PCC Project Vendor Data Submittal Cover Page

Vendor: PET All Manufacturing Inc

PO # 58KG8260-HH060102

Document Title: Manual,%0

Document Number: 3.1.32 Document Category : A 23

Date (Document Date): //12

Revision: 0 Issued Purpose: Issued for Review

Tag Numbers: 54V840400 A/B/C/ D

3.1.32.1 Rev 03 1
 Tag #: 54V840400 A/B/C/D User Manual Rev 02

3.1.32.1 Rev 03 2
 Machine information
Machine Model: IBM 300/700

Machine name: One-step Full-automatic Plastic Injection and Blow Molding Machine

Phase: 3 voltage: 380/460 frequency:5 0 / 60Hz current:125A

Total power: 50Kw mean consumption power: 28Kw

Weight: ≈8500kg

Max Injection mould clamp force: 700kn

Max blow mould clamp force: 100kn

Max pressure of hydraulic system: 14Mpa

Max air pressure: 1Mpa

Product standard No.: Q/HZY09-2006

Type of Document: User’s Manual Document code: 80061001-Z01

Serial No.: 80061001

Year of manufacture: 2009

Manufacturer: Custom assembled for CanMold Inc.

Address: 971 Division Street, Adrian MI

Postal code: 49221

Tel.: 517-403-4740
E-mail: wpriest@petallmfg.com

3.1.32.1 Rev 03 3
 Index
1 General Information.................................................................................................................. 3

2 Specification and Description ................................................................................................... 6

3 Safety ...................................................................................................................................... 33

4 Installation .............................................................................................................................. 49

5 Preparation .............................................................................................................................. 58

6 Dry cycling ............................................................................................................................. 67

7 Operation and Use................................................................................................................... 68

8 Maintenance.......................................................................................................................... 141

9 Troubleshooting .................................................................................................................... 157

10 Refuse Disposal ................................................................................................................ 179

11 Spare Parts List ..................................................................................................................... 182

12 Other Documentation........................................................................................................ 183

3.1.32.1 Rev 03 4
 1 General Information
1.1 Introduction
1.2 Guarantee
1.3 To be provided by the customer
1.4 Technical Service
1.5 Spare Parts List

3.1.32.1 Rev 03 5
 1.1 Introduction
This manual as an integral part of the machine contains the information necessary for the
purchaser and user (operators and trainers) and ensures safely using IBM300/700.
This document assumes that the plants where the machine assembly line is to be installed
respect the current work safety and hygiene regulations.
The instructions, drawings and documentation contained in this manual are of a confidential
nature and the exclusive copyright of Zhongya Machinery Co., Ltd. Neither the whole nor any
part of it may be reproduced.
Before preparing the machine for operation users are strongly required to read the
instructions in the manual attentively and scrupulously carry out the operations recommended
herein.
It is compulsory for the operator and trained engineer to understand the contents of this
manual in full.
Keep this document and all printed material supplied with it in a safe and easily-accessible
place known to all operators and training personnel.

1.2 Guarantee
All tools and consumables which may have been supplied by Manufacturer with the machine
are excluded from the guarantee.
In carrying out the work, Manufacturer shall use materials, components and mechanism of a
type, condition and quality it considers appropriate for the machine being built, and its judgment
shall be final in such matters. Even after receipt of the order, Manufacturer may make
modifications to the machine which in its judgment, once again final in such matters, represent
suitable improvements.

1.3 To be provided by the customer

To be provided by the customer, unless there are specific contractual conditions to the
contrary, the Customer shall provide the following:
- Installation site meeting logistical requirements for positioning and operation of the
machine.
- Suitable lifting equipment.
- Electrical power supply, including protection conductor commonly referred to as
“EARTH”.
- Water supply.
- Compressed air system.
- Tools and consumables.
- Lubricants.
- Anti-abrasive hydraulic oil.

1.4 Technical service

The customer can contact manufacturer directly for After Service or request a visit from their
official representative.
Such requests can be sent by fax or phone, calling the numbers on the first page of this

3.1.32.1 Rev 03 6
 manual.

1.5 Spare Parts List

The Customer must purchase original spare parts. A list of the spare parts required to keep
the injection & blow-molding machine operating efficiently and safely may be found in Chapter
11, together with detailed information on how to identify and order them.

3.1.32.1 Rev 03 7
 2 Specification and Description
2.1 General description of the machine
2.1.1 Operating principles
2.1.2 Characteristics of the machine
2.1.3 Main components of the machine
2.2 Specifications
2.2.1 Injection unit
2.2.2 Injection mould-closing unit
2.2.3 Blow mould-closing unit
2.2.4 Lifting and transferring device
2.2.5 Stripper device
2.2.6 Machine frame
2.2.7 Safety Door
2.2.8 Heat inductive oil and cooling water distribution device
2.2.9 Mould
2.3 Hydraulic system
2.3.1 Pump P1
2.3.2 Pump P2
2.3.3 Pump P3
2.3.4 Power supply and valves
2.3.5 Oil tank and connection
2.3.6 Oil integrated group
2.4 Lubrication system
2.5 Cooling system
2.6 Pneumatic system
2.7 Electrical system
2.8 Control panel
2.9 Standards certification limits
2.9.1 Technical standards applied
2.9.2 Ambient operating conditions
2.9.3 Lighting
2.9.4 Noise levels
2.9.5 Residues and environmental contamination

3.1.32.1 Rev 03 8
 2.1 General description of the machine
This machine is highly efficient equipment with HDPE、LDPE、PP、PS、PVC、some polymers
and etc. as raw materials which are processed directly through injection, blowing and other procedures
in one step for plastic containers. It is used widely in packaging of pharmaceuticals, healthy products,
food, cosmetics and chemicals.
Total size of the machine is 4100*2010*2145.

Fig.2-1General diagram of machine

2.1.1 Operating principles
Melted material is injected into moulds for preforms by the injection unit of this machine. The
preforms will then be transferred into moulds and air is blown to form plastic containers.

2.1.2 Features of the machine

1) The product is smooth with high precision of neck dimension and mouth thread, and has
very credible seal quality.
2) Feeding can be controlled precisely during production, wall thickness is even and well
proportioned with relatively small errors in product weight.

3.1.32.1 Rev 03 9
 3) The products need not trimming and there are no scraps generally.
4) A wide range of materials are applicable for this machine, such as HDPE、LDPE、PP、
PS and PVC which can all be processed in the machine for round, cubic and ellipsoidal
containers.
5) This machine has three horizontal working stations and the triangle transfer head is long
on each side which can perform process in more chambers within one mould. It can also perform
the injection, blowing and stripping separately and simultaneously so as to make the machine
highly productive. The products will be transferred stably on conveyor belt after stripping from
moulds.
6) Extracting and inserting movements can be set for bottom process, which can produce
deep bottom products and keep bottle mouth flat.
7) Adjustable devices are installed for hydraulic, pneumatic, mechanical and electrical
controls to meet the processing requirements of different raw materials and specifications.
8) A special computer is used in this machine, which enables to preset parameters by
pushing buttons. It can perform failure self-check and alarm by light or displaying the failure
content to facilitate operation and maintenance.

2.1.3 Main components of the machine

The machine comprises the following components:
- Injection unit
- Injection mold-closing unit
- Blow mould- closing unit
- Lifting and transferring device
- Stripper device
- Machine frame
- Safety guard
- Heat inductive oil and cooling water distribution device
- Moulds

3.1.32.1 Rev 03 10
 1 — Injection Group
2 — Injection Die Closing Group
3 — Plastic Blowing Die Closing Group
4 — Lifting and Transferring Device
5 —Stripper Device
6 —working platen
7 — frame
Fig. 2-2 General assembly diagram

3.1.32.1 Rev 03 11
 2.2 Specifications
The main specifications of the injection & blow molding-machine are listed in the table
below. More detailed information can be found in the chapters on each component.

Serial No. Items Unit Quantity

1 Screw diameter mm 55

2 Screw L/D L/D 24

3 Plasticization capacity(PS) g/s 29

4 Swing radius mm 610

5 Max plane size of die(L*W) mm 850*460

6 stroke of mould mm 127

7 Transfer head lift stroke mm 63．5

8 Stripper stroke mm 195

9 Min die thickness mm 254

10 Max Injection mould clamp force kn 700

11 Max Blow mould clamp force kn 100

12 Dry cycle time s 3

13 Motor power kw 30

14 Barrel and die heating power kw 16

15 Max theoretic injection capacity cm3 300

16 Pressure of hydraulic system Mpa 14

17 Max air pressure Mpa 1

18 Cooling water consumption M3/h 5

19 Machine size(L*W*H) mm 4500*2010*2145

20 Machine weight T ≈8.5

Table 2-1 Parameters of Injection & Blow Machine

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3.1.32.1 Rev 03 12
 2.2.1 Injection group
Mainly consist of heating barrel, screw, injection seat (including injection double cylinders),
hydraulic motor and seat moving cylinder etc.

1 — heating barrel
2 — screw
3 — injection seat (including injection double cylinders）
4 — hydraulic motor
5 — seat moving cylinder
6 — outlet
7 — hopper
Fig.2-3 Injection unit

This machine adopts φ55mm screw; high quality steel are used for screw and barrel,
nitriding treatment maks long lifetime. The blend head of screw guarantees the evenness of
material plasticization. A stop ring is installed in the head to prevent the flow running along the
screw during injection.
The full stroke of injection part forward and backward is done by back-installed seat moving
cylinder, which is arranged to move forward or backward based on operating requirements to
fulfill the performance of front feeding, back feeding and fixed feeding. Fixed feeding is adopted
for this machine, and nozzle of material barrel is always against the main pour point of hot flow
mould during circling.
Injection seat can be turned around the center to facilitate the disassembling of screw and
cleaning of barrel. As hopper is fixed, when replacing different plastic material, open the outlet
cover to bleed the remaining plastic and retighten the cover before feeding new plastic for
production.

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3.1.32.1 Rev 03 13
 2.2.2 Injection die closing group
This group is hydraulic closing structure and the closing force can be easily adjusted by
changing the working pressure of oil. The group mainly consists of upper and lower beam, guide
pole, two assistant cylinders, oil refilling cylinder and other parts.

platen

1 — upper beam
2 — subplaten
3 — guide pole
4 — assistant cylinder
5 — lower beam
6 — oil refilling cylinder
7 — Mould closing safety device
Fig. 2-4 Injection mould clamping unit

In order to improve the productivity, oil pump performs opening and closing by supplying
oil for the two smaller assistant tanks on the two sides to increase speed of opening and closing.
Protective function of low pressure die will act when closing. Before the upper and lower
half die closing tightly, oil pump will not force them by high pressure. If something hard is inside
the cavity will not close tightly, electrical control system will alarm for the operator to eliminate
the fault. In fault elimination, positioning supports or supporting wood blocks are needed
between molds to prevent dropping of mold-closing parts in case of open molds. Please use

12

3.1.32.1 Rev 03 14
 brass tools to clear core rods, core rod tips and parison cavities to avoid damaging molds.
Operators need to wear working gloves during operation to prevent scald and scratch by
sharp edges of molds.

13

3.1.32.1 Rev 03 15
 2.2.3 Plastic Blowing Die Closing Group
This group is hydraulic closing structure too and it is also true to adjust the closing force
conveniently only by changing the working oil pressure. It mainly consists of upper and lower
beams of blowing die, guide pole, oil tank and other parts.

1 — upper beam
2 — subplaten
3 — guide pole
4 — lower beam
5 — oil tank
6 —Mould closing safety device
Fig. 2-5 Blowing mould clamping unit

Low pressure die protective function will act when closing. Before the upper and lower half
die close tightly, oil cylinder will not force them by high pressure. If something hard is inside the
cavity to prevent closing, electrical control system will alarm for the operator to eliminate the
fault. In fault elimination, positioning supports or supporting wood blocks are needed
between molds to prevent dropping of mold-closing parts in case of open molds. Please use
brass tools to clear core rods, core rod tips and parison cavities to avoid damaging molds.
Operators need to wear working gloves during operation to prevent scald and scratch by
sharp edges of molds.

14

3.1.32.1 Rev 03 16
 2.2.4 Lifting and Transferring Device
Lifting and transferring devices mainly consist of transfer graduate mechanism, tower seat,
transfer head, transition plate, transferring shaft, lifting hydraulic cylinder, motor and other
assistant elements.

1 — transfer head
2 — tower seat
3 — transferring index box
4 — transferring shaft
5 — lifting oil cylinder
6 — motor
Fig. 2-6 Lifting and Transferring Group

Connect the mounting plate of core rod to the transition plate on transfer head first, and then
place core rod on it. Three groups of core rods are used to finish injection, blowing and stripping
separately in three stations.
Lifting oil cylinder connects the transferring shaft to drive the transfer head up and down.
Transfer head will go up and down simultaneously when machine opens and closes die. The
distance between die opening and closing is 127mm and that between up and down of the
transfer head is 63.5mm. When there is fault in transfer heads, positioning supports or
supporting wood blocks are needed between transfer heads and transfer head seats to
prevent dropping of transfer heads in case of transfer heads in rising state.
After setting the speed of die opening and closing, it will be ensured that the lifting and

15

3.1.32.1 Rev 03 17
 dropping of transfer head can be finished simultaneously with die opening and closing through
adjusting proportion flow pressure valve so as to obtain the best productivity. In order to protect
the moulds from damaging, die opening should be slightly earlier than the lifting of transfer head;
when closing the die manually, make sure the transfer head will go down to the position before
die closing to the point.
Automatically transfer head will go up following the raise of injection die and blowing die
until reaching the position, then the motor on the transferring index box will start and the tower
is turned 120º by transferring index box via transferring shaft. The transfer head will stop going
downward. Finally precise transferring position is reached exactly by the steady pin and mould
on the transfer head. With steady and precise positioning ensured, the faster speed of transferring
position is better.

16

3.1.32.1 Rev 03 18
 2.2.5 Stripper Device
This device mainly consists of stripping frame, stripping template, stripping cylinder, bottle
stripping detection and other parts.

1 — stripping detection
2 — stripping plate
3 — stripping frame
4 — stripping cylinder
5 — stripping up/down cylinder
6 — stripping arm
7 — sliding shaft
Fig. 2-7 Stripper device

Installed inside the notch of working table, this device’s function is to release the formed
bottle from core rod head and turn 90º so that the products will be sent onto conveyor belt. The
stripping template must be changed accordingly if the product is changed.
This device also cools core rod outside and detects the stripping. Since temperature of the
head of core rod is higher than that of body, external cooling will adjust temperature of the core
rod properly. A pair of laser detectors is installed on the working station to detect if any bottle
remains on the core rod; if there’s any, subsequent processes will be influenced. At this time
signals are interrupted for the detectors and the machine stops immediately. After the operator
eliminates the fault, close the safety guard and restart the machine to continue production. Please
use brass tools to clear core rods, core rod tips to avoid damaging molds. Operators need to
wear working gloves during operation to prevent scald and scratch by sharp edges of
molds.

17

3.1.32.1 Rev 03 19
 2.2.6 Machine Frame
The whole frame is constructed by welding profiled steel. On the top of frame are spheroidal
graphite cast iron working platen, injection and blowing mould device, transferring index box,
stripper device etc., in the back of frame are mainly installed with injection group, oil pump
motor, oil tank and electrical control cabinet.

2.2.7 Guard Door

Working piece station is installed with guard door frame and guard door, die injection, air
blowing, transfer head seat, transfer head and moulds are all inside, electrical protective device is
also installed inside, which will switch off circuit once guard door opens, machine then stops
working, therefore avoid man-made accidents. Do remember not to stick any part of body into
the guard door when machine is running or power is on, keep far away from die stripping device
to avoid body injury.
Protective cover is installed in the back of machine, injection accessories are inside to keep
security.
Do not open the safety guard during normal operation of the machine.
Openable protective gates around frame are all equipped with locks. They must not be
opened during normal operation of the machine. In addition keys to these locks can only be
in charge of the trained specialized staff and be used in maintenance of the device.

2.2.8 Heat Inductive Oil and Cooling Water Distribution Device

Between die temperature controller and injection dies, inductive oil distributor is used to
transmit oil of different temperature from the die temperature controllers to bottle neck of
injection dies, preform body, preform bottom and etc. to balance the temperature of bottle
preform.
On principle, inlet of feed barrel, blowing die body, hydraulic oil cooler should be cooled
down by cooling water.
Inlet of feed barrel is equipped with clampers with circling water inside, which can prevent
the stuff from bending by high temperature.
After the blowing dies body are connected with cooling water, it can ensure the products are
cooled and formed rapidly, reduce shrinking and release from dies easily.
Hydraulic oil cooler will keep a proper temperature of 35-45ºC for normally working by
connecting with cooling water.
Cooling water can be ice water, tap water or that from cooling water circulation system. The
recommended cooling water temperature is around 10-20ºC; yet it is not that the lower
temperature is the better. Otherwise water drop will condense inside cavities and on core rod,
which affects the product quality.

2.2.9 Moulds

18

3.1.32.1 Rev 03 20
 1 — blowing mould
2 — core rod
3 — sub-nozzle
4 — hot runner plate
5 — hot runner seat
6 — injection mould
7 — core rod mounting plate
8 — stripper plate
Fig. 2-8 Moulds

The complete moulds include: hot flow rail, seat and nozzle, injection dies, air blowing dies,
three core rods mounting strips, three groups of core rods (quantity of each group depends on
quantity of cavities), die stripping template.
Moulds are made by various kinds of high quality alloy steels and stainless steel, processed
by heat treatment and highly precise machining. Heating bar is installed inside hot flow rail and
thermocouple is used to detect temperature inside the rail. When temperature reaches the set
value, the heating circuit will be disconnected to prevent melted stuff from overheating.
Inside injection dies, oil of different temperature will be sent to the mouth, body and bottom
of bottles correspondingly with cooling water inside the air blowing dies.

19

3.1.32.1 Rev 03 21
 2.3 Hydraulic system
The hydraulic system normally involves the following movements:
- Opening/closing
- Transfer head up/down
- Transfer forward/backward (Electric transfer type not available)
- Stripper forward/backward
- Stripping down/up
- Carriage forward/backward
- Injection/decompression
- plasticization

20

3.1.32.1 Rev 03 22
1 2 3 4 5 6 7 8 9

3.1.32.1 Rev 03 23
1-Stripping 3-Transfer head up/down 5-Injection 7- blowing mould closing 9- Oil adding for oil tank
2- Stripper down 4- Carriage forward/backward 6- Pre-plasticization 8- Injection mold closing
Fig. 2-9 Principle of hydraulic system diagram
Note：This machine recommends anti-wearing oil（GB11119-89）, code L-HM46, oil tank 400L. MOBIL DTE 25 (SAE 10), ISO 46
There are three pumps in this machine totally, driven by a double shaft motor of 30KW

22

3.1.32.1 Rev 03 24
 2.3.1 Pump P1
Pump P1 is a constant displacement vane pump，which adopts proportion flow and pressure control.
It guarantees fulfillment of every movement in pre-plasticization, injecting, decompression, carriage
forward/backward, die opening and closing.

2.3.2 Pump P2
Pump P2 is a constant displacement vane pump，which adopts proportion flow and pressure control.
It guarantees fulfillment of stripping forward/backward, transfer forward/backward, stripper up/down,
transfer head up/down.

2.3.3 Pump P3
Pump P3 is a variable piston pump. When the machine closes mold to its place, Pump P3 begins to
increase pressure and realizes greater mold-closing force when the set pressure is reached.

2.3.4 Power supply and valve

All the power supply and solenoid valves systems are DC24V, consumption ≤30W.

2.3.5 Oil Tank and Connection

Closed oil tank is adopted. Filters are installed for oil in and out to guarantee that oil is clean in
hydraulic system, elements in the system work credibly and for a long time. A cooler is installed on oil
tank to ensure normal working.
Park brand of connectors and hoses are adopted for oil connections; seal elements are all of famous
brand, which are credible and easy to fit.

2.3.6 Oil integrated groups

There are five oil integrated groups in hydraulic system of this machine, which are:
- Proportion pressure flow, injection, pre-plasticization, decompression, seat displacing; oil
integrated groups
- Proportion pressure flow, die stripping, position transferring, transferring and lifting;
- Injection and plastic blowing die opening and closing;
- Injection opening and closing adjustment;
- Die blowing opening and closing adjustment.

3.1.32.1 Rev 03 25
 2.4 Lubrication system
Automatic lubricating pump and quantitative distributor are adopted in this system.

2.5 Cooling system

Correct cooling of the moulds and nozzles is extremely important during the production cycle since
it affects the production rate and quality directly.
Generally cooling water can be ice water, tap water or that from cooling water circulation system.
The recommended cooling water temperature is around 10-20ºC; yet it is not that the lower temperature
is the better. Otherwise water drop will condense inside cavities and on core rod, which affects the
product quality.

Zone 3 Mould temperature control

1 — water cooler
2 — supply
3 — return
4 — hot oil pipe supplied with machine
5 — injection position
6 — blowing position
Fig. 2-10 mould cooling system diagram

24

3.1.32.1 Rev 03 26
 2.6 Pneumatic system
Pneumatic system of this machine performs the internal cooling of core rod, external cooling of core
rod, blowing and expanding preform, mould closing mechanical safety (mechanical protective device
forward/backward ) and so on. No solenoid reversing valve is lubricated with oil to keep sanitary.
Power supply for all solenoid valves is DC24V, with consumption no higher than 6W.
A 10L air storing tank is configured to keep air blowing pressure steady. Actual air blowing pressure
is within 0.5-1Mpa. Core rod opens before air blowing and internal cooling. Adjust properly temperature
of core rod by internal cooling, and since temperature of core rod head is very high, external cooling
must be added for adjustment.
Air blowing can be divided into the first air blowing and the second air blowing. Normally the
second air blowing starts just after the first air blowing and pressure of the second air blowing is higher
than that of the first one. During delayed second air blowing, remove the heated air blown in bottles at
the first blowing to make room for fresh and cooler air at the second blowing, which benefit molding of
products. As to PE and PP，only the first air blowing is ok.

Internal cooling External cooling core out Core rod open Safety device Blowing

Fig. 2-11 Principle of pneumatic system diagram

Warning：
The system will only operate when the protective gates of pneumatic cabinet have all been
closed and locked. Additionally keys to the gates can only be in charge of the trained specialized
staff and used in maintenance of the device.

25

3.1.32.1 Rev 03 27
 2.7 Electrical system
Electrical control of this machine is used for program actions of main machine, assistant machine
and other group devices.
Three phase and four wire power is supplied by power net to oil pump motor of 30kw, mold
temperature controller and control box.
The whole machine adopts Austrian special PLC of B＆R for injection and blowing machine（IBM）
to control. Please refer to the manual directly for the system configuration and running instructions.

2.8 Control panel

Control panel is shown as the diagram below:

Zone Z1

Zone Z2 Zone Z3

Zone Z4

Zone Z1：
- F1-F8 function keys
- Display screen

F1 F2 F3 F4 F5 F6 F7 F8

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3.1.32.1 Rev 03 28
 F1～F8 function buttons as follows:

signs Functions explanation Note

overview

Screw Temperature

Mould Temperature

Time setting & display 1

Time setting & display 2

Mould opening & closing control

Injection control

Plasticization decompression control

F1 ～ F8
stripper serial movements control function
buttons
Machine operating monitor (screen)

Input & output monitor

Movement-selecting page

Process parameters storage

Current alarm

Alarm history

Movement limit explanation

Password grade

27

3.1.32.1 Rev 03 29
 Zone Z2：

← OK →

Large numbers of illustrations are adopted in this system to make it easy for operators to remember
visually the functions of each button in all screens. Notes of Zone Z2 are as following:

28

3.1.32.1 Rev 03 30
 Signs Explanations of functions Notes

pump
Buttons for
panel functions
Lubricating

Conveyor

Reset（initialization for automatic cycle）

Manual

Semiautomatic

Full automatic

Heating power supply

Screw heating

Runner heating

Alarm clearing

Screw speed

Main page

Time I page

Time II page

Temperature I page

Preheating page

Mould-opening & closing setting page

Injection setting page

Plasticization setting page

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3.1.32.1 Rev 03 31
 Other movements setting page

Movement-selecting page

Machine monitoring page

Processing technical parameters storing page

Current alarm page

Alarm history record page

Password grade changing page

Zone Z3：Digital keys

Zone Z4：

B B

B B B

30

3.1.32.1 Rev 03 32
 Remarks for Zone Z4:

Signs Explanations of functions Notes

Buttons for panel

Injection
functions

Plasticization

Decompression

Carriage forward

Carriage backward

Mould opening

Transfer head lifting

Transfer forward

Stripper forward

Stripper down

Transfer head dropping

Mould closing

Transfer backward

Stripper up

Stripper backward

Core rod opening

Blowing 1

Blowing 2

Vacuum inspiration

Internal cooling

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3.1.32.1 Rev 03 33
 External cooling

Core out

Core in

Pressurizing

2.9 Standards-certification-limits

2.9.1 Technical standards applied

The reference technical standard is:
Q/HZY 09-2006

2.9.2 Ambient operating conditions

- Temperature：No higher than 35°C and no lower than 5°C where the machine is installed.
- Humidity: No lower than 30% or no higher than 85%，no sharp change or condensation.
- Altitude: ＜1000 meters
- Atmosphere: Dust, acid, salt and corrosive gas is forbidden in surrounding air of working place.
- Power supply：3N+PE AC 60Hz 480V/220V ±10%
- Air supply: 0.8Mpa≤ pressure ≤1.2 Mpa Consumption 1-1.5m3/min Dry、Clean、free from
oil.
- Cooling water: tap water（≤20°C The users can recycle it after treatment.）.
The machine shall be kept from shock and vibration. The manufacturer’s specification must be
followed in installation and use of the machine. The user must notify manufacturer in case of special
installation and working environment.

2.9.3 Lighting
Ambient lighting conditions within a normal range are sufficient for correct use of the Injection &
Blow Molding Machine.

2.9.4 Noise levels

Under normal operating condition the noise level of the machine is kept under 85dB.

2.9.5 Residues and environmental contamination

The machine does not produce any residues in normal use because the scrap can be generally
recycled in the production process. Waste oil and water should be disposed of in compliance with the
regulations in force in the user’s country.

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3.1.32.1 Rev 03 34
 3 Safety
3.1 General information for operating place
3.1.1 General information
3.1.2 Notices to all personnel
3.1.3 Notices to operators
3.1.4 Notices to those responsible for maintenance
3.1.5 Notices regarding pneumatic circuits
3.1.6 Operators, managers and supervisors
3.1.7 Notices for fume and poisonous gases
3.1.8 Notices for fire
3.1.9 Extinguishing equipment
3.1.10 Notices in disassembling the machine
3.1.11 Work, control and safety zones
3.2 Hazards, guards, warnings and cautions
3.2.1 Hazards, guards, warnings and cautions
3.2.2 Hazards in the machine installation area
3.2.3 Hazards on the machine
3.2.4 Hazards
3.3 Limit switch
3.4 Safety guards and signs

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3.1.32.1 Rev 03 35
 3.1 General information for operating place
3.1.1 General information
The employer or safety manager must provide personnel training on accident hazards, safety devices
and the general accident-prevention rules specified in legislation in the country where the machine is
installed.
DANGER
Operators must know the positions and functions of all the controls as well as the
characteristics of the machine.
They must have read this manual in full and respect the instructions, warning and general
safety rules contained in this manual.
NOTE
This machine must be used by operators who are already experts in the operation of Injection
& Blow Molding Machine.
Carefully reading of this manual will provide valuable general information, above all on
safety-related matters, even for expert operators. It will also provide information on any possible
improvements which have been made to facilitate operation of the plant together with new technical
solutions adopted.
In cases where a Customer has purchased their first plant, we recommend that the engineer who has
been put in charge of the machine is sent to Manufacturer to follow suitable training. Alternatively, they
must be aided by Manufacturer engineers during the installation and start-up of the plant on the
customer’s premises.
Maintenance operations must be carried out by trained engineers after the machine has been set up
as required.
Tampering with or replacement of one or more parts of the machine and/or the use of accessories or
tools without written permission from the manufacturer can be the cause of risks of injury and would, in
this case, relieve the manufacturer of civil and penal responsibility.
Any operations which need to be performed in high temperature zones should be carried out with
heat-insulated and fire-retardant gloves.

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3.1.32.1 Rev 03 36
 Fig.3-1 Operating with gloves

DANGER
The clothing of personnel operating or carrying out maintenance operations on the machine
must comply with the essential safety requirements and the laws in force in the country of use.
WARNING
The work area must never be occupied by pallets, trolleys and any other matter which could
interfere with the operators’ freedom of movement in an emergency.
It is advisable to delimit this area by painting yellow lines on the floor.

3.1.2 Notices to all personnel

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3.1.32.1 Rev 03 37
 Notices to all personnel related to the machine.
- During operation of the machine, do not climb it, nor contact any moving parts of it. They may
cause unexpected injuries and accidents.
- When handling is needed on the machine, stop the supply of compressed air and shut off main
power supply. Then affirm the positions of pneumatically up-and-down movable parts. In case of rising
position, insert wood block or orienting support in the movable parts to prevent possible falling.
- Prepare for clothes suitable for working. During operating or maintaining the machine, relevant
personnel is forbidden to have long hair exposed outside, carry articles with themselves and wear draggy
clothes, which are all easily entangled into machine.
- Operation, maintenance and repair of the machine should be assigned to those trained by us or
technical staff equally proficient.
Please do not use such thread parts as screws and nuts not prescribed for the machine. For example,
British and metric system are used for composing parts of cooling water and air tubing, oil pressure
tubes and oil pressure valves; different requirements are set for number of screwing threads. Please do
not use the parts whose threads do not meet requirements.
- During maintenance, examination, cleaning and etc. do shut off power supply and absolutely do
not operate the machine if working inside the machine is needed.
- Nobody is allowed enter the safety guard of machine during operation.
Notice
Do shut off air supply before working and make sure the pressure of decompressing valves
indicates at 0. Pneumatically up-and-down movable parts will drop suddenly or after a period
because the air pressure is 0. To prevent possible dropping, insert wood pieces or orienting
supports in the movable parts. Pay attention to it in working.

