Battenfeld PLUS 250/50 User Manual

Manual

Injection moulding machine PLUS

Austria

Type of machine: PLUS 250/50

Control system: UNILOG 1020

Machine number: 114899-100
Year of manufacture: 1993

Version: PL120102 06/93

Injection MoldingInjection Molding

Injection Molding

Injection MoldingInjection Molding

Battenfeld Kunststoffmaschinen Gesellschaft m.b.H.

Wr.Neustädter Straße 81 • 2542 Kottingbrunn • Austria

Tel. [phone] • Fax [phone]

[e-mail]

www.battenfeld-imt.com

DIN EN ISO 9001

Table of Contents

1 General

2 Safety

3 Technical Data

General instructions for this Battenfeld machine.

This chapter has to be read and understood by each employee
who has contact with the machine.

Contains technical data, installation plans and platen
drawings.

4 Transport - Siting

Important details relating to the transport, siting and startup
of the Battenfeld machine.

5 Structure and Function

?

UNILOG

Structure and function of each individual build group and user
manual for the control.

6 Operation

All important details for user operation of the Battenfeld
machine.

A: PL120100.IN1
B: PL120100.IN1
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: INH

Page: 1

Table of Contents

7 Maintenance

All details for servicing, maintenance and fault-finding.

8 Spare parts / Drawings

Detailed description and spare parts lists as well as hydraulic
and electrical drawings displaying existing parts.

9 Service

10 Index

Dieser Text dient

A

nur als Hinter­grund. Das Kapitel
Stichwortverzeich-

B

nis und Glossar
zeigt Ihnen die ent-
sprechenden Sei-

C

ten im Text auf und
ver-

11

Contact addresses of all service partners.

Explanation of the most important machine-related terms.

Additional chapter for special modules.

12 Accessories

A: PL120100.IN1
B: PL120100.IN1
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Technical documentation of details and build groups of
suppliers.

Chapter: INH

Page: 2

Table of Contents

1 General

2 Safety

1.1 Introduction

1.2 Area of application

1.3 Explanation of symbols

1.4 Copyright

1.5 Statement of delivery

2.1 Safety regulations

2.2 Alarm signs

2.3 General drawing

2.4 Electrical access protection

2.5 Hydraulic access protection

2.6 Mechanical access protection

2.7 Guarding

2.8 Safety device for handling unit

2.9 Safety device supervision

3 Technical Data

4 Transport - Siting

3.1 Dimensions of machine

3.2 Rating

3.3 Diagram / Injection pressure

3.4 Diagram / Injection velocity

3.5 Diagram / Injection volume

3.6 Diagram / Injection stroke

3.7 Diagram / Screw speed
3 .8 Diagram / Closing pressure

3.9 Diagram / Closing velocity

3.10 Diagram / Closing stroke

3.11 Fitting dimensions of machine

3.12 Dimensions of mould

4.1 Spatial requirement plan

4.2 Transport of machine

4.3 Siting of machine

4.4 Oil filling

4.5 Table of hydraulic oils and lubricants

4.6 Connection to cooling water distributor

4.7 Oil cooler fitting

4.8 Connection to power line

4.9 Corrosion protection

4.10 Storage

A: PL120101.IN2
B: PL120100.IN2
E: 03.93 / T. Weiß
G: 05.94 / G. Krajnik

Chapter: INH

Page: 3

5 Structure and Function

Table of Contents

?

5.1 Overview of build groups

5.2 Closing unit

5.2.1 Technical description

5.2.2 Mould fitting

5.2.3 Instructions for fitting - adjustment of fitting height

5.3 Injection unit

5.3.1 Technical description

5.3.2 Nozzle change

5.3.3 Instructions for setting - nozzle centre

5.3.4 Change and prestressing of synchronous belt

5.3.5 Screw change and screw cylinder change

5.4 Hydraulic unit

5.4.1 Pump element

5.4.2 Oil tank

5.4.3 Oil filter

5.4.4 Electrical oil filter clogging display (optional)

5.4.5 Oil cooler

5.4.6 Supervision and indication device

5.4.7 Variable capacity pump setting

5.4.8 Relief valve amplifier

5.4.9 Velocity selection of relief valve amplifier

5.4.10 Pressure selection of relief valve amplifier

5.4.11 Setting for maximum pressure protection for
variable capacity pump

5.4.12 Hydraulic oil preheating

5.4.13 Hydraulic core pull (optional)

5.4.14 Hydraulic screw-off device (optional)

UNILOG

1020

Chapter: INH
Page: 4

5.5 Pneumatic unit

5.5.1 Material feeder device UNIFEED (optional)

5.5.2 Pneumatic core pull

5.6. Electric unit

5.6.1 Electric drive

5.6.2 Control box

5.7 Control

5.7.1 Description of electronic system

5.7.2 UNILOG user manual

A: PL120101.IN2
B: PL120100.IN2

E: 03.93 / T. Weiß

G: 05.94 / G. Krajnik

Table of Contents

6 Operation

6.1 Startup

6.2 Starting the machine after Emergency Stop

6.3 Machine shutoff

7 Maintenance

7.1 General

7.2 Maintenance schedule

7.3 Table of hydraulics and lubricants

8 Spare Parts / Drawings

8.1 Guidelines for ordering spare parts

8.2 Basic machine data

8.3 Closing component

8.3.020 Accessories for machine frame

8.3.025 Photoelectric safety device (optional)

8.3.072 Closing platen support

8.3.080 Closing cylinder

8.3.140 Mechanical closing protection (optional)

8.3.150 Ejector coupling

8.3.170 Hydraulic screw-off device (optional)

8.3.220 Protecting guard for closing unit

A: PL120101.IN2
B: PL120100.IN2
E: 03.93 / T. Weiß
G: 05.94 / G. Krajnik

8.4 Injection component

8.4.294 Unit for nozzle drive and nozzle movement

8.4.330 Complete nozzle unit

8.4.330 Heater band for screw cylinder

8.4.330 Screw cylinder

8.4.360 Cylinder cover

8.4.362 Sheathing of injection unit

8.4.380 Hopper for granulated moulding material

8.5 Hydraulic system

8.5.1 Drawing of hydraulic system

8.5.2 List of hydraulic components

8.6 Electrical installation

8.6.1 Drawing of electrical installation

8.6.2 List of electrical components

Chapter: INH

Page: 5

9 Service

10 Index

Dieser Text dient nur

A

als Hintergrund. Das
Kapitel Stichwortver­zeichnis und Glossar

B

zeigt Ihnen die ent­sprechenden Seiten
im Text auf und ver-

C

Table of Contents

8.7 Pneumatic system

8.7.380 Material feeder device UNIFEED (optional)

8.7.700 Pneumatic core pull

10.1 Description of technical terms

10.2 Index

11

12 Accessories

Chapter: INH
Page: 6

A: PL120101.IN2
B: PL120100.IN2

E: 03.93 / T. Weiß

G: 05.94 / G. Krajnik

General

Chapter 1: General

1.1 Introduction

This user manual has been written specifically for the
personnel in charge of this Battenfeld product moulding
machine and should be read, understood and precisely
followed by them.

The complete technical documentation should always be
kept close by the machine; it should be accessible to the
operating and maintenance personnel at all times.

It is only through closely following this manual, in particular
chapter 2 “Safety”, that hitches in the operation of the
machine can be avoided, and smooth functioning will be
guaranteed. For this reason, it is essential to make this
manual available to the competent personnel. This should be
done before the startup of the machine since we accept no
liability for any defect or breakdown of the machine arising
out of the ignorance of this manual on the part of the
corresponding personnel!

There exists the possibility to have your personnel trained by
us, either at our plant or at yours. Please contact our Training
Department for further details.

In the case that difficulties should occur in spite of the above,
please contact our Service Department or one of our licensed
representatives (addresses in chapter 9 “Service”) who will
be glad to be of assistance.

This user manual applies only to machines commissioned
according to chapter 3 “Technical Data”.

With respect to the information and data given in this user
manual, we reserve the right to any technical modifications
that may become necessary in order to improve this injection
moulding machine.

A: PL120100.010
B: PL120100.010
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: 1

Page: 1

1.2 Area of application

The injection moulding machines of the PLUS series were
conceived for the processing of thermoplastics, thermosets
and elastomers as well as for LIM.

Applications going beyond this definition do not conform to
the original intended use of the machine. The manufacturer
accepts no liability for defects arising from this type of misuse

- the risk is borne solely by the operator.

1.3 Explanation of symbols

The safety symbol is featured in all instructions for work
safety contained in the present manual that refer to possible
hazards to human life and health. Please observe these
instructions and proceed with the utmost caution.

Safety

Communicate all instructions for work safety to other users
as well. Apart from the instructions contained in this user
manual, it is also necessary to observe the general instructions
for safety and prevention of accidents.

General

ATTENTION!

Voltage

Environmental

hazards

This Attention! sign appears wherever it is especially
important to comply with guidelines, instructions and
indications, and to observe the correct operation of routines
and machine cycles as precisely as possible, and wherever
it is vital to avoid any damage to, or destruction of, the
machine and/or other elements of the installation.

The voltage symbol concerns all passages in the manual
which refer to the staff coming into contact with electrical
installations and equipment. Please always observe the
local regulations in force with respect to the safety of electrical
installations.

The symbol for environmental hazards refers, inter alia, to
the environmental hazards posed by the disposal of various
materials. When carrying out repair and maintenance work,
please take care that such wastes are properly disposed of.

Chapter: 1
Page: 2

A: PL120100.010
B: PL120100.010

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

General

1.4 Copyright

1.5 Statement of delivery

The copyright for this user manual rests with Battenfeld
Ges.m.b.H. This user manual is destined for the staff in
charge of the fitting, operation and supervision of this machine.
The technical instructions and drawings contained in it may
not be copied, disseminated, commercialized for competitive
purposes or communicated to third parties without
authorization by Battenfeld.

The purpose of the statement of delivery enclosed in this
user manual is to document the handing-over of the machine
and to ensure the completeness of the user manual. After
verification, please fill in and sign the statement of delivery,
and return it to the “Documentation” department.

A: PL120100.010
B: PL120100.010
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: 1

Page: 3

Telefaxtransmission

To: Documentation Department (0)2252 404-402

From:

Statement of Delivery

ensuring the delivery of the Technical Documentation

to the end customer

01

General

(1) Type of machine

Number of machine

(2) Address of customer

(3) The machine specified in item (1) above was acquired by us.

Together with the machine, (number)

user manual(s) was/were handed over to us.

Signature of customer

(4) Date of delivery

(5) Address of authorized dealer or importer.

Date

(6) The machine was delivered to the customer
in accordance with the manufacturer’s
specifications.

Signature of customer service specialist

Chapter: 1
Page: 4

Date

Company stamp/Signature

Company stamp/Signture if not identical to (5)

A: PL120100.010

B: PL120100.010
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Safety

Chapter 2: Safety

2.1 Safety regulations

Numerous safety devices of the injection moulding machine
and the robot contribute to its operational safety and the
prevention of accidents. The operator is responsible for the
smooth functioning of the safety devices.

