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 conditions.
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 7-29 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 7-30.
a. Select "Follow programmed sequence..." (1).
or
b. Select "Ignore programmed sequence..." (2).
Press the Accept button (3), go to step 11..

Figure 7-30 Program Option

1. Follow Sequence 2. Ignore Sequence 3. Accept Button
9. Follow instructions on screen. Refer to Figure 7-31.

a. Check mold shutheight and enter measurement (1).
b. Press the Accept button.
Figure 7-31 Shutheight

1. Shutheight Measurement 2. Accept Button

10. HMI displays the ejector core option. Refer to Figure 7-32.
a. Select Auto sequence (1).
or
b. Leave Auto sequence unselected.

11. New screen displays. Follow instructions on screen. Refer to Figure 7-33.
Figure 7-33 Mold Close Instructions

12. Confirm mold is closed on the HMI screen and press the Accept button (1). Refer
to Figure 7-34.
Figure 7-34 Confirm Mold Closed

1. Accept Button
13. HMI screens displays for calibrating mold. Refer to Figure 7-35.
Figure 7-35 Calibration Screen
14. HMI Clamp-up screen displays. Refer to Figure 7-22.

a. Follow instructions on screen.
b. Press the Accept button

Figure 7-36 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 7-37.
or



• "Auto Sequence in Manual selected..." Refer to Figure 7-38.
• "Auto Sequence in Manual not selected..." Refer to Figure 7-46.

1. Auto Sequence
7.7.2.3 Previously Installed Mold

The following procedures can be used on molds already installed in the machine.
Figure 7-39.
2. Select, Calibrate Previously Installed Mold (2). Refer to Figure 7-39.
3 2
Figure 7-39 Start Calibration

1. Data Entry Fields 2. Calibrate Button 3. Accept Button

3. HMI Programmed Sequence screen displays. Refer to Figure 7-40.

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 7-25, then
proceed to step 5. on Page 7-31.
Figure 7-40 Programmed Sequence

1. Follow Sequence 2. Ignore Sequence 3. Accept Button
4. HMI instructional screen displays. Refer to Figure 7-41.

a. Read instructions.

1. Accept Button

5. HMI message displays. Refer to Figure 7-42.
Figure 7-42 Ready to Calibrate
6. HMI message displays. Refer to Figure 7-43.

a. Read message and perform procedure.
Figure 7-43 Check Mold

1. Accept Button

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

Figure 7-45.
or
Figure 7-45 Auto/Manual Sequence Screen

1. Auto Sequence 2. Accept Button


• "Auto sequence in Manual not selected..." Refer to Figure 7-46.
• "Auto sequence in Manual is selected..." Refer to Figure 7-38.
7.8 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 7.9.
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 7.20.
NOTE: You cannot recall machine setups if you do not have suitable user access
rights.
NOTE: The machine must be idle to recall the machine setup.
NOTE: 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.
v 3.02 - March 2003 7–33 Recalling Machine Setups

Figure 7-47 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 7-47):
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 7.8.1.
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.
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.
Recalling Machine Setups 7–34 v 3.02 - March 2003

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.

7.8.1 Copying Machine Setups

If copying machine setup from a diskette, insert a diskette containing previously saved
machine setups into the floppy drive in the PC. Open the panel (1) on the electrical
cabinet (2) to access the floppy drive. Refer to Figure 7-48.
CAUTION!
Risk of damage to software and PC hardware. Scan diskette for viruses before
using in machine.
S01-101100.eps
Figure 7-48 Accessing the Floppy Drive.

1. Panel 2. Electrical cabinet
NOTE: You cannot copy machine setups if you do not have suitable user access
rights.
NOTE: 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.
NOTE: 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 permanent storage device such as the local hard disk or a floppy
diskette or a network 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 7-47, item 1).
2. Touch the Copy Setup button (refer to Figure 7-47, item 4) to display the COPY
MOLD SETUP pop-up window – refer to Figure 7-49.
Recalling Machine Setups 7–36 v 3.02 - March 2003

Figure 7-49 COPY MOLD SETUP Pop-up Window.

1. Source icons 2. Machine setup files 3. Destination icons
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.
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 7.9.

7.9 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.
7.9.1 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).
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.
1
2
3
4 5
Figure 7-50 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
4. Press the Calibration button on the toolbar to display the CALIBRATION screen.
5. Press the Ejector button.
Configuring Mold Functions 7–38 v 3.02 - March 2003

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

Figure 7-51.
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".
Figure 7-51 EJECTOR CALIBRATION Screen.

1. Start button 2. Measured Ejector Position field 3. OK button
8. Select the EJECTOR/CORE tab (1). Refer to Figure 7-52. 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 3.02 - March 2003 7–39 Configuring Mold Functions

Figure 7-52 Setting Up Mold Functions, Air and Valve Gates.

1. EJECTOR/CORE tab 2. AIR tab 3. VALVE GATES tab
7.9.1.1 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 7.10.
Configuring Mold Functions 7–40 v 3.02 - March 2003

7.10 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 7.11.
7.11 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 7.12.
7.12 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 7.13.
7.13 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 7-53.
v 3.02 - March 2003 7–41 Checking Robot Functions

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.
1 5
2
3
Figure 7-53 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 7-54.
NOTE: You must have access rights to use the Zone Setup screens.
7. Enter suitable values in the High Alarm (1) and Low Alarm (2) fields.
8. Select Auto (3) or Manual (4) radio button, Auto Tune Enable (5) and
Thermocouple Enable (6) check boxes, if applicable.
Turning Heats On 7–42 v 3.02 - March 2003

1
2
3
4
5
6
Figure 7-54 SETUP MACHINE HEATS Screen.

1. High Alarm field 2. Low Alarm field 3. Auto radio button 4. Manual radio button
5. Auto Tune Enable check box 6. Thermocouple Enable check box
7.13.1 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 7-55.
v 3.02 - March 2003 7–43 Turning Heats On

2
3
Figure 7-55 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 7-56.
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) radio button, Auto Tune Enable (5), Thermocouple
Enable (6), and Enable (7) check boxes, as required.
1
2
3
4
5
6
7
Figure 7-56 SETUP MOLD HEATS Screen.

1. High Alarm field 2. Low Alarm field 3. Auto radio button 4. Manual radio button
5. Auto Tune Enable check box 6. Thermocouple Enable check box 7. Enable check
box
Turning Heats On 7–44 v 3.02 - March 2003

7.13.2 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).
2
3
Figure 7-57 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 7.14.
v 3.02 - March 2003 7–45 Turning Heats On

7.14 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 7-58.
2. If the machine is equipped with a direct feed system (2), open the feed lines to the
machine.
S01-100032
1 2
Figure 7-58 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).
Opening Process Material Feed 7–46 v 3.02 - March 2003

7.14.1 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 7-59.
2. Push the slider until the detent pin in the knob locks.
3. Tighten the knob.
1 2
S01-100133.eps
Figure 7-59 Process Material Feed Manual Shutoff.

1. Manual shutoff knob 2. Slider
7.14.2 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 7-60.
2. Select the Hopper Open check box (2).
v 3.02 - March 2003 7–47 Opening Process Material Feed

Figure 7-60 Process Material Feed Auto Shutoff.

1. RECOVERY tab 2. Hopper Open check box
7.14.3 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 7-61.
1
S01-100033
Figure 7-61 Opening Magnet Drawer.

1. Magnet drawer handle
After opening process material feed, refer to Section 7.15.
Opening Process Material Feed 7–48 v 3.02 - March 2003

7.15 Setting Up/Checking Injection
Set up injection, hold and recovery parameters using the instructions below.
7.15.1 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 7-62.
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 – Time (6), Position (7), or Hydraulic
Pressure (8). Then enter a suitable value in the field adjacent to each selected
check box.
5. Select the Cooling Time (9), and Max Fill Pres. (10) fields and enter suitable
values, as required.
6. If required, select the Excess Injection (11) field, and enter a suitable value.
4
2
5
3
9 10
6 11
7
8
Figure 7-62 INJECTION Tab.

1. INJECTION tab 2. Speed Profile field 3. Position Profile field 4. Pressure Profile
field 5. Time Profiles field 6. Time check box 7. Position check box 8. Hydraulic
Pressure check box 9. Cooling Time field 10. Max Fill Pres. field 11. Excess injection
field
v 3.02 - March 2003 7–49 Setting Up/Checking Injection

7.15.2 Setting Up Recovery Parameters

Set up recovery parameters using the instructions below.
1. Select the RECOVERY tab (1). Refer to Figure 7-63.
2. Select the Speed (2), Position (3), and Back Pressure (4) Profile fields and enter
suitable values.
3. Enter Pre-Pullback (5) and Post-Pullback (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.
2
3
4
5 6
11
12
7 9
8
10
Figure 7-63 RECOVERY Tab.

1. RECOVERY tab 2. Speed field 3. Position field 4. Back Pressure field 5. Pre-
Pullback field 6. Post-Pullback 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 7.16.
Setting Up/Checking Injection 7–50 v 3.02 - March 2003

7.16 Purging Barrel Before Production
Purge the barrel before production using one of the following methods:
• Manual purging
• Auto purging
7.16.1 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.
v 3.02 - March 2003 7–51 Purging Barrel Before Production

6. Press and hold the <CARRIAGE FORWARD> key until the carriage is in the purge
zone.
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 7-65
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.
Figure 7-65 INJECTION Tab.

1. INJECTION tab 2. Injection position value

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.
Purging Barrel Before Production 7–52 v 3.02 - March 2003


1. RECOVERY tab
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.

7.16.2 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.
Figure 7-67 Auto Purging the Barrel.

1. BARREL screen 2. Barrel temperature field

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.
Purging Barrel Before Production 7–54 v 3.02 - March 2003


1. RECOVERY tab 2. Auto Purge Cycles field 3. Hopper Open check box
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.

7.17 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 7-69.
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.
Cleaning Nozzle Tip & Purge Guard 7–56 v 3.02 - March 2003
S01-100988.eps
2
Figure 7-69 Cleaning Nozzle Tip and Purge Guard.

1. Purge guard 2. Molten material
After cleaning the nozzle tip and purge guard, refer to Section 7.18.
7.18 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 7.19.
v 3.02 - March 2003 7–57 Cycling and Fine-tuning Machine

7.19 Setting Up SPC (Optional)
Set up SPC after the process has stabilized. Refer to Appendix A to set up and run
SPC quickly.
After setting up optional SPC, refer to Section 7.20.
7.20 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 removeable media, refer to Section 7.8.1.
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.
Figure 7-70 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.
Setting Up SPC (Optional) 7–58 v 3.02 - March 2003

3. Touch the Save Setup button (Figure 7-70, item 2) to display the SAVE MOLD
SETUP pop-up window – refer to Figure 7-71.
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 7-71 SAVE MOLD SETUP Pop-up Window
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.
v 3.02 - March 2003 7–59 Saving Machine Setups

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).
7.21 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.
7.22 Logging Off
Once the machine has been set up, the operator can log off the machine, and the
machine will run unattended. Section 7.22.1, and Section 7.22.2.
7.22.1 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 7-72.
The HMI displays the message “Are you sure you want to log off?”
2. Press the Yes button to log off the machine.
Figure 7-72 Log Off Button.