3.1.3 Notices to operators

Notices to those who operate the machine daily.
- Do not contact any movable parts and accessories of machine with hands or body during
operation.
- Absolutely do not enter the safety guard during operation. Absolutely do not extend your hands
into the machine from below the safety guard.
- Do not place tools or other articles on the machine, nor should you leave anything behind. This
may cause operators’ tumble and foreign bodies left on the machine may also cause short circuit in the
electrical circuit and damages to machine.

Clear plastic material:

- Operators and staff around should wear masks, safety helmets, overall protective suits and gloves
when clear plastic material in the injection means and barrels.
An example is introduced for easily observing the state of plastic material for reference.
- Fully heat the barrel to dissolve plastic in it.
- Observe front end of barrel nozzle before clearing plastic. If melted plastic is flowing out from
nozzle, plastic in the barrel can be considered in a state relatively suitable for clearing.
- If some hard plastic accumulates around the front end of nozzle, plastic in the barrel can be
considered in relatively low temperature.

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3.1.32.1 Rev 03 38
 - Meanwhile prepare containers to hold waste resulting from clearing.
- Too long heating time of plastic may cause its degradation and reduction in viscosity. At the same
time accumulation of high-pressure gas produced leaves the barrel in a high-pressure state.
- If the machine stops temporarily or for more than 10 minutes, screw will stop at middle position
and such phenomenon is likely to appear. Clearing in this case will be dangerous and please pay
attention to it. Please carry out clearing of resin at low-speed.
- Please keep the screw’s position at the front end during machine stop, which is favorable for safe
working and restarting machine.

Mold-closing device
- During mold installing, maintenance or molding adjustment, do use positioning stand or
supporting wood blocks to prevent mold-closing parts dropping if adjustments are needed in
mold-closing parts.
- Plastic grains scattering around the machine should be cleaned immediately. They are likely to
make operators slip.
- Make sure pressure in valves is totally eliminated before dismantling them. Gas produced by
high-temperature plastic is likely to create high-pressure gas in valves. Firstly stop adding plastic to
injection means and then clean it to make sure it is completely clean in valves without leftover.

3.1.4 Notices to those responsible for maintenance

Notices to technical staff those are responsible for maintenance and examination.
- Shut off main power supply and lock the switch before maintenance and examination. The key to
machine should be handed to those responsible.
- Protective enclosure and safety guard are equipped around the machine to protect operators. Limit
switch is installed on the safety guard and door of electric cabinet. The machine cannot start if these
doors are not fully closed. Operation cannot begin if these doors are removed.
- Stop the machine immediately in case of oil leaking. Find out causes and take measures. Oil
pressure tubing is injured quickly and may cause damage to other parts. Oil leakage in machine will
spread to electric control panel, which is greater harmful. Leaking oil flowing out of the machine will
cause slippery machine and likely slipping of operators. Please pay attention in operation. Burning point
of hydraulic oil is about 230ºC. Leaking oil diffusing like fog will cause fire on such high-temperature
parts as heating circles.
- Pressure setting of oil pressure and air circuit has been adjusted by the device leaving factory. In
case of necessary further adjustment, the pressure should not exceed the prescribed upper limit;
otherwise the machine will be damaged.
- Compressed air is used in the molding machine manufactured by us. During dismantling and
replacing air valves, cylinders, safety valves, joints, piping and etc., do release fully pressure in the
circuit and make sure pressure of remaining air is 0. When the up-and-down movable parts in pneumatic
system are in rising position, insert orienting supports in the movable parts to prevent possible falling
after a long time. Apply suds in joints after the operation to check if there’s air leakage. This step should
also be carried out during regular maintenance.
- Make sure all the parts are in dropping position before maintaining pneumatic or hydraulic
circuits. Dismantling circuits in rising position will create possibility of sudden dropping and cause

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3.1.32.1 Rev 03 39
 accident.
- If maintenance has to be carried out in rising position for pneumatic or hydraulic circuits moving
up-and-down, positioning supports or wood blocks must be set to prevent dropping.
- Cooling water is used in heat exchangers of molds or hydraulic oil. Check regularly the water
tubing for leakage. Water contacting electric parts is likely to cause faults in device.
- Please employ pressure standards permitted by the machine for the water and air tubing set by
your company.
- Normal tools should be used in maintenance and examination. Torque should be correct in fitting
screws and nuts.
- Before adding oil to the machine or lubricating it, make sure the machine is completely stopped.
- Examine the machine regularly.
- Do shut off main switch of the machine and lock it during maintenance of machine or electric
circuit.
- Do not contact electric equipment with wet hands.
- When operation in case of contacting power supply is needed for electric maintenance, do use
pressure-resistant and insulated protection (clothes, shoes, gloves, helmets) and insulated tools
(wrenches, tweezers). Do not wear jewelry or other metal articles. When more than 2 people work, make
sure that safety measures are taken for each other.
- For electric equipment and wires, please follow: creepage protectors should be set in front of main
machine connected to your power supply; suitable ground leads installed in specified location on the
frame of main machine. Creepage protectors should be checked and replaced regularly because their
reducing insulating capacity leads to malfunctioning after being used for a long time; please use fuse and
switch with correct capacity; please use insulating cables which ensure electric capacity. Please connect
the cable with main switch in the electric cabinet.
- After repairing the machine, make sure again there is no potential risks after electrifying and no
tools are left in the machine and check again the repaired parts before electrifying.

Blowing molding machine:

- If foreign bodies are blocked at nozzle of hot runner or barrel, please remove the nozzle from the
machine and then eliminate them. Do not apply unnecessary heating or pressure to the machine (e.g. the
nozzle cannot be directly heated with gas blowtorch.) Such unnecessary heating to the machine or mold
may cause heat produced by decomposition of plastic to form dangerous pressure in machine parts.
- If concretion of plastic grains is found at passageway of barrel below hopper, please clear it away.
Plastic melting after long-time exposure in high temperature will produce degrading and decomposing
gas. Because of gas sealed in barrels, high-temperature plastic in the form of liquid may spill out of
passageway of barrel during removing plastic. To prevent such risk, please pay attention to the following
during plastic elimination: ensuring sufficient time to cool barrel; protecting all exposing parts on the
head with protective masks. Veils, protective gauze masks, thick gloves and protecting suits (preferably
uniforms specially for welding) should also be used.

3.1.5 Notices regarding pneumatic circuits

Compressed air may cause casualties or greater risks during containers bursting. Please follow these
in installing pneumatic circuits:

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3.1.32.1 Rev 03 40
 - Pressure set for decompressing valves must not exceed the pressure range specified by us.
- When release pressure in operating air circuits, do stop the machine firstly, stop supply of
compressed air, and open slowly the exhaust valves for pressure in circuits to drop gradually.
- For the device with air tank, do stop the machine firstly, stop supply of compressed air, open
slowly the exhaust valves (stop valves) below the tank, and then remove pressure in the tank and circuits.
Pay attention not to hit air tank.
- Stop completely supply of air to the machine. Do not dismantle parts until it is ensured that
pressure in pneumatic circuits is totally removed.
- Do the following in case of non-operation for a long time. Release the pressure and make sure
remaining pressure is totally removed in the machine. Carry out antirust and anticorrosive treatment for
the interior.
- Do the following affirming after installing pneumatic circuits again. Supply air after reducing
pressure of decompressing valves and check every part in low pressure. Then set the maximum pressure
permitted by the machine and check if all the operations are normal.

3.1.6 Operators, managers and supervisors

All the personnel related to the machine should follow strictly the requirements set by this
specification.
- Please arrange at least 2 staff members in maintenance to ensure safety.
- Please arrange only those qualified technical staff those have been trained in relevant matters in
maintenance and management of the machine.
- It is advised to have a major repair of the machine at least every 5 years after its acceptance to
make it operate efficiently and securely. Major repair is regular maintenance and must be carried out
with daily examination.
- Please do not alter the machine, molds and attaching machines without our permission and
approval. We shall not assume any responsibility for the users who alter the machine, molds and
attaching machines without our permission and approval.

3.1.7 Notices for fume and poisonous gases

Due to additives in plastic, fume or poisonous gases are usually produced from heating.
Please consult with manufacturers of plastic material and additives to acquire information about
possibility and conditions for producing fume and poisonous gases and their relevant properties.
Please set up gas exchangers in the installation site of main machine to ensure secure and
comfortable operating environment.

3.1.8 Notices for fire

On the main machine are hydraulic oil and heating circles which produce high temperature. Some
types of machine need to be adjusted with gas blowtorch.
Pay great attention in using fire:
- Adding oil, dismantling and other operations should be carried out after complete stop of the
machine.
- Hydraulic oil, heat-conducting oil (used in molding temperature controller) and lubricating oil
should not be close to fire; otherwise will be potential risks for fire.
- Dispose correctly oiled rags, incorrect management of which is likely to cause fire.

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3.1.32.1 Rev 03 41
 - Please clean immediately oil spilled around the machine.

3.1.9 Extinguishing equipment

Please set suitable extinguishing equipment close to the factory and machine.
Working staff should be informed of location and usage of fire extinguishers.
Make sure regularly fire extinguishers function sufficiently.
Extinguishing agent includes CO2, foam, dry powder, spray and etc. The type of dry powder is
recommended for earlier fire of machine.
Please cut off fire source and then use dry powder extinguishers in case of the fire caused by
hydraulic oil or kerosene and other carbide.
Please cool down surrounding combustible material and buildings with water spraying to prevent it
fires again.
Please use breath-protecting equipment depending on the circumstances.

3.1.10 Notices in disassembling the machine

Disassemble the machine after making sure that pneumatic circuits are completely depressurized.
Please clear away all the hydraulic oil (which is combustible) in hydraulic circuits before
disassembly.
Please treat oil from elimination as castoff.

3.1.11 Work, control and safety zones

The operator must stay in Zone A and Zone B during normal operation of the machine.
The operator must, in other words, monitor the injection & blowing unit in Zone A and handle the
control panel in Zone B.

A — operating zone
B — key controlling zone

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3.1.32.1 Rev 03 42
 C — mould temperature controlling zone
Fig.3-2 Work area
WARNING
No one should ever under any circumstances climb up on the machine while it is operating.

3.2 Hazards, guards, warnings and cautions

3.2.1 Hazards, guards, warnings and cautions
The following are definitions applied.
- DANGER ZONE: a zone inside or near the machine where the presence of an exposed person
constitutes a hazard for the health and safety of that person.
- EXPOSED PERSON: any person located partly or wholly in a danger zone.
- OPERATOR: person responsible for installing, operating, adjusting and carrying out routine
maintenance and cleaning operations on the machine.
All the machine’s hazard zones have been assessed and the necessary precautions have consequently
been taken to prevent risks to people and damage to the components of the machine itself.
DANGER
Check at regular intervals all the safety devices.

3.2.2 Hazards in the machine installation area

The area where the machine is to be installed must satisfy the requirements detailed in section 2.9.2
and take into account the information provided in section 2.9.3.

3.2.3 Hazards on the machine

After having considered the possible risks of the injection & blowing molding machine (see section
3.2.4), technical solutions for preventing or limiting the dangers for exposed persons have been adopted.
Guard systems have also been adopted on the machine (see section 3.3). The following residual
risks remain:
Heat-related hazards:
- Risk of burning on heating the protective device of barrel
- Risk of burning on heating any part of hot runner
- Risk of scalding by parisons and products
- Risk of burning on heating any part of transfer head
- Risk of burning on mould temperature controller, inductive oil hose and distributor
- Risk of burning on electric elements

Mechanical hazards:
- Risk of crushing near nozzle
- Risk of crushing and impact during injection and decompression
- Risk of severing on speed-detecting disc in plasticization
- Risk of crushing and impact during carriage forward & backward
- Risk of crushing and impact during transferring
- Risk of falling on platform
- Risk of crushing in mould closing and opening

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3.1.32.1 Rev 03 43
 - Risk of crushing and impact during stripping
- Risk of severing on fans
- Risk of crushing and impact on mould-closing mechanical safety device

Electrical hazards:
- Shock hazard due to short circuits or failures

CAUTION
Never move close to the injection & blowing device when wearing clothes that do not comply
with the accident prevention regulations (ties, chains, bracelets, etc.).

DANGER
Never tamper with the machine’s guards and safety devices.

3.2.4 Hazards
Hazards and danger areas of injection & blow molding machine.
Hazards due to the stored hydraulic or pneumatic energy.
Danger of crushing, severing, impact due to the energy stored in hydraulic or pneumatic system.

Mechanical hazards during the moulds adjustment process

Danger of crushing, severing, impact due to movement of:
- the injection & blowing moulds and their parts
- plasticization device
- stripper turnover
- transfer head lifts & drops
- transferring forward & backward
- mould opening & closing

Electrical hazards
- electric shocks due to direct or indirect contact with live parts
- electric shocks due to electrostatic Symptom

Heat hazards
Burns and/or scalds due to the temperature of:
- hot surfaces
- temperature control circuit connecting pipes/hoses
- fluid leaks
- hot melt

Noise hazards
- hydraulic or pneumatic system
- mechanical parts
- blowing and emission of gas

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3.1.32.1 Rev 03 44
 3.3 Limit switch

1-electronic distance sensor for injection 2-button for emergency stop

3-Photoelectric detecting of mold-locking station 4-Detecting with laser electric eye
5-Photoelectric detecting of stripping forward/ backward
6-Electronic distance sensor for injection 7-Electronic distance sensor for transfer
8-Photoelectric detecting of transfer 9-Photoelectric detecting of blowing mold-opening
/closing 10-Electronic distance sensor for transfer head up/down
11-Photoelectric detecting of transfer head up/down
12-Photoelectric detecting of injection mold-opening /closing
Fig.3-3 Positions of main control switches

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3.1.32.1 Rev 03 45
 Serial
Name Function descriptions Note
No.
Electronic distance sensor for Checking positions of injection and
1.
injection decompression

2. Button for emergency stop Used in emergency stop

Affirming stopping position of mold-locking. The

Photoelectric detecting of SQ22
3. signal sent out is one of conditions for injection
mold-locking station SQ23
and blowing.
Detecting with laser electric Checking if any remnants are at top of core rods
4. SQ27
eye after finishing stripping.
SQ8
Photoelectric detecting of Checking stopping position of stripping forward/
5. SQ9
stripping forward/ backward backward.
SQ10
Electronic distance sensor for Checking position of blowing mold-opening
6.
injection /closing
Electronic distance sensor for
7. Checking position of transfer forward/ backward Backup
transfer
Photoelectric detecting of Checking stopping position of transfer forward/ SQ1
8.
transfer backward. SQ5
Photoelectric detecting of Checking stopping position of blowing mold, SQ12
9.
blowing mold-opening /closing mold-opening or closing. SQ4
Electronic distance sensor for Checking position of transfer head up/down real
10.
transfer head up/down time.
Photoelectric detecting of Checking stopping position of transfer head SQ13
11.
transfer head up/down up/down. SQ2
Photoelectric detecting of
Checking stop position of injection mold-opening SQ11
12. injection mold-opening
or closing. SQ3
/closing
Electronic distance sensor of Checking position of injection mold-opening
13.
injection mold /closing.
Table3-1 Function descriptions of limit switch

Seria Cod Seria

Name Note Name Code Note
l No. e l No.
Transfer forward Transfer
1 SQ1 1 D12 V11
stop forward
Transfer head Transfer head
2 SQ2 2 D15
falling stop falling V21 V20
Injection mold Injection mold V8 V9 V10 V14
3 SQ3 3 D9
closing stop closing V15
Blowing mold closing Blowing mold V8 V9 V10 V12
4 SQ4 4 D9
stop closing V13

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3.1.32.1 Rev 03 46
 Transfer backward Transfer
5 SQ5 5 D11 V11
stop backward
Carriage
6 Carriage forward stop SQ6 6 D5 V4 V3
forward
7 Nozzle opening stop 7 Nozzle open
8 Injection 8 Injection D8 V6
9 Pressure hold 9 Pressure hold D8 V6
10 Nozzle closing stop 10 Nozzle closing
Preplasticizing Preplasticizi
11 11 D7
stop ng V6
12 Decompressing stop 12 Decompressing D6 V5
Carriage backward Carriage
13 13 D4
stop backward stop V4 V3
Stripper second Stripper
14 SQ7 14 D19
forward stop forward V24
15 Electric eye 15 Vacuum head
16 Turnover stop 16 Turn over D17 V22 V23
Stripper-backward
Stripper
17 stop/stripper-forwa SQ8 17 D20
backward
rd stop V24
18 Turnback stop 18 Turn back D18 V22 V23
Striper second External
19 SQ9 19 D21
backward stop cooling V34
Core rod forward SQ1 Core rod
20 20 D23
stop 0 forward
Injection mold SQ1 Injection mold V8 V9 V10 V14
21 21 D10
opening stop 1 opening V15
Blowing mold opening SQ1 Blow mold V8 V9 V10 V12
22 22 D10
stop 2 opening V13
Transfer head SQ1 Transferring
23 23 D16
lifting stop 3 head lifting V21 V20
Core rod backward SQ1 Core rod
24 24
stop 4 backward
Transferring SQ1 Pressurizatio
25 25 D3 V2
detection 5 n
SQ1
26 Oil level 1 26 Alarm
6
SQ1
27 Oil level 2 27 Core rod open D27
7 V30
Oil absorb pressure Internal
28 28 D22
differential cooling V33
Oil return pressure SQ1
29 29 Air blowing1 D24
differential 8 V31

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3.1.32.1 Rev 03 47
 SQ1
30 Safety door1 30 Air blowing2 D25
9 V31
SQ2 Air blowing
31 Safety door2 31 D26
0 switch
SQ2 Double pump
32 Safety door3 32 D1
1 proportionP1 V1
Injection electric Double pump
33 33 D2
sensor proportionQ1 V1
Injection mold
Single pump
34 closing electric 34 D13
proportionP2
sensor V18
Blowing mold closing Single pump
35 35 D14
electric sensor proportionQ2 V18
Transferring head Stripper
36 lifting elctric 36 cylinder D32
distance sensor down-pressing V35
Stripper
37 Counter probe 37 cylinder D33
lifting V35
Confirmation for Locking
38 D28 V32
motor start forward
Locking
39 Pressure switch D29 V32
backward
Liquid
Air pressure
40 charging D30 V17
detection
control valve
Stripper cylinder SQ2 Mold closing
41 D31
downpressing stop 4 safety valve V25
Stripper cylinder SQ2
42
lifting stop 5
SQ2
43
Locking forward 2
SQ2
44
Locking backward 3
Table3-2 Input/output point code list

3.4 Safety guards and signs

The machine is fitted with the following guards and signs to ensure the health and safety of exposed
persons:
- Safety switches
- Hydraulic safety switches

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3.1.32.1 Rev 03 48
 1 — safety switch 1
2 — safety switch 2

Fig. 3-4 Positions of safety switch

There is neither automatic nor manual movement when the safety guard switch 1 and 2 are not
closed. If only safety guard switch 1 is open, there are no mould-opening & closing, transfer head lifting
& dropping, transfer forward & backward, stripper forward & backward and down & up. Here the
movements protected by safety guard 2, such as carriage forward & backward, plasticization,
decompression, injection and etc., are set at a slower speed. If only safety guard switch 2 is open, there
are no carriage forward & backward, plasticization, decompression, injection and etc. At this time
movements protected by safety guard 1, such as mould-opening & closing, transfer head lifting &
dropping, transfer forward & backward, stripper forward & backward and down & up, are set at a slower
speed.
No mould-closing movement occurs when the hydraulic safety switch is not closed. Refer to
sections 2.2.2 and 2.2.3 for mechanical safety device preventing mould-closing.
The openable protective doors on the machine frame are all equipped with locks and can be opened
only by special keys so as to prevent unallowed entry. The special keys can be used only by specialized
responsible personnel or trained maintenance personnel in safety adjustment and examination. It is
forbidden to open the door in normal working.
The safety guard of electrical cabinet is also equipped with safety switch. The system is
automatically cut off from power if any door is opened. In normal working it is forbidden to open these
safety doors, for which special keys are prepared and can be used only by specialized adjustment
personnel or trained maintenance personnel in safety adjustment and examination.
Operators and maintenance personnel must follow above regulations strictly. manufacturer declines
all legal responsibility for damages caused by violating these regulations in operation.

DANGER

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3.1.32.1 Rev 03 49
 Under no circumstances ever tamper with or remove the warning sign plates and guards on
the injection and blow moulding machine. The manufacturer declines all responsibility for the
safety of the machine if this instruction is ignored.

Safety signs Detailed explanation

Risk of high voltage. No touching.

Risk of high voltage and high temperature. No

touching.

Danger zone. Be careful in operation.

High temperature, don’t touch.

Rotating, keep hands and any object away.

High temperature, don’t touch.

Table 3-2 Safety signs

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3.1.32.1 Rev 03 50
 4 Installation
4.1 Packing, handling and transport
4.2 Choice of installation site and verification of installation requirements
4.3 Preparations for installation and foundations
4.4 Assembly
4.4.1 Cleaning the machine
4.5 Connections to supply systems
4.5.1 Connection to the electrical supply
4.5.2 Connection to the compressed air supply
4.5.3 Connection to the cooling unit
4.5.4 Filling the hydraulic system with fluid
4.5.5 Greasing before start-up
4.6 Checks before start-up

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3.1.32.1 Rev 03 51
 4.1 Packing, handling and transport
The personnel responsible for handling the injection & blow molding machine and its accessories
must have the necessary expertise in this aspect to avoid incorrect operations in the handling of heavy
loads. It is therefore advisable to use trained personnel for these operations and consider providing
ground assistance by someone giving clear signals if the dimensions of the load prevent the operator of
the handling machinery from gaining a sufficient view of the area.
Transport by heavy goods vehicle.
CAUTION
The customer must, however, check the condition of the goods upon delivery, irrespective of
the means of transport used.
The parts of injection & blow molding machine must be hoisted as shown in Fig. 4-1.

hoisting ring

hoisting ring

hoisting ring

hoisting ring

Fig. 4-1 Hoisting diagram

WARNING

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3.1.32.1 Rev 03 52
 The capacity of the hoisting equipment must be at least equal to the weight (taking the related
safety margins into account) of the different parts which need to be handled plus the increase in
capacity required by the safety regulations.
WARNING
Never handle the machine using equipment that does not comply with the safety regulations.
The user must comply with the conveying regulations in force in the country where the plant is
installed.
Manufacturer declines all civil and penal responsibility for damages caused to the machinery by
incorrect handling operations or carried out by incompetent personnel or using unsuitable equipment.
The machine, around 8500 kg in weight, is equipped with fixed positions for mounting hooks to
prevent its tilting in hoisting.

4.2 Choice of installation site and verification of installation requirements

The purchaser must have a room offering sufficient clear space around injection & blow molding
machine to enable personnel to operate in safety during the installation, maintenance and normal
operation of the machine.
The room must be fitted with water, compressed air and electricity supply connection points,
together with everything else necessary for the operation of the machine.
The customer shall be responsible for preparing the place of installation in compliance with the
regulations in force and safety requirements regarding ventilation, earthing, etc.

4.3 Preparations for installation and foundations

The machine stands on the concrete base by eight M30 shock-proofed feet; meanwhile prepare a
piece of steel mat 100×100×20 placed in the front of machine frame. See the floor mounts diagram
below.
Install the main machine longitudinally, with the transverse level within 0.1/1000mm，and adjusting
screws are tightened against the steel mat.

floor mount

mat position

Fig.4-2 floor mount layout map

The minimum spaces required by the machine installation are 6m*4m*2.5m。

4.4 Assembly

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3.1.32.1 Rev 03 53
 Having unpacked every part or component, proceed to position the machine in the point desired.
Hoist the machine following the instructions in section 4.1.
Slowly lower the machine, bringing it to rest in the point prepared.
Plant for installation should be equipped with smoke-venting device and exhaust due to
decomposition of plastics and a large amount of hot gas produced. Refer to fig. 4-3 to prepare for
exhaust device.

Fig.4-3 Position of exhaust mantle

4.4.1 Cleaning the machine

The unpainted parts of the machine (such as guide poles, slide bushing and guide pins) are protected
with grease during transport.
WARNING
Clean the machine carefully, removing dust and foreign bodies and soiling substances with
special detergent (we advise against solvents, though they have a very strong decontamination
capacity).
The personnel involved in this operation must be provided with individual protective gear
(overalls, gloves, etc.)

4.5 Connections to supply systems

4.5.1 Connection to the electricity supply

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3.1.32.1 Rev 03 54
 The machine must be connected to the main power supply in compliance with the regulations in
force in the country of use.
Three phase and four wire power 380V（480V）is supplied by power net to control box.

WARNING
Make sure all the connections between the machine and electrical cabinet have been
completed before connecting the machine to the main supply.
DANGER
The user must install a different countercurrent circuit breaker for the machine’s main switch.
WARNING
Under no circumstances ever connect the earth cable and neutral cable incorrectly.

4.5.2 Connection to the compressed air supply

Refer to Fig.2-10 Principle of pneumatic system diagram for connection of pneumatic elements.
The customer must provide gas hose enduring 2Mpa to be used in connecting the machine’s
pneumatic elements.
CAUTION
The Customer must install a backpressure valve for the pneumatic system for use in case of
need.

4.5.3 Connection to the cooling unit

The hydraulic system in this machine is cooled by running tower water through a tube and shell type
heat exchanger. The end of this machine has two 1-inch NPT threaded holes, labeled “in” and “out”
respectively, in the bottom rear corner. They are for the tower water connections. It is important that the
supply is connected to “in” (bottom) hole and the return to “out” (top) hole. Gate valves should be put in
both lines if future servicing to the system is necessary. It is good practice to install a “T” pipe
connection at the two ports for the mould temperature controllers’ water supply. Most of these
controllers require the same type of tower water as the machine.
Refer to Fig.2-9 for connection of cooling unit and Fig.4-4 connection in cooling system.
WARNING
Cooling water can be ice water, tap water or that from cooling water circulation system. The
recommended cooling water temperature is around 10-20ºC; yet it is not that the lower
temperature is the better. Otherwise water drop will condense inside cavities and on core rod,
which affects the product quality.
NOTE
Water is sent through internal conduit to the desired places, so no other water connection is
needed.

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3.1.32.1 Rev 03 55
 Fig.4-4 Connection in cooling system

4.5.4 Filling the hydraulic system with fluid

Hydraulic oil

1 — tank
2 — level indicator
oil filled to 31 of oil 3 — oil inlet
level meter

Fig.4-5 Hydraulic oil feeding position in hydraulic system

WARNING
Check the oil level on the indicator after 4 h work and fill oil if oil level is invisible.

Anti-wear General purpose

Standard No.
Company
46 46

MOBIL MOBIL OIL

MOBIL
DTE 25 MED. MOBIL

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3.1.32.1 Rev 03 56
 HYD.OIL 38

ESSO NUTO H 46 TELESSO 46

SHELL TELLAS
SHELL SHELL TELLAS OIL 46
OIL 46

CALTEX RAND OIL HD 46 RAND OIL 46

Table 4-1 Recommended hydraulic oil

4.5.5 Lubricating before start-up

Automatic lubricating system is adopted for the machine. 1.5L of grease is added into the
lubricating pump oil tank before start-up. Push lubricating key to start lubricating pump until all grease
points have sufficient grease.
The following units require greasing with a manual grease gun. Recommended specification of
lubricating oil is shown as Table 4-2:
- Injection moulds guide poles
- blowing moulds guide poles
- Lifting transfer head

Standard no.
Company
3 46 68

VACTRA OIL NO.1 VACTRA OIL NO.2

MOBIL —
VACUOINE OIL 1405 VACUOINE OIL 1409
FEBIS K68
ESSO POWERLEX DP 32 —
POWERLEX DP68
SHELL SHELL
SHELL —
TONA OIL T32 TONA OIL T68
Table 4-2 Recommended lubricating oil

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3.1.32.1 Rev 03 57
 A — Injection moulds guide poles
B — Blowing moulds guide poles
C — Lifting transferring shaft
Fig. 4-6 Mould position of manual grease points layout

A. — lubricating pump
B. — grease point
Fig.4-7 Grease points in machine

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3.1.32.1 Rev 03 58
 4.6 Checks before start-up
- Check the air pressure in the pneumatic system;
- Check there are no foreign bodies in the cavities of moulds or on the seam face of moulds;
- Check that the main power supply is suitable for the machine.

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3.1.32.1 Rev 03 59
 5 Preparation
5.1 Preparation and checks before start-up
5.1.1 Direction of rotation of electrical motors
5.1.2 Checking the machine’s movements
5.1.3 Mould: fitting/check
5.1.3.1 Fitting the moulds
5.1.3.2 Fitting core rod holder
5.1.3.3 Fitting core rods
5.1.3.4 Fitting the hoses
5.1.3.5 Fitting the nozzle
5.2 Adjustment of the machine
5.2.1 Adjustments on the hydraulic system
5.2.2 Adjustments to the pneumatic units

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3.1.32.1 Rev 03 60
 5.1 Preparation and checks before start-up
It is important to carry out a number of checks before starting the machine in order to prevent
problems or hazards during the first start-up phase.
DANGER
The preparation and check operations before the first start-up must be carried out by a
trained engineer from Manufacturer or by the purchaser’s own expressly trained personnel.
Carry out the following checks:
- Connect power according to the requirements of electrical system, and working voltage must be in
conformity with the specified voltage for the machine;
- Check buttons, keys, stroke (proximity) switches and electronic measures are connected;
- Check if the cores of hydraulic valves and pneumatic valves move flexibly, if any one is stuck.;
- Check if screws, bolts and nuts on the machine are fastened tightly;
- Check if the hopper is clean or there is any impurity inside;
- Connect cooling water and check if there’s leakage in the connections;
- Make sure the oil tank is clean before filling with clean hydraulic oil. Recommended oil is
anti-wearing oil with code L-HM46 for this machine;
- Connect hydraulic oil and check each connection is suitable and tight. No leakage is permitted;
- Clean the oil spot and dirt on the machine. Grease or oil is supplied to each grease point of sliding
parts. Refer to the related diagrams of machine composition and structure for each lubricating and grease
point. See fig. 4-4 positions of manual grease points;
- Air for pneumatic system must be free of water and dust and compressed air containing no oil with
total impurities less than 10mg/m3 and dust diameter no larger than 5 micron. Air pressure is 1.0MP with
air supply about 0.6 m3/min.
DANGER
Make sure that movement in the transit areas around the machine is not hampered by poorly
positioned cables, constituting a danger to personnel.
WARNING
All the checks must be carried out by trained technical personnel responsible for the machine.

