Maquinas LG PDF

Document No.
: LSM - MNL - 011

Version : 1.0
Date : August 2008
INSTRUCTION MANUAL
FOR
INJECTION MOLDING MACHINE
Model: LGH25N, LGH50N, LGH75N, LGH100N, LGH140N,
LGH160N, LGH200N, LGH350N, LGH450N,
LGH550N, LGH650N, LGH850N, LGH1000N
Customer : Controller : HICOM300 TFT LCD

Serial No. : Language : English
Copyright LS Mtron ltd. ⓒ 2008

First Printing, January 1999 Printed in Korea
LS Mtron Ltd. has developed this document for its licensees and customers.
The information contained herein is the property of LS Mtron Ltd. and may not be copied, used, or disclosed
to others without prior written approval from LS Mtron Ltd. Users are cautioned that the material contained
herein is subjected to change by LS Mtron Ltd. at any time and without prior notice.
Foreword LSM-MNL-011/Ver. 1.0
FOREWORD
CONGRATULATIONS
Thank you for selecting the LS Injection Molding Machine.
LS Mtron strives to produce the highest quality and most reliable injection molding machines to
satisfy today’s molding requirements.
To ensure that the machine provides the maximum satisfaction and operates in the most efficient
manner it is important provides information regarding the construction, operation, maintenance,
safety and other special features of the machine.
LS Mtron Ltd. And LS International Co. Will not be responsible for improper
operation, maintenance, abuse, alteration of safety features or non-compliance with written
instructions that cause machine damage or injury.
If there is a need for additional information, please contact LS International or the LS Mtron
service group.
We will provide any assistance you may require.
The information contained in this manual may change from time to time without notice, and it is
also considered propriety in nature for the use of LS user.
Do not copy and refrain from letting others use this machine manual.
LS SALES AND SERVICE :
PLANT : 778,YONGAM-RII,BONGDON-EUP,WANJU-GUN
JEOLLABUK-DO, 565-904,KOREA
TEL : INT+82-63-279-5610~15, 5620~24
FAX : INT+82-63-279-5070
OVERSEA SALES DEPARTMENT :

2FL SEONJI BLDG. 1505-17, KWANGYANG-DONG, DONGAN-GU,
ANYANG-SI, GYEONGGI-DO, KOREA
TEL : INT+82-31-450-3610
FAX : INT+82-31-450--3639
http://www.lginjection.co.kr
U
0-1 NM011C00
SAFETY OPERATION
1. This manual contains important safety operation concerning the maintenance,

use and operation of this product.
2. Failure to follow the instructions contained in this manual may result in serious
injury.
3. If you are unable to understand the contents of this manual, please bring it to the
attention of your supervisor or foreman.
4. Do not operate the equipment unless you have read and understood the
contents of this manual.
0-2 NM011C00
Our police concerning Environment, Health and Safety
LS Mtron thinks …
harmony with environment, and aims to be a leading company,
together with people, in relations to the Environment , Health, Safety
Observance of related laws/regulations and improvements

We abide the environmental, safety, and health laws and regulations, set
strict
i t l l ti d ti l i th l l
Active preventions through technology developments
With vast experience and innovative technological development, prevent
environmental pollution and dangerous elements in advance.
Transparent management that respect the environment and people

In development, design, production, service, and disposal, we think environment,
health and safety first as our principal element in management, establish concrete
purpose, examine and evaluate regularly and publicize the results.
Response formation and voluntary participation
Trainings with active participation from all of the staff.
Performance of individual duties with sincerity for the attainment of the goal in
pursuit of company working together with local community.
Rules about “usage and disposal “

The following are recommended to our customers about usage and disposal of the product
in relation to environmental preservation.
1. When you inject oil (hydraulic, lubricant, grease, etc.) before using the injection-molding
machine, use oil recommended by the company.Using inappropriate oil may result in
shorter machine life and reduced performance. It also could cause oil waste and
result in early part replacements.
2. After changing oil, do not discard oil at any place for it may result in water and soil
pollution.
Oil injection and change should be serviced by authorized sellers with oil feeders.
3. Do not burn or dispose molding resulted resin or plastic materials.

Poisonous gas produced from burning may become main cause of air pollution.
Disposal should be done by a specialist.
4. The expired machines should be disposed by a specialist and should not be left without
direction.
Disposed machines leak rust water and oil that cause environmental pollution.
Disposal should be done by a specialist.
0-3 NM011C00
TABLE OF CONTENTS
U
Chapter 1. SAFETY PRECAUTIONS
1.1. Important Notices .................................................................................................................2

1.1.1. Qualified Personnel....................................................................................................3
1.1.2. Danger Notices ..........................................................................................................3
1.1.3. Principle Safety Objective ..........................................................................................4
1.1.4. General Safety Rules .................................................................................................5
1.1.5. Overview of Machine..................................................................................................6
1.1.6. MAJOR SPECIFICATION OF INJECTION MOLDING MACHINE.............................8
1.2. Safety Feature and Devices...............................................................................................12
1.2.1. Electrical Safety Device ...........................................................................................13
1.2.2. Hydraulic Safety Device ...........................................................................................14
1.2.3. Mechanical Safety Device........................................................................................14
1.2.4. Emergency Stop Button ...........................................................................................14
1.2.5. Nozzle Safety Cover (Option) ..................................................................................15
1.2.6. Working on the machine ..........................................................................................15
1.2.7. Operating the machine.............................................................................................18
1.2.8. Essential Safety Checks (ESC’s).............................................................................19
1.3. Daily Inspection Prior to Machine Operation......................................................................21
1.3.1. Inspection Prior to Operation ...................................................................................21
1.3.2. Precautions Before Machine Operation ...................................................................21
1.3.3. Checking the Safety Device .....................................................................................22
1.4. Inspection Every Ten Days ................................................................................................23
1.5. Precautions for Injection ....................................................................................................24
1.6. Precaution for Clamping ....................................................................................................25
1.7. Precaution for the Hydraulic System..................................................................................25
1.8. Precaution for the Electric System .....................................................................................26
1.9. Other Precautions ..............................................................................................................27
1.10. Four Principles Regarding Safety ....................................................................................27
1.11. Level of sound pressure...................................................................................................28
1.12. Illumination.......................................................................................................................28
1.13. Training ............................................................................................................................28
0-4 NM011C00
Chapter 2. Installation of the Machine
2.1. Preparations for Installation .................................................................................................2

2.2. Machine Location.................................................................................................................3
2.3. Foundation ...........................................................................................................................3
2.4. Installation............................................................................................................................4
2.4.1. Moving the Machine ...................................................................................................4
2.4.2. Installing the Machine (To be Performed by the Customer).....................................10
2.5. Electrical Work ...................................................................................................................11
2.5.1. Electric Power System Wiring ..................................................................................11
2.5.2. Prevention of Electric Shocks ..................................................................................17
2.6. Piping for Cooling Water (To be performed by the Customer) ..........................................18
2.7. Hydraulic Fluid ...................................................................................................................20
2.8. Cleaning.............................................................................................................................21
2.9. Lubricating Oil ....................................................................................................................21
2.10. Reference of the Lubricating Point...................................................................................21
Chapter 3. Preparation for Operation
3.1. Inspection Prior to Starting Operation..................................................................................2

3.2. Confirmation of Safety Devices............................................................................................2
3.2.1. Safety Gates ..............................................................................................................3
3.2.2. Mechanical Safety Devices ........................................................................................4
3.2.3. Emergency Stop Push Button Switch ........................................................................6
3.3. Starting the Machine ............................................................................................................7
3.3.1. LAY-OUT of the Operating Panel...............................................................................7
3.3.2. Test Run of the Pump Motor ......................................................................................8
3.4. Inspection After Starting Operation....................................................................................10
3.5. Mold Set - Up .....................................................................................................................12
3.5.1. Preparation ..............................................................................................................12
3.5.2. Replacement of Ejector Pins....................................................................................14
3.5.3. Mold Mounting..........................................................................................................16
3.5.4. Mold Replacement Work..........................................................................................19
3.5.5. Purging Air from the Clamping Cylinder...................................................................21
3.5.6. Spacer Replacement for Mold Thickness Adjustment .............................................22
3.6. Hopper Dryer .....................................................................................................................24
3.7. Hopper Loader ...................................................................................................................24
0-5 NM011C00
Chapter 4. START-UP ADJUSTMENT
4.1. Adjustment of the Clamping Unit .........................................................................................2

4.1.1. Adjustment of Clamp Side Control .............................................................................2
4.1.2. Adjustment of Mechanical Safety Device...................................................................8
4.2. Adjustment of Hydraulic Ejector ...........................................................................................8
4.2.1. Movement ..................................................................................................................8
4.2.2. Setting the Ejection Stroke.........................................................................................9
4.2.3. Adjustment of Ejecting Speed ..................................................................................10
4.3. Adjustment of Injection Unit ...............................................................................................11
4.3.1. Adjustment of Injection.............................................................................................12
4.3.2. Adjustment of Nozzle ...............................................................................................16
4.4. Timer Functions and Settings ............................................................................................18
4.5. Injection amount data sheet...............................................................................................19
Chapter 5. Molding Operation
5.1. Preparations Prior to Molding ..............................................................................................2

5.1.1. Tools Required for Molding ........................................................................................2
5.2. The Part of Selection ...........................................................................................................4
5.2.1. Nozzle Selection ........................................................................................................4
5.2.2. Screw Tip Selection ...................................................................................................5
5.3. Setting the Barrel Temperature............................................................................................6
5.4. Setting the temporary set value on each profile...................................................................8
5.5. Molding Operation................................................................................................................8
5.5.1. MANUAL Operation ...................................................................................................8
5.5.2. OBTAIN Good Product.............................................................................................12
5.6. Troubleshooting of the injection molding ...........................................................................17
5.6.1. Typical problem & solution. ......................................................................................17
5.6.2. Solutions related to the condition of molded products .............................................19
5.6.3. Uneven and Poor Charging......................................................................................25
5.6.4. Uneven Color and Color Dispersion.........................................................................26
5.7. OPTIMIZE Cycle Time .......................................................................................................26
5.8. SEMI-AUTOMATIC Operation ...........................................................................................27
5.9. AUTOMATIC Operation .....................................................................................................28
5.10. Material and Color Change ..............................................................................................29
5.11. Completion of Molding Operation ....................................................................................31
0-6 NM011C00
5.11.1. What You Should Do After Operation ....................................................................32

5.12. Removing the Mold ..........................................................................................................33
Chapter 6. Replacing the Parts.
6.1. Replacing the Screw and Barrel ..........................................................................................2

6.1.1. Screw Replacement ...................................................................................................2
6.1.2. Installation and Removal of the Nozzle and Barrel Head...........................................5
6.1.3. Screw Removal ..........................................................................................................6
6.1.4. Screw Tip Removal ....................................................................................................7
6.1.5. Barrel Replacement ...................................................................................................8
6.1.6. Mounting the Barrel....................................................................................................9
6.1.7. Mounting the Screw Tip .............................................................................................9
6.2. Replacing the Filter Element in the Oil Cleaner .................................................................10
6.3. Replacing the V - Packing..................................................................................................11
6.4. U Packing...........................................................................................................................13
6.5. Replacing the Contractor ...................................................................................................15
0-7 NM011C00
Chapter 7. Inspection and Maintenance
7.1. Daily Inspection....................................................................................................................2

7.2. Periodic Inspection...............................................................................................................6
7.2.1. Weekly (Every 150 Hours) .........................................................................................6
7.2.2. Monthly (Every 700 Hours) ........................................................................................9
7.2.3. Three Months (Every 2000 Hours)...........................................................................13
7.2.4. Six Months (Every 4000 Hours) ...............................................................................13
7.2.5. One Year (Every 8000 Hours)..................................................................................14
7.3. Maintenance ......................................................................................................................15
7.3.1. Three-phase Induction Motor ...................................................................................15
7.3.2. Cleaning the Air Breather Element...........................................................................20
7.3.3. Cleaning the Heat Exchanger ..................................................................................21
7.3.4. Heater Maintenance and Inspection ........................................................................23
7.3.5. Checking the Check Ring Wear Condition...............................................................24
7.3.6. Action to be Taken for an Excessively Risen Oil Temperature ................................25
7.4. LS WARRANTY .................................................................................................................27
7.5. PART REQUISITION FORM..............................................................................................29
Chapter 8 TROUBLESHOOT FLOW CHART
8.1. Pump Motors don’t start......................................................................................................2

8.2. Motors don’t run continuously..............................................................................................3
8.3. Mold doesn’t open in Automatic Mode ................................................................................4
8.4. Mold doesn’t close in Automatic Mode ...............................................................................6
8.5. Nozzle does not Retract in Automatic Mode ........................................................................7
8.6. Nozzle does not advance in Automatic Mode ......................................................................8
8.7. Injection does not work in Automatic Mode .........................................................................9
8.8. Charging does not work in Automatic Mode ......................................................................11
8.9. Suck-back does not work in Automatic Mode ...................................................................13
0-8 NM011C00
Annex
1. HYDRAULIC AND LUBRICATING OIL..........................................................................................3
1.1. Outline..................................................................................................................................3
1.2. Hydraulic Oil.........................................................................................................................3
1.3. Recommended Hydraulic Oil ...............................................................................................5
1.4. Selection of Recommended Oil ...........................................................................................5
1.5. Maintenance and Control of the Hydraulic System ..............................................................6
1.5.1. Oil Supply...................................................................................................................6
1.5.2. Periodic Testing of Oil Properties ..............................................................................8
1.5.3. Flushing ...................................................................................................................10
1.5.4. Oil Change Time ......................................................................................................12
1.5.5. Remarks Concerning Maintenance and Control ......................................................12
1.6. Selection of Lubricating Oil ................................................................................................13
1.7. Maintenance and Control of the Lubricating System .........................................................13
1.7.1. Maintenance and Control .........................................................................................13
1.7.2. Lubrication Maintenance ..........................................................................................14
1.8. Properties and Qualities of Hydraulic Oil ...........................................................................14
1.8.1. Viscosity ...................................................................................................................14
1.8.2. Viscosity Index .........................................................................................................15
1.8.3. Oxidation Stability ....................................................................................................15
1.8.4. Rust - Resistant Characteristics...............................................................................16
1.8.5. Wear - Resistant Characteristic ...............................................................................16
1.8.6. Miscellaneous ..........................................................................................................16
2. SCREW COLD START PREVENTING FUNCTION ....................................................................17
2.1. Outline................................................................................................................................17
2.2. Movement ..........................................................................................................................17
0-9 NM011C00
▣Attached Drawings List (Mechanical Part)

The contents of ( ) are for U.S.A only.
MODEL LGH450N LGH550N LGH650N

(LGH500N) (LGH610N) (LGH720N)
DRAWING
GENERAL VIEW PIM0702424 PIM0702438 PIM0702452
FOUNDATION PIM0702426 PIM0702440 PIM0702454
MOLD MOUNTING PIM0702425 PIM0702439 PIM0702453
CLAMPING PART LIST PIM0702427 PIM0702441 PIM0702455
INJECTION PART LIST PIM0702428 PIM0702442 PIM0702456

HEATER LIST PIM0702429 PIM0702443 PIM0702457
NOZZLE PIM0702430 PIM0702430 PIM0702430
OIL SPECIFICATION PIM0702431 PIM0702431 PIM0702431
PRESSURE DIAGRAM PIM0702432 PIM0702444 PIM0702458
HYDRAULIC CIRCUIT PIM0702433 PIM0702445 PIM0702459
TIME CHART PIM0702437 PIM0702448 PIM0702462
HYDRAULIC PART LIST PIM0702434 PIM0702446 PIM0702460
VALVE ARRENGEMENT PIM0702436 PIM0702447 PIM0702461
MAINTENANCE TOOLS PIM0702435 PIM0702435 PIM0702435
0-10 NM011C00
▣ Attached Drawings List (Electrical Part)
MODEL
LGH25~160N LGH200N LGH350N
DRAWING
MOTOR DRIVE PART(1) NE301115 NE301116 NE301117
MOTOR DRIVE PART(2) NE301120 → NE301121
HEATER CIRCUIT → → NE301125

OPERATING KEY
→ → NE301129
INTERFACE
MOTHER INPUT CARD → → NE301130
SSR OUTPUT CARD(1) → → NE301131
EXTENTION I/O CARD → → NE301133

SSR OUTPUT CARD(2) -
- NE301134
MOLD MOVE ON CHARGE
EXTENTION I/O CARD
→ → NE301135
MOLD MOVE ON CHARGE
ROBOT INTERFACE → → NE301136
MODEL
LGH450N LGH550N LGH650~1000N
DRAWING
MOTOR DRIVE PART(1) → NE301118 NE301119
MOTOR DRIVE PART(2) → NE301122 NE301123
HEATER CIRCUIT NE301126 NE301127 NE301128

OPERATING KEY
→ → NE301129
INTERFACE
MOTHER INPUT CARD → → NE301130
EXTENTION I/O CARD → → NE301133

SSR OUTPUT CARD(2)
→ → NE301134
MOLD MOVE ON CHARGE
EXTENTION I/O CARD
→ → NE301135
MOLD MOVE ON CHARGE
ROBOT INTERFACE → → NE301136
0-11 NM011C00
- N Series -
0-12 NM011C00
Safety Precautions LSM-MNL-011/Ver. 1.0
Chapter 1. SAFETY PRECAUTIONS
1.1. Important Notices ..............................................................................................................2

1.1.1. Qualified Personnel .................................................................................................3
1.1.2. Danger Notices ........................................................................................................3
1.1.3. Principle Safety Objective ........................................................................................4
1.1.4. General Safety Rules...............................................................................................5
1.1.5. Overview of Machine ...............................................................................................7
1.1.6. MAJOR SPECIFICATION OF INJECTION MOLDING MACHINE...........................9
1.2. Safety Feature and Devices ............................................................................................13
1.2.1. Electrical Safety Device .........................................................................................14
1.2.2. Hydraulic Safety Device.........................................................................................15
1.2.3. Emergency Stop Button .........................................................................................15
1.2.4. Mechanical Safety Device( Option ).......................................................................15
1.2.5. Nozzle Safety Cover (Option) ................................................................................18
1.2.6. Working on the machine ........................................................................................18
1.2.7. Operating the machine ..........................................................................................20
1.2.8. Essential Safety Checks (ESC’s) ..........................................................................21
1.3. Daily Inspection Prior to Machine Operation ...................................................................23
1.3.1. Inspection Prior to Operation .................................................................................23
1.3.2. Precautions Before Machine Operation .................................................................23
1.3.3. Checking the Safety Device...................................................................................24
1.4. Inspection Every Ten Days..............................................................................................25
1.5. Precautions for Injection ..................................................................................................25
1.6. Precaution for Clamping ..................................................................................................26
1.7. Precaution for the Hydraulic System ...............................................................................27
1.8. Precaution for the Electric System ..................................................................................27
1.9. Other Precautions............................................................................................................28
1.10. Four Principles Regarding Safety.................................................................................28
1.11. Level of sound pressure ...............................................................................................29
1.12. Illumination ...................................................................................................................29
1.13. Training ........................................................................................................................29
1-1 NM011C01
1. Safety Precautions
Read this chapter before operating this machine. This chapter explains precaution and pro-
hibitions on the machine. Make sure to understand all of the items explained in this chapter
before operation.
1.1. Important Notices
LS Mtron cannot accept any liability whatsoever, which may result in legal action from failure
to comply with the regulations, or any consequential loss, claim or counter claim for damage,
personal injury, or death arising as a result of any modification, alteration or addition to the fit-
ting of ancillary equipment.
This document provides the information required for the intended use of the injection molding
machine. The documentation is written for technically qualified personnel such as engineers,
programmers or maintenance specialists who have been specially trained and who have the
specialized knowledge required in the field of instrumentation and control. A knowledge of
the safety instructions and warnings contained in this document and their appropriate applica-
tion are prerequisites for safe installation and commissioning as well as safety in operation
and maintenance of the product described. Only qualified personnel have the specialized
knowledge that is necessary to correctly interpret the general guidelines relating to the safety
instructions and warnings and implement them in each particular case.
For the sake of clarity, not all details of all versions of the product are described in this docu-
ments, nor can it cover all conceivable cases regarding installation, operation and mainte-
nance. Should you require further information or face special problems that have not been
dealt with in sufficient detail in this document, please contact the manufacturer specified on
cover page.
We would also point out that the contents of this product documentation shall not become a
part of or modify any prior or existing agreement, commitment or legal relationship. The Pur-
chase Agreement contains the complete and exclusive obligations of LS Mtron Ltd. Any
statements contained in this document do not create new warranties or restrict the existing
warranty.
1-2 NM011C01
1.1.1. Qualified Personnel

Persons who are not qualified should not be allowed to handle the injection molding machine.
Non-compliance with the warnings contained in this document or appearing on the machine it-
self can result in severe personal injury or damage to property. Only qualified personnel
should be allowed to work on this injection molding machine.
Qualified persons as referred to in the safety guidelines in this document as well as on the
machine itself are defined as follows ;
z Operating personnel who have been trained to work with injection molding machine and
are conversant with the contents of the documents in as far as it is connected with the ac-
tual operation of the plant;
z Commissioning service personnel who are trained to repair such injection molding ma-
chine and who are authorized to energize, enervate, clear, ground and tag circuits,
equipment and systems in accordance with established safety practices.
1.1.2. Danger Notices

The safety notices and warnings for protection against loss of life (the users or service per-
sonnel) or for protection against damage to property are highlighted in this document by the
terms and pictograms defined here. The terms and pictograms used in this document and
marked on the equipment itself have the following significance;
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor
or moderate injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
IMPORTANT
if “IMPORTANT” should appear in this document, draw attention to any particular information
described.
1-3 NM011C01
1.1.3. Principle Safety Objective
1) The principle safety objective is to remove the possibility of any hazard or risk to the
health or safety of the machine operator or service personnel.
2) Extreme caution must be exercised while servicing or installing the machine. Do not
manually actuate any safety switches, particularly with the guards removed, as this may
cause unanticipated machine response.
3) The only safe policy when working or inspecting the machine is to follow the instructions in
this manual. Wherever possible shut off all electrical power and follow the procedures out-
lined in section 1.2.6..
4) Accident prevention should become part the of standard working, operating and mainte-
nance procedures, and training should be provided to ensure safety standards are under-
stood. Part of the safety training should include the instructions detailed in this section.
5) Certain processed polymer materials may give off harmful or irrational gases. This must
be taken into account when designing the installation area and adequate provision should
be included for removal of any gases.
6) If ancillary equipment is to be fitted ensure this is done in accordance with the relevant
standards, and that all requirements for safety are fully met
7) Always ensure servicing and maintenance tasks are carried out by suitable qualified per-
sonnel. The operator should understand the limits of their responsibility, and the training
should reinforce the importance of not exceeding them.
8) The essential routine safety checks play an important role in ensuring the machine contin-
ues to work in a safe manner. These checks must be carried out in accordance with the
instructions at the recommended intervals.
9) If there are any questions or doubts regarding any aspect of machine safety or operation
or maintenance, please contact the help line number shown on the front of this manual.
1-4 NM011C01
1.1.4. General Safety Rules

Good practice
1) Ensure all personnel who work on the machine are familiar with the safety features and
have read and understood the contents of this section.
2) Maintain a constant training program to ensure operator and service personnel keep a
high level of safety awareness.
3) Initiate a planned maintenance program which must include the essential safety checks as
detailed in section 1.2.8.
4) Report any machine fault quickly, particularly those directly related to safety such as loose
guarding, exposed electrical wiring or circuits, etc.
5) In case of accident, or to stop the machine quickly in an emergency, press the emergency
STOP button. The position of the emergency STOP button and other safety features are
shown in section 1.2.
6) When working on the machine, or changing mold tools, where directed, turn off the factory
electrical supply and the machine electrical isolator.
7) After working on the machine reassemble all guards and complete the essential safety
checks (section 1.2.8.) before operation.
8) Wear the appropriate safety clothing in accordance with the prevailing factory regulations.
9) Keep the machine and working area clear and clean at all times. Clear up any oil spill-
age’s so there is no possibility of personnel slipping.
Bad Practice
1) Do not remove any safety devices. This may cause a serious accident and may result in prosecu-
t i o n .
2) Do not clean, lubricate or service any parts on the machine while it is running unless it is
specifically intended to be done. Follow the instructions in this manual.
3) Do not manually actuate any switches during serving or maintenance operations. This
may cause unanticipated machine movements.
4) Do not start the machine unless you are sure that it is safe to do so, and no danger exists
to other personnel.
5) Do not wear loose clothing, jewelry, ties etc., while operating or working on the machine.
6) Do not place tools or other equipment on the machine while it is running.
7) Do not leave the machine in an unsafe condition, or in a condition which will allow it to
operate in an unsafe manner.
8) Do not allow unauthorized or untrained personnel to operate the machine.
1-5 NM011C01
1-6 NM011C01
1.1.5. Overview of Machine
This machine is a horizontal injection molding machine, equipped with an in-line screw injec-
tion unit and a direct - lock system of composite clamping unit.
The injection molding machine can perform MANUAL,SEMI-AUTOMATIC and AUTOMATIC
operations with hydraulic power and electrical control.
This machine is originally developed by LS Mtron and is recently given further improvements,
and has following characteristic.
1-7 NM011C01
With the use of recommended optional equipment, the great improvement of running rate is possi-
ble by better operability and shortened preparatory planning time of large size unit.
1) The floor space is greatly reduced compared with conventional units.
2) The machines controlled by means of the hydraulic circuit consisting of the binary pump,
electromagnetic relief valve, and flow control valve, originally developed by LS Mtron for
the purpose of energy saving, high speed cycle operation, and stable molding, in combi-
nation with electric control by means of the sequence controller
4) Mold thickness setting spacers make it possible to shorten mold changing time and en-
able the coping with FMS application.
5) This machine is designed to attain high performance which assured stable molding and
high product quality by the use of a lock type clamp mechanism with high injection pres-
sure and great rigidity.
6) Perfect monitoring systems such as a failure diagnostic system, and alarm display or an
oil cleaning system are provided to raise the running rate of the machine and to attain
the machine free of maintenance.
7) The machine can be used for the injection molding of various thermoplastic resins to
produce molded products of excellent quality. It operates at a high cycle rate, produces
very little noise, and has a high-capacity pump.
8) Special consideration has been given to the importance of safety during machine han-
dling and operation. The machine has three safety gate and several safety devices op-
erated by the hydraulic / electrical safety valve.
1-8 NM011C01
1.1.6. MAJOR SPECIFICATION OF INJECTION MOLDING MACHINE

*: Standard
Model
I t e m LGH 25N LGH 50N LGH 75N LGH 100N LGH 140N
Unit
Screw Code Y *A B Y *A B Y *A Y *A Y *A
Screw Diameter mm 22 25 28 25 28 32 32 36 32 36 40 45
Injection Capacity Calculated ㎤ 43 55 69 55 69 90 88 112 129 163 250 320
g 27 45 60 45 60 80 81 103 118 150 230 294
Injection Capacity PS 2.9 3.6 4.2 5.3 8.1 10.4
OZ 0.9 1.5 2.1 1.5 2.1 2.8
Injection Unit
g 22 36 47 36 47 63 64 82 94 119 180 233

PE 2.3 2.9 3.3 4.2 6.4 8.2
OZ 0.7 1.2 1.6 1.2 1.6 2.2
Injection Pressure kg/㎠ 2,680 2,070 1,650 2,520 2,000 1,530 1,775 1,400 2,l80 1,720 1,960 1,550
40 52 65 61 76 99 50 63 91 116 162 206
Injection Rate ㎤/sec
(34) (43) (54) (50) (63) (83) (42) (53) (76) (96) (135) (171)
20 35 48 35 48 55 33 47 56 80 86 113
Plasticizing Capacity(PS) kg/ hr (27) (38) (47) (67) (71) (93)
(17) (30) (41) (35) (46) (55)
380 380 380 320 190 325 325 255 255
Maximum Screw Rotation Speed R.P.M.
(325) (380) (360) (320) (155) (270) (270) (210) (210)
Clamping Force ton 25 50 75 90 140
Mold Opening Force ton 2.5 3.6 3.6 6.7 9.1
Distance Between Tie Rods
mm 260 X 260 310 X 310 310 X 260 370 X 370 450 X 450
(HxV)
Platen Dimensions(H X V) mm 380 X 380 480 X 480 460 X 420 565 X 565 645 X 645
Clamping Stroke mm 280 370 270 460 450
Clamping Unit
Daylight Without spacer mm 430 530 550 630 800

With spacer mm 450 - 640
Min. Mold Thickness mm 150 160 180/280 170 190/350
Mold Closing Speed High m/min 38 37 22.7(18.9) 40.4(33.5) 48.4(40.2)
Low m/min 2.5 2.5 3.1(2.6) 4.6(3.7) 5.6(4.6)
Mold 0pening Speed High m/min 31 30.5 19.5(16.2) 40.5(33.6) 47.4(39.4)
Low m/min 3.0 3.0 - 2.7(2.2) 2.3(1.8) 2.7(2.3)
Ejection Force ton 1.7 2.2 2.2 2.5 3.7
Ejection Stroke mm 50 60 55 63 80
Utilized Oil Quantity ℓ 105 130 200 400 560
Electrical Requirement of Pump
kW 7.5 11 11 15 22
General
Motors
3.9
Heater Capacity kW 3.92 5.4 5.1 5.1 6.6 5.12 6.34 10.2
2
Machine Dimension( LXWXH) m 3.1X1.1X1.7 3.1X1.2X1.8 3.5X1.2X1.8 4.6X1.3X2.0 4.8X1.4X2.2
Machine Weight ton 1.91 2.5 2.5 4.9 6.0
Notes
9 The above values are based on a supply of 220V / 60Hz.
9 Figures in ( ) are for 380V±10%, 50Hz±5%.
9 Injection capacity, injection rate and Plasticizing capacity will vary according to the utilized resin and the
molding conditions.
1-9 NM011C01
*: Standard
Model
I t e m LGH 160N LGH 200N LGH 75N
Unit
Screw Code Y *A B Y *A B Y *A B
Screw Diameter mm 40 45 50 45 50 55 55 60 65
Injection Capacity Calculated ㎤ 289 368 451 397 490 594 784 930 1,094
g 266 341 415 366 450 546 721 855 1,007
Injection Capacity PS 9.4 12 14.6 12.9 15.9 19.2 25.4 30.0 35.5
Injection Unit
OZ
g 211 270 329 290 355 434 572 680 799
PE 7.4 9.5 11.6 10.2 12.5 15.3 20 23.6 28.1
OZ
Injection Pressure kg/㎠ 2,080 1,645 1,330 1,950 1,580 1,305 1,950 1,640 1,400
153 194 239 201 248 301 304 362 425
(127) (161) (199) (167) (207) (250) (254) (303) (355)
86 113 159 91 128 164 156 191 231
Plasticizing Capacity(PS) kg/ hr (71) (93) (131) (75) (106) (136) (128) (157) (188)
Maximum Screw Rotation Speed R.P.M. 255(210) 205(170) 195(160)
Clamping Force ton 160 200 350
Mold Opening Force ton 9.9 13.8 20.2
mm 520 X 520 540 X 540 710X710
(HxV)
Platen Dimensions(H X V) mm 740 X 740 790 X 790 1000 X 1000
Clamping Stroke mm 500 560 710
Clamping Unit
Daylight Without spacer mm 900 1,000 1,250

With spacer mm 720 800 1,010
Min. Mold Thickness mm 220/400 240/440 300/540
Mold Closing Speed High m/min 37.7(31.3) 36.2(30.1) 43.9(36.7)
Low m/min 4.4(3.6) 4.0(3.3) 2.0
Mold 0pening Speed High m/min 39.6(32.9) 32.6(27.1) 42.3(35.5)
Low m/min 2.2(1.8) 1.9(1.5) 3.2
Ejection Force ton 4.6 5.3 8.9
Ejection Stroke mm 90 100 125
Utilized Oil Quantity ℓ 560 700 900
22 37 45
General
kW
Motors
Heater Capacity kW 10.2 11.72 18.57
Machine Dimension( LXWXH) m 5.2X1.4X2.2 5.7X1.5X2.2 7.1X1.7X2.4
Machine Weight ton 7.0 8.0 17
Notes
molding conditions.
1-10 NM011C01
*: Standard
Model
I t e m LGH 450N LGH 550N
Unit
Injection unit code i27 i33 i33 i54
Screw Code *A B *A B *A B *A B
Screw Diameter mm 70 80 75 85 75 85 90 100
Injection Capacity Calculated ㎤ 1,480 1,930 1,820 2,330 1,820 2,330 3,140 3,880
g 1,360 1,780 1,670 2,150 1,670 2,150 2,890 3,570
Injection Capacity PS
Injection Unit
OZ 48 62.7 59 75.8 59 75.8 102 126

g 1,080 1,410 1,330 1,700 1,330 1,700 2,290 2,830
PE
OZ 38 49.7 47 60 47 60 80.7 99.8
Injection Pressure kg/㎠ 1,820 1,400 1,790 1,400 1,790 1,400 1,720 1,400
419 548 427 548 513 669 533 658
(346) (453) (352) (453) (418) (549) (444) (546)
Plasticizing Capacity(PS) kg/ hr 262 330 295 367 295 367 403 467
180/149 160/117 170/117 150/89 170/142 150/108 140/71 127/71
Maximum Screw Rotation Speed R.P.M.
(180/120) (160/94) (170/107) (144/72) 170/130 150/188 116/58 116/58
Clamping Force ton 450 550
Mold Opening Force ton 24.4 30.1
mm 830 X 830 860X860
(HxV)
Platen Dimensions(H X V) mm 1,200 X1,200 1,230X1,230
Clamping Unit
Clamping Stroke mm 1,100 1,200

Daylight mm 1,450 1,600
Min. Mold Thickness mm 350 400
Mold Closing Speed High m/min 44.3(37.4) 43.9(36.5)
Low m/min 2.0 2.0
Mold 0pening Speed High m/min 46.7(37.8) 43.5(36.2)
Low m/min 2.1(1.7) 2.2(1.8)
Ejection Force ton 13.3 15.8
Ejection Stroke mm 160 160
Utilized Oil Quantity ℓ 1,300 1,600
37+22
General
kW 45+22
Motors
Heater Capacity kW 23.7 27.8 26.9 26.9 26.9 26.9 40.0 44.8
Machine Dimension( LXWXH) m 8.6X1.8X2.7 8.8X1.8X2.7 9.5X1.9X2.7 9.9X1.9X2.7
Machine Weight ton 25 26 30 31
Notes
molding conditions.
1-11 NM011C01
*: Standard
Mod
I t e m el
LGH 650N LGH 850N LGH 1000N
Unit
Injection unit code i54 i90 i90 i115 i90 i115
Screw Code *A B Y A B Y *A B A B Y *A B A B
Screw Diameter mm 90 100 100 105 115 10 105 115 115 125 100 105 115 115 125
Injection Capacity Calculated ㎤ 3,140 3,880 4,535 5,000 5,990 4,535 5,000 5,990 6,570 7,760 4,535 5,000 5,990 6,570 7,760
g 2,890 3,570 4,170 4,600 5,500 4,170 4,600 5,500 6,040 7,140 4,170 4,600 5,500 6,040 7,140
Injection Unit
Injection Capacity PS
OZ 102 126 147 162.2 194 147 162.2 194 213 251.8 147 162.2 194 213 251.8
g 2,290 2,830 3,310 3,650 4,370 3,310 3,69 4,370 4,790 5,660 3,310 3,69 4,370 4,790 5,660
PE
OZ 80.7 99.8 116.7 128.7 154.2 116.7 128.7 154.2 169 199.6 116.7 128.7 154.2 169 199.6
Injection Pressure kg/㎠ 1,720 1,400 1,950 1,770 1,475 1,950 1,770 11475 1,740 1.470 1,950 1,770 1,475 1,740 1,470
㎤ 692 854 612 675 810 820 905 1,080 915 1085 820 905 1,080 915 1085
Injection Rate (904)
/sec (576) (711) (510) (562) (674) (683) (75) (903) (76) (904) (683) (753) (903) (765)
594 594
Plasticizing Capacity(PS) kg/ hr 403 467 467 500 571 467 500 571 571 467 500 571 571 (487)
(487)
94/75/63 94/75/63
Maximum R.P. 140/90 127/92 127/70 120/70 110/70 127/90 120/90 110.90 110/90 127/90 120/90 110/90 110/90
(77/62/51 (77/62/51
Screw Rotation Speed M (140/75) (127/75) (115/57) (115/57) (115/57) (127/77) (120/77) (110/77) (110/77) (127/79) (120/77) (110/77) (110/77)
) )
Clamping Force ton 650 850 987
Mold Opening Force ton 40 63.5 68
mm 980X980 1,100X1,100 1,270X1,270
(HxV)
Platen Dimensions(H X V) mm 1,420 X1,420 1,580X1,580 1,800X1,800
Clamping Unit
Clamping Stroke mm 1,350 1,750 1,750

Daylight mm 1,800 2,250 2,250
Min. Mold Thickness mm 450 500 500
Mold Closing Speed High m/min 43.8(36.5) 41(34.1) 40(33.3)
Low m/min 2.0 2.4(2.0) 2.4(2.0)
Mold 0pening Speed High m/min 43.2(36.0) 34.7(28.8) 30(25.0)
Low m/min 1.7(1.4) 1.1(0.9) 1(0.8)
Ejection Force ton 21.5 24.7 24.7
Ejection Stroke mm 200 250 250
Utilized Oil Quantity ℓ 2,300 3,100 3,500
kW 45 + 45 37 + 37 +37 37 +37 +37
General
Motors
Heater Capacity kW 40.0 4.8 53.6 56.3 58.7 53.6 56.3 58.7 0.5 66 53.6 56.3 58.7 60.5 66
Machine Dimension
m 10.5X2.3X2.6 10.9X2.3X2.6 12.3X2.5X2.8 12.6X2.5X2.8 12.7X2.8X2.8 12.7X2.8X3.1
( LXWXH)
Machine Weight ton 35 37 54 58 59 62
Notes
molding conditions.
1-12 NM011C01
1.2. Safety Feature and Devices
Since the injection molding machine allows large mold clamping, and injects melted resin at
high temperatures, unexpected contingencies can occur. However, the daily checking of
safety devices and proper operation can prevent contingencies.
This machine has trifle safety devices, which are the mechanisms to cut off the electrical and
hydraulic circuits for clamping by means of opening the safety gates and also the mechanism
to mechanically prevent the moving of the movable platen.
1-13 NM011C01
Rear Side(Non-operating Side)

Safety Gate C LS1C
L1 Safety Gate A LS1

LS1A
Front Side(Opreating Side)
1.2.1. Electrical Safety Device
This safety device shuts off the electrical circuit when

Dog
the safety gate is opened. Safety Gate A
1) The operation side safety gate A is equipped

with two gate close limit switches (LS1 and
LS1A). when the safety gate is opened, LS1
and LS1A turn OFF, preventing mold closing.
Limit Switch(LS1,LS1A)
Mold opening is continued if the safety gate is
open only when the SEMI_AUTOMATIC key on
the operating panel is depressed.
Dog
2) The non-operation side safety gate C is
equipped with a gate close limit switch(LS1C).
When the safety gate C is opened, LS1C turns
OFF and pump motor is stopped, preventing
mold closing.
Limit Switch(LS1C)
NOTE :
When the machine stops by opening a safety gate, Operating Mode keys
follow the procedures below to restart the machine.
FULL SEMI MANUAL SET-UP
AUTO AUTO
1) Close the safety gate.

