HyPET Operator Course

HyPET OPERATOR COURSE v1.
Keeping our customers in the lead
Machine Manual
Safety Summary
Chapter 1
Safety Summary
The Safety Summary describes general requirements and conditions for safe
installation, operation, and maintenance of injection molding equipment. Personnel
must read, understand, and follow all safety precautions listed in the equipment
manuals. Personnel must follow applicable industry and regulatory safety
requirements for safe installation, operation, and maintenance of equipment.
1.1
Manuals
Husky manuals aid in the safe and proper use of the machine, robot, and mold. The
manuals provide instructions on installation, operation, and maintenance. A separate
Drawing Package includes parts lists and drawings.
Personnel should review all manuals thoroughly prior to performing any tasks.
Proceed with tasks only if all instructions are understood. Follow applicable workplace
safety requirements.
Keep manuals in a convenient location for future reference.
Signal words are used in the manuals according to the degree of severity, and
classified as: Danger, Warning, or Caution. Signal words alert the user to hazardous
situations that arise during routine installation, operation, and maintenance.
DANGER!
The term DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING!
The term WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION!
The term CAUTION indicates a potentially hazardous situation which, if not
avoided, can result in property damage.
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11
Manuals
Hylectric PET Injection Molding Machine
1.2
Safety Signs
Safety signs clearly mark potentially hazardous areas in or around equipment. For the
safety of personnel involved in equipment installation, operation, and maintenance,
use the following guidelines:
1. Verify all signs are in the proper locations. Refer to the Drawing Package for
details.
2. Do not alter signs.
3. Keep signs clean and visible.
4. Order replacement signs when necessary. Refer to the Drawing Package for part
numbers.
The table below describes safety symbols appearing on safety signs. Each safety sign
could include a detailed explanation of the potential hazard and associated
consequences.
Safety Symbol
General Description of Symbol

General Warning
This symbol indicates a potential personal injury hazard. It is usually
accompanied by another pictogram or text to describe the hazard.
Danger Hazardous Voltage

Contact with hazardous voltages will cause death or serious injury. Turn off
power and review electrical schematics before servicing equipment.
Electrical cabinet can contain more than one live circuit. Test all circuits
before handling to make sure circuits have been de-energized.
Warning Molten Material and/or High Pressure Gas
Contact with molten material or high pressure gas can cause death or
severe burns. Wear personal protective equipment while servicing the
feed throat, nozzle, mold areas, and when purging the injection unit.
Warning Lockout/Tagout
Servicing equipment without disabling all internal and external power
sources can cause death or serious injury. De-energize all internal and
external power sources. Electrical, hydraulic and pneumatic are examples
of energy sources to consider.
Warning Crushing and/or Impact Points
Contact with moving parts can cause serious crushing injury. Do not reach
over, under, around, or through guards. Always keep fixed and movable
guards in place.
Warning Crushing and/or Impact Points
Contact with moving parts can cause serious crushing injury. Do not reach
over, under, around, or through guards. Always keep fixed and movable
guards in place.
Safety Signs
12
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Machine Manual
Safety Summary
Safety Symbol
General Description of Symbol

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

Sudden release of high pressure gas or oil can cause death or serious
injury. Discharge all gas and hydraulic pressure before disconnecting or
disassembling accumulator.
Warning Hot Surfaces
Contact with exposed hot surfaces will cause serious burn injury. Wear
protective gloves when working near these areas.
Warning Slip, Trip, or Fall Hazard
Personnel climbing on equipment surfaces may slip, trip, or fall causing
injury. Do not climb on equipment surfaces.
Warning Crushing Hazard

Contact with the rotating screw can cause serious crushing injury. Do not
insert body parts into the feed throat opening while the machine is
operating. Install a hopper or a direct feed system.
Warning Read Manual Before Operation
Personnel involved with equipment operation and maintenance should be
properly trained. Personnel should read and understand all instructions in
the manuals before working on equipment.
Warning Class 2 Laser Beam
Personal injury will result with prolonged exposure to the laser beam. Do
not stare directly into the laser beam and avoid exposure. Unplug the
connector to switch off the laser beam.
Warning Barrel Cover Grounding Strap
Contact with an energized barrel cover can cause death or serious injury.
The barrel cover can become energized upon removal of grounding
strap(s). Complete Lockout/Tagout before removing the barrel cover. Make
sure grounding strap(s) are connected before applying power to machine.
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Safety Signs
1.3
Qualified Personnel
Only fully trained personnel should be permitted to operate, maintain, and service
equipment. In addition, make sure:
1. Only one qualified person operates the equipment at a time
2. The area around the equipment is safe at all times.
1.4
Training
Skilled personnel are required to operate and maintain Husky equipment. Contact a
Husky Regional Service and Sales office to arrange training.
1.5
Guards And Interlocks

Guards are provided where hazards exist. There are two types of guards: movable
and fixed. Movable guards are interlocked to stop hazardous motion when the guards
are moved or removed. Fixed guards are not interlocked. Fixed guards must be
installed and completely secured anytime power is applied to the machine.
Before operating the equipment, make sure:
1. Safeguards are in place.
2. Safeguards are not bypassed or modified.
3. Safeguards are tested and inspected regularly for correct operation.
4. Only qualified personnel perform maintenance tasks.
1.6
Lockout/Tagout
The Lockout/Tagout procedure must be performed before maintenance and service
tasks. Lockout/Tagout includes isolation or depletion of stored energy from all
integrated ancillary equipment. For detailed Lockout/Tagout instructions, refer to the
equipment manual and local regulations and codes.
After performing Lockout/Tagout and disconnecting the supply voltage, allow 10
minutes for the extruder servo DC Bus to discharge residual voltage to less than 50
Volts before performing any electrical procedures.
When troubleshooting electronics, Lockout/Tagout may not be possible. In this case,
Service Personnel must secure the work cell by installing a Danger sign at all isolation
points and cordoning off the area around the equipment.
Qualified Personnel
14
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Machine Manual
Safety Summary
1.6.1 Performing Lockout/Tagout

Special Tool Required
1
Hydraulic pressure gauge suitable to 210 bar (3000 psi) with quick-disconnect fitting
Perform Lockout/Tagout using the following instructions:
DANGER!
Electrocution hazard risk of death or serious injury. Install danger sign at all
isolation points and rope off the area around the machine. When live
troubleshooting is required, do not work alone. Have emergency medical
assistance nearby throughout the procedure.
WARNING!
Hazardous voltages, high pressure fluids, crushing or impact hazards risk of
death or serious injury. Perform Lockout/Tagout procedure in accordance with
local codes. After performing Lockout/Tagout procedure, allow 10 minutes for
residual voltage to discharge to less than 50 Volts before performing any
electrical procedures.
Only qualified personnel should perform Lockout/Tagout procedure.
1. Turn off the power supply to the machine at the main disconnect switches, Q1M
and Q3M. If your machine is equipped with a Q2M mold heat switch, turn off the
power. Attach a lock and a tag. Then wait 10 minutes for residual voltage to
discharge.
2. Verify that all power to the machine is switched off using an voltmeter that has
been tested on a known source.
3. Lift open the power pack cover and turn the manual dump valve (1) on the power
manifold (2) off to ensure that the accumulators are fully discharged.
4. Tun the manual dump valve (3) on the injection manifold (4) off.
5. Check the pressure gauge on the power manifold to verify the accumulators are
completely discharged.
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15
Lockout/Tagout
Figure 1-1 Manual Dump Valve Locations

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

3. Shutoff lever 4. Air regulator 5. Lock
Lockout/Tagout
16
6. Tag
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Machine Manual
Safety Summary
1.6.2 Removing Locks and Tags

Remove Locks and Tags using the following instructions:
WARNING!
Hazardous voltages risk of death or serious injury. Perform Lockout/Tagout
removal procedure in accordance with local codes.
Only qualified personnel should be permitted to perform Lockout/Tagout
procedure.
1. Check all power cables are properly connected.
2. Verify the danger zone around the machine is clear of all personnel before
attempting to remove the lock and tag at the main disconnect switch.
3. The lock and tag should only be removed by the person who installed them.
If the person is unable to personally remove the lock and tag, verbal instructions
can be given to remove the lock and tag. The instructions must also include any
specific measures required to return the machine to safe operating condition.
If the person cannot be contacted, then a supervisor and a qualified technician who
has a thorough understanding of the machine should perform the following checks:
a. Check all isolation points to make sure that hoses, wires, and/ or systems are
set to a safe condition.
b. Verify that the danger zone around the machine is clear of all personnel.
c. Remove the lock and tag only when both the supervisor and the technician
agree that all systems are in order, and there is no potential for injury.
4. Turn on the power supply to the machine at the main disconnect switches.
5. Turn the manual dump valves on the power manifold and the injection manifold to
close the hydraulic circuit.
6. Remove the lock and tag on the air regulator. Use the shutoff lever on the air
regulator to turn on the air supply to the machine. Refer to Figure 1-2.
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Lockout/Tagout
1.7
Safety Hazards
Some common safety hazards associated with injection molding equipment are:
1. Mechanical (pinching, shearing, crushing)
2. High Pressure Leak
3. Thermal
4. Spray
5. Electrical
6. Noise
7. Gas, Vapor, and Dust Emissions
8. Slipping, Tripping, or Falling
9. Lifting.
1.7.1 Mechanical Hazards

1.7.1.1 Worn Hoses and Safety Restraints
Regularly inspect and replace all flexible hose assemblies and restraints.
1.7.1.2 Cooling Water Hoses

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

Hydraulic circuits in Injection and Clamp Units contain high pressure accumulators.
Before servicing hydraulic systems, perform the Lockout/Tagout procedure to
discharge all stored energy. When servicing hydraulic systems, read equipment
manuals and refer to hydraulic schematics for additional details.
Safety Hazards
18
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Machine Manual
Safety Summary
1.7.2 High Pressure Leak Hazards

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

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

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

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

1.7.4.1 High Pressure Explosion
Pressure can build up in a nozzle or feed throat area and cause some process
material to explode. In some cases, molten material can be ejected unintentionally due
to insufficient pre-drying or degradation of process materials. These areas are clearly
marked with safety signs. Be aware of these areas. Wear appropriate personal
protective equipment when accessing these areas.
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19
Safety Hazards
1.7.5 Electrical Hazards

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

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

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

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

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

Wear appropriate personal protective equipment when working on or near equipment.
Standard personal protective equipment includes: safety glasses, face shield, heat
resistant gloves, hearing protection, and safety shoes.
Personal Protective Equipment and Safety Equipment
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Machine Manual
Safety Summary
1.8.2 Safety Equipment

Use appropriate safety equipment when working on or near equipment. Standard
safety equipment for clearing frozen resin includes: telescopic mirrors, brass
hammers, and brass rods.
1.9
Ancillary Equipment
Husky is only responsible for the interaction of the machine with ancillary equipment
when Husky is the system integrator. If ancillary equipment is removed, proper
safeguards must be installed. For information about integrating non-Husky ancillary
equipment, contact a Husky Regional Service and Sales office.
1.10 Material Safety Data Sheet (MSDS)

The Material Safety Data Sheet (MSDS) is a technical document which indicates the
potential health effects of a hazardous product, and contains safety guidelines to
protect personnel. Before handling a product, refer to the MSDS. These sheets identify
hazards related to use, storage, and handling of the product, including emergency
procedures. Contact the material supplier to obtain a copy of the MSDS sheet.
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Ancillary Equipment
1.11 Materials, Parts, and Processing

To prevent personal injury or damage to the equipment, make sure:
1. The equipment is only used for its intended purpose, as described in the manuals.
2. The operating temperatures do not exceed the specified permissible maximum
value.
3. The maximum temperature setpoint is set below the ignition point of the material
being processed.
4. Lubricants, oils, process materials, and tools used on equipment meet Husky
specifications.
5. Only authentic Husky parts are used.
Materials, Parts, and Processing
112
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Table of Contents
1 Overview
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
List the Steps in the Injection Molding process

Machine Cycle Operation
Explain How Auxiliary Components Affect the Process
Identify the Basic Components of the Mold
Identify the Basic Components of the Machine
Interpret Machine Nomenclature for Machine Specifications
Contact the Correct Source for Troubleshooting Assistance
Test for Understanding
2 HyPET Safety
2.1
2.2
2.3
2.4
2.5
2.6
2.7
13
Operator-side Safety Gates