1. Log Off button
7.22.2 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 7-73.
Starting Production 7–60 v 3.02 - March 2003

Figure 7-73 Datakey.

1. Datakey
v 3.02 - March 2003 7–61 Logging Off

v 3.02 - March 2003

Machine Manual Stopping Machine
Chapter 8 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
v 3.02 - March 2003 8–1

8.1 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 8-1.
2. After clearing any problems, turn the button clockwise to reset the Emergency Stop
(2).
3. Restart the machine as usual. Refer to Chapter 7—Starting Machine.
S01-101089.eps
S01-101063.eps
1 2
Figure 8-1 Emergency Stop Button (Typical).

1. Pushing the Emergency Stop button 2. Resetting the Emergency Stop button
Stopping Machine in an Emergency 8–2 v 3.02 - March 2003

8.2 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 8.3.3.
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 8-2.
3. Select the Standby check box (2) to reduce machine heats.
Figure 8-2 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 8-3.
5. Select the Standby check box (2) to reduce mold heats.
v 3.02 - March 2003 8–3 Pausing Machine

Figure 8-3 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 8-4.
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.
Figure 8-4 NOZZLE TIPS Tab.

1. NOZZLE TIPS Tab 2. Standby check box
When ready to start production, restart the machine as usual. Refer to Chapter 7—
Starting Machine.
Pausing Machine 8–4 v 3.02 - March 2003

8.3 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 8.3.1
2. Shut Off Process Material – refer to Section 8.3.2
3. Purging Barrel After Production – refer to Section 8.3.3
4. Cleaning Nozzle Tip and Purge Guard – refer to Section 8.3.4
5. Emptying Hopper (optional) – Section 8.3.5
6. Turning Heats Off – refer to Section 8.3.6
7. Cleaning Mold – refer to Section 8.3.7
8. Turning Mold Cooling Off (optional) – refer to Section 8.3.8
9. Removing Mold (optional) – refer to Section 8.3.9
10. Turning Pumps Off – Section 8.3.10
11. Turning Air Off (optional) – Section 8.3.11
12. Powering Down (optional) – refer to Section 8.3.12
8.3.1 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.
8.3.2 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 8-5.
2. Shut off external process material supply to the hopper or direct feed tube.
v 3.02 - March 2003 8–5 Stopping Machine in a Controlled Manner

S01-100135.eps
Figure 8-5 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 8-6.
4. Deselect the Hopper Open check box (2).

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 8-7.
Stopping Machine in a Controlled Manner 8–6 v 3.02 - March 2003

6. Pull the slider until the detent pin in the knob locks it in the first position after the
feed throat. Tighten the knob.
S01-100126.eps
Figure 8-7 Manual Shutoff Knob (Typical).
1. Manual shutoff
8.3.3 Purging Barrel After Production

Purge the barrel after production using one of the following methods:
• Manual Purging – refer to Section 7.16.1
• Auto Purging – refer to Section 7.16.2
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 8-8 Purging Barrel.

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

Clean the nozzle tip and purge guard after purging the barrel – refer to Section 7.17.

8.3.5 Emptying Hopper

Empty the hopper or direct feed tube, when necessary, using the following instructions.
Otherwise, refer to Section 8.3.6.
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 8-9.
1
S01-100127.eps
Figure 8-9 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 8-10.
5. Select the Hopper Open check box (2).


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 8-11.
1
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.

8.3.6 Turning Heats Off

Turn off machine heats, mold heats, and nozzle tip heats using the following
instructions.
8.3.6.1 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
8.3.6.2 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 8-13.
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 8-13 MOLD Tab.

1. MOLD tab 2. Mold Heats Enable check box
8.3.6.3 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 8-14 NOZZLE TIPS Tab.

1. NOZZLE TIPS tab 2. Nozzle Heats Enable check box
8.3.7 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.
8.3.8 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.
8.3.9 Removing Mold

If it is necessary to remove the mold, use the following instructions. Otherwise, refer to
Section 8.3.10.
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 8-15.
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
2
S01-100585.eps
1
6
Figure 8-15 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. Press and hold the <MOLD CLOSE> key to close the mold.
WARNING!
Crushing hazard – risk of death or serious injury. Install safety latches and a
lifting eye bolt before removing mold. Use suitable lifting equipment, and ensure
that the mold is level and balanced as it is hoisted.
9. Remove the bolts (5) holding the mold to the moving platen.
10. Press the <MOLD OPEN> key and move the moving platen out of the way.
11. Remove the bolts (6) holding the mold to the stationary platen.
12. Hoist the mold out of the machine and set it on a clean working surface. Refer to
the mold manual for storage instructions.

8.3.10 Turning Pumps Off

Turn off the pumps using the following instructions.
1. Press the <PUMP MOTOR OFF> key to shut off all pumps.
8.3.11 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 8-16.
1
S01-101075.eps
Figure 8-16 Turning Air Off.

1. Shutoff lever

8.3.12 Powering Down

Power down the machine using the following instructions.
1. Switch the main machine breakers Q1M (1) and Q3M (2) to the OFF position to
switch off the power supply. Refer to Figure 8-17.
2. If the machine is equipped with mold heats, switch the mold heats breaker Q2M (3)
to the OFF position to switch off power.
2
3
1
S01-101110.eps
Figure 8-17 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 Section 9.1.
8.4 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 7—Starting Machine.
v 3.02 - March 2003 8–17 Unexpected Machine Stoppage

v 3.02 - March 2003

Machine Manual Maintenance
Chapter 9 Maintenance
This chapter contains a maintenance schedule, and maintenance procedures for all
preventative and corrective maintenance tasks.
9.1 Maintenance Schedule
Table 9-1 shows the daily, weekly, monthly, quarterly, semi-annual and annual
maintenance schedule.
Table 9-1 Maintenance Schedule – Hylectric Machines.

Item Frequency Task Description Reference
1 Daily Drain water in air regulator Section 9.2.1
2 Daily Clean nozzle tip, stationary platen, and purge guard Section 7.17
3 Daily Check machine safety devices Section 7.3
4 Daily Clean the machine and HMI Section 9.2.2
5 Weekly Check accumulator precharge (NOTE: This check needs Section 9.2.3
to be performed once at the end of the first week after
charging the accumulator)
6 Weekly Check hydraulic tank oil quality (NOTE: This check needs Section 9.2.20
to be performed once at the end of the first week after
filling the hydraulic tank)
7 Weekly Checking Oil Filter Section 9.2.6
8 Weekly Inspect and clean magnet drawer Section 9.2.8
9 Weekly Inspect and clean hopper, optional hopper magnet Section 9.2.8
10 Weekly Check oil recovery pocket Section 9.2.10
11 Monthly Check electrical components Section 9.2.11
12 Monthly Check all hydraulic cylinders, valves, and manifolds Section 9.2.12
13 Monthly Check all hydraulic hose assemblies and fittings Section 9.2.13
14 Monthly Check system pressure Section 9.2.15
15 Monthly Check all cooling water components Section 9.2.16
16 Monthly Check all pneumatic valves and hoses Section 9.2.17
17 Monthly Lubricate mold stroke column guide bushings Section 9.2.18
18 Monthly Lubricate locking cylinder rod ends Section 9.2.19
19 Quarterly Check accumulator precharge Section 9.2.3
v 3.02 - March 2003 9–1 Maintenance Schedule

Table 9-1 Maintenance Schedule – Hylectric Machines.

Item Frequency Task Description Reference
20 Quarterly Check oil quality in the hydraulic tank Section 9.2.20
21 Quarterly Check oil level in the hydraulic tank Section 9.2.21
22 Quarterly Check gearbox oil level Section 9.2.24
23 Quarterly Check electric motor Section 9.2.26
24 Quarterly Check mold stroke column guide bushings Section 9.2.27
25 Quarterly Check optional nozzle shutoff bushings and pins Section 9.2.28
26 Semi-annual Lubricate linear bearings – moving platen (H/HL225 - H/ Section 9.2.30
HL500)
27 Semi-annual Lubricate linear bearings – optional stack mold carrier Section 9.2.31
28 Semi-annual Lubricate linear bearings – injection piston Section 9.2.32
29 Semi-annual Replace oil filter element Section 9.2.33
30 Semi-annual Check carriage cylinder bushings and pins Section 9.2.34
31 Annual Level machine and adjust nozzle concentricity Section 9.2.35
32 Annual Replace breather cap filter element Section 9.2.36
33 Annual Replace air filter element Section 9.2.37
34 Annual Lubricate pump motor bearings Section 9.2.38
35 Annual Replace gearbox oil Section 9.2.25
36 Annual Replace the ITT water saver valve diaphragm Section 9.2.39
37 As required Replace hydraulic oil Section 9.2.22
38 As required Check safety devices (NOTE: This check needs to be Section 9.2.40
performed after upgrading software or performing
maintenance on an interlock component)
39 As required Replace heater band Section 9.2.41
40 As required Change the plasticizing screw and check valve Section 9.2.42
41 As required Calibrate the machine Section 9.2.43
Maintenance Schedule 9–2 v 3.02 - March 2003

9.2 Maintenance Procedures
9.2.1 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 9-1.
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
9.2.2 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.
v 3.02 - March 2003 9–3 Maintenance Procedures

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.
9.2.3 Checking Accumulator Precharge
Special Tools Required
1 Accumulator charging kit (Part number 732452)
Refer to Section 2.12 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 9-2.
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).
Maintenance Procedures 9–4 v 3.02 - March 2003

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.
8. Note the accumulator precharge pressure.
9. If necessary, adjust the precharge pressure – refer to Section 9.2.4. 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.
13. Remove Lockout/Tagout – refer to Section 1.7.2.
5
1
9
8
2
6
3
7
4
S01-101035.eps
Figure 9-2 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

9.2.4 Precharging the Accumulators
Special Tools/ Materials Required
2 Nitrogen gas (at least 99.995% pure)
Refer to Section 2.12 for accumulator capacity and precharge pressure.
Precharge the accumulators using the following instructions:
Precharging/Increasing Precharge Pressure:

Figure 9-3.
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!
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.

5
8
5 11
1 6 7
2 12
3
4
14
13
S01-101034.eps
10
Figure 9-3 Precharging Accumulator (Typical).

10. Charging hose 11. Check valve 12. Shutoff valve 13. Nitrogen tank
14. Accumulator nut
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 9.2.5.
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.

