3 - Manual FlexEVO 1.3 - US

CONTROL flexEVO
ENGLISH
OPERATING INSTRUCTIONS
LWB Steinl operating instructions .
LWB Steinl GmbH & Co.KG

Sonnenring 35
D-84032 Altdorf, Germany
Phone:+49 871 308-0
Fax:+49 871 308-180
e-mail: contact@lwb.de.com
www.lwb-steinl.com
Record of changes
Version Change Date

1.0 Initial creation 07/02/2019
1.1 Chapter 6 - Automatic release switch 27/05/2020
1.1 Nozzle lift position sensor system and injection
1.3 Chapter 8 Temperature unit with Powerlink; Remote
maintenance
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1 ABOUT THIS USER MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2 TARGET AUDIENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.3 LEGAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.4 CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.1 INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.2 PRESENTATION OF THE SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .10
2.3 GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.4 MACHINE-RELATED SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.5 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.6 EMERGENCY STOP DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2.7 RESIDUAL RISKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.1 DESIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.1.1 C-FRAME DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.1.2 FRAME DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.1.3 COLUMN DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.2 INJECTION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
3.2.1 INJECTION SYSTEM “E”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
3.2.2 INJECTION SYSTEM “EF” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3.2.3 INJECTION SYSTEM “EFD” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
3.2.4 INJECTION SYSTEM “EFE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3.2.5 INJECTION SYSTEM “F”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
3.2.6 INJECTION SYSTEM “RS” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
3.3 INJECTION METHOD/PRESSING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
3.3.1 CM METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
3.3.2 TM METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
3.3.3 IM METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
3.3.4 ITM METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
3.3.5 ICM METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
3.4 PROCESS TIMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
3.4.1 IM METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
3.4.2 ITM METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
3.4.3 ICM METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
3.5 MACHINE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3.5.1 CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3.5.1.1 PUSH-BACK OF THE SEPARATOR THROUGH THE CLAMP . . . . . .63
3.5.2 INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
3.5.3 CASCADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
3.5.4 NOZZLE LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
3.5.5 EXTRUDER POSITIONING UNIT / NOZZLE SEAL . . . . . . . . . . . . . . . . . . . .74
3.5.6 EXTRUDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
3.5.7 TOP SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
3.5.8 BOTTOM SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
3.5.9 SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
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3.5.10 SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

3.5.11 CORE PULLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
3.5.12 DPS - SAFETY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
3.6 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
3.6.1 GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
3.6.2 MACHINE-SPECIFIC TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . .81
3.7 TYPE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
4 TRANSPORT, ASSEMBLY AND COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
4.1 TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
4.2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
4.3 ELECTRICAL CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
4.4 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
5 OPERATION/CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
5.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
5.1.1 OPERATING PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
5.1.1.1 STATUS PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
5.1.1.2 MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
5.1.1.3 STATUS BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
5.1.1.4 MACHINE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
5.1.1.5 OPERATING MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
5.2 GENERAL OPERATING NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
5.2.1 GENERAL OPERATING FUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
5.2.2 LOGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
5.3 MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
5.3.1 SEQUENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
5.3.1.1 CURRENT STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
5.3.1.2 DEMOLDING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
5.3.1.3 MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
5.3.1.4 LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
5.3.1.5 SAVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
5.3.2 TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
5.3.2.1 TEMPERATURE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . .119
5.3.2.2 TEMPERATURE TOLERANCE . . . . . . . . . . . . . . . . . . . . . . . . .121
5.3.2.3 HEATING CURRENT MONITORING TEMPERATURE . . . . . . . . . .124
5.3.2.4 TEMPERATURE CONTROL PARAMETERS . . . . . . . . . . . . . . . .126
5.3.2.5 HEATING TREND TEMPERATURE . . . . . . . . . . . . . . . . . . . . . .127
5.3.2.6 TEMPERATURE OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .129
5.3.2.7 TEMPERATURE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . .131
5.3.2.8 TEMPERATURE TIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
5.3.2.9 TEMPERATURE CONFIGURATION . . . . . . . . . . . . . . . . . . . . . .134
5.3.3 TIMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
5.3.3.1 OVERVIEW OF TIMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
5.3.3.2 SEQUENCER TIMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
5.3.4 PROCESS MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
5.3.4.1 PROCESS DATA ACQUISITION (PDA) . . . . . . . . . . . . . . . . . .138
5.3.4.2 STATISTICAL PROCESS CONTROL . . . . . . . . . . . . . . . . . . . . .142
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5.3.4.3 CYCLE TIME ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

5.3.4.4 PRODUCT MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .145
5.3.4.5 ADJUSTMENT DATA SHEET . . . . . . . . . . . . . . . . . . . . . . . . . .149
5.3.4.6 QUALITY MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
5.3.5 DATA MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
5.3.6 SPECIAL APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
5.3.6.1 EM 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
5.3.7 SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
5.3.7.1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
5.3.7.2 USER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
5.3.8 SYSTEM STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
5.3.8.1 ALARM HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
5.3.8.2 SYSTEM DIAGNOSTICS MANAGER (SDM) . . . . . . . . . . . . . . .172
5.3.8.3 TRACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
5.3.9 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
5.3.9.1 MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
5.3.9.2 MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
5.3.9.3 OPERATIONAL PERFORMANCE OVERVIEW . . . . . . . . . . . . . . .179
5.3.9.4 CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
5.3.10 MACHINE CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
5.3.10.1 SAFETY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
5.3.10.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
5.3.11 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
5.3.12 ENERGY MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
5.3.12.1 POWER CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
5.3.12.2 ENERGY CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
5.3.12.3 AXES ENERGY CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . .188
5.4 MACHINE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
5.4.1 CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
5.4.1.1 CLOSING THE CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
5.4.1.2 OPENING THE CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
5.4.1.3 CLAMP DEGAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
5.4.1.4 CLAMP TREND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
5.4.1.5 CLAMP PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
5.4.1.6 CLAMP SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
5.4.1.7 CLAMP PROFILE TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . .198
5.4.1.8 CLAMP CONFIGURATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .200
5.4.2 INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
5.4.2.1 INJECTION - FORWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
5.4.2.2 INJECTION - BACKWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
5.4.2.3 INJECTION TREND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
5.4.2.4 INJECTION PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . .206
5.4.2.5 INJECTION SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
5.4.2.6 INJECTION PROFILE TUNING . . . . . . . . . . . . . . . . . . . . . . . . .209
5.4.2.7 INJECTION CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . .210
5.4.3 CASCADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
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5.4.3.1 CASCADE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

5.4.3.2 CASCADE ACTUAL VALUES . . . . . . . . . . . . . . . . . . . . . . . . . .212
5.4.3.3 CASCADE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
5.4.4 NOZZLE LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
5.4.4.1 NOZZLE LIFT - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .214
5.4.4.2 NOZZLE LIFT OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
5.4.4.3 NOZZLE LIFT SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
5.4.4.4 NOZZLE LIFT PROFILE TUNING . . . . . . . . . . . . . . . . . . . . . . .220
5.4.4.5 NOZZLE LIFT CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . .221
5.4.5 EXTRUDER POSITIONING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
5.4.5.1 EXTRUDER POSITIONING UNIT - GENERAL . . . . . . . . . . . . . . .222
5.4.5.2 EXTRUDER POSITIONING UNIT OPTIONS . . . . . . . . . . . . . . . .223
5.4.5.3 EXTRUDER POSITIONING UNIT SET UP . . . . . . . . . . . . . . . . . .224
5.4.5.4 EXTRUDER POSITIONING UNIT PROFILE TUNING . . . . . . . . . . .225
5.4.5.5 EXTRUDER POSITIONING UNIT CONFIGURATION . . . . . . . . . . .226
5.4.6 NOZZLE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
5.4.7 EXTRUDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
5.4.7.1 EXTRUDER - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
5.4.7.2 EXTRUDER TREND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
5.4.7.3 EXTRUDER OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
5.4.7.4 EXTRUDER PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . .231
5.4.7.5 EXTRUDER SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
5.4.8 TOP SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
5.4.8.1 TOP SEPARATOR - GENERAL . . . . . . . . . . . . . . . . . . . . . . . .234
5.4.8.2 TOP SEPARATOR OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . .236
5.4.8.3 TOP SEPARATOR SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . .237
5.4.8.4 TOP SEPARATOR PROFILE TUNING . . . . . . . . . . . . . . . . . . . .238
5.4.8.5 TOP SEPARATOR CONFIGURATION . . . . . . . . . . . . . . . . . . . .239
5.4.9 BOTTOM SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
5.4.9.1 BOTTOM SEPARATOR - GENERAL . . . . . . . . . . . . . . . . . . . . .240
5.4.9.2 BOTTOM SEPARATOR OPTIONS . . . . . . . . . . . . . . . . . . . . . . .242
5.4.9.3 BOTTOM SEPARATOR SET UP . . . . . . . . . . . . . . . . . . . . . . . .243
5.4.9.4 BOTTOM SEPARATOR PROFILE TUNING . . . . . . . . . . . . . . . . .244
5.4.9.5 BOTTOM SEPARATOR CONFIGURATION . . . . . . . . . . . . . . . . .245
5.4.10 SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
5.4.10.1 SHUTTLE - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
5.4.10.2 SHUTTLE OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
5.4.10.3 SHUTTLE SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
5.4.10.4 SHUTTLE PROFILE TUNING . . . . . . . . . . . . . . . . . . . . . . . . . .249
5.4.10.5 SHUTTLE CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . .250
5.4.11 CORE PULLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
5.4.11.1 CORE PULLER - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . .251
5.4.11.2 CORE PULLER OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
5.4.11.3 CORE PULLER PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . .253
5.4.11.4 CORE PULLER SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
5.4.11.5 CORE PULLER PROFILE TUNING . . . . . . . . . . . . . . . . . . . . . .256
Page 4
5.4.11.6 CORE PULLER CONFIGURATION . . . . . . . . . . . . . . . . . . . . . .258

5.4.12 MOLD SAFE GUARDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
5.4.13 CLOSING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
5.4.13.1 CLOSING PLATE - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . .260
5.4.13.2 CLOSING PLATE OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . .261
5.4.13.3 CLOSING PLATE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . .263
5.4.13.4 CLOSING PLATE SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
5.4.13.5 CLOSING PLATE PROFILE TUNING . . . . . . . . . . . . . . . . . . . . .265
5.4.14 CLOSING PLATE CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
6 INSTALLING THE MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
6.1 INSTALLING THE MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
6.2 CHECKING THE NOZZLE SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272
6.2.1 MOLD CENTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273
6.2.2 GEOMETRY OF THE NOZZLE AND THE MOLD . . . . . . . . . . . . . . . . . . . .274
6.2.3 TESTING THE MOLD NOZZLE SEAT WITH A PAPER IMPRESSION . . . . . . .276
6.2.4 NOZZLE SEAT GEOMETRY ON THE EXTRUDER HEAD . . . . . . . . . . . . . . .277
6.2.5 TESTING THE EXTRUDER HEAD NOZZLE SEAT . . . . . . . . . . . . . . . . . . .279
6.3 DETERMINING THE REQUIRED VALUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
6.4 AUTO ACCEPT-SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281
1 FAULTS / TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
1.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
1.2 ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
1.3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286
1.4 BEHAVIOR IN AN EMERGENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293
2 MAINTENANCE/REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
2.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
2.2 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
2.3 PURGING OF THE THROTTLE CHANNELS FOR AN EFE UNIT . . . . . . . . . . . . . . .303
2.4 CHECKING THE SAFETY DEVICES AND EMERGENCY STOP DEVICES . . . . . . . . . .305
2.5 CHECKING THE HOSE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
2.6 CASCADE CONTROL DIAPHRAGM ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . .308
2.7 CHECKING THE ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .309
2.8 SETTINGS FOR A REXROTH PROPORTIONAL CARD . . . . . . . . . . . . . . . . . . . . . .313
3 DECOMMISSIONING AND DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
3.1 DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
3.2 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
3.3 DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
Page 5
Page 6
LWB Steinl operating instructions 1. About this user manual
1 About this user manual
1.1 Introduction
General information
• The German version of the operating instructions are the original ope-
rating instructions. All other language versions are translations of the
original operating instructions.
• These operating instructions describe the intended use, intended pur-
pose, and proper operation of this machine.
• For safe working and trouble-free handling, carefully read this docu-
mentation before commissioning and observe all safety instructions
and warnings.
• The operating instructions must be kept in an easily accessible location
and must be consulted if there is the slightest doubt about the correct
procedure.
• The applicable standards and statutory regulations as well as any in-
house regulations must be observed when operating this machine.
Other applicable documents

Also observe the following other applicable documents:
• Declaration of conformity (optional)
• Technical data (machine-specific)
• Maintenance schedule
• Electrical plan with part list
• Hydraulic plan with part list
• Pneumatic plan with part list (optional)
• Mechanical assembly drawings with part lists
• Supplier documentation
Page 7
LWB Steinl operating instructions 1. About this user manual
1.2 Target audience

The operating instructions are directed at the operator of the machine. The
operator must ensure that the specialist personnel who are responsible for
the operation, troubleshooting and maintenance or repair of the machine
have read and understood the information included in the operating inst-
ructions.
1.3 Legal information

Exclusion of liability
The manufacturer accepts no liability for damage to persons or property
or to the machine itself, which arises due to improper use, unintended use
(misuse) or due to non-observance or insufficient observance of the safety
criteria included and procedures described in these operating instructions,
or that is caused by modifications to the machine or use of unsuitable
spare parts.
Regulations and standards

The machine has been built according to Machinery Directive 2006/42/EC.
The device-specific standards and directives for the machine can be found
in the declaration of conformity.
1.4 Changes
In the interest of the customer, the manufacturer reserves the right to
make changes and further developments to the individual machines in
order to improve product functionality without special notice.
Page 8
LWB Steinl operating instructions 2. Safety
2 Safety
2.1 Intended use

Intended use
This injection molding machine may only be used to produce molded parts
from corresponding raw materials.
The injection molding process includes the preparation and injection of the
molding compound in injection molds suitable for this.
Thermoplastics without wear-intensive and corrosion-intensive additives,
such as natural rubber or synthetic rubber, or silicon without wear-inten-
sive and corrosion-intensive additives, are approved as molding com-
pounds.
To determine which molding compound is approved for your machine,
please observe the “Technical data” documentation.
Special equipment is required for the injection unit for all wear-intensive
and corrosion-intensive materials. It is optionally available at LWB.
Foreseeable misuse
Any use other than that specified under "Intended use", or use that
extends beyond this, is deemed improper use.
Changes to the machine as well as use of spare parts, accessories and
equipment, which have not been tested and approved by the manufac-
turer, can influence the safety of the machine and are not permitted.
Page 9
2.2 Presentation of the safety instructions

Introduction
The machine corresponds to the state of the art and the recognized safety
regulations. Nevertheless, dangers can arise during operation and mainte-
nance and repair work.
These dangers are pointed out in this user manual with safety instructions.
The safety instructions precede the relevant descriptions or work steps.
Structure of the safety instructions

The safety-related instructions consist of a general warning symbol and
are structured as follows:
Signal word
Type and source of danger
Potential injuries and/or property damage if the warning is not observed.
• Measure to prevent injuries and/or damage.
Example
DANGER
Risk of crushing
Toppling machine parts can lead to serious injuries or death.
• Only use proper lifting equipment with sufficient load capacity.
Page 10
Danger levels
The different danger levels are presented by means of the following signal
words:
DANGER
This signal word is used to indicate an imminently dangerous situation
which, if not avoided, will result in death or serious injury.
WARNING
This signal word is used to indicate a potentially dangerous situation
which, if not avoided, could result in death or serious injury.
CAUTION
This signal word is used to indicate a potentially dangerous situation
which, if not avoided, could result in minor injury.
ATTENTION
This signal word is used to indicate a possible risk of property damage.
NOTE
This signal word points out additional information useful to the reader,
such as operating conveniences and cross-references.
Page 11
Hazard symbol
Hazard symbol Description

General hazard symbol
If the required safety instructions are not observed, this can
lead to death, serious injuries and significant property dam-
age.
Electricity
lead to death or serious injuries due to dangerous electrical
voltage.
Hot surfaces
lead to serious injuries due to hot surfaces.
Risk of crushing
lead to serious injuries due to crushing of hands or other
body parts.
Risk of poisoning
lead to serious injuries due to toxic substances.
Risk of explosion
lead to serious injuries due to an explosion.
Page 12
Information sign
Information sign Description

Important note
This symbol indicates important information which should
be observed in order to avoid problems with the product.
Note
Detailed information on this subject can be found in the
documentation mentioned here (e.g. supplier documenta-
tion).
2.3 General safety instructions
DANGER
Danger of death, injury and property damage
Disregarding the safety instructions can be life-threatening and cause
damage to health or property.
• Carefully read the safety instructions before initial commissioning and
working on the machine.
Documentation
Observe all information in these operating instructions.
Keep these operating instructions in a safe place near the machine.
As the operator of the machine, ensure that all persons who work on the
machine have access to the operating instructions, have read them and
can also understand them.
Obligations of the operator

The operator of the machine is obligated to only operate the machine in
perfect condition. He must check the condition of the machine before its
use and ensure that defects are remedied before commissioning. Operat-
ing the machine is not permitted if defects have been discovered.
Check that the operating instructions are being followed.
Page 13
Protective equipment
The following protective equipment must be worn when working on the
machine:
• Safety shoes
• Long-sleeved heat protection clothing
• Gloves
• Safety glasses (when processing TPE)
Workstation
DANGER
Risk of crushing!
The hydraulically closing machine parts can lead to serious injuries or
death.
• Make sure that there are no persons other than the operator inside the
protected area and danger zone of the machine.
• Do not climb on the machine.
The workstations are located in front of the machine (loading and demold-
ing) and on the side at the strip feeding (material supply).
Regardless of the existing
safety devices, the workstation of the machine is only defined for one
machine operator. The machine operator is responsible for ensuring that
there are no other persons inside the protected area and danger zone.
The operator of the system must ensure that the machine environment can
be viewed unobstructed by the responsible machine operator and that the
machine operator has been instructed accordingly.
Make sure that the workstation environment is always clean and unclut-
tered.
Page 14
Trainees or apprentices
Trainees, apprentices or persons under the age of 18 who are under super-
vision are not allowed to carry out any work on the machine.
This does not apply to persons who are at least 16 years of age if:
• the work on the injection molding machine is required to achieve the
training objective
• the safety of the person is ensured through supervision of an experi-
enced expert
• only work equipment, molds and protective equipment which preclude
injuries are used
Specialist personnel
Specialist personnel are persons who, on the basis of their professional
training, knowledge and experience, as well as knowledge of the relevant
standards and regulations, are able to assess the work assigned to them,
recognize possible dangers and take the necessary measures to eliminate
the risk of accidents.
Specialist personnel charged with operation, maintenance and repair must
have received special instruction on the possible dangers. Without the
required instruction, no one may work on the machine, even if only briefly.
All work on the machine must be performed by instructed personnel,
according to the specifications in the operating instructions.
Repairs may only be performed by trained specialists.
Inspection personnel
Inspection personnel must fulfill the following requirements:
• instructed personnel
• special hydraulic expertise is not required
Maintenance personnel
Maintenance personnel (filter changes, oil changes) must fulfill the follow-
ing requirements:
• instructed personnel
• special hydraulic expertise is required
Page 15
Repair personnel
Repair personnel must fulfill the following requirements:
• instructed specialist personnel
• The repair personnel must be able to understand the function of the
entire hydraulic system, of subsystems, as well as the interaction with
the function of the entire machine.
• The repair personnel must be able to read hydraulic circuit diagrams,
interpret sub-functions on the individual components, and understand
functional diagrams.
• The repair personnel must have knowledge of the functions and design
of hydraulic elements.
Qualified electricians
Work on the electrical equipment may only be carried out by an authorized,
qualified electrician, or by instructed persons under the direction and
supervision of a qualified electrician, according to the electrical regula-
tions.
Training
The operator must regularly train the personnel in the following areas:
• Observance and use of the operating instructions as well as the statu-
tory provisions
• Proper operation of the LWB injection molding machine
• Observing the instructions of factory security
• Behavior in an emergency
Page 16
Emissions
Noise
“Noise directive” 2003/10/EC, valid as of 2/15/2006, applies.
Vapors
DANGER
Risk of poisoning!
Some rubber compounds develop harmful vapors, especially if the pro-
cessing temperature is too high.
• Refer to the data sheets for the respective compounds for the maxi-
mum processing temperatures.
• Ensure sufficient ventilation and suction.
EMC
Through the use of an isolating transformer for the control voltage and the
assembly of all electrical components in a grounded sheet steel switch
cabinet, the system is sufficiently protected against electric radiation.
Page 17
2.4 Machine-related safety instructions