This injection moulding machine has been designed and
built in keeping with the currently valid regulations for technical
safety according to European Standard EN 201 and is
operationally reliable. However, hazards may arise if this
machine is either misused by personnel not specifically
trained to handle it or is used for other than its intended
purposes.

For reasons of safety, all unauthorized modifications or
changes of the machineand the robot are prohibited and
require Battenfeld’s approval.

When processing synthetic materials that cause the emission
of gases, dust or steam hazardous to human health, the
operator of the machine must ensure that appropriate
ventilation is provided for the protection of the operating
personnel.

All persons in charge of the siting, startup, operation,
maintenance and repair of the machine or a robot in the
enterprise of the user must first have read and understood the
user manual and in particular the “Safety” chapter. This
manual must at all times be accessible to the abovementioned
personnel. The head of the workshop, the shift foreman or
any other staff members responsible for the operational
safety of the machine must be immediately notified of all
extraordinary occurrences regarding the machineand the
robot . Under certain circumstances, it may become necessary
to switch off the machine immediately using the Emergency
Stop switch and the master switch.

A: PL120100.020
B: PL120100.020
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Any process impairing the operational safety of the machine
is to be avoided.

Chapter: 2

Page: 1

Safety

The operating enterprise shall ensure that no unauthorized
persons on the installation will handle the machine. The
machine may be operated only by persons

- over 18 years of age;

- with of the necessary technical knowledge;

- to be expected to comply with their task in a reliable
and sensible manner.

The operating enterprise shall employ appropriate instructions
and checks to safeguard that the work area around the
installation is clean and tidy. All components, in particular the
safety devices, shall be subject to regular checkups to ensure
perfect operating conditions. The operating personnel shall
continuously check the machine and the work area, especially
if a robot is used, with respect to possible hazards and
eliminate these IMMEDIATELY, interrupting the operation of
the machine until this has been achieved.

All warning and safety devices of the installation shall be
complied with.

For the operation of the machine and the robot, the local
provisions for work safety and the prevention of accidents
apply unconditionally. It is principally prohibited to remove,
modify or put out of operation any of the safety devices. If
siting, repair or maintenance work should require the removal
of a safety device, this safety device shall be re-installed
immediately after the completion of the maintenance and
repair work.

When working on the machine and the robot, it is principally
required to switch off the master switch and protect it against
unauthorized reactivation. All components, in particular the
safety devices, shall be checked regularly to ensure that they
are in perfect working condition. After electrical fitting and
repair works have been carried out, the installed safety
devices (e.g. earthing resistance) must be rechecked.

Chapter: 2
Page: 2

A: PL120100.020
B: PL120100.020

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Safety

2.2 Alarm signs

Before putting the installation into operation,
always read and familiarize youself with the
operating manual, especially chapter 2 “SAFETY”!

DANGER OF INJURY!

The machine must not be put into operation
if the protective guard has been removed!

WARNING! HIGH VOLTAGE!

Do not activate the master switch if the

control box is open!

WARNING!

Only fill the tank with clean hydraulic oil, purity
class 15/12 in keeping with ISO standard 4406!

WARNING!

Check the hydraulic filter daily for clogging. If

the filter is exchanged, only replace

with original filter elements!

WARNING!

Check oil level daily!

WARNING!

Lubricate the grease lubrication

nipple every 2,500 working hours!

WARNING! HOT!

Do not touch the screw cylinder

of the injection unit!

A: PL120100.020
B: PL120100.020
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

ENVIRONMENTAL HAZARD!

Dispose of waste oil in accordance

with national regulations!

Chapter: 2

Page: 3

2.3 General drawing

Safety

2.6

Chapter: 2
Page: 4

Bild: Pl-0001.TIF

2.42.5

Bild: Pl-0002.TIF Bild: Pl-0004.TIF

A: PL120100.020
B: PL120100.020

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Safety

2.4 Electrical access protection

The various positions of the protective guard are monitored
by means of two guided switches safeguarding the position
of the guard.

Position - Protective guard closed;
Position switch 1 (S 24) actuated.
Position switch 2 (S 25) not actuated.

Position - Protective guard open;
Position switch 1 (S 24) not actuated.
Position switch 2 (S 25) actuated.

A: PL120100.020
B: PL120100.020
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Pos 1

Pos 2

Bild: Pl-0004.TIF

All other positions trigger the “Protective guard monitoring”
device which in its turn deactivates the hydraulic drive.
If the protective guard is open, the output signals of all
machine movements as well as the valve circuits of the
closing unit are interrupted.

Chapter: 2

Page: 5

Protective guard monitoring device

This device monitors the correct functioning of the following

elements:

a) Alternating operation of position switches (S 24, S 25)

b) Limit switch of hydraulic access protection (S 34).

c) Guided auxiliary contactors (K 288, K 289) in the valve

circuits of the closing unit.

If an error is identified in the above elements, an error message

“Protective guard” is visualized on the display.

2.5 Hydraulic access protection

Safety

Chapter: 2
Page: 6

Bild: Pl-0002.TIF

If the protective guard is open, a mechanically actuated

distributing valve will prevent any movement of the machine.

If the distributing valve is actuated, the entire oil flow is

interrupted, and the contents of the cylinders are emptied into

the tank. The position of the valve is monitored by means of

a limit switch that is activated when the protecting guard is

opened. Moreover, this limit switch also interrupts all electric

output signals.

A: PL120100.020
B: PL120100.020

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Safety

2.6 Mechanical access protection (optional)

Bild: Pl-0003.TIF

2.7 Guarding

It is the task of the mechanical access protection system to
prevent any unintentional access of the closing unit when the
protective guard is still open.
Basically, the setup consists of the toothed bumper bar,
which is rotatably connected to the nozzle platen, and the
limit stop fastened to the closing platen.
When opening the protective guard, the weight of the toothed
bumper bar causes it to fall onto the limit stop; this activates
a blocking function that prevents the closing unit from closing.
If a machine error has occurred, thereby triggering the
mechanical access protection, contact Battenfeld Customer
Services or the competent representative office.

In order to prevent accidents, the closing unit is completely
covered by a guard. The front of this guard forms a one-part
covering cap. It may be removed for adjusting by unscrewing
four screws.
The working area between the closing and nozzle platens is
protected by a pivotable plexiglass guard providing excellent
view of the working area.

A: PL120100.020
B: PL120100.020
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: 2

Page: 7

In order to prevent the occurrence of accidents when the

protecing guard is opened, all movements are blocked both

hydraulically and electrically (including closing, opening,

ejection, nozzle, metering, decompression and injection

movements).

2.8 Safety device for handling unit (optional)

In accordance with the provisions for accident prevention,

the handling unit must be equipped with a suitable

protective device preventing interference with the system,

in order to protect the operating personnel.

Safety

WARNING!

"We decline any responsibility in case of non-

compliance with the safety requirements!"

For this purpose, we have designed suitable safety

devices which - if included in the order package - are

installed on your handling unit. If the handling unit was

delivered without any safety device, upon the customer’s

request, it is the sole responsibility of the customer and the

user to employ adequate safety measures.

2.9 Safety device supervision

The safety devices of this machine can only serve their

purpose properly if their correct functioning is safeguarded.

For this reason, their efficiency must be continuously checked.

1. Check electrical access protection

Stable setting of position switches required.

2. Check hydraulic access protection

Stable setting of mechanically actuated distributing valve

required.

Chapter: 2
Page: 8

3. Check mechanical access protection

Smooth movement of bumper bar on nozzle platen required.

If a machine error has occurred, thereby triggering the

mechanical access protection, contact Battenfeld Customer

Services or the competent representative office.

A: PL120100.020
B: PL120100.020

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Safety

4. Check operator guard

Smooth pivoting movement and stable setting of limit switches
required.

5. Check guarding

Stable setting of all fastening screws and perfect condition
required.

6. Monitoring of safety device for handling unit
(optional)

All fastening screws must be tight, and the device must be
in a satisfactory condition.

A: PL120100.020
B: PL120100.020
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: 2

Page: 9

Safety

Chapter: 2
Page: 10

A: PL120100.020
B: PL120100.020

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Technical Data

Chapter 3: Technical Data

3.1 Dimensions of machine

Please find the dimensions in the enclosed machine
drawing at the end of this chapter.

3.2 Rating

PLUS 250 PLUS 350

Injection unit

Screw diameter

Specific injection pressure

Theoretical shot volume

Max.shot weight (polystyrene)

Max.shot weight (polyethylene)

Screw L/D ratio 20 16 14 20 16 14 13,5

Nozzle stroke

Nozzle contact pressure

Screw stroke

Max.screw revs (stand.) min-1 400 400

Screw torque (stand.)

Plastification capacity (stand.)

mm

(inch)

bar

(psi)

ccm

(cu in)

g

(oz)

g

(oz)

mm

(inch)

kN

(sh tn)

mm

(inch)

Nm

(ft lb)

g/s

(oz/s)

18

(0,71)

2431

(35250)

25,4

(1,551)38(2,320)49(2,991)

23,1

(0,815)

18

(0,635)27(0,952)

6,5

(0,229)

50 70

22

(0,87)

1627

(23590)

34,5

(1,217)

150

(5,91)

35

(3,9)

100

(3,9)

160

(217)

9,5

(0,335)12(0,423)

25

(0,98)

1260

(18270)

44,6

(1.573)

34,8

(1,228)18(0,635)27(0,952)

18

(0,71)

3038

(44050)

25,4

(1,551)38(2,320)49(2,991)

23,1

(0,815)

6,5

(0,229)

22

(0,87)

2034

(29500)

34,5

(1,217)

9,5

(0,335)12(0,423)13(0,459)

150

(5,91)

35

(3,9)

100

(3,9)

190

(258)

25

(0,98)

1575

(22840)

44,6

(1.573)

34,8

(1,228)

30

(1,18)

1094

(15860)

70,6

(4,310)

64,2

(2,265)

50,1

(1,767)

Max.screw revs (aux.) min-1 320 320

Screw torque (aux.)

Plastification capacity (aux.)