9.2.5 Discharging Accumulator Precharge
Discharge the accumulator precharge using the following instructions:

Figure 9-4.
5
1
9
8
6
2
3
7
4
S01-101035.eps
Figure 9-4 Discharging Accumulator Precharge (Typical).

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.
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.

9.2.6 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 9-5. When
the filter is dirty, the LED is red in color.
If necessary, replace the dirty filter element – refer to Section 9.2.33.
S01-100817.eps
Figure 9-5 Hydraulic Filter.

1. LED 2. Oil Filter

9.2.7 Inspecting and Cleaning Hopper
1. Remove the lid, and clean the inside of the hopper (1) with a clean cloth – refer to
Figure 9-6.
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.
1
S01-101013.eps
Figure 9-6 Hopper and Optional Hopper Magnet (Typical).

1. Hopper 2. Optional hopper magnet

9.2.8 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 8.3.5.
S01-101084.eps
4

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.

9.2.9 Clearing Feed Throat

Clear feed throat using the following instructions:
1. Perform Lockout/Tagout – refer to Section 1.7.1.
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 9-8.
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 9-8 Cleaning Feed Throat (Typical).

1. Knob 2. Slider 3. Feed throat opening

9.2.10 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 9.2.10.1.
9.2.10.1 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 9-9.
3. Clean up any oil, grease, or process material in and around the oil recovery pocket
(2) or (3).
4. Replace the plexiglass panel.
2 3
S01-101106.eps
Figure 9-9 Cleaning Oil Recovery Pocket (Typical).

1. Plexiglass panel 2. Oil recovery pocket 3. Oil recovery pocket

9.2.11 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 1.7.1, then wait 10 minutes

for residual voltage to discharge.
2. Check the electrical cabinet is mounted securely to the base through the vibration
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.
9.2.12 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.

9.2.13 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 9-10. 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 2.13.

S01-101079.eps
Figure 9-10 Inspecting Hose Assemblies.

1. Blister 2. Wear 3. Radial crack
9.2.13.0.1 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 RESITANT
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 RESITANT: 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.

9.2.14 Replacing Hydraulic Hose Assemblies
9.2.14.1 Removing Hydraulic Hose Assemblies

Remove hydraulic hose assemblies using the following instructions:
1. Perform Lockout/Tagout procedure – refer to Section 1.7.
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.
2. Disconnect the hydraulic hose, and drain it into a suitable container.

3. Cap the fitting to prevent oil contamination.
4. Carry out maintenance procedure.
9.2.14.2 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.
2. Reinstall the hose assembly, and torque all connections to Husky specifications –
3. Remove Lockout/Tagout – see Section 1.7.2.
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.
9.2.15 Checking System Pressure
1. Press the <PUMP MOTOR OFF> key to stop the motor.

2. Remove the cap on the gauge port marked “PP6G” on the power manifold located
within the power pack assembly.
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 2.12.
7. Remove the pressure gauge and cap the gauge port.
9.2.16 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.

9.2.17 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 9.2.17.1.
2. Tighten any loose pneumatic hose fittings.
9.2.17.1 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 2.13.
5. Listen for air leaks. If necessary, perform Lockout/Tagout procedure and check the
hose fittings.
9.2.18 Lubricating Mold Stroke Column Guide Bushings

2. Wipe the grease fittings on the four guide bushings (1) – refer to Figure 9-11.
3. Apply food grade grease indicated on Section 2.9 to the grease fittings. Wipe off
any excess grease.

S01-101028.eps
Figure 9-11 Lubricating Mold Stroke Column Guide Bushings.
1. Guide bushing (Typical)
9.2.19 Lubricate Locking Cylinder Rod Ends

2. Wipe the grease fittings on the locking cylinder (1) – refer to Figure 9-12.
S01-101029.eps
Figure 9-12 Lubricating Locking Cylinder Rod Ends.

1. Locking cylinder (Typical)

3. Apply extreme pressure moly grease indicated on Section 2.9 to the two grease
fittings. Wipe off any excess grease.
9.2.20 Checking Hydraulic Tank Oil Quality
1 Hydraulic fluid sampling kit (Part number 742225)
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.
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.
1. Clean the outside of port PP1G (1) in the power manifold and connect the
sampling valve (2) – refer to Table 9-13.
Figure 9-13 Oil Quality

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
(.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 sampling vial with oil, rinse the vial with the oil then dump into the container,
repeat, then fill the vial to within 1 cm (.5 in) of the top.
4. Turn the handle on the sampling valve to fully close the valve.
5. Immediately cap the vial containing the sample to prevent the possibility of external
contaminants.
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.
If sourcing your own fluid analysis service, Husky recommends sending samples to
an independent laboratory that does not hold interests in hydraulic oil sales. For
hydraulic oil parameters, refer to Table 9-2.
Table 9-2 Hydraulic Oil Parameters
Parameter Warning Limit Comments
Viscosity at 40°C 46 ± 10% Indicates oxidation and/or

contamination
Total acid number 1.5 mg KOH/g Indicates oxidation limit
Zinc 50% of new oil level Indicates additive depletion
Phosphorous 50% of new oil level Indicates additive depletion
Calcium 50% of new oil level Indicates additive depletion
Water 250 ppm Promotes increased

oxidation

9.2.21 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 9-14.
If necessary, top up the oil level – refer to Section 9.2.22.2.
S01-101088.eps
Figure 9-14 Oil Level.

1. Sight glass (typical location)

9.2.22 Replacing Hydraulic Oil

Refer to Section 2.7 for hydraulic tank capacity, and Section 2.7 for hydraulic oil
specifications.
9.2.22.1 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 9.2.33.
1. Perform Lockout/Tagout procedure. Refer to Section 1.7.1.
2. Connect the supply hose (1) to the male quick-disconnect fitting (2) – refer to
Figure 9-15.
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. Drain the hydraulic tank.
4. Disconnect the hose.
S01-101112.eps
Figure 9-15 Draining Hydraulic Tank (Typical).

1. Supply hose 2. Male quick-disconnect fitting

9.2.22.2 Filling the Hydraulic Tank

Fill the hydraulic tank using the following instructions:
1. Perform Lockout/Tagout procedure. Refer to Section 1.7.1.
2. Connect the supply hose (1) from the transfer pump to the supplied female quick-
disconnect coupling (2). Refer to Figure 9-16.
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).
4
5
2
1
3
-101017.eps
Figure 9-16 Filling Hydraulic Tank (Typical).

1. Supply hose 2. Female quick-disconnect coupling 3. Male quick-disconnect
coupling 4. Filter 5. Sight glass
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 (5).
This is the “High Level” mark.
5. Disconnect the female quick-disconnect coupling from the filter.
6. Prime the system pump after refilling the tank. Refer to Section 9.2.23.
NOTE: The system pump does not require priming when adding additional oil to
the hydraulic tank.

9.2.23 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 1.7.1.

2. Remove the drain hose (1) at the drain port on the system pump (2) – refer to
Figure 9-17. 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
2.7 for hydraulic oil specifications.
4. Reconnect the drain hose. Check for any oil leaks.
6. Run in the machine – refer to Section 5.4.
2
S01-101018.eps
Figure 9-17 Priming System Pump (Typical).

1. Drain hose 2. System pump

9.2.24 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 9-18.
If necessary, add oil until the oil level reaches the top of the sight glass. Refer to
Section 2.9.2 for gearbox oil specifications.
9.2.25 Replacing Gearbox Oil - Electrical Screw Drive Only
9.2.25.1 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 9-18.
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.

9.2.25.2 Adding Oil

Refer to Section 2.7 for gearbox tank capacity, and Section 2.9.2 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 9-18.
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.
4. Wipe all surfaces clean.
S01-101114.eps
2
Figure 9-18 Lubricating Gearbox (Typical).

1. Sight glass 2. Gearbox 3. Breather cap 4. Overflow plug 5. Drain plug

9.2.26 Checking Electric 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.
9.2.27 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 9-19.
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 9-3.
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 9-3 Guide Bushing Wear.
Minimum Dimension "A" Minimum Dimension "A"

Machine
(mm) (in.)
H90 9.7 minimum 0.38 minimum
H/HL225 to /HL500 15.10 minimum 0.59 minimum
H/HL650 to H/HL1000 19.60 minimum 0.77 minimum

S01-101081.eps
1
Figure 9-19 Guide Bushing (Typical).

1. Screw 2. Bushing
9.2.28 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 9.2.29.

9.2.29 Replacing Optional Nozzle Shutoff Bushings and Pins

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
potential for any pressure build-up. Wear PPE while purging the barrel.
1. Purge the barrel – refer to Section 7.16.

WARNING!
3. Open the purge guard.

4. Remove the pins, and replace the bushings – refer to the engineering drawing.
5. Reassemble the nozzle shutoff mechanism, and lower the purge guard.
9.2.30 Lubricating Moving Platen Linear Bearings (H/HL90 - 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 2.9. Apply the quantity shown in
Table 9-4 to each grease fitting. Do not over-lubricate.
4. Wipe off any excess grease.

S01-101030.eps
2
1
4
3
Figure 9-20 Lubricating Moving Platen Linear Bearings (Typical).

1. Linear bearing 2. Linear bearing 3. Linear bearing 4. Linear bearing
Table 9-4 Grease Quantity for Linear Bearings.
Number of Strokesa b
Machine
16 oz grease gun 24 oz grease gun 0.5 L grease gun
H/HL90 3 2 3
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.

9.2.31 Lubricating Optional Stack Mold Carrier Linear Bearings (H/HL90 - 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 9-21.
CAUTION!
lubricant quantities specified. Also, do not mix different types of lubricants.
3. Use food grade grease indicated on Section 2.9. Apply the quantity shown in
Table 9-4 to each grease fitting. Do not over-lubricate. Wipe off any excess grease.
S01-101031.eps
1
Figure 9-21 Lubricating Optional Stack Mold Carrier Linear Bearings (Typical).
1. Linear bearing 2. Carrier

9.2.32 Lubricating Injection Piston Linear Bearings (RS80 - RS115)

2. Remove the Plexiglas panel (1) on both sides of the injection casting – refer to
Figure 9-22.
S01-101011.eps
Figure 9-22 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 9-5 to each grease
fitting. Do not over lubricate. Wipe off any excess grease.
5. Install the plexiglass panels.
Table 9-5 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
RS80 - RS115 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.

9.2.33 Replacing Oil Filter Element
Table 9-6 Spare Parts.
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.
1. Perform Lockout/Tagout. Refer to Section 1.7.1.
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 9-23.
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.