General information
• Operate the machine only in technically perfect condition. Report and
remedy all faults immediately.
• Do not take any safety components out of operation, such as limit
switches, valves and other control components.
• In case of power supply malfunctions and/or damage to the electrical
equipment, switch off the machine and secure the main switch against
reactivation.
• For programmable control systems, no changes to the program code
may be carried out by the operator. Dependencies and time correla-
tions may not be changed without prior consultation.
• Only operate the machine if all safety devices are mounted and are
fully functional.
• Make sure that the operator and the maintenance personnel have been
properly trained.
• The operator is responsible for third parties in the work area.
• Persons, who are under the influence of alcohol, other drugs, or med-
ication which influences responsiveness, may not operate the machine
and may not carry out any work on the machine.
• Do not climb onto pipelines or machine parts.
• Wear appropriate protective equipment.
• Ensure that access to the immediate operating area of the machine by
external parties is prohibited.
Faults
DANGER
Risk of death!
All faults on the machine can lead to serious injuries or death.
• Remedy all faults and errors before the machine is put in operation.
• Switch off the machine immediately if faults arise during operation.
• Only let appropriate specialist personnel remedy the fault.
Page 18
Mechanical system
DANGER
Risk of crushing!
• Make sure that the machine is set up on a firm, level and stable sur-
face.
• Do not carry out any disassembly work on a raised machine.
DANGER
Risk of crushing!
Improper movement of the cylinders and machine during set-up mode can
lead to serious injuries or death.
• Ensure safe movement processes during set-up mode.
DANGER
Risk of crushing!
death.
• Maintain a sufficient safety distance during the operation of the
machine.
WARNING
Risk of burns due to hot surfaces!
During operation, machine components (e.g. heating plates, molds, plas-
ticizing units, injection units) heat up significantly and can lead to serious
injuries.
• Do not touch the heated machine components during operation.
Page 19
Hydraulics
DANGER
Risk of crushing!
death.
• During all work on the hydraulic system, make sure that the machine
is pressureless and the main switch is turned off and secured against
reactivation.
machine.
WARNING
Risk of burns and poisoning!
Hydraulic oil may spurt out of the machine under certain circumstances
and lead to serious injuries.
• Relieve the pressure in the hydraulic system before work on the
machine.
ATTENTION
Risk of environmental damage!
Mineral oil-based hydraulic oil is hazardous to water and flammable. A
risk of environmental damage exists!
• Only use hydraulic oil, for which a corresponding manufacturer safety
data sheet is available and all measures prescribed therein are
observed.
Page 20
Electrical system
DANGER
Danger due to electric shock!
When working on the machine, there is a danger of receiving an electric
shock, which can lead to serious injuries or death.
• Before working on the machine, disconnect it from the power supply.
• Turn off the main switch.
• Secure the machine against reactivation.
• Cordon off the work area.
• Before work on the electrical system, check that the machine is free
of voltage.
Even after disconnection from the electrical energy supply (main switch
OFF), life-threatening voltage still exists in the following supply systems/
danger zones:
• Electrical system, electronics, hydraulics (e.g. accumulator)
• Main switch
• Mains supply lines
• At locations marked with an electric flash warning sign
• At cables marked orange
DANGER
In case of fires on the machine, there is a danger of serious injuries or
death if they are extinguished with water.
• Only extinguish fires with CO2.
Page 21
2.5 Safety devices

Description
DANGER
Risk of death!
Non-functioning safety devices can lead to serious injuries or death.
• Check the safety devices regularly for functionality.
• Do not alter or remove any safety device.
DANGER
Risk of crushing!
Closing machine parts can lead to serious injuries or death.
• Ensure that the two-hand operating panel is firmly anchored to the
ground at a sufficient distance from the closing area of the machine
in accordance with the relevant local accident prevention regulations.
• The emergency stop devices must remain freely accessible.
The machine is equipped with safety devices. These have been subjected
to a safety inspection and acceptance. In the event of operating errors or
misuse, dangers exist
• To the life and limbs of the operator
• The machine and other material assets of the operator
• The efficient work of the machine
All persons involved in the installation, commissioning, operation, mainte-
nance and repair of the machine must
• Be appropriately qualified
• Strictly observe these operating instructions.
Page 22
Overview
The machine has the following safety devices, shown here for a VC
machine as an example. Depending on the design, additional safety
devices are possible.
3
3
8
2
4
1
7
9 5
(1) Main switch (6) Light curtain (option)

(2) Operating doors (7) Two-hand operating panel
(option)
(3) Fixed safety guarding (8) Laser scanner (option)
(4) Contact strip (9) Safety mat (option)
(5) Safety screen Roll up door (option)
The safety guarding prevents access to the hazardous area of the

machine. The operating doors are monitored by a safety switch.
Page 23
The feed hopper is designed in such a way that reaching into the rotating
screw is prevented.
Strip feeding devices may not take the safety devices of the machine out
of operation.
Closing movements of the machine may only take place with the safety
screen closed or with two-hand operation.
Portable two-hand operating panels

To ensure safe operation of the machine with the two-hand operating
panel, the following must exist in each case:
• The minimum distance to dangerous machine movements must be at
least 300 mm and be maintained at all times. A spacer ring may not be
used for inspection.
• The two-hand operating panel must be provided with equipment which
prevents a position change during operation. Lockable castors are not
suitable for this since the two-hand operating panel could be carried
away.
Laser scanner
The laser scanner can be used as access protection, danger zone protec-
tion and well as protection from behind.
The effectiveness of the safety device must be checked daily by autho-
rized and commissioned persons. The test must also take place with each
change of the operating mode.
Clogging indicator
An alarm message “Laser scanner soiled” appears in the visualization:
• Reset the alarm message and clean the laser scanner with a soft cloth
and an anti-static plastic cleaner.
During assembly of the laser scanner at LWB Steinl, a safety certificate is
prepared. The current configuration of the laser scanner is documented
there. This certificate remains at LWB Steinl. If the configuration of the
laser scanner is changed after this (see Sick original documentation), the
conformity of the machine ceases.
The original operating instructions for the laser scanner are available in
paper form in the switch cabinet of the machine and are included in digital
form in the documentation (supplier documentation).
Safety mat
The laser safety mat can be used as access protection, danger zone pro-
tection and well as protection from behind.
Page 24
Before commissioning the machine, a functional test (see original instruc-

tions) must be performed.
The effectiveness of the safety device must be checked daily, see original
operating instructions.
The original operating instructions for the safety mat are available in paper
form in the switch cabinet of the machine and are included in digital form
in the documentation, point 10 (supplier documentation).
Roll up door
The original operating instructions for the roll up door are available in paper
form in the switch cabinet of the machine and are included in digital form
in the documentation (supplier documentation).
Page 25
Pictograms on the machine

Depending on the machine type, the following pictograms, among other
things, can be attached on the machine:
Pictogram Description
Warning of electrical voltage
lead to death or serious injuries due to dangerous electrical
voltage.
Warning of hot surface

lead to serious injuries due to hot surfaces.
Warning of risk of crushing

lead to serious injuries due to moving mechanical parts.
Warning of hand injuries

lead to serious injuries due to the closing movement of
mechanical parts of the machine.
Warning of automatic start-up

lead to serious injuries due to the automatic start-up of the
machine.
Page 26
Pictogram Description
Use hearing protection
If hearing protection is not worn, this can lead to injuries to
the ear canal.
Use safety glasses

If safety glasses are not worn, this can lead to injuries to
the eyes.
Use safety gloves

If protective gloves are not worn during work, this can lead
to injuries to the hands.
Page 27
2.6 Emergency stop devices
DANGER
Risk of death!
Non-functioning emergency stop devices can lead to serious injuries or
death.
• Check the emergency stop devices regularly for functionality.
• Do not alter or remove any emergency stop device.
NOTE
The machine can have more emergency stop devices than indicated in
these operating instructions. Information on this can be found in the
“Schematics” documentation.
The machine has the following emergency stop devices:

• Emergency stop switch cabinet
• Emergency stop operator desk
• Additional emergency stop devices
Page 28
The machine is stopped through the actuation of an emergency stop

device.
Closing movements of the machine may only take place with the safety
screen closed or with two-hand operation.
2.7 Residual risks

Residual risks are potential risks that are not obvious, such as:
• Injuries due to disregarding safety instructions, standards, directives
and regulations.
• Operation or transport without suitable safety measures.
• Injuries due to uncoordinated work.
• Dangers through work on the electrical system, mechanical system or
hydraulics.
Page 29
Page 30
LWB Steinl operating instructions 3. Description
3 Description
3.1 Designs
3.1.1 C-frame design

Description
The C-frame design offers a stable frame construction with free 3-sided
access to the mold area without bothersome side rails.
Overview
7
4
3
6
5 8
(1) Injection unit (5) Shuttle

(2) Clamp system (6) Bottom separator
(3) C-frame (7) Top separator
(4) Heating plate / bolster plate (8) Central ejection unit
Page 31
3.1.2 Frame design

Description
The frame design offers extreme bending strength in connection with a
large, fully hydraulic clamp. This ensures very high stiffness of the clamp
unit and optimal pressure distribution in the clamping plane.
Overview
9 1
7
3
10
2
6
(1) Injection unit (6) Bottom separator

(2) Clamp system (7) Top separator
(3) Frame (8)
(4) Heating plate / bolster plate (9) Top demolding kit
(5) Shuttle (10) Bottom demolding kit
Page 32
3.1.3 Column design

Description
The column design offers an ergonomic design and flexural stiffness
through the extensive, supporting clamp system.
Overview
9 1
10 5
4
2 6
(1) Injection unit (6) Bottom separator

(2) Clamp system (7) Top separator
(3) Column frame (8)
(4) Heating plate / bolster plate (9) Top demolding kit
(5) Shuttle (10) Bottom demolding kit
Page 33
3.2 Injection systems
3.2.1 Injection system “E”

Description
The injection system “E” consists of a vertically arranged injection unit (1)
and a horizontally arranged extruder (3). The extruder is moved via the
extruder positioning unit (2). The screw speed, injection pressure and
injection speed are infinitely adjustable. The injection system “E” works
with the First In - All Out principle. The injection cylinder is thereby com-
pletely emptied during each injection cycle. A non-return valve is not
required. Both rubber and TPE can be processed with injection system “E”.
Overview
2
2
3
(1) Injection unit with adjusting (3) Extruder

unit
(2) Extruder positioning unit (4) Strip feeding
Page 34
Sequence
(1) Injection unit (3) Mold

(2) Extruder
1 2
3 4
Step Function
1 Injection unit (1) is dosed.
2 Extruder (2) is moved away from the injection unit (1).
3 Injection unit (1) is moved onto the mold (3).
4 Injection unit (1) injects the compound into the mold (3).
Page 35
3.2.2 Injection system “EF”

Description
The injection system “EF” consists of an injection unit with extruder
arranged vertically to the mold plane. The extruder is integrated in the ram.
The injection cylinder and ram are equipped with temperature control. The
ball check valve opens the passage from the extruder to the injection cyl-
inder during the dosing phase. During the injection phase, the reverse
valve seals against the extruder.
Injection pressure and injection speed can be infinitely adjusted.
After injection, the injection unit can be hydraulically lifted from the mold
to avoid vulcanization problems and moved onto the closing plate. It is
thereby possible to dose the compound for the next cycle during the cure
time without contact with the hot mold. The injection unit can also lie
against the cold runner and be dosed for the next cycle.
The injection system “EF” works according to the “First In - First Out” prin-
ciple.
Overview
3
2
(1) Injection unit with adjusting (3) Strip feeding

unit
(2) Ram with extruder
Page 36
Sequence
1
3
(1) Injection cylinder (4) Mold

(2) Ram with extruder (5) Strip feeding
(3) Closing plate
Page 37
1 2
3 4
Step Function
1 The injection cylinder (1) is dosed via the extruder with ram (2). The
closing plate (3) seals the nozzle.
2 The closing plate (3) opens and the injection cylinder (1) is moved in
the direction of the mold (4).
3 The ram (2) injects the compound into the mold (4).
4 The injection cylinder (1) is emptied completely and moved away
from mold (4).
Page 38
3.2.3 Injection system “EFD”

Description
The injection system “EFD” consists of an EF injection unit (1) and a tem-
perature-controlled nozzle fitting (2). The material plasticized first is also
injected into the mold first (“First In - First Out” principle). The adjusting
unit (3) generates the required surface pressure during the injection pro-
cess.
Overview
(1) EF injection unit (3) Adjusting unit

(2) Nozzle fitting
Page 39
Sequence
1 3 2
5
(1) Injection cylinder (4) Nozzle fitting
(2) Extruder (5) Mold
(3) Ram with non-return valve
Page 40
1 2
Step Function
1 The injection cylinder (1) is dosed via the extruder (2).
2 The ram (3) injects the compound into the nozzle fitting (4).
3 The ram (3) injects the compound through the nozzle fitting (4) into
the mold (5). The EF injection unit is emptied completely.
Page 41
3.2.4 Injection system “EFE”

Description
The injection system “EFE” consists of the horizontal EF injection unit (2)
and the vertical E injection unit (1). A “Rapid Cure” element between the
two injection units enables a homogeneous temperature distribution in the
compound, so that the temperature not only increases at the edges, but
also inside the material flow. Since the vertical injection unit also sprays
out the material completely, the compound can be introduced into the
mold at a higher temperature. A shortening of the cure time is thereby pos-
sible.
Overview
Incorrect image -
no spring adjust-
1 ment - vacuum ele-
ment - rapid cure
element?
(1) E injection unit (2) EF injection unit
Page 42
Sequence
7 6 1 2
5
4
3
8
(1) EF piston with non-return (5) E piston
valve
(2) EF injection cylinder (6) Rapid cure element
(3) Extruder (7) Vacuum unit
(4) E cylinder (8) Mold
Page 43
1 2
3 4
5 6
Page 44
Step Function
1 The EFE injection system is emptied.
2 The EF cylinder (2) is dosed via the extruder (3).
3 The E piston (5) is in vacuum position. The vacuum unit (7) opens to
evacuate the system.
4 The E piston (5) is located in the throttle position (rapid cure element)
(6). The EF piston (1) injects the compound into the mold (8) via the
E cylinder (4).
5 The EF cylinder (2) is emptied.
6 The E piston (5) injects the remaining compound out of the E cylinder
(4) into the mold (8).
Page 45
3.2.5 Injection system “F”

Description
The injection system “F” has an extruder (3) that is flange-mounted later-
ally on the ram (1). The injection unit is equipped with a ball check valve.
This ensures safe dosing. Due to the small piston diameter and fast reac-
tion time, a high injection accuracy is guaranteed. The injection system
“F” works with the “First In - First Out” principle.
Overview
1
2
(1) Injection unit (3) Extruder

(2) Adjusting unit (4) Strip feeding
Page 46
Sequence
(1) Injection cylinder (3) Extruder

(2) Ram with ball check valve (4) Mold
Page 47
1 2
Step Function
1 The material arrives in the injection cylinder (1) via the extruder (3).
2 The injection cylinder (1) is filled completely. The ball check valve in
the ram (2) closes.
3 The ram (2) injects the compound into the mold (4).
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3.2.6 Injection system “RS”

Description
The injection unit “RS” consists primarily of a screw rotating in a fixed,
heatable cylinder.
For injection, it is shifted in the direction of the nozzle like a piston and
rotates back to its starting position under the back pressure of the mass
during plasticizing.
The axial movement is achieved through a hydraulic cylinder. The plasti-
cized molding compound is injected into the mold cavity through the axial
movement of the screw in the direction of the nozzle. During the injection,
the screw acts as a piston.
The injection unit is heated by independently controlled heater bands
based on self-optimizing regulators. The desired temperature is pro-
grammed and controlled via the machine control.
The injection process (speed and pressure profile) as well as the back pres-
sure control is controlled via a servo valve. Switching to holding pressure
is possible depending on distance, time and pressure.
Overview
(1) Injection system “RS” with (3) Heater bands

adjuster
(2) Material hopper
Page 49
Sequence
1
2
3
(1) Injection cylinder (3) Mold
(2) RS screw
Page 50
1 2
Step Function
1 The cylinder (1) is dosed. The RS screw (2) in the cylinder is pulled
axially upwards so that the material is conveyed into the free space
in front of the screw tip.
2 The screw (2) injects the mass out of the cylinder (1) into the mold
(3).
Page 51
3.3 Injection method/pressing method
3.3.1 CM method
Sequence
1 2
The “compression molding” method occurs without an injection system.

It is performed as follows:
Step Description
1 The rubber is inserted into the open mold by hand or with a handling
device.
2 The mold is closed with clamping force. The rubber is pressed into
the desired mold by the punch.
3 After the cure time, the mold is opened again.
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3.3.2 TM method
Sequence
1 2
3 4
5 6
Page 53
7 8
The “transfer molding” method occurs without an injection system. The

method is performed as follows:
Step Description
1 The mold is opened
2 The rubber is inserted into the open mold in the TM pot by hand or
with a handling device.
3 The mold is closed.
4 The rubber is thereby injected through the TM piston into the mold
and held under pressure. Excess rubber is pressed into the sprue.
5 The clamp runs a controlled, time-dependent pressure profile.
7 The mold part can be removed.
8 The sprue can be removed.
Page 54
3.3.3 IM method
Sequence
1 2
3 4
The “injection molding” method is performed as follows:
Step Description
1 The rubber is extruded into the ram.
2 The mold is closed.
3 The rubber is injected into the mold under pressure.
Page 55
3.3.4 ITM method

Sequence
1 2
3 4
5 6
Page 56
7 8
The “injection transfer molding” method is performed as follows:
Step Description
1 The rubber is extruded into the injection cylinder.
2 The mold is closed to the embossing gap.
3 The rubber is injected into the transfer pot with the preset injection
parameters. It is also possible to work without a pot, in which case
injection is made directly into the embossing gap.
4 The ITM profile now begins.
5 The mold is held closed with pressure. The clamp runs a regulated
or controlled, time-dependent pressure profile.
7 The mold part can be removed.
8 The sprue can be removed.
Page 57
3.3.5 ICM method

Injection method
1 2
3 4
Page 58
The “injection compression molding” method is performed as follows:
Step Description
1 The rubber is extruded into the ram.
2 The mold is closed to the embossing gap.
3 The rubber is still injected into the open mold with the settings from
the IM method.
4 The mold is closed with clamping force.
5 After the cure time, the mold is opened again. The mold part can be
removed.
Page 59
3.4 Process times
3.4.1 IM method
Page 60
3.4.2 ITM method
Page 61
3.4.3 ICM method
Page 62
3.5 Machine functions
3.5.1 Clamp
General
The clamp has the task of picking up the injection molding tool, opening
and closing the mold and applying the mold holding force.
Details on operation can be found in chapter “Clamp” on page 190.
3.5.1.1 Push-back of the separator through the clamp

The closing behavior of the mold can be determined with this option. This
option affects the following functions:
• Closing the clamp
• Top separator
• Bottom separator
NOTE
Special machine hydraulics are a prerequisite for the "push-back" func-
tion.
Page 63
A 4 plate mold is assumed. The following sketch shows the basic design.
8 1
2
3
4
5
6
9 7
(1) Bolster plate (6) Bottom heating plate

(2) Top heating plate (7) Bolster plate
(3) Mold upper part (8) Separator
(4) Mold center plates (9) Separator
(5) Mold lower part
The following variants can be selected for the push-back:

• Without push-back
• Push-back top separator
• Push-back bottom separator
• Push-back top separator before bottom separator
Page 64
Push-back bottom separator before top separator
Without push-back
To close the mold, the separator must be in the final position.
Page 65
Push-back top separator

The clamp begins with the top separator extended. The clamp pushes
back the top separator into the upper final position.
1 2
3 4
Page 66
Push-back bottom separator

The clamp begins with the bottom separator extended. The clamp pushes
back the bottom separator into the lower final position.
1 2
3 4
Page 67
Push-back top separator before bottom separator

The clamp begins with the top separator extended and the bottom separa-
tor extended. First, the top separator is pushed back into the upper final
position. If the clamp reaches the preset switching distance, then the bot-
tom separator is also pushed back.
Page 68
1 2
3 4
5 6
Page 69
Push-back bottom separator before top separator