2) Depress the MANUAL key .
3) Restart the machine.
1-14 NM011C01
1.2.2. Hydraulic Safety Device
Safety Gate A
This safety device prevents mold closing by shutting
off the hydraulic circuit when the operation side
safety gate A is opened.
When the safety gate is opened, the cam valve (L1)
lever is pressed. Then the hydraulic circuit is acti-
vated to forcibly close the logic valve that controls
the mold closing action, and safety is obtained.
Cam Valve(L1)
1.2.3. Emergency Stop Button
User can stop machine immediately by using the

push button. An EMERGENCY STOP button is pro-
vided on both sides (operation and non-operation) of
the machine.
NOTE :
When the machine has been stopped by pressing the EMERGENCY STOP button, follow the
procedures below to restart the machine.
Operating Mode keys

(1) Turn the EMERGENCY STOP button clockwise
to unlock. FULL SEMI MANUAL SET-UP
AUTO AUTO
(2) Depress the MANUAL key or the MOLD SET-

UP key.
(3) Press the Pump Motor operation button to restart the machine.
1.2.4. Mechanical Safety Device( Option )

z Adjusting of meachanical safety device( LGH25N ~ 75N, LGH350N ~ 1000N ).
LGH25N ~ 75N
Shaft Hook Sleeve Lock Nut Lock Nut
Hook
Moving platen
Clamping cylinder Clamping cylinder
1-15 NM011C01
LGH350N ~ 1000N
Shaft Clamping cylinder Tie bar Moving platen

Hook
Hook
Sleeve
Bolt Lock Nut Flange
Bolt
Clamping cylinder
Safety gate A
1 Loose the Lock nut, and move the sleeve to the direction of
the moving platen.
2 Set your machine to the mold set up mode.
3 Start the pump.
4 Retract the moving platen to the retract limit position by
pushing the mold retract manual key.( LS3 turns ON )
5 Open the Safety gate A with the moving platen being at the Shaft Flange of sleeve Lock Nut
retract limit position. In this case, the hook must swing into
the groove of the sleeve completely.
6 Move the sleeve to the direction as shown until the flange
of the sleeve touches a clamping cylinder.
Fix the sleeve on the shaft by the lock nut on such a touch-
ing condition.
Clamping cylinder Sleeve
7 While Closing the safety gate A, check whether the hook is
swinged upward.
8 Setting is finished. Now check that the operation is normal.
z Close the platen, then open it to the mold open limit
position.
z Open the safey gate A with the moving platen being at
the retract limit position. If the hook swings into the
of the sleeve completely, the operation is OK.
9 Close the mold by pushing the mold close manual key and
turn off the pump motor.
1-16 NM011C01
z Adjusting of meachanical safety device( LGH100N ~ 200N ).
LGH100N ~ 200N
Hook Safety Bar Lock Nut
Hook Safety gate A
Moving platen
Clamping cylinder
Clamping cylinder
Note : Model of LGH100N ~ 200N uses a safety bar instead

of a shaft and a sleeve adopted on the others.
1 Loosen the Lock nut, and move the safety bar to the direc-
tion of the moving platen.
2 ~4 Same as LGH25N ~ 75N model. Refer to the previous
page.
5 Open the Safety gate A with the moving platen being at Safety bar Flange
the retract limit position. In this case, the hook must swing
into the groove of the safety bar completely.
6 Move the sleeve to the direction as shown until the flange
of the safety bar touches a clamping cylinder.
Fix the safety bar on the moving platen by the lock nuts on Safety bar
such a touching condition.
Clamping cylinder
7 While Closing the safety gate A, check whether the hook
is swinged upward.
8 Setting is finished. Now check that the operation is normal.
z Close the platen, then open it to the mold open limit
position.
z Open the safey gate A with the moving platen being at
the retract limit position. If the hook swings into the
groove of the safety bar completely, the operation is
OK.
9 Close the mold by pushing the mold close manual key and
turn off the pump motor.
CAUTION : Mechanical safety device is used for your safety and determination of the mold
retract limit position mechanicaly. Resetting of the device must be carried If the mold is
changed with new one.
NOTE : The available range of the mechanical safety device has the limit as the distance
between both platens, and it is shown below.
1-17 NM011C01
ℓ
Model ℓ(mm) Model ℓ(mm)
LGH 25N 300 ~ 400 LGH 200N 240 ~ 1,000
LGH 50N 300 ~ 530 LGH 350N 300 ~ 1,250
LGH 75N 180 ~ 550 LGH 450N 700 ~ 1,450
Clamping Moving Stationary LGH 100N 140 ~ 630 LGH 550N 800 ~ 1,600
cylinder platen platen LGH 140N 190 ~ 800 LGH 650N 900 ~ 1,800
LGH 160N 220 ~ 900 LGH 850N 1,000 ~ 2,250
1.2.5. Nozzle Safety Cover (Option)
This nozzle safety cover is intended to eliminate the

danger of splashed resin at the time of purging.
This cover is equipped with a limit switch (LS1Z)
used as an interlock for safety. When the cover is
opened ,LS1Z turns OFF preventing injection or
nozzle advancement.
1.2.6. Working on the machine
General
1) Wherever possible before beginning any maintenance or cleaning operations on the machine,
push the emergency stop button and disconnect the electrical supply at the main supply isolator.
2) There are no access points on the machine.
3) Always follow the safety information in this manual, and the labels attached to the machine,
and the instructions given in the maintenance section.
4) Do not attempt to by pass any of the safety systems or guarding.
5) If other personnel are also working on the machine, always advise them of the work which has
been carried out. Identify one person who will be responsible for starting the machine.
Communicate often, clearly and effectively.
Clamping Unit
1) Press the stop button and disconnect the electrical supply and ensure the hydraulic pump will
be stopped before placing any part of your body inside the molding area.
2) Do not attempt to operate the machine with any part of the safety guarding removed or with
the safety system disabled.
1-18 NM011C01
Injection Unit
1) Before starting any work on the injection unit, close the hopper shut off and remove any re-
maining material in the barrel by purging thoroughly. Once purging is completed, decompress
the barrel by retracting the screw.
Any residual polymer in the barrel may generate excess gas pressure in the barrel. For this
reason, do not attempt to remove solidified material from the nozzle until this process has
been completed.
2) Excessive pressure may cause molten polymer to be ejected from the barrel, nozzle or sprue bush
3) When removing the screw assembly from the barrel do not stand in front of the screw.
4) Keep hands and face away from the barrel/nozzle area. Always wear protective clothing, such
as a gloves, eye and face protection.
5) When working on the feed throat area, always press the stop button, disconnect the electrical
supply and check the screw rotation stops before attempting to fix any problem.
Hydraulic System
1) High pressure hydraulic oil under may cause serious injury.
2) Do not attempt to repair hydraulic system, pipe work or valves until the stop button has been
pressed, the electrical supply has been disconnected and the system has been bled correctly.
3) Regularly inspect the hydraulic hoses, pipes and joints for signs of cracking, chafing or other
deterioration. Replace suspicious parts immediately with correct LS Mtron factory replace-
ments parts or approved equivalent.
4) Regularly inspect the security of plugs, connectors, fixing bolts and other fittings, and if neces-
sary tighten to the correct torque setting. Inspect for signs of oil leaking and report any re-
maining leaks immediately.
Electric System
1) Maintenance and repairs on electric circuits should be carried out only by qualified personnel,
authorized by the employer.
2) Before commencing any work on the electric circuits, disconnect and lock the main isolator in
the “off” position.
3) Always follow the appropriate code of practice and factory regulations.
1-19 NM011C01
1.2.7. Operating the machine
General
1) Read and fully understand all aspects of the safety systems employed on the machine.
Do not attempt to pass over any of the safety procedures or instructions.
2) Ensure you are fully aware of all operating functions, particularly with the machine setting pa-
rameters.
3) Maintain the machine in clean condition.

Do not leave tools or other equipment on the machine while it is in operation.
4) Do not eat any food or drinks on the machine while in operation.
5) There is no access point on the machine.
6) Regularly inspect the machine for loosened fixings, guarding and other assemblies.
Report any machine fault immediately.
7) Regularly check the tightness of the mold mounting clamp bolts, as they may loosen during
normal operation.
8) Always ensure the barrel temperatures are set according to the recommendations of the mate-
rial suppliers.
Some materials, including polyvinyl chloride, acetyl’s etc., will degrade if left in the heated
condition for too long time.
These materials must be purged in the correct manner and in accordance with the supplier in-
struction after use.
Always ensure the machine operators are fully conversant with the properties of the material
being processed.
The maximum operating temperature of the injection unit should not exceed 350°.
CAUTION :
Obtain Material Safety Data Sheets (MSDS) from the supplier. Follow the safety requirements.
1-20 NM011C01
1.2.8. Essential Safety Checks (ESC’s)
The essential safety checks are the most important part of the operator’s responsibility. The pur-
pose of the ESC’s is to ensure the safety features of the machine are functioning properly, and
thus the machine is in a safe condition for use.
In addition to the operator it is recommended that regular additional ESC’s are carried out by the
responsible person and that a record is maintained.
If any of the ESC’s are in the “fail” condition, do not operate the machine. Immediately notify the
responsible person of the company and contact the LS Mtron Service department as soon as pos-
sible.
1. Confirm the machine settings and condition are correct for operation, and the machine is ready
for production.
2. Press “Motor Start Button” and start the hydraulic pump motor.
3. Depress the MANUAL key.
Essential Safety Checks

Group 1. Front safety guard
Open the front safety guard a minimum of 50mm wide and check the following conditions
Condition
ESC Description
O.K Fail
1A No clamp movements are possible
1B No ejector forward or back movements are possible
1C No injection movements are possible
1D Screen displays “GUARD OPEN” error message
Close the front safety guard
Group 2. Rear safety guard
Open the rear safety guard a minimum of 50mm wide and check the following conditions
Condition
ESC Description
O.K Fail
2A Hydraulic pump motor stops
2B No machine movements are possible
Close the rear safety guard and start the hydraulic pump motor
1-21 NM011C01
Group 3. Nozzle Safety Cover (Option)
Open the purge guard and check the following conditions
Condition
ESC Description
O.K Fail
3A No screw injection movements are possible
Closed the purge guard (nozzle cover)
Group 4. Emergency stop front
Press the front emergency stop button and check the following conditions
Condition
ESC Description
O.K Fail
Reset the front emergency stop button
Group 5. Emergency stop rear
Press the rear emergency stop button and check the following conditions
Condition
ESC Description
O.K Fail
Reset the rear emergency stop button
Group 6. General
Visual inspection
Condition
ESC Description
O.K Fail
7A Hydraulic system
7B Electric system
7C Machine guarding
1-22 NM011C01
1.3. Daily Inspection Prior to Machine Operation
The structure, functions and safety of the machine must be thoroughly understood prior to machine
operation and handling.
This chapter provides instruction regarding safe operation and injection procedures for the safety
device.
1.3.1. Inspection Prior to Operation
1) Confirm that earthling work has been performed.

If such work has not been performed, do it before
operating the injection molding machine.
2) Confirm that the leak breaking device for the preven-

tion of electric shocks has been equipped. If this de-
vice has not been equipped, do installation of the de-
vice before operating the injection molding machine.
3) Perform the above items not only for the main body of the injection molding machine but also
for other machines and instruments around the main body of the injection molding machine.
4) Confirm that materials and instruments around the injection molding machine have been
cleaned and keep in order.
1.3.2. Precautions Before Machine Operation
1) Confirm any of Operating Mode keys is not de- Operating Mode keys
pressed, that is , the lamps attached on the keys FULL SEMI MANUAL SET-UP
do not light up. Before starting the pump, check AUTO AUTO
the Emergency Stop button and close the Back

safety door .
NOTE :
The pump can be operated under no condition other than that specified above.
2) Checking Pump Starting

With the safety gate closed, start and stop the
pump several times, and ensure that no me-
chanical movements are allowed.
1-23 NM011C01
1.3.3. Checking the Safety Device
The checking procedure is as follows. With the moving platen approximately 50mm
(1.97") from the retract limit (with the mechanical safety device deactivated), per-
form the following checks 1) and 2).
1) After depressing the MANUAL key, open Operating Mode keys

the safety gate slightly the position where
cam valve (L1) is not turned ON and (LS1) AUTO AUTO
and (LS1A) are OFF. Then set the MOLD
CLOSE button.
a) Confirmation of (LS1)
Push (LS1A) by hand, and if the mold
does not close, (LS1) is NORMAL.
b) Confirmation of (LS1A)
Push (LS1) by hand, and if the mold does not close, (LS1A) is NORMAL.
When pushing both (LS1) and (LS1A) by hand, the mold is closed.
2) Depress the MANUAL key and completely open the safety gate.
Confirmation of (L1)
When pushing both (LS1) and (LS1A) by hand and push MOLD CLOSE key, if the
mold does not close, (L1) is NORMAL.
3) Depress the MANUAL key and open the safety gate on the machine rear side
completely. If the pump is stopped, (LS1C) is considered to be NORMAL.
4) Regarding MANUAL, SEMI-AUTOMATIC and AUTOMATIC operations, confirm

that the mold is stopped when the safety gate is opened during high-speed
mold closing (machine operation side)
5) Check the EMERGENCY STOP push button.

Depress the EMERGENCY STOP push button switch while the moving platen is
closing, and ensure that all mechanical movements and the pump are stopped.
If more than one EMERGENCY STOP push button switch is equipped, each of
them must be checked.
6) Checking the Mechanical Safety Device
a) When the safety gate is opened at the

movable platen open limit, ensure that
the hook is securely positioned in the
sleeve or safetybar groove.
b) Ensure that the sleeve or safetybar

lock nut is not loosened.
1-24 NM011C01
1.4. Inspection Every Ten Days
1) Confirming the strength of the safety gate. Grip the knob and shake it slightly
back and forth and then up and down, to ensure that the safety gate has not
been damaged. Additionally, examine the transparent panel to ensure that
it adheres sufficiently to the gate.
2) Ensure that the safety gate rail is securely fixed. Check to ensure that the
roller for the rail and the gate have no abnormal play or that the rail supporting
bracket is not loosened, which could result in derailing of the safety gate.
3) Check to ensure that bolts have not been loosened.
4) Check to ensure that the safety gate open and close stopper installation bolts
are not loosened.
5) Check to ensure that the safety gate limit switch (LS1, LS1A, LS1C) installation
bolts are not loosened.
6) Check to ensure that the safety gate limit switch pushing cam is not bent.
7) Check to ensure that the cam valve (L1) roller has no play.
8) Check to ensure that the cam valve (L1) pushing dog or cam has no play, and
that the installation bolts are not loosened.
9) Check to ensure that all other bolts related to the safety gate and the rail are
not loosened.
10) Check to ensure that the installation bolts for the tie rod nuts, barrel, barrel
head and other components are not loosened, and perform additional tighten-
ing.
1.5. Precautions for Injection
1) During purging, such as when starting and

changing molding materials, perform in-
jection with the injection speed lowered to
prevent decomposed resin from dispersing.
During the operation, stay away from the
nozzle.
2) Turn OFF the power switch before remov-

ing the screw. Do not stand in the screw
removal direction, in order to avoid injury
if the screw jumps out.
3) Prior to removing the nozzle and the barrel

head, empty the barrel of any resin by
closing the shutter and repeated charges
and injections. If the nozzle and the bar-
rel head are removed with some resin re-
maining, flowing resin can interrupt the work. If decomposed resin flows out,
it can be very dangerous.
1-25 NM011C01
4) Keep hands and face away from the nozzle tip after the barrel temperature
risen. Gas pressure can cause molten resin to gush out even when it is not
injected.
5) Wear face, hand and arm protectors when inspecting and cleaning the hopper.
Molten resin or gases may gush out.
6) In the vented type injection molding machine, vented resin should not be re-
moved during screw rotation or injection. Molten resin or gases may gush out
of the vent port while vented resin is being removed, or when the vent port is
inspected. Be sure to wear a face protector.
7) Thermal resins such as polyvinyl chloride and polyacetal resins, which are
likely to thermally decompose, must be purged after completing molding opera-
tions, and must be replaced with stable resins, i.e. polytyrene.
8) Never remove dripping resin from the nozzle when it is advancing. Your hands
may get caught between the nozzle and the mold. The nozzle must be
stopped before removal of dripping resin.
9) Do not step on the nozzle safety cover or the barrel cover. This cover is de-
signed to prevent burns and electric shocks. If can be extremely dangerous.
10) Never operate the machine if the hopper has been removed.
11) Confirm that the temperature control of the barrel is proper. If the tempera-
ture is too high, heat loss will occur, and molten resin could gush out.
1.6. Precaution for Clamping
1) Danger of inserting finger through the wire mesh of the safety gate or the
transparent panel requires immediate repair. Never remove molded products
from a hole. Be sure to open the safety gate before taking out molded prod-
ucts.
2) During machine operation, never put your hands into the injection molding ma-
chine over or around a safety gate. Never touch moving parts of the injection
molding machine.
3) Inspect the safety devices daily.
4) Check the mold mounting blots. If the mold is not properly secured, the mold
may slide or fall during the injection molding process. Extreme caution should
be exercised, especially while nozzle continue to advance. Give sufficient
consideration to the maximum clamp opening force and nozzle sealing force,
and maintain the proper bolt size, number of bolts and tap depth. The tap
depth should be more than 1.5 times the bolt diameter. Pay attention to en-
sure that the mounting bolts are evenly fitted to the upper, lower, right and left
sides of the mold. Periodic additional tightening is required, as the mounting
bolts may become loose during molding operations.
5) If the safety device is opened or the machine is stopped while the mold is being
closed, the moving platen may open slightly. If the mold is not clamped to the
platen with installation bolts, a mold which is not equipped with a locating ring
may fall, which is very dangerous. The mold should be lifted by a crane or
1-26 NM011C01
some other means until clamping with installation bolts is completed.
1.7. Precaution for the Hydraulic System
1) Do not set hydraulic pressure higher than the prescribed value. If the pres-
sure exceeds the prescribed value, it may not only shorten the effective life of
the injection molding machine, it may also cause a serious accident.
2) Do not attempt to hold the pipe, flange or other parts with your hands to pre-
vent oil leakage. High-pressure oil can cause serious injuries.
3) Ensure that hoses have no cracks or signs of deterioration. Spouting oil from
a torn rubber hose is very dangerous.
4) Since high-pressure hydraulic fluid is flowing in the hydraulic system, check

plugs, valve plugs and clamping bolts for looseness, and tighten them. If they
are loose, the plugs could come out, and the highly pressurized oil could spout
out due to damage caused by repeated load, which is extremely dangerous.
5) If hydraulic fluid temperature is below 15℃ , operate the pump with no load until
the temperature risen to 15℃ .
1.8. Precaution for the Electric System
1) Ensure that the machine frame and operation panel are grounded, and that the
connections are not corroded. Always exercise extreme care to avoid short
circuiting.
2) Do not unplug a connector under a loaded condition.
3) Ensure that the heater wiring is not loose, and that bare wires are not ex-
posed. Be sure to Turn OFF the heater power and measure the voltage at in-
spection points to ensure that the power is OFF before inspection. Insulate the
heater wire connections with heat-resistant tape. Vinyl tape should not be util-
ized because it melts.
4) Replace damaged power supply and motor drive indicator lamps, so that they
always reflect actual operating conditions. Replace other damaged parts even
when machine operation is not directly affected by them.
5) Be sure to close the operation panel cover before operating the machine. Do
not put your hands into the cover carelessly to avoid dust entry and electric
shocks
6) Use your right hand to turn ON and OFF the power switch. Keep your left
hand away from the instruments and the machine body.
7) After the machine has been stopped, confirm that the machine is on the MAN-
UAL operating mode, that is any of Operating Mode key is not depressed ex-
cept for the MANUAL key. If this is not done, the sudden restart of the ma-
chine could cause a serious accident.
8) Be sure to turn OFF the power and measure the voltage at check points to en-
1-27 NM011C01
sure that the power is OFF before doing any electric work. If testing of elec-
tric circuits is required with supplying of electric power, remove all tools and
other materials, and perform the check with special care. Also, ensure that
the work area is dry and use electrically insulated shoes and gloves.
9) When performing electric work, be sure to remove any metallic tools, watches,
jewelry and eye glasses.
10) Do not leave the operating panel cover or control panel door open.
11) Ensure that the machine is properly grounded.
12) Ensure that a ground leakage breaker for preventing electric shocks is in-
stalled.
13) Points ”11)” and ”12)” also apply to any peripheral devices.
1.9. Other Precautions
1) Perform machine maintenance, adjustment oil supply, cleaning, etc. only after
stopping the machine.
2) When performing maintenance or repair, be sure to place an " UNDER REPAIR"

sign on the machine.
3) When there are several workers for mold set-up, machine maintenance, repair,
adjustment, oil supply or cleaning, do not operate the machine before checking
the position of each worker and notifying each worker.
4) If a step or a machine cover has been removed, reinstall it and make sure that
the bolts are securely tightened.
5) If necessary, order additional caution plates to ensure that all safety precau-
tions in this manual are observed.
6) Follow basic safety precaution, in order to ensure safe operation of the ma-
chine at all times.
1.10. Four Principles Regarding Safety
Strictly observe the following four safety rules.
1) Be absolutely sure that the safety gate is open before placing your hands into
the mold.
2) Stop the operation of the pump before placing the upper part of your body be-
tween the mold platens for the purpose of checking and repair.
3) Always be sure to turn OFF the power supply before entering between the mold
platens.
4) Do not touch any moving portion of power supply before entering between the
molding machine.
1-28 NM011C01
NOTE :
The above four safety principles are the most important regarding safe operation.
These principles should take precedence over all others. Please contact LS
Mtron, if there is any points in this instruction manual which you do not com-
pletely understand.
NOTE :
The electric and hydraulic circuits of this injection molding machine are equipped
with interlocks to ensure the safety of the machine operators. As unproved
changes of these circuits may result in bodily injury or damage to the machine,
always contact “LS Mtron” before attempting any modifications. LS Mtron will not
be responsible for any accidents caused as a result of modifications to the machine,
especially regarding parts related to safety and electric circuits.
1.11. Level of sound pressure
Level of sound pressure according to 86/188/EEC, 89/336/EEC, measured according to
prEN 50144:
Lpa (sound pressure) 90.0dB(A)
(Note : at the operator’s ear)
Take appropriate measures for the protection of hearing
1.12. Illumination
Illumination of the working area and of adjusting, setting-up, and maintenance zones shall be pro-
vided by user ; (Minimum 300 Ix).
Flicker, dazzling, shadows and stroboscopic effects shall be avoided if they may cause a risk.
1.13. Training
Contact the manufacturer specified on the cover page for information on training courses to aid
you in becoming familiar with this equipment / system .
1-29 NM011C01
Installation LSM-MNL-011/Ver. 1.0
Chapter 2. Installation of the Machine
2.1. Preparations for Installation .................................................................................................2

2.2. Machine Location.................................................................................................................3
2.3. Foundation ...........................................................................................................................3
2.4. Installation............................................................................................................................4
2.4.1. Moving the Machine ...................................................................................................4
2.4.2. Installing the Machine (To be Performed by the Customer).....................................10
2.5. Electrical Work ...................................................................................................................11
2.5.1. Electric Power System Wiring ..................................................................................11
2.5.2. Prevention of Electric Shocks ..................................................................................17
2.6. Piping for Cooling Water (To be performed by the Customer) ..........................................17
2.7. Hydraulic Fluid ...................................................................................................................20
2.8. Cleaning.............................................................................................................................21
2.9. Lubricating Oil ....................................................................................................................21
2.10. Reference of the Lubricating Point...................................................................................21
2-1 NM011C02
2. Installation of the Machine
2.1. Preparations for Installation
The following should be prepared prior to installation.
1) Location
Location preparation should be done according to the "FOUNDATION".
▷ (Please refer to the attached drawing for FOUNDATION details)
2) Hydraulic Fluid and Lubricating Oil

Hydraulic fluid and lubricating oil should be selected from the table of
"Recommended Hydraulic Fluids and Lubricants."
▷ (Refer to the hydraulic fluid list for descriptions of the hydraulic fluid, at the
end of this instruction.)
3) Cooling Water Hoses, Hose Couplings, and Hose Bands

The above items should be prepared according to the sizes, and positions of
the water supply and drain ports shown on the "FOUNDATION".
▷ (Please refer to the attached drawing for FOUNDATION details)
4) Power Supply Wiring Materials

Prepare cables to be connected from the distribution board of your plant to the
power terminals of the machine. Cables must meet the maximum load capacity
of the machine.
▷ ( See Specifications)
5) Entrance and Pathway

Determine the size of the machine from the " GENERAL VIEW " and check that
the entrance and pathway to the installation site are of adequate size.
▷ (Please refer to the attached drawing for GENERAL VIEW details)
☞ (FOR MACHINE DIMENSIONS, REFER TO THE "GENERAL VIEW OR FOUNDATION")
2-2 NM011C02
2.2. Machine Location

To operate this machine with optimal efficiency and improve productivity, it is necessary
to find a suitable location for the machine and its related equipment.
Avoid placing the machine in a narrow space where operator’s movement is limited.
Select a dry location where dust is not excessive, to prevent fouling of the machine and
molded products.
Observe the following precautions when selecting an installation site:
1) Ensure ample space for material supply.
2) Ensure ample space for product take-out.
3) Ensure ample space for related equipment.
4) Ensure ample space for swivel the injection unit.
5) Ensure ample space for mold set-up and machine maintenance.
6) Ensure ample space to open machine and building doors.
7) Ensure ample space for removing tie rods, motors and pumps.
8) Ensure ample adjacent space for parts inspection and repair.
9) Avoid installing the machine in the following locations:
▷ Locations subject to direct sunlight or whose ambient temperature is not
between 5℃ and 45℃
▷ Locations whose relative humidity is not between 30 and 95% or
where condensation can occur because of a sudden change in temperature
(over 10℃ /hr).
▷ Locations subject to corrosive or combustible gases.
▷ Locations subject to excessive dust, salt or iron filings.
▷ Locations where the keyboard is subject to solder splashes or welding spark.
2.3. Foundation
It is necessary to build a firm foundation to ensure the accuracy and proper functioning
of the machine. For details, refer to the drawing for " FOUNDATION PLAN "
2-3 NM011C02
2.4. Installation
2.4.1. Moving the Machine

Use a crane or rollers to move the machine to the installation site.
When using a crane, attach cables illustrated below and balance the load to prevent
excessive mechanical stress.
LGH25N~LGH350N
LGH450N, LGH550N
2-4 NM011C02
LGH650N, LGH850N, LGH1000N
2-5 NM011C02
☞ Machine Dimension &Gross Weight & Wire Specifications
The contents of ( ) are just for U.S.A.

LENGTH WIDTH HEIGHT WEIGHT WIRE SPEC
MODEL L1[mm](in) B1[mm](in) H1[mm](in) W1[TON](lbs) (US)
3107 1065 1695.5 1.9 Ø16mm x2.2 m x 1EA

LGH25N( 30N)
(122.3) (41.9) (66.8) (4,189) (Ø5/8in x86.6in x 1EA)
3402 1227 1856 2.5 Ø16mm x 1.6m x 1EA
LGH50N( 55N) (Ø5/8in x62.0in x 1EA)
(133.9) (48.3) (73.1) (5,512)
3478 1193 1745 3.5 Ø16mm x2.2 m x 2EA
LGH75N( 85N)
(136.9) (47.0) (68.7) (7,716) (Ø5/8in x86.6in x 2EA)
4544 1250 1988 4.9
LGH100N( 100N)
(178.9) (49.2) (78.3) (10,802)
4794 1350 2055.5 6.0
LGH140N( 150N)
(188.7) (53.1) (80.9) (13,227)
5160 1385 2190 7.0 Ø24mm x 5.5m x 2EA
LGH160N( 180N)
(203.1) (54.5) (86.2) (15,432) (Ø15/16in x216.5in x 2EA)
5621 1450 2165 8.0
LGH200N( 220N)
(221.3) (57.1) (85.2) (17,636)
7026 1698 2332 16.5
LGH350N( 350N)
(276.6) (66.9) (91.8) (36,376)
8100 1723 2655 25 Ø36mm x6m x 2EA
LGH450N( 500N)
(318.9) (67.8) (104.5) (55,125) (Ø1-7/16in x236.2in x 2EA)
9525 1940 2726 30 Ø36mm x 6m x2EA
LGH550N( 610N)
(375) (76.4) (107.3) (66,150) (Ø1-7/16in x236.2in x 2EA)
INJECTION 3460 9 Ø24mm x 6m x 4EA
UNIT (136.2) (19,842) (Ø15/16in x236.2in x 4EA)
LGH650N 2273 2600 34 Ø36mm x 5.8m x 2EA
( 720N) CLAMPING 6385 (89.5) (102.4) 26 (74,958) (Ø1-7/16in x228.3in x 2EA)
UNIT (251.4) (57,320) Ø36mm x 6.1m x 2EA
(Ø1-7/16in x240.2in x 2EA)
UNIT (188.2) (30,865) (Ø15/16in x236.2in x 4EA)
LGH850N 2500 2710 54 Ø36mm x 5.8m x 2EA
UNIT (292.9) (88,185) Ø36mm x 6.1m x 2EA
(Ø1-7/16in x240.2in x 2EA)
UNIT (208.7) (33,070) (Ø15/16in x236.2in x 4EA)
LGH1000N 2770 2710 58 Ø36mm x 5.8m x 2EA
UNIT (299.6) (94,799) Ø36mm x 6.1m x 2EA
(Ø1-7/16in x240.2in x 2EA)
Precautions
1) Use moving equipment (crane, rollers, cables, hooks) that can take the weight of the
machine.
2) Where cables come in contact with the machine, place a mat (lin) or wooden piece
to prevent damage to the machine.
3) Never remove wooden packing materials until transportation is completed.
2-6 NM011C02
SCREW BARREL
☞ Moving the Screw & Barrel

SCREW BARREL
WIRE SPEC.
DIAMETER WEIGHT WIRE SPEC DIAMETER WEIGHT (US)
MODEL [mm](in) [kg](lbs) [mm](in) [kg](lbs)
LGH25N Ø 25 3.5 - Ø 80 30.2 Ø 6mm x 1m x 2EA
(LGH30N) (0.98) (7.7) (3.15) (66.6) (Ø 1/4in x 39.4in x 2EA)
LGH50N Ø 28 4.1 - Ø 90 41.2 Ø 6mm x 1m x 2EA
(LGH55N) (1.1) (9.0) (3.54) (90.8) (Ø 1/4in x 39.4in x 2EA)
LGH75N Ø 36 4.5 - Ø 90 42.8 Ø 6mm x 1m x 2EA
(LGH85N) (1.42) (9.9) (3.54) (94.4) (Ø 1/4in x 39.4in x 2EA)
LGH100N Ø 36 5.6 - Ø 90 70.1 Ø 6mm x 1m x 2EA
(LGH110N) (1.42) (12.3) (3.54) (154.5) (Ø 1/4in x 39.4in x 2EA)
LGH140N Ø 45 10.7 - Ø 120 140.2 Ø 6mm x 1.5m x 2EA
(LGH150N) (1.77) (23.6) (4.72) (309.1) (Ø 1/4in x 59.1in x 2EA)
LGH160N Ø 45 11.7 - Ø 120 145 Ø 6mm x 1.5m x 2EA
(LGH180N) (1.77) (25.8) (4.72) (319.7) (Ø 1/4in x 59.1in x 2EA)
LGH200N Ø 50 16.4 Ø 6mm x 1.5m x 2EA Ø 120 159.5 Ø 6mm x 1.5m x 2EA
(LGH220N) (1.97) (36.2) (Ø 1/4in x 59.1in x 2EA) (4.72) (351.7) (Ø 1/4in x 59.1in x 2EA)
(LGH390N) (2.36) (61.1) (Ø 1/4in x 59.1in x 2EA) (5.91) (715.0) (Ø 1/4in x 59.1in x 2EA)
(LGH500N) (2.76) (102.5) (Ø 1/4in x 59.1in x 2EA) (7.87) (1,159.2) (Ø 1/4in x 59.1in x 2EA)
LGH550N Ø 75 56 Ø 6mm x 1.5m x 2EA Ø 200 594.6 Ø 6mm x 1.5m x 2EA
LGH650N Ø 90 98 Ø 6mm x 2m x 2EA Ø 250 989.8 Ø 8mm x 2m x 2EA
LGH850N Ø 105 163.5 Ø 290 1812.6
(LGH950N) (4.13) (360.5) Ø 6mm x 2m x 2EA (11.42) (3,996.1) Ø 8mm x 2m x 2EA
LGH1000N Ø 105 163.5 (Ø 1/4in x 78.7in x 2EA) Ø 290 1812.6 (Ø 5/16in x 78.7in x 2EA)
(LGH1100N) (4.13) (360.5) (11.42) (3,996.1)
2-7 NM011C02
☞ Hydraulic Installation Guide
LGH650N, LGH850N, LGH1000N
2-8 NM011C02
☞ Electric Installation Guide
The model over 650ton has a structure to be disassembled into injection unit and clamping unit.
It is required to check the electric wires which are disassembled for transportation of injection
molding machine at installation, start up and should be re-connected after main power is off as
follows;
▶ When disassembling ( Check that main power is off)
1) Main Control Box.
-. Loosen the Quick mate for in/output that is in connection with inside of main control box.
-. Loosen the cable connected with controller.
-. Loosen the fixing screw of cover located at left- lower part of main control box.
-. Take the electric wires out.
2) Terminal Box
-. Loosen the fixing screw of B2 box cover which includes heater wire connection or manifold,
external input wire.
-. Loosen the fixing screw of electrical wire connected with terminal plate within B2 box.
-. Loosen the fixing ring of flexible tube at box side.
▶ When connecting (Check that main power is off)
-. Take the reverse step of disassembly when connecting electric wires and make sure to connect
with identical number of Quick mate before connecting Quick mate in control box.
Also make sure to check the number and connect when connecting the electric wires in
terminal plate of B2 box
2-9 NM011C02
2.4.2. Installing the Machine (To be Performed by the Customer)
Place the machine on the concrete base. Insert the liners (attachments for base) in
the gap between the machine and the base (at both sides the Foundation Bolt), fix
the Foundation Bolt, and fill the pit with mortar. As for the mortar, mix it with
some quick-dry aid (NON-SHRINK OR ITS EQUIVALENT)for filling.
The machine will be able to open in two or three days.
*LEVEL PAD (OPTIONAL)

Construction of the leveling pad and adjustment method may differ according to the manufacturers.
2-10 NM011C02
2.5. Electrical Work
2.5.1. Electric Power System Wiring

Only qualified personnel should interface this machine to the power supply after becoming
thoroughly familiar with all warnings, safety notices in the manual.
Should you are competent to do this, proceed as instructed below.
If you are in doubt, contact LS Mtron Service personnel or a qualified electrician immediately.
IMPORTANT !
Before attempting to interface power system, read all the instructions in the manual.
For safe operation :
z Keep the work area clean. Cluttered areas and benches invite injuries.
z Consider work area environment. Do not expose the tool to rain. Keep work area well lit.
Do not use power tools in the presence of flammable liquids or gases.
z Keep visitors away. Do not let visitors touch the system or tool. All visitors should be kept
away from work area.
z Do not force the tool. It will do the job better and safer at the rate for which it was intended.
z Use the right tool. Do not force small tools or attachments to do the job of a heavy duty tool.
Do not use tools for purposes not intended.
z Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving and
extruded parts. Non-skid footwear is recommended when working outdoors. Wear
protective hair covering to contain long hair.
z Use protective equipment. Use safety glasses and if the cutting operation is dusty, a face
or dust mask.
z Do not abuse the cord (if fitted). Never carry the tool by its cord or yank it to disconnect it
from the socket. Keep the cord away from heat, oil and sharp edges.
z Secure your work. Use clamps or a vice to hold your work. It is safer than using your hand
and it frees both hands to operate the tool.
z Do not overreach. Keep proper footing and balance at all times.
z Avoid unintentional starting. Do not carry the tool with a finger on the switch.
z Stay alert. Watch what you are doing. Use common sense. Do not operate when you are
tired.
2-11 NM011C02
1) POWER SYSTEM :
This system is designed for the 200V-220V, 50/60 Hz of three (3) phase power distribution system
having separate neutral (1) and protective earth (1) conductors. Ensure that the power supply
voltage and frequency are correct before power system interface. If you have any questions on
the electric ratings, see each nameplate located on the surface of Control Box. Five (5) cored
power service cable is required for the electrical power system interface with suitable conductor
size as explained on the drawings titled “FOUNDATION” which are enclosed herewith. And the
maximum load capacity is as follows
The contents of ( ) are just for U.S.A. (Unit : KVA)

25N 50N 75N 100N 140N 160N 200N 350N
Model
(30N) (55N) (85N) (110N) (150N) (180N) (220N) (390N)
Capacity 24 32 29 40 60 74 87 128
Model LGH450N(550N) LGH550N(610N)

i27 i33 i27 i33 i54
Hz A B A B A B A B A B
60 165.4 173.6 171.8 184.6 178.6 193.4 187.8 187.8 214 223.6
50 137.8 144.7 143.2 153.8 148.8 161.2 156.5 156.5 178.3 186.3
LGH650N(720N) LGH850N(950N)
i33 i54 i90 i54 i90
Hz A B A B Y A B A B Y A B
60 233.8 233.8 260 269.6 287.2 292.6 297.4 302 311.6 329.2 324.6 339.4
50 194.8 194.8 216.7 224.7 239.3 243.8 247.8 251.7 259.7 274.3 278.8 282.8
Connect the aforementioned power supply to the primary side terminal of the no-fuse breaker
(NFB) in the electromagnetic control cabinet built in the injection molding machine proper.
2-12 NM011C02
2) PREPARING CABLE :
a. Preparing cable for crimping shall consist of removing the insulation by use of hand or
machine wire stripping tools exposing the copper conductor. The trimmed edge of the
insulation on stripped wires shall be neat, smooth and uniform. The insulation must be
complete and intact with no cuts, bums, or tears.
b. The prepared cable conductors shall have no broken strands or damaged insulation.
Precision type wire strippers should be used to remove the insulation from conductors. The
wire should be placed in the correct stripping hole for the corresponding wire size to avoid
cutting wire stands.
c. To maintain the lay of the wires in its original form, the insulation being removed should be
twisted when removed. Outer jacket of cable should be neatly stripping and filler of cable
neatly trimmed at end of outer jacket. No cut in conductor insulation is allowed.
d. Shielding braid, if any, should not be cut, frayed or nicked, and should be neatly tapered to
pigtail.
(Example of wire stripping)
PREFERRED
Insulation does not have

frayed edges. Wire strand is
not cut or damaged.
UNACCEPTABLE
Insulation damaged.
Wire stand is cut.
2-13 NM011C02
3) SOLDERLESS TERMINATIONS :
a. Terminal lugs of ring type are required for the connections.
b. All mechanically crimped terminals shall be capable of withstanding minimum tensile

strength requirements on a force gauge. The tensile strength requirement is minimum 60
pounds.
c. Crimps shall be clearly evident in the barrel of the lug, but shall not damage the conductor.
d. Crimps in the insulation of the lug shall not damage the insulation of the wire.
e. Broken, nicked or loose strands of wire shall be avoided. Bent or damaged connectors are
unacceptable.
(Example of solderless termination)
PREFERRED
Insulation crimp and conductor crimp

in proper locations on lugs.
Conductor extents less than 1/16 inch

beyond conductor portion of crimp.
Insulation is fully inserted.
UNACCEPTABLE
Conductor exceeds maximum

dimension of 1/6 inch beyond
conductor portion of crimp
2-14 NM011C02
4) CLAMPING TERMINAL LUGS :
a. Open a door of Control Box and access to the field-wiring terminal block for external power
connection located at right/bottom on panel.
b. Route the prepared power cable through grommetted cable inlet opening at the bottom of
control box.
c. Ensure the phases (L1, L2, L3, N) and protective earth (PE) conductors of the prepared power
cable are correct before clamping terminal lugs to the field-wiring terminal block assigned for
power interface.
d. All electrical connection shall be clamped tightly with the torque of 2.0 TO 2.2 inch-pounds.
And the tightness shall be inspected at 80% of the torque value.
e. WARNING : Never connect phase conductors (L1, L2, L3) or neutral conductor (N)to the
protective earth terminal marked PE.
2-15 NM011C02
5) ELECTRIC SAFETY CHECK :
When the electric power interface has been fully completed, the following tests shall be performed:
a. CONTINUITY OF THE PROTECTIVE BONDING CIRCUIT :
The protective bonding circuit shall be visually inspected for compliance with items 1) to 5)
mentioned above and a check for tightness of the connection of the protective conductors shall be
made according to item 5).
In addition, the continuity of the protective bonding circuit shall be verified by injecting current of at
least 10A at 50Hz derived from a PELV source for a period of at least 10s. The test shall be
made between the PE terminal and the various points of test shall not exceed the value given in
the table below:
Table. Verification of the continuity of the protective bonding circuit
Minimum effective protective Maximum measured

Conductor cross-sectional voltage drop (V)
area of the branch under test
(square mm)
1.0 3.3
1.5 2.6
2.5 1.9
4.0 1.4
6.0 or larger 1.0
b. INSULATION RESISTANCE TESTS:
The insulation resistance measured at 500 V Dc. between the power circuit conductors protective
bonding circuit shall be not less than 1 mega ohms.
C. VOLTAGE TESTS
The electrical equipment shall withstand a test voltage applied for a period of at least 1 s between
the conductors of all circuits, excluding those intended to operate at or below PELV voltages, and
the protective bonding circuit.
The test voltage shall :
- have a value of twice the rated supply voltage of the equipment or 1000 v, whichever is the
greater;
- be at a frequency of 50 Hz ; and
- be supplied from a transformer with a minimum rating of 500VA.
Components which are not rated to withstand this test shall be disconnected during testing.
2-16 NM011C02
2.5.2. Prevention of Electric Shocks
To prevent accidents caused by leakage or electric shock, observe the following

precautions.
1) Ensure that the machine is properly grounded.

Operating voltage under 400V .............. Resistance to ground < 100 ohms
Operating voltage over 400V ................ Resistance to ground < 10 ohms
High voltages ...................................... Resistance to ground < 10 ohms
All metal chassis of related equipment must be directly connected to the main
ground terminal of the machine. This keeps all metal bodies at the same
electric potential, reducing the chance of an accident.
2) Grounding of the machine cannot completely prevent electric shocks.