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 9-23 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

9.2.34 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 9-24.
S01-101082.eps
Figure 9-24 Carriage Cylinder Bushings and Pins (Typical).
1. Bushing 2. Pin

9.2.35 Leveling Machine and Adjusting Nozzle Concentricity
1 Precision level (1 division = 0.05 mm/m or 0.006 in/10 in)
2 Heavy duty straight edge 1 m (39 in) long minimum
3 Matched set of Vee blocks 60 mm (2.37 in) high
4 Inside vernier caliper capable of measuring up to 200 mm
Machine leveling directly affects product quality and machine wear. Although each
machine undergoes extensive leveling adjustments during the factory test, variations
in the floor level at the operating site require some of these tasks to be repeated.
Husky recommends checking level after every mold change.
Level the machine and check nozzle concentricity in the following order:
1. Level the clamp unit – refer to Section 9.2.35.1.
2. Level the injection unit and adjust nozzle concentricity – refer to Section 9.2.35.2.
3. Check nozzle concentricity (while leveling the injection unit) – refer to Section
9.2.35.3
4. Level the power pack – refer to Section 9.2.35.4.
5. Level the electrical cabinet – refer to Section 9.2.35.5.
6. Level the pump assembly – refer to Section 9.2.35.6.
CAUTION!
Risk of damage to the machine. The machine must be level to within a tolerance
of 0.15 mm per m (0.0018 in per ft). Failure to level the machine to specified
tolerances can impair machine performance, and increase component wear. To
ensure proper level, do not level the machine until the hydraulic tank is filled,
and the mold is installed.
9.2.35.1 Leveling the Clamp Unit

Level the clamp unit lengthwise and side-to-side using the following instructions.
NOTE: Levelling must be performed with the mold installed.
NOTE: Do not use the tiebars as a reference surface to level the clamp.
1. Loosen the mounting bolts that connect the injection base to the clamp base.
2. Make sure the moving platen is in its mold shutheight position, with no leader pin or
mold contact.

3. Place a precision level at the end of the guide rail on the operator’s side, and note
the level (ref. L1, Table 9-7). Adjust the levelling mounts as necessary until level
per specification.
4. Place a precision level at the opposite end of the guide rail on the operator’s side
(ref. L2, Table 9-7). Adjust the levelling mounts as necessary until level per
specification.
5. Repeat steps 3 and 4 on the Non-operator’s side.
6. Place a set of Vee blocks (1) and (2) on the guide rails at the stationary platen (3)
and (4) in the clamp unit as shown. Refer to Figure 9-25.
NOTE: Ensure the guide rails are clean and free of surface defects.
7. Place a heavy duty straight edge (5) across the two Vee blocks.
8. Place a precision level (6) on the straight edge, and note the level (ref. L3,
Table 9-7).
9. Repeat steps 6 through 8 at the opposite end of the clamp (ref. L4, Table 9-7).
WARNING!
10. Adjust the level of the clamp unit at the side where the precision level indicates
maximum deviation. If necessary, first lift the machine using a pancake cylinder (7).
Slacken the locknut (8), and turn the bolt (9) to raise or lower the machine. Tighten
the locknut.
11. Remove the pancake cylinder and check the level of the clamp unit again.
12. Continue to adjust the level until the machine is level per specification in all planes
(Ref.Table 9-7).
13. Use a precision box level to measure the vertical position of the platens (ref. L5
and L6, Table 9-7) and the clamp casting (L7).
14. If the faces are not vertical (and perpendicular to the leveled base) to 0.15 mm per
1000 mm (0.0018 in. per 12 in.) contact the Husky Regional Area Service
Department.
15. Tighten all locknuts.

6
3 4
6
5
1 8
S01-1010019.eps
2
Figure 9-25 Leveling Clamp Unit (Typical).

1. Vee block 2. Vee block 3. Guide rail 4. Guide rail 5. Heavy duty straight edge
6. Precision level 7. Pancake cylinder 8. Locknut 9. Bolt
Complete the following checklist while performing the leveling procedure for the clamp
units.

Table 9-7 Leveling and Parallelism Checklist.
A: Leveling Values B: Parallelism Values
Unit OPS NOPS Tolerance Unit OPS NOPS Tolerance
L1 mm/m ± 0.15 mm/ L5 mm/m ± 0.10 mm/

m m
L2 mm/m ± 0.15 mm/ L6 mm/m X 0.10 mm/m

m (factory setting)
Unit Across Tolerance L7 mm/m 0.10 mm/m

(factory setting)
L3 mm/m ± 0.15 mm/
m
L4 mm/m ± 0.15 mm/

m
L7 L6 L5
A
NOPS OPS OPS NOPS
L3 L4
S01-101098c

9.2.35.2 Leveling the Injection Unit

The injection unit and nozzle concentricity are adjusted by raising or lowering the
leveling mounts. As adjustments made for one task will directly affect the other, check
the injection unit level and nozzle concentricity simultaneously.
1. Verify the hydraulic tank and extruder gearbox reservoir are filled with lubricant in
accordance with the Site Preparation Manual.
2. Make sure the power pack and the electrical cabinet are seated on their mounts
and not suspended on the injection base.
NOTE: Ensure the injection rails are clean and free of surface defects.
3. Place a precision level along one end of the operator’s side guide rail and measure
the level - refer to Figure 9-26.
4. If the rail is not level to 0.8 mm per m (0.0096 in per ft), adjust the leveling mounts
as necessary.
5. Place a precision level at the opposite end of the rail and measure the level.
6. If the rail is not level to 0.8 mm per m (0.0096 in per ft), adjust the leveling mounts
as necessary.
7. Repeat steps 3 through 6 on the non-operator’s side guide rail.
8. Span the precision straight edge across the guide rails. Place the level on the
straight edge and measure the level across the unit.
9. If the injection unit is not level to 0.8 mm per m (0.0096 in per ft), adjust the leveling
mounts as necessary.
10. Span the precision straight edge across a different location on the two guide rails.
11. Place a precision level on the straight edge to measure the level across the two
rails.
12. Adjust the leveling mounts until the unit is level to 0.8 mm per m (0.0096 in per ft).
13. Continue to adjust the level until the injection unit is level to within 0.8 mm per m
(0.0096 in per ft) in all planes.
14. Check the nozzle position for concentricity and adjust the mounts if necessary.
Refer to Section 9.2.35.3.

2
3
S01-101097.eps
S01-101020.eps
1
7 4
Figure 9-26 Leveling Injection Unit (Typical).

1. Heavy duty straight edge 2. Precision level 3. Precision level 4. Pancake
cylinder 5. Locknut 6. Bolt 7. Vibration mount
WARNING!
15. Tighten all locknuts.

16. Torque the bolts that connect the injection base to the clamp base – refer to
Section 2.13.

9.2.35.3 Checking Nozzle Concentricity
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:
Vertical Adjustment:
1. Measure the vertical distances (C and D) between the nozzle tip and the locating
ring. Refer to Figure 9-26.
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.
3. If necessary, first lift the injection unit using a pancake cylinder (4). Slacken the
locknut (5), and turn the bolt (6) to raise or lower the injection unit. Tighten the
locknut.
4. Repeat Step 1 and Step 2.
Horizontal Adjustment:
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 9-27.
2. Use a vernier caliper to measure the horizontal distances (A and B) between the
nozzle tip and the locating ring (3).
3. Check that the difference between the two horizontal measurements do not exceed
1 mm (0.04 in).
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 9-27 Checking and Adjusting Nozzle Concentricity.

1. Nozzle tip 2. Stationary platen mounting surface 3. Locating ring 4. Cap screw
5. Barrel assembly 6. Eccentric ring

9.2.35.4 Leveling the Power Pack

Level the power pack using the following instructions.
1. Remove the cover over the power pack. Place a level (1) on the power manifold (2)
– refer to Figure 9-28.
S01-101021.eps
2
3
4
1
Figure 9-28 Leveling Power Pack (Typical).

1. Level 2. Power manifold 3. Bolt 4. Locknut
WARNING!
2. Lift the power pack using a pancake cylinder, and turn the bolts (3) to raise or lower
the power pack. Remove the pancake cylinder, and check the level again. Tighten
the locknuts (4).

9.2.35.5 Leveling the Electrical Cabinet

Level the electrical cabinet using the following instructions.
1. Place a level (1) on the top surface of the electrical cabinet (2) – refer to
Figure 9-29.
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 9-29 Leveling Electrical Cabinet (Typical).

1. Level 2. Electrical cabinet 3. Locknut 4. Bolt

9.2.35.6 Leveling Pump Assembly

Level the pump assembly using the following instructions:
1. Check the pump motor is turned off.
3. Place a spirit level (1) over the pump assembly, as shown in Figure 9-30.
1
S01-101078.eps
Figure 9-30 Leveling Pump Assembly (Typical).

1. Spirit level 2. Locknut 3. Screw 4. Base
4. Check the pump assembly is level. If necessary, slacken the locknut (2), and
remove the screws (3). Turn the base (4) to adjust the height. Fasten the screws,
and tighten the locknut after adjustments.
5. Install the cover over the hydraulic power pack.

9.2.35.7 Final 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 9-8 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 9-8. If the difference between any of the
measurements is larger than the specification, contact the Husky Regional Area
Service Department for assistance.
Table 9-8 Parallelism Specification
Clamp Size Parallelism Specification
H90 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 in accordance with
instructions in the Mechanical Connections section of Chapter 4. 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.

9.2.36 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 9-31.
3. Turn the breather cap, and remove it.
4. Install a new breather cap and tighten it.
S01-101077.eps
Figure 9-31 Replacing Breather Cap (Typical).

1. Breather cap

9.2.37 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.
At intervals specified in the Maintenance Schedule, replace the filter element in the air
regulator using the following instructions:
1. Turn the shutoff lever (1) to shut off the air supply – refer to Figure 9-32.
2
3
8
6
9
S01-101076.eps
Figure 9-32 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.
9.2.38 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 2.9.
2. Remove the outlet plugs (1) and (2) on both sides of the motor – refer to
Figure 9-33.
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 9-9. 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 one hour with the outlet plugs removed to expel excess or used
grease.
11. Wipe off any grease from the outlet plug areas, and install the outlet plugs.
12. Install the cover over the hydraulic power pack.
13. Press the Machine Function Mode Selector on the toolbar, and select the Normal
button.
S01-101032.eps
5
1
Figure 9-33 Lubricating Electrical Motor Bearings (Typical).

1. Plug 2. Plug 3. Grease fitting 4. Grease fitting 5. Motor nameplate

Table 9-9 Grease Quantity for Motor.
Number of Strokesa b – Drive-end Number of Strokes – non-Drive-end

Grease Fitting Grease Fitting
Motor Frame Size
16 oz gun 24 oz gun 0.5 L gun 16 oz gun 24 oz gun 0.5 L 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
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
b. A standard 40 MPa 0.5 L grease gun delivers approximately 1.4 cm3 of grease with each stroke of the
hand pump.