Locate and Describe Machine Safety Gates-Non Operator Side
Identify the Purge Guard and Describe the Purge Zone
Identify Devices Engineered to Add Personal Protection
Perform Check of Safety Devices
Perform a Lockout/Tagout
3 Using the HMI

3.1
3.2
3.3
3.4
5.1
5.2
6 Clamp Components
6.1
6.2
6.3
6.4
6.5
6.6
6.7
49
Identify and Describe the Function of Clamp Components

Explain How Clamp Positions are Measured and Monitored
List the Steps in the Clamp Cycle
Clamp Setup Screens
Clamp Setup
Identify the Valves Which Control the Clamp
7 Mold Functions
7.1
7.2
7.3
7.4
7.5
45
Explain Hydraulic Oil Conditioning Circuit

Explain the Hydraulic Oil Distribution
65
Identify and describe the function of ejection components

Setup The Ejector
Setup Air Ejection
Setup Valve Gates
25
7 Areas of the HMI

Manage User IDs
Using the Alarms screens
8 Injection Components
8.1
8.2
8.3
8.4
4 Machine Services
4.1
4.2
4.3
4.4
4.5
5 Hydraulic Components
39
Identify Services Supplied to the Machine

Electricity
Air
Process Water
8.5
8.6
8.7
8.8
9 Machine Heats
9.1
9.2
9.3
69
Identify and Describe the Function of Injection Components

Injection Unit Components
Explain How Carriage Position is Measured and Monitored
Explain How Screw / Injection Piston Position is Measured
and Monitored
List the Steps in the Injection Cycle
Use the HMI Setup Screens to Control Injection Cycle
Identify the Valves Used to Control Injection Components
83
Identify and Describe the Function of Machine Heat Components

Use the HMI Setup Screens to Control Machine Heats
Copyright 2004, Husky Injection Molding Systems Ltd., Technical Training

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical or otherwise, without the written permission of the publisher.
HyPET Operator Training
Contents

10 CoolPik and Tooling Plate
Contents
93
10.1 CoolPik
10.2 CoolPik Cooling Fans / C-Axis Motor
10.3 Tooling Plate
10.4 CoolPik / Tooling Plate Setup Screen
10.5 Diagnostic Screen
10.6 Sequence Screen
10.7 Configuration Screen
10.8 HyPET Mold/Tooling Installation
10.9 Tooling Plate Removal
10.10 CoolPik Sensor Set-up / Adjustment
10.11 Air Picker Maintenance
11 Startup, Monitor, Shutdown

11.1
11.2
11.3
11.4
11.5
11.6
113
Filling the Manifold

Manual Mode Start-up
Switching to Semi Automatic Mode/Robot Engagement/Auto
Monitor Machine Conditions during Operation
Shutdown
Glossary
135
1 Overview
Objectives
List the steps in the injection molding process

Explain how auxiliary components can affect the process
Identify the basic components of the mold
Identify the basic components of the machine
Interpret machine nomenclature for machine specifications
Contact the correct source for troubleshooting assistance
1 Overview
1 Overview
1.1 List the Steps in the Injection

Molding process
Key Points:
Recovery (Mix and Melt the resin)

Screw Transfers mass to shooting pot
Close and clamp the mold
Injection
Hold
Cool the part, same time Transfer next shot to
shooting Pot
Open the mold
Robot Take off Plate Into Molding area
Ejectors Transfer Parts to Take off plate
Robot Take off Plate Out
1.2 Machine Cycle Operation

Clamp (2)
Injection (1)
9
6
3
8
The HyPET injection molding machine consists of a two-stage injection unit (1), and a hydro-mechanical clamp unit (2). Process material
pellets are fed into a heated extruder barrel (3) in the injection unit where a hydraulically driven plasticizing screw (4) rotates and turns
them into a molten mass. When enough material has been plasticized, the screw transfers the mass to the shooting pot (5) and continues to plasticize more pellets.
The two halves of a mold are attached to the stationary platen (6) and the moving platen (7). The stationary platen is pinned to the base
(8), and the moving platen is attached to the clamp unit. Additional clamping force is then applied to keep the mold halves from separating during the injection stage.
The injection piston injects a preset amount of plasticized material at very high speed into the mold cavity. This allows the molten material to fill and pack the mold cavity. Pressure is maintained until the molded part has a chance to cool. Pressure is then removed, and the
plasticizing screw transfers more molten material to the shooting pot for the next injection. At the same time, clamping force is removed
from the two platens, and as the two mold halves begin to separate an ejector (9) pushes the molded part off the mold.
1 Overview
1 Overview
1.3 Explain How Auxiliary Components Affect the Process

Key Points:
Process water
- Scaling and corrosion
- Bacteria
- Ambient temperature affects cooling
Resin distribution system
- Introduction of contaminants
Dryers
- Pellet temperature
- Air temperature
- Dew-point
- Air volume
- Residence time
- Dryer efficiency
Resin supply
- Material
- Batch or lot number
- Ship date
- Weight
- Melt index
- Properties (color, fines, IV, Acetaldehyde,
etc.)
Electrical Connections
1.4 Identify the Basic Components of

the Mold
Manifold
Leader Pins
Valve Gate
Locating Ring
Sprue Bushing
Core
Gate
Heater
Runner
Cavity
1 Overview
1 Overview
1.5 Identify the Basic Components of

the Machine
Key Points:
Electrical Panel
Hydraulic Power Unit
Clamp
Extruder Motor
User Interface (HMI)
Product Handling
Power Manifold
Hopper
1.6 Interpret Machine Nomenclature

for Machine Specifications
Key Points:
Hylectric Series
Long clamp base (option)
Tonnage
MODEL
MODEL
SERIES
HL120PET
HYD.PRESSURE
P100/110 E120
MODEL
MODEL
MAX
WEIGHT
Machine series
Long clamp base option
Extruder type
Extruder model
Screw diameter
Main supply
Mold heat supply
Kg
THIS EQUIPMENT OR ITS USE MAY BE
COVERED BY ISSUED OR PENDING
PATENTS. SEE INFORMATION SCREEN
AT CONTROL STATION FOR DETAILS
SERIAL#
DATE
HUSKY INJECTION MOLDING SYSTEMS LTD.

560 QUEEN STREET SOUTH
BOLTON, ONTARIO, CANADA, L7E 5S5
Two Stage Injection Unit

Model P100/110 injection unit
120mm screw diameter
Main
Supply
SUPPLY No.1 LOAD

LARGEST MOTOR
TOTAL HEAT LOAD
460 V
57 A
14 A
127 A
Mold Heat
Supply
SUPPLY No.2 LOAD

LARGEST MOTOR
TOTAL HEAT LOAD
230 V
A
74 A
74 A
MACHINE TYPE
DIAGRAM Number
60 Hz 3P+GND
SHORT-CIRCUIT
INTERRUPTING-CAPACITY
SYSTEM
10 KA
60 Hz 3P+GND
SYSTEM
10 KA
HL 120PET P100/110 E120
SERIAL Number
HUSKY INJECTION MOLDING SYSTEMS LTD.

BOLTON, ONTARIO, CANADA L7E 5S5
1 Overview
1 Overview
1.7 Contact the Correct Source for

Troubleshooting Assistance
Key points:
User Interface
Machine documentation
Husky telephone hotline
Husky technical service representative
Husky Technical Training courses
1.7.1 User Interface

Key Points:
The user interface (HMI) is the first source of
technical assistance.
Husky engineers have programmed several
features into the HMI which will provide trouble-shooting assistance:
- Alarms
- Events
- Reports
- Cycle Time Breakdown
- Pressure/Velocity Graphs
- Valves Status
- Statistical Process Control (SPC)
- HMI Help
1 Overview
1 Overview
10
1.7.2 Machine Documentation
All Husky machines are shipped with Operation and Maintenance manuals, assembly diagrams, hydraulic schematics, and electrical
schematics. This documentation may be
printed or provided on a CD (in Adobe Acrobat .pdf format).
1.7.3 Husky Telephone Hotline

Husky maintains a 24-hour technical assistance hotline to provide immediate support to
our customers. If you have a question about
the machine operation or maintenance which
cannot be answered by reading the machine
manual, please call the hotline.
North America: (800) 465-4875

Europe: (352) 52 115 4300
1.7.4 Husky Technical Service Representative

You may encounter a problem which you cannot solve without expert, on-site assistance
from Husky.
Husky has regional service and sales offices
located around the world.
Check the listing in your machine manual for
the closest location
1.7.5 Husky Technical Training

Courses
The www.huskytraining.com website allows
you to research and register for a wide variety
of hands-on courses. You can also call our
Training Coordinator at (248) 735-6339.
1 Overview
11
1 Overview
12
1.8 Test for Understanding
1. Put the steps in the injection molding process into the correct order, beginning with Mix and Melt the resin.
___2___
_______
_______
_______
1. Ejectors Transfer Parts to Take off Plate

2. Recovery (Mix and Melt the Resin)
3. Robot Takeoff Plate into Molding Area
4. Screw Transfers Mass to Shooting Pot
_______
_______
_______
5. Injection
6. Close and Clamp the Mold
7. Open the Mold
8. Nozzle Close / Transfer
_______
_______
_______
9. Robot Take off Plate Out

10. Hold
11. Open Machine Nozzle
12. Cool part, Transfer next shot to shooting pot
2. Locate the basic components of the Husky HyPET machine.
1. Electrical Panel
2. Extruder Motor
3. HMI
4. Hopper
5. Product Handling
3. For machine HL120PET P100/110 E120, the plunger diameter is __________ mm.
4. The Husky hotline number is _______________________________________
2 HyPET Safety
Objectives
Identify and understand the function of machine safety gates

Identify the purge guard
Describe the purge zone
Identify devices on the machine designed to add personal protection
Perform a check of safety devices
Perform a Lockout/Tagout
2 HyPET Safety
13
2 HyPET Safety
14
2.1 Operator-side Safety Gates

Key Points
Purge guard
Operator gate
Clamp access
1
7LS 352LS 333LS 8LS
1LS
(1)
(2)
(3)
2.2 Locate and Describe Machine

Safety Gates-Non Operator Side
Key Points:
4. Robot Conveyor Door
5. Robot Vacuum Door
646LS
648LS
647LS
649LS
ROBOT RESET PUSHBUTTON

Press pushbutton to restart
machine after opening the robot
conveyor door (4).
695LS
2 HyPET Safety
15
2 HyPET Safety
16
2.3 Identify the Purge Guard and
Describe the Purge Zone
Key Points:
Injection is restricted unless the nozzle is
within the purge guard (10mm, 0.4 overlap)
Use PPE when clearing the nozzle or sprue
bushing
Limit switch S1LS monitors the purge guard
and triggers an alarm when the purge guard is
opened. If the switch is not made, injection is
not possible
Limit Switch S1LS
2.4 Identify Devices Engineered to

Add Personal Protection
Key Points:
Manual Dump Valve
2 HyPET Safety
Emergency Stop (E-stop) Pushbutton

Manual Dump Valve
C.E.N. Valve
Automatic Dump Valve (internal - not shown)
Mechanical Safety Device
17
2 HyPET Safety
18
2.5 Perform Check of Safety Devices

Key Points:
695LS
647LS
Gate
646LS
Open
Gate
Closed
1LS
333LS 352LS
CEN
Gate
Open
Emergency Stop pushbutton

Operator Gates
Purge Guard
C.E.N. valve
WARNING!
Hazardous voltages, high pressure fluids, crushing or impact hazards - risk of death or serious injury. Perform Lockout/Tagout procedure in accordance with local codes. When testing the machine or
troubleshooting electronics, it may not be possible to perform Lockout/Tagout. In such cases, install a danger sign at all isolation
points, and rope off the area around the machine. Only qualified personnel should perform Lockout/Tagout procedure.
2.6 Perform a Lockout/Tagout