Under normal conditions, the machine will not cause an electric shock.
However, if a power line contacts the metal body of the machine, or insulation
failure causes a ground-fault, a large current may flow to ground causing the
voltage of the machine body to increase. Therefore, equipment such as a leak-
breaking device is required.
3) Regarding the Role of the Earth Leakage Circuit Breaker.

For machines and instruments with low voltage, which are provided with a
metal outer box and utilize voltage over 60 volts, a device which automatically
breaks the electric line when electric current begins to leak to the ground must
be equipped at the electric line installed at the location where there is a danger
of the machine operator(s) easily contacting the machine or instrument.
4) The setting location is indicated as follows.

Except in the case where the machine or instrument is equipped with a leakage
breaker, the breaker is equipped on the side of the distribution panel or in the
distribution panel. It has been found that the leak-breaking device should be
equipped near the power source of the electric line, if at all possible.
2.6. Piping for Cooling Water (To be performed by the Customer)
Cooling water is required for the material supply part (injection bracket below the
hopper), and heat exchanger (for hydraulic fluid). Install hoses to the supply and drain
2-17 NM011C02
ports as indicated on the "FOUNDATION".
Observing the following precautions.
1) Since the amount of water required varies depending on ambient temperature,

molding conditions, and cooling water temperature, a stop valve must be provided
midway through the respective water lines.
2) Avoid using hard water to prevent clogging of the cooling water system.
3) Minimum required amounts of water are indicated below. It is necessary to install

hoses that can handle three times theses flow volumes.
4) If ambient temperatures are likely to be below 0 ℃ ,drain cooling water after

operation.
5) Install separate lines to the heat exchanger/hopper throat and mold.

A branch from the same pipe causes more water to flow to the heat exchanger /
hopper throat side, making it impossible to accurately control the flow to the mold.
※ Amount of Cooling Water(25℃ [77。 F])
▶ Mold and Material Supply Port

LGH25N~ LGH200N LGH350N LGH450N~ LGH650N LGH850N~ LGH1000N
(LGH30N~ LGH220N) (LGH390N) (LGH500N~ LGH720N) (LGH950N~ LGH1100N)
25ℓ /min 35ℓ /min 35ℓ /min 50ℓ /min
(6.6 U.S.gal/min) ( 9.2 ) ( 9.2 ) ( 13.2 )
▶ Oil Cooler
The contNts of ( ) are just for U.S.A.
LGH25N~ LGH200N LGH350N LGH450N~ LGH650N LGH850N~ LGH1000N
(LGH30N~ LGH220N) (LGH390N) (LGH500N~ LGH720N) (LGH950N~ LGH1100N)
25ℓ /min 30ℓ /min 40ℓ /min 70ℓ /min
(6.6 U.S.gal/min) ( 7.9 ) ( 13.2 ) ( 18.5 )
2-18 NM011C02
Well or industrial water is normally used as the coolant for the barrel, etc.
This water usually contains a variety of substances. Over long periods, these
substances can adhere to the inside of the water pipes, which can lower cooling
efficiency and also cause corrosion.
We recommended the use of cooling water in accordance with Water Quality standards
listed below.
If optional equipment such as a mold temperature controller or mold cooling unit are
installed, observe the water quality standards recommended by their manufacturers.
Reference Value Reference Value

Item for for
Cooling Water supply water
pH [25℃ ] 6.0 ~ 8.0 6.0 ~ 8.0
Electric conductivity[25℃ ](μ Ω /cm) < 500 < 200
Chlorine ion CI- (PPM) < 200 < 50
Sulfuric acid ion SO₄ ²- (PPM) < 200 < 50
Total iron Fe (PPM) <0. 5 <0. 3
Methyl orange alkalinity CaCO₃ (PPM) < 100 < 50
Total hardness CaCO₃ (PPM) < 200 < 50

Sulfur ion S²-(PPM) No trace No trace
Ammonium ion NH₄ + (PPM) No trace No trace
Silica SiO₂ (PPM) < 50 < 30
NOTE:
(1) The supply water values are for the cooling tower.
(2) Consult water treatment specialist to carry out periodic water maintenance.
(3) Clean the inside of cooling pipes in the heat exchanger at least once a year.
(4) It is recommended to install a filter preventing foreign materials from clogging the
cooling pipes in the heat exchanger.
2-19 NM011C02
2.7. Hydraulic Fluid
The oil tank is located inside the injection frame. Supply the specified hydraulic fluid through the oil port
on the injection frame, as show in the figure below. Check the hydraulic fluid volume
using the oil level gauge.
On starting the pump, the piping valves are filled with hydraulic fluid, and the fluid level
will goes down. When the machine is started, every cylinder is started, every cylinder is
filled with hydraulic fluid, and the fluid level may go down further. If this occurs, locate
the mold at the open limit and the screw at the advance limit, then add hydraulic fluid up
to the upper limit of the level gauge.
See Principal Specifications and Values or the Instruction Manual for hydraulic fluid.

MODEL LGH25N LGH50N LGH75N LGH100N LGH140N LGH160N
(30N) (55N) (85N) (110N) (150N) (180N)
Oil Supply Quantity 105 150 200 400 560 560
Liter(Galons) (27) (40) (53) (106) (148) (148)
LGH200N LGH350N LGH450N LGH550N LGH650N LGH850N LGH1000N
(220N) (390N) (500N) (610N) (72N) (950N) (1100N)
700 900 1300 1600 2300 3100 3100
(185) (238) (343) (422) (609) (819) (819)
NOTE:
(1) Refer to the Hydraulic Fluid List for descriptions of the hydraulic fluid, at
the end of this instruction.
(2) Mixing of different brands of hydraulic fluids should be strictly avoided.
(3) The customer must contact the manufacturer prior to the utilization of a fire
resistant hydraulic fluid.
2-20 NM011C02
2.8. Cleaning
Check for loose screws, damaged parts and flaws when cleaning respective
components of the injection molding machine.
Avoid using files or sandpaper to correct flaws on sliding surfaces.
Use an oilstone to finish the surface until it is level.
Rust proofing oil and paper covering the unpainted components should be completely removed.
Kerosene used to remove the oil dust should be completely removed from the tie rods,
booster ram, injection piston and other components, since it may cause damage to bushings or
packing.
2.9. Lubricating Oil
(1) Supply lubricating oil to the thrust bearing of the injection unit.
(2) Coat the respective sliding portions with grease, using the attached grease gun.
(3) Refer to the attached drawing "LUBRICATING SPECIFICATIONS" of hydraulic fluid
lubrication for details regarding lubrication point.
2.10. Reference of the Lubricating Point
The lubricating point shown on the “LUBRICATING SPECIFICATION”.
Please refer to the attached drawing for LUBRICATING SPECIFICATION details.
2-21 NM011C02
Preparation for Operation LSM-MNL-011/Ver. 1.0
Chapter 3. Preparation for Operation
3.1. Inspection Prior to Starting Operation..................................................................................2

3.2. Confirmation of Safety Devices............................................................................................2
3.2.1. Safety Gates ..............................................................................................................3
3.2.2. Mechanical Safety Devices ........................................................................................4
3.2.3. Emergency Stop Push Button Switch ........................................................................6
3.3. Starting the Machine ............................................................................................................7
3.3.1. LAY-OUT of the Operating Panel...............................................................................7
3.3.2. Test Run of the Pump Motor ......................................................................................8
3.4. Inspection After Starting Operation....................................................................................10
3.5. Mold Set - Up .....................................................................................................................12
3.5.1. Preparation ..............................................................................................................12
3.5.2. Replacement of Ejector Pins....................................................................................14
3.5.3. Mold Mounting..........................................................................................................16
3.5.4. Mold Replacement Work..........................................................................................19
3.5.5. Purging Air from the Clamping Cylinder...................................................................21
3.5.6. Spacer Replacement for Mold Thickness Adjustment .............................................22
3.6. Hopper Dryer .....................................................................................................................24
3.7. Hopper Loader ...................................................................................................................24
3-1 NM011C03
3. Preparation for Operation
3.1. Inspection Prior to Starting Operation

1) Checking the Hydraulic Fluid Level.
Use the oil gauge (in front of the OIL HIGH LEVEL
injection frame on the operation side)
a) If the oil level is below the lower

limit, add oil through the oil supply
port. OIL LOW LEVEL
b) If the oil level is above the upper
limit, extract oil through the oil
supply port.
2) Checking Lubricating Oil.

Visually check that the sliding surfaces of the machine are lubricated. Refer
to the hydraulic fluid and lubricant list for details about lubrication intervals,
amounts, and methods of application.
3) Checking Cooling Water.
a) Check that cooling water is flowing through the bottom of the hopper by using
the flow gauge,.
b) Check that water is flowing through the heat exchanger by observing the
water drain port. No water drains when the oil temperature is above 40℃ .
4) Checking the Power Supply
Check that the power supply indicator in the electromagnetic control cabinet is
on.
3.2. Confirmation of Safety Devices

This injection molding machine is equipped with safety gates, a mechanical safety
device and an EMERGENGY STOP push button switch to improve operational
safety. Confirm that the safety devices are operated properly, according to the
following order.
3-2 NM011C03
3.2.1. Safety Gates
Order Operation Confirmation
1 Depress the MOLD SET-UP key on the Operating Mode keys

operating panel.
AUTO AUTO
Operate the pump by depressing the pump
motor START push button switch on the
electrical control panel.
2 Set the LOW PRESSURE CLOSING to the

minimum value which makes the mold can
close completely by using R3 valve(Relief
Control Valve for low pressure).
It should be 35 ~ 70kgf/㎠ , and you can

identify it on the pressure gauge G1.
On the machines 200 tonnage and
Refer to chapter 4.1.1 4)Setting the Low below the cock of the G1 does not
Pressure of Clamping
exist. Only the gauge is equipped.
3 Keep depressing the MOLD OPEN key until
the movable platen retract for a specified Mold
distance.
When the movable platen reaches the proper
position, pull your hand out of the key.
4 Open the safety gate

5 Depress the MOLD CLOSE key, with the safety
gate opened. Mold
Then confirm that the movable platen does not

move. If the platen move, the safety gate has
problem.
6 While pressing the MOLD CLOSE key The movable platen advances.
continuously, close the safety gate.
7 Open the safety gate while the mold is The movable platen stops.
closing(During step 6, 7, the MOLD CLOSE
key must be depressed uninterruptedly).
8 After confirmation, pull your hand out of the Release the MOLD selector switch
MOLD CLOSE key button.
NOTE :
Confirm only the safety gate on the machine operating side safety gate A according
to the above precautions. Confirm that the pump is stopped when the safety gate
on the machine rear side safety gate B is opened.
3-3 NM011C03
3.2.2. Mechanical Safety Devices
Perform the setting and adjustment of the mechanical safety devices according to
the following procedures.
When the safety gate of operation side is opened while the mold is at the open limit,
the guide roller comes off from the safety gate and the hook is swung to the clamp
cylinder side. Then, the hook fits into the groove on the shaft preventing the
advance of the movable platen. When safety gate of operation side is closed, the
guide roller moves along the safety gate cam and the hook is swiveled away from
the clamp cylinder. The hook moves out of the groove on the shaft allowing the
advance of the movable platen.
Operating Mode keys

1) Start the pump motor.
Keep on depressing the MOLD OPEN key, AUTO AUTO
until the mold is moved up to the open limit

(LS3 ON), and then pull your hand out of the
key.
Confirm that the machine is in the mold setting
Mold
mode by check the LED on the MOLD SET-
UP .key lighting up.
1) Open the safety gate at the position of the

mold open limit. The hook should completely
come down into the shaft groove.
2) Open the Mold to the open limit (LS3 ON) by

adjusting mold open position (LS3) until the hook is securely positioned in the groove of
the rod.
3) Confirm that the hook has entered the shaft groove.
3-4 NM011C03
4) Confirm that the hook is lifted up by closing the safety gate.

The hook is lifted up by closing the safety gate, and is moved down by opening
5) After closing the mold once, open the mold up to the open limit. Open the safety gate and
confirm that the hook has entered the shaft groove.
6) Close the mold entirely, and then stop the pump motor.
7) Move the hook several times by pushing the guide roller.

Check that the hook moves smoothly.
NOTE :
The mechanical safety device is necessary for safety and for determination of the mechanical
open limit. After replacement of the mold, be sure to perform re-adjustment of the
mechanical safety device.
3-5 NM011C03
3.2.3. Emergency Stop Push Button Switch
Confirm the EMERGENGY STOP push button switches for correct operation according
to the following order.
1) Keep on depressing the MOLD CLOSE key on the operating panel to advance
the mold.
2) Depress the EMERGENGY STOP push button switch on the operating panel
during mold closing.
3) Confirm that the pump motor is stopped and that the mold is completely
stopped.
NOTE :
When the injection molding machine has
been stopped with the EMERGENCY STOP
push button switch during automatic
operation, depress the pump motor START
push button switch to restart the injection
molding machine, after eject has retracted
fully, mold has opened fully, and screw has
retracted fully,
3-6 NM011C03
3.3. Starting the Machine
3.3.1. LAY-OUT of the Operating Panel
①
③ ① Operation Mode Selection keys
② Manual Working keys
③ Screen Selection keys

②
④ ④ Numeric keys
⑤ Cursor keys
⑥ Lock key
⑤
⑦ Printer port
⑦ ⑥
3-7 NM011C03
3.3.2. Test Run of the Pump Motor
Perform the following of pump motor test procedure to confirm that it is operating
properly.
Operation panel G2, SV2

HICOM 300 TFT controller
G1, SV1 Controll panel Power switch
Power Pilot Lamp Pump Motor Power Switch

Pump Motor Start Push Button Heater Power Switch
Heater Operation Switch
Procedure
1) Confirm that the Power Lamp on the Electromagnetic control cabinet is lighting
ON.
2) Before starting the pump, ensure that the Emergency Stop button is unlocked and Rear
safety door is closed .
3) Set the set values for each pressure setting on HICOM controller to zero.
4) Turn ON the Pump Motor power switch (NO Fuse Breaker).

When multiple motors exist, turn ON all the Pump Motor power switches.
3-8 NM011C03
4) Press the Pump Motor start button to

revolve the pump motor.
NOTE :
To turn on the pump for the first time,
revolve the motor only for several seconds, but do not drive it continuously.
CAUTION :
☞ Confirm that the revolving direction of the motor is the same as the arrow on the
pump. If the revolving direction is reverse, exchange any two of the three wires
on the primary side of the power supply.
3-9 NM011C03
3.4. Inspection After Starting Operation
1) Temperature of Hydraulic Fluid.

Check that the hydraulic fluid
temperature is between 15 and 55℃ by
using the oil temperature gauge,.
a) If the oil temperature is below 15℃ ,

run the machine dry. Ensure that the
oil temperature is above 15℃ before
starting molding operations. Use the
hydraulic fluid warming-up equipment
if installed to raise the oil temperature. (For details, refer to option device)
b) If the oil temperature is above 55℃ , check the flow of cooling water to the
heat exchanger.
c) If cooling water is not being supplied to the heat exchanger, supply it.
2) Noise and Vibration.

Listen and look for any abnormal noise and vibration.
CAUTION
If abnormal sound or vibration is found, trace the cause and resolve it.
3) Filter Clogging.
Check that the oil cleaner vacuum gauge
does not read over 10 mmHg when
hydraulic temperature is 40℃ .
CAUTION
If pressure exceeds 10 mmHg replace the
filter. (Refer to Chapter 6 " Replace the
part")
3-10 NM011C03
4) Oil Leakage.
Check the valve mounting face, hydraulic pipe joints, and cylinder packing for
oil leakage visually and by touching them.
CAUTION
If oil leakage is found, Refer to Chapter " Inspection & Maintenance"
5) Lamp Burnout.
Check the power supply lamp (pilot lamps),back lighted push button lamps for
burnout.
IMPORTANT
If any lamp is burned out, replace it immediately.
3-11 NM011C03
3.5. Mold Set - Up
3.5.1. Preparation
V
Prior to mounting a mold, check the following
items to determine whether the mold
H
matches the injection molding machine.
1) Is the size of the mold correct for the Minimum Mold Size[STANDARD]
machine? Model SIZE[H,V×T] mm (in)
25N(30N) 150×150 (6.0×6.0)
a. Confirm the mold mounting space 50N(55N) 185×160 (7.3×6.3)
according to the platen dimensions, 75N(85N) 182×180 (6.2×7.1)
clamping stroke, minimum mold 100N(110N) 220×170 (8.7×6.7)
thickness and open daylight. Also, limit 140N(150N) 262×190 (10.3×7.5)
the minimum mold dimensions to those 160N(180N) 300×220 (11.8×8.7)
shown on the right, when using the mold 200N(220N) 315×240 (12.4×9.4)
under maximum clamping force. 350N(390N) 410×300 (16.1×11.8)
450N(520N) 485×350 (19.1×13.8)
b. As if the dimensions are set less than 550N(610N) 485×400 (19.8×15.7)
those at right, flash marks will appear on 650N(720N) 570×450 (22.4×17.7)
the mold products. Release the clamping
850N(950N) 640×500 (25.2×19.7)
force in such a case.
1000N(1100N) 735×500 (28.9×19.7)
The contents of ( ) are only for U.S.A
2) Is the injection capacity sufficient ?

Check the injection capacity according to the
specifications of the machine.
3) Is the diameter of the locate ring hole proper?

Confirm whether the sprue bushing of the
mold matches the locating ring hole in the Model Locating Hole
stationary platen. LGH25N ~
Φ100mm
LGH650N
(Φ4in)
(30N ~720N)
LGH850N ~
Φ120mm
LGH1000N
(Φ5in)
(950N~1100N)
3-12 NM011C03
4) Is the nozzle spherical radius proper?

Check the spherical radius and bore of the
sprue bushing of the mold and nozzle.
Model B C
LGH25, 50N
(LGH30, 55N) φ3
LGH75, 100, 140N (φ3)
(LGH85, 110, 150N)
R19
LGH160, 200, 350N φ4
(R12.5)
(LGH180, 220, 390N) (φ4)
LGH450, 550, 650, 850, φ5
1000N (φ5)
(LGH500 ~1100N)
5) Do the ejector pins match the injection

molding machine?
a. Confirm that the position, diameter and

length of the ejector pins match the
machine.
b. The ejector stroke (ℓ 3) is the total of the

effective ejector stroke (ℓ 1) and the
length from the mounting surface to the
ejector plate (ℓ 2).
6) Is the mold parallel to the platen mounting

surface?
Model Eject Stroke Model Eject
(ℓ1) Stroke
(ℓ1)
25(30N) 50mm(1.97in) 200(220N) 100(3.94)
CAUTION 50(55N) 60mm(2.36) 350(390N) 125(4.92)
75(85N) 55mm(2.16) 450(500N) 160(6.3)
If they are not parallel, uneven force will be
100(110N) 63mm(2.48) 550(610N) 160(6.3)
placed on the tie rods, causing them to break. 140(150N) 80mm(3.15) 650(720N) 200(7.87)
160(180N) 90mm(3.54) 850(950N) 250(9.8)
1000(1100N) 250(9.8)
3-13 NM011C03
3.5.2. Replacement of Ejector Pins
Replace the ejector pins in the following manner. Prepare new ejector pins, a
single-ended wrench, etc.
Operating Mode keys

1) Depress the MANUAL key then close the
safety gate. Ascertain the set values of AUTO AUTO
Ejector Count, speed, and pressure are

not zero at HICOM 300 controller’s
MODL & EJECTOR screen.
2) Depress the pump motor start push [ Mold & Ejector ] Auto
button switch on the electromagnetic 0350 mm
control cabinet, to operate the pump. Check it Ejector Mold N

Ejector Count : 2 00 Clamp E
Ejector B Pos.: 0100 mm Quick M
3) Keep on depressing the EJECT ADV. key Check it Cycle Ti
PEF 50.0 %
020.0
until it is allowed the ejector pins to VE1 40.0 % VE2 30.0 % 000.0
protrude from the mold mounting surface. TRE1 00.5sec TREH 00.0sec
PER 50.0 % Inter. Ti

4) After the ejector plate has reached the ㅿ 003.0
VE4 20.0% VE3 30.0% 000.0
ejection limit, depress the pump motor TRE2 00.5 sec
STOP button.
Eject
5) Open the safety gate.
6) Remove unnecessary pins by turning

them with a spanner. (Right-hand screws
are utilized)
3-14 NM011C03
7) Install ejector pins in the required

positions. At this time, confirm that the
ejector pins are securely screwed into
the ejector plate.
8) Depress the pump motor START button
10) Keep on depressing the EJECT RET.

Eject
Key until the ejector reach the ejector
retract limit.
11) Confirm that the ejector pins are set

back from the mold mounting surface.
CAUTION
☞ Confirm that the pump motor is stopped before entering the injection molding
machine to replace the ejector pins.
3-15 NM011C03
3.5.3. Mold Mounting
Mount the mold according to the following procedures.

Prepare mold mounting bolts, washers, closed wrench, clamps, etc.
1) Depress the MOLD SET-UP key on Operating Mode keys
the operation panel. Press the

AUTO AUTO
pump motor START button on the
Electromagnetic control cabinet to
operate the pump .
2) Keep on depressing the MOLD OPEN

key, until the mold reaches the mold
Mold
open limit, and then pull your hand out of
the key.
3) Keep on depressing the NOZZLE

RETRACT key until the nozzle reaches Nozzle
the retract limit, and then pull your hand
out of the key.
4) Stop the pump by pressing the motor

STOP button.
3-16 NM011C03
5) Suspend the mold. Position the mold by

inserting the locating ring in the hole on
the stationary platen side.
6) Press the motor START button. Keep

on depressing the MOLD CLOSE key, to
advance the movable platen, then pull
your hand out of the key when the
movable platen contacts mold.
1) Check that the mold is mounted

perpendicularly.
8) Attach the mold to the stationary platen

and the movable platen with bolts. Use
bolts with a threaded depth of 1.5d to 2d
mm (d = Bolt Diameter). Although the
method of fixing the mold depends on
the type of mold, the method shown in
the following figures is generally used.
3-17 NM011C03
① Attach the mold securely to the platen with clamps.
Model Bolt Used Screw Depth

LGH50~200N M16 35mm
LGH315N M20 40mm
LGH25N M12 25mm
② Attach the mold directly to the platen
with bolts.
9) Remove the cables supporting the mold.
10) Press the motor START button and push

the MOLD OPEN and MOLD CLOSE key
several times alternately.
Confirm that the guide pins of the mold
mesh properly
CAUTION :
Confirm that the pump motor is stopped before entering the injection molding
machine to replace molds.
Keep the mold suspended using a crane until the completion of mold set-up to
ensure that it may not fall.
3-18 NM011C03
3.5.4. Mold Replacement Work
To replace with the next mold after a molding work, follow the procedure below.
Operating Mode keys
1) Depress the MANUAL key and press the FULL SEMI MANUAL SET-UP
AUTO AUTO
Pump Motor Start button to start the
pump.
2) Keep on depressing the MOLD CLOSE

key until the mold reaches the mold Mold
close limit, then pull your hand out of the
key.
3) After confirming that the mold has

completely been completely closed,
press the Pump Motor Stop button to
stop the pump.
4) Lift up and fix both movable mold half

and stationary mold half, and detach the
clamp bolt.
5) Depress the MOLD SET-UP key, then Operating Mode keys
start the pump. FULL SEMI MANUAL SET-UP

AUTO AUTO
NOTE:
Be certain to select the MOLD SET-UP.
Especially to replace a thin mold with a thick one, mold closing or mold opening will
not be activated without the MOLD-SET-UP mode.
3-19 NM011C03
6) Keep on depressing the MOLD CLOSE

key until the mold reaches the mold Mold
close limit, then pull your hand out of the

key.
7) Press the Pump Motor Stop button to

stop the pump.
8) With the mold lifted up, take the Sprue

Bush out of the locate hole of the
stationary platen and then detach the
metallic mold.
9) Attach the next mold. Work in the

procedure of step 5) to 10) of the 3-5-3
‘Mold Mounting’.
CAUTION :
When part of your body must be inserted in the machine for replacing the
metallic mold, be certain to stop the Pump Motor first.
Lift up the Mold until the mold replacement work is completed, so that it may
not fall.
3-20 NM011C03
3.5.5. Purging Air from the Clamping Cylinder
Air should be purged from the clamping cylinder at the time of mold mounting.
If air is in the clamping cylinder, mold open and close movements will become
irregular.
Operating Mode keys

1) Depress the MANUAL key.
AUTO AUTO
2) Depressing the MOLD CLOSE key ,until

the mold reaches the close limit ,and at
that moment keep touching the key so
that high-pressure clamping operation is Mold
performed at the close limit.
At this time, Purge air by slowly opening
the purge valve. Before purging the air,
repeat OPEN and CLOSE several times.
3) After air purging, close the purge valve.

If this valve is not closed, the movement
may be irregular and clamping pressure
may not increase.
NOTE :
After the machine has been stopped for a long time, be sure to purge air prior
to operation.
3-21 NM011C03
3.5.6. Spacer Replacement for Mold Thickness Adjustment
※ To be applied the LGH350N and Smaller Machines if fitted.
Order Operation Confirmation, Precaution

Operating Mode keys

Depress the MOLD SET-UP key. AUTO AUTO
1 Then push the ,pump-motor-START push

button to operate the pump.
Keep on depressing the MOLD CLOSE key Mold
until the mold reach sufficient position for

2
spacer removal. Then pull your hand out
of the key to stop the mold.
Stop the pump by push the pump motor

3
STOP push button switch.
Remove clamping bolt (1) which connects

4
the ejector box and spacer, with a spanner.
Operate the pump.
Depress the MOLD OPEN key until the

mold reach the mold open limit, then
5
separate the ejector box (moving platen)
from the spacer.
Stop the pump.
3-22 NM011C03
Hook a wire rope on the hanging bolt of the

spacer, and hoist the spacer.
6
Then remove clamping bolt (2), which
connects the clamping ram and the spacer.
Operate the pump,
Depress the MOLD OPEN key to open the

mold and separate the spacer from the
7
clamping ram.
Stop the pump.
8 Hoist up the spacer and remove it.
Operate the pump
Depress the MOLD CLOSE key to close the

9
mold and connect the ejector box (moving
platen) to the clamping ram.
Connect the ejector box to the clamping

10
ram with removed clamping bolt (2).
The Mounting of spacer is the reverse order

11
of above procedures.
NOTE
The pump motor must be stopped during mounting and dismounting of the spacer, before
putting any part of your body in the injection molding machine.
3-23 NM011C03
3.6. Hopper Dryer
For direct installation to the hopper mounting

on the injection unit, mount the hopper dryer
according to the mounting dimensions insert
on the attached drawing for " GENERAL
VIEW". The hopper dryer exit dimension
should be 1 to 2 mm smaller than the hopper
opening. If the exit dimension is larger, resin
change and color change will be more
difficult.
3.7. Hopper Loader
For installation of a hopper loader on the molding machine, machining is required.

Consult the source of your purchase before the machine is delivered.
3-24 NM011C03
Start-up adjustment LSM-MNL-011/Ver. 1.0
Chapter 4. START-UP ADJUSTMENT
4.1. Adjustment of the Clamping Unit .........................................................................................2

4.1.1. Adjustment of Clamp Side Control .............................................................................2
4.1.2. Adjustment of Mechanical Safety Device...................................................................8
4.2. Adjustment of Hydraulic Ejector ...........................................................................................8
4.2.1. Movement ..................................................................................................................8
4.2.2. Setting the Ejection Stroke.........................................................................................9
4.2.3. Adjustment of Ejecting Speed ..................................................................................10
4.3. Adjustment of Injection Unit ...............................................................................................11
4.3.1. Adjustment of Injection.............................................................................................12
4.3.2. Adjustment of Nozzle ...............................................................................................16
4.4. Timer Functions and Settings ............................................................................................18
4.5. Injection amount data sheet...............................................................................................19
4-1 NM011C04
4. START-UP ADJUSTMENT
4.1. Adjustment of the Clamping Unit
4.1.1. Adjustment of Clamp Side Control

After the completion of mold mounting, perform the setting of clamp side control
and pressure adjustment according to the following order. (Refer to the
instruction manual for HICOM controller)
First read the following paragraphs and then use the picture below for better
understanding.
2)-⑥ 40%
[ Mold & Ejector ] Auto SET 08-25 FRI 09:31
T2 50% 2)-⑤ 40%
0350 mm Speed 250mm/s R2 30%
Ejector Mold No.: 01 2)-④

Ejector Count : 2 00 Clamp Energy Saving : ON 06.0 sec after Inj. Out
Ejector B Pos.: 0100 mm Quick Mold Opening : OFF 2)-③ 100mm
PEF 50.0 % Cycle Time VC1 VC2 TR-6

020.0 sec 00.0
VE1 40.0 % VE2 30.0 % 000.0 60.0 % 70.0 % 02.5 sec 2)-② Zero
TRE1 00.5sec TREH 00.0sec LS2B LS2A LS2 calibration
ㅿ0250 ㅿ0090 ㅿ01.0 mm
2)-① Proper value
PER 50.0 % Inter. Time VO3 VO2 VO1 for escaping
ㅿ 003.0 sec
the product
VE4 20.0% VE3 30.0% 000.0 30.0 % 70.0 % 40.0 %
TRE2 00.5 sec LS3 LS3B LS3A
ㅿ0350 ㅿ0250 ㅿ0030 mm
3)-④ 40%
3)-③ 40%
LS3A + LS3P
3)-③ LS3B =
2
3)-① 50mm
The initial set values of each profile
1) Depress the MOLD SET-UP key, and start the pump by depressing the pump
4-2 NM011C04
Operating Mode keys
motor START push button switch. FULL SEMI MANUAL SET-UP

AUTO AUTO
2) Setting of Mold closing movement:

As shown right, mold closing movement of
Mold closing speed

100
our machine has three sections. User can set
VC1 VC2
these set values on Hicom300 controller’s 40% 40%
[Mold & Ejection] screen.
LS3 LS2B LS2A LS2
Mold closing stroke
① LS3(Mold open limit) :
1. After a new mold is set on the machine, check that the machine is in the mold
setting mode by ascertaining the LED on the MOLD SET-UP key lighting up. If not
depress the MOLD SET-UP key.
Then enter the maximum mold opening stroke on the LS3 profile.
2. Depress the MOLD OPEN key until the mold reach a proper stroke, then pull your
hand out of the key.
3. Check the stroke at which the mold is stoped is enough for the molded product to
escape from the mold by ejection or by a take-out robot.
4. Set the present value shown at the mold position display field on MOLD & EJECT
screen of the Hicom 300 controller to the LS3 profile.
② LS2(Mold close limit) & Calibration of zero position

1. Check that the machine is in the mold setting mode by ascertaining the LED on
the MOLD SET-UP key lighting up.
2. Close the mold by depressing the MOLD ADVANCE key.
3. When mold closing is finished, push [*](asterisk) key for 5 Seconds on the KEY
panel and then the Hicom300 controller calibrate the zero position automatically.
③ LS2A(Mold prevention start position; low speed)

This position is very important for the mold prevention. When the moveable platen moving
at high speed is reached at the position LS2A, the speed of the platen is changed to
low speed to reduce the shock produced by contact of the two platens.
Set the stroke so that there is no shock, when the platens contact each other.
At the beginning,set LS2A to little long then gradually make is short.
For initial set value, set it to 100mm.
4-3 NM011C04
④ LS2B(Changeover position from the speed VC1 to VC2)

This position is used to make the movement of the mold various.
For the initial value set the middle position of LS2A and LS3
LS3 + LS2A
LS2B =
2
Then later, to shorten the cycle time, increase this set value to the point the shock does not
occurred.
⑤ VC1(Primary mold closing speed; fast mold closing speed)

For the initial set value, set it to 40%.
⑥ VC2(Secondary mold closing speed; fast mold closing speed)

3) Setting of Mold opening movement :

As shown right, mold closing movement of our
Mold opening speed
machine has four sections. User can set these

100 50
values on Hicom300 controller’s [Mold &
Ejection] page. VO3 VO2
40% 40% VO1
40%
① LS3A(the slow mold opening position) LS3 LS3P LS3B LS3A LS2
The mold retracts at slow speed and high Mold opening stroke
pressure to this stroke so that the molded
product which may be heavy can be separated safely from the fixed platen without
damage.
For initial set value, set it to 50mm.
② LS3P(Changeover position from the mold opening high speed VO3 to low speed)
The mold is retract at slow speed from this stroke so that the shock does not occur.
This set value is not on the MOLD & EJECT page of Hicom 300 controller. User can set this
value at the LS3 Prior field on SYSTEM VALUE SET page of Hicom 300 controller but it
has been already set to the optimal value by LS Mtron engineer. Therefore, there is no
need to be set by user.
4-4 NM011C04
③ LS3B(Changeover position from the speed VO1 to VO2)

This position is used to to make the movement of the mold various.
For the initial set value, set the middle position of LS3A and LS3P
LS3A + LS3P
LS3B =
2
④ VO1(Primary mold opening speed; slow speed and high pressure)

⑤ VO2, VO3(secondary, third mold opening speed; fast mold opening speed)
4) Setting the Low Pressure of Clamping :
During Mold closing movement, especially the distance from LS2A to LS2, is
performed at the low pressure, the Low Pressure of Calmping, so that a mold can
be prevented from damage.
In addition if the SET-UP operation mode is selected, machine operates at the
pressure, therefore the Low Pressure of Clamping is important for preventing
damage of a mold.
Turn the handle of the R3( Relief Control Valve for low pressure) and set it to the
minimum value which makes the mold can close completely.
It should be 35 kg/cm 2 ( 500psi) ~ 70 kg/cm 2 (1000 psi), which is indicated on
clamp pressure gauge G1.
Operating Mode keys

5) Setting Clamping Pressure :
AUTO AUTO
Depress the MANUAL key and keep on touching the
MOLD CLOSE key to advance the mold and to turn
the machine into the high pressure clamping
operation.
When the machine is on high-pressure clamping

operation, turn gauge cock (SV1) of clamp pressure Mold
gauge (G1) to open position. Then gradually turn
the handle of (R1) clamp pressure setting relief valve
in the clockwise direction. Fix the handle when the
(G1) pressure gauge indicator reads the set pressure.
4-5 NM011C04
① The maximum clamping pressure is
MODEL engineering UNIT lb & in UNIT
LGH25N 146 kg/cm 2 2076 lb /in 2

LGH50N 148 kg/cm 2 2105 lb /in 2
LGH75N 158 kg/cm 2 2247 lb /in 2
LGH100N 168 kg/cm 2 2389 lb /in 2
LGH140N 158 kg/cm 2 2247 lb /in 2
LGH160N 140 kg/cm 2 1191 lb /in 2
LGH200N 141 kg/cm 2 2005 lb /in 2
LGH350N 171 kg/cm 2 2446 lb /in 2
LGH450N 170 kg/cm 2 2418 lb /in 2
LGH550N 167 kg/cm 2 2375 lb /in 2
LGH650N
173 kg/cm 2 2460 lb /in 2
LGH850N
LGH1000N 176 kg/cm 2 2503 lb /in 2
NOTE : Never increase the pressure over the specified value.
② When a mold which is nearly half as large as the distance between tie rods is
utilized, lower the clamping pressure to the extent where flash is not
produced on molded products. If this is not done, excessive force will be
imposed on the injection molding machine. Generally, lowering the clamping
pressure to the point where flash is not produced will reduce electric power
consumption and prolong the life of the injection molding machine.
5) Final setting
To make the optimal setting, change the set values of LS2B, LS2A, LS3P, LS3B,
VC1, VC2, VO1, VO2, and VO3 as described below
① Turn the OPERATION selector switch to MANUAL position
② Gradually Increase VC1, VC2, VO1, VO2 and VO3 while closing and opening
the mold.
③ The fastest set of mold closing movement is achieved by decreasing the
values of LS2B and LS2A, until shock does not happen at the moment of mold
contact.
④ The fastest set of mold opening movement is achieved by increasing the
4-6 NM011C04
value of LS3B and decreasing LS3A, until shock does not happen.
No Shock No Shock No Shock

Mold closing speed
Mold opening speed

100 fixed 50
VC1 VC2
40% 40% VO3 VO2
40% 40% VO1
40%
LS3 LS2B LS2A LS2
LS3 LS3B LS3A LS2
LS3P
Mold closing stroke Mold opening stroke
6) Setting (PS1) for Confirming Clamp Pressure Increase :

This emits the signal of the next movement (nozzle advance – injection) by means of
detecting the clamping pressure increase and, at the same time, unloads all pumps except
clamp holding pump PF1. Accordingly, when the detecting pressure more than the
clamping pressure is set, the clamping pressure increase cannot be detected. Set the
value slightly lower than the clamping pressure. When turning the handle in the clockwise
direction, the pressure becomes high, and when turning the handle in the counterclockwise
direction, the pressure becomes low.
But the value has been already set to optimal value by LS Mtron. Therefore there is no need to
be set by user.
7) Over stroke Prevention (LS11) in case of LGH75,140, 160,200, 350N

① The proximity switch LS11 is set to prevent the over stroke of clamping cylinder.
② When the machine is shipped from LS Mtron at first, the over stroke limit of LS11 is
fixed with the spacer mounted.
NOTE :
Please unfasten the socket bolt (2-M5x8) and remove the dog.
After setting clamp side control according to the preceding procedures, confirm movements by
setting a operation mode of the machine to MOLD SET-UP and repeating OPEN and CLOSE
with the MOLD key on the operation panel.
CAUTION :
Never change the position of clamp side control while the mold is moving. Be sure to
perform setting after the mold has stopped.
4-7 NM011C04
4.1.2. Adjustment of Mechanical Safety Device.

The mechanical safety device is necessary for safety and for determination of the mechanical
open limit. After replacement of the mold, be sure to perform re-adjustment of the
mechanical safety device. For details, refer to chapter 3.2.2
4.2. Adjustment of Hydraulic Ejector

This unit discharges (ejects) molded products by utilizing an hydraulic cylinder. This unit is
automatically activated harmonized with the movement of the injection molding machine, and
single movement can also be performed by MANUAL operation. The ejection movement is
not activated if the mold is not at the retract limit during either SEMI-AUTOMATIC or MANUAL
operation. The ejection movement can be selected to one time, two times or three times as
standard.
4.2.1. Movement
Movement Line Diagram Explanation of Movement
ONE TIME EJECTION Ejection is performed when mold limit signal
(LS3) is activated and at the same time interval
timer (TR4) starts timing. Ejection retract is
performed when ejection advance limit proximity
switch (LS31) is activated. Mold closing is made
possible when ejection retract limit proximity
switch(LS32) is activated and interval timer
completes timing
TWO TIME EJECTION Ejection is repeated twice when mold retract

limit signal (LS3) is activated. Set ejection count
needed on the Mold & Ejector page of HICOM
300 controller.
4-8 NM011C04
4.2.2. Setting the Ejection Stroke
ORDER SETTING OPERATION CONFIRMATION

1 Depress the MANUAL key, and keep Is the signal for the mold
on pushing the MOLD OPEN key until open limit (LS3)
the moving platen reach the retract activated?
limit.
Then pull your hand out of the key.
Mold
2 Setting Cam LS31 Keep on depressing the EJECT

for Ejector Advance ADVANCE key to run ejection..
Eject
Limit At this time, set the ejector count to
1.
Move the ejector plate by only the

required quantity, matched to the
ejecting stroke of the mold, and pull
your hand out of the key.
Loosen the bolt for the ejector
advance limit, move the cam to the
position where proximity switch (LS31)
is turned ON, and clamp the bolt.
3 Setting the Adjusting Loosen the lock nut which locks the
adjusting screw on the ejector plate
and set the screw by matching it to the
ejector stroke. Set both screw on the
operation side and rear side of the
machine to the same vallue.
4-9 NM011C04
4 Setting Cam LS32 Depress the EJECTOR RETRACT

for Ejector Retract key. When stopping ejector retract at
Limit an optional position, it can be stopped
Eject
by adjusting the cam for the ejector
retract limit. However, generally
retract the ejector to the point just a
few millimeters before the stroke end
(retract limit) and set the cam to turn
ON the proximity switch at this
position.
NOTE :
Check the following items after the completion of setting.
1) Operate the ejector, and ensure that the ejector plate does not encounter trouble at the
advance limit or the retract limit.
2) Ensure that the ejector stroke adjusting screws on the machine operation side and the
machine rear side evenly touch the moving platen at the same time
3) Ensure that the lock nuts are not loosened.
4.2.3. Adjustment of Ejecting Speed
Two stage advance speed is possible ; slow and fast.