9.2.39 Replacing ITT Water Saver Valve Diaphragm
Special Equipment Required
1 ITT water saver valve diaphragm (Part number 2234954)

2. Shut off the air and cooling water supply to the machine.
3. Clean the area around the ITT water saver valve (1) – refer to Figure 9-34.
4. Remove the bolts (2) and the cover plate (3). Note the orientation of the diaphragm
(4).
5. Remove the used diaphragm from the valve.
6. Remove the insert spacer (5) from the used diaphragm and transfer to a new
diaphragm.
7. Place the new diaphragm in the valve and reattach the cover plate using the four
bolts.
8. Turn on the air and cooling water supply to the machine, and check for leaks.
4
3
5
S01-101105.eps
Figure 9-34 ITT Water Saver Valve Diaphragm (Typical).

1. ITT Water saver valve 2. Bolt 3. Cover plate 4. Diaphragm 5. Insert spacer

9.2.40 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:
9.2.40.1 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 9-35. Check that the ALARMS
screen displays the message “Front Gate Open” in red.
2 S01-101113.eps
Figure 9-35 Front Operator Safety Gate and Rear Guard (Typical).
1. Front operator’s gate 2. Rear guard 3. Limit switch (typical)
2. Close the front operator’s gate, and check the “Front Gate Open” alarm is inactive.
NOTE: The limit switch must be tripped before the alarm can be reset.
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.

9.2.40.2 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 9-36.
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 9-36 Mechanical Safety Device (Typical).

1. Solenoid valve 2. Proximity switch 3. Pin

9.2.40.3 Checking CEN Valve

Please refer to the hydraulic schematic for details specific to your machine.
9.2.40.3.1 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.
9.2.40.3.2 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.
9.2.41 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 1.7.1.
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 9-37.
9. Disconnect the thermocouple from the faulty heater band (3) at the bayonet
adaptor (4).
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.
2
S01-101080.eps
Figure 9-37 Replacing Heater Band (Typical).

1. Grounding strap 2. Barrel cover 3. Heater band 4. Bayonet adaptor 5. Screw
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.

9.2.42 Changing the Plasticizing Screw and Check Valve
9.2.42.1 Removing Plasticizing Screw
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.
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.
If screw change is performed at the end of production, leave the machine heats on,
and go to Step 3 below.
2. Press the <HEATS> key to display the BARREL screen. Select "Machine Heats
Enable" checkbox. Do not enable mold heats.
Allow the machine to come up to processing temperatures for process material in
the barrel.
3. Shut off process material supply to the feed throat. Drain all material from the feed
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.
4. Turn on the pumps, and purge the barrel – refer to Section 7.16.
5. Press the <INJECT> key until the injection piston is fully forward.
6. 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.
7. 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 caution when working in the screw connection area.
8. Remove the finger guard (1) on the injection casting (2) – refer to Figure 9-38.
4 5
4
1
3
S01-101085.eps
Figure 9-38 Inserting Screw Wrench (Typical).

1. Finger guard 2. Injection casting 3. Plasticizing screw 4. Boss 5. Screw
wrench

9. 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.
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.
10. Jog the <SCREW ENGAGE> button on the sidebar to turn the plasticizing screw
so that the two flat surfaces on the screw are vertical.
11. Press the <PUMP MOTOR OFF> key to stop the pumps.
12. 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
exposes a hazardous area. Entanglement with the rotating screw can cause
serious injury. Use caution when working in the screw connection area.
13. Remove the Plexiglas panel (6) – refer to Figure 9-39.

14. Place a horizontal mark on the injection piston (7) with a felt marker. This mark
enables you to determine when the screw has disengaged.
15. Press the <PUMP MOTOR ON> key to restart the pumps.
16. Jog the <SCREW DISENGAGE> button on the sidebar so that the mark on the
piston has rotated approximately 90o.
17. Press the <PUMP MOTOR OFF> key to stop the pumps.
18. Remove the screw wrench.
19. Press the <PUMP MOTOR ON> key to restart the pumps.
20. 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).
21. Press the <SCREW DISENGAGE> button on the sidebar until the plasticizing
screw disengages completely from the injection piston.
22. 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.
24. Release the latch, and swing the HMI out of the way.
25. Remove the bolts (10), and disconnect the two carriage cylinders (11) from the
stationary platen.
27. Press the <CARRIAGE FORWARD> key to fully retract the carriage cylinders.

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.
29. Lift the purge guard (12) and leave it in the open position, or:
30. Remove the bolts (13), and remove the purge guard.
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
Figure 9-39 Barrel Assembly Exploded View (Typical).

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

WARNING!
Electrocution hazard – risk of death or serious injury. The barrel cover can
become energized upon removal of grounding strap. Complete Lockout/Tagout
before removing the barrel cover. After performing Lockout/Tagout procedure,
allow 10 minutes for residual voltage to discharge to less than 50 Volts.
31. Switch off the power supply. Perform Lockout/Tagout procedure – refer to Section
1.7.1, then wait 10 minutes for residual voltage to discharge.
REMINDER: After switching off the power, perform the remaining steps in this
procedure without any delay before the barrel cools down.
WARNING!
32. 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.
33. On machines with a barrel support (16), continue on. Otherwise skip to Step 36.
34. Remove the screws (17) and the side plates (18).
35. 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.
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.
36. 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.
37. Wear a face shield, and carefully remove the nozzle tip (20).
38. Remove the socket-head screws (21), and the retaining ring (22).
39. On machines equipped with a nozzle shutoff option, continue on. Otherwise, skip
to Step 53.
40. Remove the thermocouple (23) from the nozzle adaptor (24).

WARNING!
Electrocution hazard – risk of death or serious injury. Ground the nozzle adaptor
to prevent electrocution in the event the heater in the adaptor is faulty.
41. Ground the nozzle adaptor. Connect an alligator clip to the adaptor, and ground it
to an unpainted surface on the machine base.
42. 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 electrical
wires. Place it on a protective surface to prevent damage to the machine.
43. Remove the pin (26), and disconnect the clevis (27) from the nozzle shutoff (28).
44. Remove the thermocouple (29) from the nozzle shutoff.
45. Remove the socket-head screws (30) and the retaining ring (31).
46. If it is necessary to reheat the barrel continue on, otherwise skip to Step 51.
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.
47. 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 oC. Set the deviation
setpoints, as required, to prevent a High Deviation alarm.
48. Remove Lockout/Tagout – refer to Section 1.7.2. Switch on the power supply, and
log on to the machine.
49. Select the Machine Heats Enable checkbox on the BARREL screen.
50. 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.
WARNING!
Electrocution hazard – risk of death or serious injury. Ground the nozzle shutoff
to prevent electrocution in the event the heater in the shutoff is faulty.
51. Ground the nozzle shutoff. Connect an alligator clip to the nozzle shutoff, and
ground it to an unpainted surface on the machine base.

52. 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.
53. On machines without a nozzle shutoff option, remove the thermocouple (23) from
the nozzle adaptor (33).
54. Remove the bolts (25), and the nozzle adaptor (24).
55. 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!
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.
56. Fasten the heater band to the barrel. Torque the screws to Husky specifications –
57. Use an Allen wrench to remove the bolts (36), and the barrel head (9).
58. 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.
59. If it is necessary to reheat the barrel continue on, otherwise skip to Step 63.
60. Remove Lockout/Tagout. Switch on the power, and log on to the machine.
61. Select the Machine Heats Enable checkbox on the BARREL screen.
62. 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.
63. Use a wooden pry bar to force the plasticizing screw out of the barrel.
WARNING!
Burn hazard – risk of serious injury. Machine surfaces are hot. Wear PPE.
64. Grab the plasticizing screw at the nozzle end of the barrel with heat resistant
gloves, and pull it out.
65. To change plasticizing screw check valve, refer to Section 9.2.42.2.
66. To reassemble the plasticizing screw into the barrel, refer to Section 9.2.42.4.

9.2.42.2 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 9.2.42.
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 9-40.
S01-100151.eps
1
Figure 9-40 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 9.2.42.3.

9.2.42.3 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
9.2.42.2.
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 9-41.
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 9-41 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 optimoly paste 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 9.2.42.4.
9.2.42.4 Reassembling Barrel
REMINDER: Two persons are needed to perform this procedure.
REMINDER: When assembling the barrel, use Optimoly paste on all bolts or screws
exposed to high temperatures.
Special Materials Required
1 High temperature Optimoly Paste TA. Husky part number 644751 (1 kg, 2.2 lb)
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
2.13.
1. Remove Lockout/Tagout, 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 oC.
3. Select the Machine Heats Enable checkbox on the BARREL screen. Do not enable
mold heats.
4. Perform Lockout/Tagout procedure after the machine comes up to processing
temperature for the process material in the barrel.
REMINDER: After switching off the power, perform the remaining steps in this
procedure without any delay before the barrel cools down.
5. Apply high temperature Optimoly paste on the threads of the plasticizing screw (1)
WARNING!
Burn hazard – risk of serious injury. Machine surfaces are hot. Wear PPE.
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!
Slip, trip, or fall hazard - risk of serious injury. Use a safe platform to access the
barrel assembly area.
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.

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
Figure 9-42 Barrel Assembly Exploded View (Typical).

1. Plasticizing screw 2. Barrel 3. Injection piston 4. Barrel head 5. Bolt
6. Screw 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
9. Align the barrel head (4) such that the inner holes are upright, as shown. Apply
Optimoly paste 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!
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.
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.
NOTE: Check that the drool hole in the bottom of the barrel head is not covered by
the heater band.
11. On machines equipped with a nozzle shutoff option, continue on. Otherwise, skip
to Step 17.
NOTE: Make sure all contact surfaces of mating parts are free of process material
and other debris before reattaching them.
12. Apply Optimoly paste to the threads of the bolts (8), and reattach the nozzle shutoff
(9). Allow the temperature of the nozzle shutoff to equalize with the barrel, then
torque the bolts to Husky Specification HGT-50.
13. Reattach the retaining ring (10).
14. Reconnect the nozzle shutoff mechanism using the pin (11).
NOTE: Check that the washers (12) are installed correctly before installing the pin.
15. Reattach the thermocouple (13) to the nozzle shutoff.
16. Apply Optimoly paste to the threads of the bolts (14), and reattach the nozzle
adaptor (15) to the nozzle shutoff. Allow the temperature of the nozzle adaptor to
equalize with the barrel, then torque the bolts to Husky Specification HGT-50.
17. On machines without a nozzle shutoff option, apply Optimoly paste to the bolts
(15), and reattach the nozzle adaptor (16). Allow the temperature of the nozzle
adaptor to equalize with the barrel, then torque the bolts to Husky Specification
HGT-50.
18. Reattach the thermocouple (17) to the nozzle adaptor.
19. Reattach the retaining ring (18).
20. Apply Optimoly paste to the threads of the nozzle tip (19), and reattach it to the
nozzle adaptor. Tighten the nozzle tip with a hand wrench.
21. 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 plexiglass panel before
operating the machine.
22. Install the plexiglass panel (23) and the finger guard (24).