Key points:
Electrical power
Stored hydraulic pressure
Air supply
Test
1. Turn OFF Q1M Main Power and Q3M Motors Power disconnect switches on
the front of the electrical cabinet. Attach a lock and a tag each switch.
2. Verify all power to the machine is off using an ammeter that has been tested
on a known source.
3. Remove the cap on the gauge port marked PP6G in the power manifold
assembly.
4. Attach a hydraulic pressure gauge to the gauge port PP6G.
5. Turn the manual dump valve counterclockwise to ensure that the accumulator
is completely discharged.
6. Turn OFF the shutoff lever on the air regulator to remove the air supply to the
machine. Lock out the shutoff lever using a lock and tag.
Main Power
Q1M
Motors
Q3M
2 HyPET Safety
19
2 HyPET Safety
1. Complete the following chart:
Pressed when
Gate OPEN
Gate
Front Operator Door
=04 / S8LS
20

Pressed when
Gate CLOSED
=04 / S7LS
Alarm Message
Front Door Open
Operator Side Clamp

Access Door
Robot Conveyor
Door
Robot Vacuum Door
Purge Guard
C.E.N. Limit Switch
C.E.N. Prox Switch
Mechanical Safety
Device Limit Switch
Mechanical Safety
Device Prox Switch
2. At the machine, find one location for each of the following tags. Explain why the
tag was placed at that location:
Location:__________________________________________
Reason:__________________________________________
Location: __________________________________________
Reason:
__________________________________________
Location: __________________________________________
Reason:
__________________________________________
Location: __________________________________________
Reason:
__________________________________________
Location: __________________________________________
Reason:
__________________________________________
Location: __________________________________________
Reason:
__________________________________________
2 HyPET Safety
21
2 HyPET Safety
22
Activities on this page are normally performed as a group.
3. Locate the accumulator manual dump valve. Open the manual dump valve. Turn on the pump and attempt to close the mold. Is
motion possible with the manual dump valve open (circle correct answer)?
YES
NO
4. List two effects on machine operation if the dump valve is left open:
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
5. Locate the C.E.N. indicator on the Clamp Valve Status page on the HMI. Is the indicator on when the C.E.N. valve is open or closed
(circle correct answer)?
OPEN
CLOSED
6. List 4 locations that hot plastic can suddenly explode out of:
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
QUESTIONS
7. Which of the following safety mechanisms are used on the injection molding machine: electrical, hydraulic, mechanical?
a) electrical and hydraulic
b) electrical and mechanical
c) hydraulic and mechanical
d) electrical, hydraulic, mechanical
8. Observe the clamp valves status screen and observe the C.E.N. valve indicator. If the indicator is off (i.e. not white) it means:
a) the pump is not running

b) oil is being delivered to the clamp unit
c) the pump is running, all gates are closed but the switch on the C.E.N. valve has malfunctioned
d) the C.E.N. valve is closed
e) the C.E.N. valve is open
9. Will the moving platen close if the air supply to the machine is turned off?
a) yes
b) no
10. If the electricity supply to the machine is turned off, there are times when it is safe to unbolt and remove a hydraulic valve, or loosen
a hydraulic line fitting without first opening the accumulator manual dump valves.
a) true
b) false
2 HyPET Safety
23
2 HyPET Safety
24
3 Using the HMI
Objectives
Identify and explain the function of the 7 areas on the HMI
Manage User IDs
Use the Alarms screens to diagnose machine issues
3 Using the HMI
25
3 Using the HMI
26
3.1
7 Areas of the HMI
Key Points
Cycle Mode Keys

Robot Home Key
Robot Enable Key
Manual Function Keys
Message Bar
Status Bar
Toolbar
Sidebar Functions
Information Screens
3.1.1 Cycle Mode Keys

Key Points
Cycle Start
Auto
Semi
Manual
Robot Enable
Robot Home
Pump Motor On
Pump Motor Off
3.1.2 Manual Function Keys

Key Points
3 Using the HMI
Mold Open/Close
Unclamp/Clamp
Ejector Auto/Backward
Ejector Forward
Inject
Screw Rotate
Carriage Forward/Back
Mold Cooling
Valve Gate Open
27
3 Using the HMI
28
3.1.3 Message Bar
11:13:24 AM - Front Gate : Gate Open

Active
Inactive
Red
Gray
Yellow
Gray
Key Points
Most recent Alarm message
Machine Stop Alarm Active/Inactive
Machine Warning Alarm Active/Inactive
3.1.4 Status Bar

C
60 - 140
58 - 136
Pump off
Key Points
Pump off after 5 minutes
No Auto Cycle after 30 minutes
55 - 130
High Oil Temperature alarm
53 - 127
Normal operating temperature
47 - 116
Low Oil Temperature alarm
45 - 113
5 - 41
Oil temperature too low machine in oil warming

Pump off
Cycle Mode Indicator

Machine Cycle Time
Oil Temperature
Current User
3.1.5 Toolbar
Key Points
Normal
Dry Cycle
Screen Capture
Administration Utility
Calibration
Machine Function Mode
Alarm horn On/Off
HMI Configuration
User Log On/Off
Datakey (HPN 2280038)
Help (not available)
Auto Purge
Mold Set
Unload Pumps
Screw Change
3 Using the HMI
29
3 Using the HMI
30
3.1.5.1 HMI Configuration
Key Points
Password
Units
Language
Shifts
Others
3.1.6 Sidebar Functions

Display pre-programmed function groups
Key Points
Function Group / Status
Area of machine
Both Sidebars (left and right) have identical

functions
Sidebars can show:
- Process values
- Manual operation functions
- Pre-programmed function groups
- User-programmed function groups (2 user
function groups available)
- Programming the function groups is
accessed through User Group #2
Process or affected component
Process Value
User Groups
3 Using the HMI
31
3 Using the HMI
Alarm - Alarms M
- Events History M
- Reports Selection M
- Report View M
- Log Transfer P
Overview - Machine Specifications M
- CycleTime Breakdown M
- Graph M
Setup - Production Setup P
- Mold Setup P
- Mold Installation P
Clamp - Overview O
- Setup P
- Graph M
- Valves Status M
Options - Ejector/Core P
- Ejector Setup P
- Air P
- Valve Gates M
Extruder - Overview O
- Injection P
- Injection Graph M
- Recovery P
- Recovery Graph M
- Valves Status M
Heats - Barrel P
- Mold P
Robot - Production M
- Program Manager P
- Sequence Editor P
- Diagnostic M
- Settings M
SPC - Summary M
- Details P
- History M
- Group M
- Setup P
32
3.1.7Information Screens
Key Points
M -Monitor-level screens (no setpoints

which can affect process)
O -Operator-level screens (restricted variation in setpoints)
P -Process-level screens (full process control)
3.2 Manage User IDs
Key Points
3 Using the HMI
Users
Groups
Rights
Others
33
3 Using the HMI
34
Table 1: User Rights Summary

View
View Operator screens
Adjust sliders
Change Operator setpoints
Change Process setpoints
Calibrate machine
Switch languages and units
Manage machine users and rights
Recall mold setup parameters
Change machine
Change date and time formats
Set shifts
Install molds
Operator
Processor
Maintenance
Administrator
3.3 Using the Alarms screens
Key Points
Alarms
Events
Reports Select
Reports View
Log Transfer
3.3.1Alarms
Alarms are shown as active or inactive
3.3.2Events
3 Using the HMI
Event Count = number of events displayed

in current filtered list (20,000 maximum)
First column shows an appropriate icon
related to the type of event
Click on the title at the top of each column to
sort results by that column
<Filter> is designed to make it easier to analyze Events History
35
3 Using the HMI
36
3.3.3Reports Select
Left side of screen manages on-demand

reports
Right side of screen manages on-schedule
reports
3.3.4Reports View
Summary at end of report lists types of

events and frequency
3.3.5Log Transfer
Event Log - allows retention of Event History

Data Log - all SPC variables which are
tracked by the machine
Data Log (SPC) - SPC variables which have
been selected for monitoring
Transfer copies data to a floppy disk in a
.csv (comma-separated variable) file which
can be read by a spreadsheet program.
When a log is full, oldest entries are
dropped as new entries are added

1. Use the letters to identify the areas on the
HMI
A
B
C
D
E
F
G
H
Toolbar
Manual Function Keys
Message Bar
Information Screens
Sidebar Functions
Status Bar
Cycle Mode Keys
Sidebar Functions
2. Create the following user on the machine:

Name: morning crew
Password: husky
Access Level: Process
Login using the new user. Increase the tonnage
by 1T. Change the tonnage back to its original
value. Logoff.
3. Use the Event History screen to determine
which setpoint has been changed most
often in the last 3 weeks - __________
4. How many times has that setpoint been
changed? ______________
5. As a class, discuss the setpoint changes Are the number of changes reasonable? Do
any of the changes point to a maintenance
or process issue? What are some examples of situations where multiple setpoint
changes might be masking a problem?
3 Using the HMI
37
3 Using the HMI
38
4 Machine Services
Objectives
Identify the services supplied to the machine
Describe the function of each machine service
Locate the control and monitoring devices for each service
4 Machine Services
39
4 Machine Services
40
4.1
Identify Services Supplied to the

Machine
Key Points
Electricity (Lockout/Tagout location)

Air (Lockout/Tagout location)
Robot air (Lockout/Tagout location)
Becker vacuum pump air (Lockout/Tagout
location)
Process Water
Mold Cooling Water - Mold cooling water
supply specifications are dependent upon
the mold. Refer to the mold manual for
details.
4.2
Electricity
Key Points
4 Machine Services
Lockout
Process or machine monitor devices
- Limit/Proximity Switches
- Temposonic Rods
- Pressure Transducers
- Thermocouples
Machine control devices
- Pump Motor
- Variable Displacement Pumps
- Valves
- Screw Motor
- Barrel Heats
- Mold Heat
41
4 Machine Services
42
4.3
Supply
(70-150psi)
Auxiliary Functions
(Robot)
Air
Key Points
Regulator / Lockout
Filter
Pressure Switch
Water Saver valve
Hopper Open valve
Air Ejection or Valve Gates (optional)
4.4
Process Water
Key Points
4 Machine Services
Feed Throat
Hydraulic Oil
Robot
Extruder Motor
Pump Motor
Electrical Panel / Servo Drive cooling (large
systems)
Required Temperature/Flow/Pressure
Quality
Adverse effects from improper process
water supply
43
4 Machine Services
1. Which of the following is NOT a service supplied to the machine?

A C -
Hydraulic Oil
Process Water
B D -
Electricity
Chilled Water
2. When the machine has 3 main electrical disconnect switches, what do they control? (Circle 2 answers)
A C E -
Mold heating
Clamp functions
Machine functions
B D F -
Machine heating
Injection functions
Pump Functions
B D -
70psi
150psi
3. What is the minimum air pressure required?

A C -
0psi
90psi
4. Circle all of the following qualities which are important to cooling water.
A C E -
Inlet pressure
Inlet temperature
Flow
B D F -
Pressure drop
Outlet temperature
Amount of scale
Note: The next activities should be performed as a group at the machine.