5.1.1 Direction of rotation of electrical motors

The electric motors which drive the hydraulic system’s pump and the oil circulation pump must both
turn in a clockwise direction.
Proceed as follows to check the motors are running in the correct direction:
- Switch on the main power switch
- Switch on the main control switch
- Dot motor-starting button
Check if the pump is running in the correct direction. Check and adjust the circuit if the alarm
sounds due to phase-absence or phase-converse. Exchange any two lines in three-phrase line in the case
of phase-converse.

WARNING
Never swap over the connections on the individual motors.
The electrical connections inside the machine have been done by Manufacturer.

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3.1.32.1 Rev 03 61
 NOTE
Carefully check the pressures in the hydraulic loop immediately after you have checked the
machine.

5.1.2 Checking the machine’s movements

WARNING
Every manual movement can be controlled only with closed safety gates at normal work
speed.

5.1.3 Mould: fitting/check

Before proceeding to fit the moulds it is necessary to check that all the machine’s safety systems are
operating correctly.
DANGER
Never carry out any operations on the system without notifying the engineer who assists with
fitting.
WARNING
The work zone must be clear; oil and gas flow must be fluent.
Before positioning the mould:
- Make sure that the plates on the machine which it rests upon are clean;
- Spread a thin film of protective oil over them using a cloth.
It is also necessary to:
- Check the moulds themselves are clean;
- Check that there are no impurities in the groove profile;
- Make sure the cooling loop is unobstructed and allows correct water flow. This check is carried
out by blowing compressed air into the loop and checking that it flows out through the other end;
- Check that there are no dents in the nozzle;
- Check that the air and water hoses are free from scale or other obstructions.
The procedure for fitting the moulds and their accessories correctly can be divided into the
following operations:
- Fitting the moulds
- Fitting core rod holder
- Fitting the core rods
- Fitting the hoses
- Fitting the nozzles

5.1.3.1 Fitting the moulds

Molds are installed into the machine from the sides. Ample space should be available for mold lifts
on the side of machine. The machine should have both clamps open, the transfer head is lifted up, and
the carriage is back when molds are to be set.
Fitting the moulds in the following order:
1) Main power switch in cabinet “On”;
2) Cycle switch “Manual”;
3) Safety gate open, insert keys in the gate switch;

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3.1.32.1 Rev 03 62
 4) Main control switch “On”;
5) Pump start “On”;
6) Carriage backward is ended, mould opening is ended.
A good installation is started with a clean platen area and clean molds. The platens and transfer head
should be wiped clean with a cloth and light oil base solvent. A slight film of penetrating oil, such as
WD-40, will help protect the working platen when sprayed on exposed metal parts before molds are
installed.
Molds should be wiped clean in the same way, especially the top and bottom of both mould frames.
From the side of the machine, open the gates and set the parison mold on the lower platen with the
mould guide poles towards the carriage end of the machine. This step is best accomplished when a small
amount of lubricating oil is put on the platen first. Then with the mold lifted to the same level as the
platen, slide, do not drop, the mold onto the machine. The oil will help reduce the friction generated
between the ground surfaces of the mould and the platen.
Slide the mold forward, be careful not to hit the machine tie bar or nozzle. Move the mold close to
the mold centering key.
All IBM molds designed for the machine require two 82mm thick shims between the mould and the
locating head. Steel shim should be used for this purpose.
This process is repeated for the blow molds.
When both molds are in place, clamp the bottom platen of the mould to the working platen with
packing board, either mold first, using a pack screw to pre-tighten them.
After pre-tightening all clamping board, checking molds and upper mould surface is clean.
Close the mould clamping unit.
The top half of the molds are secured to the machine beam by bolts that pass through the sub-platen
and thread into the mould top platen.
When all molds are secured in place, start the motor. Do this by turning cycle switch to “Man”,
safety gates are closed, main control switch “On”, push “Pump Start”, oil pump motor runs, open molds,
push “Pump Stop”, then remove any cardboard or protective paper in the molds.

5.1.3.2 Core rod holder installation

Do this in following order:
1) Locate the core rod holder and transfer head with locating pins.;
2) Tighten the core rod holder with screws.
New machines, when shipped without molds installed, in case of do not have the “Trigger Bars”
installed in the transfer head. This needs to be done before the core rod holders and core rods are
attached to the machine.
The trigger bars are 3 pieces of flat hardened steel bar stock cut to the same length as the slot in each
face of the transfer head. Insert one of the trigger bars into the slot on the side of the head facing the
stripper station (front of machine). The bar should have a relatively symmetrical “Gap” around its edges
and the slot’s edges, when installed properly. Core rod holders are installed after installing trigger bars.
Otherwise the centrifugal force developed during rotation will cause the trigger bar to “Fly” out of the
head and can cause body injury or damage to mold.
Core rod holders are installed next. They are 3 pieces of rectangular aluminum bar stock cut to the
same length of one side of the transfer head with holes bored in them. They are installed by putting them

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3.1.32.1 Rev 03 63
 on locating pins, already in the head, and bolting them in place. The core rod holders have guide
bushings for the locating pins on one side. Put one core rod holder on the head by letting it rest on the
pins. There is no “Top” to the holder as the locating pins are diagonally opposed. Do not force the core
rod holders in place; palm pressure is all that should be required. Using socket head cap screws (or those
provided with core rod holders) secure the core rod holder in place. Do not over tighten these bolts. The
core rod holders are jig bored, hardened, precision ground and stress released. They are as critical a part
of the tooling as either mold or core rod and proper care should be taken any time they are handled.
Next check and see if there are “O” rings inside the large holes that the core rods slip into. There are
grooves cut in these holes just for the “O” rings.

Fig.5-1 Core pin holder unit

5.1.3.3 Core rod installation

NOTE
If machine has never been dry cycled, do not install core rods until it has been dry cycled.
Next install the core rods in the holder secured to the head. Be sure that the core rod cam nuts on all
the core rods are evenly adjusted. This ensures even core rod tip movement stroke when the core rods
are opened in the blow mold. The cam nut should be set approximately 2mm beyond the end of the core
rod. Adjustments are made by loosening the star nut and turning the cam nut in or out, then retightening
the star nut against the cam nut. Use a core rod adjustment tool to do this. Do not force the core rods into
place. Palm pressure is all that should be required.
When all the core rods are in place at the first station, secure them in place with the core rod
retainers. The core rod retainers are flat strips of metal with “U” shaped notches cut in them at the same
center lines as the holes core rod holders. The “U” shaped notches match perfectly the undercut notch in
each core rod that is directly in front of the holder. Align the “U”s notch with the top of the notches in

62

3.1.32.1 Rev 03 64
 the core rods and slide them onto the cores. The cores may have to be slid in or out slightly in the holes
to allow the retainer to lock into the notch. Push the cores and retainers into place against the core rod
holder and secure with M5 socket head cap screws (provided with core rod holders). Be sure to put one
screw in each hole in the retainer. If split retainers are used, be sure to repeat the procedure for the
bottom half.
After one set of core rods are installed, open moulds manually. Transfer head lifting, transfer
forward, the core rod is between up and down injection moulds. Then press transfer head down which
will allow the transfer head to drop slowly and the core rods to “Nest” in their respective cavities.
Check to see that the core rod’s bearing surfaces and match perfect and are totally inside the neck
ring pockets. Tooling is designed to allow 0.076mm-0.127mm between the core rod and inclined plane
of the neck ring. If the inclined plane of the neck ring is preventing the core rods from dropping all the
way into the pocket, move the mold in towards the center of the transfer head.
This is done by first lifting the transfer head and cores up, then by loosening mold packing boards’
screws. The new shims sizing will depend on how much of the core rod’s bearing area is hitting the neck
ring, the more contact the more shim to be removed.
Push the mold back in place. Tighten the lower packing boards’ screws and the upper mould’s bolts,
then check the core rods again by lowering the transfer head and cores into the repositioned mold.
When the first set of core rods sets into the parison molds properly and easily, raise the head,
transfer the head one position forward (control “On”, alarm “Reset”, “Transfer”). The first set of core
rods should be positioned between the blow mold halves.
Lower the head (control “Off”) into the blow molds to see that the core rods set clearly into the blow
molds. Adjust accordingly, as with the parison molds, by adjusting the shims.
When the molds are in position at the second station and the first set of core rods set clearly into
both molds, begin installing the other two sets of core rods. Don’t forget to put the trigger bars in place
before installing the core rod holders.
When the second set of core rods is installed and secured, check to see that they set into the parison
and blow mold correctly either.
After the second set of core rods is checked, install the third set of core rods. Be sure to check the
third set to see that they set into both molds correctly either.

5.1.3.4 Hose installation

Procedure: Mold hose sets provided by Manufacturer consist of two types of hoses and fittings. One
type of parison mold hoses is stainless steel braided, reinforced high temperature-resistant hoses; another
is rubber hoses cut to two different lengths.
The parison molds should have fittings already in them. If not, install them. Most molds have PT1/4
threads in the coolant passage access ports. Parison mold hoses supplied by Manufacturer require
M14*1.5 fittings. To connect hoses supplied by Manufacturer to the parison molds, put fittings into all
the holes in the mold both upper and lower halves, front and back. Be sure to use Teflon tape on the ends
threading into the mold.
The short hoses (rubber hoses) are used on the side of the mold facing the front of the machine. One
at a time, connect the hoses to the mold. One end of the first hose is connected to the first fitting on top,
the other end to the first setting on bottom, creating a “Loop”. Tighten this hose before connecting the
next one, as their closeness will not allow it to be done later. The second hose connects to the second

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3.1.32.1 Rev 03 65
 fittings, third to the third, etc. Be sure to tighten each hose before starting the next one.
When the hose connections on the front side of the parison mold are complete, start the connections
on their rear side. High temperature-resistant oil hoses are used on the rear side.
Connect one end of a hose to the fitting on the top mold half closest to the fitting. Connect the other
end of the hose to the manifold on the “Mold Supply” side of the first temperature control unit. Tighten
the hose on the fitting before putting on any other hoses. Connect the loose end to the manifold on the
“Mold Return” side of the same temperature controller that the first hose is connected to.
This connection, if proper, will create a continuous loop from the first temperature controller，
through the top and bottom half of the mold, and back into the temperature controller. Use a manifold as
a jumper and connect it to the same supply and return manifold on the first temperature controller. This
will allow more flow through the pump for more heat transfer.
Plug the remaining holes on the first temperature controller’s manifolds with 3/8 NPT plug. Mark
this temperature controller “bottom”.
The other lines to the parison mold are connected in the same way. The passages to the body zone
connections and any others remaining, excluding the passages through the neck ring, are connected to
the middle temperature controller. Label the controller “body”.
The final temperature controller is connected to the passage that goes through the thread area of the
parison. Sometimes it is also connected to the other neck ring passages to keep the bearing area of the
core rod hot. Label the controller “Neck”.
When all the oil lines are connected and manifold holes plugged, turn on the temperature controller
and open valves. Bring them up to processing temperature and check for leaks.
Connect the blow mold hoses: Blow mold cooling hoses supplied by Manufacturer are plastic and
cut to two lengths. They are connected in much the same way as the parison hoses. Loop the hoses in the
front and connect the rear mold hoses to the cooling water manifolds. Alternate the supply from top to
bottom on every other water passage for even heat transfer. Plug any holes not used on the chiller
manifolds. Turn on the chiller supply and check for leaks.
Refer to figure 2-9cooling system diagram.

5.1.3.5 Fitting the nozzle

If the nozzle is not already on the parison mold, it will need to be installed. Although there are many
different manifold designs, they are basically composed of the same components. The parts are usually
the base, the “L” brackets or clamps, the hot runner itself, cartridge heaters with leads, individual cavity
nozzles, nozzle clamping block and bolts and sometimes adiabatic parts are used between the hot runner
and the base. A streamlined manifold for heat sensitive plastics consists only of the hot runner system,
cartridge heaters, nozzles, clamps and bolts. The base is usually an integral part of the hot runner block.
All multi-cavity molds should have a balanced set of nozzles. Nozzle balancing is achieved by
drilling out the orifice of the nozzle tips to accommodate the pressure drop in the runner system that
occurs as the plastic is injected into the manifold, towards the cavity. Outside nozzles have larger
orifices than those on the inside and in the middle. Each material and mold structure varies so each
manifold will normally require different balancing techniques and nozzle orifices.
When all the nozzles and thermocouples are in place, turn on the heating buttons and the mold
temperature control units. set them both to reach the desired temperature. Turn off the pump only at this
point.

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3.1.32.1 Rev 03 66
 When both the manifold and temperature control units are up to the set temperature, leave the molds
closed and clamped, tighten the manifold base bolts and the nozzle clamping blocks’ bolts, in order like
this. It is very important to have the molds and the manifold heats up before tightening.

Fig.5-2 Assembling diagram of manifold unit

5.2 Adjustment of machine
5.2.1 Adjustments on the hydraulic system
The adjustments on the hydraulic system must be carried out by trained personnel with a perfect
knowledge of the operating layout and position of the individual units in the hydraulic system.
The unit is set to the correct adjustment values by Manufacturer during the factory tests on the
system.
The adjustments carried out are:
- Adjusting the pressure and flowrate of Pump A;
Press the button of Carriage Backward and assistant buttons for this movement in manual mode. Set
the percentage of pressure and flowrate increasingly in “Other movements page” described in Item
7.3.3.4.11 and observe if indicators on the pressure gauge of Pump A change proportionally. Execute the
movement of carriage forward/backward repeatedly and observe if the speed of carriage backward
changes proportionally.
- Adjustment of pressure and flowrate in Pump B;
Press the button of stripper Backward and assistant buttons for stripper backward in manual mode.
Set the percentage of pressure and flowrate increasingly in “Other movements page” described in Item
7.3.3.4.11 and observe if indicators on the pressure gauge of Pump A change proportionally. Execute the

65

3.1.32.1 Rev 03 67
 movement of stripper forward/backward repeatedly and observe if the speed of stripper backward
changes proportionally.
- Adjustment of pressure in Pump C;
Pressure compensator type, variable displacement piston pump, used in mold-clamping and
pressurizing. Pressure must be adjusted when there are molds, mold-closing stops, and pressurizing key
and assistant keys are pressed. Then observe changes of indicators on the pressure gauge of Pump C and
see if it finally rests on the maximum value.
NOTE
The aforesaid adjustments must be made with the mode in “manual”.

5.2.2 Adjustments to the pneumatic unit

The 3 decompression valves are adjusted individually in the pneumatic cabinet. Pressures can be set
for the first & second blowing and internal & external cooling. Pull the knob up; turn it clockwise to
increase the pressure or counter-clockwise to decrease it. Press the knob down after adjustment.

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3.1.32.1 Rev 03 68
 6 Dry cycling
The dry cycle will check the automatic operation of the machine without plastic injection. The dry
cycling can be done with or without air supply on and should be done without core rods the first time.
Only after the installation of the machine, auxiliary equipment and molds are complete, should a dry
cycle be attempted.
1) Turn on cooling water supply to machine hydraulic system and temperature controllers;
2) Close safety gates;
3) Main power switch on electrical cabinet to “On”;
4) mode switch to “Manual”;
5) Main control switch to “On”;
6) Pump start “On”;
7) Injection units carriage backward;
8) Open molds manually, transfer head lifting, transfer forward, transfer head dropping, mold
closing. Stripper forward, stripper down/ up, stripper backward;
9) Press “Reset” button to restore every movement to prepare for automatic. Blowing time is set to
“0”;
10) See Fig.7 to 27 Movement selecting page, close the injection action and carriage action;
11) Press “Semiautomatic” button to make machine carry out a dry cycling;
12) After validating the movement, switch to “Auto” and enable the machine to operate dry cycling
automatically.
If pneumatic pressure is on during dry cycling, check to see that all air valves are operating. Such as
1 blow, 2nd blow, core rod open, internal and external cooling.
st

Hydraulic system pressures should be checked. The pressure and speed of every movement can be
adjusted during machine operation if necessary.

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3.1.32.1 Rev 03 69
 7 Operation and Use
7.1 General information
7.2 Uses, zones, operators
7.3 Control and indication devices
7.3.1 General information
7.3.2 Electrical power board
7.3.3 Control panel
7.3.3.1 buttons on panel
7.3.3.2 Terminal block collocate
7.3.3.3 Illuminating the system
7.3.3.3.1 Panel function introduction
7.3.3.3.2 Status bar illustration
7.3.3.4 Page operation
7.3.3.4.1 Welcome Page
7.3.3.4.2 Overview Page
7.3.3.4.3 Temperature control Page
7.3.3.4.4 Page of heating plan
7.3.3.4.5 Page of process time setting
7.3.3.4.6 Page of process time limit
7.3.3.4.7 Page of mold opening & closing setting
7.3.3.4.8 Injection setting page
7.3.3.4.9 Page of plasticization & decompression setting
7.3.3.4.10 Page of transfer forward/backward
7.3.3.4.11 Page of Stripper setting
7.3.3.4.12 Machine action monitoring page
7.3.3.4.13 I/O monitoring page
7.3.3.4.14 Page of I/O modular status
7.3.3.4.15 Page of movement selection
7.3.3.4.16 Page of receipt management
7.3.3.4.17 Alarm page
7.3.3.4.18 History alarm page
7.3.3.4.19 Page of authorization change
7.3.3.4.20 System setup page
7.3.3.4.21 System option page
7.3.3.4.22 Page of system running information
7.3.3.4.23 Passward change page

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 7.3.3.4.24 Temperature optimization page
7.3.3.4.25 Temperature exception time page
7.3.3.4.26 Page of electronic distance sensor adjustment
7.3.3.4.27 Page of valve opening & closing time
7.3.3.4.28 Pressure slope page
7.3.3.4.29 Flowrate slope page
7.3.3.4.30 Flux safety gain page
7.4 Alarm
7.5 Loading raw material
7.6 Starting the machine
7.6.1 Initial checks
7.6.2 Starting procedure
7.6.3 Starting machine in automatic production
7.6.4 Checking dimensions of finished parts
7.6.5 How to make parisons
7.7 Machine stopping and disassembly
7.8 Normal operation: procedures and status of controls and indicators
7.8.1 Manual mode
7.8.2 Automatic mode
7.9 Checking the performance and settings
7.9.1 General information
7.9.2 Functional checks and tests on the safety devices
7.9.3 Closing the mould
7.9.4 Adjusting the blowing unit
7.10 Fault, emergency and alarm situations
7.10.1 General information
7.10.2 Bottle conveying faults
7.10.3 Parison faults
7.11 Stopping the machine
7.11.1 Voluntary stop
7.11.2 Emergency stop
7.12 Cleaning and preparation for periods of non-use
7.13 Cleaning after production

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 7.1 General information
After the injection & blow molding machine has been set up, started and adjusted by trained
engineers as described in the previous chapter, the normal production cycle can begin.
DANGER
Operation of the machine must be entrusted to trained operators who have carefully read and
understood the instructions. They must be aware of the safety measures applied and which need to
be applied.
NOTE
Carefully read Chapter 3 on safety.
WARNING
In the event of unknown or serious faults, stop the machine and contact trained in-house
engineers or the Manufacturer Technical Assistance Service.

7.2 Uses, zones, operators

The injection & blow molding machine is applicable for processing the following material:
- HDPE
- LDPE
- PP
- PS
- PVC
Any use of other material in the machine is not permitted and the manufacturer declines all
responsibility for any injury to people or damage to things resulting from such uses.
The operator is responsible for the following operations on the machine:
- Loading material in the hopper if the plant is not fitted with automatic devices;
- Changing and closing the boxes containing the bottles produced;
- Keeping the area around the machine free from any possible obstacles;
- Checking that the bottle produced does not have any aesthetic defects;
- Notifying the technical personnel responsible for maintaining the machine of any faults.
CAUTION
Operators must never carry out operations for which they have not been authorized or which
are not described in this manual.
DANGER
Maintenance, setting up and repair operations must only be carried out by trained personnel
with the machine stopped and in safety conditions.

7.3 Use of control and indication devices

7.3.1 General information
WARNING
The operator must have a perfect knowledge of the meaning of all the controls on the machine
and must be trained in how to behave in the event of an emergency stop or operating fault.

7.3.2 Electrical power board

The electrical cabinet’s panel features the following devices:

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3.1.32.1 Rev 03 72
 - Main switch
- Selector

7.3.3 Control and instrumentation panel

7.3.3.1 Buttons on panel
IBM300/700 Injection & blow molding machine employs programmable controller ( B&R pp250)
as main control unit and interface display unit, and realize parameters input, alarm display, orders
transmission and other functions with new-type multi-button operating panel (10.4-inch TFT screen).

Fig.7-1 Multi-button panel

Multi-button operating panel is adopted for the system to arrange all buttons’ function layout as
reasonably as possible and to divide function areas for certain buttons by different requirements.

7.3.3.2 Terminal block collocate

Installation diagram of terminal block:

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3.1.32.1 Rev 03 73
 Fig.7-2 Installation diagram of terminal block
7xx426
- Connection

Fig.7- 3：7XX426

72

3.1.32.1 Rev 03 74
 Fig. 7- 4：7XX426

73

3.1.32.1 Rev 03 75
 - 7XX426 - 1 Configuration

Serial No. Name

1 24V（+）

2 24V（-）

3 Power for blowing & injection electronic distance sensor（+）

4 Injection mold-closing electronic distance sensor

5 Blowing mold-closing electronic distance sensor

6 Power for blowing & injection electronic distance sensor（-）

7 Power for injection electronic distance sensor（+）

8 Injection electronic distance sensor

10 Power for injection electronic distance sensor（-）

11 Transfer head dropping stop

12 Transfer head lifting stop

13 Injection mold-opening stop

14 Injection mold-closing stop

15 Blowing mold-opening stop

16 Blowing mold-closing stop

17 Transfer forward stop

18 Transfer backward stop

Table 7 – 1：7XX426-1 Analog & digital signal input config.

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 Serial No. Name

1 24V（-）

2 24V（+）

3 Proportional pressure of pump A（+）

4 earth（-）

5 Proportional flowrate of pump A（+）

6 earth（-）

9 Pressure sensor（+）

10 earth（-）

11 Barrel section 1 heating

12 Barrel section 2 heating

13 Barrel section 3 heating

14 Nozzle 1 heating

15 Nozzle 2 heating

16 Runner 1 heating

17 Runner 2 heating

18 Automatic /preparation

Table 7- 2：7XX426-1 Analog & digital signal output config.

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3.1.32.1 Rev 03 77
 - 7XX426 - 2 Configuration

Serial No. Name

1 24V（+）

2 24V（-）

Power for transfer electronic distance sensor

3
（+）

4 Transfer electronic distance sensor

6 Power for transfer electronic distance sensor（-）

Power for transfer head electronic distance

7
sensor（+）

8 Transfer head electronic distance sensor

Power for transfer head electronic distance

10
sensor（-）

11 Carriage forward stop

12 Carriage backward stop

13 Stripper forward stop

14 Stripper 1 backward stop

15 Stripper 2 backward stop

16 Transfer inspecting

17 Air pressure inspecting

18 Motor starting successfully

Table 7- 3：7XX426-2 Analog & digital signal input config.

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 Serial No. Name

1 24V（-）

2 24V（+）

3 Proportional pressure of pump B（+）

4 earth（-）

5 Proportional flowrate of pump B（+）

6 earth（-）

10

11 Section 1 heating permitted

12 Section 2 heating permitted

13 Section 3 heating permitted

14 Section 4 heating permitted

15 Nozzle section heating permitted

16 Runner section heating permitted

17 Conveyor

18 Alarm

Table 7- 4：7XX426-2 Analog & digital signal output config.

7XX412
- wire

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3.1.32.1 Rev 03 79
 Fig.7- 5：7XX412

Fig.7 - 6：7XX412 Connection earth

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3.1.32.1 Rev 03 80
 - 7XX412 Configuration
Serial No.
Name
No.

1 Earthing 1

2 Earthing 2

3 Barrel section 1（+）

4 Barrel section 1（-）

5 Barrel section 2（+）

6 Barrel section 2（+）

7 Barrel section 3（+）

8 Barrel section 3（-）

9 Nozzle area 1（+）

10 Nozzle area 1（-）

11 Nozzle area 2（+）

12 Nozzle area 2（-）

13 Runner area 1（+）

14 Runner area 1（-）

15 Runner area 2（+）

16 Runner area 2（-）

17 Oil temperature 1（+）

18 Oil temperature 1（-）

Table 7- 5：7XX412 Temperature config.

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 Output Name

1 24V+

2 24V+

3 Transfer forward

4 Transfer backward

5 Transfer head lifting

6 Transfer head dropping

7 Mold opening

8 Mold closing

9 Carriage forward

10 Carriage backward

11 Stripper forward

12 Stripper backward

13 Stripper down

14 Stripper up

15

16

17

18
Table 7 - 6 ：7XX412 Output config.
7XX408
- Wire

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 Fig.7 - 7：7XX408

Fig.7 -8：7XX408 Connection

- configuration

Serial No. Name

1 （+）

2 （-）

3 Core rod detecting

4 Oil level detecting

5 Safety guard 1

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 6 Safety guard 2

7 Injection & mold-closing stop

8 Blowing & mold-closing stop

9 Manual assistant button

10 Screw speed detecting

11 Emergency stop button

12 Main control

Mechanical protective device

13
forward stop
Mechanical protective device
14
backward stop
15 Pressure difference in suction

16 Pressure difference in back oil

17 Phase sequence

18
Table 7- 7：7XX408 Input config.

Output Name

1 24V+

2 24V+

3 Injection

4 Plasticization

5 Decompression

6 Pressurizing

7 External cooling

8 Internal cooling

9 1st blowing

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 10 2nd blowing

11 Blowing switch

12 Core rod opening

Mechanical protective device

13
forward
Mechanical protective device
14
backward

15 Fan 1

16 Fan 2

17 Lubricating pump

18 Oil pump-starting permitted 允

Table 7- 8：7XX408 Output config.

7.3.3.3 Illumination of system graphs

7.3.3.3.1 Panel function buttons
Large numbers of graphs are used in the system to facilitate operators’ visually remembering all
buttons’ function in all pages. Their explanation has been stated in 2.8 and is not mentioned here.

7.3.3.3.2 Status bar functions

：No alarm ：Alarm

：Screw heating power not started ：Screw heating power started

：No oil-filling ：Oil being filled

：No heating ：Being heated

：Oil pump-starting not permitted ：Oil pump-starting permitted

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 ：Automatic conditions unsatisfied ：Automatic conditions satisfied

：Conveyor not started ：Conveyor started

：Temperature optimization not started ：Temperature optimization started

：Manual ：Automatic

：Adjustment ：Semiautomatic

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 7.3.3.4 Operation and use of every page
7.3.3.4.1 Welcome Page

Fig.7–9 Welcome page

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 7.3.3.4.2 Overview Page

Fig.7–10 Overview page

：Press and enter temperature control page.

：Press and enter the page of time setting and display.

：Press and enter the page of mold movement control.

：Press and enter movement monitoring page.

：Press and enter movement selection page.

：Press and enter process parameters storage page.

：Press and enter current alarm page.

：Press and enter the page of password grade.

Current temperature of each zone is above the machine diagram.

Times of lubricating cycle: Lubrication is started when the times of machine cycles reach this value
and the lubricating time is “setting time”.

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 7.3.3.4.3 Temperature control page

Fig.7–11 Screw temperature page

：Press and enter the page of heating plan.

：Press and enter the page of time setting and display.

：Press and enter the page of mold movement control。

：Press and enter movement monitoring page.

：Press and enter movement selection page.

：The key is pressed to move the cursor left for heating ON/OFF.

：The key is pressed to move the cursor right for heating ON/OFF.

：The key is pressed to begin or stop heating the area with current cursor for heating ON/OFF.
Upperlimit temperature: Alarm sounds if actual temperature exceeds it.
Downlimit temperature: If actual temperature is below it, screw cannot start, nor can
injection occur.
Heating percent: The efficiency of current heating. 0 means no heating and 100 full
power heating.
Heating enable: The status of current heating, ON means it is heating currently, OFF it is

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 not heating currently.
Upper & lower limit and temperature setting are restricted by login password grade.
Unable to move cursor for setting is caused by a low ogin password grade.

7.3.3.4.4 Page of heating plan

Fig.7-12 Page of preheating time setting

：Press and back to parent page or homepage.

：Press and enter the page of time setting and display.

：Press and enter the page of mold movement control.

：Press and enter movement monitoring page.

：Press and enter movement selection page.

：The key is pressed to move the cursor upward.

：The key is pressed to move the cursor downward

：The key is pressed to start or turn off the heating plan.

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 7.3.3.4.5 Page of process time setting

Fig.7-13 Page of process time 1

：Press and enter temperature control page.

：Press and enter Page of time setting and display.

：Press and enter the page of mold movement control.

：Press and enter movement monitoring page.

：Press and enter movement selection page.

：Press and enter process parameters storage page.

：Press and enter current alarm page.

：Press and enter the page of password grade.