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.
23. Install the barrel cover (25). Connect the grounding strap (26) where available.
24. Close the purge guard (26) or, if removed in Step 30, reattach the purge guard
using the bolts (27).
25. Reconnect the machine heat connector (+E-X24) if it has been disconnected.
26. Remove Lockout/Tagout. Switch on the power supply, and log on to the machine.
27. 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.
28. 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.
30. 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.
31. Press the <CARRIAGE BACK> key to extend the carriage cylinders (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).
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.
32. 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.
Similarly, reattach the other carriage cylinder.
33. Press and hold the <CARRIAGE FORWARD> key until the carriage is in the purge
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.
34. Press the <SCREW ENGAGE> button on the sidebar until the plasticizing screw is
fully engaged.

35. Press the <INJECTION FORWARD> button on the sidebar until the injection piston
is fully forward.
Press the <INJECTION> key, and select the INJECTION tab – refer to Figure 9-43.
Verify that the value in the Injection Position field is approximately zero.
Figure 9-43 INJECTION Screen.
CAUTION!
Risk of damage to the machine. Remove all tools from the machine before
switching machine back to Normal mode.
36. Press the Machine Function Mode Selector on the toolbar and select the Normal
button.
37. Recover and purge out the barrel.

9.2.43 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 9-44. 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.
Figure 9-44 CALIBRATION MENU Screen.
Select any calibration button to display the individual calibration screen for that
component.
9.2.43.1 When to Calibrate

The following table describes when to calibrate the different components:
Table 9-10 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.

Table 9-10 Calibration Conditions.
Component When to Calibrate
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.
9.2.43.2 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.
Touch the Clamp Calibration button to display the CLAMP CALIBRATION pop-up
window – refer to Figure 9-45.
Figure 9-45 CLAMP CALIBRATION Pop-up Window.
9.2.43.2.1 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 9-45.
4. Touch the Start button. The HMI displays the next screen – refer to Figure 9-46.
Figure 9-46 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 Step 6.
Otherwise, touch the Manual Opening option button and the Confirm button. Then
skip to Step 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 9-47 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 Step 14.
10. If the Manual Opening option button in Figure 9-46 is selected, the HMI displays
the screen below – refer to Figure 9-48.
Figure 9-48 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 Steps 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 9-49.
16. Exit the CLAMP CALIBRATION pop-up window.
Figure 9-49 CLAMP CALIBRATION Screen 4.

9.2.43.3 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 9-50 INJECTION CALIBRATION Screen.

9.2.43.3.1 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 9-50.
4. Touch the Start button. The HMI displays the screen shown below.
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.
v 3.02 - March 2003

When calibration is completed, the field beside the Start button displays
"Calibrated".
9.2.43.4 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 9-51 CARRIAGE CALIBRATION Screen.
9.2.43.4.1 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 9-51.

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".
9.2.43.5 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 9-52.
Figure 9-52 CAVITY SENSOR CALIBRATION Screen.
9.2.43.5.1 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 9-52.
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 9-53.
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.

Figure 9-53 CAVITY SENSOR CALIBRATION Screen.

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.

v 3.02 - March 2003

Machine Manual Electrical
Chapter 10 Electrical
This chapter discusses PC controls and the various components of the PC controls
system.
10.1 PC Control System
The heart of the PC controls system consists of an 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 10-1. The user interacts with the machine through the touch screen HMI (2).
The HMI is discussed in Chapter 6—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 3.02 - March 2003 10–1 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 10-1 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 10–2 v 3.02 - March 2003

10.1.1 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 10-2 shows the various
devices on the PC.
1 2
5 6
16 10 (Top view of computer)

14 12
15 11
13
Figure 10-2 Beckhoff Industrial PC (Typical).

1. LED (hard disk) 2. LED (power) 3. 1.44 Mb floppy drive 4. CD-ROM 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
1
2
3
5
S01-101100.eps
Figure 10-3 Access Panel in Electrical Cabinet (Typical).

1. Keyboard port 2. Mouse port 3. Printer port (LPT1) 4. Modem port 5. Serial port
(COM2)
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 10-2) are
discussed in Table 10-1.
Table 10-1 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 10-2 lists common fault diagnostics related to the PC.
Table 10-2 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

10.1.1.1 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 10-4.
S01-100632.eps
RX
TX
3 1
2 2 2
Figure 10-4 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 10.1.3.1).

CAUTION!
remove the cover on the PC except to inspect the status LEDs on the interface
cards.
Figure 10-5 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
BOOT
3
TM0
TM1
SCB S3 RESJ
OPEN
4
S01-100548.eps
JP2 JP1
RX 5
IRQ 7 DL3 DL4
X3
TX
Figure 10-5 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

10.1.1.2 PROFIBUS Interface Card

The Beckhoff PROFIBUS interface card links the various PROFIBUS devices.
Figure 10-6 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 10-6. 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.

10.1.2 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 10-3.
Table 10-3 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

10.1.3 Servo Drive

The servo drive consists of a V Controller (1) and power supply – refer to Figure 10-7.
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 10-7 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 10.1.3.1.

10.1.3.1 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 10-8. 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 10-8 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).

10.1.4 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 10-9. 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.
2 4
1
S01-100471.eps
PROFIBUS
RUN
BF
DIA 24 V 0 V
I/O RUN + +
I/O ERR
BECKHOFF
- -
PE PE
3
5
Figure 10-9 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.

10.1.4.1 PROFIBUS Bus Coupler
10.1.4.1.1 Beckhoff BK3100, BK3110 Bus Couplers
1 2
6
7
8
9
10 3
4
5
11
12
15
13
14
Figure 10-10 Beckhoff BK31XX Bus Coupler (Typical).

1. LED (24 V bus coupler power supply) 2. LED (supply to bus terminals) 3. K-bus
contacts 4. LED (I/O RUN) 5. LED (I/O ERROR) 6. LED (RUN) 7. LED (BF)
8. LED (DIA) 9. LED (reserved for future use) 10. PROFIBUS connector 11. Power
supply to bus coupler (24 V DC/Ground) 12. Input power contacts 13. Output power
contacts 14. Configuration port 15. Address selector
The BK3100 handles both digital and analog signals, but the BK3110 handles digital
signals only.
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 10-10.
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 (4) lights up to
indicate fault-free operation. The red bus terminal I/O ERROR LED (5) 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.
10.1.4.2 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.

10.1.5 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 10-11 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 10-11. 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.

10.2 Creating Recovery Disk Image/Restoring Hard Disk on IPC Type

10, 11
The following procedures are used to create a Recovery Disk Image and restore a
hard disk on an IPC Type 10, 11 only. For IPC Type 1, 2, 3, 4 procedures refer to
paragraph 10.3.
NOTE: Type 10 and 11 IPCs have a built-in CD-RW device.
NOTE: A mouse and keyboard are required to perform the following procedures.
Attach them to the connectors provided on the front panel of the main
electrical cabinet.
Figure 10-12 IPC Type 10, 11 (Typical)

1. IPC Type 10, 11 Label 2. CDRW Drive
Creating Recovery Disk Image/Restoring Hard Disk on IPC Type 10, 1110–16 v 3.02 - March 2003
10.2.1 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.
10.2.1.1 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.
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.
10.2.1.2 Creating a Recovery Disk Image Using the Built-in CD-RW Device
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 paragraph 10.2.1.3.
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 paragraph 10.2.1.4.
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”.
v 3.02 - March 2003 10–17 Creating Recovery Disk Image/Restoring Hard Disk on IPC Type
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.
10.2.1.3 Scanning the Hard Disk for Errors

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 Options pop-up window 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. Click “Yes” and allow scandisk to run autocheck. This will take a
few minutes.
10.2.1.4 Modifying the Boot-Up Sequence

The following procedure describes how to modify the boot-up sequence to start the
IPC from either the CD-ROM or the A:\ drive.
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.
8. The IPC will then reboot from the CD-ROM or A:\ drive as selected above.
10.2.1.5 Restoring a Hard Disk from a Recovery Disk Image

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. For IPC Type 1, 2,
3, 4 procedures refer to paragraph 10.3.1.
If the machine is not connected to a network, the steps marked with an asterisk (*) can
be ignored.
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.

2. If the hard drive has no errors then check that the IPC is set to boot up from the
CD-ROM – refer to paragraph 10.2.1.4.
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.
NOTE: If the machine is part of a domain the machine will need to be reconnected by
an IT professional.
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 (\Pqcd0 HL-DT-ST-CD-RW GCE-8240B 1.06 24x40)
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 (the process now
restores the image… this may take a few minutes).
19. Click “Yes” to acknowledge the warning message that the partition may 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.
22. Restart the IPC.
24. Confirm the computer name and the IP address are correct. If necessary, correct
the settings and reboot the IPC.
NOTE: If the machine is part of a domain it will need to be reconnected by an IT
professional using the domain name.
25. Change the boot sequence to C:\ drive.
26. Restore any machine data using the Backup/Restore utility on the HMI
CONFIGURATION screen, as required.
10.3 Creating Recovery Disk Image/Restoring Hard Disk on IPC Type

1, 2, 3, 4
The following procedures are used to create a Recovery Disk Image and restore a
hard disk on an IPC Type 1, 2, 3, 4 only. For IPC Type 10, 11 procedures refer to
paragraph 10.2.
NOTE: Type 1, 2, 3, and 4 IPCs have a built-in CD-ROM device, with no write
capability.
NOTE: A mouse and keyboard are required to perform the following procedures.
Attach them to the connectors provided on the front panel of the main
electrical cabinet.
Figure 10-13 IPC Type 1, 2, 3, 4 (Typical)

1. IPC Type 1, 2, 3, 4 Label 2. CD ROM Drive
10.3.1 Creating a Recovery Disk Image

Use the following procedures to create a Recovery Disk Image and restore the hard
disk on an IPC Type 1, 2, 3, 4 only. For procedures to create a Recovery Disk Image
and restore a hard disk on an IPC Type 10, 11 refer to paragraph 10.2.1.2.
Hardware/Software Requirements:
• Laptop running Windows NT, 2000 or 95.
• CD Burner and supplied software.
• Network card installed in the laptop.
• Ethernet cross over cable.
• Shared folder on the C or D drive called “IMAGE” with a minimum 650 megabytes
free space.
• Three Floppy Disks
• Software – Pc To Pc.exe and Restore Disk Boot Files.exe
A kit can be ordered using BOM HPN 2477584 which includes:
• A CD Burner suitable for use in UL or CE countries (plug adapter required but not
included) HPN 2474042,
• An Ethernet Crossover Cable (6 feet Rj45-Rj45) HPN 2476900, and two blank
Recordable Compact Disks. Additional disks can be purchased locally or ordered
using HPN 2332461.
10.3.1.1 Laptop Setup Procedure
10.3.1.1.1 Laptop Setup Procedure For Windows NT

If your laptop runs Windows NT as the operating system follow these instructions. For
Windows 95 laptops refer to paragraph 10.3.1.1.2.
1. Log onto your Windows NT PC (laptop).
2. Create a new folder on the laptop’s C or D drive called “image”. You will require a
minimum of 650MB of free disk space on the drive where this folder is created.
3. Using Windows Explorer, right click on the folder, then select the Sharing tab,
Share as and set the Share Name as IMAGE. Click on OK to complete the
process.
If you do not see the Sharing tab you have to start the Server service under the
Windows NT control panel. Go to Start | Settings | Control Panel | Services. Select
the Server Service and then Start.
Creating Recovery Disk Image/Restoring Hard Disk on IPC Type 1, 2, 3, 410–22 v 3.02 - March 2003
If the service fails to start contact your IT support personnel.