Injection rate

Cylinder heating capacity kW 2,76

Number of controlled zones 2

A: PL120100.030
B: PL120000.030
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Nm

(ft lb)

g/s

(oz/s)

ccm/s

(cu in/s)

5,2

(0,183)

38,4

(2,344)

210

(285)

7,6

(0,268)

57,3

(3,498)74(4,518)

9,6

(0,339)

5,2

(0,183)

38,4

(2,344)

7,6

(0,268)

57,3

(3,498)74(4,518)

260

(353)

9,6

(0,339)

10,4

(0,367)

106,6

(6,508)

Bild: PL-0037.TLB

Chapter: 3

Page: 1

Closing unit

Technical Data

Closing force

Opening force

Space between the bars

Tiebar diameter

Size of nozzle platen

Size of closing platen

Min. mould height
(variabel)

Opening stroke

Max. possible distance of platen

Ejector force

Ejector stroke

kN

(sh tn)

kN

(sh tn)

mm

(inch)

mm

(inch)

mm

(inch)

mm

(inch)

mm

(inch)

mm

(inch)

mm

(inch)

kN

(sh tn)

mm

(inch)

250

(27,5)

28

(3,087)

270

(10,630)

60

(2,362)

470 x 280

(18,504 x 11,024)

450 x 259

(17,717 x 10,197)

150 - 250

(5,906 x 9,843)

200

(7,874)

450

(17,717)

26,2

(2,889)

100

(3,937)

350

(38,5)

28

(3,087)

270

(10,630)

60

(2,362)

470 x 280

(18,504 x 11,024)

450 x 259

(17,717 x 10,197)

150 - 250

(5,906 x 9,843)

200

(7,874)

450

(17,717)

26,2

(2,889)

100

(3,937)

Dry cycle time 45 45

Drive

Drive capacity kW 7,5 7,5

Oil filling

l

(gal)

125
(33)

125

(33)

Dimension of machine

Dimensions of case h x w x l

Gross /net weight

mm

(inch)

kg

(lb)

1500 x 900 x 2300

(59,055 x 35,433 x 90,551)

1100 / 1000

(2473 / 2248)

1500 x 900 x 2300

(59,055 x 35,433 x 90,551)

1100 / 1000

(2473 / 2248)

Bild: PL-0038.TLB

Chapter: 3
Page: 2

A: PL120100.030
B: PL120000.030

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Technical Data

3.3 Diagram / Injection pressure

Injection component 50

1

Screw D = 18 mm (0,709 inch)

Screw D = 22 mm (0,866 inch)

2

3

Screw D = 25 mm (0,984 inch)

p [%]

100

Bild: PL-0015.WMF

2431 bar (35250 psi)

1627 bar (23590 psi)

1260 bar (18270 psi)

3 2 1

90

80

70

60

50

40

30

20

10

400200 1200 1400 200018001600 2200 24001000800600

2900 5800 8700 11600 14500 17400 2320020300 26100 29000 31900 34800

bar

psi

A: PL120100.030
B: PL120000.030
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: 3

Page: 3

p [%]

Injection component 75

1

Srew D = 18 mm (0,709 inch)

3038 bar (44050 psi)

2

Screw D = 22 mm (0,866 inch)

2034 bar (29500 psi)

3

Screw D = 25 mm (0,984 inch)

1575 bar (22840 psi)

4

Screw D = 30 mm (1,181 inch)

1094 bar (15860 psi)

Technical Data

100

90

80

70

60

50

40

30

20

10

4 3 2

Bild: PL-0016.WMF

400200 1200 1400 200018001600 2200 2400 3000280026001000800600

2900 5800 8700 11600 14500 17400 2320020300 26100 29000 31900 34800 37700 4350040600 psi

1

bar

Chapter: 3
Page: 4

A: PL120100.030
B: PL120000.030

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Technical Data

3.4 Diagram / Injection velocity

These technical data refer only to the injection flow directed
to atmosphere.

cm3 / sec

(inch3 / sec)

(6,10)

100

(5,49)

90

(4,88)

80

(4,27)

70

(3,66)

60

(3,05)

50

(2,44)

40

(1,83)

30

(1,22)

20

(0,61)

10

cm3 / sec

(inch3 / sec)

(3,36)
(3,02)

49,5
(2,68)
(2,35)

38,5
(2,01)
(1,68)

27,5
(1,34)
(1,01)

16,5
(0,67)
(0,34)

Bild: PL-0017.WMF

Bild: PL-0017.WMF

55

44

33

22

11

5,5

Screw D = 30

Screw D = 22

cm3 / sec

(inch3 / sec)

Bild: PL-0017.WMF

70

(4,27)

63

(3,84)

56

(3,42)

49

(2,99)

42

(2,56)

35

(2,14)

28

(1,71)

21

(1,28)

14

(0,85)

v [%]

100908070605040302010

(0,43)

7

Screw D = 25

v [%]

100908070605040302010

cm3 / sec

(inch3 / sec)

Screw D = 18

v [%]

v [%]

(2,14)
(1,92)
(1,71)
(1,49)
(1,28)
(1,07)
(0,85)
(0,64)
(0,43)
(0,21)

35

31,5

28

24,5

21

17,5

14

10,5

7

3,5

Bild: PL-0017.WMF

A: PL120100.030
B: PL120000.030
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

100908070605040302010

100908070605040302010

Chapter: 3

Page: 5

3.5 Diagram / Injection volume

Technical Data

(4,27)
(3,84)
(3,42)
(2,99)
(2,56)
(2,14)
(1,71)
(1,28)
(0,85)
(0,43)

(2,44)
(2,20)
(1,95)
(1,71)
(1,46)
(1,22)
(0,98)
(0,73)
(0,49)
(0,24)

cm

(inch3)

70

63

56

49
42
35
28
21

14

7

cm

(inch3)

40
36
32
28
24
20
16
12

8
4

3

Bild: PL-0017.WMF

3

Bild: PL-0017.WMF

Screw D = 30

Screw D = 22

3

cm

(inch3)

Screw D = 25

s [%]

100908070605040302010

50
45

40

35

30

25

20
15

10

5

cm

Bild: PL-0017.WMF

3

(3,05)
(2,75)
(2,44)
(2,14)
(1,83)
(1,53)
(1,22)
(0,92)
(0,61)

s [%]

100908070605040302010

(0,31)

(inch3)

Screw D = 18

s [%]

s [%]

(1,53)
(1,37)
(1,22)
(1,07)
(0,92)
(0,76)
(0,61)
(0,46)
(0,31)
(0,15)

25

22,5

20

17,5

15

12,5

10

7,5

2,5

Bild: PL-0017.WMF

5

Chapter: 3
Page: 6

100908070605040302010

100908070605040302010

A: PL120100.030
B: PL120000.030

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Technical Data

3.6 Diagram / Injection stroke

mm

(inch)

Bild: PL-0017.WMF

100

(3,94)
(3,54)
(3,15)
(2,76)
(2,36)
(1,97)
(1,57)
(1,18)
(0,79)
(0,39)

90

80

70
60
50

40

30
20

10

Spritzaggregat 50
Spritzaggregat 75

s [%]

100908070605040302010

3.7 Diagram / Screw torque

1

screw torque 400 min-1 (stand.)

screw torque 320 min-1 (aux.)

2

v

[%]

Bild: PL-0018.WMF

100

90

80

70
60
50

40

30
20

2

1

A: PL120100.030
B: PL120000.030
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

10

40 80 120 160 200 240 280 320 400360

min-1

Chapter: 3

Page: 7

3.8 Diagram / Closing pressure

Technical Data

kN

(shtn)

Plus 250

(27,5)
(24,8)
(22,2)
(19,3)
(16,5)
(13,8)
(11,0)

(8,2)

(5,5)

(2,8)

250
225
200
175
150
125

100

75
50

25

Bild: PL-0018.WMF

10 20 30 40 50 60 70 80 10090

3.9 Diagram / Closing velocity

p

[%]

(38,5)
(34,7)
(30,9)
(27,0)
(23,2)
(19,3)
(15,4)
(11,6)

(7,7)

(3,9)

kN

(shtn)

350
315
280
245
210
175

140

105

70

35

Bild: PL-0018.WMF

10 20 30 40 50 60 70 80 10090

Plus 350

p

[%]

Chapter: 3
Page: 8

(18,50)

(16,65)

(14,80)

(12,95)

(11,10)

(9,25)

(7,40)

(5,55)

(3,70)

(1,85)

mm / sec

inch / sec

Bild: PL-0018.WMF

470
423
376
329
282
235

188

141

94

47

10 20 30 40 50 60 70 80 10090

Plus 250
Plus 350

v [%]

A: PL120100.030
B: PL120000.030

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Technical Data

3.10 Diagram / Closing stroke

mm

(inch)

200

180

160

140

120

100

80

60

40

20

Bild: PL-0017.WMF

(7,87)
(7,09)
(6,30)

(5,51)

(4,72)
(3,94)
(3,15)

(2,36)

(1,57)
(0,79)

Plus 250
Plus 350

s [%]

100908070605040302010

3.11Fitting dimensions of machine

Please find data in the enclosed platen diagram at the end of
this chapter.

3.12 Dimensions of mould

A) Minimum mould diametre

The closing system with the two closing cylinders provides
an even transmission of the closing force to the mould and
thus ensures the precise distribution of forces. These
functions, however, can only by fulfilled if a minimum mould
diametre is observed, thus keeping the deflection of the
platens within acceptable limits.

A: PL120100.030
B: PL120000.030
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: 3

Page: 9

Technical Data

Since the measuring precision of the injection pieces, the
additional load for the mould and the mould functions (in case
of complicated designs, such as multiplate moulds, slide
moulds etc) are influenced by the degree of deflection of the
platens, the observance of these standard values ensures
that inacceptable overloading of the closing unit and mould
is excluded. For this reason, the following minimum mould
dimensions should be respected while generally maintaining
adequate closing pressure, in accordance with the required
closing force to keep mould wear and energy consumption
low.

ATTENTION !

ATTENTION !

PLUS 250 minimum mould diametre 160 mm (6,3 inch)
PLUS 350 minimum mould diametre 160 mm (6,3 inch)

Special attention should be paid to eccentricities (if any) of
the mould and the seal surface which might cause
deformations of both mould and closing unit, thus greatly
reducing the life of the guiding and sealing elements.

B) Maximum mould weight

The required measuring precision of the injection piece, the
mould stress and the mould functions (in case of complicated
designs, such as multiplate moulds, slide moulds etc) are
highly dependent on the plane parallel alignment of the
platens.

The plane parallel alignment stipulated by EUROMAP 9 is
observed if the following total mould weights are observed:

PLUS 250 max. mould weights 140 kg (315 lbs)
PLUS 350 max. mould weights 140 kg (315 lbs)

Chapter: 3
Page: 10

The weight of the closing plate half of the mould must not
exceed 2/3 of the specified total mould weight.

A: PL120100.030
B: PL120000.030

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Transport - Siting

Chapter 4: Transport - Siting

4.1 Spatial requirement plan

855

2348

4.2 Transport of machine

Bild: PL-0005.TIF

At least 600 mm (23.62 in.) of clearance should be left around
the injection moulding machine for maintenance works.

The machine frame contains four clearance holes (D = 50
mm); thus the machine may be transported by means of an
appropriate hoisting devices as well.
In addition, the wooden planks secured to the bottom of the
machine allow for transport by forklift truck.

A: PL120100.040
B: PL120100.040
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: 4

Page: 1

(2248 lb)

(2,56 inch)

Transport - Siting

Bild: PL-0006.TIF

Chapter: 4
Page: 2

A: PL120100.040
B: PL120100.040

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Transport - Siting

4.3 Siting of machine

4.4 Oil filling

No special foundation is required for siting the machine. The
machine frame contains borings (3 x M 16) for fastening the
vibration-absorbing elements. The machine must be balanced
properly before startup.

