操作说明书Operating instructionsManuel d’instructionsManual de instruccionesManual de instruçõesIstruzioni di servizioMachinehandboekBetjeningsvejledningDriftsinstruktionKäyttöohjeInstrukcja obsługiNávod k obsluzeManual di operareKullan I m k I lavuzuFerromatik Milacron Maschinenbau GmbH Riegeler Str. 4, D-79364 MalterdingenTel. ++49-7644-78-0, Fax ++49-7644-6885 email: fm_marketing@, Typ MM500 - MM1000 Maschinen Nr. 680 005 Baujahr 2004 Datum 08.06.20041在开始工作之前......------------------------------------------------------------------------------------------ 111.1 序言------------------------------------------------------------------------------------------------------------------------- 111.2操作说明书和机器上的警告标记、禁令标记和禁止标记---------------- 111.2.1人身危险警告标记 --------------------------------------------------------------------------------------- 111.2.2 本操作说明书上的禁止标记 -------------------------------------------------------------------------- 121.2.3 机器上的禁令和禁止标记----------------------------------------------------------------------------- 122 使用规定----------------------------------------------------------------------------------------------------------------------- 132.1 欧共体合格声明------------------------------------------------------------------------------------------------ 143 安全 ------------------------------------------------------------------------------------------------------------------------------ 153.1 序言------------------------------------------------------------------------------------------------------------------------- 153.2 机器运营商的一般原则 -------------------------------------------------------------------------------------- 153.3 操作和维修人员的一般原则 ------------------------------------------------------------------------------ 163.4 安全检查 --------------------------------------------------------------------------------------------------------------- 173.5 机器操作安全说明----------------------------------------------------------------------------------------------- 173.6机器调整、保养和修理的安全说明 ------------------------------------------------------------- 183.6.1 在气动或充气设备上的工作*--------------------------------------------------------------------------- 194 结构和功能 ------------------------------------------------------------------------------------------------------------------ 204.1 机器概述----------------------------------------------------------------------------------------------------------------- 204.2 合模单元 -------------------------------------------------------------------------------------------------------------- 224.3 注射单元----------------------------------------------------------------------------------------------------------------- 254.4 液压设备----------------------------------------------------------------------------------------------------------------- 284.5 电气设备----------------------------------------------------------------------------------------------------------------- 284.6操作和控制零件-------------------------------------------------------------------------------------------------- 294.6.1操作终端概述 --------------------------------------------------------------------------------------------------- 294.6.2屏幕操作区 -------------------------------------------------------------------------------------------------- 294.6.3机器操作键盘 --------------------------------------------------------------------------------------------------- 354.6.4 特殊功能操作区(附加的选装设备) -------------------------------------------------------------------- 354.6.5 操作区: 开关和接口 ----------------------------------------------------------------------------------------- 354.6.6运行模式选择开关 ------------------------------------------------------------------------------------------ 364.6.7钥匙开关 ---------------------------------------------------------------------------------------------------------- 384.6.8IQT网络用的读卡器(选装设备) ---------------------------------------------------------------------- 394.6.9急停按钮 ---------------------------------------------------------------------------------------------------------- 41 5安装 -------------------------------------------------------------------------------------------------------------------------------- 425.1 安装地点的技术数据------------------------------------------------------------------------------------------ 425.1.1安装图: MAXIMA 500 - MAXIMA 1000------------------------------------------------------------ 445.1.2噪音排放值 --------------------------------------------------------------------------------------------------- 465.1.3允许的环境影响------------------------------------------------------------------------------------------------ 465.2 安装机器----------------------------------------------------------------------------------------------------------------- 465.2.1机器供货时的准备工作------------------------------------------------------------------------------------- 465.2.2在工厂内部运输的准备工作---------------------------------------------------------------------------- 