4. Manually set up the IP address on the Laptop to 192.168.0.2. To set the IP address
go to Start |Settings |Control Panel | Network. Select the Protocols tab, TCP/IP
Protocol and then the Properties button. In the Properties window go to the IP
Address tab and select the option “Specify an IP address”. Click on the IP address
field and enter 192.168.0.2. Enter the Subnet Mask as 255.255.255.0. Click on Ok
to close all windows.
An example of the address settings:
NOTE: If you are going to use your laptop on the Husky network be sure to put your
network settings back to “Obtain a IP address from a DHCP server” after you
have imaged the machine. Go to Start | Settings | Control Panel | Network.
Select the Protocols tab, TCP/IP Protocol and then click on the Properties
button. In the Properties window go to the IP Address tab and select the option
“Obtain an IP address from a DHCP Server”. If you do not do this you will NOT
be able to log onto the HUSKY network.
5. Proceed to next section to set up the machine.
10.3.1.1.2 Laptop Setup Procedure For Windows 95

If your laptop runs Windows 95 as the operating system, follow these instructions. For
Windows NT laptops refer to paragraph 10.3.1.1.1.
1. Log onto your Windows 95 PC (laptop).
3. Using Windows Explorer, right click on the folder, then select Sharing, Share as
and set the Share Name as IMAGE. Set the access type to Full. Click on Ok to
complete the process.
4. If you do not have the Sharing tab you need to enable file and printer sharing as
follows:
• Right click on Network Neighborhood and go to Properties.
• Click on the Configuration tab then click on the ADD button.
• Select Service then click ADD.
• Click on Microsoft, then File and printer sharing for Microsoft networks. Click on
Ok.
• From the Configuration screen click on the File and Printer Sharing… button.
Verify that the option “I want to be able to give others access to my files” is
checked.
• Click Ok to close the File and Print Sharing window, then click Ok again to
close the Network window.
• You will be asked to restart your computer, select Yes. Once the computer has
restarted set the image folder to allow sharing.
5. Manually set the IP address on the Laptop to 192.168.0.2 as follows:
• Go to Start|Settings|Control Panel|Network.
• Select the Configuration tab.
• Select the TCP/IP Protocol of the network card installed in the laptop and then
the click on Properties.
• In the Properties window go to the IP Address tab and select the option
“Specify an IP address”. Enter the IP address 192.168.0.2 then enter the
Subnet Mask as 255.255.255.0. Click on Ok to close all windows.
• Windows will need to restart the computer to make the changes. Select Yes
when prompted.
network settings back to “Obtain an IP address Automatically” after you have
imaged the machine. If you do not do this you will NOT be able to log onto the
HUSKY network. To do this, go to Start|Settings|Control Panel|Network. Select
the Configuration tab. Select the TCP/IP Protocol of the network card installed
in the laptop and then the click on the Properties button. In the Properties
window go to the IP Address tab and select the option “Obtain an IP Address
Automatically”.
6. Proceed to Section paragraph 10.3.1.2 to set up the machine.
10.3.1.1.3 Laptop Setup Procedure For Windows 2000
Set Up Account With Windows 2000 Users:

1. Log onto the PC to the Local Area Network (LAN domain) in which your laptop
accounts are assigned.
2. Right-click on MY COMPUTER icon | Select MANAGE | Select LOCAL USERS
AND GROUPS | Select USERS | Right-click on USERS & add NEW USER | Enter
your information.
3. Make your password the same as your Local Area Network (LAN domain)
password.
4. Click on CREATE to complete the account setup.
5. Close the window. The new account will appear in the windows on the right.
6. Right click on the user and select properties. Make this user part of the
ADMINSTRATOR GROUP.
7. Click on the ADD button.
8. Click on ADMINISTRATOR then click on the ADD button.
9. Click on OK to complete the setup. Close all windows.
Set up Laptop for Image Folder and IP Address

1. Log onto your Windows 2000 PC (laptop).
3. Using Windows Explorer, right click on the folder, then select the Sharing tab,
Share as and set the Share Name as IMAGE. Click on OK to complete the
process.
4. If you do not see the Sharing tab, you must start the Server service under the
Windows 2000 control panel. Go to Start|Settings|Control Panel|Services. Select
the Server Service and then Start.
If the service fails to start you will have to contact your IT support personnel.
5. Manually set up the IP address.
In Windows 2000, Manually set up the IP address on the Laptop to 192.168.0.2. To
set the IP address go to Start|Settings|Control Panel|Dail & Network. Select Local
Area Connection, Properties, the Internet Protocols tab, TCP/IP Protocol, then you
can see the IP Address tab.
network settings back to “Obtain a IP address from a DHCP server” after you
have imaged the machine. Go to Start|Settings|Control Panel|Network. Select
the Protocols tab, TCP/IP Protocol and then click on the Properties button. In
the Properties window go to the IP Address tab and select the option “Obtain
an IP address from a DHCP Server”. If you do not do this you will NOT be able
to log onto the HUSKY network.
6. Proceed to next section to set up the machine.
10.3.1.2 Machine Setup Procedure

2. Unzip the files in PC TO PC.EXE to a temporary folder (e.g. C:\TEMP\PC TO PC\)
then run Mkdisk.bat and follow the instructions to create the 2 floppy boot disks.
These disks are used to set up a connection between the laptop and IPC.
NOTE: FOR WINDOWS 95 LAPTOPS: Each disk is formatted before the files are
copied to it. Once the first disk is formatted it will ask you if you want to format
another diskette. Select No and the files will start to be copied. After the first
disk is copied insert the second disk into the floppy drive and it will be
formatted. Once the second disk is formatted it will again ask you if you want
to format another diskette. Select No and the files for the second disk will start
to be copied.
After you run Mkdisk.bat it will ask you to view the readme.txt file on floppy disk
one for instructions on how to complete the floppy boot disks. The following is
based on those instructions:
• To complete the floppy boot disk setup you must select which hard drive you
would like to map to. Using windows explorer, right click on the autoexec.bat
file on floppy disk one and select EDIT. Enter the path to the image folder you
have created on your laptop’s C or D drive.
Example: net use w: \\your_computer_name\image
• You can determine the name of your computer (the laptop) by going to
Start|Settings|Control Panel|Network then selecting the Identification tab and
reading the Computer Name field.
For Windows 2000 the computer name can be found by Start|Settings|Control
Panel|System|
Save and close the Autoexec.bat file.
3. Reboot your laptop and log in locally using the local computer name.
4. Check the IPC hard drive for temp files under C:\temp or C:\winnt\temp. Delete all
files. Remove all unnecessary files you may have placed on the hard drive.
5. Check the IPC PC BIOS to ensure you can boot from the floppy boot disks as
follows:
• Reboot the IPC. When the first screen appears press the DELETE key several
times. The blue BIOS screen should appear.
• Using the Up/Down arrow keys, go to the BIOS FEATURES Setup. Press Enter
when the section is highlighted.
• Go down to the BOOT SEQUENCE section, and use the page up/page down
keys to change the boot order. The order must be set so that A is the first drive
in the boot sequence (e.g. A,C,CDROM). Press the ESCAPE key when
finished.
• Go to SAVE AND EXIT and press the Enter key. Answer Yes when asked if you
want to save to BIOS.
6. Connect the crossover cable from the laptop to the IPC. Place the first floppy boot
disk in the IPC. Now select Save & Exit Setup in the BIOS setup. Answer Yes
when asked if you want to save to the CMOS and exit. The machine will reboot
automatically.
7. Proceed to the next section to create the image file.
10.3.1.3 Creating An Image File

1. During the boot-up using the floppy disks you will be prompted for a User name.
Enter the same name you use to log onto your laptop. Enter the password when
prompted. Answer No if you are asked whether or not you want to create a
password list file. A drive letter will be mapped to the shared image folder on your
laptop you created previously. Insert the second floppy boot disk when prompted.
2. Click on CREATE IMAGE then SELECT ALL and finally NEXT.
3. Browse to the shared drive (Example: w: \\your_computer_name\image) and use
PQER.PQI for the image file name. Click on OK then NEXT.
4. Choose HIGH compression then click on NEXT.
5. Click on FINISH.
6. When complete, reboot and reset the PC BIOS to boot from CDROM, C, A.
7. Proceed to the next section to create the Recovery Disk.
10.3.1.4 Creating A Recovery Disk

The following procedure describes how to burn the image file created in the last step
onto a rebootable CD-ROM:
NOTE: These instructions were written for use with Easy CD Creator V4.0 software.
The steps for other CD writing programs may be different and will not be
covered here.
1. Ensure the CD burner is attached and powered before you boot up the laptop/
desktop.
2. Run RESTORE DISK BOOT FILES.EXE and unzip the files into a temporary folder
(e.g. C:\TEMP\BOOT FILES\). Run Mkdisk.bat and follow the instructions to create
a Restore Boot Floppy Disk. Label it “Restore Boot Floppy Disk”.
3. Start Easy CD Creator.
4. From the startup menu select DATA CD (if prompted).
5. Select New Bootable CD (File|New CD Layout|Bootable CD).
6. You will be prompted to insert a bootable floppy disk. Make sure that the Restore
Boot Floppy Disk you created in Step 2 is in the drive.
NOTE: Deselect the option "Use the floppy image file” if prompted and click OK.
7. In the Explorer window (located in the top left hand corner), select the folder
containing the image file. In the top right hand window select the image file (MUST
be named PQER.PQI) then click on the ADD button on the toolbar.
8. Right Click on the disk shown in the CD layout window (bottom left corner) and
rename it to BSTXXXXXXX (where XXXXXXX is the serial number of the
machine).
9. Make certain that a new blank CD is inserted in the CD burner.
10. Click on CREATE CD in the top Tool Bar.
11. Select the CD writer and the write speed (4x). The default values should be
correct. Under Advanced Options select Create CD. Under Write Method select
Track-at-once, Close Session, and Leave CD Open. Click on OK to initiate the
process of burning the CD. Depending on the size of the image and write speed, it
can take up to 30 minutes to burn a CD. You may cancel the Transfer Speed test
for the hard drives.
12. When data writing is complete, label the Recovery disk.
10.3.2 Restoring a Hard Disk from a Recovery Disk Image