The combined filling and ventilation aperture becomes
accessible by screwing off the cover sheet at the back of the
machine. 125 l (33 gal) of hydraulic oil are required for the first
filling of the integrated oil tank.

ATTENTION !

ATTENTION !

Only fill the tank with clean hydraulic oil, purity class 15/
12 in keeping with ISO standard 4406!

The oil level must be checked daily.

The oil inspection glass is situated in the bottom right area of
the machine front.

An oil change should be carried out after approximately
4,000-5,000 operating hours. The quality of the hydraulic oil
must be checked by an expert provided by the oil supplier.

Special attention should be paid to waste oil disposal. This
must correspond to the legal provisions of the respective
countries.

A: PL120100.040
B: PL120100.040
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: 4

Page: 3

4.5 Table of hydraulic oils and lubricants

Transport - Siting

Lubricating point

acc. to DIN

Hydraulic installation

HLP 68 DIN 51524 T 2

Agip OSO 68

Aral Vitam GF 68

Avilup RSL 68

BP Energol HLP 68

BP Energol HLP - D 68

CASTROL Hyspin

AWS 68

Nuto H 68

Greasing points

K 2 K DIN 51825

Agip GR MU 2

Aral Aralub HL 2

AVIA Mehrzweckfett Avilup RL10-C

BP Energrease LS 2 BP Energol HL 10

CASTROL Spheerol

AP 2

Beacon 2 Spinesso 10

Pneumatic

control device

HL 10 DIN 51524 T 2

Agip OSO 10

Agip Radula 10

Aral Vitam DE 10
Aral Vitam GF 10

CASTROL Hyspin

AWS 10

Chapter: 4
Page: 4

FINA Dydran 68

Mobil D.T.E. 26

Shell Tellus Oel 68

Rando Oil HD C 68

FINA Marson L 2 FINA Cirkan 10

Mobilux 2

Shell Alvania Fett R 2 Shell Tellus Oel C 10

Multifak 20

Multifak 2

Mobil D.T. 21

Mobil Velocite Oil 6

Rando Oil 10

It is also possible to use products by another manufacturer if
they are clearly equivalent.

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

A: PL120100.040
B: PL120100.040

Transport - Siting

4.6 Connection to cooling water distributor

The cooling water distributor is situated at the back of the
machine. The connection diametre is R 1/2".

4.7 Oil cooler fitting

The oil cooler is connected to the 2nd cooling water distribution
circuit. The nominal width of a hose is NW 10 mm (0.394
inch).

Cooling water connection R 1/2"

Oil cooler connection NM 10 (0.394 inch)

Oil inspection glass

Bild: PL-0007.TIF

A: PL120100.040
B: PL120100.040
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: 4

Page: 5

4.8 Connection to power line

Transport - Siting

ATTENTION
!

ATTENTION !

This injection moulding machine may only be connected to a
power supply network corresponding to the specifications of
the rating plate (control box) with respect to type of current,
voltage and frequency.

The PLUS-series will be constructed with two different
voltages.

a) Voltage 3-230/400 volt

The mains voltage was defined as 3-230/400 volt (+6%, ­10%), in accordance with the standard IEC 38. It is likewise
possible to operate the mould in 3-220/380 volt and 3-240/
415 volt networks within the above voltage tolerances. For
this purpose, however, a neutral conductor connection is
required.

b) Voltage 3-230 volt

The machine may be likewise connected to networks with a
nominal frequency of 50 Hz or 60 Hz. For this, a neutral
conductor connection is not necessary.

The applicable national regulations regarding grounding
and safety measures (excess-current release device,
residual current operated device) of TN, IT and TT networks
must always be complied with by the operator.
The external conductors and the neutral conductor (IT
networks) must be protected in accordance with the
indications given on the machine rating plate.

Chapter: 4
Page: 6

A: PL120100.040
B: PL120100.040

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Transport - Siting

Basically, two types of electrical connection are possible:

1) Direct connection

The machine is connected via the master switch. Please
observe the correct phase-sequence (clockwise rotation).
The master switch is also equipped with a leading switching
contact N for all-polo separation.
The cable link is provided by one of two PG 29 inputs located
at the side of the control box.

b)a)

L2 L3 N

L1

L2 L3

L1

5 (L1, L2, L3, N, PE) 5 (L1, L2, L3,PE)

Bild: PL-0019.DRW

2) Transformer connection

If a transformer is added, the machine may be run on different
supply networks.
The transformer must comply to the following requirements:

1. Type of current 3 ~

2. Nominal capacity 20 kVA

3. Frequency 50 Hz oder 60 Hz

4. Primary voltage 3 x 200 V, 2 x 220 V, 3 x 230 V, 3 x 380 V,
3 x 440 V, 3 x 460 V, 3 x 480 V or only one
nominal voltage each.

5. Secondary voltage a) 3 x 230/400 V or
b) 3 x 230 V

6. Winding Two-part winding (primary and secondary)

7. Connection symbol a) Ynz5 (fully current-carrying star-point) or
b) Yd5

8. Operation mode S 1 (permanent operation)

A: PL120100.040
B: PL120100.040
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: 4

Page: 7

Transport - Siting

9. Type of design Open design (including star-point and
grounding) on terminals, angles for securing
the machine to the ground, fully impregnated
under vacuum conditions.

10. Short circuit voltage max. 4%

11. Insulation class E or F (with excess temperatures of 75°K or
100°K)

12. Ambient temperature 40 °

13. Standards VDE 0110, VDE 0532, VDE 0550, IEC 76,
IEC 529, DIN 40050 and all relevant national
regulations.

a) b)

4 (L1, L2, L3, PE)

5 (L1, L2, L3, N, PE)

Maschine

3~230/400 Volt

4.9 Corrosion protection

4.10 Storage

4 (L1, L2, L3, PE)

4 (L1, L2, L3, PE)

Maschine

3~230 Volt

Bild: PL-0020

In order to protect the machine, all plain parts have been
treated with a preservative. The small components included
in the package (worm tips, stop rings etc.) are protected by a
wax dipping process.
In order to protect the machine against moisture, several
moisture-regulating bags were installed in the machine.

Chapter: 4
Page: 8

It is standard procedure to pack the machines in such a way
that they will not be damaged during normal transport periods.
Upon their delivery by the transport company, however, they
must be put into operation immediately.
In case of a longer storage period, we strongly advise you to
get into contact with our local permanent representative.

A: PL120100.040
B: PL120100.040

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Structure and Function

Chapter 5: Structure and Function

5.1 Overview of build groups

5.2 Closing unit

5.3 Injection unit

5.4 Hydraulic unit

5.5 Electric unit

5.6 Pneumatic unit (optional)

5.7 Control

5.2 5.3

?

A: PL120100.051
B: PL120100.051
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

5.4 5.5 5.7

Bild: PL0008.TIF

Chapter: 5.1

Page: 1

?

Structure and Function

Chapter: 5.1
Page: 2

A: PL120100.051
B: PL120100.051

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Structure and Function

5.2 Closing unit

5.2.1 Technical description

The closing unit mainly consists of a cast iron closing plate
(Item 1) with an integrated hydraulic ejector (Item 2), a cast
iron nozzle plate (Item 3) with a clearance (Item 4), which
doubles as an injection protection for the injection equipment.
Moreover, the guiding rails for the piston rods of the closing
cylinder (Item 5) are integrated into the nozzle plate.
The two closing cylinders consist of the cylinder tubes (Item

6), the piston rod (Item 7), the quick-action cylinder piston
(Item 8), the seal sleeve (Item 9) and the fastening nuts (Item

10) and the sliding plate (Item 11) for the closing plate.

?

11

274 6

35 8910 1

Bild: PL-0011.TIF

A: PL120100.052
B: PL120100.052
E: 03.93 / T. Weiß
G: 03.93 / T. Weiß

Chapter: 5.2

Page: 1

?

Structure and Function

Description of function:

The unit is linked to the machine frame via a nozzle plate. The
standard version of the closing plate is supported so that the
weight forces are transmitted to the machine frame.

ATTENTION!

The sliding plates of the closing platen must be
lubricated every 2,500 working hours.

The closing force is exerted via two closing cylinders. The
extremely stable construction of the square closing and
nozzle plates ensures ideal closing force distribution.

The quick-action cylinder provides for a rapid closing process
and at the same time ensures senstive mould protection.

The closing force is developed via the piston surface of the
piston rod, which permits the full closing force buildup at a
hydraulic pressure of 210 bar (3045 pai). This intentionally
low closing pressure ensures the long life of the seals and
guiding devices in the guiding sleeves.

The piston rod is guided in the nozzle plate. We have given
particular attention to the distance to the seals in order to
safeguard the intactness of the hydraulic seals in case of
damage to the piston rods during siting.
A clearance is put between the seals and the guiding device;
leaking oil is collected there and flows off through a leakage
oil duct.

Chapter: 5.2
Page: 2

The ejector is a double-action hydraulic cylinder and was
integrated into the square construction of the closing plate.

A: PL120100.052
B: PL120100.052

E: 03.93 / T. Weiß

G: 03.93 / T. Weiß

Structure and Function

5.2.2 Mould fitting

?

The mould is inserted into the closing unit from above by
means of a suitable hoisting device. An eccentric ring (D=110
f7; 4,33 inch) is used to position the mould close to the nozzle
plate.

The unit may be fastened in three different ways:

1. Screw to platen with at least two diagonal threads per half
of mould (M12, torque 70 Nm; 95 ft lb).

2. Screw through platens by means of 4 head cap screws
M12x95 (torque 70 Nm; 95 ft lb), using the provided holes
(D=14; 0,55 inch).

3. Fasten by means of at least two clamping brackets per half
of mould; with the brackets arranged diagonally on each
platen.

5.2.3 Instructions for fitting - adjustment of fitting height

The minimum fitting height is preset at 150 mm (5,9 inch) in
the factory. The fitting height can, however, be adjusted by
means of the fastening nuts, thus permitting the full use of the
opening stroke. The height is adjusted in the following manner:

1. Mark the current nut position of the fastening nut (item 1)
with respect to the closing plate.

2. Remove (item 2) fastening nuts.

3. Unscrew back tightening nut (item 3) until end of piston rod

is reached.

4. Calculate necessary number of rotations for the fastening
nut. The thread pitch is 4 mm, from which the adjustment
stroke can be calculated as follows:
If the result is not an even number, round down to next even

A: PL120100.052
B: PL120100.052
E: 03.93 / T. Weiß
G: 03.93 / T. Weiß

Chapter: 5.2

Page: 3

?

Structure and Function

number.
Adjust the fastening nuts.

5. Withdraw the closing platen (Item 4) towards the
fastening nut until the limit stop is reached. Make sure that
the markings match.

6. Pull back closing plate to nut until limit stop is reached.

7. Screw festening nut close to fastening nut (distance 2 mm)

and observe compatibility of fastening bore.

7. Insert and tighten fastening screws (torque 40 Nm).
The long guiding device of the piston rod and closing plate

ensures that no plate parallelism error can occur as a result
of fitting height adjustment.