475.2.3 机器的运输 --------------------------------------------------------------------------------------------------- 475.2.4 机器调整 -------------------------------------------------------------------------------------------------------- 595.2.5校准合模单元 ------------------------------------------------------------------------------------------------- 595.2.6校准注射单元 --------------------------------------------------------------------------------------------------- 645.2.7将合模单元用地脚螺栓固定在地面上(MAXIMA1000) ----------------------------------- 695.3 机器的清洁、加油和连接 ----------------------------------------------------------------------------------- 695.3.1机器供货后的清洁-------------------------------------------------------------------------------------- 695.3.2安装料斗 -------------------------------------------------------------------------------------------------------- 705.3.3 首次润滑 ---------------------------------------------------------------------------------------------------------- 705.3.4 加注液压油----------------------------------------------------------------------------------------------------- 725.3.5冷却水接口------------------------------------------------------------------------------------------------------- 735.3.6电气连接 ---------------------------------------------------------------------------------------------------------- 745.4 注塑机的拆卸 ----------------------------------------------------------------------------------------------------------- 76 6调试 -------------------------------------------------------------------------------------------------------------------------------- 776.1 接通机器----------------------------------------------------------------------------------------------------------------- 776.2检查电机转向 ------------------------------------------------------------------------------------------------------ 776.2.1检查电机功能和转向 ---------------------------------------------------------------------------------------- 776.2.2 调整电机转向------------------------------------------------------------------------------------------------ 786.2.3 检查电机和液压管路--------------------------------------------------------------------------------------- 796.3检查安全装置 --------------------------------------------------------------------------------------------- 796.3.1检查急停按钮 --------------------------------------------------------------------------------------------------- 796.3.2 检查正面安全门------------------------------------------------------------------------------------------------ 796.3.3 检查后面安全门---------------------------------------------------------------------------------------------- 806.3.4检查顶出装置护罩 -------------------------------------------------------------------------------------------- 816.3.5检查喷嘴护罩 --------------------------------------------------------------------------------------------------- 826.3.6 检查安全踏板(自MAXIMA 800起)---------------------------------------------------------------- 826.4 检查液压功能 --------------------------------------------------------------------------------------------------------- 846.5 液压设备的排气-------------------------------------------------------------------------------------------------- 846.5.1 注射油缸的排气---------------------------------------------------------------------------------------------- 856.5.2合模单元注射油缸的排气 ------------------------------------------------------------------------------- 866.6 补充液压油 ---------------------------------------------------------------------------------------------------------- 877 运行和操作---------------------------------------------------------------------------------------------------------------- 887.1模具安装和机器调整------------------------------------------------------------------------------------------ 897.1.1 模具检验 -------------------------------------------------------------------------------------------------------- 897.1.2 准备模具安装------------------------------------------------------------------------------------------------ 917.1.3 模具安装--------------------------------------------------------------------------------------------------------- 927.1.5 连接冷却水管路---------------------------------------------------------------------------------------------- 947.1.6连接压缩空气管路 ------------------------------------------------------------------------------------------ 947.1.7 连接模具加热装置 ------------------------------------------------------------------------------------------ 947.1.8 连接顶出装置 ------------------------------------------------------------------------------------------------- 94 7.2 调整合模单元 ------------------------------------------------------------------------------------------------------ 957.2.1 模具厚度调整------------------------------------------------------------------------------------------------ 957.2.2调整合模速度------------------------------------------------------------------------------------------------ 967.2.3 