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 Fig.7-14 Page of process time 2

：Press and enter temperature control page.

：Press and enter Page of time setting and display.

：Press and enter the page of mold movement control.

：Press and enter movement monitoring page.

：Press and enter movement selection page.

：Press and enter process parameters storage page.

：Press and enter current alarm page.

：Press and enter the page of password grade.

Following is the function of each time setting:
Mold close delay: Mold closing starts after the delay of this time setting.

Mold close end delay: Mold closing will continue until this time setting.

Injection delay: Injection will not start until this time setting.

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 Blowing delay: Blowing will not start until this time setting.

First blowing time: The duration time of first blowing.

Second blowing delay: The secondary blowing will start after the delay of this time setting.

Second blowing time: The duration time of the secondary blowing.

Core rod open delay: Core rod open will start after the delay of this time setting.

Core rod open time: The duration time of core road open.

Stripper down time: The duration time of stripper down.

Stripper up time: The duration time of stripper up.

Internal cooling delay: Internal cooling will start after the delay of this time setting.

Internal cooling time: The duration time of internal cooling.

External cooling time: The duration time of external cooling.

Stripper forward delay: Plasticizing will start after the delay of this time setting.

Delay Plastication: Plasticizing will start after the delay of this time setting.

Carriage backward time: The duration time of carriage backward.

Transfer head up delay: Transferring head lifting will start after the delay of this time setting.

Core forward delay: Core forward will start after the delay of this time setting.

Core forward time: The duration time of core forward.

Cycle interval: The duration time of core forward.

Bottle cooling time: Display the stay time of bottle in mold.

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 7.3.3.4.6 Page of process time limit

Fig.7-15 Page of process time limit 1

：Press and enter temperature control page.

：Press and enter Page of time setting and display.

：Press and enter the page of mold movement control.

：Press and enter movement monitoring page.

：Press and enter movement selection page.

：Press and enter process parameters storage page.

：Press and enter current alarm page.

：Press and enter the page of password grade.

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 Fig.7-16 Page of process time limit 2

：Press and enter temperature control page.

：Press and back to parent page or to homepage.

：Press and enter the page of mold movement control.

：Press and enter movement monitoring page.

：Press and enter movement selection page.

：Press and enter process parameters storage page.

：Press and enter current alarm page.

：Press and enter the page of password grade.

The following is all time functions:

Cycle period limit：If operating time exceeds this set time in a cycle, the machine stops.

Transfer forward time limit：If transfer forward operating time exceeds this set time, the machine
stops

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 Mold-closing time limit：If mold-closing operating time exceeds this set time, the machine stops.

Transfer head dropping time limit：If transfer head operating time exceeds this set time, the
machine stops.

Transfer backward time limit：If transfer backward operating time exceeds this set time, the
machine stops.

Stripper forward time limit：If stripper forward operating time exceeds this set time, the series
movements of stripper stop.

Stripper 1 backward time limit：If Stripper 1 backward operating time exceeds this time, the
series movements of stripper stop.

Stripper 2 backward time limit：If Stripper 2 backward operating time exceeds this time, the
series movements of stripper stop.

Carriage forward time limit：If carriage forward is selected and its operating time exceeds this
time, the machine stops.

Injection time limit：If injection operating time exceeds this time, the series movements of
injection stop.

Period of packing hold：Duration of packing hold.

Plasticization time limit：If plasticization operating time exceeds this time, the series movements
of injection stop.

Decompression time limit ：If decompression operating time exceeds this time, the series
movements of injection stop.

Mold-opening time limit：If mold-opening operating time exceeds this set time, the machine stops.

Transfer head up time limit：If transfer head lifting operating time exceeds this set time, the
machine stops.

Stripper Pneumatic cylinder down time limit: If the running time for stripper pneumatic cylinder
down exceeds this time, the machine stops.

Stripper Pneumatic cylinder up time limit: If the running time for stripper pneumatic cylinder up
exceeds this time, the machine stops.

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3.1.32.1 Rev 03 96
 Clamp locking time limit: Set the running time for the action of clamp locking.f

7.3.3.4.7 Page of mold opening & closing setting

Fig.7-17 Page of mold opening & closing setting

：Press and enter the temperature control page.

：Press and enter the page of time setting and display.

：Press and enter the injection controlling page.

：Press and enter the movement monitoring page.

：Press and enter the movement selecting page.

：Press and enter the process parameters storage page.

：Press and enter the current alarm page.

：Press and enter the page of password grade.

Note: Mold-closing setting data decrease from slow closing à low-pressure mold-closing stop;
mold-opening setting data increase from slow opening à mold-opening stop.
Mold-opening & closing position depends not only on the location of current electronic distance
sensor, but also on mold-opening & closing stop proximity switch.

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 7.3.3.4.8 Injection setting page

Fig.7-18 Injection setting page

：Press and enter the temperature control page.

：Press and enter the page of time setting and display.

：Press and enter the page of plasticization & decompression movement control.

：Press and enter the movement monitoring page.

：Press and enter the movement selecting page.

：Press and enter the process parameters storage page.

：Press and enter the current alarm page.

：Press and enter the page of password grade.

Note: Setting data decrease from Injection Position 1 à Packing Hold Stop Position 3.

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 7.3.3.4.9 Page of plasticization & decompression setting

Fig.7–19 Page of plasticization & decompression setting

：Press and enter the temperature control page.

：Press and enter the page of time setting and display.

：Press and enter the page of transfer movement control .

：Press and enter the movement monitoring page.

：Press and enter the movement selecting page.

：Press and enter the process parameters storage page.

：Press and enter the current alarm page.

：Press and enter the page of password grade.

Note: Plasticization setting data increase from Plasticization Position 1 à Plasticization Position 3.
Plasticization position setting should be bigger than injection stop setting data. Decompression position
setting should be bigger than injection stop setting data.

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 7.3.3.4.10 Page of transfer forward/backward

Fig.7–20 Page of transfer forward/backward setting

：Press and enter the temperature control page.

：Press and enter the page of time setting and display.

：Press and enter the page of stripping movement control.

：Press and enter the movement monitoring page.

：Press and enter the movement selecting page.

：Press and enter process parameters storage page.

：Press and enter the current alarm page.

：Press and enter the page of password grade.

Note: Transfer forward setting data increase from slow transfer forward à transfer forward stop;
transfer backward setting data decrease from slow transfer backward à transfer backward stop.
Transfer forward & backward position depends not only on the location of current electronic
distance sensor, but also on transfer forward & backward stop proximity switch.

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 7.3.3.4.11 Page of Stripper setting

Fig.7–21 Page of stripper setting

：Press and enter the temperature control page.

：Press and enter the page of time setting and display.

：Press and back to parent page or to homepage

：Press and enter the movement monitoring page.

：Press and enter the movement selecting page.

：Press and enter process parameters storage page.

：Press and enter the current alarm page.

：Press and enter the page of password grade.

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 7.3.3.4.12 Machine action monitoring page

Fig.7–22 Monitoring page of machine movement

：Press and enter the temperature control page.

：Press and enter the page of time setting and display.

：Press and enter the page of mold movement control.

：Press and enter IO monitoring page.

：Press and enter the movement selecting page.

：Press and enter process parameters storage page.

：Press and enter the current alarm page.

：Press and enter the page of password grade.

Display the machine’s running of current movement.

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 7.3.3.4.13 I/O Monitoring Page

Fig.7–23 I/O Monitoring page

：Press and enter the temperature control page

：Press and enter the page of time setting and display

：Press and enter the page of mold movement control.

：Press and enter I/O monitoring page

：Press and enter the movement selecting page

：Press and enter process parameters storage page

：Press and enter the current alarm page

：Press and enter the page of password grade.

Display the input&output status of analog and digital signals of current modular..

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3.1.32.1 Rev 03 103

 Fig.7–24 I/O Monitoring page

：Press and enter the temperature control page

：Press and enter the page of time setting and display

：Press and enter the page of mold movement control.

：Press and enter I/O monitoring page

：Press and enter the movement selecting page

：Press and enter process parameters storage page

：Press and enter the current alarm page

：Press and enter the page of password grade.

Display the input&output status of analog and digital signals of current modular..

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3.1.32.1 Rev 03 104

 Fig.7–25 I/O Monitoring page

：Press and enter the temperature control page

：Press and enter the page of time setting and display

：Press and enter the page of mold movement control.

：Press and enter I/O monitoring page

：Press and enter the movement selecting page

：Press and enter process parameters storage page

：Press and enter the current alarm page

：Press and enter the page of password grade.

Display the input&output status of analog and digital signals of current modular..

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3.1.32.1 Rev 03 105

 Fig.7–26 I/O Monitoring page

：Press and enter the temperature control page

：Press and enter the page of time setting and display

：Press and enter the page of mold movement control.

：Press and enter I/O monitoring page

：Press and enter the movement selecting page

：Press and enter process parameters storage page

：Press and enter the current alarm page

：Press and enter the page of password grade.

Display the input&output status of analog and digital signals of current modular..

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3.1.32.1 Rev 03 106

 Fig.7–27 I/O Monitoring page

：Press and enter the temperature control page

：Press and enter the page of time setting and display

：Press and enter the page of mold movement control.

：Press and enter block status page

：Press and enter the movement selecting page

：Press and enter process parameters storage page

：Press and enter the current alarm page

：Press and enter the page of password grade.

Display the input&output status of analog and digital signals of current modular.

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 7.3.3.4.14 Page of I/O modular status

Fig.7–28 Page of I/O modular. status

：Press and enter the temperature control page

：Press and enter the page of time setting and display

：Press and enter the page of mold movement control.

：Press and back to parent page or homepage.

：Press and enter the movement selecting page

：Press and enter process parameters storage page

：Press and enter the current alarm page

：Press and enter the page of password grade.

Display the current status of modular, means modular in normal running, means modular
not at communication or not working.

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 7.3.3.4.15 Page of movement selection

Fig.7–29 Page of movement selection

：Press and enter the temperature control page

：Press and enter the page of time setting and display

：Press and enter the page of mold movement control.

：Press and enter the movement monitoring page

：Press and back to parent page or homepage

：Press and enter process parameters storage page

：Press and enter the current alarm page

：Press and enter the page of password grade.

Press up/down arrow to move the cursor and press the selection of TAB in the center of arrows. This
selection will be available only in the automatic process.

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 7.3.3.4.16 Page of receipt management

Fig.7–30 Page of receipt management

：Press and enter the temperature control page

：Press and enter the page of time setting and display

：Press and enter the page of mold movement control.

：Key “Name changing”

：Key “Storage”

：Press and back to parent page or homepage.

：Press and open receipt file.

：Press to store the parameters on USB memory disk

：Key “Enter”

：Key “Cancellation”
Name changing process: press up/down arrow to select the number of the process parameter to be

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 stored，press ，to display and press to confirm，Press to cancel this process.

Storing process: press up/down arrow to select the number of the process parameter to be stored，

press ，to display ，and press to confirm.，Press to cancel the process.

Opening process: press up/down arrow to select the number of the process parameter to be opened，

press to display ，and press to confirm.，Press to cancel the process.

Process of storing on USB memory disk: press , and press to confirm, or press to
cancel the process. Parametera are stored on the USB memory disk which is connected to the screen via
USB port.

7.3.3.4.17 Alarm page

Fig.7–31 Alarm page

：Press and enter the temperature control page

：Press and enter the page of time setting and display

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3.1.32.1 Rev 03 111

 ：Press and enter the page of mold movement control.

：Press and enter the movement monitoring page

：Press and enter the movement selecting page

：Press and enter process parameters storage page

：Press and enter the alarm history page

：Press and enter the page of password grade.

Pressthe “ ” on the panel to cancel the alarm.

Fig.7–32 Alarm page

：Press and enter the temperature control page

：Press and enter the page of time setting and display

：Press and enter the page of mold movement control.

：Press and enter the movement monitoring page

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3.1.32.1 Rev 03 112

 ：Press and enter the movement selecting page

：Press and enter process parameters storage page

：Press and enter the alarm history page

：Press and enter the page of password grade.

Pressthe “ ” on the panel to cancel the alarm.

7.3.3.4.18 History alarm page

Fig.7–33 History alarm page

：Press and enter the temperature control page

：Press and enter the page of time setting and display

：Press and enter the page of mold movement control

：Press and enter the movement monitoring page

：Press and enter the movement selecting page

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3.1.32.1 Rev 03 113

 ：Press and enter process parameters storage page

：Press and enter the current alarm page

：Press and enter the page of password grade.

Display alarm history, first in first out, 1000 pcs of alarm messages showed.

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 7.3.3.4.19 Page of authorization change

Fig.7–34 Page of authorization change

Key in Passwords, display the icon according to password grade:
When the password is at grade 0, only F1 icon is displayed

：Press and return to main page.

When the password grade is bigger than 2, icons displayed as follow:

：Press and enter system setup page.

：Press and enter passward change page.

：Press and enter temperature optimization page.

：Press and enter the calibration of elctric distance sensor page.

：Press and enter valve delay page.

：Press and enter pressure slope page.

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 ：Press and enter flux safety gain page.

7.3.3.4.20 System setup page

Fig.7-35 System setup page

：Press and enter the page of password grade.

：Press and back to the previous page.

：Press and turn to the next page, and enter system option page(See the next page).

：Press and enter system information page.

：Key for detecting pressure of pump 1.

：Key for detecting flowrate of pump 1.

：Key for detecting pressure of pump 2.

：Key for detecting flowrate of pump 2

Input instructions:
Contrast: Contrast shown by liquid crystal display screen

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 Brightness: Lighteness shown by liquid crystal display screen
Screen-saving time: The screen-saving time of TFT display screen; screen-saving interface is
entered when reaching the time.
Date: Key in the date displayed by system.
Time: Key in the time displayed by system.
Black screen time: The black time of LCD, by which LCD will enter black screen status
Alarm circle output: Alarm will start upon reaching this set value of circle.
Melt pressure: The maximum corresponding pressure value to the set 10 V electric voltage.
Conveyor speed: The highest revolving speed of motor under set maximum 50HZ frequency..
Length of electronic distance sensor: Length setting of every electronic distance sensor will
influence display. Be cautious in changing it!
Limit of oil temperature for alarm&machine stop: Upper limiting temperature of oil; exceeding it
will cause alarm sounding and machine stop.
Pressure & flowrate detecting: Current setting of pump 1 and 2 pressure & flowrate detecting. Only
corresponding detecting keys pressed will lead to corresponding pressure & flowrate output, with the
range 1-100.

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 7.3.3.4.21 System option page

Fig.7–36 System option page

：Press and enter the page of password grade.。

：Press and enter the previous page.

：Press and switch the running mode of machine.

：Press and switch between the temperature degrees of Celsius and Fahrenheit..

：Press and switch the languages.

：Press and switch the alarm lamp mode.

：Press and open the function of remote monitoring.

7.3.3.4.22 Page of system running information.

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3.1.32.1 Rev 03 118

 FiFig.
7–37 Page of system running information

：Press and enter the page of password grade.

: Press and turn to the previous page.

This page displays the running information of system hardware.

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 7.3.3.4.23 Passward change page

Fig.7–38 Pressure slope page

：Press and enter the page of password grade.

: Grade 1

: Grade 2

: Grade 3
Note: It is required to enter the passward two times for passward change. A message will appear to
show passward change successful if passwards entered in these two times are identical.

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 7.3.3.4.24 Temperature optimization page

Fig.7-39 Temperature optimization page

：Press and enter the page of password grade.

：Press and back to the previous page.

：Press and turn to the next page, and enter system option page(See the next page).

：The key to move optimization status cursor leftward

：The key to move optimization status cursor rightward

：The key to start optimizing of the current cursor area.

Condition of starting optimization: The setting temperature > current temperature +70°C ;
otherwise 40 is displayed for the optimization step in starting optimization zone. 2 is displayed in
normal condition.

Optimization process:

1） Move keys or and to make the optimization status of the zone to be optimized

ON.
2） Return to temperature control and heat the zone to be optimized.

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 3） This page shows optimization steps 2 – 3 – 4 – 9 – 0
4） Optimization ends.

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 7.3.3.4.25 Temperature exception time page

Fig.7–40 Temperature exception time page

：Press and enter the page of password grade.

: Press and turn to the previous page.

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 7.3.3.4.26 Page of electronic distance sensor adjustment

Fig.7-41 Page of electronic distance sensor adjustment

：Press and enter the page of password grade.

：Press and enter calibration mode

：The key pressed to move the cursor of every electronic distance sensor in increasing
direction.

：The key pressed to move the cursor of every electronic distance sensor in decreasing
direction.

：The key to confirm adjustment.

In adjustment mode, if the cursor is on a certain electronic distance sensor, and pressure &

flowrate are not 0, move and press to confirm when reaching the ideal position.

At zero target position, can be pressed to confirm if the current position is smaller than half

of electronic distance sensor, is pressed to confirm invalidity if it is bigger.

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 At maximum target position, can be pressed to confirm if the current position is bigger than

half of electronic distance sensor, is pressed to confirm invalidity if it is smaller.

Note: Be cautious in using adjustment which brings quite big influence!
Press F5 to switch units of temperature between centigrade and Fahrenheit in this page.

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 7.3.3.4.27 Page of valve opening & closing time

Fig.7–42 Page of valve opening & closing time

：Press and enter the page of password grade.

: Press and turn to the previous page.

: Press and turn to the next page.

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 Fig.7–43 Page of valve opening & closing time

：Press and enter the page of password grade.

: Press and turn to the previous page.

: Press and turn to the next page.

Advantages of valve opening & closing delay: Moderate delay at the beginning and end will reduce
impact by the movement which is made milder.
Disadvantages: Cycle period is lengthened.
Delay shorter than 0.5 second is recommended.

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 7.3.3.4.28 Pressure slope page

Fig.7–44 Pressure slope page

：Press and enter the page of password grade.

: Press and turn to the previous page.

: Press and turn to the next page.

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 Fig.7–45 Pressure slope page

：Press and enter the page of password grade.

: Press and turn to the previous page.

: Press and turn to the next page.
Advantages of pressure slope: Pressure rising & falling according to the slope at the beginning and
end will reduce impact by the movement which is made milder.
Disadvantages: Cycle period is lengthened.

7.3.3.4.29 Flowrate slope page

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 Fig.7–46 Flowrate slope page

：Press and enter the page of password grade.

: Press and turn to the previous page.

: Press and turn to the next page.

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 Fig.7–47 Flowrate slope page

：Press and enter the page of password grade.

: Press and turn to the previous page.

: Press and turn to the next page.
Advantages of flowrate slope: Flowrate rising & falling according to the slope at the beginning and
end will reduce impact by the movement which is made milder.
Disadvantage: Cycle period is prolonged.

7.3.3.4.30 Flux safety gain page

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 Fig.7–48 Flux safety gain page

：Press and enter the page of password grade.

Flux safety gain: Regulating the flowrate.

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 7.4 Alarm
When there is failure somewhere in the machine, alarm will sound and machine stops at a position
of the cycle. After elimination of the failure, switch on starting button again to recover production.
Alarm will occur in the case of following conditions:
- When there are impurities inside cavities, the machine equipped with low pressure
mould-protecting device will alarm and stop if the moulds remain unclosed by the set time;
- When moulds open, the real stroke value on electronic distance sensor of mould opening &
closing must be at least 10mm larger than that on electronic distance sensor of transfer head; otherwise
the machine will alarm and stop;
- When moulds close, the real stroke value on electronic distance sensor of mould opening & closing
must be at least 10mm larger than that on electronic distance sensor of transfer head; otherwise the
machine will alarm and stop;
- Check the condition immediately after stripping. Interrupted signals for the laser sensor indicate
remaining products on core rod; then the machine alarms and stops running. After removing of
remaining products, close the safety guard and press relevant automatic keys to continue the cycle;
- If temperature of stuff barrel has not reached the set value, cold-starting protection will prevent
starting of screw plasticization, injection and decompression;
- If any working cycle exceeds the set time in full automatic operation, machine will alarm and stop;
- If temperature of hydraulic oil exceeds 55ºC, machine will alarm, automatically stop series
movement of injection and stop after operating next two cycles.

7.5 Loading
DANGER
Take care not to spill any granules on the platform and floor since this could cause operators
to slip and fall.
CAUTION
The material must be stored in a dry room in cloth bags that are perfectly sealed and in good
condition.
- Switch on the automatic hopper loader.
WARNING
Make sure the hopper’s flashboard is open when you start production.

7.6 Starting the machine

WARNING
Other hydraulic operations are permitted only at 10 seconds after the motor starts. Interval between
machine-stop and motor restarting should exceed 30 seconds. Otherwise the soft starter is easily
damaged.
7.6.1 Initial checks
Make sure the following is finished before starting:
- Before operation specifications of all equipments must be read in detail to know the structure and
movement process of every part, and functions of all related control units;
- Check carefully all fastening components and their conditions. Any loose parts must be tightened
immediately;

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 - Check all buttons, electrical switches, operating handles, handwheels and etc. for any damage or
malfunction. All switch handles or buttons should be off before starting the machine;
- Check that all safety doors function well and the safety switch can be touched at the set position;
- Check if the oil tank is filled with hydraulic oil. If not, hydraulic oil of specified model should be
poured into the tank through oil filter, with oil level between the low and up limiting lines;
- Pour lubricating oil into all lubricating passages and oiling holes to lubricate them;
- Check cleanness of machine platen, clear away all impurities and keep platen clean and neat;
- Check if any foreign body is in the hopper and fill it fully with material.
- Set time and temperature of screw barrel and hot runner:
1) If a set up sheet is available, set temperature of screw barrel and hot runner to appropriate
values. If such sheet is not available, use suggested temperature for the processed material;
2) Set all timers to appropriate values according to the set up sheet. If such sheet is not available,
use suggested temperature for the processed material ;
- Preparation of moulds:
1) Spray each set of core rods with release agent (silicone spray) on tops, bottoms and tips;
2) Rotate transfer head in around 60°. Then spray core rod head and cavities with the release
agent.

7.6.2 Start up
DANGER
You must be especially alert to the risks of scalds and burns when working in zones close to
moving parts which are at very high temperatures.
After completing above items, start the machine and auxiliary equipment in the following order:
1) Turn on chilled water supply to the barrel. Cool the barrel feeding gate to prevent raw material
obstructing it;
2) Switch on power and heat the barrel by technical requirements. The set temperature reached
should be kept constant for 0.5 h;
3) When carriage backward reaches a proper position, adjust induction rod of carriage forward
switch to cause the switch induction and employ manual open injection. Observe plasticization condition
of material; uniform plasticization means production can be started. Plastic in barrel should also be
removed through open injection before production if it has been heated for a long time. Because long
heating will change the nature of plastic, which goes against molding;
4) Carriage forward movement moves nozzle forward. Adjust the adjusting screws on front & rear
brackets to make the nozzle opposite to main sprue opening of the hot runner. After nozzle contacts fully
this opening, adjust the induction block of carriage forward to make the signal lamp of carriage forward
stop light;
5) Purging the runner and nozzle through injection is recommended for molds that have just been
installed. This will enable the operator to be sure all nozzle tips in the molds are free of obstructions and
cold material;
This is done with the molds open, the transfer head rotated half way back to clear scrap from the
molds.
Purge long enough to be sure all the nozzles are passing plastic freely (10-15 seconds in most cases
is sufficient).

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 6) Decompress plastics in the barrel and runner to prevent overflow. Then clear scraps with brass
hook.

7.6.3 Starting machine in automatic production

1) Be sure all the preceding items in this section are completed, and that the molds are clear of
foreign bodies, plastic, etc. before starting automatic operation;
2) Close all safety doors. In function selection page, close injection and stripping series
movements. Press Reset button to realize pre-automatic status;
3) Press semiautomatic button. Keep all parts of body and hands outside molding area;
4) In function selection page, open injection series movements, after a complete cycle, press
semiautomatic button, finish the cycle and automatically switch to manual mode;
5) Open the safety door, check visually that all the core rods leaving the injection molds are
carrying parisons. If so, let the safety door close and run semiautomatic cycle again;
If not, stop by pressing down manual key, machine switches to manual mode now. Try to purge
through manifold again. If necessary, improve the temperature of manifolds and nozzles until material
purges through all the nozzle tips, remove scraps and cycle again in semiautomatic. until one set of
parisons is at stripper station and strip the parisons before they cool, or while waiting for the manifold
nozzle to heat up, strip the parisons as per instructions in the following section below.
6) When the first set of unblown parisons rotates to the stripper station, use the brass knife to pull
the parisons off the rods.
Starting on the left most core rod and with gloves on, place the sharp edge of the knife on the neck
portion of the parison, grab the knife above and below the core rod and pull out from the parison. A
slight pressure against the core rod will help the knife to dig into the parison.
Some materials, such as polystyrene, may need a quick tap on the neck area. This cracks the
parisons and relieves the pressure for easier stripping.
Repeat this process with each parison as rapidly as possible before the next cycle begins. As bottles
start to be blown, continue stripping them by hand until each set of cores blows each bottle completely.
Blowing period can be set from 0.2 second. Lengthen gradually blowing time after every set of
parisons is blown evenly. But only if a set of completely blown and formed products is in front can
stripping movement be selected in the Function Selecting page.
Turn on cooling water to blow molds. If setup is proper, bottles should be ready for packing within a
few cycles.

7.6.4 Checking dimensions of products

The wall thickness uniformity of injection & blowing molding products is related not only to the
products’ strength uniformity, but also to production cost. The products’ wall thickness uniformity
becomes the key to their quality control in injection & blowing molding, and ensuring precision of
parisons is one important step in obtaining this key.
Precision of parisons is related to the following:
- Manufacturing precision in parison mould and machinery;
- Performance of polymers ( their fluidity and contractibility);
- Anti-wearing and anti-corrosion ability of parison mould and machinery;
- Technical parameters during parisons forming ( including injection speed, injection pressure,

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 packing hold pressure, parison temperature control and cooling time);
- If ununiformity in products’ wall thickness happens in production, small amount of stearic acid
Zinc can be added into the plastic (as base material). Its injection should be following dry mixing. Or
inject release agent into parison cavity or employ injection molding after granules are made after mixing
release agent and plastics.
Bottles usually have unique dimension specification and tolerance.
In conventional injection blow molding, the bottle mouth is made totally in the parison mold, as that
is where the neck and threads are made and finished in most cases. The blow mold only cools them off.
Threads are checked against product drawing or SPI standards.
If thread finish is ragged, pinched or shows flash (other than from parisons), it will be necessary to
readjust the blow mold. If marks are on the top of the threads, the blow mold must be moved towards
transfer head. If marks are on the bottom of the threads, the mold must be moved out. It is also necessary
to adjust the position of blow mold in these cases. This is done by increase or reducing the number of the
shims on the end of the distance regulating block.
New moulds usually have tight neck rings and sometimes pinch the parison necks. A small chamfer
on the edges of the neck ring partlines in the blow mold will help to eliminate this. Use a fine small hone
to do this. Do one cavity firstly to verify the necessity of this step. Molds should be removed from
machine for this procedure.
1) “S” dimension—measure from the top of bottle to the start of the first thread. This is important
as the cap has to have a correct “S” to seal properly.
With a depth gauge or dial verniers, measure this distance and compare with product drawing or SPI
specification.
If the “S” is too big, move the injection mold towards transfer head the needed distance.
If the “S” is too small, move the injection mold away from transfer head the needed distance.
It is the best to try and achieve the mean dimension on the specification.
In both cases, adding to or reducing the shims on the end of the distance regulating block. Also be
sure to recheck that the core rod flange fits into neck ring pockets.
2) “H” dimension is the overall height of the neck or the distance from the top of the mouth to the
shoulder of the bottle. It is checked and adjusted the same way as the “S”. If the “S” and “H” cannot
both be their respective mean dimensions, then adjust the molds so one dimension is on the upper
deviation and the other is on the lower deviation.
If one is impossible to bring into tolerance without losing the other, then the mold neck ring will
have to be reprocessed. Check with the tool designer on how this would be done more easily.
3) “I” dimension is the internal dimension of the opening or neck of the bottle. It is measured with
special gauges across the part line and at 90°to the part line, then both measurements are checked against
the product drawing. “I” can be adjusted slightly with variations in processing but major changes will
require changes in core rods. Contact the tool designer for assistance with this.
4) “E” dimension is the measurement of the external diameter of the neck, excluding the threads.
This is checked with special gauges across the part line and at 90°to the part line. Both measurements
are checked against the product drawing. “E” can be adjusted slightly with variations in processing but
major changes will require changes in neck rings. Contact the tool designer for assistance with this.
5) “T” dimension is the measurement of the external diameter of the neck, including the threads. It
is checked against the product drawing and adjusted like “E”. Major changes will require assistance

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 from the tool designer.
6) Wall distribution is the thickness measurements of various points on a cross section of a bottle.
Distribution is easiest checked by cutting a bottle in half at points 90°to the part line. Polyolefins can be
cut with paper knife very easily. Engineering plastics should be cut with a band saw or hack saw with
fine tooth blades. A cut this way will give you a bottle cross section from both the top and bottom mold
halves.
7) The weight of the bottle is as important as any other specification. Very minor weight variation
can be made with processing variations. Major changes need tooling changes. Check with the tool
designer for assistance.
8) Each dimensional check should be repeated and compared with bottles from each set of cores
and each individual core rod.
When all specifications check finished on all parts, bottles can be packed.
If bottles are not acceptable, a set of parisons may need to be injected.
A cooled parison will give you the exact shape of the inside of the perform mold. Knowing this
exact shape is necessary in many phases of injection blow molding.
Sampling — examine the exact distribution of plastic to determine where to increase or decrease
plastic.
Mold alignment—parisons will give you the exact location of your molds as compared to your
transfer head.
Checking for damage— if damage exists in the cavity, it will show up in the parison.