5. Check the operation of the air pressure switch on the machine (full class activity).
6. Check for water in the air filter. Bleed if necessary.
7. Identify all devices which require cooling water.
8. At this machine, how can the operator determine that water pressure drop and
flow through the heat exchanger is adequate.
A C -
Not the responsibility of our operators

Pressure gauges
B D -
Flow switch
Not possible
44
4.5
Objectives
Explain the hydraulic oil conditioning circuit
Explain hydraulic oil distribution
45
46
5.1
Explain Hydraulic Oil Conditioning Circuit
Key Points
Hydraulic Oil
Oil Tank
Filter Pump
Oil Filter
Water Saver Valve
Heat Exchanger
5.2
Explain the Hydraulic Oil Distribution
Key Points
Pumps
Accumulator
C.E.N.
- closes when an operator door opens to
block all oil used for mold stroke motion
Clamp
- Clamp Piston
- Stroke
- Ejector/Cores
Injection
- Shutoff Nozzle
- Injection Piston
- Carriage
C.E.N
Carriage
47
48
6 Clamp Components
Objectives
Identify and describe the function of clamp components

Explain how clamp positions are measured and monitored
List the steps in the clamp cycle
Use the HMI setup screens to control the clamp cycle
Identify the valves which control the clamp
6 Clamp Components
49
6 Clamp Components
50
6.1 Identify and Describe the Function of Clamp Components
Key Points
Mold Cavity and Core

Platens (stationary and moving)
Mechanical Ejection
Tiebars
Clamp Column
Clamp Lock
Clamp Piston and Clamp Cylinder
Linear Bearing
6.1.1 Clamp Lock

Key Points
(1) Mold closes

Stepless shutheight adjustment is achieved
through a combination of the clamp piston
stroke and the column teeth pitch
(2) Clamp piston rotates 30 to lock on the
column
(3) High pressure oil is supplied to the cap

end of the clamp piston to provide clamp force
Oil is supplied to the rod end of the clamp piston to re-position it to home, and to provide up
to 10% of clamp tonnage for mold break
(4) The clamp piston rotates 30 to unlock
the column
(1) Mold opens and clamp piston resets
6 Clamp Components
51
6 Clamp Components
530.8
52
6.2 Explain How Clamp Positions are
Measured and Monitored
mm
Key Points
300
Clamp Piston Position

Shutheight Position
600
to
mm
10.0 mm
Stroke Position
0.0 mm
203.0 mm
Stroke Pressure
0.0 psi
Magnetic field
Excitation
field
Twisting pulse
Protective
tube
Waveguide
Position
magnet
Sensor head
Shutheight
Mold Stroke
Clamp Piston
Temposonic Rod
- Excitation field forms along entire
waveguide for 1-3 microseconds
- Interaction of magnet field and excitation
field causes a twisting strain pulse to form
on the waveguide. The pulse travels along
the waveguide at a known speed.
- Strain gauges in the sensor head detect the
twisting pulse when it reaches the end of the
rod
- The elapsed time between the formation of
the waveguide and the time that the pulse
reaches the sensor head indicates position
6.3 List the Steps in the Clamp Cycle
Start
Inje
c
(no tion U
t in
Dry nit
Cyc
le)
6 Clamp Components
53
6 Clamp Components
54
6.3.1 Mold Close
Key Points
Begins when Cycle Start is pressed (first
cycle) or when Mold Open timer is complete
(subsequent Auto Cycle)
Center Actuator (piston/cylinder)
High Speed, Low Force
Speed Controlled
Multiple Stages (if necessary)
Pressure controlled at end for Part Interference
1
2
2000 400 mm/s
340.0 170.0
0.0 mm
6.3.2 Clamp Up
Key Points
Tonnage
0.0
Mold Break
Clamp Piston Position
Shutheight Position
Begins when Stroke Position = 0mm

Clamp Lock
High Force
Short Stroke
Tonnage as required by mold design
212 T
3.6 mm
10.0 mm
203.0 mm
6 Clamp Components
55
6 Clamp Components
56
6.3.3 Wait for Hold Complete
Key Points
Bypassed in Dry Cycle
Injection occurs in two stages - Inject (speed/
position-controlled) then Hold (pressure/timecontrolled)
6.3.4 Cooling Time

Key Points
Cooling Time
0.00 1.00 s
Begins when last hold time is complete

The time while the part is on the core before
ejection is also cooling time)
Mold cooling water temperature and flow variations affect cooling time
Part quality is affected by cooling
6.3.5 Unclamp and Mold Break

Key Points
Begins when cooling time is complete
Decompress the clamp piston
Re-position the clamp piston for teeth clearance
Clamp piston continues to retract for mold
break
Clamp Lock off
Re-position the clamp piston to home
6.3.6 Mold Open

Key Points
Begins when Clamp Lock Off proximity switch
is made
Center Actuator (piston/cylinder)
Speed Controlled
Multiple Stages (if necessary)
6 Clamp Components
57
6 Clamp Components
58
6.4 Clamp Setup Screens
Key Points:
Overview
Setup
6.4.1 Overview
Key Points
Close Safety Decel

Part Interference
Tonnage
Cooling Time
Mold Break
Open Safety Decel
Mold Open Time
6.5 Clamp Setup

Key Points:
Low Pressure Start
Mold Break
6.5.1 Mold Close Theory

Key Points
Mold Close Decel
5000 mm/s2
Mold Close Final Speed
Low Pressure
Low Pressure Start

Mold Protection Time
20 mm/s
1300 psi
5.0 mm
1.00 s
Part Interference
0.6 mm
Speed
Pressure
6 Clamp Components
Mold Close Decel

- set a predicted value so the clamp can calculate stopping distance (higher numbers
mean the moving platen can stop quicker)
- if the value is too large, the mold halves may
slam together
- a low value may increase cycle time
- larger molds with more inertia may require a
lower Close Safety Deceleration
Mold Close Final Speed
- moving platen speed when the mold halves
come together
Low Pressure
- set a value which allows the moving platen
to stall if it encounters interference (instead
of crushing an obstruction into the mold)
Low Pressure Start
- pressure in the stroke cylinder is restricted
to the Low Pressure value at this point
- if the moving platen encounters an obstruction after this point, pressure will hold at Low
Pressure, stalling the movement of the moving platen
Mold Protection Time
- after the Low Pressure Start position is
reached, the moving platen has a set
amount of time to close, otherwise the Part
Interference alarm is triggered
Part Interference
- any obstruction smaller than this value will
not interfere with the cycle
- mold closing finishes at required pressures
59
6 Clamp Components
60
6.5.2 Mold Open Theory
Key Points
Mold Open Deceleration
4200 mm/s2
Mold Break
Mold Open Final Speed
Speed
0.0 mm
15 mm/s
Mold Open Deceleration

- set a predicted value so the clamp can calculate stopping distance (higher numbers
mean the moving platen can stop quicker)
- if the value is too large, the mold stroke may
not be able to stop at the Mold Open setpoint (the mold may slam into stroke limiters)
- a low value may increase cycle time
- larger molds with more inertia may require a
lower Open Safety Deceleration
Mold Break
- use the clamp piston to open the mold
(available force is approximately 10% of full
tonnage)
Mold Open Final Speed
- moving platen speed when the the mold
open setpoint is reached
6.5.3 Mold Close Profile

Key Points
6 Clamp Components
Low Pressure Start

Low Pressure
Mold Close/Open Deceleration
Mold Close/Open Final Speed
Part Interference
Tonnage
Cooloing Time
Mold Break
Mold Open Time
Mold Stroke Position
Mold Stroke Pressure
Shuheight Position
61
6 Clamp Components
62
6.6 Identify the Valves Which Control
the Clamp
Key Points
Mold Stroke
Ejector
Clamp Lock
- holds oil on the clamp side of the clamp piston when in auto to help maintain position
- holds tonnage on the clamp when clamped
in manual
Clamp

1. Identify the components:
A F -
Stationary Platen
Clamp Column
B G -
Clamp Lock
Tiebars
C H -
Moving Platen
Mold Core
D J -
Clamp Piston
Ejector rod
E K -
Clamp Cylinder
Linear Bearing
6 Clamp Components
63
6 Clamp Components
64
2. Select the correct order of buttons to manually cycle the clamp:
1
3. If a higher mold is installed in the machine (requiring greater shutheight) the maximum mold open position will
A -
increase
B -
decrease
C -
remain the same
4. On the machine used for this class, how many stages are used for Mold Close?
Why?
5. If a heavier mold is installed in the machine, the operator will probably have to:
A -
increase Safety Deceleration
B -
decrease Safety Deceleration
C -
make no changes to Safety Deceleration
6. Mold Open begins:

A -
when Hold is complete
B -
when the Clamp Lock Off prox is made C -
when the Cooling Timer is complete
7 Mold Functions
Objectives
Identify and describe the function of ejection components

Setup the Ejector
Setup Mold Functions
Setup Air Ejection
Setup Valve Gates
7 Mold Functions
65
7 Mold Functions
66
7.1 Identify and describe the function

of ejection components
Key Points
Cylinder
Piston
Rods
Plate
Temposonic Rod
7.2 Setup The Ejector

Key Points
Speed/Pressure/Position Control
Number of Strokes
Forward Dwell
7.3 Setup Air Ejection

Key Points:
Function (moving/stationary platen)
Start Trigger
- Mold Position
- End of Cooling
- Start of Cooling
Delay Time
Blow Time
Valve Status
7.4 Setup Valve Gates

Key Points:
7 Mold Functions
Open Trigger
Mold Open End
Mold Close Start
Open Delay
Neutral During
Close Delay
Valve
Status
67
7 Mold Functions
68
1. On the Ejector Setup screen, if the Number of Strokes is set to 3, the Forward Dwell time applies each time the ejector move foward.
A - True
B - False
2. To turn on Air Ejection before the mold has started to open, select the trigger:
A - Mold Position
B - End of Cooling
C - Start of Cooling
D - It is not possible
3. When using Valve Gates, the following conditions could cause drool at the mold gate:
A - Open Delay too long
B - Open Delay too short
C - Close Delay too long
D - Close Delay too short
E - A or C
F - B or D
G - B or C
H - Valve Gate operation does not affect drool
Objectives
Identify and describe the function of injection components

Explain how the carriage position is measured and monitored
Explain how the screw / injection piston position is measured and monitored
List the steps in the injection cycle
Use the HMI setup screens to control the injection cycle
Identify the valves used to control injection components
69
70
8.1 Identify and Describe the Function of Injection Components
Key Points:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Nozzle
Shooting Pot
Barrel
Plasticizing Screw
Feed Throat
Hopper Shutoff
Injection Piston
Transfer Cylinder
Gear Box
Extruder Motor
8.2 Injection Unit Components
Extruder Motor
Injection Manifold
Barrel Heats (Profibus)
71
Forward
72
8.3 Explain How Carriage Position is
Measured and Monitored
Key Points:
Contacting Sprue Bushing
Too Far Forward
Carriage Position
41.2
mm
Forward
43.0
mm
Too Far Forward
39.0
mm
Carriage Forward Position

Nozzle Contacting Sprue Bushing
Carriage Too Far Forward Position
Carriage Position Display
Carriage Piston
Temposonic Rod
Purge Area
8.4 Explain How Screw / Injection

Piston Position is Measured and
Monitored
Key Points:
Injection Pos.
Temposonic Rod
Carriage magnet
Injection magnet
Position display
0.4 mm
73
74
8.5 List the Steps in the Injection
Cycle
Recovery (RPM and Back Pressure controlled)

note 1: Nozzle will be open if Post-Pullback selected
Mold Closing - Carriage Forward, Nozzle Open
Pullback (decompress mold and manifold)

note 2: Will take place after recovery if Post-Pullback
selected
Wait for Mold Clamped
Hold (pressure controlled)

Injection (speed controlled)
8.5.1 Recovery
Key Points
Nozzle closed
RPM
Back Pressure
Shot Size
Mixing and Compression
Process Heat
1
50 rpm
0.0
53.0 mm
45 psi
75
76
8.5.2 Injection
Key Points
Shutoff Nozzle Open
Check Valve Closed
Speed/Position Controlled
37.0
113.0 mm/s
21.0
53.0 mm
8.5.3 Hold
Key Points
Shutoff Nozzle Open
Check Valve Closed
Pressure/Time Controlled
2600
0.5
780 psi
1.5 s
8.6 Use the HMI Setup Screens to

Control Injection Cycle
Key Points
Overview
Injection
Recovery
8.6.1 Overview
Key Points
Shot Size
Fill Speed
Transition
Hold Time, Hold Pressure
Pre- and Post-Pullback Distance
Screw Speed
Back Pressure
77
78
8.6.2 Injection Profile
Key Points
Screen design follows screw orientation (left
to right motion)
Injection Profile (graph)
Injection Profile (fields)
Hold Profile (graph)
Hold Profile (fields)
8.6.3 Injection Control

Transition
- Time
- Position
- Hydraulic Pressure
- Cavity Pressure
- Pressure Enable Position
Cushion
Cushion Control
Cooling Time
Maximum Fill Pressure
Excess Injection Time
Feedback
- Injection Position
- Fill Speed
- Fill Pressure
- Shot Size
8.6.4 Recovery Profile