Ejection speed can be adjusted by VE1, VE2, VE3, VE4, PEF, and PER on the Mold & Ejector
screen of HICOM 300 controller.
1) MANUAL Operation
Check the movement in the MANUAL mode after the completion of preparation for
operation. Depress the EJECTOR ADVANCE and RETRACT key alternately to confirm
the movements.
Refer to the chapter 4.2.1 describing hydraulic ejector movement for the movement
position.
2) AUTOMATIC Operation
Set the machine operation mode to the SEMI-AUTO or the AUTO mode by depressing
the related key. after checking the movement in the MANUAL mode. In this case,
AUTOMATIC operation of the hydraulic ejector is not performed, if the operation mode of
4-10 NM011C04
the machine is not in AUTO mode by depressing the AUTO key. Depress the
SEMI-AUTO or the AUTO key or check the each LED on the keys is lighting up.
4.3. Adjustment of Injection Unit

This section introduces the initial setting of each parameters. At first, read the following
paragraphs, then use the picture below for better understanding.
For more detail adjustment, refer to the section 5.5.2.
2)-① 10 ~30% 2)-③ LS4C

= LS4 + 5~15mm
2)-③ 20 ~50% LS4A
[ Injection & Charge ] Man SET 08-25 FRI 09:31 2
2)-④ Rpm 0150 T2 88 % = 3 (LS5-LS4C)
Speed 450 mm/s R2 88 % LS4B
0105.0 mm Count 000068 R12 30 % 1
2)-⑤ 10 ~20% Inj. Time = 3 (LS5-LS4C)
PH1
TRH1 30.0% PP PI2 PI1 000.0 010.0sec
01.0 sec PH2 1)-② LS5 = S + 5
VH 50.0 % 60.0 % 40.0 % Cool Time
TRH2 30.0 % 40.0 % VI4 VI3 VI2 VI1 000.0 010.0sec
01.0 sec PH3 1)-③ Depending on
50.0 % 70.0 % 60.0% 40.0% Chg_Dy Time
2)-⑥ 20.0 % LS4 LS4C LS4B LS4A 000.0 010.0sec molded product
△015.0 △030.0△040.0△100.0 mm
Depending on Alarm 1)-④ Depending on the
Cut Over 2 V P Time 99.9sec
molded product Speed 0000ms VSB1 VS1 60 0% 2 30 0% VSB2 molding material
Char.Time 99.9sec
Press 000kgf 30.0 BP1 30.0% 2 30.0% 3 30.0% 40.0% Cush.High 99.9mm 1)-⑤ LS10
Time 00sec Cush.Low 99.9mm
△LS10A △LS5B △ △LS5 △LS10 = LS5 + 3 ~5mm
2)-② 10% of 010.0 030.0 095.0 100.0 104.0 mm Intrusion
Inj. Unit
shot size Select OFF
Nozzle Ret. Mode : 0 Continuous Shut Off Nozzle : OFF Time 03 sec
Ret. Delay Time : 0.1 sec Oper. Delay Time : 0.3 sec Velocity 40.0%
1)-⑤
The initial set values of each profile
4-11 NM011C04
4.3.1. Adjustment of Injection
1) Setting of Charging
① Torque Changeover (LGH450N ~ LGH1000N)
Shift the torque changeover lever to the 'A' position to set it to the low speed-high
torque side. on the other hand, 'B' position is high speed-low torque side.
② LS5(Charging stroke)
At first, calculate the needed stroke(S) concerned with the weight of the product by
using the formula shown below. S : the needed stroke[mm]
W : Weight of product [grams]
(W × 10) A : Sectional area of screw
S=
(A × ρ × η)
π
A= 4
D2 [cm2]
Resin name ρ × η Screw tip
ρ : Specific gravity [g/cm2]
PS 0.53 A
η : Injection efficiency
PE 0.42 A D : Screw diameter [cm]
Determine LS5 by adding a cushion amount of about 5mm to the calculated value
S.
LS5 = S + 5mm
At the beginning, set LS5 to a little shorter value then gradually make it longer observing the
condition of the molded product.
③ VS1 and VS2(charging speed)

Charging speed depends on the type of molding material.
④ BP1, BP2, BP3(screw back pressure)

In principle, some back pressure should always be used, in exception case however, it
may be dispensed with; it is ultimately the quality requirement of the melt and the
4-12 NM011C04
component which are the decisive factors.

Set the screw back pressures to the values which increase toward the end of charging.
However, it usually range from 5kg/cm2(71lb/in2) to 15kg/cm2(213lb/in2).
③ LS10A, LS10(suck-back stroke)
1st suck back Charging 2nd suck back

t k
VSB1, VSB2 :
1st, 2ndsuck back speed
VS1 :1st charging speed
VS1 VS2 VS2 :2nd charging speed
VSB1 VSB2
LS10A LS5B LS5A LS10
LS5
Our machine has two stages of suck-back.

After charging with back-pressure, the melt is under some pressure. If open nozzle is
used with your machine, there is a danger of drooling from the nozzle after sprue-break.
This cause stringing and material built-up. Without relieving the pressure on hot
runners, residual material would adversely affects the following shot. The melt is
therefore forcibly relieved of pressure after charging by sucking the screw backwards.
The suck-back is set according to the decompression required and the volume of melt
to be decompressed. It should only ever be set as high as absolutely necessary. Too
much suck-back can draw air into the melt which causes visual defects.
z LS10A(first Suck-back stroke)
z LS10(second Suck-back stroke)

Generally, we recommend 3~5 mm as proper suck-back amount, that is
LS10 = LS5 + 3 ~5mm
2) Setting of injection
① VH(Injection speed during holding)
Generally, the injection speed during the holding is set to 10 ~30%.
② LS4(Holding changeover position)

Holding pressure is important to give the molded product consistency on the quality.
When the screw reaches the advance limit, if the holding pressure does not activate on
4-13 NM011C04
the molded product , some molding problems such as sink marks, short shots, and
irregularities can be occurred. Therefore set the LS4 so that the screw can stop 2~3mm
before the advance limit at the moment the gates are sealed.
Generally, the holding changeover position is set to 5 ~10mm.
For the initial value, set the LS4 to 10% of the shot size.
③ VI1, VI2, VI3, VI4, LS4A, LS4B, LS4C(Injection speed and Injecion speed changeover
position during filling)
Set the Injection speeds VI1 VI2, VI3, and VI4 and injection speed changeover
positions LS4A, LS4B, and LS4C during filling depending on the condition of the
molded product.
VI4 is usually used for accurate control of the holding position.
For the initial value, roughly set VI1, VI2 and VI3 to 50 ~ 80%, VI4 to 20 ~
50%.
Set Injection speed changeover position LS4A and LS4B to the medium value
between the LS5 and LS4C.
Set LS4C to the value added 5 ~15mm to the LS4.
2(LS5 - LS4C) LS5 - LS4C

LS4C= LS4 + 5~15mm LS4A= LS4B=
3 3
④ PP, PI2, PI1(injection pressure)

Variable range : 00 ~99%.
With 99 percent set value, a machine has 140kgf/cm2 injection pressure. The maximum
pressure had been adjusted by engineers of LS Mtron
User can obtain a needed injection pressure by entering a percent number in
proportion to the injection pressure.
Use the formula,
A needed injection pressure

Set value(%) = 99 ×
140 kgf/cm2
and enter the calculated set value at each profiles
⑤ PH1, PH2, PH3(Injection pressure during holding)

At the beginning, set PH1, PH2, PH3 rather low (10 ~20%), then gradually increase by
4-14 NM011C04
observing the condition of the molded product.
Method of identifying PH1, PH2 and PH3.

z PH1(primary holding pressure) : Set the TRH1 little long and keep depressing the
SCREW ADVANCE key, then the value of the G2 gauge is the PH1. Set the PH1
profile to the value which is needed using the G2 gauge.
z PH2(secondary holding pressure) : Set the TRH1 to zero, the TRH2 rather long,
and keep depressing the SCREW ADVANCE key, then the value of the G2 gauge
is the PH2. Set the PH2 profile to the value which is needed using the G2 gauge.
z PH3(third holding pressure) : Set the TRH1 and TRH2 to zero, and keep
depressing the SCREW ADVANCE key, then the value of the G2 gauge is the PH3.
Set the PH3 profile to the value which is needed using the G2 gauge
⑥ TRH1, TRH2(holding changeover time)

The holding changeover time TRH1and TRH2 determine the timing at which holding
pressure is shifted.
z If TRH1 is set to zero, injection process is as below.

3rd injection 2nd holding 3rd holding
pressure (PP3) pressure (PH2) pressure (PH3)
z If TRH2 is set to zero, injection process is as below.

3rd injection 1st holding 3rd holding
pressure (PP3) pressure (PH1) pressure (PH3)
z If TRH1 and TRH2 is set to zero, injection process is as below.

3rd injection 1st holding
pressure (PP3) pressure (PH1)
4-15 NM011C04
4.3.2. Adjustment of Nozzle
Adjust the nozzle according to the following procedures.
1) Selection of Nozzle Retract Timing
Set value NOZZLE MODE

0 Continuous
1 Cooling Completion
2 Charging Completion
3 Injection Completion
① CONTINUOUS ADVANCE
This mode is utilized to avoid resin drooling from the nozzle. The cycle is shortened
because the nozzle is kept touching the mold. In this case, mount the mold on the
stationary platen with more than six(6) M16 or M20 M24 bolts: otherwise, the mold may
drop.
② COOLING COMPLETION
Generally, this is utilized for molding with the nozzle once separated from the mold
during each cycle, utilizing an open nozzle. The nozzle retracts at "time out" of cooling
timer . Set cooling timer longer than the charging time.
③ CHARGE COMPLETION
This is utilized for molding with the nozzle once separated from the mold during each
cycle, utilizing an open nozzle. The nozzle retracts at the same time as charge out.
With suck-back equipped, the nozzle starts to retract after suck-back.
④ INJ. COMPLETION
Generally, this mode is utilized when the valve type nozzle (optional specifications) is
equipped. The nozzle retracts at INJ. COMPLETION, and starts charging.
2) Confirmation of Nozzle Movement :

Depress the NOZZLE ADVANCE and RETRACT key several times alternately, and
confirm the movement. Depress the MOLD CLOSE key until the mold is reach the mold
4-16 NM011C04
close limit, then keep pushing the NOZZLE ADVANCE key until the nozzle under the
condition where the nozzle is pressed against the mold sprue bushing.
3) Setting Nozzle Advance Limit (LS7) :

Clamp the cam knob at the point where the nozzle advance limit switch (LS7) cam slightly
activates the limit switch.
4-17 NM011C04
4.4. Timer Functions and Settings
Timers displayed on the screen of HICOM-300. Set these timers optionally, according to the
molding conditions.
1) injection Timer (TR1)

This is the timer for setting the injection time, which starts at the same time that injection
is started. Injection is completed when this timer reaches the "time out' condition.
2) Cooling Timer (TR3)

This is the timer for setting mold cooling time, which starts at the same time that injection
is completed. Cooling is completed with the timer at "time out", and the mold is opened.
When an open nozzle is utilized, set this timer longer than charge out.
3) Interval Timer (TR4)

In the case of either AUTOMATIC or SEMI-AUTOMATIC operation, this timer starts from
the mold open limit. During AUTOMATIC operation, the mold restarts with TR4 at "time
out". During SEMI-AUTOMATIC operation, the mold restarts by opening and closing the
safety gate with (TR4) at "time out".
4) Low Pressure Clamping(TR6)

This timer starts timing at the same time that low-pressure clamping (LS2A) is activated.
If the timer reaches "time out" before mold advance limit (LS2) is activated (for example,
when foreign material is put between the mold halves), the buzzer which indicates an
abnormal clamping condition is activated, "Low PRESS ALAM" is shown in the lower part
of each page and the mold is automatically opened.
5) TR17 (Timer for Power Saving)

The time to start unloading the pump (PF1) for holding the clamp pressure after the
completion of injection is set with this timer. The time varies according to the molding
conditions (especially cooling time), but it is generally set at approximately one (1)
second. In a case where the cooling time is especially long, set this timer longer. (With
the snap switch set at the OFF position, unloading is performed after the completion of
charging.)
NOTE :
There is a case where charging cannot be performed when an open nozzle is utilized.
Set the cooling timer (TR3) longer than the charging time.
4-18 NM011C04
4.5. Injection amount data sheet

Refer to the Mechanical drawing.
4-19 NM011C04
End of Chapter 4
Molding Operation LSM-MNL-011/Ver. 1.0
Chapter 5. Molding Operation
5.1. Preparations Prior to Molding ..............................................................................................2

5.1.1. Tools Required for Molding ........................................................................................2
5.2. The Part of Selection ...........................................................................................................4
5.2.1. Nozzle Selection ........................................................................................................4
5.2.2. Screw Tip Selection ...................................................................................................5
5.3. Setting the Barrel Temperature............................................................................................6
5.4. Setting the temporary set value on each profile...................................................................8
5.5. Molding Operation................................................................................................................8
5.5.1. MANUAL Operation ...................................................................................................8
5.5.2. OBTAIN Good Product.............................................................................................12
5.6. Troubleshooting of the injection molding ...........................................................................17
5.6.1. Typical problem & solution. ......................................................................................17
5.6.2. Solutions related to the condition of molded products .............................................19
5.6.3. Uneven and Poor Charging......................................................................................25
5.6.4. Uneven Color and Color Dispersion.........................................................................26
5.7. OPTIMIZE Cycle Time .......................................................................................................26
5.8. SEMI-AUTOMATIC Operation ...........................................................................................27
5.9. AUTOMATIC Operation .....................................................................................................28
5.10. Material and Color Change ..............................................................................................29
5.11. Completion of Molding Operation ....................................................................................31
5.11.1. What You Should Do After Operation ....................................................................32
5.12. Removing the Mold ..........................................................................................................33
5-1 NM011C05
5. Molding Operation
5.1. Preparations Prior to Molding
5.1.1. Tools Required for Molding
1) Copper or brass "pencil" :

Used to eliminate the clogging of the mold
spurge bushing (due to resin).
2) Wooden hammer
3) Alcohol
Used to clean the mold.
4) Clean cloth :
For cleaning the mold .
5) Rags
6) Torch :
Used when the mold cannot easily be
released because part of the molded
product remains in the mold.
7) Nippers :
Used to cut the gate, etc.
8) Purge materials (PS, PE, etc.) :

Used when changing the color or resin.
9) Rust preventatives :
Used to prevent rusting when storing molds for long periods.
10) Scale :
Used to weigh products.
5-2 NM011C05
11) Surface thermometer :

Used to measure the temperature at the surface of a mold.
12) Resin thermometer :

Used to measure the temperature of the injected molten resin.
13) Mold lubricant
5-3 NM011C05
5.2. The Part of Selection
5.2.1. Nozzle Selection
With sufficient consideration given to color change, residual resin purging and other
factors, an OPEN NOZZLE is attached to this injection molding machine as
standard equipment. However, if no problems are encountered concerning the
utilization of low viscosity resin and the residual resin phenomenon, a NEEDLE
TYPE VALVE NOZZLE is available as an optional equipment. And if problems are
encountered concerning resin leakage from the nozzle for low viscosity resins or
resins with good thermal stability, a Hydraulic SHUT OFF NOZZLE is available as a
special option equipment.
Item Shape Application
Since this nozzle is the open type

Open
and free from residual resin, color
Nozzle
change is simplified. Charging is
(Standard
performed by means of the suck-back
Equipment)
movement.
Needle
When this nozzle is adopted, no
Type Valve
drooling is caused during charging,
Nozzle
because the needle is pushed by
(Optional
spring force during charging
Equipment)
Hydraulic
When this nozzle is used, leakage is
Shut Off
prevented during charging, because
Nozzle(Opti
the needle is pushed by Hydraulic
onal
force.
Equipment)
5-4 NM011C05
5.2.2. Screw Tip Selection
The screw tip should be selected according to the viscosity of the molding material
and the application. Generally, the tip which is commonly call the " A Tip ", for
application with normal resins, is equipped to this injection molding machine. The
screw tip should be selected from among the following types, for hard vinyl chloride
and high viscosity resins (Option Equipment).
Descri
Type Shape Application
ption
This tip is utilized with regular
General resins ( PS, PE, PP, PA).
Purpose(St This tip makes almost no back-
A Tip
andard flow during injection and has-
Equipment) as excellent injection
efficiency.
This tip is utilized for the
molding of HPVC, highly
C Tip viscosity resin. No friction heat
Hard Vinyl is caused, and there is no
Chloride residual resin.
(Optional This tip is utilized for the
Equipment) molding of HPVC, high
UC Tip effective for kneading.
Injection efficiency is excellent,
compared to the C tip.
5-5 NM011C05
5.3. Setting the Barrel Temperature
Molding temperature should be determined prior to the commencing of injection

depending on molding process, according to the molding material and the mold
structure. The temperatures of the NH, H1, H2, H3 and H4 zones are set according
to the intrinsic molten temperature of the molding material.
The barrel temperature is set according to the following order.
1) Open the cooling water valve and apply cooling water through the bottom
section of the hopper.
2) Confirm that the barrel zones and the positions of the thermocouples are in
conformity. To perform confirmation, pull the thermocouple out from the
mouthpiece and contact it to a heat source, such as hot water. The applicable
thermocouple is considered to be normal if the value of Actual profile on
Temperature screen of Hicom 300 controller rises. Confirm in order, from the
nozzle (NH) to the barrel (H1 - H4). For confirmation of the position of the
thermocouples, enter the temperature at the Set value profile on Temperature
screen of Hicom 300 controller to approximately the same temperature as the
room temperature.
5-6 NM011C05
Insert the tip of the thermocouple tightly into the bottom section of the barrel hole:
otherwise, temperature will be inaccurate.
3) Determine the set temperatures by entering needed temperature at the Set

value profile on the Temperature screen of the Hicom 300 controller.
Enter set value
NOTE :
When a UNI-MELT screw (optional Equipment) is utilized, set the temperature
slightly lower than the standard temperature of H1, as shearing heat may be
produced, or it can be the cause of cracked resin or corrosion of the barrel with
ABS.
5-7 NM011C05
5.4. Setting the temporary set value on each profile.

Before starting the molding operation, it is necessary to set the profiles on Mold & Ejector
page and Injection page of HICOM 300 controller.
Set each profiles as described on chapter 4 STATR-UP ADJUSTMENT.
5.5. Molding Operation
During molding operation, perform several tests using MANUAL operation, and than
switch to SEMI-AUTOMATIC operation or AUTOMATIC operation. In order to
mold products of excellent quality in an efficient manner, it is important to obtain an
optimum balance between the pressure, speed, time, temperature and other
parameters related to the operation of the injection molding machine. These
parameters can be gradually adjusted while the machine is operating in
SEMI-AUTOMATIC mode.
NOTE :
Before molding ABS or performing low-forming molding, be sure to contact our
company as these can cause corrosion of the screw or barrel.
A corrosion - proof screw and barrel are available as optional Equipment. Also,
when molding resins containing frictional materials such as fiberglass or asbestos,
which tend to cause wear, the screw or barrel may become worn.
Contact LS Mtron in this case.
A wear proof screw and barrel are available as optional Equipment.
5.5.1. MANUAL Operation
Use MANUAL mode according to the following procedures.
1) Ensure that water and cooling water are running through the oil cooler and the
bottom portion of the hopper respectively, and that each part is heated to the
proper temperature.
5-8 NM011C05
Operating Mode keys

2) Operate the machine on the manual mode
by depressing the MANUAL key. AUTO AUTO
4) Operate the pump by pressing the pump

motor START button.
5) Open the hopper port and keep on

depressing the SCREW RETRACT key Inject
until the charging is completed.
CAUTION :
☞ If there is no resin in the barrel, do not turn the SCREW selector. First turn
the screw at low speed, check that resin comes out from the nozzle, then
increase the speed.
6) Keep depressing the MOLD CLOSE key to

perform the high clamping operation. Mold
After clamping up, confirm that the
clamping pressure has increased to the
prescribed value on pressure gauge
(G1).Leave the mold at the mold close
limit position.
5-9 NM011C05
Nozzle
7) Depress the NOZZLE ADVANCE key until
the nozzle tip press against the spruce
bushing of the mold and then release the
key in such condition.
8) Set the injection holding timer :

Set the SCREW selector switch to screw retract position and set the injection
holding timer long enough to fill the mold with resin and perform the holding
operation.
9) When the SCREW ADVANCE key is

depressed, resin is injected into the cavity Inject
of the mold with the preset injection speed
VI1~VI4 and the preset injection pressures
(P1, PI2, PP).
10) When the screw advances to the shifting position from filling to holding (LS4)
in front of the screw advance limit, the injection pressure(PP) changes to
primary injection Pressure (PH1), secondary injection pressure (PH2), and
tertiary injection pressure (PH3), and injection speed (VI1~VI4) is changed to
the setting speed (VH) for holding
11) Depress the SCREW RETRACT key

after estimating the approximate holding
Inject
time ( the time required for the sprue to
cool solidify).
After the hydraulic motor for the screw is
rotated and the screw retracts at charging
out, pull your hand out off the key.
5-10 NM011C05
12) Depress the NOZZLE RETRACT key until

the nozzle is slightly retracted from the
mold(10 ~ 20mm). When resin leaks
from the nozzle tip this time, increase
suck-back amount by enter suck-back
stroke needed to the LS10(the secondary
suck-back stroke) on the HICOM 300
controller’s MOLD & EJECT page.
13) Estimate the cooling time for molded

products : Mold
Depress the MOLD OPEN key until the

movable platen will be opened
Low Speed → High Speed → Low Speed
14) The mold retracts at low speed initially for the release of the molded products.
When the position of mold reached (LS3A) and low speed changes to high
speed, the position approaches the proximity switch(LS3B), and the speed
changes to low speed. To shorten the cycle, it is important to set the stroke at
low speed to the minimum value without affecting the molded products or the
mold.
15) Keep depressing the EJECT ADVANCE

key to discharge products.
Open the safety gate and take out the
products which are adhering to the mold, Eject
unless they drop automatically after

ejection.
After the completion of product discharge,
close the safety gate and set the
EJECTION selector switch to the retract
position.
5-11 NM011C05
5.5.2. OBTAIN Good Product

To obtain good product, the key point is to understand the filling conditions of resin
into the mold cavity. User can adjust the each profile on HICOM 300 controller by
observing the condition of the molded product. When the molded product has some
problem , refer to the following section 5.5.3 , then correct the set value which are
at issue.
As followed, it is important to know the relation between the resin filling process
and the screw stroke through several test shots.
1) PI1, PI2, PP(injection pressure)

Usually set it according to the type of the molded product. However, if there is
any issue with the mold, adjust it to the strength of the mold.
2) PH1, PH2, PH3(holing pressure)

At first, set PH1, PH2, and PH3 same value for example 30 %, then correct the
holding pressures and changeover time TRH1, TRH2 depending on the
condition of the molded product. If there are some problems with the molded
product, refer to the following section 5.5.3 Troubleshooting of the molded
product.
3) LS5(charging stroke)
Refer to the section 4.3.1 Adjustment of Injecion.
(W × 10)
LS5 = S + 5
S=
(A × ρ × η)
4) VS1, VS2(charging speed)

When starting charging, do at low speed and increase the speed gradually,
while observing the filling of material. Generally, the plasticizing capacity is
increased when the screw speed is higher: However, when the speed
exceeds a certain limit, the plasticizing capacity drops in inverse relation.
The most satisfactory condition must be found and set considering such
conditions as the type of molding material, the shape of the pellets, the
temperature, the back pressure and other factors.
5-12 NM011C05
5) LS4, LS4C(holding changeover position)

To control the holding pressure accurately, decelerate injection speed to the
medium speed 20 ~50% on the position 5 ~15mm before the screw arrives at
LS4(holding changeover position). That is, set LS4C to the value added LS4 to
5 ~15mm.
6) VI1, VI2, VI3, VI4 LS4A, LS4B(injection speed)

VI4 is usually used for accurate control of the holding position
7) Correction of LS5( charging stroke)

Increase the charging stroke gradually while observing the condition of the
molded products to obtain the perfect stroke by performing test shot two or
three time.
8) Identify the stroke where molding problem is occurs.

When one molding shot is finished, the molded product may have some
problem. To solve the trouble, we should know the reason and the injection
stroke where the problem happens. The following example introduces the
method of identifying the stroke and solving some problems in a molded
product, that is sink marks and weld lines. If we can identity the position of the
screw where such problems occur, the set values of related parameters can be
changed properly.
5-13 NM011C05
A molded product having problem. Current setting which makes a bad product.
Empty space
Weld lines PH1
TRH1 30.0% PP PI2 PI1
Sink marks 01.0 sec PH2 VH 50.0 % 60.0 % 40.0 %
TRH2 30.0 % 20.0 % VI4 VI3 VI2 VI1
01.0 sec PH3 30.0 % 70.0 % 70.0% 70.0%
30.0 % LS4 LS4C LS4B LS4A
△010.0 △020.0△060.0 △090.0
Good part of
a molded product
① Identity the stroke where sink marks is occurred

Injection speed
70 1. Set VI2 to zero then injection is performed until

Injection amount
by the stroke LS4A stroke.
LS4A
2. On observing the amount which is filled, change
94 LS5
Screw position LS4A to the position where sink marks start to
appear. Injection
The new LS4A
PH1
Set to zero
01.0 sec PH2 VH 50.0 % 60.0 % 40.0 %
TRH2 30.0 % 20.0 % VI4 VI3 VI2 VI1
01.0 sec PH3 30.0 % 70.0 % 00.0% 70.0%
The injection amount from LS5 to the 30.0 % LS4 LS4C LS4B LS4A
△010.0 △020.0△060.0 △090.0
changed LS4A makes a good part of
Increase
the molded product such as below.
3. Set LS4A to the value at which the good part of
the molded product is made, namely, sink marks
are about to appear.
In the example, the stroke is 94mm and set it on
LS4A.
② Eliminate the sink marks problem.
The sink marks
problem is solved 1. Adjust the pressure or the speed of injection
performed from the stroke LS4A to LS4B by
referring to the section 5.6.
2. In the example, we decrease VI2(injection speed)
70.0%
to perform filling with slow cooling and get rid of
Injection speed
Decreased
70 the sink marks.
70.0%
40
PH1
TRH1 30.0% PP PI2 PI1 Decreased
01.0 sec PH2
60 94 117 VH 50.0 % 60.0 % 40.0 %
TRH2 30.0 % 20.0 % VI4 VI3 VI2 VI1
Screw position 01.0 sec PH3 30.0 % 70.0 % 40.0% 70.0%
△010.0 △020.0△060.0 △094.0
△090.0
With low speed, 40%, injection
Increased
is performed slower than before
for the sink marks.
5-14 NM011C05
③ Identity the stroke where weld lines is occurred

1. Set VI3 zero then injection is performed until
LS4B stroke.
2. On observing the amount which is filled, change
LS4B to the position where weld lines start to
appear.
3. Set LS4B to the value at which the good part of
the molded product is made, namely, weld lines
are about to appear.
In the example, the stroke is 64mm and set it on
LS4B. Injection
PH1 Set to zero
01.0 sec PH2 VH 50.0 % 60.0 % 40.0 %
The weld lines TRH2 30.0 % 20.0 % VI4 VI3 VI2 VI1
problem is solved 01.0 sec PH3 30.0 % 00.0 % 40.0% 70.0%
△010.0 △020.0△060.0 △094.0
Change
④ Eliminate the weld lines problem.
70.0% 1. Adjust the pressure or the speed of injection
Increased performed from the stroke LS4B to LS4C by

referring to the section 5.6.
Injection speed
90
70 2. In the example, we increase VI3(injection speed)
40 to get rid of the weld lines.
30 70.0%
20
PH1
10 20 62 94 117 TRH1 30.0% PP PI2 PI1 Increased
Screw position 01.0 sec PH2 VH 50.0 % 60.0 % 40.0 %
TRH2 30.0 % 20.0 % VI4 VI3 VI2 VI1
01.0 sec PH3 30.0 % 90.0 % 40.0% 70.0%
With high speed, 90%, injection △010.0 △020.0△064.0 △094.0
is performed faster than before △060.0

Increased
for the weld lines.
The overpacking ⑤ Eliminate overpacking problem.
problem is solved
1. We increase the injection speed VI3 and
overpacking may happen.
2. In the example, we decrease LS4(holding
changeover position) to get rid of the
overpacking.
Injection speed
90 Injection
70 PH1
40 01.0 sec PH2
30 VH 50.0 % 60.0 % 40.0 %
20 TRH2 30.0 % 20.0 % VI4 VI3 VI2 VI1
01.0 sec PH3 30.0 % 90.0 % 40.0% 70.0%
8 20 62 94 117 30.0 %
Screw position LS4 LS4C LS4B LS4A
△008.0 △020.0△064.0 △094.0
The new LS4 △010.0
Decreased
5-15 NM011C05
⑥ Adjust of Holding section.

1. While observing the condition of the molded
product, adjust PH1, PH2, PH3, TRH1, and
TRH2.by referring to section 5.6
adjust
PH1
01.0 sec PH2 VH 50.0 % 60.0 % 40.0 %
TRH2 30.0 % 20.0 % VI4 VI3 VI2 VI1
01.0 sec PH3 30.0 % 90.0 % 40.0% 70.0%
△008.0 △020.0△064.0 △094.0
⑦ An optimum setting
On watching the molded product, change the above
set values so that little problem can be solved.
If set value need changing, refer to the section 5.6
5-16 NM011C05
5.6. Troubleshooting of the injection molding

Poor molded products can be produced during the start of the injection molding
process or during the process, and this cannot be avoided. To reduce defect
rations as much as possible and to increase productivity, it is important to be
thoroughly familiar with the methods to counteract the defects. Please utilize this
chapter for details about defects and their causes during general molding.
5.6.1. Typical problem & solution.

Problem Trouble shooting Illustration
Flash Accurate controls the change in melt Decrease the speed
viscosity around the completion of step by step
filling and the shifting position from Holding changeover position
filling to holding.
Injection
speed
① Make the holding changeover position
stable at the same stroke by Screw position
decreasing injection speed step by Decrease the speed

step.
Injection
speed
② Perform filling with cooling by

decreasing the injection speed before
Screw position
the completion of filling Filling with cooling
Cracks, Use the same method as the above for
Crazing preventing flash from appearing
Flow marks Gradually increase injection speed to Increase the speed
prevent the occurrence of irregular gradually
flows for thick-wall products.
Injection speed
Lowers injection speed to prevent the increases rapidly
occurrence of irregular flows for
portions where the flow velocity is Decrease the speed at
this point
rapidly accelerated
① Perform filling slowly with cooling z In case of a simple mold
② When the resin is filled into a mold,

Injection
speed
increase the injection speed to

improve cycle time.
Screw position
z In case of a intricate mold
Screw position
At first, fill slowly then increase the speed.
5-17 NM011C05
Weld lines Increase injection speed to reduce

Holding changeover position
weld marks and changes the injection
Injection
speed shift position to change the
speed
position where weld marks are
produced.
Alter the changeover position at which

speed is changed from low to high.
Gas burning Reduces injection speed for portions

where burns are likely to occur, to
Injection
speed
allow gas to easily escape through
the air vent.
Decrease the injection speed so that air
and gas will be sufficiently vented from the
air vent.
Sink marks Perform filling with cooling by Holding changeover position

decreasing the injection speed at the
Injection
speed
location where sink marks occur.
During this stroke, sink marks occur,

therefore decrease the injection speed.
Rough Flow marks caused by residual resin
After putting the residual
surface, Flow at the nozzle tip are improved by
resin from the nozzle tip
Injection
speed
marks, and means of the following pattern. into the slug pool,
Silver streaks increase the injection
around the speed.
gates
Gate balance To improve it, decrease the injection
speed until the resin reaches all of
Injection
speed
the gates.
In this part use the low speed until the

resin reaches all of the gates.
Sink marks In case of

Injection
speed
and flash increasing the holding pressure to Holding

eliminate the sink marks, flash is changeover position
occurred because of the increased
1st injection pressure
pressure.
pressure
Injection
nd
2 or 3rd
By increasing the holding pressure injection pressure
after the skin layer has been formed
under low pressure, flash and sink
marks can be prevented.
Reduction of Molded products with little residual

1st injection pressure
residual stress can be obtained by stepped st
Injection
1 holding pressure
speed
stress of decrease of the holding pressure. nd

2 holding pressure
molded
products 3rd holding pressure
5-18 NM011C05
5.6.2. Solutions related to the condition of molded products

Causes of Defect
Defect
d
Molding machine Mold / Materials

1. Poor injection capacity. 1. Gate balance is poor.
2. Material supply quantity insufficient. (Volume and plasticizing ability)
3. Injection pressure is low. Gate, runner and sprue are small.
4. Resin temperature is low. 2. Mold temperature is low.
5. Injection speed is low. 3. Cold slugs appear.
6. Nozzle resistance is large. 4. Mold cavity is too thin.
(Diameter is small or nozzle is long) 5. Gas purging is inadequate.
7. Screw charging is poor. 6. Insert ribs or other elements to
8. Nozzle is cold. improve flow.
9. Backflow prevention ring is broken. 7. Poor flow of materials.
8. Improper lubricating treatment.
Defect
d

1. Injection Pressure is too high.
2. Clamping force is low. 1. Poor mold parallelism.
3. Excessive injection quantity. 2. Parting lines are not matched.
4. Resin temperature is too high. 3. Presence of foreign materials.
5. Injection holding pressure time is long. 4. Projection area is too large.
6. Injection speed is too fast. 5. Decrease the mold temperature.
6. Wear of the mold half parting surface.
7. Resin viscosity during molding is too low.
5-19 NM011C05
Defect
d

1. Injection Pressure is low.
2. Injection holding pressure time is short.
3. Injection speed is slow. 1. Mold temperature is too high.
4. Charging quantity is insufficient. 2. Mold temperature is not even.
5. Resin temperature is high. 3. Gate is too small.
6. Nozzle resistance is large. 4. Runner and sprue are thin.
7. Mold opening is too early. 5. Cavity thickness is uneven.
8. Nozzle is cold 6. Unsuitable ejector pin shape.
9. Backflow prevention ring is broken or 7. Resin flow is too fluid.
worn. 8. Shrinkage rate is large.
Defect
d

1. Resin temperature is low and viscosity
is too high.
2. Injection speed is low.
3. Nozzle is small. 1. Mold temperature is low.
4. Injection holding pressure time is too 2. Mold cooling is unsuitable.
short. 3. Slug pool is small.
5. Injection holding pressure. 4. Gate is large.
6. Poor cushion amount for material. 5. Resin flow is poor.
7. Cold flow marks occur due to presence
of cold slugs.
8. Nozzle temperature is low.
5-20 NM011C05
Defect

1. Poor injection capacity and plasticizing 1. Mold temperature is low.
capacity.
2. Gas purging is poor.
2. Resin dissolved due to overheating.
3. Gate position is inferior.
3. Resin is temperature is low and melting is
4. Poor cavity design.
poor.
(Rapid change of thickness etc.
4. Resin is partially cracked due to residual
5. Gate, runner of sprue is too small.
melt in barrel.
5. Injection speed is too fast.
6. Slug pool is small.
6. Air intake clogged. 7. Moisture or lubricant adhered to mold
7. Back pressure is small. surface.
8. Interior of the barrel is dirty. 8. Moisture or volatile matter
9. Screw speed is too high. included in materials.
Defect
d

1. Uneven melting of resin or resin is partially 1. Mold temperature is high.
overheated. 2. Gate, runner and sprue are small.
2. Nozzle is cold. 3. Slug pool is small.
3. Nozzle hole is small. 4. Water or oil adhered to mold surface.
4. Injection speed is too high or too low. 5. Gas purging is poor.
5. Resin is dissolved due to overheating.
6. Excessive utilization of mold release
agent.
7. Moisture and volatile matter included in
materials.
8. Volatile matter in included.
9. Other matter mixed in materials.
5-21 NM011C05
Defect
d

1. Resin temperature is low and fluidity is 1. Distance between gate and weld section is
poor. long.
2. Injection pressure is low.
2. Mold temperature is low.
3. Gate position and number are unsuitable.
4. Nozzle is cold.
4. Gate and runner are too small.
5. Back pressure is low.
5. Gas purging is poor.
6. Flow is poor.
7. Moisture and oil included in materials.
Defect
d

1. Injection pressure is low. 1. Gas purging is poor.
2. Holding pressure is low. 2. Inferior cavity design.
3. Holding time is short. (Radical thickness change)
4. Injection speed is too high or too low. 3. Gate Position is unsuitable.
5. Resin temperature is low or viscosity is too 4. Gate, runner or sprue are too small.
high. 5. Cooling time is too long.
6. Resin temperature high and gas is
6. Mold temperature is low.
produced.
7. Air intake.
7. Air intake.(Screw speed is too high)
8. Resin shrinkage percentage is large.
5-22 NM011C05
Defect
d

1. Resin flow is inhibited or settles in
one portion of barrel, and is dissolved.
2. Poor nozzle installation.
3. Burning due to adiabatic compression with 1. Grease or oil present.
material wear in barrel or air. 2. Resin is dissolved due to frictional heat at
4. Poor cooling at hopper installation section. the gate.
5. Barrel temperature is high. 3. Poor gas purging.
6. Injection pressure is high. 4. Excessive lubrication.
7. Injection speed is fast. 5. Volatile matter is included.
8. Long holding time in barrel.
9. Screw speed is too high.
10. Back pressure is too high.
Defect
d

1. Injection pressure is high. 1. Gate is too wide.
2. Resin temperature is low and viscosity is 2. Mold temperature is low.
too high. 3. Core creates vacuum at release
3. Holding pressure is high. 4. Poor cavity design.
4. Holding time is long. (Inside stress is generated: avoid
5. Product push out speed is high. concentration)
5. Product draft is small.
6. Unsuitable annealing.
7. Mold cavity: Core polishing is poor.
5-23 NM011C05
Defect
d

1. Injection pressure is high. 1. Poor releasing.
2. Holding pressure is high.
2. Unsuitable ejection.
3. Holding time is long.
3. Uneven or insufficient cooling.
4. Poor resin melting.
4. Gate is large.
5. Resin temperature is low
5. Mold temperature is high.
7. Cooling time is short.
6. Uneven thickness.
8. Utilize a correcting tool for warp after 7. Undercutting.
releasing. 8. Unsuitable annealing.
5-24 NM011C05
Defect
d

1. Injection pressure is high. 1. Resin adheres to the mold due to poor
2. Resin temperature is high or viscosity is cooling.
too low. 2. Mold temperature is high.
3. Holding pressure is high. 3. Gate is too wide.
4. Holding time is long. 4. Poor gas purging.
5. Excessive charging 5. Poor gate balance.
6. Cooling time is short.
6. Nozzle diameter is larger than sprue hole.
7. Spherical radius of nozzle tip is larger
than sprue bushing.
8. Sprue diameter and taper are unsuitable.
9. Stationary side temperature is too high.
10. Undercutting on mold and taper are
unsuitable.
11. Ejection quantity is unsuitable.
12. Mold release agent shortage.
13. Unsuitable lubrication treatment.
5.6.3. Uneven and Poor Charging
Defect Cause Countermeasures
Overtorque: Feed in feed section is Decrease the hopper side

poor, plasticizing and screw temperature.
Often appears when speed in compressed
molding with polycarbonate setting are fast. Lower the temperature in
resins. the compression section.
Lower the speed and

lengthen the cycle.
Unsuitable charging: Resin becomes lumpy Clean the screw. Cool the
under the hopper and feed feeding section. Lower the
Air shots appear and sections, excessive back pressure. Check pellet
charging time is unstable or backflow occurs, missed shape.
torque is low, Occurs often cutting is performed, or
with NYLON resins. corrosion or wear of Check the screw and barrel
screw or barrel occur. for wear and corrosion.
Temperature below the
hopper is too high.
5-25 NM011C05
5.6.4. Uneven Color and Color Dispersion

Defect Cause Countermeasures
Lower the hopper side

temperature.
Spots of pigments appear in Uncrushed pigment is
the molded products. mixed in with the molten Be sure that pigment is fully
Appear green in color. resin. crushed.
Lower the back pressure.
Increase the temperature of

Streaks which are light or Resin and pigment are not the barrel edge section.
cloudy appear, and appear kneaded uniformly.
pink in color. Increase the back pressure.
5.7. OPTIMIZE Cycle Time

The important point is to make the injection molding process to a stable production
condition rather than to achieve all the quality criteria at once.
After achieving a stead-state process, optimisation of the molding partly with the
content of the trouble shooting of the molding on this manual can be carried out.
After the quality criteria of the molding have been met, cycle optimisation can be
began. The cycle time can be optimised by modification of the parameters
governing cycle time; e.g. by shortening the cooling time and the mold open time,
reducing the number of ejector strokes, shortening the ejector stroke, etc.
It must be remembered that only one parameter should be altered at a time so that
the steady-state is not interrupted and so that alterations in quality can be
obtained.
5-26 NM011C05
5.8. SEMI-AUTOMATIC Operation
SEMI-AUTOMATIC mode can be used after test moldings in MANUAL mode are
stable and Select the SEMI-AUTOMATIC mode.
1) Determine the set time for the timers (Holding timer, cooling timer and
Interval timer) by judging the values in MANUAL mode.
① Injection timer (TR1)

(resin filling time) + (holding time)
② Cooling timer (TR3)

For an open nozzle, set the timer longer than the charging time.
③ Interval timer (TR4)

(take-out time) + (margin time)
Operating Mode keys

2) To run the machine in the semi-automatic
mode, depress the SEMI-AUTOMATIC key AUTO AUTO
and confirm the LED on the key is lighting

up.
3) Perform [OPEN]⇔ [CLOSE] of the gate.