4

1

2

3

Bild: PL-0011.TIF

Chapter: 5.2
Page: 4

A: PL120100.052
B: PL120100.052

E: 03.93 / T. Weiß

G: 03.93 / T. Weiß

Structure and Function

5.3 Injection unit

5.3.1 Technical description

?

The injection unit consists of a plastification unit (Item 1), a
holding device for the platification unit (Item 2), a fastening
nut for the screw cylinder (Item 3), a metering drive unit
including a hydraulic motor (Item 4), a cylinder block (Item 5)
with an integrated nozzle drive cylinder (Item 6), an injection
cylinder (Item 7) and the guiding roller (Item 8).

12 3

8

5

4

A: PL120101.053
B: PL120100.053
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

6

7

Bild: PL-0009.TIF

Chapter: 5.3

Page: 1

?

Structure and Function

Description of function:

The injection unit is set between the two closing cylinders by
means of the guiding rollers and the two nozzle drive cylinders.
The nozzle drive cylinders are directly connected to the
closing cylinders and have the form of double-action hydraulic
cylinders. The nozzle drive cylinders permit contact of nozzle
and mould as well as access to the nozzle when it is in the
rear end position.
The screw is driven by a slow-action hydraulic motor acting
directly on the injection cylinder piston via a toothed belt.
During the metering process, the injection piston also revolves;
this construction makes it possible to avoid rolling bearings

- which basically would be necessary for the thrust bearing of
the screw - since this function is supplied hydrostatically. At
the same time, the injection piston doubles as a screw
coupling.
The torque of the hydraulic motor can be adapted to the
requirements through selection of the appropriate hydraulic
pressure.

To extend the material life of the screw cylinder heater

ATTENTION !

bands, heat them regularly, beginning with the first day of
operation, and make sure that they are firmly anchored.

5.3.2 Nozzle change

Preconditions:

1. Eject residual material from screw cylinder.

2. Heat screw cylinder to last preset material temperature.

Process:

1. Pull back nozzle drive cylinder of injection unit to rear

limit stop.

2. Disconnect and dismount nozzle heater band.

3. Unscrew nozzle with suitable spanner.

4. Insert new nozzle; bear in mind that the thread must be

greased with heat-resistant material.

5. Screw in nozzle to limit but do not tighten yet.

6. Mount and connect nozzle heater band.

7. Tighten nozzle after heating to operating temperature.

5.3.3 Instructions for setting - nozzle centre

Chapter: 5.3
Page: 2

A: PL120101.053
B: PL120100.053

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Structure and Function

?

In the factory, the nozzle centre is set at the centre of the
nozzle plate. If it becomes necessary, however, to correct the
nozzle centre (e.g. exchange of the injection unit), observe
the following steps:

1. Measure the deviation of the nozzle centre from the diameter
of the eccentric ring both horizontally and vertically.

2. Loosen the cheese head screws (Item 1; 3x) of the
connecting pins (Item 2). First correct the horizontal deviation
by adjusting the nut (Item 3) on one of the two lower connecting
pins; then correct the vertical deviation by adjusting the nut on
the upper connecting pin.

3. Tighten cheese head screws (Item 1; 3x) (maximum
tightening torque: 250-400 Nm; 340-540 ft lb). Admissible
deviation: +/- 0.2 mm (0.008 in.) of nut offset.

5.3.5 Screw change and screw cylinder change

1

3

2

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Chapter: 5.3

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Structure and Function

5.3.4 Change and prestressing of synchronous belt

1. Uncouple screw and move injection cylinder to rear end

position.

2. Loosen fastening screws (Item 1; 3x) and hand-tighten so
that no gap can form between the guiding platen (Item 2) and
hydraulic motor.

3. Move hydraulic motor to upper end position by means of
cam (Item 3).

4. Remove synchronous belt wheel (Item 4) from shaft.

5. Put synchronous belt over wheel and position on shaft; in

doing so, take care to push the synchronous belt also over the
upper synchronous belt wheel.

6. Use cam (Item 3) to prestress synchronous belt (in keeping
with instruction item 2. above), with a pressure of 140 N acting
on the centre of the synchronous belt; depth of impression: 2
mm (0.08 inch).

7. Secure hydraulic motor with fastening screws (Item 1; 3x)
(maximum torque: 80 Nm; 110 ft lb).

2

1

4

3

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Structure and Function

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Preconditions:

1. Eject residual material from screw cylinder.

2. Heat screw cylinder to last preset material temperature,

disconnect and dismount heater bands and thermocouples.

4321

Process:

Bild: PL-0012.TIF

1. Pull back nozzle drive cylinder to rear limit stop.

2. Advance injection cylinder to front limit stop.

3. Disconnect machine by turning off master switch.

4. Dismount protective sheathing of screw cylinder.

5. Disengage screw coupling (Item 1, 2 x M6).

6. Remove disk from thrust piece (Item 2); remove feather key

(Item 3).

7. Loosen screw cylinder nut (Item 4) and unscrew from
thread.

8. Remove screw cylinder in the direction of the nozzle platen
and lift it.

9. Disconnect the tube

10. Insert new screw cylinder and tighten together with nut.

11. Recouple screw.

12. Fasten protective sheathing.

13. Connect screw cylinder, the tube and the thermocouples.

14. Connect machine via master switch and heat to attain

material temperature.

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Structure and Function

Chapter: 5.3
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Structure and Function

5.4 Hydraulic unit

5.4.1 Pump element

5.4.2 Oil tank

?

A continuously active electric motor is mounted with the
pump. This electric motor drives the hydraulic pressure pump
via the coupling. The hydraulic pressure pump is a variable
capacity pump connected to the central hydraulic block by
means of tubing.
The maximum system pressure is 210 bar (3045 psi).

The oil tank is a fixed component of the machine frame; it is
equipped with filler necks plus an air filter and an oil level
indicator.
The control reacts if the oil level is too low; in this case, refill
oil until the oil level indicator mark is again attained.
In order to clean the tank properly, unscrew the fastening
screws and remove the tank cover.

5.4.3 Oil filter

3

2

bar

0

HYDAC

Bild: PL-0036.WMF

10

In order to increase the operational safety and material life of
the hydraulic elements and seals, the hydraulic unit is
equipped with a return filter integrated into the oil tank.
This return filter is situated at the back of the machine, below
the central hydraulic block; it is equipped with an optical
clogging indicator which should be checked daily.
If the arrow of this indicator is in the red area, it is necessary
to replace the filter element at once.

Optional: Electrical clogging indicator
If the filter is clogged, a visual error message is issued on the
display. In this case, immediately replace the filter element.

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Attention: In order to safeguard the operational safety and

long material life of the machine, only original filter elements
may be installed (Hydac 0165R010BN/HC; item No. MB628).

5.4.4 Oil cooler

An oil suction cooler installed inside the oil tank ensures
adequate cooling of the hydraulic oil.
When connecting the machine to the water supply system,
take care that the water is not polluted. If working with polluted
water, always use a water filter in order to safeguard the
correct functioning of the cooling water valve. This valve is
installed in front of the water supply connection and accepts
only the quantity of water that is necessary to cool the oil.
Reducing the water flow will thus not save water.

5.4.5 Supervision and indication device

Structure and Function

System pressure:

The hydraulic system pressure is indicated by a manometer
located on the front of the machine beside the control box.

Dynamic pressure:

At the back of the machine, there is a manometer for dynamic
pressure measuring. During the metering stroke phase, the
dynamic pressure can be regulated using this manometer.

Oil level indicator:

An oil inspection glass is situated in the right front area of the
oil tank. Refill hydraulic oil (see chapter 7.3) if the level
indicated is too low. Check the oil level every day to avoid
disruptions of the production process.

Hydraulic filter clogging indicator:

The hydraulic filter clogging indicator is situated to the right of
the ejection shaft. Replace filter immediately if indicator is in
the red area (see chapter 5.4.3).

5.4.6 Variable capacity pump setting

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Structure and Function

ATTENTION !

?

After selecting a pressure of appr. 70 bar (1015 psi) and a
material quantity of appr. 50%, the “Withdraw nozzle”
movement adjusts the p setting of the output regulation of the
variable capacity pump. The control block connection points
MPP (pressure before quantity decrease) and MPS (pressure
after quantity decrease) are used as measuring points.

The measuring process should be carried out using the same
pressure sensor and hydraulic pressure.

The pump output regulator should be set at 10 bar (145 psi)
 p.

All pressure and speed settings must be carried out at an
oil temperature of 45°C (113°FAR).

5.4.7 Relief valve amplifier

5.4.8 Speed setting of proportional valve amplifier EM 1020

ReserveJ 5

Reserve
J 1
J 2
J 3
J 4

+ 24 V

0 V

Rampen­zeit

Dither

I - max.

I - min.

EM 1010
EM 1020

-

0 - 10 V

+

125

876

+

-

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Setting Jumper function: EM1010 ( pressure) EM 1020 (speed)

J 4 Jumper set J 4 Jumper set
J 1 Jumper set J 2 Jumper set

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Chapter: 5.4

Page: 3

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Structure and Function

Speed setting is done by means of a proportional choker
valve, which is activated by the proportional amplifier.

For speed setting, the following steps have to be taken in that
order:

a) Set the “Dither” potentiometer at 50% (clockwise direction,
50% are 10 rotations = original manufacturer’s setting).

b) Preset the speed at 20% for the “Metering” process.
c) Activate the “Metering” process and set the potentiometer

“I-min” so that the following speeds are attained if 20% are
preselected:
Standard hydraulic motor OMS 80 -> Screw speed 84 revs/
min (hydraulic motor speed: 92 revs/min).
Special hydraulic motor OMS 100 -> Screw speed 66 revs/
min (hydraulic motor speed: 72 revs/min).

d) Preset 100% speed for “Metering” process.
e) Activate the “Metering” process and preset the maximum

speed using the “I-max” potentiometer.
Standard hydraulic motor OMS 80 -> Screw speed 420 revs/
min (hydraulic motor speed: 462 revs/min).
Special hydraulic motor OMS 100 -> Screw speed 330 revs/
min (hydraulic motor speed: 363 revs/min).

f) Repeat setting instructions b, c, d, e until the settings are
correct.

g) Set potentiometer “Rampenzeit” at 0% (anti-clockwise
rotation to limit stop = 50 msec = original manufacturer’s
setting).

5.4.9 Pressure setting of proportional valve amplifier EM 1010

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Structure and Function

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Pressure setting is done by means of a proportional pressure
control valve which is activated by the proportional amplifier.

For pressure setting, the following steps have to be taken in
that order:

a) Set the “Dither” potentiometer at 50% (clockwise direction,
50% are 10 rotations = original manufacturer’s setting).

b) Set the speed at 100% for the “Withdraw nozzle” process.
c) Set the pressure at 10% for the “Withdraw nozzle” process.
d) Activate the “Withdraw nozzle” process and use the “I-min”

potentiometer to set a pressure of 21 bar (304.5 psi) at the
metering point MPS.

e) Set the pressure at 95% for “Withdraw nozzle” process.
f) Activate the “Withdraw nozzle” process and use the “I-max”

potentiometer to set the pressure at 200 bar (2,893 psi). The
maximum system pressure at 100% is 210 bar (3,045 psi).