Key Points
Screw RPM
Back Pressure
Profile Graph
Profile Fields
Pre-Pullback (decompress mold and manifold
before Recovery)
Post-Pullback (use Back Pressure during
Recovery as additional Hold time/pressure)
Hopper Open
Screw Rotation Delay (after Pullback)
Auto Purge Cycles
Nozzle Shutoff Enable (maintain Nozzle
Open)
Nozzle Open Delay (after the start of Mold
Close)
Carriage Forward
- At Mold Close
- At 10% Tonnage
- At Tonnage
- Maintain
Sprue Break (Sprue Break will be automatically 0mm with Maintain Carriage Forward)
79
80
8.7
Identify the Valves Used to Control Injection Components
Key Points:
Injection servo valve
Carriage Forward/Back digital valves
Nozzle Shutoff digital valve
8.8
1. Identify the following components
A - Feed Throat
F - Plasticizing Screw
B - Shooting Pot
G - Injection Piston
C - Hopper Shutoff
H - Transfer cylinder
D - Barrel
I - Extruder Motor
E - Gear Box
J - Nozzle
2. The carriage position when it is contacting the sprue bushing on a particular machine is 36.2 mm. Fill in the fields shown with appropriate values.
Carriage Position
mm
Forward
mm
Too Far Forward
mm
81
3. Put the parts of the Injection Cycle in the correct order:

___ Pullback
___ Hold
1 Recovery
___ Injection
___ Nozzle Open
4. During Hold, plastic:

A - continues to enter the mold as the plastic shrinks
B - decompresses the mold by flowing back through the sprue bushing
5. For the mold shown, the injection speed when the plastic is flowing through section 1 should be:
A - faster than section 2
B - slower than section 2
C - the same as section 2
6. Changing the transition point so that it occurs earlier in the cycle will tend to:
A - Increase part weight
B - Decrease part weight
C - Have no effect on part weight
7. In order to maintain the Shutoff Nozzle open:

A - Check Nozzle Shutoff Enable
B - Uncheck Nozzle Shutoff Enable
82
9 Machine Heats
Objectives
Identify and describe the function of Machine Heat components
Identify and locate all Machine Heat zones
Use the HMI setup screens to control the Machine Heats
9 Machine Heats
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9 Machine Heats
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9.1 Identify and Describe the Function of Machine Heat Components
Key Points:
Barrel
Heater Band
Thermocouple
Thick heat-insulating backing

Thin, heat-conducting
inner layer
Stainless-steel
sheath
Coiled heater
element
Electrically-insulating,
heat-conducting mineral layer
around heater element
9.2 Use the HMI Setup Screens to

Control Machine Heats
Key Points:
Barrel Setup Screen

Mold Setup Screen
Nozzle Tips Screen
Machine Heats Setup Screen
Heats Scheduler Popup Screen
9.2.1 Barrel Setup Screen

Key Points:
Machine Heats Enable
Resin Temperature
9 Machine Heats
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9 Machine Heats
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9.2.2 Mold Setup Screen
Key Points:
Mold Heat Zones
Mold Heats Enable
Global Control
9.2.3 Nozzle Tips Screen

Key Points:
Mold Heats Enable
9 Machine Heats
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9 Machine Heats
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9.2.4 Heats Setup Screen
Key Points:
Machine Heats
- Machine Heats Enable
- Soft Start
- Self Tune
- Use Heat Scheduler
- Soak Time
- Standby
- M/C Idle Standby Delay
Mold Heats
- Mold Heats Enable
- Soft Start
- Self Tune
- Use Heats Scheduler
- Soak Time
- Standby
- M/C Idle Standby Delay
Nozzle Tip Heats
- Nozzle Heats Enable
- Soak Time
Global alarms
click
9.2.5 Setup Machine Heats

Key Points:
High Alarm (absolute) or High Deviation (calculated range) triggers Heat Contactor off
Low Alarm (absolute) or Low Deviation (calculated range) inhibits extruder functions
Soft Start is used to reduce heater band failure
At the conclusion of Soft Start, normal heats
control is restored
Auto Control allows the controller to attempt
to maintain the setpoint
Manual Control (where available) allows the
operator to set the Heat On %
Auto Tune allows the controller to re-calculate
Heat control settings to reduce hunting
around setpoint
High Deviation
Setpoint (target)
Low Deviation
k
clic
Global (all zones)

change to displayed
settings
k
clic
Min/Max Value
550
0
Thermometer
Display
Range
9 Machine Heats
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Mon
Tue
9 Machine Heats
Wed
Thu
Fri
Sat
Sun
90
9.2.6 Heats Scheduler Popup Screen
Barrel
Key Points:
Mold
Use
ON
OFF
Setting 1
Monday
Monday
20
Setting 2
Tuesday
Tuesday
20
Setting 3
Wednesday
Wednesday
20
Setting 4
Thursday
Thursday
20
Setting 5
Friday
Friday
20
Setting 6
Saturday
30
Saturday
30
Setting 7
Sunday
30
Sunday
30
Week-at-a-Glance
Current date/time indicator
7 programmable zones
Program the machine heats based on production shifts and process requirements
6
9
8
2
1
10
1. In order to open the Soft Start Control settings window, select item ________
2. If the heat zones are not able to maintain precise temperatures, try selecting item ________
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3. To limit the minimum temperature for extruder operation for a specific zone, select item ________
4. The main heat contactor will turn off if the High Alarm is triggered.
True
False
5. The main heat contactor will turn off if the high deviation for a specific zone is triggered.
True
False
6. To set the Soft Start Soak Time, select item ________
7. The 15% value for Extr. 1 means:

a) the temperature is within 15% of the setpoint
b) the heater is on at 15% of rated amps
c) the heater is on for 0.15 seconds, off for 0.85 seconds
d) the heater is manually set to cycle at 15%
8. To change the visible range of the thermometer, select item ________
9. When Standby is selected, all barrel zones will be reduced

a) by 175oF
10. If Extr.1 is set too low, Extr. 2 may run too high
b) to 175oF
True
False
10 CoolPik and Tooling Plate
Objectives
Identify and understand CoolPik operation

Identify and understand Tooling Plate operation
HyPET Mold/Tooling Installation
Tooling Plate Removal
Interpret Setup Screen
HyPET CoolPik Sensor Set-up and Adjustment
Pre-stretching the Air Pickers
Installation of Air Pickers
CoolPik and Tooling Plate
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94
10.1 CoolPik
Key Points:
(1)
CoolPik removes preforms from tooling plateand transfers preforms to conveyor.

CoolPik Bladder, air picker (1)
CoolPik Rotation
- Vertical
- Horizontal
CoolPik Rotation Speeds
- Auto/Manual
- Jog
- Mold Position for CoolPik Safe to Rotate
Fiber Optic Part Detection (2)
Fiber-optic Connections
(2)
(1)
10.2 CoolPik Cooling Fans / C-Axis

Motor
Key Points:
(2)
CoolPik in drop position over fiber-optic cable

(1)
Cooling fans (2)
C-Axis Motor (3)
(3)
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96
10.3 Tooling Plate

Key Points
(1)
Tooling Plate In/Out Speeds

- Auto/Manual
- Jog
Machine Protection
- Tooling plate photo-eyes (1)
- Mold Position for Tooling Plate Safe to Enter
- Ejector Position for Tooling Plate Safe to
Exit
Tooling plate photo-eye reflectors
10.4 CoolPik / Tooling Plate Setup

Screen
Key Points
Tooling Plate In/Out
- Wait Position
Stage Enabled
- In Position
- Out Position
- Occupied
- Vacuum
- Air Blow
- In
- Out
CoolPik Bladder
- Part Drop Duration
CoolPik Rotation
- Vertical
- Horizontal
CoolPik Rotation Speeds
- Auto/Manual
- Jog
Tooling Plate In/Out Speeds
- Auto/Manual
- Jog
Machine Protection
- Mold Position for Tooling Plate Safe to Enter
- Mold Position for CoolPik Safe to Rotate
- Ejector Position for Tooling Plate Safe to
Exit
97
98
10.5 Diagnostic Screen

Key Points
Machine Status
- Mold Open
- Mold Closed
- Ejector Retracted
- Ejector Forward
- No Part Available
- Ready for Part Pick
Tooling Plate
- Cooling
- Vacuum Relief
- Tooling Plate In/Out
CoolPik
- CoolPik Rotation
Product Handling Status
- Permit Mold Close
- Permit Clamp Motion
- Permit Ejector Forward
- Permit Ejector Back
Conveyor
- Forward
- Reverse
Photo Eyes Clear
- Tooling Plate
- CoolPik
- Mold
10.6 Sequence Screen

Key Points
Product Handling Sequence
- Mold Cooling
- CoolPik Bladder Inflated
- Vacuum Off, Air Blow and Mold Open
- Check Tooling Plate Photo Eyes Clear
- Vacuum ON
- Mold Open at Tooling Plate Safe to Enter
- Tooling Plate to in stage Position
- Mold Open at CoolPik Safe to Rotate
- CoolPik to Horizontal
- Ejector A Forward
- Ejector Retracted
- Tooling Plate to Out Stage Position
- Check CoolPik Photo Eyes Blocked
- CoolPik Bladder Deflated
- Check CoolPik Photo Eyes Clear
- CoolPik to Vertical
- Permit Mold Close
99
100
10.7 Configuration Screen

Key Points
Part Drop Signal
Tooling plate photoeyes and CoolPik photoeyes enable
Mold photoeyes enable
Mold sensor enable
10.8 HyPET Mold/Tooling Installation

1. Place the machine in Mold Set mode.
2. Install the mold.
3. Open the shutheight enough to work inside (approximately). Some molds may require installation of the core side and the cavity side
in separate operations.
4. Perform machine clamp calibration (must be done before the CoolPik calibration).
5. Calibrate CoolPik axis without CoolPik plate. Once the calibration is complete the axis will rotate to the setpoint of 90 degrees, which
will be approximately vertical orientation.
6. Calibrate tooling plate axis without the tooling plate installed.
7. Move the tooling plate carriage to maximum in-mold nominal position.
WARNING!
Complete the Lockout/Tagout procedure in accordance with applicable local codes before performing maintenance
activities. Failure to do so can result in injury or death.
8. Lockout / Tagout the machine.

9. Open the gates, move tooling plate carriage by hand and install alignment pin through the tooling plate carriage casting into the beam
(this locates the stage 1 IN position for the system for any mold).
10. Save this exact position in the software/program. Stage 2 and 3 positions are calculated from the stage 1 position.
11. Remove the alignment pin and close the gates.
12. Remove Lockout / Tagout. Removing Lockout/Tagout, page 1-16.
13. Move the tooling plate axis out of molding area until the tooling plate mounting face on the carriage is adjacent from the outer vertical
edge of the plenum (the carriage will be approximately 200mm from the outboard bumpers).
14. Close the mold/moving platen until the shutheight is approximately 700mm.
NOTE: This step must be performed without the tooling plate attached to the carriage, or CoolPik plate attached to the plenum casting.
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102
16. Measure the horizontal distance from the tooling plate mounting surface of the carriage to the CoolPik plate mounting surface of the
plenum casting at the locations of the two dowels. Measure dimensions A and B.
17. Remove Lockout / Tagout.