The following procedure describes how to check the hard drive for errors then restore
the hard drive on an IPC Type 1, 2, 3, 4 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.
If the machine is not connected to a network the steps marked with an asterisk (*) can
be ignored.
2. If the hard drive has no errors then check that the IPC is set to boot up from the
CD-ROM – refer to paragraph 10.2.1.4.
4. Note the computer name. If the machine is part of a domain, make a note of the
domain name as well.
NOTE: If the machine is part of a domain the machine will need to be reconnected by
an IT professional.
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. Open the CD-ROM device door, and leave it open with the Recovery Disk Image
CD-ROM in it.
7. Reboot the machine, and check that it boots up from the CD-ROM.
8. Follow the on-screen prompts and read all Warning message carefully.
9. Reboot the IPC when the hard disk restore is complete.
10. Log on to the HMI using the Administrator key again.
12. Confirm the computer name and the IP address are correct. If necessary, correct
the settings and reboot the IPC.
NOTE: If the machine is part of a domain it will need to be reconnected by an IT
professional using the domain name.
Machine Manual SPC (Optional)
Appendix A SPC (Optional)
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).
A.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 A.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 A.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 A.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.
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.
v 3.02 - March 2003 A–1 SPC Quick Start

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 A.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 A.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 A.3 to enter specification limits for any of the monitored variables.
SPC Quick Start A–2 v 3.02 - March 2003

A.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 A-1.
Figure A-1 SUMMARY Screen.
Table A-1 describes each screen element shown in Figure A-1.

NOTE: You cannot select variables or buttons, or modify any of the selectable fields if
you do not have access rights.
v 3.02 - March 2003 A–3 SUMMARY Screen

Table A-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 A–4 v 3.02 - March 2003

A.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 A-2.
Figure A-2 DETAILS Screen.
Table A-2 describes the general fields shown on the DETAILS screen in Figure A-2.
v 3.02 - March 2003 A–5 DETAILS Screen

Table A-2 DETAILS Screen Descriptions.
Field Description
(Variable Drop Down Box) Use the drop down box to select a variable from the list.
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.
DETAILS Screen A–6 v 3.02 - March 2003

A.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.
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 A-3 describes the remaining screen elements shown in Figure A-2.
Table A-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.

Field Description
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
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.

Field Description
Scale Trend By
Data Press this radio 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 radio 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.

A.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 A-3.
Figure A-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.

A.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 A-4.
Figure A-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 A-4 below.
Table A-4 Data Log Duration.
Cycle Time (seconds) Cycles/Day Log Duration (Days)
60 1440 7
30 2880 3.5
15 5670 1.7
v 3.02 - March 2003 A–11 HISTORY Screen

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.
Table A-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 radio 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.
HISTORY Screen A–12 v 3.02 - March 2003

Table A-5 HISTORY Screen Descriptions.
Field Description
(Selection Period) Use the drop down box to select the display period for the three
data streams. The options are:
• 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.
v 3.02 - March 2003 A–13 HISTORY Screen

A.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.
Press <SPC> key, then select the GROUP tab. Refer to Figure A-5.
Figure A-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.
GROUP Screen A–14 v 3.02 - March 2003

Table A-6 GROUP Screen Descriptions.
Field Description
Trend Press this radio button to display statistical information for

variable data by trend.
Xbar Press this radio button to display statistical information for

variable data using Xbar patterns.
R/s Press this radio 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 3.02 - March 2003 A–15 GROUP Screen

A.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 A-6.
Figure A-6 SETUP Screen.
Table A-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 radio button to display all SPC variables. Table A-8 lists
all available SPC variables.
Configured variables Use this radio button to restrict the display list to those variables
that have been configured.
SETUP Screen A–16 v 3.02 - March 2003

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 3.02 - March 2003 A–17 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 the
Learning Limits 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 A-8 lists SPC process variables and their descriptions.

Table A-8 Variable Definition List.
Name Description
Back Pressure (psi) Pressure measured at 75% of stroke during Recovery.
Cavity Pressure at Transition Cavity pressure measured at transition from Fill to Hold
(psi) 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 Injector position at maximum forward position.

(mm)
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 Injection pressure of transition from fill to hold.

(psi)
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 Temperature in zone 1 when full tonnage is reached.

(°C)

Name Description

(°C)

(°C)

(°C)
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 Temperature in nozzle when full tonnage is reached.

(°C)
Nozzle Shutoff Temperature Temperature in nozzle when full tonnage is reached.

(°C) Nozzle extension temperature monitoring is an option.
Nozzle Tip Temperature – 1 (°C) Temperature in zone 1 when full tonnage is reached.
Nozzle Tip Temperature – 10 Temperature in zone 10 when full tonnage is reached.

(°C)

(°C)

(°C)

(°C)

(°C)

(°C)

Name Description

(°C)
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

A.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 A-7.
Figure A-7 CONTROL LIMITS Screen.
CONTROL LIMITS Screen A–22 v 3.02 - March 2003

Table A-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.
v 3.02 - March 2003 A–23 CONTROL LIMITS Screen

A.8 SPC Concepts
A.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:
• 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)
• 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 informa-
tion 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.
A.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.
A.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.
SPC Concepts A–24 v 3.02 - March 2003

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.
A.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.
A.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 A-8.
S-10-100151.eps
1800
S01-100152.eps
+3σ
-3σ
400 cycles
1500
Trend Chart Distribution Chart
Figure A-8 Trend and Distribution Charts.
v 3.02 - March 2003 A–25 SPC Concepts

A Distribution chart divides the range of readings into sub-ranges and displays them
graphically. Refer to Figure A-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 A-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.
A.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.
A.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.

A.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 A.8.13 for details.

In the example in Figure A-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 A-9 Process Capability Index, Cpk = 3.

In the example in Figure A-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 A-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 A-11 Process Capability Index, Cpk = 0.5.

In the example in Figure A-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
Cpk = 2
S01-100157.eps
1800
1725 +3σ
1650
1575 -3σ
1500

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

A.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.
A.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 A-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 A-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 A-16 shows an example of an Xbar chart with one sample average outside the
control limits.
Xbar Chart -
S01-100160.eps
UCL
Average
LCL
Figure A-16 Xbar Chart - Limits.
Figure A-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 A-17 Xbar Chart – Run.
Figure A-18 shows an example of an Xbar chart with six or more consecutive sample
averages trending upwards or downwards.
Xbar Chart –
S01-100162.eps
UCL
Average
LCL
Figure A-18 Xbar Chart - Trend.

Figure A-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 A-19 Xbar Chart - Alternating Data.
A.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 A-20 shows an example of an R/s chart.
R/s Chart
S01-100164.eps
UCL
Average
LCL
Figure A-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.
∑ ( Xi – X )
2
s = ⁄ (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 A-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 A-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.

A.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 A-10 lists the different SPC alarm types.
Table A-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".

A.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 ( R )
2
LCL x – bar = X – A ( R )
2
where A2 is a control chart factor – see Table A-11, R is range chart average
4. Xbar control limits – see standard deviation chart
UCL x – bar = X + A ( s )
3
LCL x – bar = X – A ( s )
3
where A3 is a control chart factor – see Table A-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 A-11
7. Sigma (population estimate),
R-
σ̂ = ----
d2
where d2 is a control chart factor – see Table A-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 A-11
11. Sigma (population estimate),
s-
σ̂ = ----
c4
where c4 is a control chart factor – see Table A-11

12. Process Capability (Cpk)
USL – X-
Cpk = --------------------
3σˆ
or
Cpk = X – LSL-
-------------------
3σˆ
use whichever specification limit is closer to X

Table A-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

A.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.

v 3.02 - March 2003

Machine Manual Customer Specials
Appendix B Customer Specials
This chapter describes special options ordered by the Customer. In some instances,
the descriptions here replace the corresponding items in the rest of this manual.
This section will be blank if your machine does not contain documented customer
specials.
v 3.02 - March 2003 B–1

v 3.02 - March 2003

Husky Injection Molding Systems Ltd.
Hylectric Machines
Technical Documentation Group
530 Queen Street South
Bolton, ON
Canada L7E 5S5
Fax: (905) 951-5315
Manual: Machine Manual - Hylectric Injection Molding Machine
Version: v 3.02 - March 2003
Customer:
Machine Serial number:
User Feedback
To help us continually improve the quality of this manual, we appreciate your input. Please answer the
following questions, and fax the completed questionnaire directly back to the number above.
1. Is this manual easy to use?
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S01-101056.

Hylectric Injection Molding Machine

Clamp Model: H/HL90 to H/HL1000

Issue: v 3.02 - March 2003

ii v 3.02 - March 2003

SUPPLY No.1 LOAD V A Hz SYSTEM

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

HUSKY INJECTION MOLDING SYSTEMS LTD.

Telephone Support Numbers

v 3.02 - March 2003 iii General Information

Husky Regional Service and Sales Offices

Americas Europe/Africa Asia Pacific

Husky Regional Service and Sales Offices iv v 3.02 - March 2003

Americas Europe/Africa Asia Pacific

v 3.02 - March 2003 v Husky Regional Service and Sales Offices

Standard Worldwide Warranty Conditions

Exceptions, warranted for 13 months

Standard Worldwide Warranty Conditions vi v 3.02 - March 2003

• Failure, or damage due to noncompliance with maintenance procedures, as speci-

Safety and Indemnity

v 3.02 - March 2003 vii Standard Worldwide Warranty Conditions

This page intentionally left blank

v 3.02 - March 2003

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Chapter 1: Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

v 3.02 - March 2003 ix

1.8.7 Gas, Vapor, and Dust Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10

Chapter 2: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

Chapter 3: Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

x v 3.02 - March 2003

3.1.2.2 Front Operator’s Gate and Rear Guard . . . . . . . . . . . . . . . . . . . . 3–7

Chapter 4: Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

v 3.02 - March 2003 xi

Chapter 5: Commissioning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

Chapter 6: User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

2–xii v 3.02 - March 2003

Chapter 7: Starting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

v 3.02 - March 2003 2–xiii

7.7.1 Checking Suitability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14

Chapter 8: Stopping Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

2–xiv v 3.02 - March 2003

8.3.5 Emptying Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9

Chapter 9: Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

v 3.02 - March 2003 2–xv

9.2.22.1Draining Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–26

2–xvi v 3.02 - March 2003

9.2.43.2Clamp Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–78

Chapter 10: Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

v 3.02 - March 2003 2–xvii

A.2 SUMMARY Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3

2–xviii v 3.02 - March 2003

Purpose of this Manual

v 3.02 - March 2003 xix Purpose of this Manual

Contents of this Manual