The injection molding machine will operate
automatically for one cycle and stop. The
cycle is activated continuously with the
opening and closing of the safety gate for
each cycle.
5-27 NM011C05
5.9. AUTOMATIC Operation

When products can be automatically discharged and taken out, the injection
molding machine can be operated in AUTOMATIC mode.
Operating Mode keys

1) To run the machine in the automatic mode,
depress the AUTOMATIC key and confirm AUTO AUTO
the LED on the key is lighting up.
2) Open and close the safety gate. After that,

the injection molding machine can be
operated in AUTOMATIC mode.
3) Set the interval timer (TR4) shorter than

that of SEMI-AUTOMATIC operation
according to the molded product and the
sprue and runner discharge timing.
NOTE :
Even if the cooling timer is set to reach "time out" before the completion of
charging, mold opening cannot be performed until charge out or suck-back is
completed.
5-28 NM011C05
5.10. Material and Color Change
Follow below to carry out material and color changes efficiently without washing
resin. For preparation, purge all old resin with high screw back pressure and
clean the hopper thoroughly. Then supply new resin into the hopper.

Stop material supply to the barrel, and purge
resin until the screw will not retract and the
1 Close the shutter.
condition where minimum quantity of resin
remains.
Set the temperature on the injection unit to
2 the value lower than that for the next molded
products by 10~15℃ .
Clean the materials from the material line up
3
to the barrel by blowing compressed air.
After cleaning the interior of the hopper,
4 charge the materials for the next molding
process.
Change the screw speed to low and turn the Refer to Chapter 4.3.1 for
5 back pressure relief valve(R12) to the setting the back pressure and
optimum position. the screw speed.
Start to supply the materials to the barrel, Inject

keep pushing the SCREW RETRACT key
6
and charge the materials until the condition
where resin is drooling from the nozzle port.
5-29 NM011C05

Under this condition, lower the back pressure to
approximately 5 Kgf/cm², change to 1/3 of the full injection
7
stroke and perform injection (purging).
Repeat charging and injection several times, there by

completing material change (or color change). Increase the
8
setting temperature to normal level and commence the
molding operation.
NOTE :
The procedure described above is for resin and color changes at the same molding
temperature. Special care must be exercised for new resins with a different
molding temperature. When changing a resin with a molding temperature of 180℃
with another one with a molding temperature of 300℃ resin, for example, change
the oil resin with the resin of intermediate molding temperature such as PE before
the final change.
5-30 NM011C05
5.11. Completion of Molding Operation
Follow the procedure below to stop molding operation.
1) Stop supplying resin to the barrel.

① Close the shutter of the hopper.
Operating Mode keys

2) To turn the machine into the manual
AUTO AUTO
operation mode, depress the MANUAL key
and check the LED on the key is lighting up.
Retract the nozzle, repeat INJECTION and
CHARGE with the SCREW ADVANCE and
RETRACT key, and fully purge the resin
from the barrel. Inject
NOTE :
When only a small amount of resin is left in the
barrel, set the screw speed low.
3) Retract the screw to the retract limit.
4) To stop the molding operation temporarily, either cut off the heater or lower the
preset temperature, and lower the temperature for resins which decompress
easily (PA, PVC). Prevent overheating decomposition by performing
occasional paging.
5) Clean the mold thoroughly and keep it closed to prevent damage from the
outside.
6) Stop the pump by pressing the STOP push button for the pump motor.
5-31 NM011C05
7) Switch both the power switch and the

heater power switch to the OFF position.
8) Close the cooling water valve.
9) Inspect for oil or water leakage, and clean

up such materials if detected.
5.11.1. What You Should Do After Operation
1) Clean the mold mounting surface of the mold platen with a rag. When the
machine is not to be used for an extended period of time, apply rust
preventatives to the inner surface of the mold.
2) Dispose of purged resin.
3) Turn OFF the primary power of the machine.
4) Clean the respective parts of the machine and the floor.
CAUTION :
Any resin remaining in the barrel will decompose due to the remaining heat in the
barrel, and will require extra heat-up time during the next molding process.
Otherwise, resin will remain unmerited even though the barrel reaches the preset
temperature, so this resin may cause unexpected problems, such as damage to the
screw tip.
5-32 NM011C05
5.12. Removing the Mold
To remove the mold, follow the procedure described below. Prepare hanging bolts,
wire, a fixed wrench or bar wrench, a pipe, and rust preventatives.
1) Remove the mold cooling hose. Check

that the molding surface is free from water,
oil, etc.
2) When the mold is not to be used for an

extended period of time, open the mold and
apply rust preventatives to the stationary
and movable molds.
3) Close the mold.
4) Attach the hanging bolts to the mold and suspend the mold using a hoist or
crane.
5) Remove the mold mounting bolts.
6) Set OPERATION selector switch to MOLD SET-UP position and place the mold
at the mold open limit.
7) Pull out the mold locate ring from the

stationary platen hole.
8) Lift the mold using the hoist or crane and

move it to a safe place for storage.
CAUTION :
☞ When lifting the mold, be careful not to allow the mold to hit the tie rods.
5-33 NM011C05
Replacing the Parts LSMNL-011/Ver. 1.0
Chapter 6. Replacing the Parts.
6.1. Replacing the Screw and Barrel ..........................................................................................2

6.1.1. Screw Replacement ...................................................................................................2
6.1.2. Installation and Removal of the Nozzle and Barrel Head...........................................5
6.1.3. Screw Removal ..........................................................................................................6
6.1.4. Screw Tip Removal ....................................................................................................7
6.1.5. Barrel Replacement ...................................................................................................8
6.1.6. Mounting the Barrel....................................................................................................9
6.1.7. Mounting the Screw Tip .............................................................................................9
6.2. Replacing the Filter Element in the Oil Cleaner .................................................................10
6.3. Replacing the V - Packing..................................................................................................11
6.4. U Packing...........................................................................................................................13
6.5. Replacing the Contractor ...................................................................................................15
6-1 NM011C06
6. Replacing the Parts
6.1. Replacing the Screw and Barrel

The barrel swivel device and the injection ram advance/retract device are utilized
when cleaning and replacement of the screw and barrel are required.
6.1.1. Screw Replacement( For LGH450 ~ LGH1000N model )

(1) Stop Supplying material to the barrel (close the shutter of the hopper), and
perform molding until either the molded product is short shot or purging is
repeated, to remove as much resin from the barrel as possible.
(2) Turn OFF the heater power switch on control panel.
(3) Keep depressing the NOZZLE RETRACT key
Nozzle
until the unit reaches the retract limit position.

(4) Depress the INJECTION RAM RETRACT
switch to retract the Injection ram.
INJ. RAM
(5) Remove the heater and thermocouple from the ADV. RET.
nozzle.
(6) Remove the nozzle and barrel head with the
maintenance tool.
(7) Push down the lever and fix it with hook.
(Confirm that LS6B[Limit Switch for Nozzle
Swivel Enable] is activated)
(8) Dismount the guide plate on the machine
operation side and machine non-operation side. LS6B
Only for LGH450N ~ LGH1000N

(9) Pull out the pin connecting the nozzle touch moving
cylinder and injection unit.
(10) Depress the NOZZLE ADVANCE key to advance

the nozzle touch moving cylinder. The nozzle
touch moving cylinder stops when the cam of the
joint of the nozzle touch moving cylinder turns
off LS6A[Limit Switch for Nozzle Normal Nozzle
Position].
6-2 NM011C06
(11) Turn the nozzle touch moving cylinder by

pulling it by hand, and fit joint hole to flange Joint Hole
hole, then insert the pin pulled out at
paragraph 9.
LS6A
Flange Hole
(12) Apply a sufficient amount of grease to the

swiveling surface by utilizing the grease gun
maintenance tool.
(13) After Confirming no man around projecting

part with swiveling, and turn the NOZZLE NOZZLE SWIVEL
SWIVEL key switch to the swivel position and LS6B
swivel the injection unit slowly.
NOTE :
In the case of returning the injection unit as usual, turn the NOZZLE SWIVEL key
switch to the return position operation of the paragraph 7 ~11.
(14) Remove the split collar connecting the screw

and shafts. (Remove the hexagon socket head
bolts and then remove the split collar.)
NOTE :
LS6A, LS6B is used only on the model of LGH450N ~ LGH1000N equipped with an
Auto Nozzle Swivel Unit. However, model of LGH25N ~ LGH350N, a small size
group, adopts Manual Nozzle Swivel Unit. In small model, follow below procedure
for screw replacement.
6-3 NM011C06
(1) ~(6) Same as the procedure of LGH450N ~ LGH1000N.

(7) Remove the pin(LGH100N ~LGH350N) or the nut(LGH25N ~LGH75N)
connecting a moving cylinder and a injection unit.
(8) Apply a sufficient amount of grease to the swiveling surface by utilizing the
grease gun maintenance tool.
(9) Remove the stopper located on the operating side of a machine, then turn
the injection unit counterclockwise by hand.
(10) Remove the split collar connecting the screw and shafts. (Remove the
hexagon socket head bolts and then remove the split collar.)
6-4 NM011C06
6.1.2. Installation and Removal of the Nozzle and Barrel Head

(1) Use the accessory eye spanner to remove the nozzle. A gentle blow to the
spanner will easily loosen the nozzle.
A [right-hand screw] is utilized for the nozzle.
(2) Before mounting the nozzle, clean the threads and

sealing thoroughly and apply metal lubricant. After
the temperature of the nozzle has increased to the
set temperature, apply an additional clamp. To
remove or attach the barrel head, use the attached
bar spanner.
6-5 NM011C06
6.1.3. Screw Removal
Operate the pump, push the INJ RAM push button to the ADVANCE position,
change to the RETRACT position at the advance limit and disconnect the screw
and shaft S.
(1) Place a wooden wedge between the screw and shaft S, and set the INJ RAM
selector switch to the ADVANCE position. When the injection ram reaches the
advance limit, set the key switch to the RETRACT position, and then set it
again to the ADVANCE position with the next wooden wedge placed in
between.
CAUTION :
☞ Before pushing the push button ON, ensure that no one is standing in the
direction of the advancing screw.
(2)The screw protrudes from the

barrel tip after several
repetitions:
then pull the screw out using a
rope to suspend the screw tip.
6-6 NM011C06
(3) After the screw comes out to some extent, suspend it with another rope and
pull it out completely
(4) Installation of the screw is the reverse of the removal procedure. Carefully
install the screw so that the key on the screw and shaft S are aligned
6.1.4. Screw Tip Removal

To remove the screw tip, apply a blow with the
eye spanner accessory tool when the screw tip
has come out from the barrel to some extent.
(when the screw is on the key way).
A(left-hand screw) is utilized.
CAUTION :
☞ Avoid heating the back flow stop ring directly with a burner during screw tip
removal. Material decomposition may cause cracks or wear.
6-7 NM011C06
6.1.5. Barrel Replacement

(1) Swivel the injection unit according to the
steps (1 ~ 7) for Screw Replacement.
(2) Remove the split collar connecting the

screw and shaft S. (Remove the hexagon
socket head bolts and split collar.)
(3) Operate the pump, push the INJ. RAM

push button to the ADVANCE position, and then to the RETRACT position when
the advance limit is reached. Disconnect the screw and shaft S.
(4) Remove the following :

Heater cover of the barrel thermos-couples, heater connection wires, nozzle
heater and nozzle thermocouple.
6-8 NM011C06
(５ ) Remove the barrel Mounting bolt with the barrel suspended by wires hooked on
the eye bolts.
(6) Suspend and remove the barrel after it is drawn out
6.1.6. Mounting the Barrel

To mount the barrel, reverse the removal procedures.
6.1.7. Mounting the Screw Tip

Before installation, lean all the parts and apply metal lubricant completely to the
threads.
6-9 NM011C06
6.2. Replacing the Filter Element in the Oil Cleaner

The oil cleaning system cleans the hydraulic oil. Filter element change is required
when the pressure indicated on the vacuum gauge is 4 kgf/㎠ or more (at a
hydraulic fluid temperature of 40℃ ) or when the pump operating time exceeds
3,000 hours.
Filter Element Change Procedure
(1) Stop the pump.
(2) Turn the handle counterclockwise to loosen it,

then hold the handle with your hands and pull
up the filter element.
(3) Change the pre-filter and column filter with new

ones.
(4) Hold the handle with your hands, insert the

filter element, and turn the handle clockwise to tighten it.
(1) Start the pump.
(2) Loosen the air purge valve to purge air

from the case.
6-10 NM011C06
6.3. Replacing the V - Packing

If oil still leaks from the tightened V-Packing , replace the packing as follows.
1) Prepare the necessary tools besides the standard tools Prepare a wooden
hammer, packing stick (wood), hard-wood spike, special pipe, grease, etc.
2) Stop the movable platen in the middle of its stroke, remove the connecting bolt
with the booster ram, and retract the booster ram.
3) Remove the V - Packing in the following manner.

Run the machine in the mold set-up operation Operating Mode keys
mode by depress the MOLD SET-UP key. FULL

AUTO
SEMI
AUTO
MANUAL SET-UP
Slowly open the mold so that the V-Packing will

come out together with the bush due to the
mold open pressure.
Note that excessive supply of oil can
cause oil to splash out. Pull out the
V-Packing.
4) Push only the innermost bush against the

end.
6-11 NM011C06
5) Install new packing pieces from the

male adapter in the order in which old
packing pieces were assembled. Apply a
small amount of grease to the lip of the
V-packing to prevent damage to it. Be
careful not to turn up the lip. When
inserting the V-Packing, bleed off excess
air as shown in the figure on thet right.
Push each V-Packing piece against the
end.
In the above operation, use a wooden
hammer and hardwood stick so as not to
damage the booster ram.
Operating Mode keys

1) Slowly advance the ram until it touches the
mating spacer or stationary platen. After AUTO AUTO
finishing the above operations, clean the ram

and surface and then open and close the mold
in MOLD SET-UP mode. After checking that
there are no abnormal conditions, mount the
mold and run the machine dry.
CAUTION :
If the V-Packing is excessively tight, the mold may fail to advance or retract in
normal low-pressure closing. Loosen the Packing gland mounting belt by an
proper amount.
When properly done, oil should be slightly on the ram surface.
6-12 NM011C06
6.4. U Packing
If oil drips from the clamping cylinder piston rod area or a large amount of oil flows
into the drain hose, replace the packing.
(1) Purge the resin of barrel.
(2) Move the injection ram to the retract limit using the injection ram retract push
button switch.
(3) Remove the set screws using the wrench.
(4) Use the wrench over the width-across-flats part of the piston rod, turn the
piston rod, and remove the screw parts (2 places).
(5) Run the machine in the mold set-up operation mode by depressing the MOLD
SET-UP key.
(6) Keep depressing the SCREW ADVANCE key until the piston rod reach the
advance limit.
(7) Turn the pump OFF.
(8) Remove the socket head screw and remove the cover
(only the cover on the leaking oil needs to be removed.)
(9) Remove the U packing from the cover.
(10) Install a new U packing into the cover in the following manner. Change the
shape of the packing into an oval. With one end pushed into the slot, fit in the
entire packing while holding with your finger.
NOTE :
① Before assembling the packing, apply hydraulic fluid or grease the packing and
cover to make them slippery.
② Before installing the packing, check the seal direction.
6-13 NM011C06
③ When handling the packing, be extremely careful not to excessively elongate or

change its shape.
(11) Before assembling the cover, slip a protective cover over the thread and width
across flats, because the packing lip passes the thread and width across flats.
(12) Mount the cover.
(13) Turn the pump ON.
(14) Depress the injection ram retracting push button switch to retract the injection
piston.
(15) At the position where the piston touches the flange, release your finger from
the injection ram retract push button switch to stop the piston.
(16) By turning the piston with the wrench, screw it into the mating flange at the
required torque. At this time, be sure to assemble the split collar and spring
ring.
(17) Tighten the set screws.
(18) After assembling, repeatedly advance and retract the injection ram to bleed
the injection cylinder of air. Be careful not to make excessive elongation or
changing in its shape.
6-14 NM011C06
6.5. Replacing the Contractor
The contractor whose contact has been welded or worn should be replaced in the
following manner.
1) Open the doors of the control cabinet.
2) Turn OFF the NH and H1~H4 breakers.
3) Turn OFF the heater power or main power of the molding machine.
4) Remove the wires to the contractors, one by one.
5) Remove the contractor mounting screws.
6) Install new contractors.
7) Follow the above procedure in reverse for re-assembly. Be careful not to make
mistakes in wiring .
6-15 NM011C06
End of Chapter 6
Inspection and Maintenance LSM-MNL-011/Ver. 1.0
Chapter 7. Inspection and Maintenance
7.1. Daily Inspection....................................................................................................................2

7.2. Periodic Inspection...............................................................................................................6
7.2.1. Weekly (Every 150 Hours) .........................................................................................6
7.2.2. Monthly (Every 700 Hours) ........................................................................................9
7.2.3. Three Months (Every 2000 Hours)...........................................................................13
7.2.4. Six Months (Every 4000 Hours) ...............................................................................13
7.2.5. One Year (Every 8000 Hours)..................................................................................14
7.3. Maintenance ......................................................................................................................15
7.3.1. Three-phase Induction Motor ...................................................................................15
7.3.2. Cleaning the Air Breather Element...........................................................................20
7.3.3. Cleaning the Heat Exchanger ..................................................................................21
7.3.4. Heater Maintenance and Inspection ........................................................................23
7.3.5. Checking the Check Ring Wear Condition...............................................................24
7.3.6. Action to be Taken for an Excessively Risen Oil Temperature ................................25
7.4. LG WARRANTY.................................................................................................................27
7.5. PART REQUISITION FORM..............................................................................................29
7-1 NM011C07
7. Inspection and Maintenance
7.1. Daily Inspection
The operator should check the following items each day while the machine is
operating.
Equipment to be
Item Check procedure Note
checked
If abnormal sound or
Loop and listen for
vibration is found, trace
Motor and pump abnormal noise or
the cause and resolve
vibration.
it.
Look and listen for If abnormal sound or
Noise and Hydraulic piping abnormal noise or vibration is found, trace
Vibration and valve vibration visually and the cause and resolve
aurally. it.
If abnormal sound or
Movable platen Look listen for abnormal
vibration is found, trace
and injection unit noise or vibration visually
the cause and resolve
sliding section and aurally.
it.
Check the oil If the temperature is
temperature gauge for higher than 55℃ , cool
the hydraulic oil the oil by referring to
temperature. chapter 7.3.6
Temperature
Oil temperature
of Hydraulic
gauge
Oil
7-2 NM011C07
Equipment
Item to be Check procedure Note
checked
Pressure Check the pressure gauge Make sure that the pointer
gauge pointer when the machine is returns to ０ kg/㎠ . If the
stopped. pointer does not return
to０ kg/㎠ , set the pointer
to the zero point.
Check the pressure gauge Make sure that the pointer
pointer when the machine is in does not point above the
Pressure
operation. red line. If the pointer
of
swings abnormally or
Hydraulic
unstable, close the gauge
Oil
lock and replace the
pressure gauge.
Check the pointer for abnormal

swing.
Valve Check each area for oil leakage If oil leakage is found,
mounting visually and by touching tighten the bolts. If the
face, joint additional tightening does
screw not stop the leakage,
Oil section, replace the O rings.
Leakage connection
section of
piping with
joints, and
cylinder
packing
section
7-3 NM011C07
Equipment to be
checked
Check the oil cleaner vacuum Make sure that the

gauge and the filter alarm gauge does not read
lamp on the Electromagnetic over 4kgf/㎠ and that
Filter
Oil cleaner control panel. the filter alarm is off. If
Blinding
the gauge is over
4kg/㎠ , or the alarm is
on, replace the filter.
Check the connections for If water leakage is
water leakage and the found, tighten the
pipes for breakage and water joints. If the additional
leakage. tightening does not
stop the leakage,
rewind the seal tape.
Cooling Cooling water
Wind in the direction of
Water piping and joint
the threads.
Flow checker Check the oil checker. Make sure that the
required amount of
Cooling cooling water is flowing
Water If a small amount of
cooling water piping for
leakage.
7-4 NM011C07
Equipment to be
checked
Electromagnetic Check the power If a lamp is burned
Lamp control panel indicating lamp, back out, replace the lamp
Burnout lighted push button lamp immediately
and pilot lamp for
burnout.
Mold open and close Check the mold open and Purge hydraulic oil of
operation close operation. If air is air through the air
in the hydraulic oil purge valve on the top
the mold open and close the clamp cylinder
Air in the will be unstable. Perform air purge also
Hydraulic if the machine have
Oil been stopped for a
long period of time, or
after hydraulic oil has
been replaced.
Nuts and Nut and bolt of the Check for looseness. If any bolt or nut is
bolts moving section loose, tighten it with a
wrench.
① Tie Bar Bush Check lubrication visually Make sure that each
② Movable Platen part is lubricated
Sliding Surface sufficiently If not,
③ Injection unit lubricate with a
Lubrication sliding face grease gun or grease
pump.
(for details, refer to
Specifications for
Lubricating Oil)
7-5 NM011C07
7.2. Periodic Inspection
7.2.1. Weekly (Every 150 Hours)

Equipment to be
checked
Check each If the electromagnetic
electromagnetic valve by valve generates
touching it. abnormal heat or
vibration, reassemble
the valve and check the
solenoid coil, spool,
Electromagnetic valve
and springs for
breakage.
Watch the action Check that the solenoid
indicator lamp of each valve is switched
solenoid valve by eye normally
viewing.
Check the lock nut of the If the lock nut is loose,
pressure setting handle and the set pressure is
Hydraulic for looseness. changed, reset the
Relief valve
parts pressure and tighten
the lock nut with a
wrench.
Check the hydraulic Check that the pointer
pressure and amount. of the pressure gauge
The pressure is checked indicates no difference
by the difference from from the set value. and
the set pressure using that there is no much
the pressure gauges(G1, difference between the
Oil Pressure Pump
G2). mold-close/open speed
The amount is checked and the set value.
by eye viewing the
difference from the set
value of the mold-close/
open speed.
Item Equipment to be Check procedure Note
7-6 NM011C07
checked
Check by eye viewing if Check that there is no

Oil Leak Entire Machine any oil leaks from each oil leakage.
part of the machine.
Check lubrication Make sure that each
visually. section is lubricated
Injection unit guide
Lubrication sufficiently. If not,
face(2 places)
lubricate it with a
grease gun.
Check the following. Additionally tighten
1) The mounting bolts the bolt.
for looseness or Remove resin from
breakage. the band heater.
2) The band heater for Replace the lead
Heat
Band heater adhering resin wire with a new
Control Unit
3) The lead wire for one.
breakage. Additionally tighten
4) The lead wire the lead wire
connecting terminal connecting
for looseness. terminal.
Insert the thermocouple If not normal, adjust
into the barrel hole so the cap position to
that the tip of the allow the tip of the
thermocouple adheres thermocouple adhere
closely to the bottom of closely to the bottom
Heat the hole of the hole. Loosen the
Thermocouple
Control Unit screw and move the
insertion section
(Continued) cap left to fix the
screw.
Item Equipment to be Check procedure Note
7-7 NM011C07
checked
Remove the mold and

set the ejector plate at
the retract limit, then
check to make sure that
the ejecting rod does not
protrude from the mold
mounting face of the
If the ejecting rod is
movable platen.
Ejector Ejection rod loose, tighten it with a
wrench.
If the mold cannot be
removed, check to make
sure that there is no
clearance between the
ejecting rod and the
threaded portion of the
ejector plate.
7-8 NM011C07
7.2.2. Monthly (Every 700 Hours)
Equipment to be
checked
Grip the knob, etc. of the
Make sure that the
safety gate, and shake it
safety gate has no
slightly back and forth,
abnormal play.
and up and down.
Make sure that the
Push the transparent
transparent panel or
panel or the net of the
the net adheres
safety gate lightly.
sufficiently to the gate.
Open and close the Make sure that the
safety gate. roller for the rail and
Safety gate A
the roller for the safety
gate have no abnormal
Safety gate C
play. If either roller is
loose, replace it with a
new one.
Make sure that roller
fixing bolts of the
Safety
safety gate are not
Device
loose.
Make sure that the rail
supporting bracket is
not loose or broken, so
that the safety gate
will not derail.
Open and close the
safety gate to the open
Safety gate open and If any bolt is loose,
and close limits, and
close stopper tighten it.
strike the gate against
the stoppers lightly.
Safety gate If the roller or lever is
Check the roller and
levers(Operating side, broken, replace it with
lever for breakage.
Non- operating side) new one.
Check if the dog
Repair the dog if it is
attached to the gate is
transformed.
transformed.
7-9 NM011C07
Equipment to be
checked
Check the installation If any bolt is loose,
bolts for looseness. tighten it.
If the roller or lever is
Safety gate limit Ch eck the roller and
broken, replace it with
switch(LS1, LS1A, leve r for breakage.
new one.
LS1C )
Check the cam attached
If the cam is deformed,
to the safety gate for
replace it.
deformation.
Check the installation If bolt is loose, tighten
bolts for looseness. it.
If the roller or lever is
Check the roller and
broken, replace it with
lever for breakage
new one.
Cam valve (L1) Check if the cam
If transformed, replace
safety attached to the gate is
it with a new one.
Device transformed.
Check if the Cam Valve
Check that it is not
lever is loosened or
loosened or broken.
broken.
Check the rail fixing
If any bolt is loose,
bracket installation bolts
tighten it.
for looseness.
Safety gate rail Check the roller
installation bolts of the If any bolt is loose,
safety gate for tighten it.
looseness.
Check if the fixing bolts Fasten them if
Nozzle safety cover a re loosened. loosened.
limit switch (LS1Z) Check if the roller lever If broken, replace it
is broken. with a new one.
7-10 NM011C07
Equipment to be
checked
Check the barrel
Barrel installation bolts for Tighten each bolt.
looseness.
Make sure the bolts
are not cracked, the
threads are not
striped, and that the
Clamp Bolt wrench setting portion
Check for damage to the
on the bolt head is not
Mold mounting bolts mold mounting bolts
damaged such that it
visually.
cannot be tightened
thoroughly.
If any bolt is broken,

replace it.
Make sure the power
supply voltage is
Power Measure the power
Electromagnetic within the range of the
Supply supply voltage using a
control panel rated voltage±10%. If
Voltage voltmeter.
the voltage is outside
the range, adjust it.
Check the bolts on the
connection sections of
the terminal block and
Electromagnetic electric equipment for
Electric If any bolt is loose,
control panel and looseness.
wiring tighten it.
terminal boxes ☞ Be sure to turn off
the power switch and
check the voltage at
inspection points.
Watch and the oil

If the oil is too dirty,
level gauge take a Check by eye viewing if
Working oil replace it with new
sample of the oil in the working oil is dirty or
one.
the tank. there are air bubbles in
it.
7-11 NM011C07
Equipment to be
checked
Make sure the oil level
reaches the center of
the gauge, and that
the oil is not black.
More oil should be

added if oil level is too
Direct drive Check the oil gauge.
low and the oil should
Lubricating
be changed if it is
oil
black and thick.
(For details, refer to

Specification for
Lubrication oil.)
Cam-operated valve Check the roller and shaft for play due to wear.
roller bushing Lubricate the parts.
Limit switch roller (see specification for Lubrication Oil).
Disassemble the barrel By observing its worn
adapter and check the condition, check if the
Barrel adapter end face and inner face part is usable. Also
for wear or other consider replacing with
Screw Unit abnormalities a spare part.
Disassemble the screw

If a spare part is not
Screw tip tip and check it for wear
available, place an
or other abnormalities.
order.
Hydraulic Pipe joints and Check the joints and If any joint or bolt is
Piping hydraulic flanges bolts for looseness. loose, tighten it.
① If there are dents on a tie rod or sliding
surface, flatten them with a fine oil stone.
② Remove excess hydraulic oil or grease. Metal

Cleaning of and other dust are apt to adhere to it, lowering
the The whole machine machine accuracy and causing wear.
Machine
③ Remove pellet overflow near the hopper. It
can mix with hydraulic oil during repair,
damaging the pump or valves.
7-12 NM011C07
7.2.3. Three Months (Every 2000 Hours)

Item Items to be checked
Check the quality of the hydraulic oil.
1
Ask a reputable oil manufacturer to check the dirtiness of oil.
7.2.4. Six Months (Every 4000 Hours)

Consider the service life of the screw head assembly, pressure gauge,
packing and electric equipment (heater, times and others), and make the
1
necessary preparations for replacement, as the guarantee period for these
components and parts is six(6) months.
Replace the contact points of the heater connectors and replace worn
2 parts if wear is detected. For the replacement of the heater connectors,
refer to Chapter 6.
Excessive dust adhering to the winding or iron core duct of the drip- proof
motor may cause burnout due to overheating winding, and wet dust can
reduce resistance. Also, dust adhering to the motor can cause vibration
due to incorrect balance, and dust entering the bearing causing can cause
damage to the bearings. Consider the items mentioned above, and
3
perform periodic cleaning (disassembly or blowing off with dry air). The
cleaning intervals will vary according to the degree of dust. However,
cleaning should be performed once or more every six(6) months to one(1)
year. Regarding maintenance of the three-phase induction motor, refer
to chapter 7.3.1.
Lubricate the following parts (see specification for Lubrication).
Tie rod bushing(4 points)
Movable platen slide way (2 points)
4
Ejector plate guide bushing (4 points)
Direct drive bushing (2 points)
(Refer to attached drawing "Lubrication Spec." for detail.)
Check the discharge pressure and capacity of the hydraulic pump. By
observing the pressure gauges(G1, G2), check for difference between the
5 discharge pressure and the set pressure. For the capacity, check for
difference between the set value and specification value of mold
opening/closing speed.
7-13 NM011C07
7.2.5. One Year (Every 8000 Hours)

Check the bearings in the direct drive and the bushings of the sliding units
1
and sliding surfaces for wear.
The cooling jacket of the heat exchanger and the barrel may become
2 clogged with scales. If scales are found, clean the equipment. Regarding
the cleaning procedure for the heat exchanger, refer to Chapter 7.3.3
To assure smooth opening and closing of the movable platen, inspect and
adjust the wedges (on the operation and non-operation side). To adjust,
control adjusting bolts in front of the wedge to equalize upper and lower
clearances of the tie rod bushing and tie rod.
LGH25N ~ LGH200N(optional)
Measure the insulation state of the motor with a mugger. Normal insulation
4
should be 10 MΩ and over when using a DC500V mugger
7-14 NM011C07
7.3. Maintenance
7.3.1. Three-phase Induction Motor
This section describes operation and maintenance for the motor.
1) Storage
When the motor is to be stored or stopped for and extended period of time
(6months min., and 3 months min. in a high temperature and humidity area as a
standard) note the following points.
(1) Where the humidity is high or there is the possibility of infiltration of water by
foreign material , cover the entire motor with a polyethylene sheet and seal
up with descanting agent in it. The descanting agent should be replaced from
time to time.
(2) Measure the insulation resistance with a 500V mugger every three months to
check that it is a minimum of 1M ohms.
(3) To prevent the bearing from rusting, race the motor about five minutes every
three months.
(4) Before using the motor, measure the insulation resistance and check the
bearing and the connection with the power supply to check that there are
no abnormal conditions.
2) Operation
(1) After installation and wiring, once again check the wiring and ground.
(2) After inspection, turn on the switch to operate the motor. Should the motor
fail to operate normally, refer to Table 1, "Motor Problem and Its Remedy."
(3) If a power failure occurs during operation, be sure to turn off the power
switch, or there is a danger of causing contingency due to the motor
operated without knowing when power is restored.
(4) Use the motor in a place with an ambient temperature of 15 to 45 ℃ .
7-15 NM011C07
3) Maintenance
Disassembly and Inspection

The motor which is continuously operated night and day should be disassembled
and inspected once every two or three years. In an intermittent operation, it is
subject to disassembly and inspection once every three years. However, motors
manufactured for special uses or under special specifications must be
disassembled and inspected at the specified intervals.
4) Records
(1) Items to be recorded at certain intervals every day
Measured date, time, weather

Voltage, load current, frequency
Ambient temperature (room temp.)
Bearing noise and ambient temperature,
Stator winding temperature, frame surface temperature (totally enclosed
type)
Unusual vibration and noise
(2) Items to be measured or investigated and recorded periodically
Insulation resistance and its relative humidity

Amplitude of vibration
Color of bearing discharged grease and presence of foreign material
Contamination of the inside and outside of motor (including the filter,
accessory devices, and parts)
Coupling direct coupling accuracy, belt tension
Looseness of motor tightening bolts and other tightening bolts
Oil level, oil contamination, and oil leakage of lubricating oil
(3) Of the items of the above measurement and inspection, those having
tolerances are as follows
7-16 NM011C07
▷ Voltage fluctuation .......................................... Rated value±10%

(at rated frequency)
▷ Frequency fluctuation .........................................Rated value±5 %

(at rated voltage)
▷ Simultaneous voltage and frequency fluctuation

Sum of absolute values of both
fluctuation percentage to be within 10 %
▷ Rated temperature rise value (max. ambient temp. 45℃ )

TM: Temperature measurement
RM: Resistance measurement
Class "E" Class "B" Class "F" Class "H"

Machine Type of insulation insulation insulation insulation
Part Housing
TM RM TM RM TM RM TM RM
Other than 65 75 70 80 85 100 105 125

Stator
totally enclosed
Winding
type 70 75 75 80 90 100 110 125
40℃ when measured from outside.
45℃ when temperature indicator element is buried.
Bearing
Where heat-resisting grease is used, permissible
temperature (55℃ ) for the grease.
7-17 NM011C07
5) Motor Problem and Its Remedy
Motors should be disassembled and cleaned once every one or two years in places
with high humidity, salt damage or much dust, and about once every five years in
normal places, to assure their good performance. For reference, daily
maintenance and inspection items are listed in Table 1, Motor Problem and Its
Remedy." For other problems, consult with out service personal.
For troubles of the products and other questions. contact the source of your
purchase, stating the following items.
(1) Items on data plate (particularly type, for, pole, kW, serial No.)
(2) For troubles, machine model name, details of trouble, delivered date, operating
conditions, etc.
Even if the nearest designated vendor is unknown, please feel free to contact us.
7-18 NM011C07
Table 1: Motor Problem and Its Remedy
Large Protectiv
Phenomenon Overheat Electric Insulation
Shaft noise Irregular e relay
Leakag resistance Remedy
broken and rotation actuate
Possible Cause Body Bearing e reduced
vibration d
High ambient temp ◎ ○ ◎ Provide good ventilation
High humidity ○ ◎ Consult with us
Locati Much water or oil ○ ○ ◎

Installation
Prevent splash
on splash
Obstacle near motor ◎ ○ ○ Set 20cm away
External vibration,
◎ ○ ○ Vibration proofing
large shock
Foundation weak ◎ Make strong
Direct Cores misaligned ○ ◎ ○ Align cores

Loan and its
coupling
coupli Large imbalance of

ng coupling ◎ Correct coupling balance
Dirt on rotational area ◎ ○ Remove dirt

Check wire thickness and
Large drop in voltage ◎ ○ ◎ length and consult with electric
company
Ground incomplete ○ ◎ Establish a ground
Wiring
Single-phase operation ◎ ◎ ◎ Check connection circuit
Voltage imbalance ◎ ○ ○ Consult with electric company
Overload ○ ◎ ◎ Reduce load
High start frequency ○ ◎ ○ Reduce start frequency
Large load inertia ◎ ○ Consult with us

Load
Large vibration of mating

◎ ◎ Check connection circuit
machine
Large imbalance of load ◎ ○ Correct balance
Bearing abnormal ◎ ◎ ○ Repair at special factory

Other
Motor coil broken ○ ○ ◎ ◎ ◎ Repair at special factory

* ◎ : Phenomenon closely related to cause
○ : Phenomenon related to cause
7-19 NM011C07
7.3.2. Cleaning the Air Breather Element
The air breather is utilized for inhaling and exhaling air according to the change
of oil level in the oil tank, and this air breather must always be kept clean. The air
breather must be inspected once at an absolute minimum of every 500 hours
When removing the inner element for inspection and cleaning of the inner element,
it can be easily installed and removed by removing the upper nut and the cover. In
this case, when there is considerable dust on the element surface, the dust may
intrude to the inside, so exercise caution.
In the case of the polluted element, clean it as follows.
(1) In the case of dry dust

Blow compressed air from the inside to the outside of the element, or brush
and provide proper vibration.
(2) In the case of wet dust (Oil and Other Substance)

Perform the above operation by soaking in gasoline, washing oil or synthetic
cleaners. Acetone, Toluene, coating thinner or similar materials must be
utilized.
7-20 NM011C07
7.3.3. Cleaning the Heat Exchanger
Be sure to clean the heat exchanger a least once a year to prevent decrease of
cooling efficiency and leakage due to corrosion.
1) Turn the pump OFF.

2) Stop the circulation of cooling water using the main valve.
3) Remove the hydraulic pipes (2 places)at the top of the heat exchanger.
4) Remove the inlet and outlet pipes for cooling water

5) Remove the drain port plug to discharge water from the inside.
6) Remove the plug at the oil drain port to discharge oil from the inside.
7) Remove the bolts securing the heat exchanger body, and take out the heat
exchanger.
8) Remove the cover (right).
7-21 NM011C07
9) Remove the cover (left).
10) Check the inside of the tube and clean with a wire brush. For the wash liquid,
use a commercially available weak-alkali wash liquid.
11) Also clean the covers (right, left).