5.4.10 Setting for maximum pressure protection for variable capacity pump

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Chapter: 5.4

Page: 5

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Structure and Function

This setting is only necessary if the pump type plate does
not give 210 bar for DR.

ATTENTION !

a) For “Withdraw nozzle” movement set pressure at 100%
and speed at 70%.

c) Initiate “Withdraw nozzle” movement and set “Amplifier”
potentiometer at a pressure of 220 bar (3190 psi).

d) Initiate movement “Withdraw nozzle” and set maximum
pressure regulation of pump at 210 bar (3045 psi).

e) Repeat pressure setting of relief valve amplifier.

5.4.11 Hydraulic oil preheating

The cold hydraulic oil is automatically preheated as soon as
the hydraulic pump starts working until the preset heating
temperature of 40°C (104° FAR) is attained.
If the oil temperature is below this level, an error message is
issued on the machine display, and the machine cannot be
started. After the 40°C (104° FAR) level has been attained,
the hydraulic oil preheating is switched off, and the machine
is ready for operation.

5.4.12 Core pull (optional)

During operation, the oil temperature is continuously kept at
45°C (113° FAR). This is achieved by opening and closing
the cooling water valve of the oil cooler.
If the oil temperature exceeds 60°C (150° FAR), the machine
control is switched off.
Always ascertain the cause of this temperature rise and
eliminate the defect (e.g. cooling water defect, solenoid valve
of oil cooler closed).

You can restart the hydraulic unit after pressing the stop
button once. Thus the oil can be recooled. During this cooling
phase the machine remains inactive.

The hydraulic core pull consists of a base plate which holds

Chapter: 5.4
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Structure and Function

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the required hydraulic valves and the consumer’s terminals
(2 x R1/4").
This function module is mounted on the left connecting wall
of the piece ejection shaft.
The delivery package does not include a connection to the
mould core pull cylinder.
Furthermore, it must be borne in mind that the available
hydraulic pressure is 210 bar (3045 psi). All connecting
elements must withstand this pressure!

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Structure and Function

Chapter: 5.4
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Structure and Function

5.5 Pneumatic unit

5.5.1Material feeder device UNIFEED (optional)

1) Area of application

The material feeder device was conceived for use with a
plastics processing machine; it is installed directly above the
screw cylinder (instead of the hopper).
This device is characterized by high operational reliability
since it does not contain any movable components; furthermore,
it is easy to operate and to maintain.
The following granulate materials are recommended for use
with UNIFEED:
PE-HD, PE-LD, PS, PA, PA+GF, PP, ABS, POM, PPO.

2) Setup and function

?

If during the metering process the level of the granulated
material sinks below the proximity limit switch (Item 1), this
switch activates an air valve (Item 2), and compressed air
flows into the material feeder device. The compressed air is
blown through the air jet (Item 3) into the suction pipes (Item

4) and thus creates a negative pressure which is transmitted
into the suction chamber (Item 5) and the container pipe (Item

6). This negative pressure then sucks a mixture of granulated
material and air mixture through the suction lance (Item 7) and
the suction tube (Item 8) into the container pipe.
A primary filter (Item 9) separates the granulated material
from the accompanying air. This air leaves the device through
a secondary filter (Item 10), retaining the fine dust which might
escape the primary filter.
When the level of the granulated material once more has
attained the proximity limit switch, the switch disconnects the
inflow of compressed air, and the feed process is terminated.
Whenever a feed process is terminated, a small quantity of
compressed air is transported, pulse-type, into the suction
chamber. Thus all adhering material dust is automatically
removed from the primary filter.

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Structure and Function

8

11

2

12

6

7

1

3

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Page: 2

10

4

5

9

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Structure and Function

3) Processing of reclaimed material

The UNIFEED device is principally suited for feeding
regenerated material together with new granulated material.
However, the grain size must not exceed 3-4 mm (0.12-0.16
inch).
It must be said that a higher degree of contamination entails
increased clogging of the filter; thus it is imperative to clean the
device more frequently.

3) Maintenance

The secondary filter should be checked depending on the
quantity of dust gathered, but at least once per week, and
cleaned if necessary.
Its material life is limited; for this reason, it should be
exchanged (by simply pushing it out of the guiding device) at
the first sign of the fibres becoming loose.
The primary filter is automatically cleaned by compressed air
after each feed cycle. In case of heavy clogging, proceed as
follows:

1) Remove knurled nuts (Item 11);

2) Lift cover (Item 12);

3) Clean filter.

ATTENTION !

When installing the filter, make sure that the O-ring is
afterwards carefully reinserted in its correct position.

?

Transport capacity PA

kg / h

(lb / h)

(562)

(450)

(338)

(225)

(112)

4) Material transporting capacity

With a pneumatic pressure of 6 bar (87 psi), full action time
(100%) and a tube with a nominal width of 19 mm (0.75 inch),
of which 4 m (13 ft) are laid vertically:

250

200

150

100

50

10 20 30 40 50 600

(112) (112) (112) (112) (112) 60

Bild: PL-0033.WMF

Length of tube

m

(ft)

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Structure and Function

5) Air consumption

Q in case of 100% action time

1

Q in case of 50 kg (115 lb) of material per hour

2

Q in case of 35 kg (80 lb) of material per hour

3

Air consumption Q

n / min

250

200

150

100

50

0

6) Noise level

71

70,5

3

(44)

4

(58)

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6

5

(87)

(72)

Bild: PL-0034.WMF

7

(101)

1

2

3

Pneumatic pressure (abs.)

bar

(psi)

Chapter: 5.5
Page: 4

Noise level

dB / A

70

69,5

69

68,5

68

3

(44)

(58)

Pneumatic pressure (abs.)

4

(72)

(87)

(101)

7

6

5

bar

(psi)

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Structure and Function

5.5.2 Pneumatic core pull (optional)

The pneumatic core pull consists of an electrical 4/2 pulse
valve including all service connections for a plastic pipe, NW

6.
This functional module is installed on the left connecting wall
of the ejector shaft.
The hook-up to the core pull cylinder supplied by the
manufacturer is not part of the delivery package.
Moreover, it must be borne in mind that the pneumatic
compressed air supplied for the purpose must be dried and
oiled, and that the pneumatic pressure must not exceed 6 bar
(87 psi). All connecting elements must be strong enough to
withstand this pressure!

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Structure and Function

Chapter: 5.5
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Structure and Function

5.6 Electric unit

5.6.1 Electric drive

?

The pump unit is driven by a 4-pole three-phase asynchronous
motor.

Bild: Pl-0026.DRW

The drive motor is coupled directly to the hydraulic pump and
connected in accordance with the operating voltage of the
relevant circuit ( Y or ).

If the machine is properly connected (the phase sequence
must produce a clockwise rotary field, see chapter 4.8), the
drive motor must run in the anticlockwise direction (to D end).
D end: Drive end.
N end: Non-drive end.

∆∆

∆ 230V

∆∆

L1 L2 L3

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W2 V 2U2

Y 400V

L1 L2 L3U1 W1V1

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Chapter: 5.6

Page: 1

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5.6.2 Control box

1

Structure and Function

The control box is easily accessible; it is located at the front
of the machine and contains the majority of the electrical
devices necessary for operation.

Front view of control box:

5

3

9

10

2

4

6

11

7

8

Bild: Pl-0022.TIF

1) EMERGENCY STOP button

2) Manual control panel

3) Input panel

4) Auxiliary control panel

5) Pull-out error-indication lamp

6) Outlet filter

7) Inlet filter

8) Control box door

9) Door lock

10) Door handle

11) Master switch

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Structure and Function

depending

?

Right-hand view of control box:

1) Combined cycle counter and time meter

2) Outlet filter

3) Inlet filter

4) Main input point, top

5) Main input point, bottom

6) Type plate

7) Rating plate

Left-hand view of control box:

1) EMERGENCY STOP button

2) Socket holding plate

3) Device for switching to follow-up pressure,
on the pressure inside the mould (optional)

Bild: Pl-0023.TIF

1

1

2

4

6

7

3

5

2

2

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Back view of control box:

23

61

Structure and Function

45

879

1) Cable outlets

2) Socket heater band - nozzle

3) Socket heater band - zone 1

4) Socket heater band - zone 2

5) Reserve

6) Cable thermocouple sensor - nozzle (optional)

7) Cable thermocouple - zone 1

8) Cable thermocouple - zone 2

9) Reserve

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Structure and Function

5.7 Control

5.7.1 Description of electronic system

1) General

The real-time control system UNILOG 1020 is the centre of all
control tasks required to run the machine properly.

The control system consists of two system units:
a) operating unit for the display and presetting of all process­relevant data.
b) control unit for process control and regulation.

The control rack has a modular structure and was conceived
for the Europe card format. All modules are housed in a
protected plug-in case.

?

2) Structure

STU-BUS

ALS-BUS

Operating unit

(CTD)

Control unit

(STU, ALS)

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STU

500

AIO
172

KOP

500CC11

CA16CA

16

CE
32

DNT

24

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Chapter: 5.7

Page: 1

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Structure and Function

3) Description of individual components

3.1 Operating unit (CTD)

The operating unit provides all necessary functions for the
communication of operator and machine. All information
items are represented by symbols, i.e. are independent of
language.
The unit consists of the following areas:
a) Set value input panel for displaying and inputting individual
set values.
b) Error dialogue panel for calling-up individual error
messages.
c) Process parameter selection panel for selecting individual
set values.

The operating unit is linked to the control unit by means of a
data cable and a feeder cable.

STU 500

AIO 172

KOP 500

CC 11

3.2 Control unit (STU, ALS)

16-bit processor card

This is the main control system which controls, regulates,
communicates, manages and checks all other units.

Analog card

Transforms analog signals into digital ones and vice versa.
Permits the connection of five temperature probes (FeCo)
and of two analog inputs and outputs each.

Coupling card

For coupling the STU-BUS system to the ALS-BUS system.

1-bit processor card

This is the control subsystem which controls all input and
output units. An LED signals the reset of this system following
“Netz Ein” and “Netzausfall” (power outage).

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Structure and Function

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CA 16

Digital output card

For outputting 16 digital signals with a maximum capacity of

2.5 A.

Each output is tested for overload and short-circuiting. If this
monitoring function reacts, all output cards of the control
system are deactivated. An LED indicates the defective
output card. After defect elimination the machine is restarted
by pressing the “Netz Aus/Ein” key.

CE 32

Digital input card

For inputting 32 digital signas.

DNT 24

Power pack

Power supply for the entire control system. 23 VDC supply;
a voltage tolerance of +/- 20% has no influence on the output
voltage. An LED indicates that the machine is ready for
operation.