调整锁模装置------------------------------------------------------------------------------------------------ 967.2.4调整合模力----------------------------------------------------------------------------------------------------- 977.2.5 调整开模 -------------------------------------------------------------------------------------------------------- 977.2.6 设置顶出装置 ------------------------------------------------------------------------------------------------- 987.2.7设置空气阀 -------------------------------------------------------------------------------------------------- 1017.2.8 定位注射喷嘴 ------------------------------------------------------------------------------------------------ 1027.2.9调整抽插芯机构 ------------------------------------------------------------------------------------------- 1037.2.10设置模具加热装置 ------------------------------------------------------------------------------------- 104 7.3 设置注射单元 --------------------------------------------------------------------------------------------------- 1077.3.1 设置料筒加热装置 ----------------------------------------------------------------------------------------- 1077.3.2设置喷嘴回退 ------------------------------------------------------------------------------------------------ 1107.3.3 设置喷嘴保持压力 --------------------------------------------------------------------------------------- 112 7.4 设置塑化过程 ----------------------------------------------------------------------------------------------------- 1157.4.1基础 ---------------------------------------------------------------------------------------------------------------- 1157.4.2 与行程或容积有关的参数----------------------------------------------------------------------------- 1157.4.3螺杆转速 ------------------------------------------------------------------------------------------------------- 1177.4.4背压 ---------------------------------------------------------------------------------------------------------------- 1177.4.5 螺杆回程---------------------------------------------------------------------------------------------------- 1187.4.6 背压释放或者螺杆极限位置控制 ---------------------------------------------------------------- 1187.4.7液压自闭式喷嘴（选装设备） ----------------------------------------------------------------------- 1187.4.8塑化延时 ------------------------------------------------------------------------------------------------------- 1197.4.9挤出充模 --------------------------------------------------------------------------------------------------------- 1197.4.10冷却时间 ------------------------------------------------------------------------------------------------------- 119 7.5 设置注射过程 ------------------------------------------------------------------------------------------------------- 1197.5.1注射级数 --------------------------------------------------------------------------------------------------------- 1207.5.2注射压力 --------------------------------------------------------------------------------------------------------- 1207.5.3注射速度 --------------------------------------------------------------------------------------------------------- 1217.5.4注射时间，依据时间进行切换 ------------------------------------------------------------------------- 1217.5.5切换压力、依据压力进行切换 ------------------------------------------------------------------------- 1217.5.6切换点、依据行程进行切换----------------------------------------------------------------------------- 1227.5.7依据模腔压力进行切换（需要加装设备） ------------------------------------------------------- 122 7.6 设置机器监控系统----------------------------------------------------------------------------------------------------- 1237.6.2 塑化时间监控 ------------------------------------------------------------------------------------------------ 1267.6.3 塑化行程监控----------------------------------------------------------------------------------------------- 1277.6.4注射参数监控 ------------------------------------------------------------------------------------------------ 128 7.7 可自由组合的屏幕页面--------------------------------------------------------------------------------------- 1297.7.1 组合页面------------------------------------------------------------------------------------------------------ 1297.7.2 修改可自由组合的页面 ------------------------------------------------------------------------------ 1307.7.3将设定值输入到可自由组合的页面上----------------------------------------------------------- 130 7.8 可自由描述的屏幕页面--------------------------------------------------------------------------------------- 131 7.9 可组态的数字输入和输出 ---------------------------------------------------------------------------------- 1327.9.1可组态的数字输入 ------------------------------------------------------------------------------------------- 1327.9.2可组态的数字输出 --------------------------------------------------------------------------------------- 1337.9.3 可组态的模拟输出(选装设备) ------------------------------------------------------------------------ 1347.10标准图形------------------------------------------------------------------------------------------------------- 1367.10.1 