12) After washing, rinse them thoroughly with water.
CAUTION :
☞ Do not wash the oil outlet and inlet ports with water.
13) Follow the above procedure in reverse for re-assembly.
CAUTION:
☞ Do not install the heat exchanger with water or oil staying in the frame. Be
sure to drain water and oil using a sponge or rags.
7-22 NM011C07
7.3.4. Heater Maintenance and Inspection
A band heater or aluminum cast heater is usually used to heat the injection cylinder
barrel. Most of our injection molding machines use band heater-nichrome wire is
placed between stainless sheets and insulated by mica. The heater should be
maintained and inspected as shown below.
1) The main cause of broken wires is often attributable to tightening failure. The
watt density of the heater is about 3 to 5W/㎠ . A less contraction area with the
barrel results in almost dry baking and eventually breaks wire. Additionally
tighten the heated heater at least once a month.
2) When additionally tightening the heater

above, check the screws at the heater
wiring area (including the screws for
the terminal box, contractors, etc.) for
looseness.
3) The mega of the heater is more than a

few megohms after being heated once.
A mega of less than 1MΩ will
adversely affect the human body due to
leakage current. Identify the cause of
the problem. If no cause is known, replace it.
4) When additionally tightening the heater, also check the inserted condition
of the thermocouple to see if it is secured.
7-23 NM011C07
7.3.5. Checking the Check Ring Wear Condition
The check ring wear condition of the screw head should be checked in the following
manner.
1) Close the mold in MANUAL mode.
2) Advance the nozzle to touch the mold.
3) Keep depressing the SCREW RETRACT key until the charging operation for
one shot is completed.
4) Keep depressing the SCREW ADVANCE key until the filling of the mold with
resin is completed.
5) After injection, depress the SCREW RETRACT key. Upon completion of

charging, pull your hand out of the key.
6) Depress the SCREW ADVANCE key.
7) If the screw advances, the check rings worn.
7-24 NM011C07
7.3.6. Action to be Taken for an Excessively Risen Oil Temperature
1) In case the oil temperature exceeds

55℃ , stop the machine.
Check if the IN side stop valve for heat

exchanger cooling water is open.
▷ If not, open the valve and operate the

pump to drop the oil temperature,
before operating the machine.
2) Where a filter is installed on the

cooling water IN side, check the filter for clogging.
▷ If the filter is found clogged, clean the filter and operate the pump to allow
cooling water to flow. Before operating the machine, check that the oil
temperature has dropped.
7-25 NM011C07
3) Remove the hydraulic fluid temperature regulating valve.
Check the valve for clogging.
▷ If the valve is clogged with foreign material, remove the foreign material. After
assembling the temperature regulating valve, allow cooling water to flow and
operate the pump. Before operating the machine, check that the oil
temperature has dropped.
4) Clean the heat exchanger.
▷ After installing the heat exchanger, allow cooling water to flow and operate the
pump. Before operating the machine, check that the oil temperature dropped.
7-26 NM011C07
7.4. LG WARRANTY
1. Warrantor : LG Cable & Machinery Ltd.
2. Warranty Period : The warranty period begins on the date of start-up or 60days after
purchase order, whichever occurs first.
3. Basic Coverage : This warranty covers any repair or replacement of parts which
becomes necessary due to defects in material and/or workmanship, for machines run
under normal operation. The entire program applies only to the original customer at
the original place of installation.
4. Basic Warranty :
No Details Year Related Parts, classified
1 Durable items, described as 3 Castings, Tie Bars, Injection Cylinder,
Clamping Cylinder, Booster Ram, Welding,
and Frame.
2 Electric Motors and Printed 2 SSR, CPU, MCU, Power Supply, Main Board,
Circuit Boards I/O Board, Temperature Board, etc.
3 All remaining items 1
4 Labor & Transportation 1
5. Definition of Non Warranty.
Problems caused by the following are not covered under the warranty.
1) Consumable and Maintenance Items
2) Improper Operation
• Machine Operation as instructed in manual is required.
7-27 NM011C07
3) Improper Handling
• Physical Damage
• Storage and Environmental Condition.
• Improper choice of resin, i.e. mixture of metal chip with resin.
• Periodic Maintenance as instructed in the Manual is required.
4) Screw and Barrel Assembly Screw Tip Assembly :

• Warranty is void when material with fillers or color additives
5) Hydraulic Components :
• Warranty is void if hydraulic oil has been contaminated with metal chip, water, dirty,
etc., including air cavitation.
6) Specification Change and/or additional Configuration for option.
7-28 NM011C07
7.5. PART REQUISITION FORM
Use this form when ordering parts. To speedily handle all parts order, all pertinent information
should be provided with this form. Fax or Mail this form to following service center nearest
your location.
1. USA OFFICE :
TEL) INT+1-847-301-2800
FAX) INT+1-847-301-2818
THAILAND OFFIE :
TEL) INT+662-260-6608
FAX) INT+662-260-8557
INDONESIA OFFICE :
TEL) INT+62-21-515-3266
FAX) INT+62-21-515-3423
2. CUSTOMER
CUSTOMER NAME
ADDRESS
CITY / STATE / ZIP CODE
ATTENTION
TELEPHONE
FAXIMILE
3. MACHINE
MACHINE MODEL
SERIAL NO. OF MACHINE
NAME OF CONTROLLER
INJECTION CAPACITY
DATE OF PURCHASE
VOLTAGE OF MACHINE
4. PART REQUISITION
7-29 NM011C07
NO. PART NO. / PART NAME / SPECIFICATION QUANTITY LOCATION /

STOCK NO. DESCRIPTION ABBREVIATION
5. SKETCH & LOCATION OF PART

( IF NECESSARY TO IDENTIFY THE REQUEST PARTS.)
6. 1) DELIVERY DATE :
2) SHIPPING METHOD :
3) PURCHASE ORDER NUMBER :
AUTHORIZED BY :
7-30 NM011C07
TROUBLE SHOOT FLOW CHART LSM-MNL-011/Ver. 1.0
Chapter 8. TROUBLESHOOT FLOW CHART
8.1. Pump Motors don’t start......................................................................................................2

8.2. Motors don’t run continuously..............................................................................................3
8.3. Mold doesn’t open in Automatic Mode ................................................................................4
8.4. Mold doesn’t close in Automatic Mode ...............................................................................6
8.5. Nozzle does not Retract in Automatic Mode ........................................................................7
8.6. Nozzle does not advance in Automatic Mode ......................................................................8
8.7. Injection does not work in Automatic Mode .........................................................................9
8.8. Charging does not work in Automatic Mode ......................................................................11
8.9. Suck-back does not work in Automatic Mode ...................................................................13
8-1 NM011C08
8. TROUBLE SHOOT FLOW CHART
8.1. Pump Motors don’t start
Power Lamp(MPL) ON ?
No Customer’s Power from

outside of the machine
Yes isn’t supplied
Does Pressing
Push Button PB1 turn PB1 lamp
ON ?
Yes No
NFB1(for Motor1) and

NFB6(for Controller) ON?
Is
Electromagnetic Contactor MY1 Is front and
turned ON? rear side Emergency stop switch
EPB2,EPB3 ON?
No
No Release
Yes EPB2, EPB3
Yes
Check Check Instantaneous Is rear side
*NC Contact of MY1 *NC Contact of STR1 Safety gate limit switch
LS1C ON?
OK OK No Close Rear
Check wiring of the Motor Check Safety Gate
and Motor Control Circuit *NC Contact of MD1 Yes
OK OK Is select switch at
MANUAL or SETUP MODE?
Motor Problem in itself Check the Coil of MY1 Turn it to
No
for Disconnection MANUAL or SETUP
Yes MODE
Check Fuses is correct
from F1 to F2
OK
Check Jumpers is correct
from J1 to J7
OK
Check Over Load Relay
OL1, OL2
OK
Check Voltage between
Line1 and 2 is AC 100(V)
OL1, OL2
NOTE OK
*NC : Normal Close Check defective Wiring of
*NO : Normal Open EPB2, EPB3, PB1 and PB2
8-2 NM011C08
8.2. Motors don’t run continuously.
Does Motor stop by

releasing the push button
PB1 ?
Yes No
Is Timer STR1
activated ?
Yes No
Self-holding circuit
has problem
Does Magnetic Contactor
MD1 operate?
OK
Yes No
Check Instantaneous
*NO Contact of STR1
Check Wiring of Motor Check *NO Time Limit
OK and Motor-Drive-Part Contact of STR1
with Electric drawings
Check
*NO Contact of MD1 OK OK
Motor has problem Check
*NC Contact of MY1
in itself
OK
Check the coil of MD1
for disconnecting
Check the coil of STR1

for disconnection
OK
The timer STR1
has problem in itself
NOTE
*NC : Normal Close
*NO : Normal Open
8-3 NM011C08
8.3. Mold doesn’t open in Automatic Mode
Turn Operating Switch to

Manual Mode
Turn Selector Switch to

Mold Open
Is Mold Opened ? Check belows

on I/O Register screen
No
Cool Out Timer TR3 up?
Yes Charge Complete LS5 on?
Auto-circuit problem, Suck-back Complete LS10 on?
Check it out as below
OK
Turn off all option; core,
ejection,take out robot,etc
Semi-Auto Mode
Is Mold Opened ?
Check
voltage between 4 and X011 Yes No
terminal
DC 0V DC 24V Problem of interlock
circuit for option device
Output part OK and Check Selector Switch
Input signal OK, CS4 for problem
so may be software OK
sequence problem
Check wiring and
Connectors for contacts
Check the sequence of
Auto-Mode by using Ladder
OK
May be Input-card
fault in itself
Go to next page
8-4 NM011C08
NOTE From front page

*M1a : 75 ~ 200EN model
M1b : 315 ~1000EN model
*M5b : 75 ~ 200EN model Check on the lamp of
Is *M1a ON ?
M5a : 315 ~1000EN model the valve with eyes MOLD OPEN
*M7b : 315 ~1000EN model
ON OFF
Is *M5a ON ? Check Y080

HIGH PRESSURE CLAMPING on I/O Register screen
ON OFF
Output Signal for Valve

*M5a has problem
Is *M7b ON ?
PREFILL VALVE OPEN
Check Y086
ON OFF
Check Check
Valve voltage between Software sequence using
20 and Y086 Ladder
ON OFF
Output Signal for Output Signal for Valve

Valve *M7b is OK, M7b has problem
so it is hydraulic
circuit problem
Check Y116
ON OFF
Check Check
20 and Y116 Ladder
ON OFF
Input part and Output

of Controller is OK Output signal of
Output part has problem Controller has problem
Check Check voltage

Valve voltage between between 4 and X024
20 and Y080 (MOLD OPEN)
AC 100V AC 0V
Check Valve coil Disconnection is

for disconnection possible, check wiring
DC 0V DC 24V
OK OK
Check Check Fuse F11,14 Check sequence of MOLD- Check Selector Switch
Valve fault in itself for burning out OPEN by using Ladder CS10 for problem
OK OK OK OK
Hydraulic circuit SSR OUTPUT CARD has INPUT-CARD has problem, Disconnection is
has problem problem Replace possible, check wiring
8-5 NM011C08
8.4. Mold doesn’t close in Automatic Mode

NOTE
Turn Operating Switch to *M1b : 75 ~ 200EN model
MANUAL MODE M1a : 315 ~1000EN model
*M5b : 75 ~ 200EN model
Turn Selector Switch to M5a : 315 ~1000EN model
MOLD CLOSE
Check belows
Is Mold closed ? on I/O Register screen
No EJECT OUT LS32(X013) on?
Yes SAFE GATE SUHT LS1(X014) on?
Auto-circuit problem,
Check it out
as previous example OK
Is *M1b ON ?
MOLD CLOSE
ON OFF
Is *M5b ON? Check Y081

ON OFF

*M5b has problem
Output Signals
for Valve *M1b, *M5b are OK,
so it is hydraulic circuit
problem Check Y086
ON OFF
Check Check
20 and Y086 Ladder
ON OFF

of Controller is OK. Output signal of
Check Check voltage

Valve voltage between between 3 and X004
20 and Y081 (MOLD CLOSE)
AC 100V AC 0V

DC 24V DC 0V
OK OK
Check Check Fuse F11 Check sequence of MOLD- Check Selector Switch
Valve fault in itself for burning out CLOSE by using Ladder CS10 for problem
OK OK OK OK
Hydraulic circuit SSR output card has Input-card has problem, Disconnection is
has problem problem Replace possible, check wiring
8-6 NM011C08
8.5. Nozzle does not Retract in Automatic Mode
Check LS6(NOZZLE RETRACT)

setting is proper
OK
MANUAL MODE

NOZZLE RETRACT
Does Nozzle retract?

No
Yes
Auto-circuit problem, Is M3a ON ?
Check it out as below NOZZLE RETRACT
ON OFF

Is charging finished? Valve M3a is OK, M3a has problem
so it is hydraulic
OK circuit problem
Is suck back finished? Check Y090

OK
ON OFF
SEMI-AUTO MODE
Output part Input part
has problem has problem
Check
voltage between 4 and X011
terminal Check Check
DC 0V DC 24V Valve voltage between 20 voltage between 4 and K011
and Y090 (NOZZLE RETRACT)
sequence problem
Check wiring and
Check Software sequence
using Ladder
OK
May be INPUT-CARD
fault in itself
AC 100V AC 0V DC 0V DC 24V
Check Valve coil Disconnection is Check sequence of NOZZLE Check Selector Switch
for disconnection possible, check wiring RETRACT using Ladder CS3 for problem
OK OK OK OK
Check Check INPUT-CARD has problem, Check wiring and
Valve fault in itself Fuse F12 for burning out Replace Connectors for contacts
OK OK
Hydraulic circuit SSR OUTPUT CARD has

fault problem. Replace
8-7 NM011C08
8.6. Nozzle does not advance in Automatic Mode

MANUAL MODE

NOZZLE ADVANCE
Is
NOZZLE ADVANCED ?
No
Yes
Auto-circuit problem, Check belows
Check it out as below on I/O Register screen
NOZZLE SAFETY COVER LS1Z(X015) on?

NOZZLE ADVANCE LIMIT LS7(X017) on?
SEMI-AUTO MODE
Is M3b ON ?
NOZZLE ADVANCE
Check
voltage between 4 and X011 ON OFF
terminal
DC 0V DC 24V Output Signal for
Valve M3b is OK,
Output part OK and Check Selector Switch so it is hydraulic Output Signal for Valve
Input signal OK, CS4 for problem circuit problem M3b has problem
sequence problem
Check wiring and Check Y091
Connectors for contacts on I/O Register screen
Check Software sequence
using Ladder ON OFF
OK
Output part Input part
May be INPUT-CARD has problem has problem
fault in itself
Check Check voltage

Valve voltage between between 4 and X007(NOZZLE
20 and Y091 ADVANCE)
AC 100V AC 0V DC 0V DC 24V
Check Valve coil Disconnection is Check sequence of NOZZLE Check Selector Switch
for disconnection possible, check wiring ADVANCE using Ladder CS3 for problem
OK OK OK OK
Check Check Fuse F12 Check wiring and
Valve fault in itself for burning out INPUT-CARD has problem,
Replace Connectors for contacts
OK OK
Hydraulic circuit OUTPUT CARD has

fault problem. Replace
8-8 NM011C08
8.7. Injection does not work in Automatic Mode

MANUAL MODE

INJECTION MODE
Is Check belows
Injection performed ? on I/O Register screen
No
PRESSURE SWITCH PS1(X025) on?
Yes NOZZLE SAFETY COVER LS1Z(X015) on?
Auto-circuit problem, NOZZLE ADVANCE LIMIT LS7(X017) on?
OK
SEMI-AUTO MODE
Is
injection performed ?
Check
terminal
sequence problem
Check wiring and
Auto-Mode by using Ladder
OK
May be Input-card
fault in itself
Go to next page
8-9 NM011C08
From front page

NOTE
*M2b :All model except for
75 and 850EN M2a Check on the lamp of
*M5b : 75 ~ 200EN model Is *M2b ON ?
the valve with eyes INJECTION
M5a : 315 ~1000EN model
*M27b : All model except for
ON OFF
25 ~75EN
Is *M5b ON ? Check Y105
ON OFF

*M5a has problem
Is *M27b ON ?
R1 PORT CONTROL
Check Y086
ON OFF
Check Check
20 and Y086 Ladder
ON OFF

Valve *M27b is OK, *M27b has problem
so it is hydraulic
circuit problem
Check Y115
ON OFF
Check Check
20 and Y115 Ladder
ON OFF

of Controller is OK Output signal of
Check Check voltage

Valve voltage between between 4 and K007
20 and Y105 (INJECTION)
AC 100V AC 0V

OK OK DC 0V DC 24V
Check Check Fuse F11,13,15 Check sequence of INJE- Check Selector Switch
Valve fault in itself for burning out CTION by using Ladder CS2 for problem
OK OK OK OK
Hydraulic circuit SSR OUTPUT CARD has INPUT-CARD has problem, Check wiring and
has problem problem Replace Connectors for contacts
8-10 NM011C08
8.8. Charging does not work in Automatic Mode

Is Charging stroke
setting(LS5) correct ?

MANUAL MODE

CHARGE MODE
Is Screw rotated ?
No
Yes
Auto-circuit problem,

SEMI-AUTO Mode
Is Screw rotated ?
Check
terminal
sequence problem
Check wiring and
AUTO-MODE by using Ladder
OK
May be INPUT-CARD
fault in itself
Go to next
page
8-11 NM011C08
NOTE
From front page
*M4b : All model
except for 75EN M2b
*M5b : 75 ~ 200EN model
M5a : 315 ~1000EN model Check on the lamp of
Is *M4b ON ?
the valve with eyes CHARGING
ON OFF
Is *M5a ON ? Check Y106

ON OFF

*M5a has problem
Output Signals
for Valve *M4b, *M5a are OK,
problem Check Y086
ON OFF
Check Check
20 and Y086 Ladder
ON OFF

Check Check voltage

20 and Y106 (CHARGE)
AC 100V AC 0V

DC 0V DC 24V
OK OK
Check Check Fuse F11,13 Check sequence of MOLD- Check Selector Switch
Valve fault in itself for burning out OPEN by using Ladder CS2 for problem
OK OK OK OK
Hydraulic circuit SSR OUTPUT CARD has INPUT-CARD has problem, Disconnection is
has problem problem possible, check wiring
8-12 NM011C08
8.9. Suck-back does not work in Automatic Mode

Is Charging stroke NOTE
setting(LS5) correct ? *M102b : 75 ~ 200EN model
M102a : 315~1000EN model
MANUAL MODE

CHARGE MODE Check on the lamp of
the valve with eyes
Is suck-back preformed ? No
Yes Is M2a ON ?
Auto-circuit problem, INJ. RAM RETRACT
Check it out as
the previous examples
ON OFF
Is *M102b ON ? Check Y1093

PF2 LOADING on I/O Register screen
ON OFF

*M102b has problem
Output Signals
for Valve M2a, *M102b are OK,
problem Check Y092
ON OFF
Check Check
20 and Y092 Ladder
ON OFF

Check Check voltage

20 and Y093 (CHARGE)
AC 100V AC 0V

DC 0V DC 24V
OK OK
Check Check Fuse F12 Check sequence of SUCK- Check Selector Switch
Valve fault in itself for burning out BACK by using Ladder CS2 for problem
OK OK OK OK
Hydraulic circuit SSR OUTPUT CARD has INPUT-CARD has problem Disconnection is
has problem problem possible, check wiring
8-13 NM011C08
Annex LSM-MNL-011/Ver. 1.0
ANNEX
⊙ Hydraulic and Lubricating Oil
⊙ Screw Cold Start Preventing Function
Annex-1 NM011ANX
1. Hydraulic and Lubricating Oil .........................................................................................................3

1.1. Outline..................................................................................................................................3
1.2. Hydraulic Oil.........................................................................................................................3
1.3. Recommended Hydraulic Oil ...............................................................................................5
1.4. Selection of Recommended Oil ...........................................................................................5
1.5. Maintenance and Control of the Hydraulic System ..............................................................6
1.5.1. Oil Supply...................................................................................................................6
1.5.2. Periodic Testing of Oil Properties ..............................................................................8
1.5.3. Flushing ...................................................................................................................10
1.5.4. Oil Change Time ......................................................................................................11
1.5.5. Remarks Concerning Maintenance and Control ......................................................12
1.6. Selection of Lubricating Oil ................................................................................................13
1.7. Maintenance and Control of the Lubricating System .........................................................13
1.7.1. Maintenance and Control .........................................................................................13
1.7.2. Lubrication Maintenance ..........................................................................................14
1.8. Properties and Qualities of Hydraulic Oil ...........................................................................14
1.8.1. Viscosity ...................................................................................................................14
1.8.2. Viscosity Index .........................................................................................................15
1.8.3. Oxidation Stability ....................................................................................................15
1.8.4. Rust - Resistant Characteristics...............................................................................15
1.8.5. Wear - Resistant Characteristic ...............................................................................16
1.8.6. Miscellaneous ..........................................................................................................16
2. Screw Cold Start Preventing Function .........................................................................................17
2.1. Outline................................................................................................................................17
2.2. Movement ..........................................................................................................................17
Annex-2 NM011ANX
1. Hydraulic and Lubricating Oil
1.1. Outline
Injection molding machines of LS Mtron Ltd. have been designed and manufactured applying
the latest techniques and innovations, based on many years of experience in the plastic
molding industry in order to provide the most powerful machines for customers. The
hydraulic equipment utilized with these injection molding machines has been specially
selected, and is extremely reliable high performance equipment. However, even though the y
are well designed, they cannot be operated within the full range of their excellent capacities
unless suitable hydraulic and lubricating oils are utilized.
These specifications, which have been prepared for customer reference, provide the methods
for selecting hydraulic and lubricating oils, the maintenance and control of oil and the LS Mtron
Ltd. concept of hydraulic and Lubrication oils utilization, based on many years of experience.
1.2. Hydraulic Oil
1) When selecting hydraulic oil, the most important consideration is to select oil which is
suitable.
2) For the hydraulic pump, which is considered to be the most vital part of the hydraulic
system, comparable to the heart in the human body. Any oil which is suitable for the
hydraulic pump is also suitable for the hydraulic cylinders, which can be considered to be
the hands and feet of the hydraulic system, and for the hydraulic piping valves and other
valves and other components, which can be considered to be the nervous system and
internal organs of the hydraulic system.
The three basic oil properties, that is viscosity, viscosity index and pour point of the
hydraulic oil, must match the hydraulic equipment to be utilized and the operation
conditions of the equipment in order to make the oil suitable for utilization. Then it is
necessary to give consideration to the qualities (such as oxidation stability, rust resistant
characteristics, wear-resistant characteristics and others) of the hydraulic oil. However,
the pour point makes trouble only in very cold weather.
Therefore, in these specifications, only the viscosity and the viscosity index are
considered to be important properties.
Annex-3 NM011ANX
3) When selecting hydraulic oil, a point which often makes trouble is the temperature of the
oil when it is being utilized. The hydraulic oil must be utilized at the temperatures
indicated below. When hydraulic oil is utilized at a temperature which significantly
deviates from the values given below, it will not only become deteriorated, but also
damage the hydraulic equipment quickly. Therefore be sure to utilize hydraulic oil only at
the specified temperature.
Temperature of the oil Suitable : 40。C ± 50。C

Maximum : 55。C
Inside the tank
Minimum : 15。C
Operation under a loaded condition must be performed after the temperature of the oil
has risen to１５℃. Operation at a temperature under １５℃ could cause trouble with
defective suction of the hydraulic pump, which could result in seizure. Therefore, the
equipment must be started under a no-load condition, and special care must be exercised
regarding suction.
4) The use of water giycolic fire-retarding hydraulic oil largely affects the life of the machine.
Before using such oil, be sure to consult the source of your purchase. The use of water-
soluble oil is not recommended at present and such oils should not be used.
Annex-4 NM011ANX
1.3. Recommended Hydraulic Oil
With respect to the injection molding machines manufactured by LS Mtron Ltd. the oil shown
under Lubricating oil type is recommended based on consideration of the operation conditions,
properties and qualities of hydraulic oil. It must be ensured that one of the recommended
types of oil is utilized.
1.4. Selection of Recommended Oil
As stated above, the hydraulic equipment referred to in these specifications is operated under
rather severe conditions. Particularly, since the hydraulic pump which is the heart of the
hydraulic system is operated under very severe conditions, ANTI-WEAR type oil is recommended
for purposes of protecting the pump. The recommended brands of hydraulic oil are those which
possess a long history of positive achievements. At the same time, these recommended brands of
oil have exhibited favorable performance.
Annex-5 NM011ANX
1.5. Maintenance and Control of the Hydraulic System
Even though suitable hydraulic oil is utilized, not only the the life of the hydraulic oil but also
the life of the hydraulic system can be considerably shortened if the daily maintenance of the
hydraulic systems are caused by dirty or deteriorated hydraulic oil, or by damaged oil supply.
1.5.1. Oil Supply
(1) Hydraulic oil must be supplied through the provided oil supply port removing the cap.
However, do not down any removed cap carelessly on the floor. Make sure that soil, sand,
lint or other foreign matter does not adhere to the inner surface of any removed cap.
(2) The inside diameter of oil supply port is approximately 70mm and a 2 ½" inch pipe for oil
supply pump can be easily inserted. The oil supply port is provided with a 60 mesh filter.
Supply oil by utilizing the oil supply pump with caution to prevent overflow due to clogging..
(3) When supplying a large machine with oil for the first time without utilizing the oil supply
port, ensure that a 60 mesh filter or a filter with a larger size is utilized. Be sure that all
tools are kept clean at all times. Utilization of a flushing unit to supply oil is
recommended.
(4) When supplying a new machine with oil or replenishing a machine with oil, it is
recommended that a reputable oil company be contracted to perform such work.
Reputable oil companies can be depended upon to supply oil properly to an injection
molding machine, taking user's convenience into their consideration.
서식 있음: 글머리 기호 및
(5) The problems described below occur when supplying an injection molding machine with 번호 매기기
oil.
① A machine which had been operated without any problems for approximately one year
was supplied with new oil. In less than ten days, the suction resistance of the pump
increased. Pump operation become noisy and soon defective because of the problem
was adhesion of small pieces of cork-like substance, lint and tar-like substance in a
Annex-6 NM011ANX
large quantity collected at the suction strainer. The cause of the problem was traced
and it was found that oil supply had been performed by tilting a drum containing new oil
on the clogged filter, stopping the flow of oil to large degree. Then the person who had
supplied the oil had removed the filter and the remaining oil had been supplied without
a filter. When the oil drum was tilted further, dust, pieces of wood, pieces of cloth and
other foreign matter fell into the oil tank. The price of such thoughtless operation was
replacement of the pump, a flushing operation and another oil change.
② In another case, the condition of utilized hydraulic oil was found to be abnormal.
Investigation showed that some water from the oil cooler had been detected. The
cause was found to be the outdoor oil storage location. In this storage location, oil
drums containing oil were stored in an upright position and rain water infiltrated into the
oil drums. When oil drums are to be stored outdoors, as a general rule, they should be
stored on their sides. Before supplying oil from any oil drum to the oil tank of an
injection molding machine, ensure that the plug is firmly tightened. Also ensure that
the oil drums are stored properly when the oil supply operation has been completed.
Annex-7 NM011ANX
1.5.2. Periodic Testing of Oil Properties
If the dirtiness and deterioration of hydraulic oil progresses, the life of the injection molding
machine will be shortened and trouble will occur. Periodic testing must be performed in order
to detect any change in oil properties. Strictly speaking, any test of the properties of oil
should be an analytical test which is performed by a reputable oil company. The test can be
done by user to some extent with performing an appearance test or the dropping test. An oil
sample should be removed directly from the tank while the oil is sufficiently stirred immediately
after the injection molding machine has been stopped.
(1) Tests which can be performed by the User
a. Appearance Test
Pour some fresh oil and some used oil into separate test tubes, and compare the two
samples. Appraise the condition of the oil according to oil color, transparency, the
existence of minute floating substances, accumulation of water at the bottom of the test
tube, and other fin an upright position, and rain water had filtered into the other factors.
b. Dropping Test
A comparison test is also suitable in this case. Drop some used oil onto a piece of
filter paper (commonly utilized blotting paper is suitable) Observe the filter paper after
２~３ hours. If the oil is deteriorated or dirty, stains will be clearly visible. However, it is
difficult to determine whether or not oil must be changed, but experience will bring a
general pattern regarding oil change period.
(2) Qualitative and Quantitative an Oil Dealer

When an abnormality is detected as a result of the appearance test or the dropping test, it
is then necessary that testing be performed at the laboratories of a reputable oil dealer.
Any experienced technician of an oil dealer will know to change the oil immediately or
whether or not the oil must be given more extensive testing.
(3) Frequency of Periodic Testing 번호 매기기
The appearance test or the dropping test should be performed at least once per month,
on a predetermined data. The qualitative and quantitative analyses performed by an oil
dealer should be done once a month for the first three months after machine operation,
Annex-8 NM011ANX
and then every three succeeding months there after.
(4) Limit of Hydraulic Oil Utilization

The oil dealer will judge if the deteriorated oil should be changed according to the results
of the qualitative and quantitative analyses. Consideration given by LS Mtron Ltd.
regarding deterioration are described below. Regarding quantitative judging methods to
determine the deterioration of hydraulic oil, the " Test for Insoluble Contamination in
Hydraulic Fluid by Gravimetric Analysis", ASTM-D-893, and the " Procedure for the
Determination of Particulate Contamination of Hydraulic Fluids by the Particle Count
Method" ARP-598, can be mentioned. In the hydraulic system described in these
specifications,oil deterioration must be controlled within the following limitations. Oil
control for ３months after delivery of the injection molding machine is especially
important. It is not an overstatement to say that oil control during this period determins
the life of the hydraulic equipment.
Measuring Method Weight mothod Counting method

weight in 100ml
Allowable oil deterioration 7 mg NAS Grade 11
NOTE :
Particles which can be measured with the counting method are over 5㎛in size. Additionally,
the reproducibility of measured values is not good. Therefore, the counting method should
be utilized only for reference purpose.
Annex-9 NM011ANX
1.5.3. Flushing
(1) Purpose and Operation

The removal of chips, dirt, sand and other foreign matter which can enter the oil tank, piping
and other components during manufacture, assembly, transportation and installation of a
injection molding machine is the primary purpose of flushing operation. The secondary
purpose of flushing operation is to clean the hydraulic system after the injection molding
machine has been in operation for a fixed period of time. If the flushing is to be performed at
the factory of the injection molding machine user, it is recommended that flushing be done
under the guidance of a service technician from an oil dealer, utilizing a flushing unit.
Today most oil dealers have gained considerable experience regarding flushing techniques
and such oil dealers usually have flushing units, called flushing cars, available to serve their
customers. A portable oil cleaner is commercially available at LS Mtron Ltd.
This device can be utilized as a bypass filter unit to maintain cleanliness of or to fill and supply
oil. The oil cleaner will not only reduce difficulties and malfunction caused by deteriorated oil,
but will also serve to prolong the life of the hydraulic equipment. This will prolong the life of
the oil which is an important and limited energy source.
(2) Flushing performed at LS Mtron Ltd.

Whenever the hydraulic system is completed at LS Mtron Ltd., it is provided with a flushing
operation without fail, utilizing a flushing unit. Before assembly, the piping of the hydraulic
system is provided with a pickling process to remove bending send, dust, welding chips and
other matter. At the same time, the hydraulic system is provided with a thorough cleaning.
After that process another flushing process is performed at the factory after assembly. The
hydraulic oil itself is utilized as a flushing oil, and flushing is performed while the injection
molding machine is operated at low pressure.
(3) Flushing at the Time of Oil Change 번호 매기기
After a particular type of hydraulic oil has been utilized for a period of time, fine metal powder
produced by the sliding sections of the hydraulic pump and other hydraulic equipment, sludge
due to oil deterioration, scales and other foreign matter will appear in the oil, even when the oil
is of the highest quality and grade. Consequently, an oil change will become necessary.
As stated above, the lifetime of any hydraulic oil is considered to be ２~３years even under
optimum utilization conditions, and when deterioration begins, such deterioration progresses
rapidly. Within a very short period of time, the condition of the oil will be such that it can no
longer be utilized,
In such a case, it is recommended that not only a flushing operation be performed, but also
Annex-10 NM011ANX
that the oil be changed with fresh oil. First completely drain the used oil. Thoroughly wipe off
the interior of the tank with a sponge to remove all used oil. Fill the tank with a flushing oil of
the same viscosity as that of the utilized hydraulic oil. Operate the machine at low speed and
perform the flushing operation with a flushing unit. A flushing operation for 4 ~８ hours will
remove most of metal powder, sludge, chips and other foreign matter. When the flushing
operation has been completed, perform oil removal securely so that a minimum quantity of oil
is to remain in the hydraulic system, and wipe off any oil which may be adhering to the interior
of the tank.
(4) Flushing
When water, chemicals, or other substances mix with the oil, when the oil becomes
exceedingly dirty, or when it is necessary to utilize flushing oil and the flushing method
selected as a result of consultation among the user, a reputable oil dealer and a service
technician from LS Mtron Ltd. Is available.
(5) Miscellaneous
As a result of extensive experience, it has been found that hydraulic oil is made unfit for
utilization as a result of the mixing of impurities or water, especially impurities, to a far greater
extent than oil deterioration. The mixing of impurities and water is due to the following
reasons:
a. Metal powder produced by the sliding sections of the pump and other hydraulic equipment.
b. Water, dust and other foreign matter mixing with the oil at the time the tank is filled with oil.
c. Dust in the atmosphere which mixes with the oil.
d. Moisture in the atmosphere which mixes with the oil.
To prevent the forementioned contamination of oil by various impurities, LS Mtron Ltd. has
utilized micronic filters in the hydraulic circuits of medium and large size machines which use a
large amount of oil, which has succeeded in prolonging the life of both the hydraulic
equipment and the hydraulic oil. However, these filters can display their true value only if they
are checked periodically, and if filter elements are replaced at optimum periods. Monthly
appearance and dropping tests of hydraulic oil and the checking of filters must be securely
performed under any circumstance.
1.5.4. Oil Change Time
Annex-11 NM011ANX
The time for oil change can be determined by performing the forementioned testing.
However, when oil temperature is suitably maintained and oil replenishment is carefully
performed, the frequency of oil change can be set as shown below.
(The following does not apply if oil is accepted at periodic quality test.)
First Change :
Change the oil approximately 2,000 hours after initial machine start-up.
Second Change :
Change the oil approximately every 9,000 hours after the first oil change has been performed.
1.5.5. Remarks Concerning Maintenance and Control
(1) Ensure that suitable oil has been selected.
(2) Test the quality of the hydraulic oil periodicallyl.
(3) Ensure that the oil temperature is maintained at the proper level (maintaining the water
flow of the oil cooler and the water temperature of the oil cooler at suitable levels). The
oil temperature should be maintained at ４０℃ ± ５℃.
(4) Perform oil change and the flushing operations of the hydraulic system in the proper
manner.
Annex-12 NM011ANX
1.6. Selection of Lubricating Oil
Lubricating oil can be roughly classified into two categories; lubricating oil for bearings and oil
for slide ways. When selecting oil for the slide ways, it is absolutely necessary to thoroughly
consider the types of bearing sections, speed, load, ambient temperature and other factors.
However, if selection is made based on strictly setting the utilization positions and utilization
conditions, many types of lubricating oil must be selected, causing many difficulties regarding
maintenance and control. Additionally, since hydraulic oil works as high quality lubricating oil if
utilization conditions are proper, hydraulic oil must also be taken into consideration, and the
many types of lubricating oil must be reduced to a minimum for the entire injection molding
machine. This point is very important and should be remembered. The recommended
hydraulic oils and lubricating oils have been selected after giving complete consideration to
the points mentioned above. Additionally, when selecting lubricating oil, it is recommended
that selection be made from among the products of the same oil company which supplies
hydraulic oil.
1.7. Maintenance and Control of the Lubricating System
1.7.1. Maintenance and Control
Unlike hydraulic oil, lubricating oil is purchased in definite quantities at one time, and is kept in
storage. For this reason, extreme caution must be exercised regarding the storage and control
of lubricating oil.
(1) Be sure to store oil cans on a wooden floor.
(2) Be sure to close the caps tightly, and whenever possible, cover the can with sheets.
(3) Do not expose the oil cans to direct sunlight. Additionally, maintain the storage space
temperature below ４０℃.
Annex-13 NM011ANX
1.7.2. Lubrication Maintenance
(1) The grease in bearings and on slide ways will deteriorate rapidly due to moisture and dust
in the atmosphere, and the grease will not perform the lubricating function after a certain
length of time. Be sure to grease each "grease point" periodically according to
predefined. If the grease at any point grows black or becomes excessively dirty, it may
be necessary to remove it with Kerosene.
(2) Pay attention to the periodic change of the thrust bearing section of the injection molding
machine. Since the thrust bearing operates under a heavy load, it must be supplied
constantly with a sufficient amount of lubricating oil. No impurities can be permitted.
Initially, change the oil ３００0 hours after the commencement of injection molding
machine operation. Additionally, ensure that the oil has been completely drained before
filling the gear box or the bearing with fresh oil. Mere oil replenishment will not be
sufficient.
1.8. Properties and Qualities of Hydraulic Oil
Hydraulic oil must possess three excellent basic properties and high quality. These basic
properties are viscosity, viscosity index and pour point. Quality includes oxidation stability,
and rust-resistant and wear-resistant characteristics For reference, a brief explanation of
each is given below.
1.8.1. Viscosity
The viscosity of hydraulic oil should be kept as low as possible, as long as the oil doesn’t lose
lts lubricity for pumps and valves. Lubricity is the formation and maintenance of an oil film
between two sliding surfaces and it has a close relationship to viscosity. For this reason,
most hydraulic equipment manufacturers designate a proper viscosity regarding hydraulic oil
for each of their products. Generally speaking, the viscosity of hydraulic oil is expressed by
kinetic viscosity (normally expressed in centi-strokes ). For hydraulic systems, hydraulic oil
with a viscosity of ２５~１５０ centi - strokes at ３７．８℃(１００℉) is often utilized. ( As
a reference, the viscosity of water at ２０℃ is approximately one ［１］contistroke.) If
Annex-14 NM011ANX
the viscosity of and hydraulic oil is too high, poor pump suction will occur, and additionally, the
operation of each piece of hydraulic equipment will loose smoothness. Also, undesirable
conditions such as pressure loss and increase in power consumption will occur. On the other
hand, if viscosity is too low, the efficiency of the pump will be reduced: the wear of moving
parts will be accelerated and the accuracy of hydraulic operation will decrease.
1.8.2. Viscosity Index
As stated above, it is desirable that the viscosity of hydraulic oil be as low as possible, as long
as lubricity is not lost. However, the viscosity of oil will decrease when the oil temperature
rises and it will increase when the oil temperature drops. The hydraulic unit is operated at a
temperature of ５℃~５５℃. Additionally, at a limited time and position, the temperature may
drop to０℃, and it may rise as high as ９０℃. The hydraulic oil must not lose the required
lubricity within the temperature range stated above. Oil which possesses a minimum
viscosity variation with the variation of temperature is said to be oil with a high viscosity index.
Any hydraulic oil is required to possess a high viscosity index, and generally speaking, oil
which possesses a high viscosity index (higher than ９５) is utilized as hydraulic oil.
1.8.3. Oxidation Stability
The life of oil is greatly influenced by the stability of the oil against oxidation. The sludge
formed when oil is oxidized will hinder the performance of the equipment in the hydraulic
system. The valves will operate abnormally and pumps and other components will often
become damaged. Additionally, the oxidation will progress rapidly when it reaches a certain
point during oil utilization. The period will differ depending upon the utilization conditions, but
some cases indicate that the period is considered to be between 15,000 and 25,000 hours.
Oxidation stability is ensured by proper selection of the base oil, the refining process and
proper inhibitors. The speed of reaction during oxidation increase if the oil temperature is
above ６０℃. Therefore the oil temperature in the tank must be maintained below ６０℃.
1.8.4. Rust - Resistant Characteristics

The hydraulic tank is equipped with an air breather or an oil port. Outside air enters the tank,
and it is difficult to keep moisture out of the tank. The interiors of the hydraulic oil tanks
Annex-15 NM011ANX
manufactured by LS Mtron Ltd. are rust-proofed by application of a special paint. However,

when the moisture in the atmosphere mixes with the oil in the tank rust will develop in the
pipes and the equipment after a period of time. Scales of rust from the rusty parts will
damage the sliding surfaces of pumps, valves and other components. Additionally, rams,
piston, packing and similar machine components will become damaged and useless. For
these reasons, a highly efficient rust inhibitor must be added to each hydraulic oil.
1.8.5. Wear - Resistant Characteristic
The latest hydraulic equipment is manufactured to be compact and highly efficient, and the
vane pump, gear pump and other components can be operated under very severe conditions.
The hydraulic oil manufactured today is required to maintain lubricity even during boundary
lubrication at high temperatures and under high pressures. Hydraulic oil containing wear
preventive agents which have been recently developed is considered to be excellent regarding
the points mentioned above. The type of hydraulic oil is recommended for hydraulic systems
which operate at pressures higher than １４０kg/㎠.
1.8.6. Miscellaneous
Explanations offered above regarding the properties and qualities of hydraulic oil are very
important. For additional details, please refer to the instruction published by the various
companies dealing with hydraulic oils.
Annex-16 NM011ANX
2. Screw Cold Start Preventing Function

[ Temperatur Mse SET 08-25 FRI
] t 09 31
Temp. Unit ( ℃ ) Pre_Heat Sel. : Heating Schedule : ON
OFF Statu Actu SetVal Pre_He Alar
Heater Weekda On Hr Off
HN l
199 199 t150 + 20 Sunda 07:30 20:20H
H1 200 200 150 + 20 yMonda 07:30 20:20
H2 200 200 150 + 20 yTuesda 07:30 20:20
H3 198 198 150 + 20 Wedne 07:30 20:20
H4 199 199 150 + 20 d
Thursd 07:30 20:20
Friday 07:30 12:30
Screw Cold Prevention : ON Saturd 07:30 07:30
Screw Operating Delay Time : 20 min
00
00......050....100....150....200....250....300....3
50 400
HN
H1
H2
H3
H4
2.1. Outline
Since the screw of the injection molding machine is driven by a hydraulic motor, prevention of
damage to the screw due to excessive torque is performed by means of the set pressure for
the hydraulic motor. However, if the screw is rotated under the condition where the resin in the
screw barrel has not been melted, the screw tip will receive excessive torque. So this function
is used to prevent damage on the screw tip with Screw Operating Delay Time which can be
set to enough time for melting the resin sufficiently.
2.2. Movement
OFF : In off mode, any operation of screw will be prevented if the actual temperature of band
heater(H1) is 20℃ lower than the set temperature of band heater(H1), and if not,
operation of screw will be possible.
ON : In on mode, even if the actual temperature of band heater(H1) is not 20℃ lower than the
set temperature of band heater(H1), any operation of screw is prevented, and the
operation is possible after expiring of Screw Operation Delay Time which is preset.
(The Screw Operation Delay Timer starts when actual temperature and set temperature
of band heater(H1) are same condition.)
Annex-17 NM011ANX
Document No.: LSM - MNL -
Version : 0.9
Date : July 2000
INSTRUCTION MANUAL
FOR
HICOM 300 CONTROLLER
Customer : Controller : HICOM600 TFT LCD