7.6.5 How to cast parisons

1) Molds should be installed in place, mold temperature controller reach set temperature and core
rods also installed.
2) Purge a small amount of plastic into the hot runner, and fill the hot runner and nozzle tips with
plastic.
3) Release agent should not be used on core rods, since it causes parisons’ cracking or incorrect
forming in the neck.
4) Close molds manually, pressurize and inject plastic into the cavity.
5) Allow approximately 2 minutes for pack hold. Decompress (screw backward) and nozzle
pressure drops.
6) Prevent plastic from leaking out of the runner after decompression.
7) Open molds completely with transfer head lifting and transposition backward. Transfer the
parison to stripper station and examine.
8) If parisons are not filled out, remove with a brass knife and start procedure again using the same
set of core rods.
9) Parisons can usually be removed without damage by transfer head lowering, shutting off
external cooling, opening internal cool valve fully, pushing internal cooling button. This would “blow”
the parisons off. Be sure to stand far away from the front of the machine and hold a box to collect them
in front of the parisons. They come off like bullets and can injure someone.
If this method does not work, use a brass knife and pull them off. Avoid damage to the threads if
possible.

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 7.7 Machine stop and disassembly
Pay attention to the following items when stopping the machine at the end of operation:
1) Select Manual for operation mode;
2) Close feeding flashboard and stop feeding to barrel;
3) Stop transfer head dropping and put the mold in closing status;
4) Injection carriage backward;
5) Eliminate remains in the barrel, and clear away the easily-decomposed plastics such as PVC in
processing with screw cleaning-specific material;
6) Set all control switches and buttons at OFF to cut off electricity, water and air;
7) Wipe and clean all parts of the machine after machine stops and clean up the surroundings.

7.8 Normal operation: procedures and status of controls and indicators

The control panel indicator lights are as follows under normal conditions:
- No messages are displayed on the monitor;
- All the LED indicators must be on.
If every procedure is correct, the produced bottles will be conveyed to package through conveyor
and no alarms are displayed on the monitor.

7.8.1 Manual mode

Operators cannot execute any wild and forcing movement on the machine to help with certain steps.
The action is quite dangerous and likely to cause burning, scalding, crushing, striking and other personal
dangers.
Manual operating details and movement essentials:
NOTE:
Assistant buttons must be pressed at the same time to realize two-hand operation.
- Mould opening prerequisite: None;
- Transfer head lifting prerequisite: transfer forward or backward stopping, mould opening
stopping;
- Transfer head dropping prerequisite: transfer forward or backward stopping;
- Transfer forward prerequisite: transfer head lifting or lowering stopping;
- Transfer backward prerequisite: transfer head lifting or lowering stopping;
- Mould closing prerequisite: Transfer head lowering stopping;
- High-pressure mould locking prerequisite: mould closing stopping;
- Injection prerequisite: temperature exceeding the set lower limit, carriage forward stopping;
- Plasticization prerequisite: temperature exceeding the set lower limit;
- Decompression prerequisite: temperature exceeding the set lower limit;
- Stripper forward prerequisite: None;
- Stripper backward prerequisite: None;
- Stripper down prerequisite: Stripper II forward stopping;
- Stripper up prerequisite: Stripper I backward stopping.

7.8.2 Automatic mode

Refer to Clause 2.8 for keys in manual and automatic mode.

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 137

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 Fig 7-41 Action flow chart
Automatic-mode operation essentials:
- If no parisons are on the core rod, press reset to realize automatic initialization and prepare for
next automatic movements.
- If Automatic key is pressed directly when automatic requirements are not satisfied, the interface
of automatic requirements appears, which can be met step by step according to the hints.
- In order for normal machine-stopping during the full automatic process, firstly close injection in
the function selecting page. Strip all bottles or parisons after finishing two cycles. Then press
Semiautomatic button, complete the cycle and switch to Manual.
- Assistant buttons must be pressed at the same time for two-hand operation in transfer from
Manual to Semiautomatic or from Semiautomatic to Full Automatic.
- In transfer from Full Automatic to Semiautomatic or from Semiautomatic to Manual, only the
corresponding Semiautomatic or Manual keys need to be pressed. Operation can be completed with
single key, which is for the purpose of safety and facilitates operation in emergency.

7.9 Checking the performance and settings

7.9.1 General information
DANGER
You must be especially alert to the risks of scalding/burning when the machine just stops with
the safety doors open.
Always wear protective clothing which complies with the safety regulations.

7.9.2 Functional checks and tests on the safety devices

Check the safety systems regularly to ensure the machine is operating correctly and efficiently.
It is necessary to check the following:
- Opening protective doors of electrical cabinet to observe if power is off.
- Opening safety guards to observe if there are corresponding alarms in the page of display screen.
- If protective gates around the frame are closed and locked.
- Adjusting laser-detecting device at core rod tip and selecting electrical eye in movement selection
page. Consciously obstructing light in automatic mode and stripper forward stop to observe if there are
corresponding alarms.
- The hydraulic mold-closing safety device. Demounting the induction block of stroke valve in the
safety guards at stripper station and executing mold-closing; the mold unable to close means the valve
functions.
- The mechanical mold-closing safety device. Opening the mold manually to the end to observe if
mechanical protective device forward is input and safety rod is extended in place in input & output page.
- Observing if all fixed protective plates are fastened in place.

WARNING
Those in charge of the machine are responsible for the machine breakdowns or faults.

7.9.3 Abnormal movements

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 Operators must stop the machine immediately and request maintenance from the engineer
responsible for the machine if movements are abnormal severely without alarms on display.

7.10 Fault, emergency and alarm situations

7.10.1 General information
In the event of any faults occurring during operation of the machine, the danger and alarm situation
will be indicated by a siren and a flashing lamp located on the control panel.

Press the key F7 Refer to Fig.7-28 Current Alarm Page for information displayed.

Pressing the key will eliminate alarm.

7.11 Stopping the machine

7.11.1 Voluntary stop
Machine stop has pause and emergency stop.
The machine generally stops at fault position in case of fault alarm and pause, and operators should
press AUTO again after removing faults so that machine restarts working from the stopping position.
Pressing MANUAL in automatic mode will lead to emergency stop, which stops all movements
with motor and heating on.
In full automatic mode without injection, press SEMIAUTO and stop the machine normally after
running the cycle.
In full automatic mode with injection, injection needs to be turned off at first in the page of
movement selection. Then press SEMIAUTO after all parisons or products are stripped from core rods
in two cycles, and stop the machine normally at the end of the cycle.

7.11.2 Emergency stops

The emergency stop is executed by pressing the mushroom-shaped buttons on the control panel. The
emergency stop allows you to disable the machine’s movements at any time and turn off motor and
heating.
WARNING
Only use the emergency stop button when really necessary, since it will stop the machine
immediately without allowing it to complete any operating cycle. In all other situations, stop the
plant by following the voluntary stop procedure.

7.12 Cleaning and preparation for periods of non-use

WARNING
Never use hard metal tools or emery cloth for the cleaning operations.
NOTE
It is much easier to remove plastic if it has not completely cooled.
DANGER
You must be especially alert to the risks of scalding/ burning when working on the machine
when it is hot. Always wear protective clothing which complies with the safety regulations.
NOTE

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 The machine should be in the status of transfer head dropping stop and mold-closing stop, and
not be pressurized for long-term non-use.
If the machine is not going to be used again for a long period of time, it will be necessary to adopt a
number of precautions to protect it and its components against dust and rust.

7.13 Cleaning after production

Proceed as follows after voluntary stop for the machine:
- Wipe the molds with an oiled rag;
- Clean all the painted parts of the machine with a non-abrasive, non-corrosive detergent which is
suitable for the purpose;
- Operate lubricating keys manually to lubricate fully all grease points;
- Any parts which are not painted and could become pitted due to the action of atmospheric agents
should be smeared with grease to provide a protective covering;
- Cover the machine with a plastic sheet, taking care not to seal it hermetically to avoid the
formation of a close danger zone.
When starting the machine again, proceed as follows to eliminate remaining plastic inside the barrel:
- Remove the sheet
- Clean off the layer of protective grease
- Carry out injection and plasticization repeatedly
- Wait for the remaining plastic to come out of the nozzle
- Start production.

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 8 Maintenance
8.1 Safety: Precautions and maintenance preparations
8.1.1 Function checks and tests on safety devices
8.2 Maintenance process
8.3 Maintenance of hydraulic system
8.3.1 Hydraulic oil selection in hydraulic drive
8.3.2 Use and maintenance of hydraulic oil
8.3.3 Hoses installation and sealing of hydraulic oil
8.3.4 Functions of oil tanks
8.3.4.1 Holding hydraulic oil
8.3.4.2 Emitting heat
8.3.4.3 Escaping of air
8.3.4.4 Depositing of impurities
8.3.4.5 Separating moisture
8.3.4.6 Installing elements
8.3.5 Notices taken in using and maintaining hydraulic system
8.3.5.1 Security
8.3.5.2 Cleanness
8.3.5.3 Replacing elements
8.3.5.4 Painting
8.3.6 Checks and maintenance
8.3.6.1 Oil tank
8.3.6.2 Oil temperature
8.3.6.3 Oil samples
8.3.6.4 Oil change
8.3.6.5 Filter
8.3.6.6 Adjustment
8.3.6.7 Cooler
8.3.6.8 Hydraulic pump
8.3.6.9 Control valve
8.3.6.10 Other checks
8.4 Emergency maintenance
8.4.1 Cleaning molds
8.4.2 Maintenance of barrels and screws
8.4.2.1 Screws
8.4.2.2 Use and maintenance of barrels

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 8.1 Safety: Precautions and maintenance preparations
In order to maximize safety operation of the machine, personnel authorized to maintain the machine
routinely and emergently must read and fully understand Chapter 3 of this manual on safety and
warnings mentioned below.
DANGER
Maintenance and servicing must be operated by trained and authorized personnel. All
operations must be done during machine stop or in safe state.
Do cut off power on the panel, turn off and lock main control switch and emergency stop switch if
you need to work in the machine’s danger zone.
CAUTION
- Be sure that main switch is OFF.
- Consider the size of the blow-moulding machine, it is important to clearly indicate that it is
in maintenance conditions so that no one inadvertently switches the power for the duration of the
maintenance.
WARNING
The main switch must be locked with a sign when cut off.
DANGER
There is still a risk of burning in working at hot area even with the power off; a certain period
is needed to cool.
Be sure to release all systems pressure before the beginning of maintenance.
WARNING
Proper equipment and personal protective tools must be available in maintaining operation.
DANGER
Operating the machine or its components is not permitted by untrained or unauthorized
personnel.
WARNING
Only trained and authorized personnel can operate important safety devices of the machine.
These devices must be confirmed and tested again before restarting the machine if they do not
function during maintenance.
DANGER
Do not lubricate or adjust any components during the machine’s operation.
CAUTION:
Always use protective gloves.

8.1.1 Function checks and tests on safety devices

Maintenance man must test the operation of safety devices.
Various safety systems must be inspected regularly and listed in the company’s preventive
maintenance program in details.
The program must be carried out repeatedly as normal maintenance routines.
Emergency button
Check the emergency button on control panel. The machine will stop immediately when the button
is pressed.
DANGER

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 The machine must be ensured to stop securely and rapidly when needed with the button.
Testing protective devices:
- Turn on main switch and start the machine normally;
- Open the safety guard;
- Open protective devices to check if the monitor shows that machine has been stopped and alarm
safety guard is not closed;
- Check if the input signal is correct for safety guard in the input & output page.
Flash lamps and sirens
- Check if the alarm lamp is flashing on the top of the machine when the monitor indicates
alarms;
- Check the sound of alarm at the same time.

8.2 Maintenance process

Necessary maintenance processes are as follows to keep the machine’s functioning and security:
Lubrication：
The following components need lubricating regularly:
- Slide parts
- Turning parts
- Mold parts
Centralized and automatic lubrication is adopted in the machine, so lubricating times and time need
to be set in the main page. At least once lubrication is required for 5000 cycles and each lubrication
takes at least 20 seconds.

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 Routine maintenance

Items Intervals Note

Cleaning filter net of electrical cabinet 120h

Cleaning compressed air filter 480h

Replacing filter core of in-return oil filter of

Annually
hydraulic oil

Replacing filter core of air filter in oil tank Annually

Cleaning oil tank 4800h

Replacing hydraulic oil 4800h

Replacing high-pressure hoses ＜4 years

Checking stability and level position of the machine Regularly

Checking fasten-ness of screws and bolts Regularly

Table 8-1 Items and intervals for routine maintenance

WARNING
Check assembly screws of every component after operation for 8-10 days.
DANGER
Fasten hose fitting immediately in the case of oil leakage.
- Check regularly hoses on hydraulic cylinders.
- Any visible scrapes are not allowed on hoses due to any abnormal friction.
- Lubricants recommended by the manufacturer are employed for oil and grease.

Electrical cabinet
Air filters in electrical cabinet need to be wiped carefully.
- Take out filters from the seating.
- Blow and clean with compressed air, or replace the filter.

Connecting belt of the heater - heating factors

- Check regularly the tightness of the connecting belt of heater and reset tight connection by turning
the fastening screw for certain purposes.
WARNING
Improper connection of the heater’s connecting belt will lead to burning and incorrect
heat-scattering.
- Be sure that the thermocouple has good contact with heat-detecting components to acquire correct
temperature measurement.

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 Cooling equipment
CAUTION
Check carefully if any cooling return and nozzle are obstructed by rust so that large quantity
of chilled water can be passed.
It is suggested to inject specially-treated liquid into return line or install water-softening agent.
This applies to all cooling return in the machine which does not use softened water.
Oil filter:
Oil filters also need replacing after working for some time (refer to Table 8-1).
Gasoline and proper brushes are used to clean the oil filter after the machine has worked for a long
time.
CAUTION
Be sure that no gasoline remains in the oil filter before restoring it to its original place.
If there is gasoline remnant, blow to dry it with compressed air.

8.3 Maintenance of hydraulic system

Hydraulic drive system provides power for the piston on oil cylinder and reciprocates according to
the working order and speed we set. Performance of this system has a direct impact on injection & blow
molding-machine’s efficiency and products quality. Therefore maintenance must be reinforced of all
working elements in the system and maintain it promptly in case of faults to ensure all parts operate
exactly and normally.
Working pressure of the machine’s hydraulic drive system has been adjusted in test running before
the machine leaving factory. Working intensity of all control valves and working oil cylinders in the
whole hydraulic system is designed by required pressure, so the pressure safety valve of all systems in
hydraulic drive cannot be adjusted randomly during acceptance test and normal production. Before
machine operation it should be verified if the pressure in specification accords with that displayed
actually by the pressure gauge in hydraulic system. The oil cylinder’s working pressure varies with
working positions and operators should not think that the higher the working pressure, the more secure
and reliable the work. Working pressure too high will not only waste energy, but also bring side-effect to
products such as flash, difficult stripping, relatively big internal stress, likely deformation and etc. If
pressure needs to be adjusted in special conditions, minimum pressure to meet technical
requirements should be followed and pressure too high is not advisable.
Use and maintenance requirements by the manufacturer must be followed to ensure the mechanical
equipment running without faults. Hydraulic systems as a part of distinct mechanical equipment differ
from each other, so the items vary to which attention should be paid in using these systems. This chapter
will explain common matters in the use and maintenance of hydraulic systems.
Maintenance of hydraulic systems includes adjustment, checks, maintenance and repair.
- Adjustment
A series of movements in commissioning new equipment or putting old one into use again,
including installation, oiling, flushing, deflation, adjustment and grinding in.
- Checks
Check is to see if the system working status and functions are correct, including observation,
measurement and test running.

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 - Maintenance
This is to ensure the system’s normal functions, reduce wearing and replace wearing parts, including
cleaning and replacing such parts as oil, filter elements and sealing elements.
- Repair
Repair is a series of movements to restore functions of faulty system. At first determine positions
with malfunction by the failure phenomenon and find out the cause, which is so-called faults diagnosis.
Then replace disabled elements to restore mechanical equipment’s running, which is repair.

8.3.1 Hydraulic oil selection in hydraulic drive

- Hydraulic oil selected should be relatively good anti-oxidation, anti-wearing, antirust agent and
scum little in working.
- It has good lubricating ability.
- Its chemical performance is stable.
- Viscosity of the oil is proper. Oil with slightly higher viscosity should be selected for summer
when temperature is higher; oil with slightly lower viscosity for winter when temperature is lower. Test
regularly the oil’s viscosity change which should not exceed 20%.
- The hydraulic oil is little corrosive to sealing elements and driving parts.
- The hydraulic oil should have high burning point (flash point) and low freezing point to adapt to
working in different temperature conditions.
- The oil tank should be equipped with dustproof cover and ventholes. Check often the chilled
water hose, where leakage is not allowed. The oil should be clean without any impurity or moisture.
- Acid value of the hydraulic oil is not larger than 2mg KOH/g.
- Surrounding temperature for running the hydraulic drive system should not exceed 35℃. Smoke
and fire are forbidden in the dustproof working ground.
- The hydraulic oil should be replaced once every 4000-5000 hours in normal working.

8.3.2 Use and maintenance of hydraulic oil

Oil used in hydraulic system is L-AN32 or L-AN46. Oil with slightly lower viscosity should be
used in winter when temperature is lower, and oil with slightly higher viscosity in summer when
temperature is higher.
Pay attention to the temperature change during hydraulic oil working; the highest oil temperature
should not exceed 55℃. If it tends to go on rising, chilled water flowrate should be increased to ensure
stability in hydraulic oil temperature. The oil is likely to degrade when working in cycles at high
temperature for a long time. The machine is specially fitted with oil temperature high alarm with which
alarm will sound and the machine stop when working oil temperature is higher than 55℃.
The hydraulic oil should be kept from impurity, moisture and air, and work in clean and ventilative
environment. The following items should be noticed in working to ensure the purity of hydraulic oil:
- The oil should be filtered when pouring it into oil tank.
- Always keep sufficient oil in the tank (full filling the tank is preferable). The machine is specially
fitted with oil level low alarm with which alarm will sound and the machine stop when the oil level is
below the warning line.
- Keep all control valves clean and avoid mixing foreign bodies and impurity into the oil in
working. Dismantled valves must be cleaned before installation during their maintenance.

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 - Check regularly the oil quality. Filter or deposit the oil to separate oil, water and impurity when
necessary.

8.3.3 Pipeline installation and sealing of hydraulic oil

In hydraulic drive system leakage at the fitting and both ends of oil cylinder appears most often in
maintenance. Oil leakage is both wasting and increasing maintenance cost; in addition, it pollutes
working environment and products and even causes fire. If checks are not made regularly in working,
leakage will lead to insufficient hydraulic oil and the equipment cannot operate normally. Accidents are
also possible. Therefore the following items should be noticed in pipeline installation and sealing of
hydraulic oil:
- Check to see if there is leakage at the fitting of all parts and oil cylinder during work handover.
Leakage positions found should be reported to personnel concerned and eliminated promptly.
- In fitting pipelines, connecting threads or end surfaces of flange should be clean and level; all
threads should be fastened with even force.
- In fitting the sealing ring, slot should be clean without burrs. Sealing rubber ring should be
cleaned before fitting with proper pressure.
- The rubbing surface moving against the rubber ring should be level and smooth; meantime sealing
medium should be clean because they are all factors to speed up the wearing of rubber ring. Above
requirements must be stressed to reduce leakage and prolong working life of rubber sealing ring.

8.3.4 Functions of oil tanks

Oil tanks are mainly for storing oil. Moreover, they have a certain surface area which can emit heat
produced by working oil; they can deposit impurities in the oil, help air filtering into oil escape and
separate moisture. Sometimes oil tanks function as mounting platforms for hydraulic elements and
manifolds.

8.3.4.1 Holding hydraulic oil

Oil tanks must be able to hold all oil in the system. The hydraulic pump takes out oil from tanks and
sends it to the system; oil returns to tanks after it completes the task of transmitting power in the system.

8.3.4.2 Emitting heat

Power loss in the hydraulic system leads to oil temperature rising. A quite big part of the heat
brought by oil from the system is emitted into surrounding air by oil tank walls. This requires that oil
tanks have sufficient size and be located in drafty places. Radiators are mounted on the external walls of
oil tanks to increase heat-emitting ability when necessary.

8.3.4.3 Escaping of air

Oil bubble causes noise and damage to hydraulic elements and brings gas corrupting especially in
hydraulic pumps. When pressure in low-pressure zone is lower than saturating point of dissolved air,
suction pipes leak or oil level is too low, vortex function causes hydraulic pumps to suck air and
returning oil stirring will all lead to bubbles. Undissolved air can escape from the oil tank; therefore oil
surface is desired as big as possible and oil should be kept in the tank longer.

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 8.3.4.4 Depositing of impurities
Small contamination not captured by filters, such as grinding bits or oil aging resultant, can be
deposited on the bottom of oil tanks.

8.3.4.5 Separating moisture

Due to the temperature change, steam in air is condensed on the internal wall of oil tank to water
which drops into oil. Small amount of water is dissolved in oil and the undissolved will make the oil
emulsified and go bad. Oil tanks provide a chance to separate oil from water so that the dissociated
water accumulates at the tank bottom to facilitate eliminating it.

8.3.4.6 Installing elements

In the hydraulic system for middle and small sized equipment, hydraulic pumps and some hydraulic
valves are sometimes mounted directly on the top plate of oil tanks which must be firm enough to
support these elements. Firm oil tanks also play a role in reducing noise.

Internal clapboards should be mounted in oil tanks, especially those with a capacity exceeding 100L
in order to prolong oil’s staying time in tanks, promote oil circulating in tanks, make more oil involved
in system cycles to perform better heat-emitting, deflation, depositing and other functions. The
clapboard separates oil-returning zone from oil-sucking zone of the system and makes oil circulate along
tank walls as much as possible. It can hold deposited contamination in the oil-returning zone. Should
have a flow gate big enough to get a circumfluence speed of 0.3-0.6m/s. Setting plates brings certain
difficulty to cleaning tanks internally. Pay attention to it in major repair or cleanout.
Electrical signals detected by floating-type oil level sensor remind operators and provide necessary
protecting signals.
Oil inlet and ventholes are generally combined into one. Oil can be filled after removing its cover
and the cover becomes filter when putted back. Its capacity should be double that of pumps flowrate so
that atmospheric pressure can be kept or pressure-dropping not exceeding 0.1Kpa inside tanks even
when the oil level drops rapidly during the system peak need.

8.3.5 Notices taken in using and maintaining hydraulic system

8.3.5.1 Security
The most important issue is security in using and maintaining hydraulic systems. Loosening fitting,
thread connection or elements is forbidden with pressure in system to ensure security. You must unload,
stop pump running and release pressure oil from accumulator (the machine does not have accumulators),
and then disassemble components.
Though many practical safety taboos have become common knowledge, attention is often focused
on faults and potential danger neglected. Therefore standardized machine-stopping process should be
executed before repairing the system and standardized restarting process when running machine again
after repairing.
Machine-stopping process:
- Stripping suspending load or supporting it mechanically, such as mold-closing stop.
- Stripping system pressure.
- Stripping pressure oil from accumulator (the machine does not have).

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 - Stripping pressure oil at the ends of pressurizer
- Cutting off electrical control system.
- Cutting off power
Restarting process:
- Eliminating malfunction causes.
- Cleaning up or flushing system by requirements if contamination enters system during elements’
malfunction or replacing.
- Confirming elements are replaced correctly.
- Confirming hydraulic connection is correct.
- Confirming electrical connection is correct.
- Adjusting the adjustable elements to safe status.
- Filling pumps and motor with oil.
- Providing the system with oil-filling and deflation by requirements.
- Relieving safety interlocking protection.
- Ringing the alarm bell or informing all personnel on the spot that system is restarting.
- Starting the system.

8.3.5.2 Cleanness
Pay attention to cleanness in inspection and maintenance. Absolutely clean conditions must be
stressed in maintaining hydraulic systems, because contamination is the most dangerous hidden trouble
for the system. Hydraulic components and surroundings should be cleaned before disassembling them.
In disassembling threads connections, all loose paint dross should be removed and all open ports
wrapped so that impurity and dust will not enter system during machine stop. Polishing and welding are
not allowed at the maintenance site. Cotton silk and rags are not permitted in clearing oil tanks. Oil must
be filled into the system through filters.

8.3.5.3 Replacing elements

Models of elements must be correct. If elements with the same model are not available so that
similar elements have to be used, notice if their functions, parameters and connection measurements are
consistent. Old sealing rings must be replaced and reuse is not allowed. Fittings of screws and threads
must be tightened uniformly to specified moment. Parameters of elements such as pressure valves,
flowrate valves and variable displacement piston pump should be reset.

8.3.5.4 Painting
Cover all flexible sealing elements, mounting seats, bearings, shaft pins, electroplated pieces, guide
track and marks if painting again is necessary.

8.3.6 Checks and maintenance

8.3.6.1 Oil tank
Oil level must be checked often and oil added promptly. When oil in the system is reduced below
the minimum level, it possibly causes temperature rise, accumulating of undissolved air, and pump
failure due to air pockets, and condensing water will gather on cooling pipes showing outside immersion
heat exchanger.

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 8.3.6.2 Oil temperature
Working temperature of oil depends on many factors, usually within 40-90℃. Recommended
highest temperature is 55℃ for mineral oil, because higher temperature will quicken oil aging and
shorten the life of sealing elements and hoses. Oil temperature in tanks must be monitored continuously.
Gradually rising oil temperature means possible pollution or forming gum, or wearing of sealing
elements or metals. Sudden rising of oil temperature brings warning signal, and machine should be
stopped immediately for a check.

8.3.6.3 Oil samples

Oil aging depends on various working parameters, such as temperature, pressure, air humidity and
polluted environment. It can be judged by observing samples visually to determine if the oil can be used.
Analysis of oil status is shown in the table below.

Appearance Contamination Causes

Darkening Oxidized results Overheat, mixed oil (other oils enter)

Emulsification Water or bubbles Water or air entry

Water layering Water Water entry, such as chilled water

Air entry, such as due to low oil level or gas

Bubbles Air
leakage in oil-sucking hose
Suspending or depositing
Solids Wearing, pollution, aging
contamination

Tar smell Aging results Overheat

Table 8-2 Analysis of hydraulic oil status

8.3.6.4 Change Oil

Oil is changed immediately after the first adjustment. If oil quality is not analyzed in labs regularly,
it should be changed once every 4000-5000 hours. But what is important is that the highest oil
temperature must not exceed 60℃, and filters should be cleaned or replaced promptly. Oil change
intervals can be greatly prolonged if oil is treated finely and analyzed regularly.
To judge if hydraulic oil is deteriorated, generally take oil samples on the spot and adopt qualitative
and quantitative means. The former includes observing its color, smell, any deposit and compare it with
new oil; the latter means sending the samples to labs for analysis and assessment.
Blotter spot test is a simple method and can be carried out on the spot. Drop a drop of oil onto a
piece of blotter. No color or only some light yellow on the blotter and uniform color means oil still can
be used. Obvious ringed traces in the spot mean that oil should be changed. If the centre is obvious dark
spots and light-colored oil scatters, the oil change time is over and oil is bringing or has brought such
oxidation products as oil deposit into system.
Sound change is also related to oil status. If sound of working system varies, which generally means

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 sound is louder or different from normal one, oil status should be assessed.

8.3.6.5 Filters
Filters without clogging sensors must be replaced immediately after the first adjustment and is
replaced once after every one to six months by future working conditions.
Monitor continuously filters with clogging sensors. Check every day when the working temperature
reaches normal. Alarm possibly due to relatively big flowing resistance during temperature rising does
not mean that filter core is clogged.
Intervals for checking and cleaning up or replacing filter core depend on environmental conditions.
Structure of filters:：
Main components of filters are filter body and filter cores.
- Filter body
Filter body is generally divided into filter head and filter barrel, as well as relief valves, pressure
difference indicators and other accessories.
Oil enters filters from inlet of filter head and passes filter core radially from outside to inside.
Granule contamination in oil is captured by filtering layer of the core, and oil entering inside the core is
clean oil which flows out of filters from outlet of filter head.
With filters working time increasing, filtering layers of the core capture more and more granules and
pressure difference is bigger and bigger between inlet and outlet. Clogging sensors are used to indicate
the pressure difference between filter inlet and outlet, and are important reference for users to know
clogging conditions of filter cores and to replace cores promptly. If cores are not replaced promptly
when they reach limiting pressure difference, relief valve will open if the difference increases to a
certain value to avoid filter cores cracking.
- Filter core
This is the key component in filters, whose filtering performance mainly depends on structure of
filter cores and categories of filtering material. Core structure includes wires style, Sintering style,
Cylinder folding style and so on.
To wind wires around core framework and capture granule contamination in oil with clearance
between wires.
Sintering filter cores, made by sintering metal powder, capture granule contamination in oil with
clearance between powder.
Cylinder folding filter cores, most commonly-used class, have such advantages as big filtering area,
big capacity for contamination, wide range of filtering precision and etc.

8.3.6.6 Adjustment
All signal devices should be adjusted in original adjustment such as pressure-controlling valve,
flowrate-controlling valve, pump adjuster, pressure relay, stroke switch and thermorelay. Monitor
continuously all set values at initial stages and check them regularly in the future.
The system pressure should be set as low as possible to prevent unnecessary oil heating. In certain
situation, the set value can be 0.4-1.5Mpa higher than necessary static pressure to overcome dynamic
pressure drop or reach correct acceleration.
There is always an additional safety valve for protection in using pressure compensator-type
variable displacement piston pump or unloading relief valve system. The opening pressure of the safety

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 valve should be 1-3Mpa higher than the set pressure of pump adjuster or unloading relief valve.