The closing process begins with the top separator extended and the bot-
tom separator extended. First, the bottom separator is pushed back into
the lower final position. If the clamp reaches the preset switching dis-
tance, then the top separator is also pushed back.
Page 70
1 2
3 4
5 6
Page 71
3.5.2 Injection
General
A description of the injection process can be found under “Injection sys-
tems” on page 34.
The injection process is divided into two different phases. The injection
process begins with the speed-controlled phase 1, the filling of the mold.
As of an adjustable threshold, switching to the pressure-controlled phase
2 takes place.
The plasticized molding compound is injected into the mold cavity through
the axial movement of the ram in the direction of the nozzle.
Setting the zero point
ATTENTION
These settings are only to be done in the set-up/service operating mode.
When using the Novotechnik IOLink displacement transducer, the proce-

dure is as follows:
Step Function
1 Move the injection completely forward/backward.
2 Push the "Teach sensor" button on the "Injection Configura-
tion" screen, see Chapter 5.4.2.7,
3 The injection path displays 0 mm
3.5.3 Cascade
General
The job of the cascade control is to balance the filling of the mold during
the injection process.
The cascade control consists of pneumatic or hydraulic equipment, as well
as hardware and software for controlling one or more locking nozzles in
the cold runner or hot channel.
Page 72
With the help of the cascade control, individually controllable locking noz-
zles can be used. The nozzles are pneumatically or hydraulically operated
and can be controlled depending on dosing volume and time. The nozzles
are closed before and after the injection process.
3.5.4 Nozzle lift

General
The nozzle lift is required in order to build up a jacking pressure between
the machine nozzle and the nozzle seat on the mold and to maintain it over
the nozzle contact time. The spray nozzle can be lifted off the mold with
the hydraulic nozzle lift.
Lift position sensor system

The reference point for the nozzle lift position sensor system is the posi-
tion of the nozzle lift on the mold.
ATTENTION
These settings are only to be done in the set-up/service operating mode.
ATTENTION
When using an LWG potentiometer, the nozzle lift must be moved com-
pletely back/up. The LWG potentiometer cannot be moved or adjusted
because it has a ball head on both sides.
When using a Novotechnik IOLink displacement transducer, the nozzle lift
must be moved completely forward/downward. For this, the upper, or
injection side, half of the mold must be removed. The Novotechnik dis-
placement transducer cannot be moved or adjusted, because it has seve-
ral magnets per displacement transducer
When using the LWG potentiometer, the procedure is as follows:
Page 73
Step Function
1 Move the nozzle lift completely back/up.
2 On the "Nozzle lift configuration" screen, tap the "Teach sen-
sor" button, see chapter 5.4.4.5
3 The potentiometer zero point is saved
4 Move the nozzle lift onto the tool
5 On the "Nozzle lift set-up" screen, tap the "Teach position"
button, see chapter 5.4.4.3
6 The mold zero point is saved
When using a Novotechnik IOLink displacement transducer, the procedure

is as follows:
Step Function
1 Move the nozzle lift completely forward/downward.
2 On the "Nozzle lift configuration" screen, tap the "Teach sen-
sor" button, see chapter 5.4.4.5
3 The displacement transducer zero point is saved
4 Move the nozzle lift onto the mold
5 On the "Nozzle lift set-up" screen, tap the "Teach position"
button, see chapter 5.4.4.3
6 The mold zero point is saved
3.5.5 Extruder positioning unit / nozzle seal

General
The extruder positioning unit has the task of moving the extruder to the
dosing position (front) or the injection position (rear).
In EF, F and SK injection systems, the extruder positioning unit is replaced
by a pneumatically driven nozzle seal. It has the task of closing the injec-
tion nozzle before the extrusion process.
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3.5.6 Extruder
General
The extruder has the task of drawing in, conveying, plasticizing, feeding
and tempering the rubber or granulate.
Rubber
NOTE
The minimum temperature required in order to be able to start the
extruder function is 50°C.
For pure rubber injection presses, the temperature of the extruder is con-
trolled via a temperature unit. Depending on the equipment, a tempering
medium of water or thermal oil can be used on the machine.
The size of the rubber strip cross sections depends on the diameter of the
screw and the feed area.
Depending on the equipment and size of the machine, the injection and the
extruder are equipped with one common temperature unit or several sep-
arate temperature units.
TPE injection presses
NOTE
Reaching a minimum temperature is not necessary for TPE and polyvalent
machines.
For polyvalent or TPE presses, the temperature of the extruder is con-

trolled via electric heating bands. The feed area is cooled through a cooling
jacket.
Extruder backward
The extruder backward function is predominantly used for TPE machines
(E unit).
The internal pressure of the extruder barrel arising during the dosing pro-
cess can be balanced by the backward movement.
Page 75
The backward rotation occurs automatically after reaching the injection

volume. The screw should be rotated backward slowly.
3.5.7 Top separator

General
The top separator has the task of moving the center mold plate during the
demolding of an article.
If the cylinder is completely retracted, then the zero position is reached.
3.5.8 Bottom separator

General
The bottom separator has the task of moving the center mold plate during
the demolding of an article.
If the cylinder is completely retracted, then the zero position is reached.
3.5.9 Shuttle
General
The shuttle is used for better accessibility of the mold during demolding of
the article, assembly and disassembly of the mold. The shuttle moves for-
ward out of the press.
3.5.10 Shuttle
General
The shuttle is used for better accessibility of the mold during demolding of
the article, assembly and disassembly of the mold. The shuttle moves to
the right and left out of the press.
3.5.11 Core puller
WARNING
When designing the core pull functions, the operator of the machine must
ensure safe operation using the two-hand control of the machine.
Page 76
General
The core pullers are hydraulic or pneumatic axes. Movable mold parts are
predominantly moved through these.
Depending on the nature of the mold, different limit switches or limit stops
(e.g. via time) can be selected.
Since the cylinders intended for these functions are usually provided and
therefore the cross sections of these cylinders are not known, the force
and speed for the core pullers are entered in "bar" and "%".
The units “bar” and “%” relate to the output of the hydraulic pump.
Up to 8 core puller functions per machine are possible. The functionality
of additional core pullers is analogous to core puller 1.
NOTE
Core puller special program
• No core puller program: the core pullers can only be moved when the
clamp is open
• Core puller program A: the selected core puller moves forward at the
start of the injection. The nozzle lift sits on the mold and pressure is built
up. The core puller moves back when the holding time is finished. Only then
does the nozzle lift move.
• Core puller program B: the selected core puller moves forward after
the clamp pressure has built up. When switching to pressure profile
takes place, the core puller moves back again.
The core puller program can be selected for each core puller.
3.5.12 DPS - Safety circuit

For the axes listed below, customer-specific safeguards can be inserted
via the "DPS axis XY direction of movement XY" tab:
Clamp, extruder positioning unit, top separator, bottom separator, core
puller, shuttle, safety screen.
Page 77
1 2 3 4
(1) Input (3) Rising edge

(2) Output (4) Falling edge
Insert DPS function
Step Function
1 Press „Edit“ button
2 Use the touch function to slide the desired DPS function onto
the drain line
Delete DPS function
Step Function
1 Press „Edit“ button
2 Use the touch function to move the selected DPS function out-
side of the frame
Page 78
3.6 Technical data
3.6.1 General data

Hydraulic oil
ATTENTION
Risk of property damage
Unfiltered oil can lead to damage to the machine.
• Only use filtered oil (filtering degree 5 µm).
Specification of the hydraulic oil:
Property Technical data

Hydraulic oil Mineral oil-based, which fulfills the requirements
according to DIN 51524.
Temperature -20 °C to +80 °(in container < 72 °C
Viscosity Recommended: 20 to 100 mm2/s
Max. permissible: 12 to 500 mm2/s
The hydraulic components used are tested with class ISO-VG 46 hydraulic
oil at 40 °C (viscosity v = 46 mm2/s).
Hydraulics
Specification of the hydraulics:

Environment temperature -20 °C to +50 °C
For pressure tank without heat transfer unit with
free air circulation: +30 °C
Relative humidity In enclosed spaces: <70 % at 22 °C room tem-
perature
Page 79
Electrical equipment
Specification for the electrical equipment:

Environment temperature +5 °C to +40 °C, provided that the average
temperature of the air does not exceed +35 °C
over a period of 24 hours.
Relative humidity 23 to 95 %, non-condensing
Altitude Up to 1000 m above sea level
Water quality
To avoid damage to the cooling circuit of the machine, the water used
must fulfill the following requirements:

Total hardness 4-18 °dH
pH value 7 - 9 KKG*
Conductance Max. 1000 μS/cm
*KKG = lime/carbonic acid balance

If water is used, it must be provided with additive RK93. Observe the
instructions in the “RK93 concentration” supplementary sheet for this.
See documentation, point 2_Technical data.
Page 80
3.6.2 Machine-specific technical data
NOTE
The machine-specific technical data can be found in the “Technical data”
documentation.
3.7 Type plate

Location
The type plate is fastened on the switch cabinet.
Overview
The type plate includes the following information:
2 7
3 8
4 9
5 10
11
6
(1) Serial number (7) Year of manufacture

(2) Type (8) Compressed air
(3) Clamping force (9) Electrical connection value
(4) Injection volume (10) Connected load
(5) Weight (11) Hydraulic oil
(6) Manufacturer’s information
Page 81
Serial number
The serial number is structured as follows:
1 2
(1) Serial number (2) Machine number
(1) Serial number: The serial number indicates the machine series.
(2) Machine number: The machine number specifies the serial number. It
is the exact identifier of a machine.
Machine name
The name of the machine consists of the components - type/injection sys-
tem (1), clamping force/injection volume (2) and design (3), closing direc-
tion, special design, etc:
(1) Type/injection system: Indicates the type and injection system of the
machine. For details, see section “Description” on page 31.
(2) Clamping force/injection volume: Indicates the clamping force and
injection volume.
(3) Design:
• Closing direction: Indicates if the machine closes from the top (top=t)
or bottom (bottom=b). The add-on “c” indicates “compact” design.
• Special design (optional): Indicates if the machine includes any special
designs.
Page 82
LWB Steinl operating instructions 4. Transport, assembly and commissioning
4 Transport, assembly and commissioning
4.1 Transport
DANGER
Risk of crushing
The machine is disassembled into the following assemblies during transport:

• Machine frame with clamp unit
• Injection unit (only dismantled for certain shipping types)
• Hydraulic unit with switch cabinet
The machine frame with clamp unit may only be transported with a crane
or forklift at the points marked.
If the injection unit is transported separately, it may only be lifted at the
eyebolts. Hydraulic screw connections may not be used for this under any
circumstances.
The transport of the hydraulic unit with switch cabinet takes place with a
suitable forklift.
Page 83
4.2 Assembly
Space assignment plan
The space assignment plan for the machine is located in the “Drawings
and part lists” documentation and in paper form in the documentation
folder, point 2.
Installation site
DANGER
Risk of crushing!
face.
• Bolt the machine to the ground using heavy-duty dowels at the fas-
tening points provided for this.
ATTENTION
Danger of property damage due to excessive floor loading
When selecting the installation site, the maximum permissible floor and
ceiling load capacities may not be exceeded. The floor condition must be
able to withstand the machine loads (no sinking, settling).
• Check the load bearing capacity of the floor before installation.
Unpacking
Proceed as follows when unpacking the assemblies:
Step Action
1 Free individual parts from foils and other packaging material.
2 Check machine parts for mechanical damage.
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Assembly
Proceed as follows during the assembly of the machine:
Step Action
1 Transport the machine frame with clamp unit to the designated place
(see space assignment plan).
• Injection unit not mounted: continue with step 2.
• Injection unit mounted: continue with step 3.
2 Lift the injection unit onto the machine frame, pin it and bolt it.
3 Transport the switch cabinet with hydraulic unit to the place desig-
nated for it (see space assignment plan).
4 Connect hydraulic tubes, temperature connections, pneumatic con-
nections, and electrical pin-and-socket connections according to the
engraved tags (keep the caps).
5 For separate temperature units:
Transport the temperature units to the place designated for them
(see space assignment plan) and fasten them if necessary.
4.3 Electrical connection

Safety instructions
WARNING
Risk of fire
Loose electrical connections can lead to a significant build-up of heat.
• If the power supply is interrupted, check all electrical connections for
tightness.
NOTE
The mains connection may only be carried out by locally approved spe-
cialist personnel.
Observe the connection values specified in the electrical plan.
Establishing the electrical connection

Carry out the electrical connection according to the specifications in the
electrical plan. The electrical plan in paper form is located in the switch
cabinet and in the “Energy schematics” documentation.
Page 85
4.4 Commissioning
Putting the machine into operation
DANGER
Risk of death!
death.
• Check the emergency stop devices individually and one after the
other for functionality.
• Do not alter or remove any emergency stop device.
Proceed as follows to put the machine in operation:
Step Action
1 Fill the hydraulic tank with hydraulic oil (e.g. ISO-VG 46) up to the
middle of the sight glass.
2 Fill the temperature units with coolant. For details, see “Technical
data” documentation.
(Coolant: e.g. water with 2% corrosion inhibitor RK93)
3 Open the mechanically actuated oil check valve (if present).
4 Open the mechanically actuated cooling line valves.
5 Open the pneumatic shut-off valve on the service unit and set the
required pressure.
6 Check the rotating field of the voltage supply with the rotation indi-
cator (clockwise direction of rotation).
7 Check the supply voltage for required values (see type plate).
8 Release all EMERGENCY STOP push-buttons.
9 Switch on the main switch, control, hydraulics.
10 Check the hydraulic pump direction of rotation (arrow mark on the
hydraulic motor).
11 Check the function of all safety devices.
12 Run all functions in manual mode and check function.
13 Switch on all heating circuits and check for function.
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Putting the servo pump in operation (optional)
ATTENTION
Risk of property damage
Disregarding the following instructions may result in damage to the servo
pump.
• Read this section carefully.
Proceed as follows to put the servo pump in operation:
Step Action
1 Attach the pump to the motor and ensure that the drive is free of
axial and transverse forces.
Max. axial coupling play: 2 mm (only necessary in case of repair or
service).
2 Fill hydraulic oil according to the level indicator.
3 Check rotating field: “clockwise”.
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Step Action
4 Detach the lock nut of the throttle valve with an SW15 open-ended
spanner and unscrew with an Allen wrench, size 4, by turning
counter clockwise to the limit stop (valve open).
5 Switch on control/hydraulics.
6 On the control, select the page Servo pump commissioning via Main
menu -> Service.
7 Start Servo pump commissioning: select “yes”.
Page 88
Step Action
8 Actuate one or two-hand until the system pressure(s) constantly
shows 5 to 10 bar for 30 seconds (indicators).
9 Screw in throttle valve with an Allen wrench, size 4, by turning
clockwise to the limit stop (valve closed) and tighten the lock nut
with SW15 open-ended spanner (9/16”).
 Commissioning of the servo pump is complete.

 Machine is ready for operation.
Page 89
Page 90
LWB Steinl operating instructions 5. Operation/control
5 Operation/control
5.1 Overview
5.1.1 Operating panel

Overview
7
2
3 4
1
5 6
(1) Operating panel with operat- (5) Emergency stop push-button

ing buttons
(2) Touchscreen (6) One-hand start push-button
(3) Spray (7) USB slot
(4) Reverse
Operating panel/touchscreen
The touch panel is switched on with the main switch of the machine. The
operating panel is controlled via the touchscreen. For the machine design
with a two-hand panel, the operating buttons are located on the desk. The
USB slot can also be on the front of the panel.
Page 91
ATTENTION
The USB port must not be used to charge electronic device (mobile
phone, etc.).
Improper use of the USB port may cause a failure in the control system.
5.1.1.1 Status page

Overview
Status page: Press the Home key to switch from any menu to the
status page.
Page 92
The following values are displayed on the status page:

• Cure time, graphic, counting • Counter total strokes (total
down in seconds cycles)
• Volume nominal value, actual • Counter shift piece cycles,
value nominal value, actual value
with reset key
• Current clamping force • Production volume nominal
value, actual value with reset
key
• Current system pressure • Current recipe, display field
• Cycles per hour nominal value, • Current order
actual value
Page 93
5.1.1.2 Main menu

Overview
4
5
(1) Status bar (4) Machine functions

folding in/out
(2) Favorites (5) Operating menu/
Machine functions
(3) Main menu
Main menu: Press the Main menu key to switch from any menu
to the main menu page.
After starting the machine, the main menu page appears. The main menu
is described in “Main menu” on page 104. Depending on the role with
which the user is logged on, the menus that the user may not work on
with the respective role are grayed out.
Page 94
5.1.1.3 Status bar

Overview
1 2 3 4 5 6 7
Functions such as printing, displaying help texts, and logging in can be

called up in the status bar. In addition, current error messages are dis-
played.
(1) Alarm messages: For details, see the supplied alarm list.
(2) Status page: For details, see chapter “Status page” on page 92.
(3) Help pages: Help pages can be called up here.
(4) Print function: for details see below.
(5) Date and time
(6) Optional display
(7) Login: For details, see chapter “Login” on page 102
Proceed as follows to save a screenshot to the USB stick:
Step Function
1 For the print function, a USB stick must be inserted into the
USB port.
2 Press the Print key and a screenshot of the current page is
saved to the USB stick.
3 If the screenshot has been successfully saved to the USB stick,
the Print button briefly lights up orange.
Page 95
5.1.1.4 Machine functions

Overview
(1) Machine functions

The machine functions are described in “Machine functions” on page 189.
5.1.1.5 Operating menu

Overview
1 2 3
(1) Operating mode (3) Testing

(2) General functions
Various machine functions can be started in the operating menu.
Page 96
Operating mode
The following operating modes are available:
Manual mode Service mode
Set-up mode Automatic mode
General functions
The following general functions are available:
Switch on control Switch on hydraulics
Emergency cooling Switch on lighting
Heating plate Mold heating
Cold runner Pre-heating cycle
Cleaning
Page 97
Testing the machine

The following options are available to test the machine:
Lamp test Clamp vacuum test
Injection vacuum test
5.2 General operating notes
5.2.1 General operating functions

Actual values
The following symbols, among other things, can be found in the “Actual
values” tabs.
Direction of movement Current position
Current dosing volume
Current speed/ Current system pressure

Current RPM
Current system pressure Current injection pressure
Page 98
Current back pressure Amperage
Residual shot size Current time
Current force Current power supply
Confirming/canceling
Your actions can be saved or canceled with the following keys.
Confirm: Press this key to Cancel: Press this key to
confirm your last action. cancel your last action.
The action is saved. The action is not saved.
Inputting numerical values
2 3 4
5
6
7
8
(1) Close window (6) Delete

(2) Minimum value (7) Number field
(3) Current value (8) Switching +/-
(4) Maximum value (9) Enter
(5) Slider
Page 99
Numerical values can be entered either with the slider (5) or with the num-
ber field (7). The values are confirmed with the “Enter” key (9).
Toggle switch
Tabs can be activated and deactivated with the following keys.
In this position, the tab is In this position, the tab is
activated. deactivated.
Value selection
Different values can be entered here for the graphic representation
depending on the graph. The automatic update time specifies the intervals
at which the graph is updated.
3
4
(1) X-axis (shot size) (3) estimated elapsed time

(2) Y-axis (time) (4) automatic update time
Page 100
Favorites
In the Favorites area, menus are displayed that have been selected as
favorites. These menus can be in the main menu as well as in the machine
functions.
(1) Favorites
If the star is filled in, the If the star is not filled in,
menu item can be the menu item cannot be
selected in the Favorites. selected in the Favorites.
Proceed as follows to add a menu item to the Favorites:
Step Action
1 Activate the Favorite star (1) in the upper right corner.
To remove a menu item from the Favorites, the star must be deactivated
again.
Page 101
5.2.2 Login
Overview
6
2
7
3
5 8
4
(1) “Login” key (5) Show password

(2) User name (6) Current user
(3) Password (7) “Login” key
(4) Language (8) “Logout” key
Page 102
Login
Proceed as follows to log in with your user profile:
Step Action
1 Press the “Login” key (1).
The Login window opens.
2 Press on the line for the user name (2) and enter your user
name on the keyboard.
3 Press on the line for the password (3) and enter your password
on the keyboard. You can make the entered password visible
by pressing the "Show password" key (5).
Logout
Proceed as follows to log out:
Step Action
The Login window opens.
2 Press the “Logout” key (8).
Setting the language

Proceed as follows to set the language:
Step Action
1 Press the “Language” key (4).
A drop-down menu opens.
2 Select the desired language.
The language can also be set in the “System control” menu. See “System
control” on page 159
Page 103
5.3 Main menu
5.3.1 Sequencer
Overview
(1) Sequencer
In the "Sequencer" menu, the option exists to generate the demolding

cycle of the machine and to save or load the mold data for an injection
mold. The sequencer offers the possibility to freely put together a process
from a collection of previously prepared commands.
Furthermore, the current steps can also be displayed.
Page 104
5.3.1.1 Current steps