Serial No. : Language : English
Copyright LS Mtron ltd. ⓒ 2000

First Printing, June 2000 Printed in Korea
LS Mtron Ltd. has developed this document for its licensees and customers.
The information contained herein is the property of LS Mtron Ltd. and may not be copied, used, or
disclosed to others without prior written approval from LS Mtron Ltd. Users are cautioned that the material
contained herein is subjected to change by LS Mtron Ltd. at any time and without prior notice.
Hicom 300 Controller Instruction LSM-MNL-H04/Ver. 2.0
Table of Contents
page
I. HICOM-300 Controller Specification 2
II. Part List of HICOM-300 Controller 3
III. Internal Function 4
IV. Key Function 6
V. Value Set Control 12
VI. Process Control 13
VII. Menu of Display 15
1-1. Mold and Ejector Display ( MOLD ) 16
2-1. Core, Air Blow off unit and Screw Ejector ( CORE ) 20
3-1. Injection and Charging Display ( INJEC ) 23
4-1. Temperature Setting Display ( TEMP ) 27
5-1. Function Select Display ( FUNC ) 30
5-2. System Value Set ( FUNC /sub ) 34
5-3. Internal Timer Set ( FUNC /sub ) 38
6-1. Input / Output Register Display ( I / O ) 41
7-1. Production Data ( REC ) 42
7-2. Shot Data ( REC /sub) 46
7-3. Mold Memory Window 48
8-1. Injection Graph ( GRAPH ) 49
9-1. Alarm Window Screen 50
10-1. User Message Window 51
11-1. Help Window Screen 55
1 NMH04V02
I. HICOM 300 Controller Specifications

This controller is very reliable in Hardware with ASIC and HYBRYD IC.
1) Hardware Unit
NO ITEM MAIN CONTENTS

1 Main Control Units - MCU Board ( plays a role as brain of controller )
(consists of 1 unit ) - Power Supply ( provides with power )
- Text Board ( a board controlling display or screen )
- Mother Board ( transmits data or signal )
- SSR Card ( a board controlling logic output )
2 Display Unit - EL (Electroluminescence )
. 640x400 dot resolution
. 192x120 effective display area
. VL = +5V, VD = +12V, total power is 11Watt
- LCD TFT ( Liquid Crystal Display Thin Film Transistor)
3 Scanning time - 3 ~ 5 msec.
4 System mode - Open loop / semi closed loop
5 Temperature control - Channel : 6 (Max ext. : 3 channel )
- P.I.D Control
6 Interface Port - Print_port ( Parallel )
- Communication_port( 78K bps isolated Lonworks )
7 Analog Input / Output - 0 / 3 : T2, R2, R12
- (Max. ext. 4 / 4 : potentiometer / R1 etc. )
8 Input / Output Address - 40 / 40
- (Max. ext. 16 / 16 )
9 Language - English, Korean & Others
10 Mold Memory - Possible to memorize maximum 42 molds
11 Position Control - 2 Ports ( Incremental Encoder 1000PR )
Mold, Injection Side
12 Key Pad Type - Button
13 Quality Control - Fixed data displays of SPC, SQC in the monitor
- Optional item using the network Lonworks
2 NMH04V02
II.Part List of HICOM 300 Controller
Part Name Specification Part No. Qty Remark

①EL Monitor 640 x 400 dot resolution ELJ640U06 1 SHARP
192 x 200 effective area
②Key Code Board Hicom-300/KEY500A EKEYCP300 1
Operation Switches
③MO500A Board Hicom-300/MO500A EMO500A 1
Mother Board
④MCU500A Board Hicom-300/MCU500A EMCU500A 1
Main Control Unit/CPU
⑤TEXT500A Board Hicom-300/TEXT500A ETEXT500A 1
Graphic Board
⑥SSR500A Board Hicom-300A/SSR500A ESSR500A 3
SSR Output Board
⑦PWR500A Board Hicom-300A/PWR500A EPWR500A 1
Power Supply Board
⑧EXTSOL500A Board Ext. A/D, D/A Conveter EEXTSO500A 11 As of option
1/2 Channels
⑨EXTI/O500A Board Ext. I/O, 16/16 points EEXIO500A 1 As of option
⑩Comm. Port Hicom-300 ECOMPORT3 1
Communication Port
⑪Memo Card Hicom-300/Memo Card 1 As of option
⑫Key Pad Board Hicom-300 1
Numeric & Alphabet
⑬a) Main Transformer 300VA, AC110V EHIC300TR 1
b) EL Switching Power DC 5V 3A, 12V 3A EPSEL10012 1
c) Printer Port Parallel Connection EPRTPORT3 1 As of option
d) RPM Sensor 1
e) Ampere Meter DC 1A 2
f) Incremental Encoder TRD-J1000-RZ, INC. ENTRDZ1000 2
g) Temperature Sensor J-Type, Isolation 4-5
h) Screw Pos. Prox. s/w NPN, HP1-5A6N NE70001010 1
i) Lock Key Monitor Key 1
j) Cable w/ Connectors Flat Cables 1
3 NMH04V02
III. Internal Function

① Proportional Control Valves Control
HICOM controller will control three(3) valves according to the set values by the percentage(%)
unit.
Channel-1 is for flow, channel-2 is for pressure and channel-3 is for back pressure.
② Timer Control
The timers will be operated by logic control or external I/O.
Number of internal timers is more than 30.
③ Position Control
Two(2) channels of optical encoder position will be controlled according to the set values.
The input is digitally detected the rpm and speed.
④ Temperature Control
Maximum six(6) channels of heater zone will be controlled by the set values.
This includes the barrel alarm display.
⑤ Analyzing Function
Processing values is recorded, alarm is displayed, graphic is recorded.
The set values of mold is memorized up to 42 molds in internal memory.
⑥ Diagnostic Function
Self checked alarms and missing control of machine will be messaged through the alarm
window and the status line of screen.
⑦ Logic Control
By the monitoring the input/output devices for self diagnosis with register, it is easy to
understand that working is performed by sequence and very convenient to maintain.
⑧ Automatic Display Off

The internal display timer will start when operator turn on the display by power reset or display
on/off, and will be switched off automatically after 5minutes.
If operator touches any key, the timer will be initiated by 5 minutes.
⑨ Screw Cold Prevention
4 NMH04V02
The screw will be prevented when the temperature of the barrel zone H1 is under the set
value. The screw cold prevention timer will be activated when the temperature reaches up to
the set value, and it is released after the setting time is up.
Setting timer for screw cold prevention is set at 20 minutes as of standard.
If the actual value goes below 20℃ (68℉) to the set value, even though screw cold
prevention timer on the screen is off, this function also operates.
⑩ Shot Count Up Detection

If the count of shot current reaches to the one of shot set for target, the current shot will blink
on the screen and the machine will stop with siren after reaching to the target shot.
⑪ Nozzle Retract Timer

In manual or setup operation with operation selector switch for nozzle retract, It is possible to
retract and stop the nozzle by the amount set (30sec.) with the nozzle retract timer without
returning the selector switch to the neutral position.
⑫ Try Again close

This device allows the machine cycle to work again even though the alarm of low pressure
clamp is outputted in automatic operation. With the alarm of mold protection, the mold opens
and ejects and then close again up to the set number of this circuit.
If the alarm is continuously outputted to the set number, the machine stops after ejection with
the mold located at the mold open limit.
⑬ Dry Cycle
This device operates the cycle of clamp without running injection unit when selected the dry
cycle. The mold closes with high pressure clamping and then the mold opens and the mold
closes again to the next cycle.
Additionally this device is possible to use by the warming up device of hyd. oil, etc.
⑭ Vibration Ejection
When selected this function, the ejector advances after the ejector retracts during TRE2 timer,
and vibration ejection is repeated during interval time.
⑮ Mold Data Memory

The memory of mold data is possible to save up to 42 molds in the internal memory.
Also, the description of mold is possible to name up to maximum 8 characters by alphabet and
numeric keys.
5 NMH04V02
IV.Key Function
[ Key Arrangement ]
①
③ ① Operation Mode Selection keys
② Manual Working keys
③ Screen Selection keys

②
④ ④ Numeric keys
⑤ Cursor keys
⑥ Lock key
⑤
⑦ Printer port
⑦ ⑥
6 NMH04V02
1. Operation mode Selection keys

FULL : Automatic Operation Selection key.
AUTO
If selected, machine is automatically driven when pushing the auto start switch after open the
safety gate and then close while platen, ejector, screw lie at retreat position.
SEMI
AUTO : Semi-auto Operation Selection key.
If selected, machine is operated by semi-auto mode.
This means it is proceeded to new cycle if pushing auto start switch after open the safety gate
and then close while platen, ejector, screw lie at retreat position.
And machine stops after 1 cycle is over.
MANUAL
: Manual Operation key.
If selected, most of functions are operated by manual.
SET-UP
: Mold Setting Operation key.
This program is applied when it will be equipped with new mold.
If this program is selected, machine will be operated to mold set up mode.
2. Manual Working keys.

This keys operate each process by manual mode. By pushing corresponding key, it will be operated,
However, in case of mold advance key. It will be continuously kept without pushing the keys once high
clamping pressure is completed.
: Ejector Retreat Manual key.

Ejector shall have retreated until pushing the key or stopping it.
: Ejector Advance Manual key.

Ejector shall have advanced until pushing the button or stopping it.
: Mold Retreat Manual key.

Mold shall have retreated until pushing the key or stopping it.
7 NMH04V02
: Mold Advance Manual key.

Mold shall have advanced until pushing the key or stopping it.
: Nozzle Advance Manual key.

Nozzle shall advanced until pushing the key or stopping it.
(Nozzle will stop at advanced position if plated doesn’t lie at advance limit position.)
: Nozzle Retreat Manual key.

Nozzle shall retreated until pushing the key or stopping it.
: Injection Ram Advance Manual key.

Injection Ram shall have advanced until pushing the button or stopping it.
(The operation will stop if holding pressure(cut over) is completed.)
: Injection Ram Retreat Manual key

Injection Ram shall have retreated until pushing the button or stopping it.
(Operation will stop if it reaches at the position of charging completion of 2nd dripping
prevention completion)
: Safety Gate Automatic Opening Manual key(Option)
: Safety Gate Automatic Closing Manual key(Option)
2 : Air Ejector Moving Die Blowing Manual key(Option)

Air blowing of moving die will be done until pushing the key or stopping it.
(The operation will stop if it reaches to setting time of air blowing timer.)
8 NMH04V02
1
: Air Ejector Fixing Die Blowing Manual key(Option)
Air blowing of moving die will be done until pushing the key or stopping it.
(The operation will stop if it reaches to setting time of air blowing timer.)
: Core 1,2,3 Retreat Manual key(Option)

Core which is related with will be retreated until pushing the key or stopping it
(The operation will stop if it reaches to the timer completion or switch retreat limit inside mold)
: Core 1,2,3 Advance Manual key(Option)

Core which is related with will be advanced until pushing the key or stopping it
(The operation will stop if it reaches to the timer completion or switch advance limit inside
mold)
Auto
Start
: Automatic cycle begins by pushing this key after safety gate is closed with cycle starting key
on auto/semi-auto operation mode.
3. Screen Selection keys
ON/OFF
: Toggle key for ON/OFF of monitor.
MOLD
: Key to select the screen of Mold & Ejector screen.
CORE
: Key to select the screen of Core.
INJECT
: Key to select the screen of Injection & Charging.
9 NMH04V02
TEMP
: Key to select the screen of Temperature and Graph.
FUNC
: Key to select the screen of Machine Function, System Value, and Times.
I/O
: Key to select the screen of Input & Output Register.
REC
: Key to select the screen of Product Data.
GRAPH
: Key to select the screen of Injection Speed and Pressure Graphs.
ALARM
: Key to select the screen of Alarm.
MEMO
: Key to select the screen of Mold Memory
SHOT
: Key to select the screen of Shot Record.
HELP
: Key to select the screen of Help
4. Numeric keys
DIP/SET
: Key to select the Mode between Set and Display.
a) This mode should be changed to ‘SET’ mode by pressing this key to change the set values.
a) In this ‘SET’ mode, automatic change of display screen and the coloring of operating
position would be stopped. However, the small inversing character will be displayed instead
of coloring.
10 NMH04V02
SHIFT
: Key to select the special character, function, etc. in advance.
a) To input the alphabet.
b) To reset the screw position.
c) To select the window screens.
d) To reset the alarms.
*
: Key(Code) to protect the set values.
a) To reset the position of mold & screw.
a) To call and write the memo of mold.
b) To reset the alarms.
CLEAR
: Key to clear the data when is erred.
This key clears all characters.
*
: Key(Code) to protect the set values.
a) To reset the position of mold & screw.
b) To call and write the memo of mold.
c) To reset the alarms.
ENTER
: Key to set the data and to toggle the switch.
0 9 YZ
: Key to input the point, number and alphabet.
~
5. Cursor keys
: Key to control(to move up, down, left and right) the cursor.
6. Lock key
: Lock Key to protect to be touched by unauthorized person.
Be sure to lock the key if the adjustment of set-value is completed.
11 NMH04V02
V. Value Set Control

Velocity(%) •
* 6
Unit & range of value : 00.0 ~ 99.9 %
5 0 ENTER
Pressure(%) •
* 7
Unit & range of value : 00.0 ~ 99.9 %
0 5 ENTER
Timer(sec) •
Unit & range of value :
* 1 5 4 ENTER
1) 00.0 ~ 99.9 sec.----- TR6, TRE1~2/H, TRH1~2, TR21~22, TR41~42, etc.

2) 000.0 ~ 999.9 sec. -- TR1, TR3, TR4, TR20, etc.
3) 0.0 ~ 9.9 sec. --------- Sequence delay times
Position(mm) •
* 0 1 5 ENTER
1) 00.0 ~ 99.9 mm ----- LS2

2) 000.0 ~ 999.9 mm -- LS4, LS4A~C, LS5, LS5A~B, LS10, LS10A
3) 0000 ~ 9999 mm ---- LS2A~B, LS3, LS3A~B, LS30
Temperature(℃/℉)
* 2 5 6 ENTER
1) 000 ~ 399 ℃ ----- HN, H1, H2, H3, H4

2) 000 ~ 699 ℉ ----- HN, H1, H2, H3, H4
Memo Write(No.)
*
Unit & range of value : 01 ~ 42
0 5 ENTER
Memo Call(No.)
*
Unit & range of value : 01 ~ 42
0 5
* * *
Time(07:36AM) •
* 0
Unit of time : Hour.Minute 01:00 ~ 24:59
7 3 6 ENTER
Date(’96.05.30) • •
*
Unit of date : Month.Date.Year
0 5
01.01 ~ 12.31, 1996 ~
3 0 6 ENTER
12 NMH04V02
VI.Control of Process
1. Mold Close
100 % Velocity
PS1
60
30
VC1 VC2 VC3
0 mm Position
LS3 LS2B LS2A LS2
LOAD LOAD BASIC
TR-6
VC1: 1st velocity of mold close with high or low speed and loading pressure.
VC2: 2nd velocity of mold close with high speed and loading pressure.
VC3: Mold protection area with basic pressure and speed.
TR6: Mold protection timer.
PS1: Pressure switch when high pressure clamping with full loading and max. flow.
2. Mold Open
100 % Velocity
60
30
VO3 VO2 VO1
0 mm Position
LS3 LS3B LS3A LS2
UNLD LOAD UNLD
VO1: 1st velocity of mold open with low speed and unloading pressure.
VO2: 2nd velocity of mold open with high speed and loading pressure.
VO3: 3rd velocity of mold open with low speed and unloading pressure.
13 NMH04V02
3. Injection & Charging
E D C
B
A E D C B A
100 % Holding Time Filling

Pressure Packing
60 TRH2 TRH1
30
PH3 PH2 PH1 PP PI2 PI1
00 Position
TR1(Injection Time) mm
100 % Velocity
[B]
60 [C] [A]
Cushion Amount [D]
30 [E]
VH VI4 VI3 VI2 VI1
00 Position
Cushion LS4 LS4C LS4B LS4A LS10 mm
LO HI LS5B LS5A
1st S/B Charging Stroke Suck Back
Amount LS10A LS5 Amount
14 NMH04V02
VII. Menu of Display

1-1. Mold and Ejector Display ( MOLD )
2-1. Core, Air Blow off unit and Screw Ejector ( CORE )
3-1. Injection and Charging Display ( INJEC )
4-1. Temperature Setting Display ( TEMP )
5-1. Function Select Display ( FUNC )
5-2. System Value Set ( FUNC /sub )
5-3. Internal Timer Set ( FUNC /sub )
6-1. Input / Output Register Display ( I / O )
7-1. Production Data ( REC )
7-2. Shot Data ( REC /sub)
7-3. Mold Memory Window ( REC /sub)
8-1. Injection Graph ( GRAPH )
9-1. Alarm Window Screen
10-1. User Message Window
11-1. Help Window Screen
The monitor of HICOM-300 consists of 11 pages plus 4 windows.

Each display is described as of following pages.
15 NMH04V02
1-1. Mold and Ejector Display

T2 50%
0350 mm Speed 250mm/s R2 30%
Ejector Mold No.: 01

Ejector B Pos.: 0100 mm Quick Mold Opening : OFF

020.0 sec 00.0
VE1 40.0 % VE2 30.0 % 000.0 60.0 % 70.0 % 02.5 sec
TRE1 00.5sec TREH 00.0sec LS2B LS2A LS2
ㅿ0250 ㅿ0090 ㅿ01.0 mm
PER 50.0 % Inter. Time VO3 VO2 VO1

ㅿ 003.0 sec
VE4 20.0% VE3 30.0% 000.0 30.0 % 70.0 % 40.0 %
ㅿ0350 ㅿ0250 ㅿ0030 mm
1. Mold Closing
Generally the mold closing starts with low(or high) velocity at first and changes into
high(or low) velocity, then it finally closes with low velocity-pressure to touch the mold.
Mold-closing of 1st velocity(VC1) : It represents the velocity between mold-open

limit(LS3) and transfer position of 2nd velocity(LS2B). ( low or high velocity range )
Mold-closing of 2nd velocity(VC2) : It represents the velocity between 2nd velocity

position (LS2B) and mold protection position(LS2A). (high or low velocity range )
Mold protection range with low pressure : It represents A range from mold protection
position to mold closing(touch) limit(LS2).
This range is to protect the mold with low velocity-pressure.

EX ) Mold protection position(LS2A) = products thickness + over 20 mm
16 NMH04V02
2. Mold Opening
Mold Opening starts to open with low pressure and changes into high velocity and
finally begins to stop with low velocity.
Mold opening of 1st velocity(VO1) :

It shows the velocity from the mold closing limit(LS2) to the transfer position of 2nd
velocity(LS3A). (low speed range)
Mold opening of 2nd velocity(VO2) :

It shows the velocity from the transfer position of 2nd velocity(LS3A) to the 3rd velocity
transfer position(LS3B). (high velocity range )
Mold opening of 3rd velocity(VO3) :

It shows the velocity from the transfer position of 3rd velocity(LS3B) to the mold open
limit(LS3). ( low velocity-pressure range )
Please set the each value according to the mold.

∴ The mold opening- closing speed is controlled by T2 (electromagnetic proportional
valve ).
3. Position
The position of mold opening- closing is controlled by the set value in the display
screen.
The sense detection for each position is controlled by the incremental encoder.
4. Pressure
Pressure of mold opening-closing : High clamping pressure or low clamping pressure

is controlled by Relief Valves mounted on the hydraulic manifold.
R1 : High clamping pressure

R3 : Low clamping pressure
Set the pressure with watching ‘G1’ Gauge.
This pressure is little bit different according to the Clamp Tonnage
17 NMH04V02
When it is high velocity range or high pressure clamping, R2 (electromagnetic

proportional valve )is fully loaded.
5. Timer
Mold Protection timer(TR6) :

This detects abnormal material between the moving mold and the fixing die mold and its
setting time range is 0 ~ 99.9 second.
If timer works at mold protection position and the mold closing is not completed during the
setting time, the alarm of low clamping pressure starts and the mold begins to open.( The
function of repetitive mold opening is possible in selective display monitor. )
Cycle over timer(TR20) :

It shows the time of a normal cycle under auto or semi-automatic operation. If a molding
cycle is prolonged longer than the time of set value, an alarm buzzer is emitted and the
cycle of machine is stopped. (Select the alarm in specification display screen )
Interval timer(TR4) :
In auto-operation, this is opening time of mold to count from the mold opening limit, and
the mold restarts with ‘time out’ of interval time.
6. Selection
Quick Mold Opening : ON / OFF

ON : When mold opening, the mold opening speed increases with hydraulic differential.
It is not applied to the IDE 25 - 75 Model.
Clamp pump unload timer(TR17) :

ON /OFF, At 00.0 second after injection completion
ON : When it need to save electricity by the transference of clamping pressure from
‘LOAD’ to ‘UNLOAD’, this circuit is used as follows.
After injection out , if cooling in cavity is progressed and as it is unnecessary to hold

maximum clamping pressure, the clamp holding pressure is switched to low pressure
when this unloading timer is ‘time out’, also this timer starts at the same time with cooling
timer.
18 NMH04V02
7. Ejector Advance
Mold opens and Hydraulic Ejector device removes

products from the mold.
Advance with 1st speed(VE1) :

Shows the speed from Ejector advance to Ejector
advance of 2nd speed during ‘TRE1’ timer.
Advance with 2nd speed(VE2) :

Shows the speed from Eject Advance with 1st speed to
Eject Advance limit ( LS31 ).
Eject pressure(PEF) :
Shows the pressure from Ejector Adv. to Ejector adv.
Limit(LS31).
Ejector Advance Holding Timer(TREH) :

Ejector is continuously kept from Ejector advance limit( LS31 ). During this time, Advance
pressure and 2nd speed are kept.
Notice) ① In case of Ejector Holding, please adjust Eject Advance stopper simultaneously.
② If the Ejector pin of mold should be retracted compulsorily with spring etc., its ejector
holding time must be appropriately adjusted.
③ This is possible at auto, semi-auto running and only the first time is worked in case of
more than twice count.
8. Ejector Retract
Ejector Retract Pressure(PER) :

Shows the pressure from the ejector advance limit ( LS31 ) to the ejector retract limit
( LS32 ).
Ejector Retract of 1st speed(VE3) :

Shows the speed from the ejector advance limit ( LS31 ) to the transfer position of 2nd
speed ejector retract during TRE2 timer.
Ejector Retract of 2nd speed (VE4) :

Shows the speed from the end of 1st speed ejector retract to ejector retract limit(LS32).
9. Ejector Position
The completion of eject advance and retract is set by ejector position dogs on the
bracket of ejector plate in the operation side of machine.
19 NMH04V02
2-1. Core, Air Blow off unit or Screw Ejector
[ Core & Air Blow ] Semi DIS 08-25 FRI 09:31

T2 50%
0350 mm Speed 250mm/s R2 30%
Core Puller Air Blow

Unit Mode In Out Unit Sel Pos Time
Core 1 A 02.0 sec 03.0 sec Core 1 ON 0040 mm 03.0 sec
Core 2 0 03.0 sec 02.0 sec Core 2 OFF 0150 mm 05.0 sec
Core 3 0 00.0 sec 00.0 sec
Timer Core ON Screw Ejector OFF
Sequence Core OFF
Air Core OFF Right Rotation Time 00.0 sec
Core B In Pos. 0000 mm Left Rot. Delay Time 00 sec
Core B Out Pos 0000 mm Left Rotation Time 00.0 sec
Mold Stop
Rotation Position 0000 mm
OFF
Core A : Core In → M.C → → M.O → Core Out → Ejt Adv.→ Ejt Ret
(Core Message is displayed by the selection of core 1 Mode )
1. Hydraulic Core Puller
Flow Chart by Mode
Core “A” :
Core Advance → Mold Close → Injection → Cooling Out
→Mold Open → Core Retract → Ejection → Core Advance
( Core advance and retract at the limit of mold opening ‘LS3’. )
Core “B” :
Mold Closing → Core Advance → Mold Close → Injection
→ Cooling Out → Mold Opening→ Core Retract → Mold Open
→ Ejection → Mold Closing.
( Core advances at the position of core ‘B’ In during the mold closing and it
retracts at the position of core ‘B’ Out during the mold opening. )
20 NMH04V02
Core “C” :
Mold Close→ High pressure clamping completion → Core Advance
→ Injection → Cooling Out → Core Retract → Mold Open
→ Ejection → Mold Close
( If high pressure clamping is completed in the limit of mold close limit, core
advances, and then core retracts after cooling out. )
Core “D”
: Core Advance → Mold Close → Injection → Mold Opening
→ Core Retract → Mold Open → Ejection → Core Advance → Mold
Close
( Core advances in the limit of Mold Opening at core “B” pulling out position ).
Core Timer : ON / OFF

ON : Core is confirmed by the timer in display screen.
OFF : Core moving is confirmed by respective switch as of limit switches.
Sequence Core : ON /OFF

ON : Core -1, - 2, (- 3) is sequentially moved.
EX) Core 1 Advance → Core 2 Advance → Mold Close Core 2 Retract
→ Core 1 Retract
Air Core : ON / OFF

ON : When core cylinder is operated by compressed air, this is used to be prepared
additional air solenoid valves for the air cylinders.
OFF : Hydraulic Core ( Standard )
2. Air Blow
It is possible to chose in display.

The time of working is when platen arrives at the
setting position, air is ejected.
∴ If Eject pin is used in case of this product, this protects the damage of products.
21 NMH04V02
3. Screw Eject
This necessary for the spiral products.

(The another driving force, for instance, motor or air
motor, is needed. )
When it reaches to rotational position during mold
opening, rotational eject begin to start.
For the right -rotation, reverse rotation must be set
at 0.00.
Flow Chart
- Mold Opening → Screw Eject Rotation → Ejector Advance→ Mold Open

rotational position : set value(mm), mold stopping is OFF
→Ejector Retract →Screw Eject reverse rotation → Next cycle .......
- Mold Opening → Mold Stopping → Screw Eject rotation → Ejector Advance

rotational position : set value(mm) ,mold stopping is ON
→ Mold Open →Ejector Retract → Screw Eject reverse rotation → Next Cycle......
22 NMH04V02
3-1. Injection & Charging Display
[ Injection & Charge ] Man SET 08-25 FRI 09:31

Rpm 0150 T2 88 %
Speed 450 mm/s R2 88 %
0105.0 mm Count 000068 R12 30 %
PH1 Inj. Time
TRH1 30.0% PP PI2 PI1 000.0 010.0sec
01.0 sec PH2 Cool Time
VH 50.0 % 60.0 % 40.0 %
TRH2 30.0 % 40.0 % VI4 VI3 VI2 VI1 000.0 010.0sec
01.0 sec PH3 50.0 % 70.0 % 60.0% 40.0% Chg_Dy Time
20.0 % LS4 LS4C LS4B LS4A 000.0 010.0sec
△015.0 △030.0△040.0△100.0 mm Alarm
Cut Over 2 V P Time 99.9sec
Speed 0000ms VSB1 VS1 60 0% 2 30 0% VSB2 Char.Time 99.9sec
Press 000kgf 30.0% BP1 30.0% 2 30.0% 3 30.0% 40.0% Cush.High 99.9mm
Time 00sec Cush.Low 99.9mm
△LS10A △LS5B △ △LS5 △LS10
010.0 030.0 095.0 100.0 104.0 mm Intrusion
Inj. Unit
Select OFF
Nozzle Ret. Mode : 0 Continuous Shut Off Nozzle : OFF Time 03 sec
Ret. Delay Time : 0.1 sec Oper. Delay Time : 0.3 sec Velocity 40.0%
1. Injection
Screw rapidly advances and inserts melting material into the mold.
Injection 1st speed ~ 4th speed : This shows the speed during filling period.
Holding pressure speed : This shows the speed during holding pressure period.
Speed of injection is controlled by T2 ( electromagnetic proportional valve ).
Notice )
Holding pressure period is controlled by pressure and screw always doesn’t advance with
setting speed.
Injection pressure means a pressure that press melting material at screw line.
Injection 1st pressure ~ 3rd pressure : a pressure during the charging cycle.
Holding 1st pressure ~ 3rd pressure : this controls the pressure in cavity and decides the
size of plastic products.
The pressure at this time is controlled by R2 ( electromagnetic proportional valve ).
23 NMH04V02
2. Cut _ Over
There are following 4 ways to change from filling to holding process, that is, cut_over.
Position(LS4) :
When screw advances to the changeover position(LS4), the pressure of screw is
changed from filling to holding. ( Standard )
Timer :
When it is a holding pressure transfer timer, it is transferred with time out.
Velocity :
The process changed from filling to holding at the moment when the velocity reaches the
set value.
Pressure :
The process changed from filling to holding at the moment when the pressure reaches
the set value.. ( Option )
∴ If all of 4 ways is selected, cut_over operation is performed according to the

condition which is satisfied at first , and the others is neglected.
* If not selected any condition, basically changed with position.
3. Suck Back
This obstructs material dripping during charging period when using the open nozzle.
1st suck back(VSB1) :

As it obstructs material dripping before charging and separates material from products, it
prevents the property of material varying.
2nd suck back(VSB2) :

With compulsory screw returning, this decreases the pressure of melting material and
prevents material dripping from the open nozzle.
4. Charge
After Injection completion, raw material is plasticizing by screw rotation.
1st charging speed ~ 2nd speed :

Shows the during charging cycle.
Screw rotation (RPM ) :

Shows actual rotational speed of screw during the charging.
5. Back Pressure
This is used to increase blending effect of material with back pressure during the charging.( If
back pressure is low, charging time is reduced because back resistance of screw is low. )
# Note ) Over 450ton, it is controlled by setting valve because it uses R12 (electromagnetic
24 NMH04V02
proportional valve. )
25 ~ 350 ton, 550 ton are controlled by manual pressure valve ( Relief valve ) which is
equipped to Manifold.
6. Nozzle Retract Time( Sprue Break )

Nozzle Retracting time is selected as follows :
“O“ : Continuous contact : Because Nozzle is continuously contacted with mold.

“A” : Cooling time out : After cooling time is out, Nozzle retracts.
“B” : Charging out : After charging is out, Nozzle retracts.
“C” : Injection out : After Injection is completed, Nozzle retracts.
When Nozzle retracting, this works after time out of retract delay until limit switch ‘LS6’ of
nozzle retract is made.
After high pressure clamping in the next cycle, nozzle cylinder advances until limit switch
‘LS7’ of nozzle advance is made(touched), then operation of injection begins to start.
7. Shut Off Nozzle ( Option )

The valve of shut off nozzle makes the orifice of open nozzle blocking after the completion of
injection operation until the completion of charging operation, so this prevent material dripping
completion, resin doesn’t drip.
8. Intrusion
Intrusion is optional equipment when the products weight is larger than maximum Injection
capacity of machine.
Thus screw rotates with additional charging during the intrusion time, melting material flows
into the mold, and it makes a partial of products before injection movement.
However, this circuit is impossible to produce the precise products.
Flow Chart
Mold Close → High Pressure Clamping→ Intrusion Completion→ Injection → Charging →

Mold Open → Ejection → Mold Close
Select charging switch at manual operation.
( Screw must be placed at suck back position. )
25 NMH04V02
9. Timer
Injection Timer(TR1) :
This is the setting time between injection filling and holding period.
Cooling Timer(TR3) :
This is the cooling time of products and works after injection is completed.
Charge Dly Time:
This is delayed time after Injection completion before charging starting.
Please change set value if condition is needed.( Standard time is 000.0)
10. Alarm
Injection filling time :

This is the transfer time from injection filling to holding period.
When it is over, alarm starts and machine is stopped after cycle.
Charging time :
This is the movement time from charging start to charging completion.
In case it takes longer than normal time of charging, it is possible there is shortage of
resin, screw or hopper problem, etc., and charging time over alarm emits and buzzer
sirens.
When it happen, machine compulsorily makes suck-back after skipping of charging process,
and machine is stopped after cycle.
Cushion alarm :
It is decided the malfunction injection process by the monitoring of screw position at the
point of injection completion.
Cushion High Alarm: If the position of screw is larger than allowable range of cushion
after injection completion, cushion high alarm emits.
Cushion Low Alarm: If the position of screw is less than allowable range of cushion after
injection completion, cushion low alarm emits.
26 NMH04V02
4-1. Temperature Setting Display
[ Temperature ] Mset SET 08-25 FRI 09:31
Temp. Unit ( ℃ ) Pre_Heat Sel. : OFF Heating Schedule : ON

Heater Status Actual SetValue Pre_Heat Alarm Weekday On Hr Off Hr
HN 199 199 150 + 20 Sunday 07:30 20:20
H1 200 200 150 + 20 Monday 07:30 20:20
H2 200 200 150 + 20 Tuesday 07:30 20:20
H3 198 198 150 + 20 Wednesd 07:30 20:20
H4 199 199 150 + 20 Thursda 07:30 20:20
Friday 07:30 12:30
Screw Cold Prevention : ON Saturday 07:30 07:30
Screw Operating Delay Time : 20 min 00
00......050....100....150....200....250....300....350....400
HN
H1
H2
H3
H4
1. Temperature
Actual value :
This shows the actual temperature in each temperature zones.
Setting value :
This shows the setting temperature in the band heater zones.
Preheating value :
To begin with, select the preheating to ‘ON’ and set the temperatures of preheating.
① Because this works preheating temperatures at power on, this prevents over heating.
② Since it is possible to keep constant temperature with Heating Off at resting hour,
the over heating of resin doesn’t happen.
If preheating selection is off, temperature is controlled by the setting valve .
Status:
It indicates the status of heating whether heater contactor is activated or not by the
displaying of rectangular cursor.
Temperature Alarm :
If temperature is over heated than allowed temperature range by the exothermic heat, this
displays message of relevant temperature zone and alarm starts.
27 NMH04V02
2. Screw Cold Prevention
Screw cold prevention : ON / OFF

OFF : If the actual temperature of band heater is lower setting temperature at 20℃, screw
compulsorily doesn’t work and it is possible to start if the actual temperature is within
20℃ below zero.
ON : Even through the present temperature of band heater is completed.
( The timer of screw cold prevention starts when the present temperature of ‘H1’ band
heater is equal to setting temperature. )
To prevent the breakage of screw, it should be worked only after the temperature is
completely risen.
3. Bar Graph
This screen is a graph for the actual temperatures of barrel.

The each heating zone is marked with bar graph at vertical axis and actual temperature is
marked at horizontal axis.
If the heater is short circuited, there will be displayed with “OFF” at each zone.
4. Heating Schedule
① Function of heating schedule is selected with ON/OFF.

② If selected automatic heating schedule, heater power is on when it is On Hr and
heater power is off when it is Off Hr which is preset.
③ If it is needed to change the time of auto heating up, switch the auto heating up
function to “OFF”.
The following data is for the melting point is widely used.

Because melting point is very different with grade even if it is same resin, following
data must be used for reference.
28 NMH04V02
5. Material Processing Guide

Type of Material Screw Cyl. Temp. Pre-Drying Mold Temp.
(Resin Name) (C° / F°) Temp.(C° / F°) Time(Hr. ) (C° / F°)
PS 180 - 260 75 - 80 More than 40 - 80
(Polystyrene) /355 - 500 /165 - 175 1 - 1.5 /105 -175
AS Resin 180 - 240 75 - 80 More than 40 - 80
/355 - 465 /165 - 175 2-4 /105 - 175
ABS Resin 180 - 260 80 - 100 More than 40 - 80
/355 - 500 /175 - 210 2-4 /105 - 175
PMMA 180 - 240 70 - 100 More than 50 - 100
(Metracryl) /355 - 465 /160 - 210 2-6 /120 - 210
PA(Nylon 6) 235 - 280 80 - 100 More than 60 - 100
/455 - 535 /175 - 210 2 - 10 /140 - 250
PA(Nylon 66) 250 - 300 80 - 110 More than 60 - 120
/480 - 570 /175 - 230 2 - 10 /140 - 210
PE 200 - 280 Not Required Not Required 20 - 50
(Polyethylene) /390 - 535 /70 - 120
PP 200 - 280 Not Required Not Required 20 - 50
(Polypropylene) /390 - 535 /70 - 120
Vinyl Chloride 165 - 200 80 - 120 More than
Rigid /330 - 390 /175 - 250 1
Vinyl Chloride 150 - 200 50 - 80 More than
Soft /300 - 390 /120 - 250 1
PC 250 - 320 100 - 120 More than 70 - 120
(Polycarbonate) /480 - 610 /210 - 250 4 - 10 /160 - 250
POM 175 - 210 80 - 90 More than 60 - 100
(Polyacetal) /350 - 410 /175 - 195 2-4 /140 - 210
Nory1 240 - 315 85 - 120 More than 80 - 120
/465 - 600 /185 - 250 2-4 /175 - 250
PF(Phenol) 80 - 110 Not Required Not Required 175 - 220
/175 - 230 /350 - 430
MF(Melamine) 80 - 100 Not Required Not Required 135 - 155
/175 - 210 /275 - 310
UF(Urea) 80 - 100 Not Required Not Required 135 - 155
/175 - 210 /275 - 310
Polyester,Pre-Mix 80 - 110 Not Required Not Required 150 - 200
/175 - 230 /300 - 390
29 NMH04V02
5-1. Function Select Display
[ Function Selection ] Auto SET 08-25 FRI 09:31
Function Select Print Select Calendar

1. Eject B Circuit OFF 1. Print Mode 1 1. Date ××.××.×
2. Vibration Eject ON 0) Off 2. Time ××.××
3. Back Pre.Release OFF 1) Every 00 Shot
4. Back Pressure(R12) OFF 2) Every 00 Min Others Select
5. Accumulator OFF 3) Every Alarm 1. Auto Purge 03 min
6. Mold Move On OFF 2. M/C Stop Delay 00 min
7. Products Sorting OFF Alarm Select 3. Auto Shut Down OFF
8. Oil Warming Up OFF 1. Cycle Time ON 4. S G Open Pos. 000 mm
9. Auto Safety Gate OFF 2. Cushion ON 5. Try Again Close 02
10.Product Detect OFF 3. V P Time(Fill) ON 6. Allowed Inj. Alarm 02
11. 4. Charge Time ON 7. Dry Cycle OFF
12. 5. 8. Auto Start Switch OFF
13. 6. 9. Buzzer ON
1. Function Select
Ejector B Circuit during the molding opening : ON / OFF ( Option )

ON : Cycle time can be reduced because ejection is done in the middle of mold retract.
( Set the ejector position ‘LS30’ at ejector screen )
OFF : Ejection is done at the position of mold open limit ‘LS3’.
Vibration Ejection : ON /OFF

ON : When selected this function, ejector advances after the ejector retracts during
‘TRE2’ timer, and vibration ejection is repeated during interval time. So this function is
very useful to remove products out for small size model.
Back Pressure Release : ON / OFF ( Option )

ON : This helps that there should be no back pressure in injection cylinder during
charging. Please use when there is over flowing of resin during charging with nozzle
retracted.
Back Pressure(R12) : ON /OFF ( Option )

ON : This is toggle switch to select the back pressure in the screen to set it.
Accumulator, Injection Boost : ON / OFF ( Option )

ON : This is for high speed of injection.
And it is very effective on the thin products.
Mold Moving On the Charging : ON / OFF ( Option )

ON : Cycle time is reduced because mold is open during the charging.
30 NMH04V02
Generally this is useful for when the charging time takes longer than cooling time.
Products Sorting : ON /OFF ( Option )

ON : This judges whether products is good or not, and it has the chute selected.
In case, there is only displayed message in spite of injection alarm and cycle is going on.
Hyd. Oil Warming Up : ON /OFF ( Option )

ON : This is a device to rise the temperature of hydraulic oil for machine operation.
This repeats unloading and loading of PF2 pump until hyd. oil reaches to set value.
All operation of machine is possible only after warming up is completed.
Auto Safety Gate : ON/OFF ( Option )

ON : This is a selector switch for the device of automatic power safety gate if equipped as
of option.
Product Detect : ON/OFF ( Option )

ON : If the product is not detected within interval time, or cycle is continuously done and
there is no signal for product detection, alarm emits and cycle is stopped.
2. Print Mode
Select the desired print mode. ( 0, 1, 2, 3 )

When not using any print mode.......
Print out Shot data in every ??? shot.
Print out Shot data in every ??? minutes.
Print out Shot data on every alarm.
3. Alarm Selection
Cycle Over Time : ON /OFF
ON : If cycle time is over the setting value, it will be a
problems of low clamping, or detection malfunction of
charging so there is an alarm in machine.
( In automatic type, machine is stopped as soon as cycle
over time out. )
OFF : Even through cycle time is over than setting valve, it
ignores and next cycle starts.
Cushion Alarm : ON /OFF

ON : This detects the residual quantity of resin in barrel after injection, and it judges
cushion.
If the screw position is larger than allowed cushion range after injection, it calls to be a
cushion high alarm.
If less than allowed cushion range, it calls to be a cushion low alarm.
OFF : Ignores cushion alarm.
V_P( Filling) Time Alarm : ON /OFF
31 NMH04V02
ON : If the injection filling time takes longer than normal working time, this regards to be
abnormal judging there is problem in filling up process. (Machine stops after process )
Injection Pressure Alarm : ON / OFF ( Option )

ON : If the pressure within the range of injection filling up is higher than setting pressure,
it takes longer than allowed time and this regards there is a problem in filling up process.
( Respective pressure sensor is needed. )
4. Real Time, Date Change

It is possible to change the date or time at set mode.
Date ××. ××. ×
• •
* 0 2
( Month )
1 2
( Day )
6
(Year)
ENTER : Current date is Monday. 12th. Feb.
The date is automatically set by setting the last decimal point of year.
1996 year set ‘6’, 2002 year set ‘2’
Time ××.××
•
* 1 2 4 5 ENTER : Current time is 12:45 PM.
5. Others Setting
Try Again Close :
When mold protection timer is out, repetitive mold close function is selected by the times
to continue operation cycle again in automatic operation.
Flow Chart ( 2nd times selection )

Mold Close → Low Clamping Alarm → Mold Open → Ejection→ Mold Reclose
→ Low Clamping Alarm → Mold Reopen →Ejection → Cycle Stop
Allowed Injection Alarm :

It is possible to set allowable count of injection alarm.
If Alarm count is set ‘3’, the cycle ignores until the 2nd alarm of injection process and the
machine stops at 3rd alarm of injection process.
Auto Purge Time :

Set the auto purge time.
With the repetition of Injection and charging, this discharges the residual resin in the
heating cylinder.
# Note ) Auto purge works at manual operation.
Flow Chart
32 NMH04V02
Auto purge selection → Injection Start → Injection Completion → Charging

UP
→ Suck Back → Time Check END
NO
Restart
Safety Gate Opening Position :

It is possible to adjust the time to open the safety gate at auto and semi-auto operation
mode.
Dry Cycle : ON /OFF

ON : The machine is running just mold open and close under automatic operation without
the process of injection unit.
Flow Chart
Mold Close → High Pressure Clamping(PS1) → Mold Open → Restart
Auto Start Switch : ON /OFF

ON : Auto start is possible with auto start switch.(When equipped safety gate open-close
device)
OFF : Automatically start with resetting the power safety gate closing.
Buzzer : ON /OFF ON : Buzzer sirens with alarm.