8.3.6.7 Cooler
Cleaning intervals for water coolers and oil coolers depend on water quality, temperature and water
quantity. Nylon brushes or chemicals can be used. Zinc rods to prevent electrochemistry corrosion in
tubular coolers should be checked regularly and replaced promptly.
Generally the cooler the cooling medium (air or water) is, the more heat is taken from oil. But this is
true only within a certain range. When the temperature of cooling medium is below a certain value,
coagulate layer will form in the oil contacting very cool surface. The cooler the cooling medium is, the
thicker the layer. This coagulate layer is equivalent to heat-insulating layer; heat-insulating ability of
stagnant 8-mm thick oil layer is equivalent to that of 2-mm thick asbestos layer. Therefore when
machine runs in cold weather, limiting the lower limit temperature or supply of cooling medium can
improve the cooler’s heat exchange ability on the contrary.
Clean soft water should be used in water cooler to prevent pipes from dirt and corrosion.

8.3.6.8 Hydraulic pump

Check connecting status of fittings in inlet and outlet, leakage, sucking pressure, volume and
efficiency. Sealing rings need to be replaced when necessary.

8.3.6.9 Control valve

Check if the set pressure of the pressure valves and the indicated flowrate of flow valves in pressure
adjusting unit are consistent with their actual values. Check dynamic properties of electro-hydraulic
valves and middle leakage of valves. Change it when necessary.

8.3.6.10 Other checks

Keep alert and watch out for details can help to discover accident symptoms and avoid catastrophe,
especially so in initial commissioning. Always pay attention to leakage, contamination, elements
damage (especially pipes and hoses) and etc. Take notice of functions of instruments and abnormal noise
from motors, pumps, couples and frame.

8.4 Emergency maintenance

This operation usually includes replacing general components or machine parts.
These components will generally no longer satisfy their functional and safety performance
requirements due to wearing and destruction.
DANGER
All emergency maintenance must be operated by trained engineers.

Hydraulic system
DANGER
Ensure that pumps are off before any operations in hydraulic system. Pressure at all points in
the circuit is 0.
Oil in hydraulic system must be changed after operation for 4000-5000 hours.
Suggestion in changing oil:

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 - Let out oil to be changed, clean the oil tank and pour new oil into the tank by oil filter pumps.
CAUTION
Detergent used should be common, facile, non-abrasive and non-corrosive.
- Clean the oil tank completely
- Replace the filter at inlet
It is wise to replace filters in recycle system once a year, though relevant indicators do not show that
they are blocked.
DANGER
Ensure that main power in recycle system is turned off before opening the cap of filters.

Hydraulic pump
Pay close attention in changing pumps.
DANGER
Electrical equipment can be changed only after turning off power switch on the main control
panel.
- Shut off input pipelines before moving pumps
- Change pumps
Personnel who change various components must ensure:
- New and changed components must have identical codes and compare their relevant nameplates;
- External seal is not lost and damaged in installation;
- Install electrical connectors securely and seal them well.

8.4.1 Cleaning molds

WARNING
Never use hard metal tools and hard rags in cleaning molds.
Only copper or brass tools are permitted with some necessary precautions.
Pay great attention in cleaning operations.
Pay great attention especially in dismantling not to damage sharp edges of some important
components.

8.4.2 Maintenance of barrels and screws

8.4.2.1 Screws
Reasons for screw damage:
- Temperature is low during material plasticization;
- Metal foreign bodies are mixed in material or many impurities are in material;
- Dry cycle time of screws is too long;
- Material selection for making screws is unreasonable;
- Screw-making precision is low, and hardness is low in heat-treatment of thread working surfaces.
Process of disassembling screws is as follows: Refer to Fig.8-1.
NOTE
Special tools should be used in dismantling screws. Striking with hammer is not allowed.
- Remove protective plates below the injection seat.
- Inject to the end and remove plastics at the front of screws.

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 - Dismantle the protecting chain fitting screws (No.6) to prevent damaging the chain due to rotation
of injection seat.
- Dismantle Screw B (No.2), loosen Screw C (No.4) and rotate about 13° counter-clockwise the
injection unit around Screw C (No.4) to make screw point between tie bar and window frame .
- Open the fan adapter and heating band at the end of nozzle.
- Unload flange at the front of barrel (connecting piece between nozzle and barrel).
- Dismantle half ring, pull screw and move it forward, separate joint of screw rear key from drive
shaft.
- When screw top comes out of barrel, dismantle immediately connecting threads of screw top (note:
most threads here are left helix).
- Dismantle check ring and sealing ring on screws.
- Such tools as brass brushes and brass scoops should be used to clear remaining material in the
dismantled nozzle, check ring, sealing ring and screws. Special material difficult to clear should be
heated in oven, with the minimum temperature enabling remnants to soften, before eliminating the
material.
- Assemble all parts on screw after clean-up; smear the heat-resistant grease molybdenum bisulfide
on all threads connection to facilitate next disassembly.
- Screws not used temporarily should be smeared with protective oil after surface cleaning,
wrapped and hung in ventilative and safe places.

1 — Screw A
2 — Screw B
3 — Half ring
4 — Screw C
5 — Plasticization oil pipe
6 — Protecting chain fitting screws
7 — Injection oil pipe

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 Fig.8-1 extraction screw diagram

Repairing and replacing screws：

- Hone or fine emery cloth can be used to grind and polish damaged parts in case of light wearing
or scratch traces on screw’s working surface;
- In case of serious wearing and deeper scars on screw’s working surface, causes of screw wearing
should be examined and analyzed, faults eliminated to prevent similar Symptom from happening again
and deeper scars renovated.
- If wearing of threads on the entire screw is serious, fitting clearance increases between screw and
barrel, melt leakage worsen and injection amount is unstable in working, external circles of thread in
screw should be sprayed with antiwear alloy. Then screw is ground by fitting clearance requirements of
parts according to actual size of barrel’s internal diameter.
- If wearing of barrel is serious, inner diameter increases after restoration and screws’ grinding after
spraying cannot satisfy size requirements of fitting clearance between barrel and screw, then screws
should be remade. The external diameter of screw threads should be processed by two parts’
requirements of fitting clearance with reference to barrel’s actual inner diameter.

8.4.2.2 Use and maintenance of barrels

Correct process of cleaning barrels:
- Heat barrel area, with temperature set at 10-20°C higher than that of processing material.
DANGER
You must be especially alert to the risks of scalding/ burning when working on the machine
when it is hot. Always wear protective clothing which complies with the safety regulations.
CAUTION
Wear protective face piece to avoid inhale smoke/gas produced by plastics.
- Plasticization and injection are done repeatedly until new material is discharged.
Items stressed in using barrels:
- Protect flange-connecting plane and the plane connecting front end and nozzle during barrel
installation and disassembly. Scratch and striking traces are not allowed. Keep the connecting plane
clean and free of any foreign bodies in installation. Tighten connecting screws with uniform force at all
points.
- When the barrel temperature rises to technical temperature, all connecting nuts should be
retightened to avoid parts distortion and melt leakage.
- Highly corrosive material such as PVC, PC and butyrate is not allowed to remain in barrels during
production stop. Barrel inside must be cleaned after machine stops and smeared with a layer of
protective oil.
- If dismantling barrels is necessary, it should be done in heating status after clearing remnant in
barrels.
- Brass brushes or emery cloth should be used in cleaning barrels; hard tools such as steel knives
are not permitted in scraping.
- Barrels with anti-wearing and anti-corrosive alloy bushing should be used in plasticization and
injection of denatured, reinforced plastic plastics containing fiberglass, carbon fiber or calcium
carbonate, because the inorganic mixture is greatly wearing and corrosive to barrels.

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 - Knocking with hammer is not allowed in dismantling barrels.
- It is not permitted to store heavy objects on barrels.

Restoring barrels:
- Hone or emery cloth can be used to grind and polish on lathe if wearing or scratch is not serious
on inner surface of barrels.
- In case of serious wearing on inner surface of barrels, check the trace depth first, and calculate if
there is still heat-treatment hardness surface on the inner wall after excluding grinding of trace. If yes,
the barrel can be ground until removing trace. Roughness of the ground inner surface should not be
larger than 1.60μm. Axis line’s precision of tolerance is Grade 7 by the standard GB1184-1980. Then
screws are made again to match the barrel inner diameter.
- If heat-treatment hard surface has not been on the ground inner surface of barrel, alloy bushing
can be made and put in the barrel. Centrifugal casting can also be employed to cast a layer of hard alloy
in the barrel inner wall and barrel can be used after machining and grinding.

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 9 Troubleshooting
9.1 Troubleshooting introduction
9.2 Hydraulic system troubleshooting
9.2.1 Causes of hydraulic striking and prevention & elimination
9.2.2 Causes and elimination of injection seat moving unstably
9.2.3 Direction valve action troubleshooting
9.2.4 Reasons for too loud noise in hydraulic drive and elimination
9.2.5 Insufficient pressure of hydraulic oil or oil pressure & flowrate fluctuating and troubleshooting
9.2.6 Reasons for hydraulic oil temperature too high and elimination
9.3 Faults-diagnosing means
9.4 Technical mistakes and eliminating means
1) Material lacking in parisons
2) Parisons flash
3) Capacity of injection instability
4) Nozzle gate drawing thread
5) Nozzle gate trace
6) Poor fusion
7) Blowing failure
8) Parisons overheating
9) Parisons adhering to core rods
10) Parison dropping down
11) Stripes or fusion traces on container surfaces
12) Burnt spot and impurity on container surfaces
13) Container cracking or thinning
14) Aberrance on neck of container
15) Container body sinking
16) Bad transparency of containers
17) Container adhering to molds
18) Container bottom whitening
19) Container neck cracking
20) Container shoulder distortion
21) Instable forming size
22) Difficult stripping of containers
23) Color stripes on container wall
24) Incomplete size of products’ structure
25) Instable outlines & size and contracting of products

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 26) Flash in products
27) Products cracking easily during stripping
28) Fusion traces on product surfaces
29) Corrugation on products’ surfaces
30) Air bubble or silver stripe on products’ surfaces
31) Poor luster of products’ surfaces
32) Injection products distortion
33) Black spots or stripes in products

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 9.1 Troubleshooting introduction
The machine has self-diagnosis system.
If a certain mistake appears, the machine will enter alarm status and alarm lamp and buzzer on the
top of machine will send out alarm promptly.
The machine will go on working in case of mistakes not so serious; otherwise it will stop.
Operators can view alarm contents by alarm record page.
Sirens can be turned off through keys. Flashlight will stop automatically when the mistake causing
alarm is rectified.

9.2 Hydraulic system troubleshooting

Hydraulic system is fitted with self-protection and alarm devices, and will give alarms automatically
in following situation:
- Insufficient hydraulic oil, to avoid affecting hydraulic drive by insufficiently sucking oil.
- The alarm for hydraulic oil temperature too high, to avoid damaging any element in hydraulic
drive and ensure normal hydraulic drive operation.

There are plenty of faults sorts in hydraulic system and the following is common:
- Noise and vibration produced by system
- Moving components crawling
- System pressure insufficient
- Moving components’ speed abnormal
- Oil temperature too high
- Directing or starting abnormal

9.2.1 Causes of hydraulic impacting and prevention & elimination

In normally-working hydraulic drive system, sudden directing or valve closing makes flow in the
system reverse immediately or stop suddenly. But because of inertia in both hydraulic flow and
mechanical movement driven by oil cylinder piston, local pressure changes rapidly in hydraulic drive.
The pressure rising much instantly forms flow pressure impact, which will damage elements in
hydraulic system. This sudden occurrence is called hydraulic impact or water hammer.

1) To prevent hydraulic impact:

- Do slow down valve closing or directing.
- Control the flow speed of hydraulic oil in the system within a certain range.
- Install safety valve to control pressure rise of hydraulic oil at inlet and outlet of oil cylinder.
2) To eliminate hydraulic impact:
- Reduce pressure of hydraulic system, increase back pressure of some pistons, check if oil
temperature is too high and eliminate gas in oil once.
- Clean and examine restrictor and check valve at directing position. It is possible that check
valve malfunction or restrictor’s opening too big causes directing spool sliding too quick and cause
hydraulic shock.
- Make several uniformly-distributing triangle grooves at the end of sliding spool of directing valve
to cushion sliding.

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 9.2.2 Causes and elimination of injection seat moving unstably
1) Gas is mixed into hydraulic oil. If so, working pressure of hydraulic oil is instable. Oil pumps
and oil-conveying pipeline will produce uneven noise with more mixed gas. Observe pressure gauge and
you will see the pointer’s big and effective sway. Instable oil-conveying pressure causes oil cylinder
piston crawling.
Solutions for the instable operation are following:
- Turn on exhaust valve at the top of oil cylinder or PQ valve to make piston reciprocate several
times until hydraulic oil spurts.
- Tighten all connecting of oil-conveying pipes to avoid leakage.
- Return and suction sections are separated with clapboard in tank.
- Clean filter element. Fill the tank with hydraulic oil to ensure sufficient oil for oil pumps’ suction
and output. Avoid air mixing.
2) Friction and resistance are big. Lubrication is bad between injection seat and guide rod when
the seat slides on. Lubricating oil film not formed or destroyed causes local dry friction between
injection seat and guide rod and increases moving resistance of injection seat.
To reduce resistance between injection seat and guide rod, the following should be executed:
- Check if lubricating oil is injected promptly so that lubricating oil film between injection seat and
guide rod is formed. Oil should be added regularly during work takeover. Do not add too much once to
avoid polluting environment.
- If strength of lubricating oil film is not good, change it with more viscous oil to increase the
strength of the oil film.
- Check if pistons of oil cylinder move parallel to guide rod longitudinally. If piston rod bends or
concentricity is bad of piston rod and piston, and pressure is too high of all positions’ sealing rubber
rings, these are all factors of increasing pistons’ moving resistance and should be resolved through
checking and maintaining oil cylinder.

9.2.3 Direction valve action troubleshooting

1) Solenoid of solenoid operated direction valves is burned with spring distorted and broken.
Foreign bodies clog inside valve. All these will cause sliding spool to stop functioning. Dismantle the
valve and clean its parts to find causes of faults and resolve them.
2) Insufficient pressure of hydraulic oil causes the sliding spool of reversing valve to move slowly.
This can be resolved through increasing the oil pressure.
3) Serious wearing in the valve seat’s internal diameter and the sliding spool’s external diameter of
reversing valve causes internal hydraulic oil to leak seriously and sliding spool to move slowly. The
reversing valve should be repaired and sliding spool with increased diameter used instead.
4) Direction valve cannot move due to big resistance between injection seat and guide rod, and
piston thrust smaller than sliding resistance of injection seat. Solve it according to Item 2 in 9.2.2.
5) Bigger damp of return oil is caused by unreasonable adjustment of which controls sliding
speed of spool for reversing valve. It is also a factor disabling reversing valve from functioning and can
be solved through proper adjustment of restrictor.

9.2.4 Reasons for too loud noise in hydraulic drive and elimination

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 1) Examining oil pumps is needed due to the following reasons:
- Possibly serious wearing in internal surface of stators
- Damage of bearing
- Vane block
- Motor adapter librates.
2) Difficulty in sucking oil and filter element choke. Filter element should be cleared.
3) Oil temperature is too high or low. Control it within 15-55℃.
4) Oil viscosity is too high. Change the oil with lower viscosity.
5) Examining control valves at all positions is needed due to the following reasons:
- Serious wearing of spool and valve bodies
- Distortion or damage of springs
- Bad contact with solenoid
- Valves clogged by foreign bodies.
6) Oil tanks should be checked due to the following reasons:
- Hydraulic oil is insufficient. Oil should be filled to the up limit;
- Return line gate is upper the oil level, mix air with oil to bring foam, return line gate should be
lower than the oil level;
- The tank walls vibrate. Rubber mat should be used under the tank body.
7) Air is mixed into oil. Air exhaust valves should be fitted at high places of oil tank and pipeline
and discharge air in the pipeline before running the machine.

9.2.5 Insufficient pressure of hydraulic oil or oil pressure & flowrate fluctuating and troubleshooting
1) Oil pumps need to be examined due to the following reasons:
- Vane scratch
- Serious wearing in internal surface of stators
- Damage of bearing
- Serious wearing of oil distributor
- Oil pumps rotating in wrong direction
- Sand hole in pump body, make high pressure and low pressure oil communicate.
2) Hydraulic oil has high viscosity and needs replacing.
3) Hydraulic oil is insufficient in tanks and oil level should be kept up to upper limit.
4) Air is mixed into oil. Exhaust valves should be fitted at high places of oil pipeline to discharge
air.
5) Pipeline leaks seriously and should be repaired promptly.
6) The pipeline possibly has clogging positions or contains oil with many impurities to affect
control valve’ normal working. It should be cleaned.

9.2.6 Reasons for hydraulic oil temperature too high and elimination
1) Flowrate of chilled water is small. Check if any clogging appears and increase the flowrate after
removing faults.
2) Serious wearing of oil pump elements and their low efficiency cause the pump body to heat and
oil temperature to rise. Oil pumps should be examined.
3) Oil pressure is too high in hydraulic working system and should be reduced adequately.

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 4) Pressure release is insufficient in return line and oil pressure is too high. Adjustments are
needed.
5) In oil pipeline, it is possible that inner diameters of control valves and pipelines do not match
which leads to big resistance and oil temperature rising. Change valves after checking them. Or maybe
the pipeline is clogged by foreign bodies and should be cleaned.

9.3 Faults-diagnosing means

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 Noise too high

Symptom Reasons Treatment

- Clean filter element with solvent able to

resolve oil
- Clean the clogged inlet pipes
- Clean or replace air filter in oil tank
Gas corrupting
- Change clogged filter element
- change Oil for system
- Check if oil temperature is too low
- Major repair or change hydraulic pumps
High noise in
- Tighten leaking fitting
pumps
- Fill the tank to proper level
Air mixed into oil - Release air from system
- Change axis seal of pumps and worn
axis
adjust and check status of sealing, bearing
Couple not in-line
and couples

Wearing or damage of pumps Major repair or change

Check status of sealing, bearing and

Couple not in-line
High noise in couple
motor Wearing or damage of motor or
Major repair or change
couple
Set value too low or too close
Adjust to correct pressure
High noise in to another valve’s set value
relief valve
Wearing of spool or valve seat Major repair or change

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 Overheat

Symptom Reasons Treatment

Overheat in oil Refer to column “overheat in oil”

- Clean filter element with solvent able to

resolve oil
- Clean clogged inlet pipes
- Clean or replace air filter in oil tank
Gas corrupting
- Change clogged filter element
- Oil change for system
- Check if oil temperature is too low
- Major repair or change hydraulic pumps
- Tighten gas-leaking fitting
Overheat in
- Fill the tank to proper level
pumps
Air mixed into oil - Release air from system
- Change axis seal of pumps and worn
axis
Set value too high for relief
Adjust to correct pressure
valve or unloading valve
- adjust and check status of sealing and
bearing
Over loading
- Check if working load exceeds
return-line design

Wearing or damage of pumps Major repair or change

Overheat in oil Refer to column “overheat in oil”

set value for unloading valve

Adjust to correct pressure
and relief valve too high
Overheat in - Adjust and check status of sealing and
motor bearing
Over loading
- Check if working load exceeds
return-line design
Wearing or damage of motor or
Major repair or change
couple

Overheat in oil Refer to column “overheat in oil”

Overheat in relief
Incorrect set value Adjust to correct pressure
valve
Wearing of spool or valve seat Major repair or change

Overheat in oil System pressure too high Adjust to correct pressure

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 set value of unloading valve
Adjust to correct pressure
too high
- Change filters
Dirty oil or low level
- Fill the tank to proper level
- Oil change for system in case of
Incorrect viscosity of oil
incorrect viscosity
- Clean up cooler
Cooling system going wrong - Change control valve of cooler
- Repair or change cooler
Damage of pump, valve,
motor, cylinder or other Major repair or change
elements

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 Abnormal flowrate

Symptom Reasons Treatment

- Change clogged filter element

- Clean up clogged inlet pipe
No oil received by pump - Clean or replace air filter in oil tank
- Fill the tank to proper level
- Major repair or change hydraulic pumps

Abnormal drive motor of pump Major repair or change

- Check if pump or its drive is damaged

Skidding of pump and couple
- Replace and adjust couples

Drive motor of pump reversing - Change rotating direction

No flowrate
- Check position of manual control
Incorrect position set for - Check solenoid operated direction
direction control valve-controlled circuit
- Repair or change control pump
Total flowrate passing
Check and adjust
overflow valve

Damage of pumps Major repair or change

Wrong assembly of pumps Major repair or change

Value set for flowrate control

Check and adjust
too small
Set values too low for relief
Check and adjust
valve or unloading valve.
- Check position of manual control
- Check solenoid operated direction
flowrate is by- passed by
valve-controlled circuit
opening valve
- Repair or change control pump
Insufficient - Major repair or change
flowrate
System leakage Tighten oil-leaking fitting

PQ valve not work Major repair or change

Incorrect rotating speed for

Change
drive motor of pump
Damage of pump, valve,
motor, cylinder or other Major repair or change
elements

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 Value set for flowrate control
Adjust
too big

PQ valve not work Major repair or change

Flowrate too
large Incorrect rotating speed for
Change
drive motor of pump
Incorrect standard of
Change
newly-changed pump

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 Abnormal pressure

Symptom Reasons Treatment

- Change clogged filter element

- Clean up clogged inlet pipe
No pressure No flowrate - Clean or replace air filter in oil tank
- Fill the tank to proper level
- Major repair or change hydraulic pumps
- Change clogged filter element
- Clear clogged inlet pipe
Exist by-pass channel
- Clean or replace air filter in oil tank
- Tighten oil-leaking fitting
Value set for decompression
Pressure too low Readjust
valve too low
Damage of decompression
Major repair or change
valve
Damage of pump, motor or
Major repair or change
cylinder
- Tighten the fitting where gas-leaking
Air mixed into oil - Fill the tank to proper level and release
gas from system

Wearing of relief valve - Major repair or change

- Change clogged filter element or oil

Irregular pressure Oil polluted
change for system
Accumulator malfunction(the - Check if gas valve leaks
machine doesn’t have - Inflate to correct pressure
accumulator) - Major repair in case of malfunction
Damage of pump, motor or
Major repair or change
cylinder
Unreasonable adjustment of
decompression valve, relief Readjust
valve or unloading valve.

Pressure too high PQ valve not working Major repair or change

Wearing or damage of
decompression valve, relief Major repair or change
valve or unloading valve.

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 Abnormal movement

Symptom Reasons Treatment

No flowrate or pressure Refer to column “abnormal flowrate”

Control device not working or

Major repair or change
incorrect adjustment

No instruction in system Recover instruction or wiring

No movement
System not working or
Adjust, restore or change
adjusted incorrectly

Valves not working Adjust, restore or change

Wearing or damage of cylinder

Adjust, restore or change
or motor

Insufficient flowrate Refer to column “abnormal flowrate”

- Check if oil temperature is too low

Oil viscosity too high - Check oil viscosity of system and
change oil if necessary
Insufficient control pressure of
Refer to column “abnormal pressure”
valves
Movement too
Lack of lubrication in guide
slow Reinforce lubrication
track or mechanism
System malfunctioning or
Adjust, restore or change
adjusted incorrectly
- Clean & adjust or change
Valve movements not smooth
- Check the system oil and filters status
Damage or wearing of pump
Adjust, restore or change
and motor

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 Irregular pressure Refer to column “abnormal pressure”

- Tighten gas-leaking fitting

- Fill the tank to proper level
Air mixed into oil - Release gas from system
- Change axis seal of pumps and worn
axis
Lack of lubrication in guide
Improve lubrication
track or mechanism
Irregular
movement Irregular instruction signals Recover instruction or wiring

System malfunctioning or
Adjust, restore or change
adjusted incorrectly
Feedback sensor
Adjust, restore or change
malfunctioning
- Clean & adjust or change
Valve movements not smooth
- Check the system oil and filters status
Damage or wearing of pump
Adjust, restore or change
and motor

Insufficient flowrate Refer to column “abnormal flowrate”

Movement too Feedback sensor

Adjust, restore or change
fast malfunctioning
System malfunctioning or
Adjust, restore or change
adjusted incorrectly

If a problem is identified as a hydraulic one, its causes can usually be found easily because most
problems are related to pressure or flowrate.
Be sure to set all pressure properly, as shown in applicable hydraulic diagram.
If the line with something wrong is recognized, check or change valves first because they are the
easiest to change.
Next check the pump supplying oil to the line to see if the pump rotates in correct direction.
Parts to be changed last should be operative components, such as mold-closing cylinder. It usually
takes the most time and labor, so their problems should be made certain before removing or changing
them.
Since this part is hydraulic, it only contains hydraulic troubleshooting instructions. Electrical and
mechanical problems are supposed to have been removed.

9.4 Technical mistakes and eliminating means

1) Material lacking in parisons
- Insufficient injection amount. Lengthen screw backward stroke;
- Injection pressure and speed too low. Increase pressure of high-pressure injection;

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 - Low material temperature, increase melt temperature;
- Temperature of hot runner too low, raise the temperature;
- Nozzle clogged, clear nozzle and increase its inner diameter;
- Low mold temperature, raise the temperature of parison mold;
- Low injection pressure, improve high-pressure injection;
- Injection period short, prolong the time;
- Feeding gate clogged, clear hopper and feeding gate;
- Not centering mold installation to make one side too thin, resistance increase and material unable
to be filled. Mold should be installed again.

2) Parisons flash
- Too much injection, shorten screw backward stroke;
- Injection pressure too high, decrease pressure of high-pressure injection;
- Injection too fast, slower the speed;
- Material temperature too high, reduce melt temperature;
- Temperature of hot runner too high, reduce the temperature;
- Nozzle temperature too high, lower it;
- Bad mold closing, adjust mold-closing system to make molds tightly closed.

3) Instable injection of parisons (sometimes insufficient injection, and sometimes flash)

- Injection pressure fluctuating, check injecting oil cylinder;
- Thermocouples loose or damaged, tighten or change them;
- Mixing nozzle elements damaged, change them;
- Temperature-controlling device of parison molds fails to work, check and change it.

4) Nozzle gate drawing thread

- Temperature of hot runner too high, lower the temperature;
- Temperature of feeding gate too high, reduce the temperature.

5) Nozzle gate trace

- Temperature of feeding gate too low, raise it;
- Diameter of feeding gate too big, reduce it properly or change into a gate with smaller diameter;
- Injection too fast, slow down the speed.

6) Poor fusion
- Bad exhaust of molds, improve the exhausting conditions;
- Injection pressure too low, increase injection pressure;
- Blowing time too long, shorten it;
- Injection remnant too little, lengthen screw backward stroke;
- Material polluted, purify it;
- Temperature of feeding gate too low, raise it.

7) Blowing failure

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 - Blowing pressure too low, raise it;
- Parison temperature too low, raise barrel temperature;
- Core rod temperature too high, lower the temperature;
- Air supply pipeline clogged, eliminate blocking stuff;
- Temperature of parison molds too low, raise it.

8) Parisons overheating
- Insufficient cooling of core rods, improve the cooling;
- Melt temperature too high, lower it;
- Local temperature of molds too high, lower it in corresponding positions of parison molds;
- Insufficiently local cooling of core rods by stripping device, adjust it;
- Temperature-controlling device of parison molds malfunctioning, check the device.

9) Parisons adhering to core rods

- Melt temperature too high, lower it;
- Improper temperature of core rods, adjust it;
- Bad stripping, spray core rods with release agent;
- Improperly control of temperature-controlling device of parison molds, check the device and
improve the internal & external air-cooling for core rods;
- Injection period short, prolong the time;
- Low injection pressure, increase injection pressure.

10) Parison drooping down

- Injection pressure too high, reduce it properly;
- Forming period too long, shorten it;
- Temperature of core rods too high, lower it;
- Melt temperature too high, lower barrel temperature.

11) Stripes or fusion traces on container surfaces

- Bad exhaust of molds, clear mold cavity and improve the exhausting conditions;
- Feeding gate clogged, clear and enlarge feeding gate;
- Improper control of injection pressure, pressure too high or too low will lead to surface stripes or
fusion traces, injection speed should be adjusted properly;
- Screw rotates too rapidly, lower the speed;
- Material mixed with foreign bodies and impurities, it should be purified;
- Melt temperature too low, raise barrel temperature;
- Temperature of feeding gate too low, raise it;
- Mold temperature too low, raise it.

12) Burnt spot and impurity on container surfaces

- Bad vent of parison molds or blowing molds, improve the exhausting conditions;
- Injection pressure too high, reduce injection pressure;
- Injection too fast, slow the speed;

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 - Melt temperature too high, lower barrel temperature;
- Temperature of feeding gate too high, lower it;
- Neck ring damaged, repair it;
- Temperature of feeding gate too low, raise it.

13) Container cracking or thinning

- Temperature of core rods too high, lower it;
- Melt temperature too high, lower runner temperature;
- Nozzle temperature too high, lower it;
- Temperature of parison molds too high, lower it;
- Material mixed with foreign bodies and impurities, it should be purified;
- Release agent used too much or its variety selected improperly, reduce usage of release agent or
change it.

14) Aberrance on internal neck of container

- Diameter of feeding gate too small, enlarge it properly;
- Neck ring damaged or surface attached by foreign bodies, neck should be trimmed and foreign
bodies eliminated;
- Blowing pressure too low, raise it;
- Injection pressure too high, reduce high-pressure injection pressure;
- Melt temperature too high, lower barrel temperature;
- Temperature of parison molds too low, raise it;
- Parison temperature too high, lower runner temperature.

15) Container body sinking

- Blowing period short, lengthen it;
- Temperature of blowing molds too high, lower it;
- Temperature of core rods too high, improve cooling for them;
- Improperly control of temperature-controlling device of molds, check the device;
- Improper design of mold cavity, modify.