设置标准图形 ---------------------------------------------------------------------------------------------- 1367.10.2显示标准图形 ------------------------------------------------------------------------------------------------ 1387.11采用后台数据组工作----------------------------------------------------------------------------------------- 1407.11.1在后台优化前台数据组 -------------------------------------------------------------------------------- 1407.11.2 在后台准备新的数据组----------------------------------------------------------------------------- 1417.11.3将前台数据组与后台数据组进行比较----------------------------------------------------------- 1427.12贮存和读入参数组 ------------------------------------------------------------------------------------------ 1427.12.1 磁盘格式化-------------------------------------------------------------------------------------------------- 1427.12.2 将完整的数据组贮存到磁盘上-------------------------------------------------------------------- 1437.12.3读出和读入特定的数据块--------------------------------------------------------------------------- 1457.13打印屏幕页面 ------------------------------------------------------------------------------------------------- 1477.13.1 连接打印机---------------------------------------------------------------------------------------------------- 1477.13.2 配置打印机参数 ----------------------------------------------------------------------------------------- 1487.13.3 打印单页 ----------------------------------------------------------------------------------------------------- 1507.13.4自动打印 ------------------------------------------------------------------------------------------------------- 1517.14准备运行------------------------------------------------------------------------------------------------------- 1527.14.1 开始工作之前的简要检查 ---------------------------------------------------------------------------- 1537.14.2接通机器 ----------------------------------------------------------------------------------------------------- 1547.14.3设置油预热-------------------------------------------------------------------------------------------------- 1547.14.4中央润滑系统 ---------------------------------------------------------------------------------------------- 1557.14.5在旁路上进行油过滤和油冷却------------------------------------------------------------------ 1577.15 开始生产 -------------------------------------------------------------------------------------------------------- 1577.15.1 用于生产开始的参数组(选装设备) ----------------------------------------------------------------- 1577.16更换材料或颜色---------------------------------------------------------------------------------------------- 1587.17 工作间歇------------------------------------------------------------------------------------------------------- 1597.18断开机器 -------------------------------------------------------------------------------------------------------- 1607.19 工作日定时开关(选装设备) ----------------------------------------------------------------------------- 1618 故障排除 ------------------------------------------------------------------------------------------------------------------- 1638.1 工步表和可能的故障信号 -------------------------------------------------------------------------------- 1638.2 在机器上发生故障时的故障查找------------------------------------------------------------------ 1668.2.1 喷嘴头发生堵塞 ------------------------------------------------------------------------------------------- 1698.2.2加料管形成“材料桥” ---------------------------------------------------------------------------------- 1708.2.3主浇套发生堵塞--------------------------------------------------------------------------------------------- 170 9维修和保养--------------------------------------------------------------------------------------------------------------- 1719.1 在注射单元上的工作--------------------------------------------------------------------------------------- 1739.1.1 转出/转回注射单元 ---------------------------------------------------------------------------------------- 1739.1.2更换喷嘴体---------------------------------------------------------------------------------------------------- 1809.1.3 更换自注射单元4880以上的螺杆和螺杆头---------------------------------------------------- 1849.1.4 注射单元10100以上的螺杆和螺杆头的拆卸-------------------------------------------------- 1889.1.5 更换3470 注射单元上的料筒 ---------------------------------------------------------------------- 1939.1.6 内装有螺杆的料筒更换(国际规格4880和6610 注射单元)----------------------------- 1979.1.7 拆卸料筒(注射单元10100及以上) ------------------------------------------------------------------- 1999.2 在液压设备上的工作--------------------------------------------------------------------------------------- 2019.2.1 在液压设备上工作时的安全措施--------------------------------------------------------------------- 2019.2.2液压油的贮存和排放-------------------------------------------------------------------------------------- 2019.2.3 液压部件更换说明 ------------------------------------------------------------------------------------------ 2029.2.4 记录液压设备上的工作 -------------------------------------------------------------------------------- 