Overview
2 3 4
(1) Current steps (3) Actual position

(2) Axis (4) Position status
In the sub-menu "Active steps", the current status of the active axis can
be viewed.
Position status red:

The axis is not in the negative end position.
Position status green:

The axis is in the negative end position.
Page 105
5.3.1.2 Demolding cycle

Overview
(1) Current process (4) Function „open end“; „Selec-

ted axis“ display field
(2) „Functions“ selection field (5) Confirm or cancel an action
(3) Selection „Slot machine“,
„Properties“
NOTE
• The process can only be edited with the appropriate user role.
• Editing the process is only possible in manual, set up and service ope-
rating mode.
The sequencer process can be edited in the "Demolding process" sub-

menu.
Page 106
Definition of symbols
The following symbols can be found in the “Sequencer” menu.
Insert a new step before Insert a new step after
Insert a new step in paral- Replace step

lel
Link macro Delete step
Slot Machine Properties
Insert a new step „open

end“ in parallel
NOTE
LWB Steinl does the parametrization for the "Properties" selection. With
the appropriate user role, changes can be made. If there are questions,
please contact LWB Steinl service.
Step Action
1 Select the desired axis in the current process (1). The "Func-
tions" selection field (2) opens.
2 Select „Slot machine“ (3)
The "Slot machine" function selection field opens.
Page 107
Overview
3
4
(1) Sequence (3) Text field

(2) "Slot machine" function (4) Confirm or cancel an action
selection field
The editor is called up in the "Sequence" submenu.
Step Function
1 Select the desired function in the first column of the "Slot
machine" function selection field.
2 In the second column, select the desired axis.
3 In the third column, select an intermediate stop and the move-
ment direction of the axis.
4 Use the scroll bar to move through the list.
5 Confirm the action to save it.
Page 108
The function selected in the second and third columns is described as a

text in a text field (3).
(1) Selected step
The selected step is displayed with red bars to the right and left of the
icon.
Explanation of symbols
You find the following symbols in the menu „Slot machine“:
Page 109
Column 1
Edit axis or Macro Edit DPS
Delay times Edit EM 67
Conditional performances
Edit axis or macro

Macro 1 and macro 2 are created by default.
• Macro 1 contains the entire injection process
• Macro 2 contains the optional squirting cycle for cleaning the injection
Combine individual steps into a macro:
Step Function
1 Select "Connect macro" in the "Functions" selection field.
2 Hold your finger longer over the first desired function.
3 Use your finger to draw a frame over the desired functions.
4 Press "Connect macro".
5 Give the new macro a name.
6 Confirm the action to save it.
Delay times
The delay time starts when the step is over. The parameters are defined
on the "Sequencer times" screen. Here a customer-specific designation
can also be given. See 5.3.3.2 „Sequencer times“.
Page 110
Conditional performances
Here conditional performances and customer inputs/outputs can be defi-
ned. Parametrization is done from the "Options" screen for the respective
axis.
• Conditional performance = 0: The cycle continues with no diversion.
If the condition is not met, the machine continues running in the cycle
and jumps to the conditioned part of the program.
• Conditional performance = 1: A parallel function is implemented. If the
condition is not met, the machine continues running in the cycle and
jumps to the conditioned part of the program.
• Customer input = 0 oder 1: The cycle stops at this point and waits
until the condition is met.
• Customer output = 0: reset
• Customer output = 1: set
Edit DPS
Here the damage protection system and poka-yoke is defined. See 3.5.12
„Safety circuit“
Edit EM67
Here the conditions for Euro Map interface 67 can be defined. See 5.3.6.1
„EM 67“.
Column 2
In column 2, the following functions can be selected, among others:
• Axis travel movements
• Load cascade pressure accumulator
• DPS functions
• Delay times 1-10
• Configuring EM 67
• Insert two hand/ one hand start
• Load pressure accumulator
Page 111
NOTE
Column 3 opens only if the function for the axis selected in column 2 is
available.
Column 3
In column 3, the following functions can be selected, among others:
• Insert intermediate stop
• Insert delay times
• Define axis movement directions
NOTE
The adjustment parameters for the selected function are set on the
respective machine function screen. Delay times are set on the "Sequen-
cer times" screen.
If, for example, an intermediate stop is inserted in the "Bottom separator"

function, the position of the intermediate stop is defined on the "Bottom
separator" screen.
Page 112
(1) Defining intermediate stop
Selecting "Confirm" or "Cancel" takes the user back to the "Demolding

process" functions menu.
Step Function
1 Select the desired insertion position.
2 Confirm the selection to save it.
Page 113
5.3.1.3 Monitor
Overview
(1) Monitor
Here the current process can be viewed during the automatic cycle. The
current step is indicated by a blue frame.
NOTE
• Editing the process is only possible with the appropriate password
level.
• Editing the process is only possible in manual, set up and service oper-
ating modes.
Page 114
5.3.1.4 Loading
Overview
3
4
(1) File filter (4) Cursor

(2) Storage location (5) Information bar 2
(3) Information bar 1 (6) Confirm/cancel
DANGER
Danger of serious injuries and death
Loading an unsuitable recipe can lead to serious injuries or death.
• Only load recipes from structurally identical machines.
Page 115
File filter
The values for current recipe/user, current frequency/user and size/created
are displayed in the “File filter” display field.
Storage location
Selection can be made between CFAST card, USB stick and FTP server.
Information bar 1
Type, file name, date of last editing and file size are displayed in the infor-
mation bar.
Information bar 2
Variable, value and description of a file are shown in information bar 2.
Page 116
5.3.1.5 Saving
Overview
3
4
6
7
(1) File filter (5) Information bar 2

(2) Storage location (6) Write protection
(3) Information bar 1 (7) Confirm/cancel
(4) Cursor
File filter
The values for current recipe/user, current frequency/user and size/created
are displayed in the “File filter” display field.
Storage location
Selection can be made between CFAST card, USB stick and FTP server.
Information bar 1
Type, file name, last edited and file size are displayed in information bar 1.
Page 117
Information bar 2
Variable, value and description of a file are shown in information bar 2.
Write protection
The “Write protection” display field shows whether the file is write-pro-
tected.
5.3.2 Temperatures
Overview
(1) Temperatures
Page 118
5.3.2.1 Temperature overview

Overview
1 2 3 4 5
(1) Group (4) Actual value

(2) Zone name (5) Status
(3) Nominal value
Nominal and actual values of individual zones are displayed in the “Tem-
perature overview” submenu. In addition, the status (5) of this zone can
be called up.
Page 119
Status
(1) Temperature (4) Heating current monitoring

L2
(2) Tolerance (5) Heating current monitoring
L3
(3) Heating current monitoring (6) Control parameters
L1
The following information for the selected zone can be called up via the
“Status” symbol:
(1) Temperature: The current actual and nominal values are displayed
here.
(2) Tolerance: The currently set tolerances are displayed here. For
details, see section “Temperature tolerance” on page 121.
(3-5) Heating current monitoring L1 - L3: The current actual and nominal
values for the individual heating current monitoring are displayed
here. For details, see section “Heating current monitoring tempera-
ture” on page 124.
Page 120
(6) Control parameters: The currently set control parameters are dis-
played. For details, see section “Temperature control parameters” on
page 126.
5.3.2.2 Temperature tolerance

Tolerance overview
1 2 3 4
(1) Select (4) Info

(2) Zone name (5) Arrow keys
(3) Parameters
The set tolerances for each zone can be seen and adjusted on the “Tem-
perature tolerance” page. The current values for the zone can be displayed
via the Info key (4).
Tolerance parameters
The warning and intervention limits relate relatively to the nominal value.
If the warning limits are exceeded or fallen below, a fault message is out-
put. The machine continues to produce.
Page 121
If the intervention limits are exceeded or fallen below, automatic mode is

also switched off. The press no longer closes. The control loop is switched
off when the maximum value is exceeded.
The following tolerance parameters can be set:
• Nominal value
• Temperature offset
• UEG (lower intervention limit)
• UWG (lower warning limit)
• OWG (upper warning limit)
• OEG (upper intervention limit)
The following maximum values apply:
Zone Material Max.

Heating plates Rubber 230°C
Polyvalent 230°C
Mold heating Rubber 230°C
(TPE hot channel)
TPE/polyvalent 300°C
Temperature units Rubber with water 90°C
(Injection / extruder)
Rubber / polyvalent with oil 120°C
Heating bands TPE / polyvalent 300°C
(Injection / extruder)
Cold runner Rubber with water 95°C
Rubber with oil 120°C
Polyvalent with water 95°C
Polyvalent with oil 120°C
Page 122
Setting the tolerance parameters

Proceed as follows to set the tolerance parameters:
Step Action
1 Select the desired zone (1).
2 Select the desired parameter that is to be changed.
3 Increase or lower the parameter to the desired value with the
arrow keys (5).
NOTE
The parameters for several or all zones can also be changed simultane-
ously.
Page 123
5.3.2.3 Heating current monitoring temperature

Heating current monitoring overview
1 2 3 4
(1) Select (4) Info

(3) Parameters
The preset parameters for the heating current monitoring and the actual
value of each zone can be seen and adjusted on the “Heating current mon-
itoring temperature” page. The current values for the zone can be dis-
played via the Info key (4).
During the heating current monitoring, the electric current of all three
phases (L1 - L3) is measured and compared with a specified nominal value
and a specified tolerance. If the actual value deviates from the nominal
value by more than the tolerance, a fault message is output.
The measuring takes place once per minute. A different control zone is
measured each minute. To measure a zone, all other zones are briefly (0.5
s) switched off. At the same time, the zone to be tested is switched on.
Page 124
The actual current of all three phases is measured. After measurement, all
zones are switched back on and normal controller operation is continued.
Heating current parameters

Up to three nominal values can be defined for each zone:
• For control loops with 220 V heaters, one nominal value can be
defined.
• For three-phase current heaters, two nominal values can be defined.
• For three-phase current heaters in star of delta connection, three nom-
inal values can be defined.
Depending on the type of heating, a corresponding number of actual val-
ues are displayed.
NOTE
When the heaters, temperature units, cold runners or mold heating are
switched on, all zones are tested one after the other. Only then is the
testing of the zones each minute started.
The following heating current parameters can be set:

• Nominal value L1
• Tolerance
Setting the heating current parameters

Proceed as follows to set the heating current parameters:
Step Action
1 Select the desired zone (1).
2 Select the desired parameter that is to be changed.
3 Increase or lower the parameter to the desired value with the
arrow keys (5).
Page 125
NOTE
The parameters for several or all zones can also be changed simultane-
ously.
5.3.2.4 Temperature control parameters

Control parameter overview
1 2 3 4
(1) Select (4) Info

(3) Parameters
The preset control parameters for each zone can be seen and adjusted on
the “Temperature control parameters” page. The current values for the
zone can be displayed via the Info key (4).
The control parameters can also be determined through auto-tuning.
Page 126
Setting the control parameters should only be performed by appropriately

qualified personnel.
5.3.2.5 Heating trend temperature

Heating trend overview
2 3
(1) Heating trend (3) Export

(2) Heating trend view (4) Parameters
The thermal response in the heating plates can be seen on the “Tempera-
ture graph” page.
Page 127
Changing the heating trend view

The view of the heating trend can be changed with the following keys:
Key Action
Moves the chronological sequence to the left.
Moves the chronological sequence to the right.
Extends the scaling of the heating trend.
Reduces the scaling of the heating trend.
View is reset to the default setting.
Heating trend parameters

The preset heating trend parameters specify the maximum value range for
the heating trends. If the values exceed or fall below the specified param-
eters, a fault message is displayed.
Page 128
5.3.2.6 Temperature options

Option overview
(1) General (3) Lower injection unit

(2) Lower divider (4) Heat through divider
General
The following settings can be made in the "General" submenu (1):
• Divider heating group can only be switched on with active mold heat-
ing group.
• Switch on divider heating group with injection unit heating group.
• Mold heating group can only be switched off when the switch-off tem-
perature is reached.
Lower divider/injection unit (TPE)

In the “Lower divider” (2) and “Lower injection unit” (3) submenu, the
respective monitoring time and temperature can be set.
Page 129
Heat through divider (TPE)

In the “Heat through divider” (4) submenu, the duration and temperature
for the process can be set.
Injection unit emergency cooling (rubber)

In the “Injection unit emergency cooling” submenu, the following settings
can be selected and the associated parameters can be entered:
• Switch off heating group after termination of the function
• Emergency cooling via time without temperature
• Emergency cooling via time with temperature
The emergency cooling is reset if the extruder or injection is started in
manual or automatic mode.
Divider emergency cooling (rubber)

In the “Divider emergency cooling” submenu, the following settings can
be selected and the associated parameters can be entered:
• Switch off heating group after termination of the function
• Emergency cooling via time without temperature
• Emergency cooling via time with temperature
Warm-up phase (rubber)
Page 130
5.3.2.7 Temperature parameters

Parameter overview
1
2
3
(1) Parameters (3) Check heating zones

(2) Group auto-tuning
Parameters
Auto-tuning of individual zones can be started in the “Parameters” sub-
menu. The current values for the zone can be displayed via the Information
key.
The following zone types can be assigned:
• Off: The respective control zone is switched off with the preselection
“Off”. Therefore, this zone will not heat or cool. No actual values or
limits are displayed, and messages with respect to the limits are also
not output.
• Control zone: The respective control zone is switched on with the pre-
selection “Control zone”. Therefore, this zone will heat and cool.
Actual values and limits can be defined and messages with respect to
Page 131
the warning and intervention limits are output (if these have been vio-
lated).
• Actual value: The respective control zone is switched off with the pre-
selection “Actual value”. Therefore, this zone will not heat or cool.
Actual values are displayed.
• Actual value + limits: The respective control zone is switched off with
the preselection “Actual value + limits”. Therefore, this zone will not
heat or cool. Actual values for this control zone are displayed. Warning
and intervention limits can be defined. Messages with respect to the
warning and intervention limits are output if these are violated.
• Actuator
Group auto-tuning
Auto-tuning of mold, injection unit and divider heating groups can be
started in the “Group auto-tuning” submenu.
Checking the heating zones

Testing of individual zones or multiple zones can be started in the “Check
heating zones” submenu.
Page 132
5.3.2.8 Temperature timer

Timer overview
(1) Heating group day timer (4) Mold heating group week
Mold clock
(2) Heating group day timer (5) Injection unit heating group
Injection unit week clock
(3) Heating group day timer (6) Heating group week clock
Divider Divider
Day timer
The individual heating groups can be switched on at a specific time on a
specific date. These settings are freely configurable.
Week clock
The individual heating groups can be switched on weekly at a specific time
on a specific day of the week. In addition, they can be switched back off
at a preset point in time. Seven periods per week can be defined. The (+)-
symbol must be pressed for this.
Page 133
5.3.2.9 Temperature configuration
NOTE
The “Configuration” submenu may only be edited by LWB Steinl service.
5.3.3 Times
Overview
(1) Times
All process-relevant nominal values for times are set here. The actual val-
ues run backwards from the nominal value entered.
Page 134
5.3.3.1 Overview of times

Overview
(1) Process times (2) Hydraulic times
Process times
The cure time, injection delay time, plasticizing delay time and lift nozzle
delay are set in the “Process times” register.
• Lift nozzle delay: This time starts simultaneously with start cure time
/ cooling time (begin holding pressure). The spray nozzle remains at the
injection point of the mold over the preset time. After expiration of the
nozzle on mold time, the nozzle lift moves to the dosing position (noz-
zle lift on extruder positioning unit, nozzle lift on nozzle seal) or, with
the corresponding preselection, the predecompression takes place on
the mold.
• Plasticizing delay: This time starts simultaneously with start cure time
/ cooling time (begin holding pressure). The dosing function can be
delayed over a desired period of time here.
Page 135
• Injection delay: Period of time by which the injection of the compound

into the mold is delayed. Starts when the nozzle lift is put on the mold.
For example, in connection with the “Vacuum” option, to achieve a
complete vacuum in the mold before starting the injection.
Hydraulic times
The hydraulic switch-off time can be set in the “Hydraulic times” register.
5.3.3.2 Sequencer times

Overview
(1) Delay times (2) Customer designation
Delay times
Up to ten delay times can be set in the “Delay times” register.
In the "Customer designation" field, customer-specific designations can be
given for the respective delay time. On the "Demoulding process" screen,
the designations from column 1 are shown, i.e. delay time 1 to 10.
Page 136
5.3.4 Process management

Overview
(1) Process management
Page 137
5.3.4.1 Process data acquisition (PDA)

Overview
(1) Process data acquisition
Process data acquisition (PDA) is used to record the process-relevant data.

The recording starts when the machine is commissioned at LWB.
The operating data is automatically saved to the hard disc and can be
transferred from there to a USB stick on demand. The saved data can be
displayed and edited in Microsoft Excel.
Page 138
5.3.4.1.1 Database
Overview
1 2
5
4
6
7 8 9
(1) Update (6) Chart

(2) Delete (7) Search
(3) Parameters (8) Scroll left/right
(4) Data (9) Export
(5) Scroll up/down
Various data is recorded depending on the design of the machine. The fol-
lowing data can be recorded:
• Date • Clamping force at end of cure
time
• Time • Injection energy
• Total cycle time • Heating plate
• Cycle time • Extruder temperature unit
• Aver. injection pressure • Injection temperature unit
• Cure time • Cold runner unit
• Injection time • Injection heating
Page 139
• Threshold • Extruder heating

• Time for mold closing • Mold heating
• Time for feeding • Compound temperature detec-
tor
Deleting operating data

Proceed as follows to delete the operating data:
Step Action
1 Press the “Delete” key (2).
Searching for parameters

Proceed as follows to search for a parameter:
Step Action
1 Press the “Search” key (7).
2 Enter the requested parameter in the text box.
Exporting operating data

Proceed as follows to export the operating data:
Step Action
1 Insert a USB stick in the USB slot of the control.
2 Press the “Export” key (9).
Proceed as follows to open/edit the operating data in Microsoft Excel:
Step Action
1 Open Microsoft Excel on your computer.
2 Insert the USB stick in your computer.
3 Use the “Open” dialog box in Microsoft Excel to open the data
in Excel.
4 Edit the data in Microsoft Excel.
Page 140
5.3.4.1.2 Parameters
Overview
(1)
5.3.4.1.3 Configuration
NOTE
The “Configuration” submenu may only be edited by LWB Steinl service.
Page 141
5.3.4.2 Statistical process control

Overview
(1) SPC
For details, see chapter “Process data acquisition (PDA)” on page 138.
Page 142
5.3.4.3 Cycle time analysis

Overview
(1) Cycle time analysis
Page 143
Cycle time analysis
3
4
5
(1) Graph (4) “SetRef” key

(2) Cycle time (5) “SelectValue” key
(3) Scaling
Page 144
5.3.4.4 Product management

Overview
(1) Product management
Page 145
Product administration
1
2
3
4
5
(1) Machine description (4) Material description

(2) Mold description (5) Order description
(3) Article description
Machine description
The following parameters are described in the “Machine description” reg-
ister:
• Machine type (entered by LWB)
• Machine number (entered by LWB)
• Machine number (customer entry)
• Nozzle (customer entry)
• Comment (customer entry)
Page 146
Mold description
The following parameters are described in the “Mold description” register:
• Mold number
• Dimensions
• Weight
• Number of cavities
• Cold runner number
• Demolding unit
• Comment
Article description
The following parameters are described in the “Article description” regis-
ter:
• Article designation
• Article number
• Article weight, net (only rubber)
• Insert 1
• Insert 2
• Insert 3
• Insert 4
• Comment
Material description
The following parameters are described in the “Material description” reg-
ister:
• Material designation
• Material number
• Material hardness
• Material color
• Batch no. / lot
• Comment
Order description
The following parameters are described in the “Order description” register:
Page 147
• Order designation
• Order number
• Production volume with nominal value and actual value display
• Current cycle time / last cycle with nominal value and actual value dis-
play
• Cycles per hour with nominal value and actual value display
• Injection counter with reset key
• Shift cycle counter with reset key
• Parts per shift counter
• Total stroke counter
• Comment
Page 148
5.3.4.5 Adjustment data sheet

Overview
(1) Adjustment data sheet
Page 149
Adjustment data sheet
(1) Data sheet
The data sheet for the machine can be seen in the “Adjustment data
sheet” menu.
Page 150
5.3.4.6 Quality management

Overview
(1) Quality management
Page 151
Quality management
(1)
Page 152
5.3.5 Data management

Overview
(1) Data management
Page 153
Data management
1 2
3
4 5
6
7
(1) USB/FTP configuration (5) Arrow keys up/down