OFF : Compulsorily buzzer is off with alarm.
33 NMH04V02
5-2. System Setting Screen
[ System Value Set ] Semi SET 08/25 FRI 09 : 31
System Setting
1. Mold Stroke 1200 1. R1 Max. 99.9 % 1. Machine No 01
2. Screw Stroke 250 mm 2. R1 Pcm. 99.0 % 2. Pump Select 00
3. Eject Stroke 150 mm 3. R1 Poh 90.0 % 3. LS6 Inverse OFF
4. Min LP Length 080 mm 4. R1 Pch 90.0 % 4. Temp. Unit ℉ OFF
5. Charge Max.RPM0160 5. R1 Pcl 90.0 % 5. R1 Change Select OFF
6. LS3 Prior 20 mm 6. R2 Poh 20.0 % 6. Eject B Circuit OFF
7. LS5 Prior 0.5 mm 7. R2 Pcm 90.0 % 7. Heater OFF
8. T2 Ejt. Adv Max. 60 % 8. R2 Pcl 90.0 % 8.
9. T2 Ejt. Ret Max 50 % 9. R2 Accumulator 30.0 % 9.
10. T2 Charge Max 99 % 10.R2 Max(Loading) 99.9 % Heater PID Set
11. T2 Suck Back 80 % 11. R2 S.Back(Uld) 40.0 % 1. NH 56
12. T2 Max.(Flow) 99.9 % 12. R2 Eject-Hold 20.0 % 2. H1 56
13. T2 Eject Hold 20.0 % 13. R2 M.O Low 40.0 % 3. H2 56
14. T2 M.Open Low 40 % 14. R2 Core Loading 60.0 % 4. H3 56
15. T2 Mold Set Up 10 % 15. R2 Mold Set Up 10.0 % 5. H4 56
16.R2 Eject Ret.Max 40 % 6.
This screen is coded for safety.

These values is preset by manufacturer according to the model.
Do not change these set values carelessly, It will make a bad influence on the machine.
1. System Set
Mold Stroke :
Preset the maximum value of clamping stroke from LS3 to LS2.
* If the mold open limit(LS3) is over set out of this stroke, mold open is not completed.
Screw Stroke :
Preset the maximum value of screw stroke in shot size LS10.
* If the shot size(LS10) is over set out of this stroke, charging is not completed.
Eject Stroke :
Preset the maximum value of ejector stroke from LS31 to LS32.
* If the eject retract limit(LS32) is over set out of this stroke, eject retract is not completed.
Min LP Length :
Preset the minimum value of mold protection range from LS2A to LS2.
* If the slow down position(LS2A) is too short within this length, mold slow down position
Charge Max. RPM

Preset the maximum value of screw turning speed at charging.
* If the screw RPM is over than this value, charging is not performed.
LS3 Prior :
Preset the distance of 50 % deceleration in 3rd mold open speed VO3. * At this prior
34 NMH04V02
value of LS3, mold open speed is reduced to 50% of VO3 to stop exact position.
LS5 Prior :
Preset the distance of 50 % deceleration in 2nd charging speed VS2.
* At this prior value of LS5, charging speed is reduced to 50% of VS2 to stop exact
position.
T2 Eject Adv. Max. :

Preset the maximum value of eject advance speed by T2 valve.
T2 Eject Ret. Max.

Preset the maximum value of eject retract speed by T2 valve.
T2 Charging Max. :
Preset the maximum value of charging speed by T2 valve.
T2 Suck Back Max. :

Preset the maximum value of suck back speed by T2 valve.
T2 Max(Flow) :
Preset the maximum value of main speed by T2 valve.
* T2 valve is of electromagnetic proportional flow(speed) control valve for main.
T2 Eject-Holding :
Preset the maximum value of eject holding speed by T2 valve.
T2 M.Open Low :
Preset the maximum value of 1st mold open speed VO1 by T2 valve.
T2 Mold Set Up :
Preset the maximum value of mold setup speed by T2 valve.
R1 Max. :
Preset the maximum value of clamping pressure by R1 valve.
* R1 valve is of electromagnetic proportional relief control valve for clamp.
R1 Pcm :
Preset the maximum value of mold moving pressure by R1 valve.
R1 Poh :
Preset the maximum value of mold open high pressure by R1 valve.
R1 Pch :
Preset the maximum value of 2nd mold clamping pressure by R1 valve.
R1 Pcl :
Preset the maximum value of clamping low pressure by R1 valve.
R2 Poh :
35 NMH04V02
Preset the maximum value of mold open high pressure by R2 valve.
R2 Pcm :
Preset the maximum value of mold moving pressure by R2 valve.
R2 Pcl :
Preset the maximum value of clamping low pressure by R2 valve.
R2 Accumulator :
Preset the maximum value when using accumulator by R2 valve.
R2 Max(Loading) :
Preset the maximum value of main(loading) pressure by R2 valve.
* R2 valve is of electromagnetic proportional relief control valve for main.
R2 S. Back(Uld) :
Preset the maximum value of suck back pressure(unloading) by R2 valve.
R2 Eject-Holding :
Preset the maximum value of eject holding pressure by R2 valve.
R2 M.Open Low :
Preset the maximum value of mold open low pressure by R2 valve
R2 Core Loading :
Preset the maximum value of core loading pressure by R2 valve.
R2 Mold Set Up :
Preset the maximum value of mold setup pressure by R2 valve.
T2 Eject Ret. Max. :

Preset the maximum value of eject retract pressure by R2 valve.
2. Machine Setting
Machine No. : Assigned the No. of machine to use the communication port.
Pump Select : Selected the machine size to load the pumps properly as of follows.
* 25 ~ 200 Ton = 0, 315 ~ 350 Ton = 4, 450 Ton = 5,
550 Ton = 6, 650 Ton = 7, 850 ~ 1000 Ton = 8
LS6 Inverse : ON/OFF

* ON : Selected a contact of nozzle retract switch LS6 to inverse.
25 ~ 350 Ton = OFF
450 ~ 1000 Ton = ON
36 NMH04V02
Temperature Unit ℉ : ON/OFF

* ON : Selected to use ℉ as of temperature unit.
OFF : Selected to use ℃ as of temperature unit.
R1 Change Select : ON/OFF

* ON : Selected the loading of PF1 pump at the range of 3rd hold pressure.
OFF : Not selected only the loading of PF1 pump at the range of 3rd hold pressure.
Eject B Circuit : ON/OFF

* ON : Selected the ejector B circuit as of optional unit.
Heater PI Set :
* Basically PI factor value at each heater zone is fixed to 56 as of follows.
1 NH 56
2 H1 56
3 H2 56
4 H3 56
5 H4 56
6 Spare
37 NMH04V02
5-3 . Timer Setting
[ Time Set ] Auto SET 08/25 FRI 09 : 31

Time Set 1pls = 0.02sec
1. M.Close Dly 03 pls 1. Injection Dly 0.2 sec 1.
2. M.C Brake Dly 03 pls 2. Injection Off Dly 0.1 sec 2.
3. PS1 Dly 05 pls 3. Suck Back Dly 0.2 sec 3.
4. H.P Loading Dly 08 pls 4. Suck Back Time 0.1 sec 4.
5. PF V/V Off Dly 02 pls 5. S.Gate Slow Start 0.2 sec 5.FilterTime 3000 hr
6. PS1 Off Dly 03 pls 6. S.Gate Cls Off Dly 0.1 sec 6.
7. Prs Release Dly 12 pls 7. S.Gate Brake Dly 0.1 sec 7.
8. M.Open Dly 06 pls 8. S.Gate Open Dly 0.2 sec 8.
9. M.O Brake Dly 03 pls 9. Acc. Off Dly 0.2 sec 9.
10. M.O Loading Dly 03 pls 10. R2 Loading Dly 0.1 sec 10.
11. M.O Stop Dly 03 pls 11. Sequence Core Dly 0.1 sec 11.
12. M.O Quick Off 03 pls 12. Oil Detect Time 0.2 sec 12.
13. Eject Adv. Dly 03 pls 13. Nozzle Ret. Time 30 sec 13.
14. Eject Vib Ret Dly 03 pls 14. Grease Sup. Time 9.0 sec 14.
15. Core Loading Dly 04 pls 15. Grease Sup. Intvl 60 min 15.
16. Core Off Dly 04 pls 16. 16.
1. Delay Time Setting
M.Close Dly :
Delay time set to protect a shock when mold closing ( M1 ).
M.C Brake Dly :

Delay time set to protect a shock when mold close braking ( M29 ).
PS1 Dly:
Delay time set to protect a shock when high pressure clamping ( M7a ).
H.P Loading Dly :

Delay time set to protect a shock when high pressure clamp loading. ( T2 / R2 )
PF V/V Off Dly :

Delay time set to protect a shock when high pressure clamping. ( M7a Off )
PS1 Off Dly :

Delay time set to protect a shock when high pressure completion( T2/R2 Off ).
Prs Release Dly :

Delay time set to protect a shock when high pressure completion. ( T2/R2 Off )
M.Open Dly :
Set the delay time of mold open ( M1a /350Ton ).
38 NMH04V02
M.O Brake Dly :

Set the delay time of mold open brake ( M29 ).
M.O Loading Dly :

Set the delay time of T2 & R2 valves loading.
M.O Stop Dly :

Set the delay time of mold open stopping.
M.O Quick Off Dly :

Set the delay time of mold quick open ( M9 ).
Eject Adv. Dly :

Set the delay time of eject advance ( M31b ).
Eject Vib. Ret. Dly :

Set the delay time of eject vibration retract ( M31a ).
Core Loading Dly :

Set the delay time of core loading ( R2 & T2 ).
Core Off Dly :

Set the delay time of core end ( R2 & T2 ).
Injection Dly :
Set the delay time of injection ( M2b ).
Injection Off Dly :

Set the delay time of injection end ( M2b ). ( Reduce the shock of injection completion)
Suck Back Dly :

Set the delay time of suck back ( M2a ).
Suck Back Time :

Set the delay time for the compulsory suck back when the charge over time alarm is
happened under automatic operation .
S.Gate Slow Start :

Set the delay time of safety gate slow start ( M51, M52 ).
S.Gate Brake Dly :

Set the delay time of safety gate brake ( M54 ).
S.Gate Open Dly :

Set the delay time of safety gate open ( M51a ).
Acc. Off Dly :

Set the delay time of pressure switch PS4 completion. ( Using accumulator )
39 NMH04V02
R2 Loading Dly :
Set the delay time to protect a shock when R2 valve is loaded.
Sequence Core Dly :

Set the delay time to protect a shock when working sequence cores.
Oil Detect Time :

Set the time to detect the hyd.oil level, this alarm sirens if hyd.oil level is not detected
within this time.
Nozzle Ret. Time :

Set the working time to retract when the nozzle retracts at manual operation without
returning the selector switch. If the nozzle retracts more, need reset to selector switch to
work.
Grease Sup. Time :

Set the time to supply the grease. ( sec.)
Grease Sup. Intvl Time :

Set the interval time to work the grease pump. ( min.)
Filter Exchange Time Alarm :

Set the desired time to exchange filter. ( Generally 3000 hr. )
40 NMH04V02
6-1. Input / Output Register Display
[ Input/Output Register ] Faut SET 08/25 FRI 09 : 31

00 □□□□□□□□ 20 ■□□□■□■□ 40 ■□□□■□□□ 60 ■□□□■□■□ 80 □□□□□■□□
01 ■□■□■□■□ 21 □□□■■□□□ 41 □■□□□■■□ 61 □■□□□■■□ 81 □□□■□■□□
02 □□□□■■□□ 22 ■□■□□■□□ 42 ■□□□■■■□ 62 ■□□□□□■□ 82 □□□■■□□□
03 □■□□■□□□ 23 □□□□□□□□ 43 □□□■□□□□ 63 ■□□■□□□□ 83 □□□□■□□□
04 ■□■□□□□□ 24 ■□■□□□■□ 44 □□□□□□□□ 64 □□□□□■■□ 84 □□□■□■□□
05 ■□□□□□□□ 25 ■■□□□□■□ 45 □□□□□□■□ 65 ■□□□■□□□ 85 □■□□□■□□
06 □□□□■□□□ 26 □□□□■□□□ 46 ■□■■□□■□ 66 □□□□■■■□ 86 □□□■□□□□
07 ■□■□□□□■ 27 ■□□□■□□□ 47 □□□□■□□□ 67 ■□□□■□■□ 87 ■□□□□□□□
08 □■□□■□□□ 28 □□■□□■■□ 48 □□□□■■□□ 68 □□□■□□□□ 88 □□□■□□□□
09 ■□□□□□□□ 29 ■□□□■■□□ 49 □□□□■■■□ 69 ■□□□■□□□ 89 □□□□□□□□
10 ■□□□□□□□ 30 ■□■■□□■□ 50 ■■■□□□■□ 70 ■□□□■□■□ 90 □□□□□□□□
11 ■■□□□■■□ 31 □□□■□■■□ 51 ■□□□■□□□ 71 ■□□□□□□□ 91 □□□■□□□□
12 ■□□□■□□□ 32 ■□□□■■■□ 52 □□□□□■■□ 72 □□□□□□□□ 92 □■□□□■□□
13 □□■□□■■□ 33 □□□■■□■□ 53 ■□□■□□□□ 73 ■□■■□□□□ 93 □□□■■■□□
14 ■□□□■■■□ 34 ■□□□■■■□ 54 ■■□■■□□□ 74 □■□□□□■□ 94 □□□□□□□□
15 □□□□■□□□ 35 ■■■□□□■□ 55 ■□□□■□□□ 75 ■□□■□□□□ 95 □□□■□□□□
16 ■□□□■□□□ 36 □□□□□□■□ 56 □□■□□■■□ 76 □■□□□■■□ 96 □□□□□■□□
17 □■□□□■■□ 37 ■□■■□□□□ 57 □□■■□□■□ 77 ■■□□□□■□ 97 ■■□□□■□□
18 ■□□□■□□□ 38 □□■■□□□□ 58 ■■■□□□■□ 78 □□□□■□□□ 98 □□□■□□□□
19 ■□■□□■■□ 39 ■□□□■□■□ 59 ■□■□□■■□ 79 ■□□□■□□□ 99 □■■□□■□□
R23 TXFF RX-C7-20-00-BF-DE-FF-FF-FF
POS AB 00-0341 04-1587 T2649
1. Input / Output Register
By the monitoring the Input / Output for self-diagnosis with register, it is easy to know
that working is performed by sequence and convenient to maintain.
When “ON” contact point, it becomes “■”.
EX ) I / O List & INPUT CARD

0 1 2 3 4 5 6 7
■ □ □ □ ■ ■ ■ □
Input ) 1.0 = Contact point is “ON” when an operation switch is selected to manual mode.
1.1 = Content point is “ON” when an operation switch is selected to semi-auto mode.
It is possible to know whether operation mode of present machine is selected to manual

or not.
41 NMH04V02
7-1. Production Data
[ Product Data ] Semi SET 08/25 FRI 09 : 31

Memory/Mold Setup Working Schedule Production Data
Mold NO : 01 Work Start : 08 Shot Set : 099999
Mold Desc . : LGVTR Shift 1 : 8 hr Shot Current : 000010
Input Date : 05/31 Shift 2 : 8 hr Good Count : 000009
Bad Count : 000001
Operation Status The Rest Count : 099989
Total M/C Pwr Hour : 0030 Days 20 hr Efficiency : 90 %
Total Running Hour : 0024 Days 12 hr Effic. :88% The Rest Time :
0079 Days 10 hr
Daily Production Data
Date Mold TO_Shot Shift_1 Shift_2 Shift_3 Bad Running Hour
08 - 25 01 0000 0000 0000 0000 0000 00 hr 00min
08 - 26 01 0000 0000 0000 0000 0000 00 hr 00min
08 - 27 03 0000 0000 0000 0000 0000 00 hr 00min
08 - 28 03 0000 0000 0000 0000 0000 00 hr 00min
08 - 29 03 0000 0000 0000 0000 0000 00 hr 00min
08 - 30 01 0000 0000 0000 0000 0000 00 hr 00min
08 - 31 01 0000 0000 0000 0000 0000 00 hr 00min
09 - 01 02 0000 0000 0000 0000 0000 00 hr 00min
1. Product Information
Shot Set :
Input the desired quantity of production by the user.
Desired quantity is the maximum of shot count and it is total cycle of machine.
Shot Current :
It shows the present product quantity(shot count of production).
Good Count :
Quantity of good production is shown(shot count of good products).
= Shot Current – Bad Count
Bad Count :
Quantity of bad production is shown(shot count of bad products).
It counts when alarm happens during the cycle of machine.
The Rest Count :

= Shot Set – Shot Current
Product Efficiency :
= Good Count ÷ Shot Current ×100 (%)
The Rest Time :

= The Rest Count × The Cycle Time of Machine
42 NMH04V02
It approximately is converted to the date and time.
2. Work Time
Work Start Time :

The starting time of working for 1st shift group.
Shift 1 group :
The production hour of 1st shift group.
Shift 2 group :
The production hour of 2nd shift group.
The production hour of 3rd shift group is the residual time except for shift 1, 2 group.
3. Operation Status Control
Total Running Power Hour :

It is total power on hour of machine until present after installing the mold.
Total Running Hour :

It is total running hour of machine under automatic operation after the operation time is
reset.
Running Efficiency :
Total Running Hour ÷ Total M/C Power Hour ×100 (%)
Push ‘SHIFT + 4’ Key to reset the above time under mold setup mode.
Also, call the Memo No. to reset the above time.
4. Memory/Mold Setup
When installing or changing the mold, select the operation switch to mold setup mode.
Change the screen mode to ‘SET’ mode and select ‘REC’ screen for product data.
Then key in as of following at the position ‘Mold No.’ of Memory/Mold Setup.
① Memo Writing : When installing new mold or saving new No.
* 0 3 ENTER
Then select Mold Information as of following No. 5.
No : 03
② Memo Calling : When installing same mold as of Mold No. 01.
* 0 1
* * *
and then mold information is shown as of following No. 5.
No : 01
Close the mold all the way to touch and reset the zero position of clamping.
Do not change Mold No. while running the machine.
Do not call Mold No. without saving the mold condition.
43 NMH04V02
Do not duplicate same Mold No.

Mold No. should be set from 01 ~ 42.
5. Mold Memory Information
If you want to name the Mold No. 01 to LG7.
① Identify whether Mold No. is at 01 in this production data screen by ‘REC’ key. ②
Move the cursor to 01 of mold No.
③ Key in LG7 as follows to name it as referring to the key pad.
*
SHIFT SHIFT SHIFT 4
*
L
SHIFT 3 G
7 7
•
④ To identify the contents as of following 7-3, press SHIFT SHIFT
*key.
At this moment, input date is automatically changed into the present date.
Mold Desc. : LG7
Input Date : 05/30
6. Daily Production Data
① 8 days production data is monitored.
② Production information is changed by Shift key in Display mode, and press the Shift key and
then you will find the latest product information.
③ Totally 16 days-product data information is available.
Date : It shows the date of production.
Mold No. : It shows the Mold No. of production at that time.
TO_Shot : It shows daily total shot count at that time.
44 NMH04V02
Shift_1 : It shows daily total shot count of 1st shift operation.
Shift_2 : It shows daily total shot count of 2nd shift operation.
Shift_3 : It shows daily total shot count of 2nd shift operation.
Bad Part : It shows daily total shot count of bad production.
Running Hour : It shows daily running hour of machine under (semi-) automatic
operation at that time. It is displayed by hours and minutes.
45 NMH04V02
7-2 . Shot Data
[ Shot Data ] Auto SET 08/25 FRI 09 : 31
SHT_NO CYC_T CUSHN S_SIZE VP_T HOL_T CHG_T MC_TM TO_TM ALARM
000008 020.0 000.0 000.0 010.0 010.0 010.0 010.0 010.0 0
000009 020.0 001.0 000.0 001.0 001.0 001.0 001.0 001.0 0
000010 020.5 000.8 000.0 000.8 000.8 000.8 000.8 000.8 0
000011 019.0 000.0 000.0 000.0 000.0 000.0 000.0 000.0 0
000012 020.0 000.0 000.0 000.0 000.0 000.0 000.0 000.0 0
000013 020.0 001.0 000.0 001.0 001.0 001.0 001.0 001.0 0
000014 021.0 000.0 000.0 000.0 000.0 000.0 000.0 000.0 0
000015 020.5 000.0 000.0 000.0 000.0 000.0 000.0 000.0 0
000016 020.0 000.0 000.0 000.0 000.0 000.0 000.0 000.0 0
000017 020.0 000.0 000.0 000.0 000.0 000.0 000.0 000.0 0
000018 020.0 000.0 000.0 000.0 000.0 000.0 000.0 000.0 0
000019 019.0 000.0 000.0 000.0 000.0 000.0 000.0 000.0 0
000020 020.0 000.5 000.0 000.5 000.5 000.5 000.5 000.5 0
000021 020.0 000.0 000.0 000.0 000.0 000.0 000.0 000.0 0
000022 020.0 000.0 000.0 000.0 000.0 000.0 000.0 000.0 0
000023 020.0 000.0 000.0 000.0 000.0 000.0 000.0 000.0 0
Alarm : 1=L.P 2=Chg T 3=VP TM 4=Cush.L 5=Cyc TM 6=Shot 7=Cush.H
To select this shot data, press ‘FUNC’ key twice.
The record of shot data is displayed up to 16 shots in one screen, and it is updated line
by line at each cycle of machine.
1. Process Value
SHOT_NO : It shows the shot No. of every production.
CYC_T : It shows the time of 1 cycle completion at auto and semi-auto operation. It
starts and stops at every beginning of mold close in the cycle of machine.
CUSHN : It shows the less position of screw during injection period.
S_SIZE : It shows the distance from injection starting position to injection completion
position.
46 NMH04V02
V.P_T : It is a time from injection beginning to filling to holding process transfer position.
HOL_T : It is a time during injection holding process after injection filling completion.
CHG_T : It is a time during charging process.
MC_TM : It is a time during mold close and high pressure clamping period.
TO_TM : It is a time during mold open and interval(mold opening) period after cooling
time out.
2. Alarm Code
It displays a code of alarms by self detection at every shot.
z LP : Mold protection alarm TR6
z CHG_T : Charging time alarm
z VP_TM : Injection filling time alarm
z CUSH.L : Cushion low alarm
z CYC_TM : Cycle time alarm
z SHOT : Maximum shot over alarm
z CUSH.H : Cushion high alarm
47 NMH04V02
7-3. Mold Memory Window
[ Product Data ] Mset SET 08/25 FRI 09 : 31

Memory/Mold Setup Working Schedule Production Data
Mold NO : 01 Work Start : 08 Shot Set : 099999
Mold Desc . : LGVTR Shift 1 : 8 hr Shot Current : 000010
Input Date : 05/31 Shift 2 : 8 hr Good Count : 000009
Bad Count : 000001
Operation Status The Rest Count : 099989
Total M/C Pwr Hour : 0030 Days 20 hr Efficiency : 90 %
Total Running Hour : 0024 Days 12 hr Effic. : 88% The Rest Time :
Mold Window 0079 Days 10 hr
No Description Date No Description Date No Description Date
01 LG7 00.00 15 00.00 29 00.00
02 LGVCR120 00.00 16 00.00 30 00.00
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
09 00.00 23 00.00 37 00.00
10 00.00 24 00.00 38 00.00
11 00.00 25 00.00 39 00.00
12 00.00 26 00.00 40 00.00
13 00.00 27 00.00 41 00.00
14 00.00 28 00.00 42 00.00
This window of mold memory is only displayed to set up the same mold No. as comparing
mold description and date.
Press key to see a window screen for mold memory.
SHIFT SHIFT
*
Description of Mold No. ?? is named like “ABCD1234” up to maximum 8 characters.
Mold setup date is automatically assigned into the present date.

Mold memory can be saved up to 42 molds.
48 NMH04V02
8-1. Injection Graph
METHOD [ ENTER ] : AUTO DISPLAY ----”

MODE [ CLEAR ] : SINGLE
GRAPH [ SHIFT ] : SPEED
SCALE [ARROW ] : GRAPH TIME
mm/sec.
250
200
150
100
050
000
05 10 15 20 sec.
This screen shows the injection speed in injection process by graph.
1. Method [ ENTER ] : MANUAL / AUTO

Auto : It automatically draws from injection starting until cooling time is over.
Manual : Graph is shown by the repetition of ENTER Key.
2. Mode [ CLEAR ] : SINGLE / OVERLAP

Overlap : This overlaps the graph of injection process.
Single : It erases the pre-recorded graph and update.
3. Graph [ SHIFT ] : SPEED / PRESSURE

Speed : A speed from Injection starting to holding pressure position.
Pressure : A pressure from Injection starting to holding pressure position.
To draw the pressure, it need a pressure sensor as an optional equipment.
4. Scale [ ARROW ] : GRAPH TIME

Time : A range adjustment is possible by Arrow Key.
49 NMH04V02
9-1. Alarm Window Screen

T2 50%
0350 mm Speed 250mm/s R2 30%


ALARM....INFORMATION
020.0 sec 00.0
VE1 40.0 % VE2 30.0 % 000.0 60.0 % 70.0 % 02.5 sec
TRE1 00.5sec TREH 00.0sec Gate Opened ! LS2B LS2A LS2
Couple Discon ! ㅿ0250 ㅿ0090 ㅿ01.0 mm
Filter Alarm !
PER 50.0 % Inter. Time VO3 VO2 VO1
ㅿ 003.0 sec
VE4 20.0% VE3 30.0% 000.0 30.0 % 70.0 % 40.0 %
ㅿ0350 ㅿ0250 ㅿ0030 mm
To see an alarm information by window, press SHIFT DSP/SET keys in ‘DSP’ Mode.
It is recorded up to maximum 8 alarms information in the window.
Alarm is sequentially recorded and alarm is disappeared after removing the errors.
Alarm window is appeared everywhere except for I/O register screen.
Alarm message is flickering on upper screen if alarm isn’t completely removed in spite of
window closing.
If alarm window is appeared, machine continuously works but key input is not possible.
However, key input is possible if the window is closed by CLEAR key.
50 NMH04V02
10-1. User Message Window
1. Machine Operation
Safety Gate Open :

It is appeared when mold closing, ejecting, charging or injecting while door opens.
To reset the alarm, close the safety gate or check the limit switches for safety.
Ejector Not Retracted :

When mold closes with ejector not retracted, it is appeared.
To reset the alarm, retract ejector all the way to sense ‘LS32’ proximity switch, or
check sensing distance of switch and dog, or replace the proximity switch by new one.
Mold Not Opened :

It is appeared when ejector advances with mold not opened.
But exclude the ejector B circuit during the mold opening.
To reset the alarm, open the mold all the way to sense ‘LS3’ position.
Purge Cover Opened :

It is appeared if nozzle safety cover is opened when injecting, charging or nozzle
advancing.
To reset the alarm, close nozzle safety cover to sense the ‘LS1Z’ limit switch.
Nozzle Not Positioned :

When nozzle is not positioned, it is appeared.
To reset this alarm, check the limit switches ‘LS6A’ is ‘ON’.
Nozzle Swiveled :
When nozzle is swiveled, it is appeared.
To reset this alarm, check the limit switches ‘LS6B’ is ‘OFF’.
High Pressure Not :

It is appeared if high pressure of clamp is not built up.
To reset this alarm, check the proximity switch ‘PS1’ and pumps loading.
Nozzle Not Retract :

It is appeared if nozzle is not retracted.
To reset this alarm, check the limit switch ‘LS6’ and nozzle loading.
Nozzle Not Advance :

It is appeared if nozzle is not advanced.
To reset this alarm, check the limit switch ‘LS7’ and nozzle loading.
Core Not Operated :

It is appeared if hydraulic core is not finished.
To reset this alarm, check the limit switch ‘LS21/22’ and core loading.
51 NMH04V02
2. Machine Condition
Hyd. Oil Low Level :

It is appeared when the level of hydraulic oil is too low.
To reset the ararm, fill up the hydraulic oil into the tank.
Thermo Couple Disconnected :

It is appeared when temperature of each heater zone indicates 399℃ ( 699℉ ).
To reset the alarm, check or replace thermo couple by new one.
Hyd. Oil Warming Up :

It is appeared if temperature of hyd. oil doesn’t reach to setting value when selected hyd.
oil warming up device.
To reset the alarm, wait until the operation of hyd. oil warming up device is completed.
Too Short LS2A :

It is appeared when LS2A slow down position is too close.
To reset the ararm, increase the value of LS2A for slow down.
Hyd. Oil Temp High :

It is appeared when the temperature of hydraulic oil is too high.
To reset the ararm, check the oil temperature and oil cooler.
Barrel Temperature Low :

It is appeared when the screw is heating up.
To reset, wait until the operation of screw cold prevention is completed.
Barrel Temperature High :

It is appeared when barrel temperature is out of range.
To reset the alarm, readjust the range of alarm temperature.
Filter Alarm :
Happens when filter timer is completed.
The standard time of filter element replacing is set 3,000 hours.
To reset the alarm, replace filter element and then press “SHIFT + 5” keys to erase
the message of alarm.
RPM High :
It is appeared when the RPM of screw drive motor is too high.
To reset the ararm, reduce the value of charging speed VS1/VS2.
3. Controller Operation
Cushion Low :
It is appeared if the cushion is lower than allowed range.
To remove the alarm, check the process of injection(pressure/speed), material and
screw, etc.
52 NMH04V02
Cushion High :
It is appeared if the cushion is higher than allowed range
To remove the alarm, check the process of injection, material and screw, etc.
Cycle TM Over :
It is appeared if the cycle time takes longer than set value.
To remove the alarm, check the process of injection & charging, material and screw,
etc.
Low Press Over : It is appeared if mold protection alarm is happened.

To remove the alarm, check the mold, product, values of position and speed,
pressures, etc.
Prod. Ejt Over : It is appeared if the product detect is not finished.

To remove the alarm, check the unit of product detect and parts, etc.
Charge TM Over : It is appeared if the charging time takes longer than set value.
To remove the alarm, check the process of charging, material, hopper, screw and
barrel, etc.
V-P TM Over : It is appeared if the injection filling time takes longer than set value.
To remove the alarm, check the process of injection, material and screw, etc.
Inj Prs Over : It is appeared if the injection pressure is over than set value.
To remove the alarm, check the process of injection(pressure/speed), material and
screw, etc.
Shot Cnt Over : It is appeared when the shot count is reached to target count.
To remove the alarm, change the mold and reset the value of shot set.
Rset Pos. Value : It is appeared when the position value is out of range.
To remove the alarm, reset the value of position again.
CR-1 L.S Check : It is appeared if the limit switch of core-1 is not made.
To reset the alarm, check the limit switches of core-1.
Mold Pos. Err : It is appeared when the mold position is not reset.
To remove the alarm, reset the mold position.
Host CPU Err : It is appeared when CPU-1 and CPU-2 system is not operated.
To remove the alarm, check the MCU board.
Hardware Err : It is when temp, rpm, input/output and encoder reading is error.
To remove the alarm, check the MO mother board.
53 NMH04V02
Back-Up Error : It is appeared when the backup battery is not charged.

To remove the alarm, check and replace the backup battery.
Pos Rset Check : It is appeared when the values of position is not in order.
To remove the alarm, reset the values of position in order.
Memo-C Not Rdy : It is appeared when the memo card is not ready.
To remove the alarm, check the memo card.
Comm. Port Err : It is appeared when the communication port is not worked.
To remove the alarm, check the communication port.
Print Port Err : It is appeared when the printer port is not worked.
To remove the alarm, check the printer port.
Data Set Err : It is appeared when data set is wrong.

To remove the alarm, set the value of data again.
Set Format Err : It is appeared when the format of data set is error.
To remove the alarm, set the value of data again.
Set Digit Err : It is appeared when the set digit is error.

To remove the alarm, reset the set digit of data.
Key Locked : It is appeared when entering the values while the key is locked.
To reset the alarm, unlock the key to enter the values.
*************** : It is appeared when the reset of position is finished.
Display Mode : It is appeared when entering the values in the display mode.
To reset the alarm, change the display mode to set mode.
54 NMH04V02
11-1. Help Window Screen

T2 50%
0350 mm Speed 250mm/s R2 30%

HELP.........INFORMATION
1. Mold “zero” Reset
Cycle Time : Press “*”
VC1Key During
VC2 5 secTR-6
PEF 50.0 %
020.0 sec: Press Shift + “*” Dur. 5 sec
2. Screw “zero” Reset 00.0
VE1 40.0 % VE23.Window
30.0 % Clear 000.0 : Press60.0 Clear%Key70.0 % 02.5 sec
4. Alarm
TRE1 00.5sec TREH Message Check : Press ShiftLS2B
00.0sec + Dsp/Set LS2A
Key LS2
5. Memo Message Check : Press Shift + Shift +ㅿ“*”
ㅿ0250 0090 ㅿ01.0 mm
6. Product Record Reset : Press Shift + 4 Key
7. Filter Alarm Reset : Press Shift + 5
PER 50.0 % Data Print Inter. Time VO3 VO2 VO1
8. Shot : Press Shift +7
ㅿ 003.0 sec
9. Set Value Print : Press Shift + 8
VE4 20.0% VE3 30.0%
10. Screen Print 000.0 : Press Shift + 9% 70.0 % 40.0 %
30.0
ㅿ0350 ㅿ0250 ㅿ0030 mm
SHIFT SHIFT DSP/SET is shown “HELP WINDOW” screen in “DISP” mode.

“HELP WINDOW” screen is shown at all pages except for I/O Register screen.
When closing “HELP” window, use CLEAR key.
Notice)
Adjustment of Mold zero(‘0’) position.
① Select mold and ejector screen.
② Select the operation mode to mold setup mode.
③ Place the lock key to “Set” position.
④ Select the screen mode to “Set” mode. ( by DSP/SET key )
⑤ Close mold all the way to touch with mold close selector switch.
⑥ Press the
* key more than 5 second until the value of mold position resets to
000.0 mm with “**********” message.
Adjustment of Screw zero(‘0’) position.

① Select Injection & Charge screen.
② Select the operation mode to mold setup mode.
③ Place the lock key to “Set” position.
④ Select the screen mode to “Set” mode. ( by DSP/SET key )
⑤ Inject the screw all the way by Injection selector switch as possible as could.
⑥ Press the SHIFT key more than 5 second until the value of screw position
*
55 NMH04V02
resets to 000.0 mm with “**********” message.

⑦ If not reset, key in I/O screen to see the absolute value of screw.
⑧ The AB position of screw should be within 580-620mm in the screen to reset.
If not, turn mechanically the pinion gear of the rotary encoder in the rear of injection
unit by manual to change the value of screw AB position to be within 580-620mm.
⑨ And then, go to ⑥to reset it again.
Print
① Press SHIFT 7 key to print out the shot data.
② Press SHIFT 8 key to print out the setting value.
③ All screen is printed out excluding I/O Register screen.
④ Press SHIFT 9 key to print out the hard copy of each screen.
⑤ All screen is printed out excluding I/O Register screen.
Printer
① Type of Printer : Recommended to use the LQ-1550 of EPSON.
② Printer_Port : Parallel
The pin number of

Signal
printer connector
Strobe 1
Data bit 0 2
Data bit 1 3
Data bit 2 4
Data bit 3 5
Data bit 4 6 Printer
Printer
Data bit 5 7 connector
Data bit 6 8
Data bit 7 9
* Busy 11
- initializing printer 16
- Ground 18-25
56 NMH04V02

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Document No.

: LSM - MNL - 011

Customer : Controller : HICOM300 TFT LCD

Copyright LS Mtron ltd. ⓒ 2008

satisfy today’s molding requirements.

manner it is important provides information regarding the construction, operation, maintenance,

safety and other special features of the machine.

operation, maintenance, abuse, alteration of safety features or non-compliance with written

instructions that cause machine damage or injury.

We will provide any assistance you may require.

also considered propriety in nature for the use of LS user.

LS SALES AND SERVICE :

OVERSEA SALES DEPARTMENT :

1. This manual contains important safety operation concerning the maintenance,

Our police concerning Environment, Health and Safety

Observance of related laws/regulations and improvements

Transparent management that respect the environment and people

Rules about “usage and disposal “

3. Do not burn or dispose molding resulted resin or plastic materials.

Chapter 1. SAFETY PRECAUTIONS

1.1. Important Notices .................................................................................................................2

Chapter 2. Installation of the Machine

2.1. Preparations for Installation .................................................................................................2

Chapter 3. Preparation for Operation

3.1. Inspection Prior to Starting Operation..................................................................................2

Chapter 4. START-UP ADJUSTMENT

4.1. Adjustment of the Clamping Unit .........................................................................................2

Chapter 5. Molding Operation

5.1. Preparations Prior to Molding ..............................................................................................2

5.11.1. What You Should Do After Operation ....................................................................32

Chapter 6. Replacing the Parts.

6.1. Replacing the Screw and Barrel ..........................................................................................2

Chapter 7. Inspection and Maintenance

7.1. Daily Inspection....................................................................................................................2

Chapter 8 TROUBLESHOOT FLOW CHART

8.1. Pump Motors don’t start......................................................................................................2

1. HYDRAULIC AND LUBRICATING OIL..........................................................................................3

2. SCREW COLD START PREVENTING FUNCTION ....................................................................17

▣Attached Drawings List (Mechanical Part)

MODEL LGH450N LGH550N LGH650N

FOUNDATION PIM0702426 PIM0702440 PIM0702454

MOLD MOUNTING PIM0702425 PIM0702439 PIM0702453

CLAMPING PART LIST PIM0702427 PIM0702441 PIM0702455

INJECTION PART LIST PIM0702428 PIM0702442 PIM0702456

PRESSURE DIAGRAM PIM0702432 PIM0702444 PIM0702458

HYDRAULIC CIRCUIT PIM0702433 PIM0702445 PIM0702459

TIME CHART PIM0702437 PIM0702448 PIM0702462

HYDRAULIC PART LIST PIM0702434 PIM0702446 PIM0702460

VALVE ARRENGEMENT PIM0702436 PIM0702447 PIM0702461

MAINTENANCE TOOLS PIM0702435 PIM0702435 PIM0702435

▣ Attached Drawings List (Electrical Part)

MOTOR DRIVE PART(2) NE301120 → NE301121

HEATER CIRCUIT → → NE301125

SSR OUTPUT CARD(1) → → NE301131

SSR OUTPUT CARD(2) → → NE301132

EXTENTION I/O CARD → → NE301133

MOTOR DRIVE PART(2) → NE301122 NE301123

HEATER CIRCUIT NE301126 NE301127 NE301128

SSR OUTPUT CARD(1) → → NE301131

SSR OUTPUT CARD(2) → → NE301132

EXTENTION I/O CARD → → NE301133

Chapter 1. SAFETY PRECAUTIONS

1.1. Important Notices ..............................................................................................................2