2029.2.5 液压油的保养措施 --------------------------------------------------------------------------------------- 2029.2.6清洁进油过滤器 ------------------------------------------------------------------------------------------- 2069.2.7更换板式换热器 ----------------------------------------------------------------------------------------- 2069.3 在蓄能器上的工作 ------------------------------------------------------------------------------------------------- 2089.3.1蓄能器概述---------------------------------------------------------------------------------------------------- 2089.3.2在气囊式蓄能器上的工作----------------------------------------------------------------------------- 2099.3.3由安全当局对蓄能器实施检验 ----------------------------------------------------------------------- 2139.3.4 检查气囊式蓄能器的氮气压力 ----------------------------------------------------------------------- 2149.4 修改调节器设置 ------------------------------------------------------------------------------------------------------ 2149.4.1优化调节器参数----------------------------------------------------------------------------------------------- 2149.4.2调整调节器---------------------------------------------------------------------------------------------------- 2169.5 检验和保养工作复检表 ------------------------------------------------------------------------------------ 2199.6 日检------------------------------------------------------------------------------------------------------------------------ 2219.6.1开始工作前作简要检查 ---------------------------------------------------------------------------------- 2219.7 每周一次和更换模具后的保养工作------------------------------------------------------------------ 2229.7.1检查安全装置----------------------------------------------------------------------------------------------- 2229.7.2检查喷嘴对中定位 --------------------------------------------------------------------------------------- 2229.7.3检查加料管冷却--------------------------------------------------------------------------------------------- 2239.7.4检查螺杆电动驱动装置冷却系统---------------------------------------------------------------------- 2239.7.5检查液压油位----------------------------------------------------------------------------------------------- 2249.7.6检查液压油温度--------------------------------------------------------------------------------------------- 2249.7.7检查中央自动润滑装置的润滑剂油位----------------------------------------------------------- 2249.7.8 检查在螺杆驱动装置上的传动轴的轴承油位-------------------------------------------------- 225 9.8每月一次或每运行200小时后的保养工作 ----------------------------------------------------- 2269.8.1清洁电控柜空气过滤器------------------------------------------------------------------------------------ 2269.8.2 清洁IQT输入单元的空气过滤器 ----------------------------------------------------------------- 2269.8.3清洁软驱------------------------------------------------------------------------------------------------------ 2279.8.4 检查泵上的软管--------------------------------------------------------------------------------------------- 2289.8.5 检查端子连接和插头连接 ------------------------------------------------------------------------------ 2299.8.6检查安全踏板(自MAXIMA 800起)--------------------------------------------------------------- 2299.8.7检查蓄能器氮气预紧压力 ------------------------------------------------------------------------------ 2309.8.8 给顶出导杆上油 ----------------------------------------------------------------------------------------- 231 9.9 每三个月一次或每运行1000小时后的保养工作 ------------------------------------ 2329.9.1首次油保养---------------------------------------------------------------------------------------------------- 2329.9.2更换油箱空气过滤器------------------------------------------------------------------------------------ 2329.9.3检查电机风扇 ------------------------------------------------------------------------------------------------ 2339.9.4检查液压泵---------------------------------------------------------------------------------------------------- 2349.9.5检查液压设备的密封情况----------------------------------------------------------------------------- 2349.9.6检查冷却水蓄电池的设置值--------------------------------------------------------------------------- 2359.9.7检查料筒上温度传感器的固定情况------------------------------------------------------------- 2359.9.8重新拧紧螺杆上的紧固螺栓 ------------------------------------------------------------------------- 2379.9.9 检查控制系统的模块和电气开关元件----------------------------------------------------------- 2379.9.10检查蓄能器的氮气预紧压力 ----------------------------------------------------------------------- 2389.9.11 检查注射油缸上的空气过滤器---------------------------------------------------------------------- 238 9.10 每运行3000小时后的保养工作------------------------------------------------------------------ 2399.10.1油保养 ----------------------------------------------------------------------------------------------------- 239 9.11 每6个月一次的保养工作 ---------------------------------------------------------------------------- 2399.11.1检查直线导轨--------------------------------------------------------------------------------------------- 