5.7.2 UNILOG 1020 user manual

The UNILOG 1020 user manual is annexed to this chapter.
This manual has its own separate table of contents and page
numbering.

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Structure and Function

Chapter: 5.7
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Operation

Chapter 6: Operation

6.1 Startup

The machine is switched on by pressing the master switch on
the control box door. If possible, the master switch should
always be activated without load, i.e. first press master switch
before switching on the heating.

Press the red EMERGENCY STOP button located on the
side of the control box and release by rotating in direction of
arrow (to check EMERGENCY STOP circuit).

Open and close protective grating (to check protective grating
circuit).

Put position selector on control panel into “Manual operation”
mode.

Press the “STOP” button on the control panel for a moment to
acknowledge error messages (if any).

Press “START” button on the control panel and check direction
of rotation of pump (see direction of arrow on hydraulic drive).
If direction is not correct, change 2 phases of the supply line
in the mains line of the machine.

The standard machine equipment includes an oil preheating
system and thus can only be put into operation after the preset
preheating temperature has been attained (this takes appr.
15 min.).

If the mould was delivered with the following options, the
corresponding option must be connected, or the “dummy
plug” provided for this purpose must be plugged in. This
“dummy plug” supplies the signals necessary for correct
operation.

a) Core pull interface
b) Ejector protection interface
c) Test balance interface
d) Interface for final ejector position safety device
e) Robot interface

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Chapter: 6

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6.2 Starting the machine after EMERGENCY STOP

After pressing the EMERGENCY STOP button, eliminate the
malfunction or error or external cause of EMERGENCY
STOP (i.e. peripheral device, e.g. robot) and unlock the
EMERGENCY STOP button by rotating it in the direction of
the arrow.

6.3 Machine shutoff

The closing unit should be returned to the normal position
(Open mould). If necessary, the piece can now be removed
from the mould by means of the ejector. The injection unit
should also be returned to its normal position (Withdraw
injection unit).

Furthermore, press the “STOP” key and set the heating
selection switch at “0”.

Operation

Shut off the machine by pressing the master switch on the
control box. If possible, the master switch should always be
activated without load.

If the injection moulding machine is out of operation for a
longer period of time, all plain parts of the machine should be
covered with an anticorrosive. The residual melted material
must be removed from the screw cylinder and the screw itself;
these parts must also be purged with polyethylene.

Chapter: 6
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B: PL120100.060

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

Maintenance

Chapter 7: Maintenance

7.1 General

The machine will only work properly and without hitches if it
is regularly serviced. We recommend cleaning the machine
every day to remove impurities and to clean it thoroughly
each week.
The protecting guard and control panel must always be kept
free of any type of impurity. Please bear in mind that dust and
granulated material are especially hazardous to electric and
hydraulic components.

7.2 Maintenance instructions

Checkup time Checkup measures

Daily

Check all safety devices (see chapter 2)
Check oil level
Check oil filter indicator (not necessary if electrical filter
monitoring device was installed)

500 working hours

2,500 working hours

5,000 working hours

Check overall condition of mould (visual checkup)
Clean control box filter

Operating manual is kept close to the machine and is in good
condition
Lubricate closing platen support
Check Emergency-Off circuit
Check whether heater bands are firmly installed and in their
correct position
Check heater bands with respect to functioning and accumulated
dirt

Visual checkup of the electrical components
Clean control box
Exchange control box filter
Exchange diaphragm of cooling water valve
Check wear and centre position of nozzle
Check oil quality (and exchange oil if necessary)

A: PL120100.070
B: PL120100.070
E: 03.93 / T. Weiß
G: 06.93 / T. Weiß

Chapter: 7

Page: 1

7.3 Table of hydraulic oils and lubricants

Maintenance

Lubricating point

acc. to DIN

Hydraulic installation

HLP 68 DIN 51524 T 2

Agip OSO 68

Aral Vitam GF 68

Avilup RSL 68

BP Energol HLP 68

BP Energol HLP - D 68

CASTROL Hyspin

AWS 68

Nuto H 68

Greasing points

K 2 K DIN 51825

Agip GR MU 2

Aral Aralub HL 2

AVIA Mehrzweckfett Avilup RL10-C

BP Energrease LS 2 BP Energol HL 10

CASTROL Spheerol

AP 2

Beacon 2 Spinesso 10

Pneumatic

control device

HL 10 DIN 51524 T 2

Agip OSO 10

Agip Radula 10

Aral Vitam DE 10
Aral Vitam GF 10

CASTROL Hyspin

AWS 10

ATTENTION !

Chapter: 7
Page: 2

FINA Dydran 68

Mobil D.T.E. 26

Shell Tellus Oel 68

Rando Oil HD C 68

FINA Marson L 2 FINA Cirkan 10

Mobilux 2

Shell Alvania Fett R 2 Shell Tellus Oel C 10

Multifak 20

Multifak 2

Mobil D.T. 21

Mobil Velocite Oil 6

Rando Oil 10

It is also possible to use products by another manufacturer if
they are clearly equivalent.

Only fill the tank with clean hydraulic oil, purity class 15/
12 in keeping with ISO standard 4406!

E: 03.93 / T. Weiß

G: 06.93 / T. Weiß

A: PL120100.070
B: PL120100.070

Spare Parts / Drawings

Chapter 8: Spare Parts / Drawings

8.1 Guidelines for ordering spare parts

The list of spare parts comprises lists of parts reflecting the
volume of the various build groups of the machine. Each
group is assigned a unit number. Each spare part is entered
under a separate item number.

In the left lower corner, these sectional drawings are assigned
DOK numbers which are also featured in the corresponding
lists of parts. This permits the unequivocal identification of the
part in question. In addition, an acknowledgement number
(RM Nr.:) is given as well.

The spare parts lists are simply and clearly structured. The
comprise the item number, an identification number, the
quantity, the quantity unit and a designation in two languages.
In addition, an acknowledgement number (RM Nr.:) is featured
above the DOK number.

8.2 Basic machine data

When ordering, please contact either your authorized
BATTENFELD dealer or BATTENFELD Austria (see
addresses and phone numbers in chapter 9).

To avoid any possible misunderstanding, please always
give the machine number when ordering spare parts. Also
stipulate the corresponding identification number (ID-Nr.),
the designation and the desired quantity.

The machine data sheet contains information on the key data
and spare parts for the mould. Since it is drawn up
simultaneously with the final inspection of the mould (the
serial numbers of the parts supplied by outside companies
are also recorded), it gives an accurate representation of the
condition of the mould at delivery.

A: PL120100.080
B: PL120100.080
E: 03.93 / T. Weiß
G: 05.94 / G. Krajnik

Chapter: 8

Page: 1

Spare Parts / Drawings

Chapter: 8
Page: 2

A: PL120100.080
B: PL120100.080

E: 03.93 / T. Weiß

G: 05.94 / G. Krajnik

Customer Service

Injection MoldingInjection Molding

Injection Molding

Injection MoldingInjection Molding

BATTENFELD INTERNATIONAL

Contact

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Contact

Service

Servicevereinbarungen

Vorbeugende Instandhaltung

Customer Service

Battenfeld Spritzgießtechnik bietet seinen Kunden ein umfangreiches und effizientes
Serviceportfolio an. Schnell, zuverlässig und kompetent betreuen die Servicestellen unsere
Kunden in mehr als 80 Ländern der Welt.

1 Kalibrier-Service

2 Basis-Service

3 Standard-Service

4 Full Service

• Erhöhung der Maschinenverfügbarkeit, Verbesserung der Produktionsqualität, folglich
Steigerung der Rentabilität

• Erhöhung der Prozesssicherheit

• Zertifizierung für DIN ISO 9000 durch Herstellerdokumentation

Ersatzteilvertrieb

Wenn Sie Ersatzteile für Battenfeld Spritzgießmaschinen oder die Automatisierungstechnik
benötigen, steht Ihnen unser Ersatzteilvertrieb für die Beratung, Prüfung der Verfügbarkeit der
benötigten Teile und für die termingerechte Lieferung zur Verfügung.

Unterstützung vor Ort

Je nach Ihren Aufgabenstellungen beraten wir Sie auch gerne in Ihrem Unternehmen, um mit
Ihnen gemeinsam direkt an den Maschinen entsprechende Optimierungen vorzunehmen.

Wir bieten weiterhin verfahrenstechnische Beratung bei der Prozessoptimierung:

• Maschineneinstellung

• Verfahrensauswahl

• Werkzeuggestaltung

• Fördertechnik

• Temperierung

• Handling der Produkte

Plastifiziereinheiten

• Plastifiziereinheiten zu fertig entwickelten Verfahrenslösungen

• Auswahlkriterien nach Verschleiß- und Prozessverhalten

• Kurze Lieferzeiten für Sonderlösungen

• Verfahrenstechnische Unterstützung

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Maschinen-Upgrades

• Steuerungsmodernisierung

• Software-Upgrades

• Nachrüstung von Zusatzspritzaggregaten für Mehrfarbentechnik

• Nachrüstung von Beistellaggregaten auch an Fremdmaschinen

• Optionsnachrüstungen (z. B. Kernzüge, Airmould®, Hilfsachsen für Roboter, EUROMAP-

Starke Partner

Bei Bedarf ermöglichen wir unseren Kunden den Kontakt zu Partnern unseres weltweiten
Netzwerkes aus den Bereichen

• Rohstoffhersteller

• Werkzeugbauer

• Peripherielieferanten

• Universitätsinstitute

Contact

Schnittstellen etc.)

• Forschungseinrichtungen

Hotline

• Verfügbarkeit von 7.00 bis 22.00 Uhr, 7 Tage pro Woche

• Erweiterter täglicher technischer Helpdesk-Service

• Erweiterte tägliche Ersatzteillieferung im EU-Raum (Annahme – Bearbeitung – Lieferung

• Ersatzteil-Bestellungen bis 22.00 Uhr)

• Weltweite Servicepräsenz

Schulungen

In unseren Seminaren vermitteln wir ein umfassendes Verständnis der komplexen
Zusammenhänge im Spritzgießprozess. Diese Ausbildung ist die Grundlage, um auf die
Herausforderungen der Praxis rasch und zielgerichtet reagieren zu können. Für Ihr Unternehmen
bedeutet dies die Wahrung technologischen und anwendungstechnischen Vorsprungs.