(2) Search (6) Input command
(3) Folder menu (7) CFast card
(4) File management
Page 154
General
Mold data is managed in the file management. Files can be copied, deleted
or renamed. A folder structure can be created. Furthermore, data can be
exported or imported via an external storage medium (e.g. USB stick).
FTP configuration
Proceed as follows to open the FTP configuration:
Step Action
1 Press the “FTP” key (1).
The following window opens:
1 4
2
3
5 6
(1) IP address (5) Cancel

(2) User name (6) Confirm
(3) Password
(4) Input field
An FTP server can be set up in the “FTP” window. Proceed as follows to

set up an FTP server:
Step Action
1 Enter the IP address (1), user name (2) and password (3) for
the FTP server in the input field (4).
2 Confirm your entries (6).
Exchanging the CFast card

• Carry out the exchange of the CFast card only when the machine is
free of voltage.
Page 155
Proceed as follows to exchange the CFast card:
Step Action
1 Switch off the machine at the main switch.
2 Press the ejector carefully with a pointed object (e.g. a pen).
3 Remove the CFast card.
4 Insert the new CFast card in the device.
5 Switch the machine back on.
Managing mold data
1 2
3 4 5 6 7
(1) File management (5) “Cut” key

(2) Arrow keys up/down (6) “Delete” key
(3) “Copy” key (7) “Rename” key
(4) “Insert” key
Page 156
5.3.6 Special applications

Overview
(1) Special applications
Page 157
5.3.6.1 EM 67
Overview
1
2
3
4
(1) Actual values (3) Configurations

(2) Label 1-20 (4) Axis selection
Actual values
Label 1 to 20 can be selected in the “Actual values” register.
Configuration
The active axis can be set by means of key (4) in the “Configuration” reg-
ister.
Page 158
5.3.7 System control

Overview
(1) System control
Page 159
5.3.7.1 System
Overview
(1) System
Page 160
5.3.7.1.1 Settings
Overview
(1) Time/date (3) Unit switching

(2) Language (4) Unit switching - times
Time/date
The system time and system date can be set in the “Time/date” register.
Language
The language can be set in the “Language” register.
Proceed as follows to set the language:
Step Action
1 Press the “Language” key.
2 Select the desired language.
Page 161
The language can also be set in the login area. See “General operating
notes” on page 98
Unit switching
The units (metric/imperial) for the following parameters can be changed in
the “Unit switching” register:
• Temperature
• Pressure
• Volume/speed
• Distance/speed
Proceed as follows to change the parameters:
Step Action
1 Press on a parameter.
2 Select the desired unit.
Unit switching - times

The unit for the time parameter can be changed in the “Unit switching -
times” register:
Proceed as follows to change the parameter:
Step Action
1 Press on the parameter.
2 Select the desired unit.
Page 162
5.3.7.1.2 Editing the actual values

Overview
(1) Overview (2) Control
Editing the actual values

The actual values can be edited in the “Edit actual values” register.
Page 163
5.3.7.1.3 Editing the user page

Overview
(1) Cell (2) Parameters

Variables can be added and deleted in the “Edit user page” register. Fur-
thermore, the cell name can be assigned.
5.3.7.1.4 Cleaning the display

General
A stopwatch of 20 seconds runs down in the “Clean display” register.
During this time, the touch function of the display is switched off and the
display can be cleaned.
Page 164
Cleaning the display
DANGER
Danger due to unintentional triggering of machine functions
Cleaning the touch screen can trigger unintentional machine functions,
which can lead to serious injuries.
• Only clean the touch screen when it is switched off or the “Clean dis-
play” tab is activated.
• Use a damp cloth to clean the touch screen.

• Only use water with detergent, display cleaner or alcohol (ethanol).
• Clean the touch screen at regular intervals.
Page 165
5.3.7.2 User
Overview
(1) User
Page 166
User
1
2
3
4
(1) Overview (3) Import

(2) Export (4) Reset
"Roles" define which access authorizations the operator can have.
NOTE
Personal data (e.g. name) can be saved in this menu.
• Inform employees about the storage of this data.
• Take the protection of this data seriously and do not pass it on to third
parties.
Page 167
Creating a user
Proceed as follows to create a user:
Step Action
1 Open the “Overview” submenu.
2 Press the (+) sign.
3 Enter all data (user name, last name, first name, system lan-
guage, password) and confirm it.
4 Assign the new user a role under the “Roles” tab.
Press the (-) sign to delete a user.
Editing a user
Proceed as follows to edit a user:
Step Action
1 Open the “Overview” register.
2 Press on the “Edit” tab.
3 Change the desired data and confirm it.
Importing/exporting the user database

Proceed as follows to export the user database:
Step Action
2 Select the desired storage medium.
Proceed as follows to import the user database:
Step Action
2 Select the desired storage medium.
Page 168
Resetting the user database

Proceed as follows to reset the user database:
Step Action
2 Select “Reset”.
5.3.8 System status

Overview
(1) System status
Page 169
5.3.8.1 Alarm history

Overview
2 3
(1) Alarm overview (3) “Export” key

(2) “Filter” key
Filtering alarm messages

The alarm messages can be filtered. The following parameters are avail-
able:
• Message
• Code
• Current status
• Last status
• Time stamp
Page 170
Proceed as follows to filter the alarm messages:
Step Action
1 Press the “Filter” key (2).
4 5 6 7
(4) Add/delete filter (6) Operator

(5) Select parameter (7) Value
Step Action
2 Add one (or more) filters (4).
3 Select a parameter (5).
4 Select an operator (6).
5 Enter a value (7).
6 Confirm your entry with “Ok”.
Page 171
Exporting the alarm history

Proceed as follows to export the alarm history:
Step Action
2 Select the storage medium.
3 Confirm.
5.3.8.2 System Diagnostics Manager (SDM)

Overview
(1) System Diagnostics Manager

The SDM page is used by LWB service in order to read the status of the
machine. No entries can be made here.
Page 172
NOTE
For further details on the System Diagnostics Manager, read the supplied
SDM documentation. For details, see chapter 10 “Sub vendor documen-
tation”.
5.3.8.3 Trace
Overview
2 3
(1) Trace overview (3) “Export” key

(2) “Filter” key
Filtering trace messages

The trace messages can be filtered. The following parameters are avail-
able:
• Date/time
Page 173
• User
• ID
• Description
Proceed as follows to filter the trace messages:
Step Action
1 Press the “Filter” key (2).
4 5 6 7
(4) Add/delete filter (6) Operator

(5) Select parameter (7) Value
Page 174
Step Action
2 Add one (or more) filters (4).
3 Select a parameter (5).
4 Select an operator (6)
5 Enter a value (7).
6 Confirm your entry with “Ok”.
Exporting the trace history

Proceed as follows to export the trace history:
Step Action
2 Select the storage medium.
3 Confirm.
Page 175
5.3.9 Maintenance
Overview
(1) Maintenance
Page 176
5.3.9.1 Machine
Overview
(1) Machine
Page 177
5.3.9.2 Mold
Overview
(1) Mold
Page 178
5.3.9.3 Operational performance overview

Overview
1
2 3
(1) Operational performance (3) Reset key

overview
(2) Parameters
In the operational performance overview, the “Machine switch-on time”

and “Cycle counter” parameters can be read and a reset of these parame-
ters can be carried out.
Resetting a parameter
Proceed as follows to perform a parameter reset:
Step Action
1 Press the “Reset” key (3).
Page 179
5.3.9.4 Configuration
Overview
1
2
3
(1) Mold operating hours counter (3) Maintenance log

(2) Mold cycle counter (4) File name
Mold operating hours counter
Mold cycle counter
Maintenance log
The maintenance database can be reset in the “Maintenance log” register
(3).
File name
The name of the mold and the machine can be specified in the “File name”
register (4).
Page 180
5.3.10 Machine configuration

Overview
(1) Machine configuration
Page 181
5.3.10.1 Safety circuit

Overview
(1) Safety circuit (3) Elements

(2) Add safety circuit (4) Edit
Page 182
5.3.10.2 General
Overview
(1) Machine type
Page 183
5.3.11 Service
Overview
(1) Service
NOTE
The “Service” menu can only be opened by LWB Steinl service.
Page 184
5.3.12 Energy management

Overview
(1) Energy management
Page 185
5.3.12.1 Power consumption

Overview
(1) Actual values (3) Last cycle trend

(2) Analysis
Actual values
The power consumption values for drives, heating, other and total value
are displayed in the “Actual values” register. The values at the current
time as well as the maximum value are displayed in each case. The values
can be reset.
Analysis
In the “Analysis” register, the value for the last cycle, the last day and the
last month are shown from the power consumption values (drives, heat-
ing, other and total).
The values are available both in kWh and as a percentage. In addition, the
three time periods are also presented graphically.
Page 186
Last cycle trend

In the “Last cycle trend” register, the last cycle is presented in graphic
form. The power consumption values can be shown individually.
The graph can be reduced or extended. Furthermore, the time axis can be
moved to the left or to the right.
The graphs can be exported.
5.3.12.2 Energy consumption

Overview
2 4
(1) Specific energy consumption (3) Cycle analysis

(2) General analysis (4) Analysis on time stamp
Specific energy consumption

The energy consumption per article and per kilogram is displayed in the
“Specific energy consumption” register.
Page 187
General analysis
The energy consumption for the last day, last week and last month is dis-
played in the “General analysis” register.
Cycle analysis
The energy consumption for the last cycle is presented in the “Cycle anal-
ysis” register. The total consumption, as well as the minimum and maxi-
mum total consumption, is displayed.
Analysis on time stamp

The energy consumption between two self-selected points in time is dis-
played in the “Analysis on time stamp” register. The points in time can be
changed as needed.
5.3.12.3 Axes energy consumption

Overview
(1) Analysis of axes energy con-

sumption
Page 188
Analysis
The energy consumption for the clamp, injection, extruder and bottom
separator can be read in the “Analysis” register. The energy consumption
for the current cycle, last cycle and second to last cycle is displayed.
5.4 Machine functions

General
All possible movements of the machine can be selected via the machine
functions pages. The setting parameters, such as speeds, forces, pres-
sures, milestones, rotation speeds and percentages, can be set and
changed there.
NOTE
The values for set-up mode and service mode are defined on the set-up
page for the machine functions. Movements are generally made slower
here and without a movement profile.
Overview
The following symbols, among other things, can be found in the “Actual
values” tabs.
Clamp Nozzle lift
Injection Extruder
Extruder positioning unit Shuttle
Core puller DPS
Page 189
5.4.1 Clamp
5.4.1.1 Closing the clamp

Overview
2
3
4
5
(1) Actual values (4) Intermediate stop

(2) Rapid speed movement pro- (5) High pressure distance move-
file ment profile
(3) Mold protection (6) DPS close clamp
Actual values
The actual values can be seen in the “Actual values” register.
Details can be found under “General operating functions” on page 98.
Rapid speed movement profile

In the “Rapid speed movement profile” register, you can switch between
table view and generator view. In table view, the values for position,
Page 190
speed and force can be seen and changed. In generator view, the values
for speed and force are presented graphically.
The clamp can be closed over 4 adjustable milestones in the
rapid speed area. Four speeds with associated clamping forces can be
entered. The speed can therefore be adapted to the requirements, e.g. to
slowly accept an additional mold plate and then move quickly again. The
force (in kN) for the rapid speeds can be entered here.
Mold protection
In the “Mold protection” register, the values for mold protection start posi-
tion, mold protection home position and mold protection monitoring time
can be changed.
Intermediate stop
The intermediate stop, intermediate stop 2 and intermediate stop 3 posi-
tions can be activated and changed in the “Intermediate stop” register.
High pressure movement profile

The values for position, speed and force can be seen and changed in the
“High pressure movement profile” register.
Upon reaching the “high pressure” position (relative value), the mold is
closed with the entered force (high pressure) in kN (10 kN correspond to
1t) and the preset high pressure speed and is held closed with pressure. If
the contact area of the mold is smaller than the heating plate or the bolster
plate, the clamping force must be decreased by the same ratio. See
“Installing the mold” on page 269.
DPS close clamp

Details can be found under “” on page 103.
Page 191
5.4.1.2 Opening the clamp

Overview
3
4
(1) Actual values (3) Intermediate stop

(2) Rapid speed movement pro- (4) DPS open clamp
file
Actual values
Rapid speed movement profile

In the “Rapid speed movement profile” register, you can switch between
table view and generator view. In table view, the values for position,
speed and force can be seen and changed. In generator view, the values
for speed and force are presented graphically.
Page 192
Intermediate stop
Up to three intermediate stop positions can be activated and changed in
the “Intermediate stop” register.
DPS open clamp

5.4.1.3 Clamp degas

Overview
(1) Actual values (4) Degas phase 2 heating time

(2) Degas phase 1 range
(3) Degas phase 2 stress
Clamp ITM
Page 193
5.4.1.4 Clamp trend

Overview
1
2
4
3
5 6
(1) Graph (4) Value selection

(2) Activate (5) Configuration
(3) Detail view (6) Cursor values
In the clamp trend submenu, the values for the clamp are shown in a
graph. Furthermore, the detail view can be selected. There, the values can
be selected. For the detail view, the values for the upper limit and lower
limit for each of the Y axes 1-4 can be configured and shown or hidden,
and settings for the cursor values can be carried out, in the configuration
menu.
Page 194
5.4.1.5 Clamp parameters

Overview
(1) Actual values (3) Handling time monitoring

(2) Open clamp monitoring (4) Close clamp monitoring
Actual values
Handling time monitoring

The maximum handling time can be changed in the “Handling time” regis-
ter.
Open clamp monitoring

The maximum mold opening time can be changed in the “Open clamp
monitoring” register.
Page 195
• Maximum mold opening time (for TPE machines): After expiration of

this adjustable time, the automatic spraying is initiated. The time runs
regardless of whether the machine was shut down at the end of shift
or whether it is in manual or automatic mode. The free spray cycle can
only be run in automatic mode. The key switch must be set to auto-
matic mode for this. The control and hydraulics must be switched on.
The clamp closes and the nozzle lift is raised completely.
• Maximum mold opening time (for rubber machines): Maximum time
that the compound may remain in the injection cylinder. After expira-
tion of this time, the red warning light flashes and a corresponding
fault message appears on the panel; the compound must be sprayed
out, i.e. completely reduced to a value of “0 ccm”. This can take place
via the automatic “Spray” function or in manual mode.
Close clamp monitoring

The maximum mold closing time can be changed in the “Close clamp mon-
itoring” register.
• Maximum mold closing time: Monitoring time which can be specified
for closing the mold to prevent damage to the mold. If the mold is not
closed within the specified time, the closing process is canceled and a
fault message is output. The clamp must be opened with the reverse
button in automatic mode, or in manual mode, after the pending fault
message and diagnosis message have been acknowledged.
Page 196
5.4.1.6 Clamp set up

Overview
1 1
(1) Actual values (3) Rapid speed forward move-

ment
(2) Rapid speed backward move- (4) Teach position
ment
Actual values
Rapid speed forward movement

The values for force and speed can be changed in the “Rapid speed for-
ward movement” register.
Page 197
Rapid speed backward movement

The values for force and speed can be changed in the “Rapid speed back-
ward movement” register.
Teach position
The value for the teach position can be changed in the “Teach position”
register.
The mold is closed completely. By pressing the “Teach position” key, the
value is reset to 0 mm. This calibrates the distance measuring system to
this value.
5.4.1.7 Clamp profile tuning

Overview
2
3
4
5
(1) Actual values (4) Tuner

(2) Forward movement tuning (5) undefined key
(3) Backward movement tuning
Page 198
Actual values
Forward movement tuning

The values from the movement profile can be calculated in the “Forward
movement tuning” register. They consist of start position, speed, negative
tolerance and positive tolerance. The calculated values are acceleration,
delay, end delay and dead time.
Backward movement tuning

The values from the movement profile can be calculated in the “Backward
Tuner
In the “Tuner” register, the settings for tuning without speed grading,
automatic profile tuning, tuning with speed grading (1st step, 2nd step,
3rd step) and automatic profile tuning can be made.
Adaptive forward position control

Only for functions with distance measuring system. For example, if the
axis moves one millimeter beyond the specified distance, the adaptive
position control corrects the distance to the specified position through an
adjustable number of movements.
The movement is shown in a bar chart in the graphic.
The bars represent the deviation of the position from the nominal value.
If the deviation of the position from the nominal value is greater than the
tolerance entered, the APC will correct the position during the next runs.
Adaptive backward position control

Same functionality as “Adaptive forward position control”.
Page 199
5.4.1.8 Clamp configuration
NOTE
The “Configuration” submenu may only be opened by LWB Steinl service.
5.4.2 Injection
General
The designation 1.1 stands for injection 1, E unit. 1.2 stands for injection
1, EF unit. The designations 2.1 and 2.2 stand analogously for a second
injection unit.
Page 200
5.4.2.1 Injection - forward

Overview
1 1
(1) Actual values (3) Phase 2 holding pressure

movement profile
(2) Phase 1 speed 1.1 movement
profile
Actual values
Phase 1 speed 1.1 movement profile

The values for volume, speed and injection pressure can be displayed in
table form and graphically in the “Phase 1 speed 1.1 movement profile”
register.
In phase 1 of the injection process, the injection is controlled via the preset
speed steps. Up to 10 speed steps (6-step for injection 1, 4-step for injec-
Page 201
tion 2) can be entered. A maximum set point adjustment for the injection
pressure is possible for both injections here.
• Only the pressure necessary for the speed is used. Exceeding the
entered nominal value is not possible during the injection in phase 1.
• For volume, the specified nominal value for the dosing volume is
entered.
Phase 2 holding pressure movement profile

The values for time, speed and injection pressure can be displayed in table
form and edited in the “Phase 2 holding pressure movement profile” reg-
ister.
The phase 2 holding pressure profile begins as of the switch volume.
In phase 2 of the injection process, the remaining volume is injected, con-
trolled based on the preset profile points.
Depending on whether the operation without throttle or operation with
throttle mode has been selected, the pressure phase takes place with the
EF unit or E unit. Up to 10 profile points are possible for the pressure pro-
file.
Operation without throttle

The injection process only takes place through the EF unit. The E unit
remains at the spraying position. The holding pressure is driven through
the E unit. This corresponds to operation with a conventional nozzle fit-
ting.
Operation with throttle

Here the injection process is combined, i.e. the EF unit injects in a speed-
controlled manner, no holding pressure is applied. Then the E unit contin-
ues to inject in a speed-controlled manner until the switch volume is
reached. After the switch volume has been reached, the E unit injects the
holding pressure profile in a pressure-controlled manner.
Page 202
5.4.2.2 Injection - backward

Overview
1 1
(1) Actual values (3) Decompression

(2) Precompression
Actual values
Precompression
The values for force, speed and position can be entered in the “Predecom-
pression” register.
The predecompression volume is used to extend the buoyancy surface
before dosing into the E unit begins. After the dosing, a decompression
(predecompression) of the injection piston takes place. The extruder there-
fore does not have to apply as much force at the beginning of the feeding
process.
Page 203
Decompression
The values for force, speed and position can be entered in the “Decom-
pression” register.
The decompression releases the compound in the injection piston of the E
unit after the dosing process. After reaching the dosage, a decompression
of the injection volume is carried out.
5.4.2.3 Injection trend

Overview
1
2
3
4
5 6
(1) Graph (4) Detail view

(3) Value selection (6) Cursor values
The values for injection1 can be presented graphically in the “Injection 1
trend” submenu. The values can be selected according to estimated
elapsed time and automatic update time. The Y axes can be configured in
the detail view. In addition, the cursor values can be set.
Page 204
Trend configuration
The following values can be configured:
• Set point injection pressure: In order to be able to use the switch pres-
sure, it is necessary to enter a switch pressure and a release volume
for the switch pressure. The injection unit injects the speed steps pre-
set in the phase 1 injection phase in a speed-controlled manner here
up to the freely adjustable position “Switch pressure release”. The cur-
rently required injection pressure is compared to the preset switch
pressure. As soon as the required injection pressure is greater than or
equal to the preset switch pressure, the injection unit automatically
switches over to the pressure-controlled injection phase 2. The com-
pound is injected into the mold with the preset profile points over the
preset time in each case.
• Actual injection pressure
• Set point injection speed
• Actual injection speed
• Actual dosing volume: In the first line of the speed profile, the specified
nominal value for the dosing volume is adopted from the “Forward
injection” screen.
• Compound temperature
• Mold cavity pressure
• Actual clamping force
• Clamp position
Page 205
5.4.2.4 Injection parameters