18. If the difference between dimensions A and B is larger than 4mm, return to the HMI and rotate the plenum assembly in the appropriate direction until the difference in the two dimensions is less than 4mm. Repeat until successful.
20. Open the mold.
WARNING!
Inadequate lifting equipment can fail and cause injury or death. Make sure the lifting eye bolts, chains/slings and
lifting device are rated for the load and in safe operating condition.
WARNING!
Crushing hazard - risk of death or serious injury. Do not work under suspended loads. To prevent injury, install
safety blocks.
21. Use a crane of sufficient capacity to lift and lower the tooling plate/CoolPik plate assembly into the machine.
NOTE: The following procedures on mold installation require the use of a crane, make sure the lifting eyebolt, lifting chain and crane can
support the weight of the plate(s).
NOTE: In some cases, it could be necessary to remove the dehumidification tent/top guard or other components that might interfere
with the crane or mold being hoisted.
22. Position the tooling plate/CoolPik plate assembly (dowel/pinned together) and install entire assembly onto the z-carriage. Torque all
mounting screws to the required specification. Refer to Recommended Torques.
23. Install the coolant hose assembly to the manifold. Torque all mounting screws to the required specification. Refer to Recommended
Torques.
24. Remove the lifting chain and crane.
25. Move/jog the tooling plate carriage to the approximate outer position where the 14 mounting holes in the CoolPik plate are aligned
with the plenum casting. More adjustments can be made later when
the plenum is brought closer to the tooling plate CoolPik plate
assembly.
27. Check that the machine is in Mold Set mode.
28. Close the mold slowly until there is a 15mm gap between the mold
parting lines.
REMINDER: The CoolPik plate is still doweled/attached to the tooling
plate.
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104
29. Check that the CoolPik plate holes are aligned with the plenum casting. If adjustments are required, the entire tooling plate carriage
with attached tooling plate/CoolPik plate assembly can be moved by hand for adjustments.
30. The HMI software set-up procedure will then request the operator to release the C-Axis/ CoolPik servo brake.
31. The HMI software set-up procedure will then allow the operator to close the mold the remaining 15mm, while the c-axis/CoolPik servo
brake is still released. This will re-align the plenum casting to some degree.
WARNING!
33. Open non-operators side conveyor bi-fold door.
34. Loosen the 4 mounting screws on the back of the tooling plate to the spacer blocks by roughly 5mm to allow the tooling plate and
CoolPik plate to separate (by 5mm).
35. Install the M10 mounting screws through CoolPik plate to the plenum casting along the non-operators vertical edge. Since the servo
brake is released, the plenum will be able to rotate to an angle which is perfectly parallel to the tooling plate. As these M10 screws are
tightened, the CoolPik plate will slide 2mm along the 4x spacer block screws towards the plenum casting.
36. Torque CoolPik mounting screws to required specifications. Refer to Recommended Torques.
37. Remove completely the 4 mounting screws securing the Coolpik plate to the tooling plate.
38. Install the air connection to the side of the CoolPik plate. (1)
39. Save this CoolPik servo angle into the software/program. This is the exact repeatable
angular position for every cycle. The calibration is only accurate to within 2 degrees. This
procedure improve the angular accuracy to less than 0.1 degrees.
40. Close the gate.
42. Reactivate the C-axis servo brake according to the HMI software set-up procedure.
43. Open the mold/moving platen to allow access to the CoolPik plate.
(1)
WARNING!

45. Open non-operators side conveyor bi-fold door, insert and tighten the remaining M10 bolts securing the CoolPik plate to the plenum
casting. (i.e. the upper and lower horizontal and the inner vertical bolts of the CoolPik plate). Torque CoolPik mounting screws to
required specifications. Refer to Recommended Torques.
We now have all 3 critical locations:
IN position for stage 1 (same for all molds), for transfer of preforms from mold to EOAT (tolerance +/- 0.1mm)
OUT position for stage 1 (varies according to the mold & cavitation), for transfer from the tooling plate to the CoolPik (tolerance +/0.2mm)
ANGLE for optimal part transfer from tooling plate to CoolPik (tolerance +/-0.1 degrees to achieve locational tolerance of +/- 0.2mm)
NOTE: ANGLE for preform drop off from CoolPik is not important except possibly with singulator applications. A 90 degree rotation is
usually prescribed.
47. Move the tooling plate into the molding area.
48. Insert the tooling plate alignment pin into the cavity plate locating hole. This check can be performed in all 3 positions, if the pin fails
to locate in position 1, repeat in positions 2 or 3.
NOTE: If the pin fails to align with the cavity plate in any position, contact your nearest Husky Service Center.
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106
10.9 Tooling Plate Removal
WARNING!
WARNING!
Inadequate lifting equipment can fail and cause injury or death. Make sure the lifting eye bolts, chains/slings and
lifting device are rated for the load and in safe operating condition.
WARNING!
Crushing hazard - risk of death or serious injury. Do not work under suspended loads. To prevent injury, install
safety blocks.
NOTE: The following procedures on mold installation require the use of a crane, make sure the lifting eyebolt, lifting chain and crane can
support the weight of the plate.
NOTE: In some cases, it could be necessary to remove the dehumidification tent/top guard or other components that might interfere
with the crane or mold being hoisted.
2. Use a crane of sufficient capacity to remove the tooling plate from the machine.
3. Shutoff the coolant supply line.
4. Remove the coolant supply hose assembly from the tooling plate manifold.
5. Remove mounting screws from the tooling plate.
6. Insert one of the mounting screws into each dowel hole, these holes are threaded,
and will act as a jacking hole on the top of the hardened dowel. Any other method
of pulling the tooling plate off the carriage is not recommended.
7. Remove the tooling plate from the machine.
10.10 CoolPik Sensor Set-up / Adjustment

CAUTION!
These steps are to be performed after installing the CoolPik plate. Ignoring this procedure may lead to significant
equipment/tooling damage.
2. Remove two orange sensor shields from upper and lower side of CoolPik plenum casting.
3. Based on the horizontal pitch of the desired mold and tooling plate.
a. Remove the mounting screws and relocate the individual sensor plates (which hold the fiber optic lenses) to the matching horizontal pitch locations.
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108
b. A label is provided to identify the different horizontal pitches 'A' through 'F'. The gray plastic wire duct can be removed to re-route
the fiber optic cables.
c. When changing the number of columns being used, only move the inner sensors, instead of the outer sensors i.e. when going from a
6-column mold to a 4-column mold, relocate sensors #2, 3, 4 and 5, and ignore sensors #1 and #6 in the software. The location of the
bladders on the CoolPik plate should be used as reference.
4. After the sensor plates are mounted in the correct pitch locations, inspect the location of the sensor vertical line-of-sight with the bladder/cooling pins.
5. Adjust/slide the entire aluminum mounting plate so that:
a. the sensor line-of-sight is not blocked by the cooling pins,
b. at the same time the line of sight is blocked by the presence of
that particular perform on the bladder/cooling pin. The sensing
diameter is approximately 5mm, varying with distance (machine
size).
6. Open the translucent cover (1) of each sensor amplifier unit (mounted on the rear lower side of the plenum casting) to access the dial
(2).
(1)
(2)
7. Adjust the sensor sensitivity/range by turning the orange dial counter-clockwise to decrease sensitivity (full range is 1 to 8).
8. Remove any performs on the bladder/cooling pins.
9. Reduce the sensitivity/range (3) of each sensor amplifier until the LED bars
(4) diminish to the last green bar, then turn up the sensitivity/range one half
rotation until the LED bars return to maximum.
10. Insert a single preform only on any bladder in that sensor column.
11. Confirm that the LED bars have diminished to the last green bar.
12. Remove the preform and confirm that the LED bars have returned to maximum.
13. Repeat steps 7 to 12 for each sensor amplifier.
(4)
(3)
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110
10.11Air Picker Maintenance
10.11.1 Pre-Stretching the Air Pickers

Pre-stretching of the air pickers should be performed with all pickers (on a new Cooljet plate) or when pickers are replaced individually.
1. Adjust the air pressure for the air picker, turn the cap (1) until air pressure has reached 50 - 55 psi.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Start up the mold, do not engage the tooling plate/CoolJet at this time.
Run machine until part quality is achieved.
Allow process to start transfer of parts into the tooling plate.
Confirm that all preforms have transferred to the tooling plate, by making a visual observation.
If intentionally a specific cavity is not being shot, the corresponding picker pin with air picker should be removed and plugged with appropriate M(X) bolt.
If unintentionally a preform has not transferred, the corresponding picker pin with air picker should be removed and plugged with appropriate M(X) bolt.
Run the mold for 20-30 cycles.
Adjust the air pressure for the air picker, turn the cap until air pressure has reached 45 - 50 psi.
Run the mold for 150 cycles.
Adjust the air pressure for the air picker, turn the cap until air pressure has reached 40-45 psi.
Run the mold for 200 cycles.
Adjust the air pressure for the air picker, turn the cap until air pressure has reached 35-40 psi.
Production can now be started.
Check that during steps 2 to 12, air pickers are not inflating without a preform.
If preform removal is not affected, lower pressure by 2-3 psi every 3000-5000 cycles.
NOTE:
Air pressure must be set to run as low as possible (below 30psi) to prevent the air picker from bursting, if not supported by preforms.
10.11.2 Installation of Air Pickers
WARNING!
2. Locate worn air picker (1).
3. Unscrew the picker pin from Cooljet plate.
4. Remove the existing air picker from the picker pin (2).
5. Install new air picker.
6. Reinstall Picker pin to CoolJet plate.
(2)
(1)
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112
Objectives
Perform the required steps to safely startup the machine
Monitor machine conditions during operation
Perform the required steps to safely shutdown the machine
113
114
11.1 Filling the Manifold

The amount of plastic in the runner system is usually in the order of 1 to 2 times the shot volume, which means that only after several
injections there will be plastic reaching the cavity.
To fill the manifold:
1. Close and clamp up the mold.

2. Close the mold valve gates.
3. Bring the injection unit forward against the mold sprue bushing.
4. Manually inject material to charge the manifold and replace any material that may be missing. Watch the injection piston and as soon
as the piston slows down release the injection button.
5. Start the extruder and ensure the extruder screw retracts to its back set point.
11.2 Manual Mode Start-up

1. Ensure Dryer is loaded and adjusted to the proper operating temperature.
2. Ensure mold enclosure de-humidifier, air compressor and tower water supplies are ON.
3. Ensure Chiller is on and adjusted to the proper operating temperature.
4. Turn ON the Mold Cooling.
5. Turn Machine Heats ON.
Machine Heats Enable
6. Turn the Mold Heats ON (manifolds and sprue bushing) to the specified start up set points as indicated in the setup guide, approximately 45 minutes before running the system.
Mold Heats Enable
115
7. Turn HYDRAULIC PUMP ON.
8. Turn ROBOT POWER ON.

9. Ensure all relevant alarms on the Alarm screen are reset.
10. Open the mold.
116
11. Turn HYDRAULIC PUMP OFF.
WARNING!
Do not look directly into the cavity. When working in the molding area ensure personnel are wearing the correct personnel protection equipment. Unexpected release of resins may cause serious burns.
12. Check that all mold cavities and surfaces are clean and free of plastic debris.
13. Allow all the Machine Heats to reach their operating temperature.
14. When the Mold Heats have reached their setpoint, enable the valve gate air selection.
15. Allow the mold heats to remain at the start up temperature for 15 minutes before running the system.
16. Start the HYDRAULIC PUMP.
17. Open the feed throat of the hopper.
Hopper Open
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118
18. Start the SCREW and make sure it fully recovers to the Extruder Back Setpoint.
WARNING!
Explosion hazard - risk of serious injury. Molten material at high pressure can be present. Wear PPE. Clear the
area of all non-essential personnel. Never purge the barrel when the nozzle tip is outside the purge guard.
20. Purge the shooting pot. Immediately afterward, start the screw as the screw begins the transfer motion.
21. When the screw has recovered again, repeat the purging procedure until the purged melt quality is visually acceptable and free of
bubbles and degradation.
CAUTION!
If the hot runner is equipped with 268W heaters, (identified by label on hot runner backing plate) the machine heats should be
set according to the Set-Up Guide. Failure to do so will cause severe damage to the hot runner.
22. Start the Mold Nozzle Tip Heats at set point and time referenced in the SET UP GUIDE - "Mold Start up Parameters". Allow the mold
nozzle tip heats to soak for a minimum of 5 - 7 minutes.
WARNING!
Burn hazard - risk of serious injury. While purging plastic, there is a danger of hot plastic spraying from the
nozzle and causing burns. Make sure the injection area is clear of personnel and wear PPE to guard
against burns.
23. During Nozzle Tip Heat up time, remove purged plastic from the machine and ensure the mold sprue bushing is free of plastic buildup.
24. Close the MOLD and CLAMP-UP.
25. Select MAINTAIN CARRIAGE FORWARD.
26. Press CARRIAGE FORWARD until the machine nozzle tip contacts the mold sprue bushing.
27. Check the VALVE STEMS are energized closed. Manually INJECT into the hot runner to "pre charge". Immediately after the injection piston stalls, release INJECT and start the SCREW.
28. Open the mold
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120
29. Disable Cycle Compression.