Unsere Schulungen bieten:

• Modernstes Präsentations-Equipment

von dringenden

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• Training an neuesten Spritzgießmaschinen

• Schulung durch bestens ausgebildete Seminarleiter

• Expertenrunden

• Zertifizierungen

Contact

Customer Service

Austria

Battenfeld Kunststoffmaschinen Ges.m.b.H.
Wiener-Neustädter-Straße 81
2542 Kottingbrunn / Austria
Tel.: [phone] (Zentrale)
Fax: [phone] (Zentrale)

Customer service - Hotline Machinery
Tel.: [phone]
Fax: [phone]
e-Mail: [e-mail]

Spare Parts - Machinery
Tel.: [phone]
Fax: [phone]
e-Mail: [e-mail]

Customer service - Hotline Automatisation
Tel.: [phone]
Fax: [phone]
e-Mail: [e-mail]

Spare Parts - Automation
Tel.: [phone]
Fax: [phone]
e-Mail: [e-mail]

Training
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Australia (VAU)

Battenfeld Australia Pty. Ltd.
3, Phoenix Court
Braeside, 3195
Melbourne / Australia
Postal address:
P.O.Box 614
Mordialloc, 3195
Melbourne / Australia
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

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Belgium (VBE)

Battenfeld Benelux N.V.
Nieuwlandlaan 1A
Industriepark
B-3200 Aarschot Belgium
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Belorussia

Vadim Zviagintsev
1 Novokuznetzkij Per. 5/7-KW 37
113184
Russische Föderation
Tel.: [phone]
Tel.: [phone]
Fax: [phone]

Bosnia and Herzegovina

Contact

Fokuma Planungs- u. Vertriebsges.m.b.H.
Further Straße 27
A-2564 Weißenbach
Tel.: [phone]

0043-2674-87413
Fax: [phone]
e-mail: [e-mail]

Brasilia (VBR)

Battenfeld do Brasil Ltda.
R. Seranouch Magdesian, 489
(antiga R. Arnaldo de Oliveira Barreto)
06210-130 Osasco-SP / Brazil
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Canada (VCA)

Battenfeld Canada Co. Ltd.
940 Westport Crescent
Mississauga
Ontario L5T 1G1 / Canada
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

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Customer Service

China

Agency for: Heilongsiang,Jilin, Liaoning, Nei Mongol, Hebei, Sichuan, Shanxi, Shaanxi, Shandong,
Gansu, Henang, Beijing, Tianjin
H & Z Import &Export
Office Beijing Room A 402
Long bo Building
Nr. 3, Nanlishi Road Xicheng District
P.C. 100037 Beijing P.R. China
Tel.: [phone]
Fax: [phone]

Agency for: Chekiang, Jiangsu, Shanghai, Hupeh, Anhui, Kiangsi, Hunan, Fukien
Royaland International
Trading (Shanghai) Ltd.
No. 631, Ling Ling Road
AI-LE Building 10H
ShanghaiTel.: 0086-21-64866856

0086-21-64866857

0086-21-64863796
Fax: [phone]
e-Mail:[e-mail]

Agency for: Guangdong (VHK)
Battenfeld Hong Kong Ltd.
2/Fl., No. 18 Dai Fat Street
Tai Po Industrial Estate
Tai Po, N.T. HONG KONG
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Croatia

Fokuma Planungs- u. Vertriebsges.m.b.H.
Further Straße 27
A-2564 Weißenbach
Tel.: [phone]

0043-2674-87413
Fax: [phone]
e-Mail:[e-mail]

Cyprus

M. Sideris & Son. Ltd.
18, Pindarus Street
P.O. Box 2353
Nicosia - Zypern
Tel.: [phone]

00357-2-755142

00357-2-758300
Fax: [phone]
e-Mail:[e-mail]

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Czech Republic

Smid Spol. sro.
Ke Kastanku 236
CZ-252 18 Uhonice / Tschechische Republik
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Danmark (VDK)

Battenfeld Danmark AS
Stengaardsvej 7
4340 Toelloese / Danmark
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

England (VUK)

Battenfeld U.K. Ltd.
6, The Valley Centre
Gordon RoadHigh Wycombe
Bucks HP13 6EQ / Great Britain
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Contact

Finland (VFI)

OY Suomen Plastmaschinen AB and SPM
Satamakatu 28
SF-24100 Salo / Finnland
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

France (VFR)

Battenfeld France S.A.
Central Parc 255, Blvd. Robert Ballanger
F-93421 Villepinte
Postal address:
8, Allée du Daim
Boite Postale 42
F-93421 Villepinte Cedex
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

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Germany

Battenfeld Kundendienst GmbH&Co.Kg
Scherl 10
58540 Meinerzhagen - Deutschland

Head Customer Service:++49 (0) 2354/72-120

Sekretary: ++49 (0) 2354/72-121 Fax:++49 (0) 2354/72-129
e-Mail: [e-mail]

Head Technical Customer Service Team National 1

Tel.: ++49 (0) 2354/72-161 Fax: ++49 (0) 2354/72-139
e-Mail:[e-mail]

Customer service - Hotline Team National 1
Tel.: ++49 (0) 2354/72-160 Fax:++49 (0) 2354/72-159
e-Mail: [e-mail]

Spare Parts Team National 1
Tel.: ++49 (0) 2354/72-131 Fax:++49 (0) 2354/72-139
e-Mail: [e-mail]

Head Technical Customer Service Team National 2

Tel.: ++49 (0) 2354/72-150 Fax: ++49 (0) 2354/72-159
e-Mail:[e-mail]

Customer service - Hotline Team National 2
Tel.: ++49 (0) 2354/72-140 Fax:++49 (0) 2354/72-159
e-Mail: [e-mail]

Spare Parts Team National 2
Tel.: ++49 (0) 2354/72-151 Fax:++49 (0) 2354/72-139
e-Mail: [e-mail]

Head Technical Customer Service Team International

Tel.: ++49 (0) 2354/72-122 Fax: ++49 (0) 2354/72-125
e-Mail:michael.matthä[e-mail]

Customer service - Hotline Team International
Tel.: ++49 (0) 2354/72-170 Fax:++49 (0) 2354/72-188
e-Mail: [e-mail]

Customer service - Hotline Team International
Tel.: ++49 (0) 2354/72-190 Fax:++49 (0) 2354/72-188
e-Mail: [e-mail]

Spare Parts - Hotline Team International
Tel.: ++49 (0) 2354/72-171 Fax:++49 (0) 2354/72-179
e-Mail: [e-mail]

Spare Parts - Hotline Team International
Tel.: ++49 (0) 2354/72-176 Fax:++49 (0) 2354/72-189
e-Mail: [e-mail]

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Customer Service

Greece

General Plastics Ltd.
Representatives - Importers
Laskaridou 143
Kallithea
17675 Athens / Greece
Tel.: [phone]
Fax: [phone]

Hong Kong (VHK)

Battenfeld Hong Kong Ltd.
Units 910-911
No. 1 Hung To Road
Kwun Tong
Kowlon
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Hungary

Contact

THEGE-PLASTIC GmbH
Dugonics u. 11
H-1043 Budapest
Ungarn
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Israel

PLAST-TECH & Co.
Industrial & Prod. Engineering
Vingait 30 A
P.O. Box 492
Zihron Ya’acov 30900 / ISRAEL
Tel.: [phone]
Fax: [phone]

Italia (VIT)

Battenfeld Italia S.r.l.
Via Donizetti
I-20020 Solaro(MI) Italien
Tel.: [phone]

0039-2-96 981040
Fax: [phone]
e-Mail:[e-mail]

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Customer Service

Korea

Beston Corporation
#302 940-2, Siheung 3-Dong
Geumchun-Gu
SEOUL
SÜDKOREA 153-861
Tel [phone]
Fax [phone]
e-Mail: [e-mail]

Malaysia (VSI)

Battenfeld Injection Moulding Technology (S) Pte. Ltd.
Blk. 196, Pandan Loop #01-16
Pantech Industrial Complex
SGP 128384 / SINGAPORE
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Mazedonia

Fokuma Planungs- u. Vertriebsges.m.b.H.
Further Straße 27
A-2564 Weißenbach
Tel.: [phone]

0043-2674-87413
Fax: [phone]
e-mail: [e-mail]

Mexico (VMX)

Battenfeld Mexico S.A. de C.V.
Antonio Noemi No. 83
Col. Lomas de Memetla
05330 Mexico, D.F. / Mexico
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Netherlands

Battenfeld Benelux N.V.
Nieuwlandlaan 1A
Industriepark
B-3200 Aarschot Belgium
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Norway

Battenfeld Sverige AB
c/o Visma Services Norge AS
Postboks 335
1601Fredrikstad
NORWEGEN
e-Mail:[e-mail]

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Poland

Battenfeld Polska
Injection Moulding Technology Sp. z.o.o.
Adamowizna 151
05-825 Grodisk Maz / Polen
Tel: [phone]
Fax: [phone]
e-Mail:[e-mail]

Portugal (VES)

Battenfeld Iberica S.A.
Poligono Industrial
La Ferreria
Avda. La Ferreria 29
E-08110 Montcada i Reixach
Espagna
Tel.: [phone]
Fax: [phone]

Sweden (VSV)

Contact

Battenfeld Sverige AB
Ryttarevägen 18A
30260 Halmstad
Schweden
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Switzerland (VSZ)

Battenfeld Schweiz AG
Brunnenstraße 7
8604 Volketswil
Schweiz
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Singapore (VSI)

Battenfeld Injection Moulding
Technology (S) Pte. Ltd.
No. 6 Tagore Drive #B1-03/04
TAGORE IND.BLDG., SINGAPORE 787623
Tel [phone]
Fax [phone]
e-Mail:[e-mail]

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Customer Service

Slovenia

Fokuma spol. S.r.o.
Gololova 18
85202 Bratislava
Slowakai
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

Slovakia

Fokuma spol. s.r.o.
Gogolova 18
SK-85202 Bratislava / Slowakei
Tel/Fax: [phone]

Spain (VES)

Battenfeld Iberica S.A.
Poligono Industrial
La Ferreria
Avda. La Ferreria 29
ES-08110 Montcada i Reixach / Espagna
Tel.: [phone]
Fax: [phone]

South Africa

D.K. Machinery Pty. Ltd.
D.K. Machinery House
No. 8, Engineering Close
KYA SAND EXT. 15 / South-Africa
Postal address:
P.O.Box 2193
2162 Northriding / SOUTH AFRICA
Tel.: [phone]
Fax: [phone]

Taiwan

Royaland Co. Ltd.
10-8 Floor, No. 104,
Ming-Chuan West Road
Taipei, Taiwan 103 / ROC
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

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Thailand

Battenfeld Injection Moulding
Technology (S) Pte. Ltd.
No. 6 Tagore Drive #B1-03/04
TAGORE IND.BLDG., SINGAPORE 787623
Tel [phone]
Fax [phone]
e-Mail:[e-mail]

Turkey

MELTEM
Makina Sanayi Ve Ticaret Ltd. Sti.
Dogu Sanayi Sitesi Block: 6 Nr. 11
Yenibosna 34520 Istanbul
Turkey
Tel.: [phone]
Fax: [phone]
e-Mail:[e-mail]

USA (VUS)

Contact

Battenfeld of America, Inc.
1620 Shanahan Drive
60177 SOUTH ELGIN, IL
USA
Tel. 001 – 847-5310015
Fax. 001 – 847-5310029
e-Mail:[e-mail]

Yugoslavia

Fokuma Planungs- u. Vertriebsges.m.b.H.
Further Straße 27, A-2564 Weißenbach
Tel.: [phone]

0043-2674-87413
Fax: [phone]
e-mail: [e-mail]

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