2399.11.2给直线导轨上油 ----------------------------------------------------------------------------------------- 240 9.12 每年一次或每运行5000小时后的保养工作----------------------------------------------- 2409.12.1 检查系统压力 ---------------------------------------------------------------------------------------------- 2409.12.2检查软管和连接 ----------------------------------------------------------------------------------------- 2409.12.3 检查软管和钢管的支架 ------------------------------------------------------------------------------ 2409.12.4检查机器校准 ---------------------------------------------------------------------------------------------- 2419.12.5 检查电子尺的固定是否牢固 ----------------------------------------------------------------------- 2419.12.6检查端子连接和插头连接 ---------------------------------------------------------------------------- 2439.12.7检查螺杆放行 ---------------------------------------------------------------------------------------------- 2439.12.8清洁冷却水蓄电池 --------------------------------------------------------------------------------------- 2439.12.9按照电机铭牌上的说明对电机进行润滑 ----------------------------------------------------- 2459.12.10 清洁IQT 输入单元和屏幕 ------------------------------------------------------------------------- 2459.12.11按照设置规范进行调整 ------------------------------------------------------------------------------ 2459.12.12检查蓄能器的氮气预紧压力------------------------------------------------------------------------- 2459.13 每3年一次的保养工作 -------------------------------------------------------------------------------- 2459.13.1 更换控制系统的缓冲器电池 ----------------------------------------------------------------------- 2469.13.2 更换IQT输入单元的缓冲器电池 --------------------------------------------------------------- 2469.14每三年一次或每运行15000小时后的保养工作---------------------------------------- 2479.14.1换油、清洁油箱、测试油位监视仪、更换空气过滤器 ---------------------------- 2479.15 每6年一次或每运行30000小时后的保养工作--------------------------------------- 2509.15.1给螺杆驱动装置传动轴轴承上油------------------------------------------------------------------ 2519.16 每6年一次的保养工作 -------------------------------------------------------------------------------- 2519.16.1更换高压软盘 ---------------------------------------------------------------------------------------------- 2519.16.2清洁电机风扇 ---------------------------------------------------------------------------------------------- 2519.17 每10年一次的保养工作 -------------------------------------------------------------------------------- 2519.17.1 由主管的安全当局实施检验--------------------------------------------------------------------------- 2519.18 售后服务 ------------------------------------------------------------------------------------------------------------- 252 10技术数据----------------------------------------------------------------------------------------------------------------- 25310.1 模板尺寸 ----------------------------------------------------------------------------------------------------------- 25710.1.1 MAXIMA 500 (标准型) ------------------------------------------------------------------------------------ 25710.1.2 MAXIMA 650 (标准型) ------------------------------------------------------------------------------------ 25910.1.3 MAXIMA 800 (标准型) ------------------------------------------------------------------------------------ 26010.1.4 MAXIMA 1000 (标准型) ---------------------------------------------------------------------------------- 26110.2 板式换热器的使用说明 ---------------------------------------------------------------------------------- 26210.3 拧紧力矩 ----------------------------------------------------------------------------------------------------------- 26310.3.1 Ferromatik Milacron公司部件上的圆柱头螺钉 (DIN 912)的拧紧力矩 ------- 26310.3.2 Bosch 公司液压件的拧紧力矩------------------------------------------------------------------- 26310.3.3 注射油缸和移动油缸上的支撑螺栓螺母的拧紧力矩 ----------------------------------- 26410.3.4喷嘴体法兰上的螺栓拧紧力矩 --------------------------------------------------------------------- 26410.3.5油箱盖螺母的拧紧力矩 -------------------------------------------------------------------------------- 26510.4 润滑剂建议 ------------------------------------------------------------------------------------------------------- 26510.4.1液压油 --------------------------------------------------------------------------------------------------------- 26510.4.2中央润滑油脂 ---------------------------------------------------------------------------------------------- 26510.4.3 电机的润滑-------------------------------------------------------------------------------------------------- 26510.4.4 直线导轨的润滑------------------------------------------------------------------------------------------- 26510.4.5螺杆驱动装置内的滚动轴承的润滑 ------------------------------------------------------------ 26610.4.6 螺杆电动驱动装置的润滑--------------------------------------------------------------------------- 266 11选用程序--------------------------------------------------------------------------------------------------------------- 267。