30. Decrease Injection Pressure Limit to 1000 psi/70 bar.
31. After the Nozzle Tip heat up time has expired, perform the following:
A. Press SEMI. Make sure Ejector is disabled (light off). Press CYCLE START.
B. After cycle is complete, switch to MANUAL and ensure all preforms have been properly molded (If not, clean cavities as necessary).
C. Eject preforms off cores. Ensure all preforms have been ejected (If not, clean cores as necessary).
D. Repeat Steps A to C until all preforms have been properly molded and ejected.
11.3 Switching to Semi Automatic

Mode/Robot Engagement/Auto
1. When satisfied with manual mode conditions, set the machine to semi-automatic mode.
2. Push mold close to begin the start of one cycle, ending with the mold in the open position.
This step may be repeated many times to:
a. Become familiar with the machines sequence of events,
b. Flush out any material in the hot runner.
Robot Engagement
1. Check that the tool plate and CoolPik are clear of preforms.
2. Select, Robot Engage on the HMI.
3. Confirm ejector is in Auto mode.
4. Select, Core Air Blow Automatic mode.
5. Select, Semi Automatic Cycle mode.
6. Press cycle start two times.
Cycle Start process:
a. Press once, CoolPik goes to home position.
b. Press second time, mold closes.
7. Perform 3 semi automatic shots.
8. Select Auto.
9. Press Cycle Start.
Switching to Automatic Mode

1. Switch to fully automatic mode when satisfied with the semi-automatic function. This switch can be used to start a cycle (from manual
or stopped position - end of semi-automatic) or while the machine is in mid-cycle (e.g. while the machine is in the middle of a semiautomatic cycle).
NOTE: It is necessary to press mold close to initially close the mold. With the machine running fully automatic mode, changes to the
set-up or processing can be made.
2. Set manifolds, sprue bushing and tip temperatures to operating levels as recommended in the Set-UP Guide, once auto cycling
begins.
3. Monitor to create an optimum preform.
4. Settings should be adjusted to the most efficient setting achievable, without freezing off any of the gates. See Power Fluctuation,
page 2-7, regarding the need for a constant supply voltage to maintain the gate operating quality.
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11.4 Monitor Machine Conditions

during Operation
Key Points
Cycle Time Breakdown
Graph Screens
- Overview
- Clamp
- Injection
- Recovery
Valves Status Screens
- Clamp
- Injection
- Mold Functions
Statistical Process Control (SPC) - see Husky
course T0401 - Statistical Process Control
11.4.1 Cycle Time Breakdown

Machine Specifications
CycleTime Breakdown
Start
Mold Closing
Shutter In
Clamp Up
Unclamp
Shutter Out
Mold Opening
Ejector Forward
Ejector Back
Mold Open
Cooling
0.00
0.27
0.38
4.34
4.57
4.67
5.00
5.96
5.22
3.34
Carriage Forward 0.46
Nozzle Open
0.92
Injection Fill
1.02
Injection Hold 2.23
Pre-Pullback
0.00
Screw Run
5.94
Post-Pullback 0.82
Cycle Time
0.00
0.27
0.10
0.22
0.23
0.10
0.54
0.76
0.31
1.06
1.00
1.52
0.10
1.20
1.10
0.00
117
0.09
6.28
0.27
0.10
0.21
0.24
0.10
0.54
0.76
0.31
1.06
1.00
1.52
0.10
1.21
1.10
0.00
1.17
0.10
6.28
0
4.0
Current
Saved
Cycle Time Limit 10.00 s
Key Points
Start and Duration
Duration
0.00
0.27
0.38
4.34
4.58
4.68
5.01
5.97
5.23
3.34
0.46
0.92
1.03
2.23
0.00
5.94
0.82
0.00
Graph
10/19/00 10:48:46 PM
8.0
Part
Removal Process Clamp
1.06
3.74
1.48
Process
59.6%
Clamp
23.2%
Checked boxes - event has occurred in current cycle

Red event - event which is in progress
Green values - saved when cycle has been
properly setup, producing good parts
Red values - current cycle
Display Options (pulldown list)
- Start and Duration
- Duration
- Start
- Name Only
Pie Chart
- Clamp: Cycle Time - Process Time - Part
Removal Time
- Process: (Start of Cooling + Cooling Duration) - (Start of Clamp Up + Clamp Up
Duration)
- Part Removal: Mold Open Duration
Part Removal 16.9%
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11.4.2 Overview Graph

Key Points
Plotting Control Keys (Run, Pause, Stop)

Cursor Display Key
Curve Selection
Graph Properties (visible grid, plot direction)
Plot Configuration (color, width, style, scale
for individual lines)
Sample Selection
- Time - single cycle or multiple cycles
- Position - based on position of moving
platen (if Stroke Position is displayed) or
injection piston (if Injection Position is displayed)
Stroke Pressure
Injection Pressure
Stroke Velocity
Injection Velocity
Stroke Position
Injection Position
Clamp Tonnage
Screw RPM
11.4.3 Clamp Graph

Key Points
Mold Closing
Mold Opening
Clamp
Current Cycle
Saved Cycle
Current Values
Display Legend
125

11.4.4 Injection Graph
Key Points
Hold Curves
Inject Curves
Current Cycle
Saved Cycle
11.4.5 Recovery Graph

Key Points
Screw Speed
Back Pressure
Screw Position
126
11.4.6 Valves Status

Key Points
Devices
- Y - Valve
- S - Switch
- B - Sensor
- P - Pump
Valves
- DQ - Digital Speed
- DP - Digital Pressure
- SD - Servo
Feedback Devices
- PX - Proximity Switch
- PT - Pressure Transducer
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128
11.5 Shutdown
1. If system downtime is expected to be more than half an hour, decrease the Dryer temperature to approximately 120C/250F.
If system downtime is expected to be more than 3 hours, decrease the Dryer temperature to approximately 80C/175F. Consult with
your resin supplier for recommended settings.
2. Immediately after completing step 1, close the feed throat of the hopper.
3. Allow the machine to run 2 cycles, then perform the following:
A. Switch to SEMI mode.
B. Press CYCLE START.
C. Repeat Steps A and B until the shotsize no longer recovers.

4.When the last cycle has been completed, switch to MANUAL mode.
5. If system downtime is expected to be less than one half hour, Enable Mold Heats Stand-By to 180C/350F. If system downtime is
expected to be more than half an hour, turn Mold Heats OFF.
WARNING!
Burn hazard - risk of serious injury. While purging plastic, there is a danger of hot plastic spraying from the
nozzle and causing burns. Make sure the injection area is clear of personnel and wear PPE to guard
against burns.
6. Press CARRIAGE RETRACT until sufficient clearance for purging has been reached, then purge any remaining material from the
Shooting Pot/Screw.
7. If system downtime is expected to be less than half an hour, Enable Machine Heats Stand-by to 180C/350F. If system downtime is
expected to be more than half an hour, turn Machine Heats Off.
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130
8. Disable the valve gate air selection.
9. Extend Ejector plate forward.
10. Turn OFF Hydraulic Pump.
WARNING!
11. Lockout / Tagout the machine power source.

12. Clean out any water or small pieces of plastic on the mold. If system downtime is expected to be longer than 6 hours, spray the
molding surface with petroleum based spray, i.e. LPS2, to prevent corrosion.

14. Turn ON Hydraulic pump.
15. Retract Ejector plate.
16. Leave the mold open with the dehumidification system running. Continue to circulate cooling through the mold and machine with
gates closed.
17. When the hot runner temperature is below 100C/212F, turn OFF mold cooling and/or chiller.
18. When the mold reaches room temperature, and no condensation appears on mold, close the mold (do not apply clamp tonnage).
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132
19. Turn OFF Hydraulic Pump.
20. Turn OFF tower water supply and air compressor as necessary.
21. Turn OFF mold enclosure dehumidifier when the mold reaches room temperature.
WARNING!
22. Lockout / Tagout the machine power source.

1. Perform all steps to safely startup the machine
2. Perform all steps to safely shutdown the machine.
3. On the Mold Setup screen, how many Setups have the same Mold ID and the same Resin Type? __________
4. Save the current Setup to an empty slot in the Machine Memory. Save the current Setup to an empty slot in Portable Memory.
Copy a Setup from the Machine Memory to an empty slot in the Portable Memory. Delete the Setup which you saved to the
Machine Memory.
5. Capture the Cycle Breakdown screen from the machine. The instructor will display the screen on the projector, use the screen to
answer questions 6-10.
6. How is the machine performing as compared to the saved cycle?
Worse
Same
Better
7. Which event takes the longest amount of time to perform? _______________