Overview
1 1
(1) Actual values (3) Switch mode 1.1

(2) General
Actual values
General
The following values can be activated in the “General” register:
• Injection into open mold allowed: One reason for activating this param-
eter could be to prevent damage to an open hot channel and bending
of a thin injection plate. The setting should be activated by default.
• Feeding to mold
Page 206
• Delay after predecompression: Dwell time between the injection move-

ments of the EF unit and the E unit. Injection 1 predecompresses after
the injection, then the delay time runs down. The rest of the rubber
mass is injected into the mold by means of the E unit at a max. of 2
possible speed steps and then with a pressure profile of up to 10 steps.
This time can be used to specify how long injection 2 should wait to
begin injection after the predecompression of injection 1.
Switch mode 1.1

The following values can be activated in the “Switch mode 1.1” register:
• Switching from phase 1 to phase 2 via volume: The injection unit
injects the speed steps preset in injection phase 1 in a speed-controlled
manner here up to the switch volume and then automatically switches
over to the pressure-controlled injection phase 2. The compound is
injected into the mold with the preset profile points over the preset
time in each case here.
• Switching from phase 1 to phase 2 via pressure: In order to be able to
use the switch pressure, it is necessary to enter a switch pressure and
a release volume for the switch pressure. The injection unit injects the
speed steps preset in the phase 1 injection phase in a speed-controlled
manner here up to the freely adjustable position “Switch pressure
release”. The currently required injection pressure is compared to the
preset switch pressure. As soon as the required injection pressure is
greater than or equal to the preset switch pressure, the injection unit
automatically switches over to the pressure-controlled injection phase
2. The compound is injected into the mold with the preset profile
points over the preset time in each case.
• Switching from phase 1 to phase 2 via time: The injection unit injects
into the mold over the speed steps preset in injection phase 1 in a
speed-controlled manner here. As soon as the injection unit begins to
inject the volume into the mold, the preset change over time starts to
count down. As soon as this time has expired, the injection unit auto-
matically switches over to the pressure-controlled injection phase 2. In
this phase, the compound is injected into the mold with the preset pro-
file points over the preset time in each case.
• Switching from phase 1 to phase 2 via mold cavity pressure
• Switching from phase 1 to phase 2 via external signal
Page 207
5.4.2.5 Injection set up

Overview
1 1
(1) Actual values (3) Backward movement 1.1

(2) Forward movement 1.1
Actual values
Forward movement 1.1

The values for force and speed can be changed in the “Forward movement
1.1” register.
Backward movement 1.1

The values for force and speed can be changed in the “Backward move-
ment 1.1” register.
Page 208
5.4.2.6 Injection profile tuning

Overview
1 1
2
3
4
(1) Actual values (3) Backward movement tuning

(2) Forward movement tuning (4) Tuner
Actual values

Page 209

Tuner
5.4.2.7 Injection configuration
NOTE
Page 210
5.4.3 Cascade
5.4.3.1 Cascade overview

Overview
(1) Actual values (2) Overview
Page 211
5.4.3.2 Cascade actual values

Overview
(1) Actual values
Actual values
Page 212
5.4.3.3 Cascade parameters

Overview
(1) Actual values (2) Injection 1
Actual values
Injection 1
The open nozzles in manual mode parameter can be activated in the injec-
tion 1 register.
Page 213
5.4.4 Nozzle lift
5.4.4.1 Nozzle lift - general

Overview
2
3
4
(1) Actual values (3) Forward movement to mold

(2) Forward movement to dosing (4) Backward movement
position
Actual values
Page 214
Forward movement to dosing position
NOTE
If the jacking pressure of the nozzle lift is set below the minimum value
of 60 bar, the cycle will not switch further and the injection process is
not started.
NOTE
The nominal value entries of the following milestones are determined and
entered by moving the respective function to the desired position and
adopting the value of the actual distance display as the nominal value.
The nozzle lift can be moved in the direction of the mold in the “Forward
movement to dosing position” register. The presentation of the values for
position, speed and force takes place in table form in the table menu. In
the generator menu, the presentation takes place graphically.
• Position: The position can be entered in up to 10 steps with adjustable
force and speed.
• Speed: The speed (in mm/s) for the forward movement to dosing posi-
tion can be entered here.
• Force: The force (in kN) for the forward movement to dosing position
can be entered here.
The position of the nozzle lift to the nozzle seal is entered for the EF unit
and F unit.
Forward movement to mold
NOTE
This position must be checked at each mold change or nozzle change and
be adjusted, if necessary (nominal value/actual value comparison of the
distances)
The position of the nozzle lift to the mold can be entered in the “Forward
movement to mold” register. The values for position, speed and force can
be presented in table form or graphically.
Page 215

force and speed.
The position of the nozzle lift to the mold is entered for RS units. This posi-
tion must be checked at each mold change or nozzle change and be
adjusted, if necessary (nominal value/actual value comparison of the dis-
tances)
The position of the nozzle lift to the mold is entered for the EF units and F
units. The values may be different from the “Forward movement to dosing
position” values. This can be necessary with a high injection pressure. This
position must be checked at each mold change or nozzle change and be
adjusted, if necessary (nominal value/actual value comparison of the dis-
tances)
Backward movement
The injection unit can be moved away from the mold in the direction of the
negative final position in the Backward movement” register. The setting of
the values for position, speed and force can be presented in table form or
graphically. The movement can be divided into ten arbitrary distances,
each with its own selectable speed and force.
force and speed.
Page 216
5.4.4.2 Nozzle lift options

Overview
(1) Actual values (2) Immersion nozzle
Actual values
Immersion nozzle
In the “Immersion nozzle” register, the values for lift nozzle lift before
feeding, position, and lift nozzle lift after feeding can be changed for
cycles with immersion nozzles. For cycles without immersion nozzles, the
settings for move nozzle lift to wait position, position, and movement
delay can be carried out.
• Move nozzle lift to wait position: Here the injection unit can be moved
into wait position after completion of the dosing function within the
cure time. The nozzle should be between the “at extruder positioning
Page 217
unit / at nozzle seal” position and the mold. If the dosing process has
not been completed within the cure time, the “Move to wait position”
only takes place after the next dosing process is finished.
• Movement delay: The value for the delay for lifting the injection unit
after completion of the dosing function can be set here. The material
located in the extruder and in the injection can “relax” during this time.
5.4.4.3 Nozzle lift set up

Overview
(1) Actual values (3) Forward movement

(2) Backward movement (4) Teach position
Actual values
Page 218
Forward movement
The values for force and speed can be changed in the “Forward move-
ment” register.
Backward movement
The values for force and speed can be changed in the “Backward move-
ment” register.
Teach position
The value for the teach position can be changed in the “Teach position”
register. See 3.5.4 „Nozzle lift“.
Page 219
5.4.4.4 Nozzle lift profile tuning

Overview
2
3
14
5

(2) Forward movement tuning (5) Adaptive forward position
control
(3) Backward movement tuning (6) Adaptive backward position
control
Actual values

Page 220

Tuner


5.4.4.5 Nozzle lift configuration
NOTE
Settings are to be made only in set-up or service mode.
Page 221
5.4.5 Extruder positioning unit
5.4.5.1 Extruder positioning unit - general

Overview
2
3
4
5
(1) Actual values (4) DPS 1 extruder positioning

unit, positive
(2) Forward movement (5) DPS 1 extruder positioning
unit, negative
(3) Backward movement
Actual values
Forward movement
The values for speed and force can be set in the “Forward movement” reg-
ister.
Page 222
The position query occurs via proximity switches.
Backward movement
The values for speed and force can be set in the “Backward movement”
register.
The position query occurs via proximity switches.
DPS 1 extruder positioning unit, positive

DPS 1 extruder positioning unit, negative

5.4.5.2 Extruder positioning unit options
(1) Actual values (2) Holding
Actual values
Page 223
Holding
The active holding forward, active holding backward, and active holding
forward and backward positions can be selected in the “Holding” register.
5.4.5.3 Extruder positioning unit set up
2
3
(1) Actual values (3) Backward movement

(2) Forward movement
Actual values
Forward movement
The values for force and speed can be set in the forward movement reg-
ister.
Page 224
Backward movement
The values for force and speed can be set in the “Backward movement”
register.
5.4.5.4 Extruder positioning unit profile tuning
2
3
4
5
6

control
control
Actual values
The actual values can be set in the “Actual values” register.

Page 225


Tuner


5.4.5.5 Extruder positioning unit configuration
NOTE
Page 226
5.4.6 Nozzle seal

General
2
3
(1) Actual values (3) DPS 1 nozzle seal, negative

(2) DPS 1 nozzle seal, positive
Actual values
Page 227
5.4.7 Extruder
5.4.7.1 Extruder - general

Overview
Actual values
Forward movement
The values for volume, torque and RPM can be presented in table form in
the “Forward movement” register. The values for speed and force can be
presented graphically. A speed profile with up to 5 steps can be set. Min-
imum is one step, maximum is 5 steps.
• Volume: Depending on the application area, the use of different screw
types is possible: Rubber screw, TPE screw, polyvalent screw
Page 228
• Torque: The desired torque of the screw can be set here. Only the pres-
sure necessary for the RPM is used; the set pressure is not exceeded.
• RPM: The associated desired RPM can be specified for each speed
step. The RPM is automatically reduced before reaching the injection
volume via a factory-set brake ramp.
Backward movement
5.4.7.2 Extruder trend

Overview
1 1 2
3
4
5 6
(1) Graph (4) Detail view

(3) Value selection (6) Cursor values
The values for extruder 1 can be presented graphically in the “Extruder 1
trend” submenu. The values can be selected according to estimated
Page 229
elapsed time and automatic update time. The Y axes can be configured in
the detail view. In addition, the cursor values can be set.
5.4.7.3 Extruder options

Overview
(1) Actual values (2) Strip feeding aid
Actual values
Strip feeding aid

In the “Strip feeding aid” register, the length of time can be entered after
which a “Strip break” alarm message is generated.
• Function: The run time of the driven roll of a strip feeding aid can be
set to an accuracy of a tenth. Due to the different properties of each
Page 230
of the rubber compounds used, a readjustment of the manufacturer

setting may become necessary.
• Strip break (optional with strip feeding aid): For machines or injection
units equipped with strip feeding aids with motors, the idle time of the
queried drive roll of the strip feeding aid can be set here. Therefore, a
strip end or strip break after the preset time is displayed by an alarm
message on the panel.
5.4.7.4 Extruder parameters

Overview
1 1
(1) Actual values (2) Extrusion monitoring
Actual values
Page 231
Extrusion monitoring
The maximum extrusion time can be set in the “Extrusion monitoring” reg-
ister.
• Switch volume: The switch volume, at which the switchover is made
from one desired RPM step to the next, can be entered here. The
switch volume relates to the current injection volume.
• Back pressure (option): With appropriate hydraulic and electric prelim-
inary setup of the machine, a positive or negative back pressure can
be set here.
• Rubber machines: The input of the value occurs between -10 bar and
+10 bar. Values greater than 0 bar generate a positive back pressure,
i.e. the injection piston is held against the extrudate. Negative input
values generate a negative back pressure, i.e. in addition to the force
of the flowing compound, the injection piston is actively retracted.
These variants are used mainly for injection units > 1000 ccm.
• Speed steps: The speed steps visible here result from the selected
number of speed steps. The speed steps are displayed in ascending
order.
• Number of speed steps: A speed profile with up to 5 steps can be set
for the extrusion process.
Page 232
5.4.7.5 Extruder set up

Overview
Actual values
Forward movement
The values for torque and rotational speed can be set in the “Forward
movement” register.
Page 233
5.4.8 Top separator
5.4.8.1 Top separator - general

Overview
2
3
4
5
6
7
(1) Actual values (5) Backward intermediate stop

(2) Forward movement (6) DPS 1 top separator, positive
(3) Forward intermediate stop (7) DPS 1 bottom separator, neg-
ative
Actual values
Page 234
Forward movement
The values for position, speed and force can be set in the “Forward move-
ment” register. The presentation occurs in table form in the table tab; in
the generator tab, the values can be edited graphically.
Forward intermediate stop

tions can be activated and changed in the “Forward intermediate stop”
register. These positions can also be approached in manual mode.
Backward movement
The values for position, speed and force can be set in the “Backward
movement” register. The presentation occurs in table form in the table tab;
in the generator tab, the values can be edited graphically.
Backward intermediate stop

tions can be activated and changed in the “Backward intermediate stop”
register. These positions can also be approached in manual mode.
DPS 1 top separator, positive

DPS 1 top separator, negative

Page 235
5.4.8.2 Top separator options

Overview
2
3
(1) Actual values (3) Vibrate forward

(2) Holding
Actual values
Holding
Vibrate forward
The number of repetitions and the backward position can be set in the
“Vibrate forward” register.
Page 236
5.4.8.3 Top separator set up

Overview
2
3

Actual values
Forward movement
The force and speed can be set in the “Forward movement” register.
Backward movement
The force and speed can be set in the “Backward movement” register.
Page 237
5.4.8.4 Top separator profile tuning

Overview
2
3
4
5
6

control
control
Actual values

Page 238

Tuner


5.4.8.5 Top separator configuration
NOTE
Page 239
5.4.9 Bottom separator
5.4.9.1 Bottom separator - general

Overview
1 1
2
3
4
5
6
7
(1) Actual values (5) Backward intermediate stop

(2) Forward movement (6) DPS 1 bottom separator, pos-
itive
(3) Forward intermediate stop (7) DPS 1 bottom separator, neg-
ative
Actual values
Page 240
Forward movement
The values for position, speed and force can be presented in table form in
the “Forward movement” register. In the generator tab, the values for
speed and force can be edited graphically.
force and speed.
Forward intermediate stop

These positions are also approached in manual mode. If the value “0 mm”
is input, this function is deactivated.
Backward movement
The values for position, speed and force can be presented in table form in
the table tab in the “Backward movement” register.
In the generator tab, the values for speed and force can be represented
graphically.
force and speed.
Backward intermediate stop

These positions are also approached in manual mode. If the value “0 mm”
is input, this function is deactivated.
Page 241
5.4.9.2 Bottom separator options

Overview
1 1
2
3

(2) Holding
Actual values
Holding
Vibrate forward
The value for repetitions and the backward position can be set in the
Page 242
5.4.9.3 Bottom separator set up

Overview
1 1

Actual values
Forward movement
The values for force and speed can be set in the “Forward movement” reg-
ister.
Backward movement
register.
Page 243
5.4.9.4 Bottom separator profile tuning

Overview
1 1
2
3
4
5
6

control
control
Actual values
The actual values can be displayed in the “Actual values” register.

Page 244

Tuner


5.4.9.5 Bottom separator configuration
NOTE
Page 245
5.4.10 Shuttle
5.4.10.1 Shuttle - general

Overview
2
3
4
5
(1) Actual values (4) DPS 1 shuttle, positive

(2) Forward movement (5) DPS 1 shuttle, negative
Actual values
Forward movement
Speed and pressure for acceleration, driving and braking can be entered in
the “Forward movement” register.
Page 246
Backward movement
Speed and pressure for acceleration, driving, and braking can be entered
in the “Backward movement” register.
DPS 1 shuttle, positive

DPS 1 shuttle, negative

5.4.10.2 Shuttle options

Overview
2
3

(2) Holding
Actual values
Page 247
Holding
The positions, active holding forward, active holding backward, and active
holding forward and backward, can be selected in the “Holding” register.
Vibrate forward
The number of repetitions and the backward position can be set in the
5.4.10.3 Shuttle set up

Overview
2
3

Actual values
Page 248
Forward movement
Backward movement
5.4.10.4 Shuttle profile tuning

Overview
2
3
4
5
6

control
control
Actual values
The actual values can be seen in the “Actual values” tab.
Page 249


Tuner


5.4.10.5 Shuttle configuration
NOTE
Page 250
5.4.11 Core puller
5.4.11.1 Core puller - general

Overview
4
5
(1) Actual values (4) DPS 1 core puller, positive

(2) Forward movement (5) DPS 1 core puller, negative
Actual values
Forward movement
Backward movement
Page 251
DPS 1 core puller, positive

DPS 1 core puller, negative

5.4.11.2 Core puller options

Overview
2
3

(2) Holding (4) Backward movement
Actual values
Page 252
Holding
The positions, active holding forward, active holding backward, and active
holding forward and backward, can be selected in the “Holding” register.
Forward movement
Backward movement
5.4.11.3 Core puller parameters

Overview
3
4

(2) Forward movement (5) Backward movement moni-
toring
(3) Forward movement monitor-
ing
Page 253
Actual values
Forward movement
Forward movement monitoring

The values for min. force, max. force, min. speed and max. speed can be
set in the “Forward movement” register.
Backward movement
set in the “Backward movement” register.
Backward movement monitoring

The monitoring time can be set in the “Movement monitoring” register.
Page 254
5.4.11.4 Core puller set up

Overview

(2) Forward movement (4) Release pressure
Actual values
Forward movement
Backward movement
Page 255
5.4.11.5 Core puller profile tuning

Overview
2
3
4

Actual values

Page 256

Tuner
Page 257
5.4.11.6 Core puller configuration
NOTE
5.4.12 Mold safe guarding

Overview
2
3
(1) Poka Yoke 1 (3) dps neg 1

(2) dps pos1
Optional mold safe guarding can be selected here.
The mold protection only affects the closing of the mold, i.e. close clamp,
top separator up, bottom separator down and close safety screen.
Page 258
The following selections are possible:

• No: Mold protection is deactivated.
• Yes: Mold protection is activated and the corresponding input must
carry signal pos. 1 so that the above movements can be carried out.
• Change: The switch(es) (proximity switches) must experience a signal
change in automatic mode, i.e. during the opening of the press, the
mold protection must carry a 1-signal and, during the demolding, the
mold protection must briefly carry a 0-signal. The mold protection
must again carry a 1-signal for closing. In manual mode, the mold pro-
tection must always carry a 1-signal with this preselection.
Poka Yoke
In the “Poka Yoke” register, the positions, digital input, poka yoke low,
poka yoke high, poka yoke low change, and poka yoke high change, can
be set.
DPS pos 1
DPS neg 1
Page 259
5.4.13 Closing plate
5.4.13.1 Closing plate - general

Overview
2
3
4
5
(1) Actual values (4) DPS closing plate, positive

(2) Forward movement (5) DPS closing plate, negative
Actual values
Forward movement
The home position and time can be set in the “Forward movement” regis-
ter.
Page 260
Backward movement
The home position and time can be set in the “Backward movement” reg-
ister.
DPS closing plate, positive

DPS closing plate, negative

5.4.13.2 Closing plate options

Options
2
3
4

(2) Program (4) Backward movement
Page 261
Actual values
Program
In the “Program” register, you can switch between core puller program 1
and core puller program 2.
Core puller program 1 moves to the positive final position before the start
of injection. The core puller moves to the negative final position after the
end of the holding pressure.
Core puller program 2 moves to the positive final position after the build-
up of clamp force. The core puller moves to the negative final position
after reaching the threshold.
Forward movement
The home position can be set in the “Forward movement” register.
Backward movement
The home position can be set in the “Backward movement” register.
Page 262
5.4.13.3 Closing plate parameters

Overview
2
3
4
5

(2) Forward movement (5) Backward movement moni-
toring
(3) Forward movement monitor-
ing
Actual values
Forward movement
set in the “Forward movement” register.
Page 263
Forward movement monitoring

The monitoring time can be set in the “Forward movement monitoring”
register.
Backward movement
set in the “Backward movement” register.
Backward movement monitoring

The monitoring time can be set in the “Movement monitoring” register.
5.4.13.4 Closing plate set up

Overview
2
3

Page 264
Actual values
Forward movement
The values for force and speed can be set in the “Forward movement” reg-
ister.
Backward movement
register.
5.4.13.5 Closing plate profile tuning

Overview
2
3
4

Page 265
Actual values


Tuner
5.4.14 Closing plate configuration
NOTE
Page 266
LWB Steinl operating instructions 6. Installing the mold
6 Installing the mold