16) Poor transparency of containers

- Cooling too slow, speed up and increase cooling capacity;
- Inside of blowing pipes unclean, air should be filtered;
- Wall thickness of parison exceeds the range for transparent walls. Generally wall thickness of
blown transparent parisons is limited within 4mm, but the range of transparent parison varies with
viscosity of plastics and mold temperature. High viscosity of plastics or high mold temperature will
easily lead to transparent parisons;
- Resistance of melt flowing is too big. For white turbid spots on the bottom of parisons and around
sprue gates, thinner sprue gates and narrower runners lead to thicker layer of white spots. Enlarge the
gates and runners, opaque layer of white spots will become thin. Therefore, raise temperature of material
and mold’s sprue gates to increase fluidity of melt material;
- Mold temperature too high, lower it;

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 - Injection of cool material causing opaque parisons. White spots and opacity produced by cool
material mainly occur on the bottom of parisons, so the temperature of nozzles or molds should be
raised;
- Too much moisture in blowing air. When compressed air is blown into containers and expands,
large amount of steam is produced. Once the steam clings on inner wall of containers, their inner surface
becomes pockmarked/spotty and is no longer transparent. Mount moisture-removing and oil-filtering
devices in air supply device to eliminate moisture and oil in air.

17) Container adhering to molds

- Injection pressure too high, reduce high-pressure injection pressure;
- Too much injection remnant, shorten screw backward stroke;
- Screw rotating too rapidly, lower the speed;
- Melt temperature too high, lower barrel temperature;
- Parison temperature too high, lower runner temperature;
- Temperature of parison molds too high, lower it;
- Insufficient release agent;
- Raise temperature of parison molds;
- Unreasonable setting of release device, it should be reset;
- Forming period too short, prolong it.

18) Container bottom whitening

- Temperature of parison molds too low, adjust it;
- Temperature of feeding gate too low, raise it.

19) Container neck crazing

- Melt material temperature too low, raise it;
- Low temperature in neck ring area of parison molds, raise the temperature;
- Temperature of core rods too high, improve cooling of them;
- Low temperature in neck ring area of blowing molds, raise the temperature;
- Too big groove at the end of core rods, reduce the groove;
- Slowly injection, raise the speed;
- Imbalanced feeding speed for every nozzle, balance the speed;
- Insufficient coaxiality of core rods, check it;
- Improperly control of temperature-controlling device of molds, check the device;
- Improper installation of stripping device or unsuitable stripping speed, check the installation and
speed;
- Small inner diameter of nozzle, increase it.

20) Container shoulder distortion

- Blowing pressure low, raise it;
- Blowing period short, lengthen it;
- Bad exhaust of seam surface in blowing molds, clear vent grooves on the seam surface;
- Low temperature of parison molds, raise it;

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 - Core rods clogged, clean or change the clogged rods;
- Stripping not smooth, adjust or change stripping device.

21) Instable forming size

- Blocking stuff in melt runners, clear barrel and mold runners;
- Blowing pressure too low, raise it;
- Injection pressure low, raise high-pressure injection pressure;
- back pressure is low, raise it;
- Too much or too little injection remnant, adjust screw backward stroke;
- Injection too rapid or too slow, adjust the speed;
- Temperature of parison molds too high, lower it;
- Melt temperature too high, lower it.

22) Difficult stripping of containers

- Stripping pressure low, raise it;
- Stripping not smooth, adjust or change stripping device;
- Too big groove at the end of core rods, reduce the groove;
- Large friction between containers and molds, add lubricant in plastics or spray molds with release
agent to reduce the friction;
- High pressure of melt injection, lower it;
- Melt temperature too high, lower barrel temperature or lower rotating speed of screws ;
- Relatively high moisture content in material, it should be dried;
- Low temperature of molds or temperature difference large at all positions;
- Rough surface of products and incorrect angle of stripping plate, grinding should be done;
- Short period of pressure holding and solidifying, prolong cooling time properly.

23) Color stripes on container wall

- Colorant mixed unevenly in material, raise back pressure and improve mixing;
- Injection pressure low, raise it;
- Melt temperature low, raise it;
- Inner diameter of nozzle too small, increase it;
- Colorant mixed unevenly in material, improve the evenness and prolong mixing time;
- Colorant not scattered well, change it;
- Poor mixing performance of screws, improve it;
- Injection too rapid, lower the speed;
- Low temperature of parison molds, raise it;
- Moisture in material, dry the material.

24) Incomplete size of products’ structure

- Temperature too low in melt plasticization, raise barrel temperature;
- Insufficient pressure or short period of pressure holding, improve properly and observe result;
- Insufficient injection melt, possibly serious wearing of screws’ external diameter or
malfunctioning of check valves;

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 - Bad contact between nozzles and sprue gates of hot runners causing much leakage during
injection;
- Temperature of nozzle position too low;
- Low speed in injection, raise it properly;
- Back pressure too low for screws causing uneven material plasticization;
- Low temperature for heating molds or temperature of all positions not uniform, temperature
difference large, check if heater is damaged or adjust the temperature properly;
- Problems in melt runners, such as low temperature of runners, small sections or rough surfaces;
- Unreasonable layout of products’ size, too small size of wall thickness in some positions.

25) Instable outlines & size and contracting of products

- Low pressure in injecting melt, raise it properly;
- Low pressure or insufficient time in pressure holding;
- High temperature of barrel, temperature too high in melt plasticization, lower barrel temperature
properly;
- Back pressure too low for screws causing imbalanced melt plasticization, raise the pressure;
- Affected by mold temperature, adjust it properly and observe results. Mainly mold temperature
too high, prolong temperature cooling and curing;
- Small inner diameter of nozzle, increase it properly;
- Slow injection of melt, adjust and improve it properly;
- Insufficient injection melt;
- Unreasonable position of molds’ sprue gates;
- Unreasonable design of products’ structure and shape causes imbalanced local stress.

26) Flash on products

- Untight closing of two half molds or rough seam surfaces, maintain and improve them;
- Pressure too high for melt injection, lower it properly;
- Insufficient force in mold-clamping, raise it;
- Melt temperature too high, lower it;
- Too much injection melt, adjust and decrease injection time, melt quantity or injection speed;
- Temperature of parison molds too high, lower it.

27) Products cracking easily during stripping

- Uneven material plasticization, raise back pressure of screws properly;
- Temperature of parison molds too low, raise it;
- Improper stripping positions or asymmetric stripping force, find out the cracking positions and
adjust stripping positions properly;
- Incorrect angle of stripping plate for products molds, improve molds and modify the angle;
- Vacuum in some positions during products stripping or unreasonable structure of molds causing
local stress to concentrate in products, molds need to be redesigned and modified;
- Sliding block not harmonizing mold-opening or stripping, modify molds;
- Rough surfaces of parison molds, grind again and reduce the roughness;
- Uneven or insufficient release agent coat.

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 28) Fusion traces on product surfaces
- Uneven material plasticization, raise back pressure of screws;
- Temperature of parison molds too low, raise it properly;
- Injection pressure and speed too low, raise them properly;
- Small inner diameter of nozzle, enlarge it to increase injection capacity in unit time;
- Small section of melt runner to influence flowrate, enlarge inner diameter of the runner;
- Moisture too high in material, dry the material to reach permitted range.

29) Corrugation on products’ surfaces

- Uneven material plasticization and melting, raise barrel temperature or back pressure of screws
properly;
- Mold temperature too low, raise it or balance temperature at all positions;
- Adjust melt injection pressure, the pressure insufficient or too high will influence surface quality
of products;
- Pressure holding time is short, prolong it properly;
- Moisture content too high in material, dry the material;
- Unreasonable injection speed of melt, the speed too rapid or too slow will influence surface
quality of products;
- Rough surfaces of parison molds, grind to reduce the roughness.

30) Air bubble or silver stripe on products’ surfaces

- High moisture content in material, dry the material to make moisture content lower than permitted
value;
- Additives in material not resisting high temperature, change them;
- High temperature of barrel or material staying too long in barrel, lower the temperature of front
section in barrel or use injection molding machine with smaller model;
- Low back pressure of screws, raise it properly;
- Low pressure or short period in pressure holding; raise the pressure and prolong the period;
- Low temperature of parison molds, raise it properly;
- Injection pressure too high, lower it;
- Injection speed too rapid, lower it.

31) Bad luster of products’ surfaces

- Imbalanced material plasticization and melting, raise barrel temperature or back pressure of
screws properly;
- Moisture content too high in material, dry the material so that moisture content does not exceed
permitted value;
- Rough surfaces or beads inside parison molds, polish and make cavity surface more roughness;
- Improper adding of additives in material, adjust and change it;
- Unclean material containing impurities;
- Temperature of parison molds too low, raise it properly;
- Small melt runner and sprue gates in parison molds leading to large resistance in melt flowing and

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 bad exhaust of molds, rebuild the mold.

32) Injection products distortion

- Unreasonable design of products’ structure, asymmetrical arrangement of shape and thickness,
design should be improved;
- Short period in pressure holding, prolong the temperature-falling period;
- Uneven temperature at all positions of parison molds, temperature difference too big, improve
evenness in temperature control to make uniform temperature at all positions;
- Asymmetric stripping force, adjust stripping positions;
- Unreasonable position laying of sprue gates, alter the position properly;
- Pressure and speed of injection melt too high, lower them properly.

33) Black spots or stripes in products

- Barrel unable to be clean and material decomposition remnants, dismantle barrel and clean off
remnants from barrel completely;
- Material containing impurities, check and change it;
- Small nozzle aperture, small aperture of sprue gates, high temperature of melt, high injection
pressure, rapid injection and other factors cause melt to become yellow or decompose easily because of
high temperature. Adjust the items one by one, observe forming quality of melt and find out faults’
causes;
- Material-storing area inside barrel or at nozzle part leads to material decomposition and spots or
stripes, dismantle barrel and nozzle, find out the material-storing area and grind.

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 10 Refuse Disposal
10.1 Definitions of waste
10.1.1 Special waste
10.1.2 Poisonous & noxious substances
10.2 Temporary storage
10.3 Traits of storing containers
10.4 Requirements for register
10.5 Treating means
10.5.1 Treating oil
10.5.2 Disposal of waste and consumables

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 In treating remaining oil and waste, purchasers are responsible for following correct process below
in accordance with laws and codes in force in local countries.

10.1 Definitions of waste

Waste is generally regarded as substances and objects deserted or to be deserted from human
activities and natural cycles.

10.1.1 Special waste

The following is considered as special waste:
- Considered as equivalent to urban waste due to its quality and quantity from industrial production,
agriculture, handicraft industry or commercial activities and service industry activities.
- Deserted machinery and equipment
- Disabled motor vehicles and components

10.1.2 Poisonous & noxious substances

Some hazardous gas may be generated during using this machine when raw material dissolves, it
can be exhausted by exhausting and venting system. The disposal should comply with the relevant
provisions and law of local country for environment protection.

10.2 Temporary storage

Temporary storage of poisonous & noxious substances generally means their planned treatment
and/or final treating methods involved. The Environmental Protection Law in force in the user’s country
must take all environmental factors into account.

10.3 Traits of storing containers

Fixed or temporary containers prearranged to hold poisonous & noxious substances must have
adequate characteristics to endure chemical, physical invasion and that from hazardous waste.
Containers to hold poisonous & noxious substances must have clear signs to indicate traits of their
contents.

10.4 Rejection requirement

When dispose the rejected components and products, waste hydraulic oil and cooling water, the
customer must follow the relevant regulations and laws of the local country.

10.5 Treating means

Special and/or poisonous waste must, through contract, be entrusted to the definitely authorized
enterprises which are essentially able to assume transport, with necessary authorization and record on
carrier’s registry.

10.5.1 Treating oil

Replacing used oil has been mentioned in previous chapters. The disposal process should accord
with laws in force of local countries.

180

3.1.32.1 Rev 03 182

 10.5.2 Treating waste and consumables
The waste disposal process must accord with laws and codes in force of purchasers’ countries.

181

3.1.32.1 Rev 03 183

 11 Spare Parts List
11.1 How to order spare parts
Users are responsible for purchasing original spare parts, which will guarantee effective and safe
running of injection & blow molding machine. Disassembly and installation must be operated according
to manufacturer’s instructions.
All identifiable information must be elaborated on machines and components requiring change
when spare parts need ordering.
Spare parts ordering can be executed as follows:
- Exact address and full name of the user company
- Quantity the user orders
- Serial No. of machines and molds
- Drawing No. of spare parts
- Coding of spare parts
- Elaboration of spare parts
- Quality requirements

182

3.1.32.1 Rev 03 184

 12 Other Documentation
12.1 Drawings and diagrams of the machine
Drawings about injection & blowing machine are supplied as following:
- Main power wiring terminal installation sketch
- Electric control panel layout
- Control system general flow chart;
- Electric control box layout 1
- Electric control box layout 2
- Power inlet circuit breaker, detector of phase order & phase lacking
- Partly small power 380V/220V transformer of loading power
- 480V-380V/220V 3-phase power transformer
- AC/DC power supply module
- Main motor soft-start main circuit and control loop
- Conveyor motor main circuit
- Electrical heating main circuit of hopper body
- Hot runner mould electrical heating main circuit
- Control system configuration diagram
- Human-machine interface and bus receiving module
- Analog and digital input/output mix unit main circuit
- Main circuit of temperature sensor input and electromagnetic control output units
- Main circuit of sensor input and control output units
- WAGO 859-730 photocoupler terminal 1
- WAGO 859-730 photocoupler terminal 2
- Control wiring diagram of fan and lubrication pump etc.(AC 220V)
- Other assistant circuit
- Double pump-proportion (pressure. P1) amplifying control valve
- Double pump-proportion (Flow. Q1) amplifying control valve
- Single pump-proportion (pressure. P2) amplifying control valve
- Single pump-proportion (pressure. Q2) amplifying control valve

183

3.1.32.1 Rev 03 185

3.1.32.1 Rev 03 186
 STM-W series
Standard Water Heaters

Date: Feb, 2006

Version: V1.0 (English)
 Contents

Contents

1. General Description 1-1

2. Technical Specifications 2-1
2.1 STM-607W 2-1
2.2 STM-607W-D 2-2
2.3 STM-910W 2-3
2.4 STM-910W-D 2-4
2.5 STM-1220W 2-5
2.6 STM-2440W 2-6
2.7 Specification List 2-7
3. Main Functions 3-1
3.1 Function Description 3-1
3.2 Working Principle 3-1
4. Safety Regulations 4-1
4.1 Signs and Labels 4-2
4.2 Operation Regulations 4-3
5. Installation 5-1
5.1 Installation Space 5-1
5.2 Mould and Water Couplings 5-2
5.3 Power Supply 5-3
6. Operation Guide 6-1
6.1 Control Panel 6-1
6.2 Machine Startup 6-3
6.3 Stop the Machine 6-4
6.4 Temperature Controller 6-4
Contents

7. Service & Maintenance 7-1

7.1 Open the Covers 7-1
7.2 Y Type Strainer 7-1
7.3 Solenoid Valve 7-2
7.4 Pipe Heater 7-3
7.5 The useful life of the key parts of the product 7-4

8. Trouble Shooting 8-1

9. Assembly Drawing and Parts List 9-1

9.1 Assembly Drawing for STM-W Single Heating Tank Series 9-2
9.2 Parts List of STM-607W/STM-607W-D 9-3
9.3 Parts List of STM-910W/STM-910W-D 9-4
9.4 Assembly Drawing for STM-W Two Heating Tanks Series 9-5
9.5 Parts List of STM-1220W 9-6
9.6 Pump 9-7

10. Electrical Circuit 10-1

10.1 STM-607W 10-1
10.2 STM-910W 10-3
10.3 STM-607W-D/STM-910W-D 10-5
10.4 STM-1220W 10-9
10.5 STM-2440W 10-12
10.6 Main Electrical Components Description 10-15

11. Maintenance Schedule 11-1

11.1 About the Machine 11-1
11.2 Check after Installation 11-1
Contents

11.3 Daily Checking 11-2

11.4 Weekly Checking 11-5
11.5 Monthly Checking 11-8
11.6 Half-yearly Checking 11-10
 1. General Description

1. General Description
Please read through this operation manual before using and
installation to avoid damage of the machine and personal injuries.

STM-W series mainly used to heat up the mould and keep its temp. at a
certain level and they can also be used in other similar fields. STM-W series
adopt accurate P.I.D. control system and German made SPECK pump with
rugged structureand attractive appearance.

Main Features:
1) P.I.D. temperature control system can keep mould temperature within the
accuracy of 1 .
2) Multiple safety devices can automatically detect and indicate by visible
alarms abnormal performance of the machine.
3) Highly reliable main power switch can be used to cut off power supply at
any emergent situation.
4) German made SPECK pump features high pressure and stability of
performance.
5) Overheated water can be cooled quickly by automatic cooling water
supply. This unit is suitable for applications demanding hot water with
constant temperature.
6) Inner parts are made of stainless steel to ensure corrosion-free operation.
7) STM-W water heaters can keep mould temperaure up to 2 .
8) Attractive appearance, easy access and maintenance.
9) Automatic drain facility can be added as an optional feature.

1-1
 2. Technical Specifications

2. Technical Specifications
2.1 STM-607W
2.1.1 Specifications Pump Performance curve

Pipe heater: 6kw

Pump power: 0.55kw 50

Max. pump flow: 30L/min 40

Max. pump pressure: 4.5 Bar 30

Cooling method: direct 20

Mould coupling: 3/8"(2 2) 10

Max. temperature: 120 0

0 5 10 15 20 25 30 35
Flow rate (L/min)

2.1.2 Outer Dimensions

630
60

735 280

2-1
2. Technical Specifications

2.2 STM-607W-D
2.2.1 Specifications Pump Performance curve

Pipe heater: 6kw 2 H

[m]
Pump power: 0.55kw 2 50

Max. pump flow: 30L/min 2 40

Max. pump pressure: 4.5 Bar 30

Cooling method: direct 20

Mould coupling: 3/8"(4 2) 10

Max. temperature: 120 0

0 5 10 15 20 25 30 35
Flow rate (L/min)

2.2.2 Outer Dimensions

630
60

735 560

2-2
2. Technical Specifications

2.3 STM-910W
2.3.1 Specifications Pump Performance curve

Pipe heater: 9kw H

[m]
Capacity(US GPM)

Pump power: 0.75kw 80

70
Total head
(feet)

Max. pump flow: 45L/min 60

50
Max. pump pressure: 6 Bar 40

Cooling method: direct 30

20
Mould coupling: 3/8"(2 2) 10

Max. temperature: 120 0

0 10 20 30 40 50 60
Flow rate (L/min)

2.3.2 Outer Dimensions

630
60

735 280

2-3
2. Technical Specifications

2.4 STM-910W-D
2.4.1 Specifications Pump Performance curve

Pipe heater: 9kw 2 H

[m]
Capacity(US GPM)

Pump power: 0.75kw 2 Total head

(feet)

Max. pump flow: 45L/min 2

Max. pump pressure: 6 Bar
Cooling method: direct
Mould coupling: 3/8"(4 2)
Max. temperature: 120
Flow rate(L/min)

2.4.2 Outer Dimensions

630
60

735 560

2-4
2. Technical Specifications

2.5 STM-1220W
2.5.1 Specifications Pump Performance curve

Pipe heater: 12kw H

[m]
0 2 4 6 8 10 12 14 16 18 20
Capacity(US GPM)
22 24 26
Total head
Pump power: 1.5kw 220 (feet)
200

Max. pump flow: 90L/min 50

180

160

Max. pump pressure: 5.5 Bar 40

140

120

Cooling method: direct 30 100

80

Mould coupling: 3/8"(4 2) 20 60

40
10
Max. temperature: 120 0
20

0
0 10 20 30 40 50 60 70 80 90 100
Flow rate (L/min)

2.5.2 Outer Dimensions

690
60

735 280

2-5
2. Technical Specifications

2.6 STM-2440W
2.6.1 Specificatios Pump Performance curve

Pipe heater: 24kw H

[m] 0 6 12 18 24 30
Capacity(US GPM)

36 42
80
Pump power: 2.2kw 70
250 Total head
(feet)

Max. pump flow: 160L/min 60 200

50
Max. pump pressure: 6.0Bar 40
150

Cooling method: direct 30 100

20
1 50
Mould coupling: 1 /2" (1 2) 10
0 0
Max. temperature: 120 0 30 60 90 120 150 180
Flow rate (L/min)

2.6.2 Outer Dimensions

790
80

810 340

2-6
2. Technical Specifications

2.7 STM-3650W
2.7.1 Specificatios
Pump Performance curve
Pipe heater: 36kw H Total head
[m] (feet)
Pump power: 4.0kw
Max. pump flow: 500L/min
Max. pump pressure: 3.5Bar
Cooling method: direct
1
Mould coupling: 1 /2" (1 2)
Max. temperature: 200

Flow rate (L/min)

2.7.2 Outer Dimensions

2-7
 2. Technical Specifications

2.7 Specification List

Pipe Pump Max. pump Max. pump Heating tank Mould

Max. Dimensions(HxWxD) Weight
heater power flow pressure Heating tank capacity Cooling coupling
Model Temp. number method
(L/min) (Bar) (L) (mm) (Kg)

STM-607W 6 0.55 30 4.5 1 2.5 630x280x735 50

STM-607W-D 6 2 0.55 2 30 2 4.5 2 2.5 2 630x560x735 100

STM-910W 120 9 0.75 45 6.0 1 2.5 Direct 630x280x735 72

STM-910W-D 9 2 0.75 2 45 2 6.0 2 2.5 2 630x560x735 140

STM-1220W 12 1.5 90 5.5 2 2.5 2 690x280x735 101

STM-2440W 24 2.8 160 6.0 6.6 790x340x810 140

STM-3650W 36 4.0 500 3.5 10 820x385x905 165

Note: 1. "D" stands for dual-heating zone.

2. Automatic drain facility can be added for all models as an optional feature.
(Model denotes "R")
3. Power supply: 3 , 400V, 50/60Hz.
4. In order to maintain stable temperature of heat transfer media, cooling water pressure
should be no less than 2 bar, but also no more than 5 bar.
5. Noise level LP = 45 dB max.

2-8
 3. Main Functions

3. Main Functions
3.1 Function Description
SHINI Standard Water Heaters are mainly used to heat up the mould and
keep its temp. at a certain level and they can also be used in other similar
fields. High temp. water from the mould will be cooled by direct cooling
method, pressurized by high pressure pump, then to be heated up by pipe
heaters and finally sent to the mould with a constant temperaure. Owning
to optimizing design, water temp. can reach up to 120 1 . Temperature
accuracy is guaranteed by OMRON temperature controller.
3.2 Working Principle
3.2.1 STM-W (single heating tank) Working Principle
I
C A. Cooling water inlet
L G B. Cooling water outlet
C. From mould
D
D. To mould
F E. Solenoid valve
F. Pipe heater
G. Pressure switch
M J
H. Pump
H I. Pressure meter
E
J. Water drainage
K K. Temp. sensor (EGO)
L. Water flow distributor
M. By-pass valve
High temp. water from mould(C) will return back to heating tank to be
heated, then sent to the mould. In this process, overheat of the water will
activate solenoid valve(E) to let cold water flow into heating tank to
reduce the temp. of process water to keep a constant temperature of it.
If water temperature remains high and reaches the upper limit of temp.
sensor(EGO)(K), the machine will raise overheat alarm.
Inside the machine, there is a by-pass between the cooling water pipe
lines. It can release system pressure to avoid damage caused by high
pressure, and distribute the cooling water to cool the high temperature
drainage water to protect water tube.

3-1
3. Main Functions

3.2.2 STM-W (two heating tanks Working Principle

I
C
L G A. Cooling water inlet
B. Cooling water outlet
D C. From mould
1 2 D. To mould
F
E. Solenoid valve
F. Pipe heater
M G. Pressure switch
J
H. Pump
E H I. Pressure meter
J. Water drainage
K K. Temp. sensor (EGO)
L. Water flow distributor

High temp. water from mould(C) will return back to heating tank 1 to be
heated, then sent to heating tank 2 to be heated again, and finally to the
mould. In this process, overheat of the water will activate solenoid valve
(E) to let cold water flow into heating tank 2 from cooling water inlet(A) to
reduce the temp. of process water to keep a constant temperature of it.
If water temperature remains high and reaches the upper limit of temp.
sensor(EGO) (K), the machine will raise overheat alarm.
Inside the machine, there is a by-pass between the cooling water pipe
lines. It can release system pressure to avoid damage caused by high
pressure, and distribute the cooling water to cool the high temperature
drainage water to protect water tube.

3-2
 3. Main Functions

3.2.3 STM-W-D Working Principle

I
C A. Cooling water inlet
L G B. Cooling water outlet
C. From mould
D D. To mould
F E. Solenoid valve
F. Pipe heater
G. Pressure switch
M J H. Pump
I. Pressure meter
E H J. Water drainage
K. Temp. sensor (EGO)
K L. Water flow distributor
M. By-pass valve

STM-W-D has two independently controlled heating zones. High temp.

water from mould will return back to heating tank to be heated, then
sent to the mould by pump(H). In this process overheat of the water will
activate solenoid valve(E) to let cold water flow into heating tank to reduce
the temp. of process water to keep a constant temperature of it. If water
temp. remains high and reaches the upper limit of temp. sensor(EGO),
the machine will raise overheat alarm.
Inside the machine, there is a by-pass between the cooling water pipe
lines. It can release system pressure to avoid damage caused by high
pressure, and distribute the cooling water to cool the high temperature
drainage water to protect water tube.

3-3
 4. Safety Regulations

4. Safety Regulations

Danger!
The unit is designed endure high temp, and high pressure. For safe
operation, do not remove the covers or switches.

Attention!
The unit should be operated by qualified personnel only.
During operation, avoid wearing gloves or clothes that may cause
danger.
Turn off main switch when power supply is off.
Stop the unit when there may be power supply problems caused by
static electricity.
Put on safety gloves and shoes during installation or relocation.
Components from our company can only be used for replacement.

Warning!
Do not touch the switch with wet objects or hands.
Do not use the machine before fully aware of its performance.
Be careful, not to touch or hit the switch or sensor.
Please keep enough operation space, and keep away obstacles.
To avoid producing statics, clean the floor from oil or water to keep
a dry environment.
Protect the machine against severe vibration or collision.
Do not remove safety signs or make it dirty.
Drunken, medicine-taking, or men without proper judgement should
not operate the machine.

4-1
4. Safety Regulations

4.1 Signs and Labels

In order to keep a stable temperature, cooling

water pressure should not be less2bar,
than
but also no more than
5bar.Clean the Y type
strainer to ensure cooling capacity of the machine.

N6148015

This is to indicate motor rotating direction.

When phase reversal happens, the alarm sounds
and indicator on control panel will indicate. Please
exchange the place of two of the electrical wires to
(Attached to pump cover) solve this problem.

High voltage! Electrical shock may happen.

Carefulness is required from the operator.

Attentions!
This is general warnings which operators should
pay attention to.

4-2
4. Safety Regulations

4.2 Operation Regulations

1) Before operation, make sure that cooling water is clean soft water without
pollutants.
Low quality water brings limescales, which may cause problems.
Low quality water may be the reasons for heater wire break, worn pump
leaf, less flow rate, that eventually affect temperature rising.
2) If problems of drainage or bad temperature control are noted, please clean
solenoid valve and cooling water inlet and outlet.
3) Do not move the unit when it is in operation.
4) When in need of repairing, wait until oil temperature falls below 30 .
5) Motor overload may be caused by phase shortage, pipe obstruction,
broken bearing , etc. Motor overload relay will trip off to stop the machine
when this happens. Fixing the problems, press RESET on overload relay
to clear the alarm.
6) Before turn off the pump, wait until oil temperature falls blow 50 . Or the
life of the unit would be affected.
7) In order to keep stable water temperature, cooling water pressure should
be 2~5bar.

4-3
4. Safety Regulations

Transportation and storage of the machine

Transportation
1) STM-W series standard water heaters are packed in crates or plywood cases
with wooden pallet at the bottom, suitable for quick positioning by fork lift.
2) After unpacked, castors equipped on the machine can be used for ease
of movement.
3) Do not rotate the machine and avoid collision with other objects during
transportation to prevent improper functioning.
4)The structure of the machine is well-balanced, although it should also be
handled with care when lifting the machine for fear of falling down.
5) The machine and its attached parts can be kept at a temperature from
-25 to +55 for long distance transportation and for a short distance,
it can be transported with temperature under +70 .

Storage
1) STM-W series standard water heaters should be stored indoors with
O O
temperature kept from 5 C to 40 C and humidity below 80%.
2) Disconnect all power supply and turn off main switch and control switch.
3) Keep the whole machine, especially the electrical components away from
water to avoid potential troubles caused by the water.
4) Plastic film should be used to protect the machine from dust and rains.

Working environment
The machine should be operated:
1) Indoors in a dry environment with max. temperature +45 and humidity
no more than 80%.
Do not use the machine:
1) if it is with a damaged cord.
2) on a wet floor or when it is exposed to rain to avoid electrical shock.
3) if it has been dropped or damaged until it is checked or fixed by a
qualified serviceman.

4-4
4. Safety Regulations

4) This equipment works normally in the environment with altitude within 3000m.
5) At least a clearance of 1m surrounding the equipment is required during
operation. Keep this equipment away from flammable sources at least two
meters.
6) Avoid vibration, magnetic disturbance at the operation area.

Rejected parts disposal

When the equipment has run out its life time and can not be used any more,
unplug the power supply and dispose of it properly according to local code.

Fire hazard
In case of fire, Co2 dry powder fire extinguisher should be applied.

Please abide by the safety guide when you operate the machine so
as to prevent damage of the machine and personal injuries.

All electrical components should be installed by qualified

electricians.
Turn off main switch and control switch during repair and
maintenance.

Warning High voltage

This mark is attached on the cover of the control box.

Warning Be careful

Be more careful when this mark appears.

Warning
High temperature, take care of hands! This label is attached on the
surface of heating parts.

4-5
5. Installation

5.1 Installation Space

During installation of the machine, keep at least 500mm installation space
around the machine as shown by the picture. Do not install the machine in
a position crowded with other objects. This would cause inconvenience to
operation, maintenance and repair.
Do not sit on the machine.
Keep away flammable and explosive goods.