8. Does the ejector forward motion start before the mold is open? YES NO
9. What percentage of the cycle is used for Mold Opening and Closing? ______
10. If the Cycle Breakdown for the current cycle is different from the saved cycle, discuss the following:
- Is the machine producing quality parts?
- Is the current cycle faster or slower than the saved value?
- Which event or events are responsible for the cycle difference?
- According to plant procedures, how will the difference be resolved (adjust current cycle, perform maintenance, or save current
cycle)?
11. If the answer to question 3 is greater than 1, which Setup is the correct one?_________ How do you know?
133
134
Glossary
Absorb
To take up or receive in by chemical or molecular action.
Acetaldehyde
A gaseous byproduct generated in extremely small quantities during the manufacture of PET chips and extrusion of
PET bottles and films. Acetaldehyde levels in PET containers are important for product taste integrity only and not a
product safety or health concern.
Alkyl
A general term for monovalent aliphatic hydrocarbon radicals which have been derived from an alkane by dropping
one hydrogen from the formula.
Amorphous
Noncrystalline, having no determinable form or crystalline structure. Amorphous polyester (PET) is clear in appearance.
Anneal
The process of inducing crystallinity by the prolonged application of heat. Subjection of formed object to heat followed by slow cooling to toughen.
Biaxial Orientation The process of stretching a hot plastic film or other articles in two directions under conditions that result in molecular
realignment.
Birefringence
A change in index of refraction with direction. Birefringence is evidenced by the ability of a material to rotate the
plane of polarized light. In crystalline polymers birefringence is made up of contributions from the crystalline and
amorphous regions plus a contribution due to the shape of the crystals or the presence of voids.
Blow-up Ratio
The ratio between the diameter of a blow molding preform and the maximum diameter of the cavity in which it is
blown.
British Thermal Unit (BTU)The amount of heat required to raise one pound of water at maximum density through 1oF
Burst Strength
A measure of the force necessary to cause a container such as a bottle to burst. Burst strength is related to the tensile strength of the polymer.
Carboxyl
COOH substituent characteristic of all organic acids. In PET, the end of the polymer chain can be terminated by
either a hydroxyl or a carboxyl high temperature and moisture conditions.
Glossary
135
Glossary
136
Compression RatioIn an extruder screw, the ratio of the volume of material held in the first flight at the hopper end to the volume held in
the last flight in the metering section. This ratio is an indication of the compaction performed on the material, and of
the amount of work done on the material by the screw. Sometimes called channel volume ratio or, in the case of a
screw of constant pitch, channel depth ratio.
Copolymer (copolyester) A substance formed by the polymerization of three or more monomers.
Creep
The adjustment that a polymeric material makes when a stress is applied. In a bottle under carbonation, creep is evidenced when the volume of the container increases.
Crystalline
Formed of crystals, a solid with shape and cleavage formed by atoms, ions or molecules in a definite pattern or lattice.
Density
The weight of a unit volume of a material.
Dibasic Acid
Containing two carboxyl (COOH) groups. (see carboxyl)
Dihydric Alcohol
Containing two hydroxyl (OH) groups. (see hydroxyl)
Diffusion
The gradual permeation of any region by a fluid, owing to the thermal agitation of its particles or molecules.
Ethylene Glycol
A diol formed by heating ethylene chlorohydrin with a solution of alkali carbonate or bicarbonate; oxidation of ethylene with air followed by hydration; or the reaction of formaldehyde, water and carbon monoxide followed by hydrogenation. One of two raw materials, the other being terephthalic acid, used to synthesize PET.
Flash
A protrusion of plastic formed on the surface of the part caused by molten material seeping into poorly mating mold
parts.
Gaylord
A large cardboard box used for storage and transportation of materials such as resin or preforms.
Glass Transition Temperature Also referred to as the Tg, gamma transition, second order transition or rubbery transition. A reversible
change that occurs in an amorphous polymer when it is heated to a certain temperature range, characterized by a
rather sudden transition from a hard, glassy or brittle condition to a flexible or elastomeric condition. Other properties
such as coefficient of thermal expansion, specific heat and density usually undergo changes at the same time. The
transition occurs when the polymer molecular chains, normally coiled, tangled and motionless at temperatures
below the glass transition range, become free to rotate and slip past each other.
Heat Capacity
A measure of the amount of heat necessary to raise a unit mass of a material one degree.
Hopper Dryer
A combination feeding and drying device for extrusion and injection molding of thermoplastics. Hot air flows upward
through the hopper containing the feed pellets.
Hopper Loader
A device for automatically feeding molding powder to hoppers of extruders, injection molding machines and the like.
The functions of drying and blending colors with the molding powders are also sometimes accomplished by loaders.
There are two general types of hopper loaders: mechanical and pneumatic. The mechanical systems use a rotating
screw in a tube, or a conveyor belt on which are fastened small containers which dump their contents into the hopper.
Hot-Runner Mold A mold in which the runners and secondary sprues are kept hot and fluid during the entire cycle and are not ejected
with the molded part. This avoids the need for handling and reprocessing scrap normally generated from runners
and sprues.
Hot-Runner System
The runner is the channel that carries molten polymer from the extruder to the mold. In a hot runner system
this channel is heated and only the molded part is ejected after each shot. The hot polymer in the runner system is
incorporated in the next part to be molded rather than as scrap to be removed.
Hydrolysis
A chemical process in which water acts upon another substance to form one or more entirely new substances.
Hydrolytic
Related to or causing hydrolysis (see hydrolysis).
Hydrolytic Degradation The reaction between a polyester and moisture which results in the cleavage of ester bonds and the loss of
molecular weight and physical properties.
Hygroscopic
Absorbs water readily.
Injection Blow Molding A blow molding process in which the preform is formed over a mandrel by injection molding, after which the
mandrel and preform are shifted to a blow mold where the remainder of the cycle is completed. While the part is
being blown, cooled and ejected, another preform is being injection molded. Advantages of the process are that a
completely finished part is formed requiring no post finishing operations, closer tolerances are possible, and preform
wall thickness can be varied at desired areas.
Injection Mold
A mold used in the process of injection molding. The mold usually comprises two sections held together by a clamping device with sufficient strength to withstand the pressure of the molten plastic when injected, and is provided with
channels for heating, cooling and venting.
Glossary
137
Glossary
138
Injection Molding The method of forming objects from granular or powdered plastics, most often of the thermoplastic type. The material is fed from a hopper to a heated chamber where it is softened. A ram or screw then forces the material into a
mold. Pressure is maintained until the mass has hardened sufficiently for removal from the mold. In a variation called
flow molding, additional molten material is forced into the mold during cooling of the initial charge to overcome
shrinkage. When a screw is used rather than a ram for applying injection pressure by forward movement of the
screw, the term reciprocating screw injection molding is applied. In another variation called the screw-piston type of
injection molding, the screw does not reciprocate but delivers the molten material to an accumulator chamber
through a check valve, then a piston forces the material from the chamber into the mold.
Injection Molding Pressure The pressure applied to the cross-sectional area of the material cylinder, expressed in pounds per square
inch (ASTM D 883-65T).
Intrinsic Viscosity An index of polymer molecular weight as determined by measuring the viscosity of a polymer solution.
L/D Ratio
In an extruder screw, the ratio of the screw length to the screw diameter. Two definitions of L/D ratio have been
established. TOTAL L/D RATIO is the distance from the rear edge of the feed opening to the forward end of the barrel bore divided by the bore diameter and expressed as a ratio wherein the diameter is reduced to unity, such as
15:1 or 20:1. EFFECTIVE (ENCLOSED) L/D RATIO is defined as the distance from the forward edge of the feed
opening to the forward end of the barrel bore and expressed as a ratio wherein the diameter is reduced to unity,
such as 15:1.
Melt Viscosity
A measure of the "thickness" of a polymer melt. It is obtained by measuring the force needed to push molten polymer through a small capillary.
Mn (Number average molecular weight) The total weight of all molecules divided by the number of molecules.
Molecular Weight The sum of the atomic weights of all atoms in a molecule. In high polymers, the molecular weights of the individual
molecules vary widely so that they must be expressed as an average (See Mw and Mn).
Monomer
Molecule or compound usually containing carbon and of low molecular weight. A simple structure which can be converted into polymer by polymerization.
Mw /Weight average molecular weight) The sum of the total weights of molecules of each size multiplied by their respective weights
divided by the total weight of all molecules.
Necking
A condition of uneven orientational development, accompanied by thinning of portions of the sample, which occurs
during drawing, spinning or blowing.
Nucleating Agent A material added to a polymer to increase the rate of crystallization.

Oligomers
Low molecular weight molecules composed of several monomer units. Smaller in size than a polymer.
Organoleptic
Relating to taste or odor.
Orientation
Molecular chains of a polymer arranged relative to one another. Parallel orientation of polymer chains gives
improved strength to materials such as polyester (PET).
Oxygen Permeability
The measure of the rate that oxygen will flow through (permeate) a film.
Parison
The initial extruded form produced in extrusion blow molding. Sometimes used interchangeably with preform.
Paraxylene
The aromatic stream extracted from crude oil which is used to synthesize terephthalic acid.
PCO Thread Finish(Plastic Closures Only) That portion of the top of a PET preform that constitutes the threads for the cap to screw
onto. Typically for beverage bottles, this will be defined as a 28mm or 38mm PCO finish depicting the diameter of
the opening. The PCO thread finish is lighter in weight than its corresponding size Alcoa thread finigh, and the PCO
finish can be delineated by observing discontinuities in the threads which act as vents for CO2 escape through when a
carbonated beverage bottle cap is removed, as opposed to vent slots as seen on Alcoa finishes such as the 1716
or the 1820 series finishes.
PCR
(Post Consumer Regrind) Polymer reclaimed as recycled post consumer materials (typically bottles or containers)
that is ground up and re-used in the extruder.
Pearlescent
A white appearance resembling that of pearls.
Permeability
The measure of the rate that a gas will diffuse through a polymer film or any other membrane.
Permeant
The gas which permeates through a polymer film.
PET
Acronym for polyethylene terephthalate.
Plasticizer
A small organic molecule used to soften a plastic.
Polyester
Generic name for a large group of synthetic resins produced by reacting dibasic acids with dihydric alcohols.
Polyethylene Terephthalate
PET, polyester resin formed from the polymerization of ethylene glycol and terephthalic acid.
Polymer
A substance, usually synthetic, composed of many monomers linked together (polymerized) in a long chain.
Polymerization
Formation of large molecules (polymer) by union of a number of simple molecules (monomer). Polyester (PET) production occurs by the condensation polymerization of reactive monomers with the elimination of by-product or
excess monomer.
Preform
As pertaining to PET containers, a form produced by injection molding. Preforms are further processed by either
stretch blow molding (reheat blow molding) or injection blow molding to form the finished container. Also see parison.
Glossary
139
Glossary
140
Quench
Refers to the freezing-in of amorphous polymer structure, or the freezing-out of crystallinity.
Ram Travel
The distance the injection ram moves in filling the mold in injection or transfer molding.
Refractive Index
The ratio of the sine of the angle of incidence to the sine of the angle of refraction for a ray of light passing through
the surface separating two media.
Regrind
Polymer scrap created during processing that is ground up and reused in the extruder.
Reheat Blow Process

The process where containers are manufactured by first molding a preform and then reheating the preform
and blowing it into a container.
Resins (synthetic) Amorphous, organic, semi- solid, or solid materials formed by the union of a large number of molecules of one, two,
or three relatively simple compounds in polymerization or condensation.
Rheology
Study of the deformation and flow of matter under conditions of stress, strain and time.
Screen Pack
A filter added to a line carrying a polymer melt for the purpose of removing particulate contamination. (As pertaining
to the processing of PET containers, a force which can, during extrusion, promote the degradation of polyester.)
Shot Capacity
Injection capacity of an injection molding machine.
Specific Heat
Quantity of heat required to raise temperature of unit mass one degree.
Solid State Process

A manner of referring to secondary polymerization (following melt polymerization) used in the manufacture of
polyethylene terephthalate (PET) resin. An economical method of achieving high molecular weight (i.e. IV greater
than 0.70).
Specific Volume
The reciprocal of density.
Spherulite
A spherical aggregate of crystalline polymer, ranging from submicroscopic to millimeters in size.
Sprue
The first part of the runner system. The first section after the extruder that takes hot polymer from the extruder to the
mold.
Stretch Blow Molding
See reheat blow process.
Terephthalic Acid A dibasic acid in the form of white crystals or powder. It is formed by oxidation of paraxylene or other alkyl aromatics
using metal salts and bromine as catalysts, or by the reaction of benzene and potassium carbonate over a cadmium
catalyst. A raw material used in the manufacture of PET.
Tc
Temperature of crystallization.
Tg
See glass transition temperature.
Thermoplastics
Usually synthetic resins that may be softened with heat but then regain original property (form) on cooling.
Take-Off Equipment
Equipment used to hold or convey sheeting for secondary processing, such as thermoforming.
Tensile Strength
The strength of a material when a stretching stress is applied to a test sample. The material may show a yield or a
break.
Tensile Modulus
The slope of the stress strain curve at a given strain.
Thermoelastic
A material which will flow at temperatures above the glass transition temperature.
Thermoplastic
Soft and pliable whenever heated without any change in inherent properties.
Tm
Melting Temperature. The temperature at which the polymer melts. Usually the maximum of the temperature range
over which a polymer exhibits melting behavior.
Ultimate Elongation
The elongation at rupture in a tensile test.
Uniaxial
Refers to deformation in one direction.
Unoriented
refers to a sheet or fiber which has not been stretched or drawn in any direction.
Viscosity
The "thickness" of a material. A measure of how readily a material (usually a liquid) flows.
Virgin Resin
Resin which has not been previously processed.
X-ray Diffraction
A method of studying a material's crystal structure by studying the pattern of X-rays scattered from the material
when exposed to the X-ray radiation.
Zero Shear Melt Viscosity
The melt viscosity extrapolated to conditions of zero shear.
Glossary
141
Glossary
142

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HyPET OPERATOR COURSE v1.

Keeping our customers in the lead

v1.0 - May 2004

Hylectric PET Injection Molding Machine

General Description of Symbol

Danger Hazardous Voltage

v1.0 - May 2004

General Description of Symbol

Warning High Pressure Accumulator

Warning Crushing Hazard

v1.0 - May 2004

Hylectric PET Injection Molding Machine

Guards And Interlocks

v1.0 - May 2004

1.6.1 Performing Lockout/Tagout

Perform Lockout/Tagout using the following instructions:

v1.0 - May 2004

Hylectric PET Injection Molding Machine

Figure 1-1 Manual Dump Valve Locations

Figure 1-2 Air Regulator (Typical)

v1.0 - May 2004

1.6.2 Removing Locks and Tags

v1.0 - May 2004

Hylectric PET Injection Molding Machine

1.7.1 Mechanical Hazards

1.7.1.2 Cooling Water Hoses

1.7.1.3 Injection and Clamp Units

v1.0 - May 2004

1.7.2 High Pressure Leak Hazards

1.7.2.2 Skin Puncture Injuries

1.7.3 Burn Hazards

1.7.3.2 Molten Material

1.7.4 Explosion Hazards

v1.0 - May 2004

Hylectric PET Injection Molding Machine

1.7.5 Electrical Hazards

1.7.6 Noise Hazards

1.7.7 Gas, Vapor, and Dust Emissions

1.7.8 Slip, Trip, or Fall Hazards

1.7.9 Lifting Hazards

Personal Protective Equipment and Safety Equipment

1.8.1 Personal Protective Equipment (PPE)

v1.0 - May 2004

1.8.2 Safety Equipment

1.10 Material Safety Data Sheet (MSDS)

v1.0 - May 2004

Hylectric PET Injection Molding Machine

1.11 Materials, Parts, and Processing

Materials, Parts, and Processing

v1.0 - May 2004

List the Steps in the Injection Molding process

Operator-side Safety Gates

3 Using the HMI

Identify and Describe the Function of Clamp Components

Explain Hydraulic Oil Conditioning Circuit

Identify and describe the function of ejection components

7 Areas of the HMI

Identify Services Supplied to the Machine

Identify and Describe the Function of Injection Components

Identify and Describe the Function of Machine Heat Components

Copyright 2004, Husky Injection Molding Systems Ltd., Technical Training

HyPET Operator Training

HyPET Operator Training

11 Startup, Monitor, Shutdown