General information
DANGER
Risk of death!
Falling machine parts can lead to significant injuries.
• Raised loads are to be secured through suitable measures (mechanical
support) against falling down or lowering.
DANGER
Risk of death!
Electric current or machine movements can lead to significant injuries.
• Maintenance and repair work may only be performed by authorized
specialist personnel.
• The machine must be disconnected from the mains during all mainte-
nance and repair work and be secured against reactivation.
NOTE
The hydraulics must be switched off during any activity on the mold.
Carry out the assembly in set-up mode using slow speeds and low pres-
sures.
The press must be moved to the following positions in manual mode (see
“General operating notes” on page 98) for mold assembly:
• Clamp open
• Shuttle at the back (option)
• Top separator all the way up (option)
• Bottom separator all the way down (option)
• Safety screen open (option)
Installing the mold
Page 267
General information
ATTENTION
The fastening elements for the mold on the heating plates or on the sep-
arators must be able to transmit the forces specified in the following
table.
Non-compliance can result in damage to the machine!
Location Force
Injection side mold plate on the injection • Clamp breaking force
side heating plate • Injection unit positioning force
Clamp side mold plate on • Clamp breaking force
clamp side heating plate
Mold plate on separator • Separator retraction force
The corresponding forces can be found in the “Technical data” documen-

tation.
The conversion to a new mold occurs in set-up mode. The press can be
moved to the position required for assembly of the mold with factory-set
slow speeds and low pressures.
In addition to the distances, speeds and pressures, the appropriate
demolding cycle is to be defined for a new mold.
Process engineering values, such as temperatures, times and even injec-
tion parameters, must be replaced with empirical values and then be pre-
cisely determined and adjusted through injection trials.
For the functions used in the cycle, such as shuttle (option), extruder and
extruder positioning unit or nozzle seal, no change of the setting parame-
ters is required.
The optimal speeds and forces for the automatic cycle can also be opti-
mized during the automatic sequence, if necessary.
After the settings have been confirmed through injection trials, save the
data using the “Load/save mold data” function (see “Data management”
on page 153).
Page 268
6.1 Installing the mold
DANGER
On a machine that closes from the top, the fastening screws of the clos-
ing plate may crack if the mold is assembled improperly.
This can cause severe injury or death.
 If the contact area of the mold is smaller than the heating plate or the bol-
ster plate, the clamping force must be decreased by the same ratio.
Description
1 2
(1) Mold the same size as the bolster plate / heating plate
(2) Mold smaller than the bolster plate / heating plate
Example:
A1 = 700 x 500 = 3500 cm2 = 100%
A2 = 530 x 330 = 1749 cm2 = 50 %
In this case, the clamping force must be reduced by 50%. See “High pres-
sure movement profile” on page 191
Page 269
Proceed as follows to assemble a mold:
Step Action
1 Position the mold on the lower heating plate with the help of a
lifting truck, forklift or mold change truck.
2 Close the clamp slowly in set-up mode.
• If the upper injection plate is equipped with a centering ring,
the mold must be aligned on the heating plate such that the
centering ring is located in the heating plate hole provided
for this.
• If no centering ring is present, the mold must be assembled
in the middle of the heating plate or bolster plate.
3 Close the clamp without any pressure.
4 Fasten the upper part of the mold or injection plate and lower
part of the mold with the help of nut stones and screws.
5 Move the top separator forward slowly to the separator plate
(center mold plate) and fasten the separator to the separator
plate with nut stones and screws using the insulating plate pro-
vided.
 Specify the current position as the top separator “Upper end
position”.
6 Move the clamp backwards to the “open” position.
7 Move the top separator with separator plate forward slowly to
the desired “Lower end position” and accept the actual posi-
tion.
8 Move the top separator backwards to the “Upper end posi-
tion”.
9 Move the bottom separator forward until the lower separator
plate (center mold plate) is touching the separator lifting beam.
Fasten the separator using the insulating plate provided with
nut stones and screws.
 Specify the current position as the top separator “Upper end
position”.
Page 270
Step Action
10 Move the bottom separator with separator plate forward
slowly to the desired “Upper end position” and accept the
actual position.
11 Move the bottom separator backwards to the “Lower end posi-
tion”.
12 Check the location of the injection plate to the nozzle. See
“Checking the nozzle seat” on page 272.
If the injection plate has a centering ring, this is generally not
necessary.
Settings for the close clamp movement

With each mold change, the clamp settings, such as positions, speeds and
forces, must be checked and adjusted. For details, see “Closing the
clamp” on page 190.
Settings for the open clamp movement

The open clamp movement takes place with an adjustable force for the
entire movement. For details, see “Opening the clamp” on page 192.
Settings for the nozzle lift forward movement

With each mold change, the nozzle lift on mold position must be adjusted.
For details, see “Nozzle lift - general” on page 214.
Settings for the bottom separator movement (option)

With each mold change, the positions, speeds and forces for the “Bottom
separator” must be adjusted to a new mold. For details, see “Bottom sep-
arator - general” on page 240.
Settings for the top separator movement (option)

With each mold change, the positions, speeds and forces for the top sep-
arator must be adjusted to a new mold. For details, see “Top separator -
general” on page 234.
Page 271
6.2 Checking the nozzle seat

General information
2
3
(1) Heating plate (3) Centering ring

(2) Machine nozzle (4) Mold
In order to be able to ensure the tightness of the nozzle seat, it is neces-

sary to precisely match the injection channel of the mold and the nozzle
taper. The precision of the alignment can be checked with a paper impres-
sion.
After assembly of the mold, the nozzle lift is moved into the uppermost
position in manual mode and the extruder positioning unit is moved back-
ward. The clamp must be closed in order to prevent damage to the mold.
Access to the mold nozzle seat via the pressure plate hole and heating
plate hole is therefore available.
A piece of paper is placed on the injection channel of the mold so that it
is covered. The injection unit is then lowered onto the mold in manual
mode with the help of the nozzle lift, and pressure is built up and reduced
again. After lifting the injection unit, the piece of paper can be removed.
From the paper impression, it is now clear if the mold or injection plate
must be readjusted and in which direction.
In order to prevent the compound from escaping between the nozzle and
the mold, adjustment must take place until a circular paper impression is
obtained.
In general, only the mold or the injection plate may be readjusted, but not
the injection unit. Checking the nozzle seat is required after each mold
change provided that no centering ring is used.
Page 272
6.2.1 Mold centering

Overview
(1) Machine heating plate (2) Mold
Description
In order to ensure an optimal nozzle fit, the fit of the mold centering must
be maintained at all times.
Page 273
6.2.2 Geometry of the nozzle and the mold

Overview
R 1
D

(D) Nozzle diameter (black) (R) Nozzle radius (red)
Mold diameter = nozzle diameter + 0.5 mm

Mold radius = nozzle radius + 0.5 mm
Optimal nozzle seat
Nozzle (1) and nozzle seat or mold geometry are matched to each other.
The radii and diameters of the mold are tailored to those of the nozzle.
Page 274
Insufficient nozzle seat
1 2
Insufficient diameter (1)

The diameters of the nozzle (1) and the mold (2) are not matched to each
other.
Insufficient radii (2)

The radii of the nozzle (1) and the mold (2) are not matched to each other.
Page 275
6.2.3 Testing the mold nozzle seat with a paper impression

Overview
(1) Nozzle (3) Paper

(2) Machine (4) Mold
Testing the nozzle seat

Proceed as follows to test the nozzle seat with a paper impression:
Step Action
1 Place a piece of paper (3) between the nozzle (1) and the mold
(4).
2 Move the nozzle downward so that the nozzle and mold latch.
3 Move the nozzle back up.
4 Remove the paper and check the impression.
Paper impression
1 2
Page 276
Optimal nozzle seat (1)

Nozzle and nozzle seat/mold geometry are matched to each other.
Insufficient nozzle seat (2)

The radius of the nozzle and the radius of the nozzle seat/mold geometry
are not matched to each other. This leads to increased wear of the nozzle
and the mold.
6.2.4 Nozzle seat geometry on the extruder head

Overview
R 1
D
2
(1) Machine nozzle (3) Extruder head

(2) Head plate (R) Nozzle radius (red)
(D) Nozzle diameter (black)
Diameter of head plate lining = nozzle diameter - 0.5 mm
Page 277
Optimal nozzle seat

(2) Head plate
Nozzle (1) and nozzle seat on the head plate are matched to each other.
The radii and diameters of the head plate are tailored to those of the noz-
zle.
Insufficient nozzle seat
1 2
1

(2) Head plate
Page 278
Insufficient radii (1)
The radii of the nozzle (1) and the head plate (2) are not matched to each
other.
Insufficient diameter (2)

The diameters of the nozzle (1) and the head plate (2) are not matched to
each other.
6.2.5 Testing the extruder head nozzle seat

Testing the nozzle seat
Proceed analogously to chapter “Testing the mold nozzle seat with a paper
impression” on page 276 to test the extruder head nozzle seat with a
paper impression.
Paper impression
1 2
Optimal nozzle seat (1)

Nozzle and nozzle seat/head plate are matched to each other.
Insufficient nozzle seat (2)

The radius of the nozzle and the radius of the nozzle seat/head plate are
not matched to each other.
6.3 Determining the required values

After the assembly of the mold has taken place, the distances for auto-
matic mode must be determined. This is best done in set-up mode or man-
ual mode.
For a smooth mechanical demolding process, the following values must be
determined:
Page 279
Clamp
• Mold closed
• Safety distance
• Start rapid open
• High pressure distance
Top separator
• Upper end position (move separator to the mechanical end position and
transmit actual value)
• Lower end position
Bottom separator
• Lower end position (move separator to the mechanical end position
and transmit actual value)
• Upper end position
Nozzle lift
In addition to these values, the value for nozzle lift on mold should also be
checked.
Besides the path positions, the appropriate demolding cycle and the nozzle
lift program must also be defined for a new mold.
If these parameters are adjusted to the new mold, then the mechanical
mold change is completed.
The optimal speeds and forces for the automatic cycle can be left from
one mold to the other for the most part, or can be readjusted during the
automatic sequence, if necessary. All other values, such as the values for
the shuttle or the extruder as well as the extruder positioning unit, can be
adopted without any changes.
Process engineering values, such as temperatures, times and even injec-
tion cylinder data, must initially be replaced with empirical values and then
be precisely determined and adjusted through injection trials. After the set-
tings have been confirmed through injection trials, the data should be
stored using Load/save mold data.
If the mold has previously been assembled in the press and the mold data
has been stored in the PLC, the data can be loaded into the working mem-
ory after the mold has been assembled.
The data described above should, however, still be checked in order to pre-
vent damage to the mold and the machine.
Page 280
6.4 Auto accept-switch (option)

Description
The auto-accept switch automatically takes over the function of two-hand
operation when the mold is almost closed and there is no risk of injury.
ATTENTION
Metal shavings near the sensor can change the switching distance.
NOTE
The sensor only accepts the SAFIX T5 actuator that is included in the
scope of delivery. If one component no longer works, both components
must be replaced.
Page 281
Top closing overview
2
5
3
6
7
(1) C-Frame (5) Fastening rail for auto-accept

switch
(2) Clamping cylinder (6) Control cam (fastened to the
closing plate)
(3) Closing plate (7) Adjustment plate with fastening
lever (fastened to the frame)
(4) Mold
Page 282
Bottom closing overview
3
6
7
2
(1) C-Frame (5) Fastening rail for auto-accept

switch
(2) Clamping cylinder (6) Control cam (fastened to the
frame)
(3) Closing plate (7) Adjustment plate with fastening
lever (fastened to the closing
plate)
(4) Mold
Page 283
Proces
Adjustment of the auto-accept switch with both a top and a bottom closing
machine:
ATTENTION
The fastening lever can release. This results in the auto-accept switch being
deactivated.

After adjustment and setting, the fastening lever must be secured such
that it is immovable.
Proceed as follows to adjust the auto-accept switch:
Step Action
1 Release the fastening lever. Slide the adjustment plate down com-
pletely. Drive the mold closed in manual mode.
2 Bring the adjustment plate in contact with the control cam.
3 Secure the fastening lever such that it is immovable.
Page 284
LWB Steinl operating instructions 1. Faults / troubleshooting
1 Faults / troubleshooting
1.1 General information

If it is not possible to correctly execute a function during operation, this
can have various safety or production-related causes. In the event of a
malfunction, the following basic requirements must be checked:
• Is the emergency stop unlocked?
• Are existing emergency doors closed?
• Is the control switched on?
• Are the hydraulics switched on?
• Is compressed air available and set to a min. of 6 bar?
• Are existing safety doors closed?
• Is the correct operating mode (manual/automatic/set up/service) set?
• Are there any pending fault messages?
• Does a diagnosis message appear when the start key or two-hand key
is pressed?
1.2 Alarms
The alarm messages can be found in the supplied alarm list.
Page 285
1.3 Troubleshooting
Fault: Clamp cannot be closed in automatic mode
Possible cause Remedy

Maximum mold opening time The compound must be sprayed out
exceeded. completely, i.e. actual volume of 0
Fault message: “max mold opening ccm. Spraying of the compound is
time exceeded”. possible via the “Forward injection”
function in manual mode and via the
The compound was in the injection purge button in automatic mode.
longer than the maximum mold open-
ing time.
LVDT wire breakage. The respective LVDT is to be checked
Due to wire breakage on the distance and readjusted by instructed specialist
measuring system, no forward move- personnel.
ment is possible. An incorrect actual
value appears in the clamp function
screen.
Fault message: “Clamp LVDT wire
breakage”
Injection volume not reached, or • Check if the extruder is still being
decompression volume not reached. actuated.
• Check if a strip break of the com-
pound has taken place.
• Check if the injection decompres-
sion function is still being actuated
or if the decompression volume
has been reached.
Various demolding functions, such as The position of the respective func-
shuttle, core puller, separator, etc. are tion must be checked. If the function
not in the initial position. A diagnosis is in its mechanical final position, the
message appears. nominal value must be corrected
accordingly. If the function is not in
the end position, it can be approached
in manual or set-up mode.
Nozzle lift is on the mold (static inter- The nozzle lift must be moved back-
lock active) ward away from the mold in manual
mode.
Temperature error messages for the In order to start an automatic cycle
heating plates or mold heating are again, the temperature of the respec-
active. The preset temperatures are tive heating zone must be within the
outside of the preset limits. warning limits entered.
Page 286
Fault: Mold is closed, however, the injection process does not start

Temperature error: Extruder, injection Wait until the temperatures are within
temperature unit the preset warning limits.
Fault message: “Temperature unit XX
limit fallen below”
Clamp does not reach “Mold closed” Check “Clamp closed” position (set
position (system pressure available). point / actual value comparison).
Clamp pressure is not reached (sys- The electrical system and hydraulics
tem pressure available). are to be checked by instructed spe-
cialist personnel.
Nozzle lift does not reach position on Check “Nozzle lift on mold” position
mold (system pressure available). (set point / actual value comparison).
Nozzle lift does not reach jacking pres- The electrical system and hydraulics
sure (system pressure available). are to be checked by instructed spe-
cialist personnel.
Fault: Clamp closes, hydraulics switch off

The minimum extruder temperature of Wait until the extruder temperature
50 °C has been fallen below. has reached the preset nominal value,
Fault message: “Minimum tempera- which must be greater than 50 °C.
ture fallen below zone 7”.
Fault: Hydraulics cannot be switched on

Emergency stop key pressed. Unlock the emergency stop key and
Fault message: “Emergency stop XX switch on the control and hydraulics.
pressed”
The shut-off device for the hydraulics Open shut-off device on the hydraulic
is closed (installed in bottom closing tank and switch on hydraulics.
machines as of a clamping force of
500 kN).
Fault message: “Hydraulics shut-off
device closed”
Page 287
Fault: Extruder does not start

Emergency stop key pressed. Unlock the emergency stop key and
Fault message: “Emergency stop XX switch on the control and hydraulics.
pressed”
Fault: Extruder does not start in manual mode

The minimum extruder temperature of Wait until the extruder temperature
50°C has been fallen below. has reached the preset nominal value,
Fault message: “Minimum tempera- which must be greater than 50 °C.
ture fallen below zone 7”.
The injection volume has already been The compound must be sprayed out.
reached
(nominal volume = actual volume).
Fault: Shuttle does not move

Static interlock active. The stated function must be moved to
Static interlock active program diag- the required end position in manual or
nosis, e.g. “Shuttle does not move set-up mode.
because clamp not in rear position”.
Dynamic interlock active. The stated function must be moved to
Dynamic interlock active program the required end position in manual or
diagnosis, e.g. “Shuttle does not set-up mode.
move because top separator not at
position xx mm”.
Page 288
Fault: Bottom separator does not move

Static interlock active. The stated function must be brought
Static interlock active program diag- to the required end position in manual
nosis, e.g. “Bottom separator does or set-up mode.
not move because clamp not in rear
position”.
diagnosis, e.g. “Bottom separator set-up mode.
does not move because top separator
not at position xx mm”.
Fault: Top separator does not move

nosis, e.g. “Top separator does not set-up mode.
move because clamp not in rear posi-
tion”.
diagnosis, e.g. “Top separator does set-up mode.
not move because bottom separator
not at position xx mm”.
Fault: Nozzle lift does not move

nosis, e.g. “Nozzle lift does not move set-up mode.
because extruder positioning unit not
in rear position”.
Page 289
Fault: Extruder positioning unit / nozzle seal does not move

nosis, e.g. “Extruder positioning unit set-up mode.
does not move because nozzle lift not
in rear position”.
Fault: Injection does not move

Temperature error In order to start an automatic cycle
Fault message: “Bottom limit fallen again, the temperature of the respec-
below zone x”. tive heating zone must be within the
warning limits entered.
Nozzle lift sits on the extruder posi- The extruder positioning unit must be
tioning unit in manual mode. Static brought into the “rear” position to
interlock is active. enable the forward movement of the
injection.
Injection into open mold not allowed In the “Forward injection” screen, set
the “Injection into open mold allowed”
setting to NO.
Fault: Heating switches itself off

Wire breakage of a thermo couple. The thermo couple for the respective
The heating switches off due to the zone is to be checked and replaced, if
max. temperature of 230 °C being necessary, by instructed specialist
exceeded. personnel.
Fault message: “There is wire break-
age in the thermo couple of zone X”.
Week clock is set incorrectly. Correct the switch-on and switch-off
times for the week clock and check
the preset date.
Page 290
Fault: Heating current monitoring activates

During operation, the fault message Check the entered heating currents
appears: “Heating current monitoring for the respective zone (set point/
phase X zone X”. actual value comparison).
The affected heating zone is to be
checked by instructed specialist per-
sonnel.
Fault: The preset temperature for the extruder / injection is not reached

Contamination in the cooling valve of The valve must be cleaned by
the temperature unit. The valve can instructed specialist personnel.
no longer close, it is continuously
cooled.
Direction of rotation of the pump The direction of rotation of the pump
motor is incorrect. Phases have been motor is to be corrected by instructed
interchanged. specialist personnel.
The thermostat for the temperature The temperature unit must be
unit has activated. Triggered due to checked by instructed specialist per-
an overtemperature (above 95 °C). sonnel.
Fault: Water constantly escapes from the overflow of the temperature unit

Contamination in the refill valve of the The valve must be cleaned by
temperature unit (water units). The instructed specialist personnel.
valve can no longer close, it is contin-
uously refilled via the water cooling
circuit.
Fault: The temperature unit does not switch on

Fill level has been fallen below. For water units: Check the filling valve
Fault message: “Temperature unit fill and supply from the cooling circuit.
level fallen below”. For other temperature media: Refill
the respective medium.
Page 291
Fault: Hydraulics switch off during operation

The maximum oil temperature of the The hydraulic tank must be cooled off
hydraulic tank (70 °C) has been (wait until the temperature lowers).
exceeded. When using an oil cooler, it must be
Fault message: “Oil temperature checked for function by instructed
exceeded”. specialist personnel.
The level of the hydraulic tank is too Check of the oil level by instructed
low. specialist personnel.
Fault message: “Oil level too low”.
The end of shift switch has been acti- Deactivate the end of shift switch,
vated. switch on hydraulics and move press
to initial position.
Fault: Automatic mode only runs when two-hand is held down

Auto accept-switches are not set cor- Set the auto accept-switch again.
rectly.
Clamp does not reach the switch posi-
tion or overruns the preset switch
position.
Page 292
1.4 Behavior in an emergency

Safety instructions
DANGER
Risk of death!
All faults on the machine can lead to serious injuries or death.
• Remedy all faults and errors before the machine is put in operation.
• Switch off the machine immediately if faults arise during operation.
• Only let appropriate specialist personnel remedy the fault.
DANGER
Risk of death!
Non-functioning safety devices can lead to serious injuries or death.
• Check the safety devices regularly for functionality.
• Do not alter or remove any safety device.
NOTE
In the event of a fire, observe the safety data sheets of the hydraulic oil
manufacturer and the site-specific fire protection measures.
• Operate the machine only in technically perfect condition. Report and

remedy all faults immediately.
• Do not take any safety components out of operation, such as limit
switches, valves and other control components.
• In case of power supply malfunctions and/or damage to the electrical
equipment, switch off the machine and secure the main switch against
reactivation. Connection conditions, operating conditions and perfor-
mance data may not be changed.
• Immediately report and remediate any fault or damage indicated or dis-
covered by the system.
• For programmable control systems, no changes to the program code
may be carried out by the operator. Dependencies and time correla-
tions may not be changed without prior consultation.
• Only operate the machine if all safety devices are mounted and are
fully functional.
Page 293
• Persons, who are under the influence of alcohol, other drugs, or med-
ication which influences responsiveness, may not operate the machine
and may not carry out any work on the machine.
• Ensure that access to the immediate operating area of the machine by
external parties is prohibited.
Behavior in an emergency
Proceed as follows in an emergency:
Step Action
1 Press the emergency stop key immediately.
2 Disconnect the machine from the power supply.
Behavior in the event of errors or other irregularities