500mm
500mm

5-1
5. Installation

5.2 Mould and Water Couplings

1 When connect mould coupling with
pipes from the mould. Use a spanner
to secure one end of the coupling,
insert mould connecting pipe and
fasten it by another spanner.
(Fig. 5.2-1)

Fig. 5.2-1

2 Unused mould couplings can be

connected with each other by a
teflon pipe, as shown in Fig. 5.2-2.

Fig. 5.2-2

Note! Cooling water inlet and outlet

as shown by the Fig. 5.2-3.

3 Connect cooling water inlet with water

supply and cooling water outlet with a
drainage pipe. After that, turn on water
supply.
Fig. 5.2-3

Cooling water outlet Cooling wate inlet

5-2
5. Installation

5.3 Power Supply

Make sure that power supply is the same as required before installation.
Mould heaters are generally set to be used with 3 400V power supply or
other specifications according to customers' requirement.

5-3
 6. Operation Guide

6. Operation Guide

6.1 Control Panel

1
2
3
4
5

7 8 6

No. Name Functions Remarks

1 Power supply Connect the machine with power supply Note! Do not remove any electrical
indicator and turn on main switch. This indicator parts or terminals after the power is on.
turns green.

2 Phase reversal When phase reversal or phase shortage Turn off the machine. Exchange the
alarm occurs, it becomes red. The buzzer place of two of the electrical wires of
sounds, and system stop working. main power supply.

6-1
6. Operation Guide

No. Name Functions Remarks

Motor overload When motor current exceeds the limits, Check that if motor shaft is blocked or
3
alarm the buzzer sounds. Motor overload the bearing is broken or setting current
alarm is red and system stops working. of overload relay is too low. After the
problems solved, wait for one minute
and then press the blue RESET button
to reset the overload relay and clear
the alarm.

When oil temperature is higher than
EGO(temperature sensor) setting
4 Overheat alarm value, this indicator becomes red. The
buzzer sounds and system stops
working.
EGO setting value should be higher
than temperature settings of
temperature controller. Check if there
are problems of temperature
detecting probe.

When there is circulating water

shortage, the alarm light will become
5 Low level alarm red. The buzzer sounds and system Ensure smooth water supply.
stops working.

6 Temp. controller Temperature setting and control.

Pump switch Turn on and off the pump. Note: motor rotating direction should
7 be correct.
Heater switch is applicable only after
8 Heater switch Turn on and off the heater. pump is turned on.

6-2
6. Operation Guide

6.2 Machine Startup

1) Turn on main power switch.

Switch on Switch off

2) Switch on the pump.

3) Turn on the pipe heater switch.
4) Set mould temperature (if it is already set, neglect this step.) Press
to set the temperature. For STM W series, maximum
temperature setting value is 120 .

Actual temperature

Set temperature

5) System overheat setting: it is set as +1 , which means that when

actual temperature exceeds setting value 1 , cooling system will
be activated automatically.

6-3
6. Operation Guide

6.3 Stop the Machine

1) Switch off heater power.
2) Wait until oil temperature falls below 50 , turn off pump switch.
3) Turn off main switch.

Warning! When main switch is turned on, be careful of electrical shock.

Note! Pump motor rotating direction should be the same as indicated.

Note! In order to prolong machine life, please do as above steps to

turn on and off the machine.

6.4 Temperature Controller

Temperature controller
control panel

6-4
6. Operation Guide

6.4.1 Temperature controller display

Practical value: display practical temperaure value or parameter code of
temperature controller.
Setting value: display set temperature value or parameter value, or
display input value when you set parameters.
Operation indicator
ALM1 (alarm 1)
This indicator becomes bright to indicate that heater 2 has stopped
working. Alarm 1 function is used to control pipe heater 2. When actual
temperaure is 5 less than setting value, heater 2 will be cut off. (Only
for machine with dual-heating zone
ALM2 (alarm 2)
Alarm 2 function is not used on this unit.
ALM3 (alarm 3)
Alarm 3 function is not used on this unit.
HB (heater break)
When heater break is detected, this indicator will become bright.
OUT1(output control 1)
OUT1 is used for heating control. When it is bright, it means that pipe
heater is working.
OUT2 (output control 2)
OUT2 is used for cooling control. When it is bright, cooling water valve
is open and cooling function is in process.
STOP (stop)
When stop indicator is bright, it means that temperature controller is not
working. Temperature controller operation mode is set to STOP.
Note! Do not set operation mode to stop, which will force temperaure
controller to stop working.

6-5
6. Operation Guide

6.4.2 Keys on control panel

(Menu) press this key to show the items you want to reset.
(mode) press this key to choose a parameter.
(increase value) press this key to increase setting value.
(decrease value) press this key to decrease setting value.

6.4.3 Choose a parameter

Press to choose a parameter or switch to next parameter.

6.4.4 Comfirm your setting

1) Press to come back to the first parameter if current screen shows
the last parameter.
2) Press and to adjust the value of parameters. Keep the
parameter unchanged for at least 2 seconds or press to confirm
your setting.

6-6
6. Operation Guide

3) Confirm your setting when changing to another menu.

4) Before power supply is cut off, press to confirm your setting.

Attention!
Before delivery, the parameters of temp. controller are set already. Do not
reset the parameters unless it is necessary.

6-7
7. Service and Maintenance

7. Service and Maintenance

Pay attention to the following rules during maintenance:
1) Need at least two persons present when checking the machine. Let the
machine cool down, turn off power supply, drain out the oil and water.
Make sure enough place before checking and maintenance.
2) The machine works in high temperature. Stop the machine, wait it to
cool down. Put on protective gloves before servicing or maintenance.
3) In order to prolong the life of the machine and to prevent accidents,
check the machine at a fixed frequency.
4) During operation, the water is heated up to a high temperature, wait it to
fall below 30 to perform repairing or maintenance. ( Please note that
it is dangerous to check or tear down the machine during operation.)

7.1 Open the Covers

1) Open the top covers of the unit. (Refer to the pictures below)

2) Take down the side covers. (Refer to the pictures below)

7-1
7. Service and Maintenance

3) Open the cover of control box. Screw off two butterfly screws to unlock
the cover. (Refer to the pictures below)

Butterfly screws

7.2 Y Type Strainer

1) Clean soft water should be used as
cooling water. Filter screen is used
in the strainer to stop impurities and
pollutants to enter into water pipe.
2) Impurities or pollutants may cause
errors and bad temperature control.
Y type strainer
Clean filter screen of the strainer
periodically.
3) Cleaning steps: turn off power and
cooling water supply. Open the top
cover of filter screen to clean the filter.

7.3 Solenoid Valve

Replace solenoid valve:
1) Open machine top cover.
2) Take down right side cover.
3) Unfix the solenoid valve for replacement.
4) Install the covers in a reverse order.

Solenoid valve

7-2
7. Service and Maintenance

7.4 Pipe Heater

1) Open machine rear cover door. (Refer to pictures below)

2) Unlock heater cap. (Refer to pictures below)

3) Unlock the screws of pipe heater to take it out. (Refer to the pictures
below.)

4) Install the pipe heater in a reverse order.

7-3
 7. Service and Maintenance

7.5 The useful life of the key parts of the product

7-4
 8. Trouble Shooting

8. Trouble Shooting

Failures Possible reasons Solutions

1 Main power indicator Did not connect through power supply. Connect through power supply.
does not become bright
Main switch broken. Replace main switch.
after main switch is
turned on. ¡£ problems.
Power supply wires Check electrical wires.
Control circuit fuse melt. Fix the fuse.
Transformer broken.¡£ Replace the transformer.

2 Both power and phase Power supply low voltage. Check power supply.
reverse indicator are Check power supply.
bright after the main ¡£
Phase shortage.
switch is turned on. Exchange two of the wires of
Phase reversal. ¡£ power supply.
The buzzer sounds to
raise alarm. PCB problems. Replace the PCB.

3 Motor overload relaly is Abnormal fluctuations of power supply. Check power supply.
bright. The buzzer
sounds and system Pump blocked. Check the pump.
stops working.
Pump motor problems. Check pump motor.

Overload relay (F1) setting value error. Set the setting current of overload
relay to equal to 1.1 times of motor
rated current. Please refer to page
10-15 for detailed description of
overload relaly.
Reset overload relay:
wait for one minute, then press the
blue button to reset.

EGO temperature setting mistakes. Correctly set EGO temperature.

4 Overheat indicator is
(EGO temperature setting value=
bright. The buzzer
temperature setting value+10 )
sounds and system stops EGO poor temperature detecting.
working. ¡£
Heater contactor K1 and K2 problems. Replace EGO.

Replace the contactor.

5 Low level indicator is Low pressure of of water supply. Increase the pressure of water
bright. The buzzer supply.
sounds and system stops Pressure switch problems.
working. Replace pressure switch.

8-1
8. Trouble Shooting

Failures Possible reasons Solutions

6 Main switch indicator PCB output relay problems. Check or replace the PCB.
won't become bright Pump switch problems. Replace the switch.
after turning on main Time relay (K5)¡£problems. ¡£
Replace time relay. (K5)
switch. Pump can not Electrical circuit problems. Check electrical circuit. ¡£
start when turning on
pump switch.

7 No display of temperature Heater switch¡£problems. ¡£switch.

Replace the
controller after turning on Temperature controller problems. Replace temperature controller.
¡£
pump and heater switch. Electrical circuit problems. Check electrical circuit.
¡£
¡£
8 Differences between Too short time after machine startup. Wait for a while.
setting temperature and Temperature parameter setting Check temperature parameters.
actual temperature is
¡£ error. Reset incorrect parameters with
Cooling water valve problems.
too big. reference to chapter 6.5.
¡£ Replace solenoid valve.

¡£
9 Temperature can't rise ¡£
Heater contactor problems. ¡£
Replace the contactor.
up. Heater problems. Replace pipe ¡£
heater.
¡£
Thermocouple problems. Replace thermocouple.
Temperature controller ¡£ controller to
Set temperature
operation mode set to STOP. working mode.
Temperature output problems. Replace or repair temperature
¡£ parameters.

¡£ ¡£

10 Circuit breaker tripping Short circuit of main circuit. Check electrical wire.
off at turning on main Transformer short circuit or¡£ Replace circuit breaker.
switch. connected with earth wire.
¡£
Problems of circuit breaker.

11 Circuit breaker tripping Pump motor coil short circuit. ¡£

Check pump motor.
off at turning on pump Problems of circuit
¡£ breaker. Replace circuit
¡£breaker.
switch.

12 Circuit breaker tripping ¡£or contact

Pipe heater short circuit Check electrical circuit.
off at turning on pipe with heating tank. Replace circuit breaker.
heater switch. ¡£ breaker.
Problems of circuit

8-2
 9. Assembly Drawing and Parts List

9. Assembly Drawing and Parts List

9.1 Assembly Drawing for STM-W Single Heating Tank Series 9-2
9.2 Parts List of STM-607W/STM-607W-D 9-3
9.3 Parts List of STM-910W/STM-910W-D 9-5
9.4 Assembly Drawing for STM-W Two Heating Tanks Series 9-7
9.5 Parts List of STM-1220W 9-8
9.6 Pump 9-10

9-1
9. Assembly Drawing and Parts List

9.1 Assembly Drawing for STM-W Single Heating Tank Series

Suitable for model: STM-607W and STM-910W.

9-2
9. Assembly Drawing and Parts List

9.2 Parts List of STM-607W/STM-607W-D

No. Name Part No.

E1416000 (STM-607W)
1 Main switch*
E1432000 (STM-607W-D)

2 Door plate T1191002

3 Control box T1191004

4 Electrical components board T1191012

5 Control box rear plate T1191009

6 Middle plate T1191006

7 EGO* E5204000

8 Right beam T1191027

9 Right side plate T1191000

10 Pump T3216000

11 Bottom plate T1160732

12 Castor A3104000

13 Heating tank T1160736

14 Pipe heater flange T1160729

15 Pipe heater cover T1191016

16 Rear plate T1160731

17 Water flow distributor T1160071

18 Ball valve T2116000

9-3
9. Assembly Drawing and Parts List

No. Name Part No.

19 Solenoid valve * T3108001

20 Rear cover T1160733

21 Plastic handle T3204000

22 Metal joint T2207005

23 Y type strainer T211000

24 Thermocouple * T3107000

25 Pipe heater M3306072

26 Left beam T1191027

27 Heating tank holding plate T1160734

28 EGO mounting plate T1160724

29 Left side plate T1191000

30 Top cover T1160730

31 Pressure meter L2201000

32 Pressure switch * T3110011

33 Cooling fan+fan guard C1100003

34 Manufacturer's plate E4128000

"*" consumable parts. Spare parts are suggested.

9-4
9. Assembly Drawing and Parts List

9.3 Parts List of STM-910W/STM-910W-D

No. Name Part No.

E1425000 (STM-910W)
1 Main switch*
E1463000 (STM-910W-D)

2 Door plate T1191002

3 Control box T1191004

4 Electrical components board T1191012

5 Control box rear plate T1191009

6 Middle plate T1191006

7 EGO* E5204000

8 Right beam T1191027

9 Right side plate T1191000

10 Pump T3216010

11 Bottom plate T1160732

12 Castor A3104000

13 Heating tank T1160736

14 Pipe heater flange T1160729

15 Pipe heater cover T1191016

16 Rear plate T1160731

17 Water flow distributor T1190101

18 Ball valve T2116000

9-5
9. Assembly Drawing and Parts List

No. Name Part No.

19 Solenoid valve * T3108001

20 Rear cover T1160733

21 Plastic handle T3204000

22 Metal joint T2207005

23 Y type strainer T211000

24 Thermocouple * T3107000

25 Pipe heater M3309101

26 Left beam T1191027

27 Heating tank holding plate T1160734

28 EGO mounting plate T1160724

29 Left side plate T1191000

30 Top cover T1160730

31 Pressure meter L2201000

32 Pressure switch * T3110011

33 Cooling fan+fan guard C1100003

34 Manufacturer's plate E4128000

"*" consumable parts. Spare parts are suggested.

9-6
9. Assembly Drawing and Parts List

9.4 Assembly Drawing for STM-W Two Heating Tanks Series

Suitable for model: STM-1220W and STM-2440W.

9-7
9. Assembly Drawing and Parts List

9.5 Parts List of STM-1220W

No. Name Part No.

Main switch*

Door plate

Control box

Electrical components board

Control box rear plate

Middle plate

EGO*

Right beam

Right side plate

Pump

Bottom plate

Castor

Heating tank

Pipe heater flange

Pipe heater cover

Rear plate

Water flow distributor

Ball valve

9-8
9. Assembly Drawing and Parts List

No. Name Part No.

19 Solenoid valve * T3108001

20 Rear cover T1112267

21 Plastic handle T3204000

22 Metal joint T2207005

23 Y type strainer T2116000

24 Thermocouple * T3107000

25 Pipe heater M3301221

26 Left beam T1112220

27 Heating tank holding plate T1112270

28 EGO mounting plate T1106724

29 Left side plate T1112258

30 Top cover T1191001

31 Pressure meter L2201000

32 Pressure switch * T3110011

33 Cooling fan+fan guard C1100003

34 Manufacturer's plate E4128000

"*" consumable parts. Spare parts are suggested.

9-9
 9. Assembly Drawing and Parts List

9.6 Pump

1 1. Pump body
2. Sleeve
2 3. O shape ring
4. Key
3
5. Pump cover
6. Socket cap screw
4
7. Neck ring
5 8. Mechanical seal
9. Rotary ring
6 10. Motor

7 8 9 10

9-10
 10. Electrical Circuit

10. Electrical Circuit

10.1 STM-607W
10.1.1 Main electrical circuit
3/PE/400V 50HZ

2.5mm2 SI-4T

Heater switch Pump switch

Q1
16A

F11
Q2
15A
OMROM
S3 S4
E5EZ

PC1
T
300 mA

Y1

Heater Water filling Pump motor Time relay

contactor valve contactor

1.6-2.5A
SET 2.0A

1.5mm2 2.0mm2

0.5KW 6KW
IN=1.8A IN=9.1A
Pump motor Pipe heater

10.1.2 Electrical components layout

F11

10-1
10. Electrical Circuit

10.1.3 STM-607W electrical components list

Symbol Name Specifications Part No.

Q1 Main switch 16A E1416000
Q2 Circuit breaker 15A E3114000
K1 Contactor 230VAC 50/60Hz E1140100
K2 Contactor 230VAC 50/60Hz E1141100
F1 Overheat relay 1.6~2.5A E1216250
T Transformer 300mA E3303000
F11 Fuse 2A E3202007
S1 S2 Alternative switch 4P(WH) E1304000
A Temperature controller 230VAC 50/60Hz E2105000

K3 Timer 230VAC 50/60Hz E2208000

S3 Overheat protector 250V 5(4)A E5204000
S4 Pressure switch AC 230V 12A T3110010
PC1 PCB 230VAC 50/60Hz E2304000
Y1 Solenoid valve 230VAC 50/60Hz T3108001
X1 Terminal board 25A E5112000
M1 Motor 400VAC 0.55KW T3204000
EH Pipe heater 400VAC 6KW ------

10-2
10. Electrical Circuit

10.2 STM-910W
10.2.1 Main electrical circuit

3/PE/400V 50HZ

2.5mm
2
SI-4T

Heater switch Pump switch

Q1
25A

Q2
F11
20A
OMROM
E5EZ S3 S4

T
300 mA

SET 2.5A

1.5mm2 2.0mm2

0.75KW 9KW
Pump motor Pipe heater

10.2.2 Electrical components layout

F11

10-3
10. Electrical Circuit

10.2.3 STM-910W electrical components list

Symbol Name Specifications Part No.

Q1 Main switch 25A E1425000
Q2 Circuit breaker 20A E3115000
K1 Contactor 230VAC 50/60Hz E1140100
K2 Contactor 230VAC 50/60Hz E1142220
F1 Overload relay 2~3.2A E1202320
T Transformer 300mA E3303000
F11 Fuse 2A E3202007
S1 S2 Alternative switch 4P(WH) E1304000
A Temperature controller 230VAC 50/60Hz E2105000

K3 Timer 230VAC 50/60Hz E2208000

S3 Overheat protector 250V 5(4)A E5204000
S4 Pressure switch AC 230V 12A T3110010
PC1 PCB 230VAC 50/60Hz E2304000
Y1 Solenoid valve 230VAC 50/60Hz T3108001
X1 Terminal board 25A E5112000
M1 Motor 400VAC 0.75KW T3216010
EH Heater 400VAC 9KW ------

10-4
10. Electrical Circuit

10.3 STM-607W-D/910W-D
10.3.1 Main electrical circuit

Symbol
a b c d e f g h i
Model

STM-607W-D 21.8 4.0 32 25 2.0 1.5 0.5 1.8 2.0

STM-910W-D 32 6.0 63 40 5.0 1.5 0.75 2.3 2.5

Symbol
j k l m n o p q r
Model

STM-607W-D 1.5 0.5 1.8 2.5 6.0 9.1 2.5 6.0 9.1

STM-910W-D 1.5 0.75 2.3 2.5 9.0 13.7 2.5 9.0 13.7

Pump 1 Pump 2 Heater 1 Heater 2

10.3.2 Control circuit

Intermediate Pump1 Heater1 Temp. Solenoid Timer1

relay Controller1 valve1

Technical requirement: positive and negative pole of thermocouple should be directly connected with
temperature controller's thermocouple input terminal, not go through the terminal board.

10-5
10. Electrical Circuit

Pump 2 Heater 2 Temp. Solenoid Timer 2

controller 2 valve 2

Technical requirement: positive and negative pole of thermocouple should be directly connected with
temperature controller's thermocouple input terminal, not go through the terminal board.

10.4.3 Electrical components layout

10-6
10. Electrical Circuit

10.3.4 STM-607W-D parts list

Symbol Name Specifications Part No.

Q1 Main switch 32A E1432000
Q2 Fuse 32A E3125000
K1 K2 Contactor 230VAC 50/60Hz E1140100
K3 K4 Contactor 230VAC 50/60Hz E1142220

F1 F2 Overload elay 1.6~2.5A E1216250

T Transformer 300mA E3303000

F11 Fuse 2A E3202007

S1 S2 S5 S6 Alternative switch 4P(WH) E1304000

K6 K8 Temperature controller 230VAC 50/60Hz E2105000
K7 K9 Timer 230VAC 50/60Hz E2208000

K5 Intermediate relay 230VAC 50/60Hz E5202004

S3 S7 Overheat protector 250VAC 5(4)A E5204000
S4 Pressure switch AC 230V 12A T3110010
PC1 PC2 PCB 230VAC 50/60Hz E2304000
Y1 Y2 Solenoid valve 230VAC 50/60Hz T3108001
X1 Terminal board 25A E5112000
M1 M2 Pump motor 0.55KW 400VAC T3104000
EH1,EH2 Pipe heater 6KW 400VAC ------

10-7
10. Electrical Circuit

10.3.5 STM-910W-D electrical components list

Symbol Name Specifications Part No.

Q1 Main switch 63A
Q2 Fuse 40A
K1 K2 Contactor 230VAC 50/60Hz
K3 K4 Contactor 230VAC 50/60Hz
F1 F2 Overload elay 2~3.2A
T Transformer 300mA

F11 Fuse 2A
S1 S2 S5 S6 Alternative switch 4P(WH)
K6 K8 Temperature controller 230VAC 50/60Hz
K7 K9 Timer 230VAC 50/60Hz

K5 Intermediate relay 230VAC 50/60Hz

S3 S7 Overheat protector 250VAC 5(4)A
S4 Pressure switch AC 230V 12A
PC1 PC2 PCB 400/230V
Y1 Y2 Solenoid valve 230VAC
X1 Terminal board 25A
X2 Terminal board 60A
M1 M2 Pump motor 0.75KW 400VAC
EH1,EH2 Pipe heater 9KW 400VAC ------

10-8
10. Electrical Circuit

10.4 STM-1220WElectrical Circuit

10.4.1 Main circuit

Pump motor Heater 1 Heater 2

10.4.2 Control circuit

SI-4T

Pump Heater 1 Heater 2 Intermediate Temp. Solenoid Timer

relay controller valve

Technical requirement: positive and negative pole of thermocouple should be directly connected with
temperature controller's thermocouple input terminal, not go through the terminal board.

10-9
10. Electrical Circuit

10.4.3 Electrical components layout

PC

S1 S2 K4

Note: motor and heater wire should be directly

connected with the contactor.

10-10
10. Electrical Circuit

10.4.4 STM-1220W electrical components list

Symbol Name Specifications Part No.

Q1 Main switch 32A E1432000
Q2 Fuse 32A E3116000
K1 K2 Contactor 230VAC 50/60Hz E1140100
K3 K4 Contactor 230VAC 50/60Hz E1142220

F1 F2 Overload relay 3.2~5A E1202050

T Transformer 300mA E3303000

F11 Fuse 2A E3202007

S1 S2 S5 S6 Alternative switch 4P WH E1304000
K6 K8 Temperature controller 230VAC 50/60Hz E2105000
K7 K9 Timer 230VAC 50/60Hz E2208000

K5 Intermediate relay 230VAC 50/60Hz E5202004

S3 S7 Overheat protector 250VAC 5(4)A E5204000
S4 Pressure switch AC 230V 12A T3110010
PC1 PC2 PCB 230VAC E2304000
Y1 Y2 Solenoid valve 230VAC T3108001
X1 Terminal board 25A E5102000
M1 M2 Pump motor 1.5KW 400VAC T3216022
EH1,EH2 Pipe heater 12KW 400VACI ------

10-11
10. Electrical Circuit

10.5 STM-2440WElectrical Circuit

10.5.1 Main circuit

Pump motor Heater 1 Heater 2

10.5.2 Control circuit

SI-4T

Pump Heater 1 Heater 2 Intermediate Solenoid Timer

relay valve

Note:The(+)and(-)pole of the thermcouple connect directly with the input terminal

of the temperature.

10-12
10. Electrical Circuit

10.5.3 Electrical components layout

PC

S1 S2 K4

Note: motor and heater wire should be connected

directly with the contactor.

10-13
10. Electrical Circuit

10.5.4 STM-2440W electrical components list

Symbol Name Specifications Part No.

Q1 Main switch 63A E1463000
Q2 Fuse 50A E3117000
K1 Contactor 230VAC 50/60Hz E1140100
K2 K3 Contactor 230VAC 50/60Hz E1142220
F1 Overload relay 4~6.3A E1204630
T Transformer 300mA E3303000
F11 Fuse 2A E3202007
S1 S2 Alternative switch 4P(WH) E1304000
K4 Temperature controller 230VAC 50/60Hz E2105000
K5 Timer 230VAC 50/60Hz E2208000

K6 Intermediate relay 230VAC 50/60Hz E5202004

S3 Overheat protector 250VAC 5(4)A E5204000
S4 Pressure switch AC 230V 12A T3110010
PC1 PCB 230VAC 50/60Hz E2304000
Y1 Solenoid valve 230VAC 50/60Hz T3108001
X1 Terminal board 25A E5101000
X2 Terminal board 60A E5103000
M1 Pump motor 2.8KW 400VAC ------
EH1,EH2 Pipe heater 24KW 400VAC ------

10-14
10. Electrical Circuit

10.6 Main Electrical Components List

Overload relay
At delivery, the overload relay is set for mannual reset. (the reset button
pointing to H). Manually reset the relay at the tripping of the switch. when
motor overload occurs, stop the machine. Check and solve the problem.
Then open the door of control box, press down the blue reset button of
overload relay. (if you can not press down the reset button, wait for one
more minute)

Description of overload relay:

1) Terminal for contactor coil A2.
2) Setting current adjusting scale
3) Reset (blue)
H: manual reset
A: automatic reset
4) Switch position indication(green)
Tripping of a manual-resetting is indicated by a pin projecting at the front
plate
5) Test button(red)
6) Auxiliary contact terminals shown in 95.96.97.98.
NC and NO contacts are shown in position 95.96. and 97.98. respectively.
7) Main circuit connection No. must correspond with terminal number of
contactor.

10-15
 11. Maintenance Schedule

11. Maintenance Schedule

11.1 About the Machine

Model: SN: Manufacturing date:

Voltage: V Frequency: Hz Total power: KW

11.2 Check after Installation

Check the installation space is enough as required.

Check the pipes are correctly connected.

Electrical installation

Voltage: V Hz

Fuse melting current: 1 Phase A 3 Phase A

Check phase sequence of power supply.

11-1
 11. Maintenance Schedule

11.3 Daily Checking

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

11-2
 11. Maintenance Schedule

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

11-3
 11. Maintenance Schedule

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the electrical wires Check all the electrical wires Check all the electrical wires

11-4
 11. Maintenance Schedule

11.4 Weekly Checking

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

11-5
 11. Maintenance Schedule

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

11-6
 11. Maintenance Schedule

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

/ / / / / /

Check machine startup function Check machine startup function Check machine startup function

Check all the eletrical wires Check all the eletrical wires Check all the eletrical wires
Check loose eletrical connections Check loose eletrical connections Check loose eletrical connections
Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Check solenoid valve Check solenoid valve Check solenoid valve

Check motor overload and phase Check motor overload and phase Check motor overload and phase
reversal alarm function reversal alarm function reversal alarm function

11-7
 11. Maintenance Schedule

11.5 Montly Checking

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

11-8
 11. Maintenance Schedule

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check loose electrical connections Check loose electrical connections Check loose electrical connections

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

11-9
 11. Maintenance Schedule

11.6 Half-yearly Checking

/ / / / / /

Check damaged pipes Check damaged pipes Check damaged pipes

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check damaged pipes Check damaged pipes Check damaged pipes

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check damaged pipes Check damaged pipes Check damaged pipes

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check damaged pipes Check damaged pipes Check damaged pipes

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check damaged pipes Check damaged pipes Check damaged pipes

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check damaged pipes Check damaged pipes Check damaged pipes

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

/ / / / / /

Check damaged pipes Check damaged pipes Check damaged pipes

Check and clean Y type strainer Check and clean Y type strainer Check and clean Y type strainer

Clean solenoid valve Clean solenoid valve Clean solenoid valve

11-10
Local Warranty Statement

Local Warranty Statement

1. Local warranty applies to the country of purchase only. Once the product is
transited out of the country of purchase, this warranty is invalidated.
2. The warranty is only applicable to the original purchaser and in the country
of purchase.
3. The warranty covers parts and labour only; and excludes freight and on-site
call-out charges.
4. Your SHINI product is guaranteed against manufacturing defects for a
period of twelve (12) months from the date of purchase locally unless stated
otherwise.
5. The warranty shall immediately cease and become void if the product is
found to have been modified or repaired by an unauthorized person.
6. The warranty is subjected to the following limitations and exclusions:
(a) Malfunctions or damages resulting from not complying with the
recommended manner as outlined in our operation manual in relation
with the application, installation, operation and maintenance.
(b) Defects from using wrong electrical supply, misuse or damage by
negligence and abuse.
(c) Malfunctions or damages resulting from natural disaster, fire, civil unrest
and/or accidents.
(d) Wear parts and accessories.
7. If your SHINI product is not the same place of purchase, you can still send
the product to your local SHINI's branch or distributor for servicing at your
full costs according to the individual country service policy.
8. If there is no SHINI's branch or distributor in your country, although
obviously there is no warranty covered by SHINI, you may direct contact
SHINI requesting for the supply of replacement parts at your full costs.
9. All the electricity installation ,connection and maintenance should be carried
out by the specialists or contact SHINI or its local agents.
Local Warranty Statement

10. The warranty is deemed valid only if the followings are completely filled in:
Purchaser's name and address:

Your supplier's name and address:

(company stamp)

Product model: Serial number:

Invoice Number: Date of purchase:

Please send all queries and comments to:

Shini Plastics Technologies, Inc.
Corporate Product & Marketing Center
1 Shini Road, Dalang, Dongguan, Guangdong, China
Tel: (0769) 8331 3588 Fax: (0769) 8331 3589
Corporate e-mail: shini@shini.com
Corporate internet: www.shini.com