Proceed as follows in the event of errors or other irregularities:
Step Action
1 Switch off the control and hydraulics.
2 Secure the main switch against unintentional reactivation.
3 Secure the danger zone so that no one can enter the danger zone
unknowingly and unchecked.
4 Notify the responsible specialist personnel immediately.
Page 294
LWB Steinl operating instructions 2. Maintenance/repair
2 Maintenance/repair
2.1 General information
DANGER
Danger of death, injury and property damage
Disregarding the safety instructions can be life-threatening and cause
damage to health or property.
• Carefully read the safety instructions before all work on the machine.
DANGER
of voltage.
DANGER
Risk of crushing!
face.
• Do not carry out any disassembly work on a raised machine.
Page 295
DANGER
Risk of crushing!
death.
• During all work on the hydraulic system, make sure that the machine
is pressureless and the main switch is switched off and secured
against reactivation.
• Secure the clamp unit against lowering during maintenance work with
a suitable means.
machine.
• Maintenance work on the machine may only be performed by specialist

personnel. Operating personnel must be informed about the perfor-
mance of maintenance and repair work.
• During all maintenance and repair work on the machine, ensure abso-
lute cleanliness of the parts being serviced as well as the tools used.
• Only use original spare parts when replacing parts.
• Check the safety equipment of the machine after all work.
• The operator of the machine must check the quality of the flexible hose
lines at regular intervals, at least annually. If damage is discovered, the
affected hose lines must be replaced. See “Checking the hose lines”
on page 307
• This also applies for all electrical lines on the machine. A visual inspec-
tion is sufficient in this case.
• Maintenance work on the hydraulics may only be performed when the
machine is switched off. The machine must be in the initial position
before being switched off, since there may still be pressure in the
hydraulic system in any other position. During operation, the hydraulic
oil is under a pressure of max. 300 bar. Opening the hydraulic system
during operation of the machine is dangerous and prohibited.
• Maintenance work on the temperature unit may only be performed
when the machine is switched off. During operation, the medium
located in the temperature unit and in the circuit can reach tempera-
tures of up to approx. 90 °C (water) and approx. 130 °C (thermal oil),
which is why special attention should be paid to this.
Page 296
2.2 Maintenance schedule

Cleaning
Activities to be performed Interval Personnel

Clean injection opening of mold Daily Operator
(heating plate hole) and injection
nozzle
• Check for dirt and material resi-
dues
• Remove contamination
Clean E ram/EF ram Daily Operator
• Remove rubber abrasion
Clean switch cabinet Annually Maintenance per-
• Carefully vacuum switch cabinet sonnel
Clean touchscreen Weekly Operator

• Call up stopwatch page
Electrical system
DANGER
of voltage.
Page 297

Check safety devices Weekly Operator
• Check emergency stop doors
and emergency stop push-but-
tons for function (control and
hydraulics must switch off)
Check operating elements, indicator Every 3 months Maintenance per-
lights, electrical lines for damage sonnel
• Replace damaged parts
Check filter mat on switch cabinet Every 6 months Maintenance per-
fan sonnel
• Check for contamination
• Clean filter mat, replace if neces-
sary
Check battery in the CPU (control) Service time Maintenance per-
A low battery is displayed by a sys- approx. 2 years sonnel
tem message. Battery change only
when supply voltage is switched
on. (Loss of data!)
• See B&R user manual in “Sup-
plier documentation”.
Hydraulics

Check hydraulic oil level Weekly Operator
Check screwed joints, Weekly Operator
hydraulic tubes and hydraulic cylin-
ders
• Visual inspection for leakage oil
Replace the hydraulics return line fil- For a new Maintenance per-
ter machine, after 50 sonnel
• For filter cartridge, see hydraulic operating hours,
part list then every
2000 operating
hours or every
12 months
Page 298

Check air filter (funnel) Check after 250 Maintenance per-
operating hours sonnel
• Clean or replace filter car- or every 3
tridge months
Check screwed joints, hydraulic Every 6 months Maintenance per-
tubes and hydraulic cylinders sonnel
• Close examination of the hoses
and cylinders for cracks and
damage
• Tightness check of the screwed
joints
Page 299

Replace hydraulic oil, clean tank Every 4,000 Maintenance per-
completely, remove residues and operating hours sonnel
sludge from the entire interior of the or annually (this
tank requires a max.
• A new filter is to be installed oil tank tempera-
with each oil change ture of 55 °C, as
well as regular fil-
• The required oil quality must be ter checks and fil-
ensured when refilling the ter changes).
hydraulic tank
Attention: The
• Prescribed oil quality: HLP-D 46 change intervals
(ISO VG 46) can be signifi-
• Attention: Fill only with filtered cantly extended
oil (filtering degree 5 μm). through appropri-
ate oil care and
checking the
pressure fluid.
After the oil has been changed, the After the oil has Maintenance per-
individual functions must be venti- been changed sonnel
lated.
Note that venting screws are avail-
able on most cylinders. On some
cylinders, the use of venting screws
is not possible due to the design!
In this case, any air present in the
system must be removed by repeat-
edly moving the machine function.
Hydraulic accumulator cascade con- Initial test Maintenance per-
trol “direct” - see sonnel
manufacturer's
test report “P0
report N2 filling
system”. For
additional test
intervals, see
manufacturer's
documentation
“Hydraulic dia-
phragm accumu-
lator”
Page 300
Other tasks

Replace the fastening screws for Annually Maintenance per-
the upper and lower heating plate or sonnel
bolster plate
• and tighten with the indicated
torque.
See maintenance schedule docu-
mentation
Check that the safety sensor and Weekly Operator
actuator of the auto-accept switch
• is intact and firmly seated.
• Remove any metal shavings
LWB-Temp temperature unit Daily Operator
Monthly Maintenance per-
• See manufacturer’s documenta- Annually sonnel
tion in “Supplier documentation” As needed
Injection spray nozzle See maintenance Maintenance per-

The spray nozzle is to be checked schedule sonnel
for the specified torque as
described in the maintenance
schedule in chapter 4.6. After reas-
sembling the spray nozzle, or if a
new spray nozzle is assembled,
check it for the specified torque
after the first 30 and 100 cycles.
Temperature unit
When using more than two temperature control units that are connected
with a Powerlink bus line, the following must be observed:
ATTENTION
If a Powerlink temperature unit is switched off or is defective, the alarm
message "TU xxx not ready" appears.
Page 301
1 2
(1) Inside switch cabinet door (2) Gender Changer
Step Action
1 If more than two temperature units are used, these are controlled
serially with a Powerlink bus.
2 If a temperature unit in this series fails or is removed, the following

temperature control units can no longer be energized and will fail.
3 In this case the bus line has to be bridged with the supplied "gender
changer".
4 The supplied “gender changer” is located in the switch cabinet door,

above the pocket for instructions and is marked with the sticker
shown above.
Page 302
2.3 Purging of the throttle channels for an EFE unit

Overview
Cross section of E unit with installed cleaning piston:
(1) E unit piston rod (3) Jack screws

(2) Channel cleaning system (4) “Open” side
Purging the EF unit

In order to purge the throttle channels, the EF unit must be sprayed out
into the E unit. For this, it is necessary to switch to service or set-up mode.
In service or set-up mode, a red background on the cleaning button indi-
cates that injection of the EF unit is possible even when the E unit is not
in the spray through position.
Page 303
Spraying through a clogged channel side

Proceed as follows to spray through a clogged channel side:
Step Action
1 Remove the E unit ram.
2 Insert the channel cleaning piston (2) (“open” (4) on the side that is
clogged).
3 Move the piston rod of the E unit (1) to the channel cleaning piston.
4 Spray the EF unit.
5 Disassemble the channel cleaning piston using the jack screws (3).
6 Insert the ram in the E unit by hand.
7 Move the piston rod to the ram and tighten the swivel nut hand-tight.
8 Move the ram hydraulically completely into the E unit.
9 Tighten the swivel nut securely.
Page 304
2.4 Checking the safety devices and emergency stop devices

Safety instructions
DANGER
Risk of death!
Non-functioning safety devices and emergency stop devices can lead to
serious injuries or death.
• Check the safety devices and emergency stop devices regularly for
functionality.
• Do not alter or remove any safety device or emergency stop devices.
Safety devices
The machine has the following safety devices:
• Main switch
• Operating doors
• Fixed safety guarding
• Contact strip (option)
• Safety screen (option)
• Light curtain (option)
• Laser scanner (option)
• Quick running roll up door (option)
• Safety mat (option)

• Check if safety devices are • At the start of Operator
mounted and securely bolted each shift
• Check functionality • After each
maintenance
or repair
• After each
mold change
Page 305
Emergency stop devices
DANGER
Risk of death!
death.
• Check the emergency stop devices individually and one after the
other for functionality.
• Do not alter or remove any emergency stop devices.
NOTE
The machine can have more emergency stop devices than indicated in
these operating instructions. Information on this can be found in the
“Schematics” documentation.
The machine has the following emergency stop devices:

• Emergency stop switch cabinet
• Emergency stop operator desk
• Additional emergency stop devices

• Check if emergency stop • At the start of Operator
devices are mounted and each shift
securely bolted • After each
• Check functionality maintenance
or repair
• After each
mold change
Page 306
2.5 Checking the hose lines

Safety instructions
DANGER
Risk of death!
Non-functioning hose lines can lead to serious injuries or death.
• Check all hose lines on your machine for safe working condition at
least annually. This check must occur through specialist personnel.
• Prevent the hose lines from coming into contact with substances that
can damage them, e.g. acids, alkalis, solvents.
• Do not use any ozone-generating lights or sparking devices in the
immediate vicinity.
• Do not use used hose lines again.
Possible defects
The hose lines must be replaced if they have the following defects:
• The outer layer of the hose line is damaged up to the lining (abrasions,
cuts or cracks).
• The outer layer is brittle (cracking of the hose material).
• The hose line is deformed or deforms in the pressureless or pressurized
state or during bending, e.g. layer separation, bubble formation, crush-
ing of kinks.
• The hose line is leaking.
• The hose line shifts out of the fitting.
• The fitting is damaged or deformed (strength of the fitting or the hose/
fitting connection is reduced).
• The fitting is corroded and the function and strength is reduced.
• The duration of use has been exceeded (see manufacturing data on the
hose fitting).
Page 307
Duration of use
Hose lines are subject to natural aging, which limits the duration of use.
The operator of the machine must ensure that the hose lines are replaced
within the time periods specified here, even if no safety defects are
detected on the hose line. The duration of use can be defined according
to empirical values in individual cases, deviating from the subsequent
table.
Storage time Duration of use

Hose 4 years
Hose line 2 years 6 years
Replacing the hose lines

When replacing the hose lines, the following must be observed:
• Only use original spare parts. This ensures that the hose lines have the
correct load-bearing capacity and the length and fittings match.
• Adhere to the original installation position. Do not alter any hose rout-
ing or bending radii.
2.6 Cascade control diaphragm accumulator
DANGER
Risk of explosion!
An incorrectly filled or manipulated diaphragm accumulator can lead to
an explosion and cause serious injuries or death.
• Only fill the diaphragm accumulator with nitrogen, class 4.0 purity.
• Work on the diaphragm accumulator may only be performed by spe-
cialist personnel.
• Do not perform any re-finishing on the diaphragm accumulator, such
as welding, soldering or other heat treatment, or mechanical process-
ing.
The diaphragm accumulator on the cascade control is delivered with the
gas precharge pressure assigned for the application.
The permissible operating temperature is between - 10 °C and + 80 °C.
Depending on the application and the frequency of the switching opera-
tions, the gas precharge pressure must be checked cyclically by a special-
ist and refilled to the assigned gas precharge pressure, if necessary.
Page 308
In addition, we recommended checking the accumulator fastening and

pipeline connections for tightness.
NOTE
For the gas precharge pressure assigned to the diaphragm accumulator,
please refer to the accompanying operating instructions for the cascade
control or the sticker on the accumulator housing.
2.7 Checking the electrical installation

Safety instructions
DANGER
of voltage.
• Work on the electrical system may only be performed by qualified
electricians.
Page 309
Continuous connection of the protective conductor system

The protective conductor system • Monthly Qualified electrician
must be subjected to a visual • Immediately
inspection for continuity and perma- after reloca-
nent connection of the protective tion and
conductors. recommis-
sioning
The continuous connection of the • Every 4 years Qualified electrician
protective conductor system must
be checked by feeding in a current
of at least 10 A at 50 Hz from a
PELV source for a period of at least
10 seconds. This test must be per-
formed between the PE terminal
and various points, which are part
of the protective conductor system.
Insulation resistance test

The insulation resistance, which is • Every 4 years Qualified electrician
measured at 500 V direct current
between the power circuit conduc-
tors and the protective conductor
system, may not be less than 1
MOhm.
Page 310
Voltage test

The electrical equipment must with- • Every 4 years Qualified electrician
stand a test voltage, which is
applied between the conductors of
all circuits and the protective con-
ductor system, for a duration of at
least one second. An exception is
equipment that is operated with a
voltage ≤ PELV voltage.
The test voltage must:
• be twice the rated voltage of the
equipment or 1000 V AC,
depending on which is the
greater value.
• be fed at a frequency of 50 Hz
and
• be fed through a transformer
with a minimum rated power of
500 VA.
• Components, which are not
designed for this test, must be
disconnected during the test.
Page 311
Checklists

Check residual current, differential • Daily User
current and ground fault voltage cir-
cuit breakers in non-stationary sys-
tems for proper function by actuat-
ing the test device.
Check the effectiveness of protec- • Monthly Qualified electrician
tive measures with residual current or electrically
and safety devices in non-stationary trained personnel
systems. using suitable mea-
suring and testing
equipment
Check residual current, differential • Every 6 User
current and ground fault voltage cir- months
cuit breakers in stationary systems
for proper function by actuating the
test device.
Check electrical systems and sta- • Annually Qualified electrician
tionary equipment in production
facilities, rooms and special sys-
tems for proper condition (VDE
0100 group 700).
Check electrical systems and sta- • Every 4 years Qualified electrician
tionary equipment for proper condi-
tion.
Page 312
2.8 Settings for a Rexroth proportional card

Overview
Additional details can be found in the document “REX.A.001_Pressure and

flow rate control system_manual_(EN)” in the “Supplier documentation”.
Checking the zero point of the pressure transducer

Switch off hydraulics: A voltage of 0 volt +/-50 mV must be set between
measuring socket 2 and ground (┴), see drawing.
If necessary, synchronize via potentiometer R1.
Checking the quantity set point

• Machine is in manual mode
• Switch on hydraulics
• Clamp is open
• Remove valve coil for “Rapid speed close” and “High pressure close”
• Enter maximum speed for “Rapid speed close” on OP
Page 313
• Actuate two-hand
The same voltage (max. -10.0 volt) must be set between measuring
socket 3 and ground (┴), which is measured on the card holder between
clamping point 14 and 16, see drawing.
Checking and correcting the valve zero point

• All distributing valves closed, no oil may flow
• Preset the swivel angle set point to 10 V (measuring socket 3 = -10 V)
(A function must be selected and the maximum quantity must be set. The
valve for the respective function must be disconnected.)
Set a system pressure of approx. 100 bar by increasing the pressure set
point (read on manometer).
The correct setting of the valve zero point can be measured between mea-
suring socket 1 and 2. At a system pressure of 100 bar, a voltage value
of 0 V +/- 0.05 V should be measured between measuring socket 1 and
2. If the control deviation is greater, this is possible by readjusting poten-
tiometer R6.
Setting the system pressure

Via the “Rapid speed force” parameter, set the system pressure such that,
when two-hand is actuated, 5 volt is measured between measuring socket
1 and ground (┴), see drawing (maximum speed for “Rapid speed close”).
Synchronize via potentiometer R2 such that a system pressure of 50% of
the maximum system pressure for the unit is set (e.g. 157 bar at max. sys-
tem pressure 315 bar).
Checking and correcting the swivel angle measurement (zero)

• Distributing valve(s) closed
• Swivel angle set point 10 V
• Preset pressure set point to 0 V (6 to 10 bar pressure can be set)
• Check if a voltage of 0 V +/- 0.1 V is measured at bushing 4
• In case of deviations, synchronize via potentiometer R8.
Alternative: Switch off enable control at 26c; pump swivels in zero oper-
ation. Synchronize the measured voltage between measuring socket 4 and
ground (┴), see drawing, with potentiometer R8 with potentiometer R8 to
0 + / - 0.1 V.
Page 314
Checking and correcting the swivel angle measurement (100%)

Switch off hydraulics: Wait until the swivel angle of the pump is extended
100 % (approx. 5 minutes). A voltage of 10 volt must be set between
measuring socket 4 and ground (┴), see drawing. If necessary, synchro-
nize via potentiometer R9.
After completing the adjustment work, install valve coils and test the sys-
tem.
Page 315
Page 316
LWB Steinl operating instructions 3. Decommissioning and disposal
3 Decommissioning and disposal
3.1 Decommissioning
Proceed as follows to take the machine out of service:
Step Action
1 Move all axes to initial position.
2 Switch off electric current.
3 Drain oil and dispose in an environmentally friendly manner. See
“Disposal” on page 317
4 Empty temperature unit - dispose tempering medium in an environ-
mentally friendly manner. See “Disposal” on page 317
5 Disconnect the water and air supply.
6 Disconnect the power supply or dismantle the cable.
If the machine is to be set up at a different location, observe the loading

instructions. See “Transport, assembly and commissioning” on page 83
3.2 Disassembly
Disassembly of the machine may only be performed by trained specialist
personnel.
Dismantling must be carried out in accordance with the relevant work and
accident prevention regulations valid at the time of dismantling.
3.3 Disposal
The disposal of the machine and its components must conform with the
relevant local disposal regulations valid at the time of disposal and the
environmental protection laws in force in the country of use.
Page 317
LWB Steinl operating instructions 3. Decommissioning and disposal
Page 318
A
Apprentices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
B
Back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
C
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
D
Design
C-frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
E
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
F
Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
G
Gender Changer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
I
Injection method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
ICM method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Injection system
“EF-E” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
“F” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
“RS” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
”E” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
”EF” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Injection time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
O
Obligations of the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Page 1
P
Powerlink bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
Protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Q
Qualified electricians . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
R
Regulations and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
S
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Safety instructions
danger levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Servo pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Space assignment plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Specialist personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
T
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Two-hand operating panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
U
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
W
Workstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Page 2

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CONTROL flexEVO

LWB Steinl GmbH & Co.KG

Version Change Date

1 ABOUT THIS USER MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.5.10 SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

5.3.4.3 CYCLE TIME ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

5.4.3.1 CASCADE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

5.4.11.6 CORE PULLER CONFIGURATION . . . . . . . . . . . . . . . . . . . . . .258

1 About this user manual

Other applicable documents

1.2 Target audience

1.3 Legal information

Regulations and standards

2.1 Intended use

2.2 Presentation of the safety instructions

Structure of the safety instructions

Hazard symbol Description

Information sign Description

2.3 General safety instructions

Obligations of the operator

2.4 Machine-related safety instructions

2.5 Safety devices

(1) Main switch (6) Light curtain (option)

The safety guarding prevents access to the hazardous area of the

Portable two-hand operating panels

Before commissioning the machine, a functional test (see original instruc-

Pictograms on the machine

Warning of hot surface

Warning of risk of crushing

Warning of hand injuries

Warning of automatic start-up

Use safety glasses

Use safety gloves

2.6 Emergency stop devices

The machine has the following emergency stop devices:

The machine is stopped through the actuation of an emergency stop

2.7 Residual risks

3.1.1 C-frame design

(1) Injection unit (5) Shuttle

3.1.2 Frame design

(1) Injection unit (6) Bottom separator

3.1.3 Column design

(1) Injection unit (6) Bottom separator

3.2 Injection systems

3.2.1 Injection system “E”

(1) Injection unit with adjusting (3) Extruder

(1) Injection unit (3) Mold

3.2.2 Injection system “EF”

(1) Injection unit with adjusting (3) Strip feeding

(1) Injection cylinder (4) Mold

3.2.3 Injection system “EFD”

(1) EF injection unit (3) Adjusting unit

3.2.4 Injection system “EFE”

(1) E injection unit (2) EF injection unit

3.2.5 Injection system “F”

(1) Injection unit (3) Extruder

(1) Injection cylinder (3) Extruder

3.2.6 Injection system “RS”

(1) Injection system “RS” with (3) Heater bands