HyPET Injection Molding Machine

Operator Manual

Original Instructions
 HyPET Injection Molding Machine

Issue: v 2.6 — April 2012

This product manual is intended to provide information for safe operation and/or
maintenance. Husky reserves the right to make changes to products in an effort to
continually improve the product features and/or performance. These changes may result in
different and/or additional safety measures that are communicated to customers through
bulletins as changes occur.
This document contains information which is the exclusive property of Husky Injection
Molding Systems Limited. Except for any rights expressly granted by contract, no further
publication or commercial use may be made of this document, in whole or in part, without
the prior written permission of Husky Injection Molding Systems Limited.
Notwithstanding the foregoing, Husky Injection Molding Systems Limited grants permission
to its customers to reproduce this document for limited internal use only.
Husky® product or service names or logos referenced in these materials are trademarks of
Husky Injection Molding Systems Ltd. and may be used by certain of its affiliated companies
under license.
All third-party trademarks are the property of the respective third-party and may be
protected by applicable copyright, trademark or other intellectual property laws and treaties.
Each such third-party expressly reserves all rights into such intellectual property.
© 2008-2012 Husky Injection Molding Systems. All rights reserved.

ii v 2.6 — April 2012

Operator Manual v 2.6 — April 2012

General Information

Equipment Identification

SUPPLY No.1 LOAD V A Hz System

LARGEST MOTOR A
1 SHORT-CIRCUIT
TOTAL HEAT LOAD A INTERRUPTING CAPACITY kA

SUPPLY No.2 LOAD V A Hz System

LARGEST MOTOR A

SHORT-CIRCUIT
TOTAL HEAT LOAD A kA
INTERRUPTING CAPACITY

SUPPLY No.3 LOAD V A Hz System

LARGEST MOTOR A

SHORT-CIRCUIT
TOTAL HEAT LOAD A kA
INTERRUPTING CAPACITY

2 5
MACHINE MODEL

3 SERIAL NUMBER
CERTIFICATION
MO/YR OF MFG.

4 ELECTRICAL DIAGRAM R
HPN 3213627 HUSKY INJECTION MOLDING SYSTEMS LTD. BOLTON, ONTARIO, CANADA L7E 555

Figure 1 Nameplate Location (Typical)

1. Machine Nameplate 2. Model Number 3. Serial Number 4. Warranty Start Date
5. Certification Symbols

Telephone Support Numbers

North America Toll free 1-800-465-HUSKY (4875)

Europe EC (most countries) 008000 800 4300

Direct and Non-EC + (352) 52115-4300

Asia Toll Free 800-820-1667 or +800-4875-9477

Direct: +86-21-3849-4520

Latin America Brazil +55-11-4589-7200

Mexico +52-5550891160 option 5

For on-site service, contact your nearest Husky Regional Service and Sales office.
For non-emergency questions and issues you may also e-mail Husky at
techsupport@husky.ca.

General Information iii

 v 2.6 — April 2012 HyPET Injection Molding Machine

Ordering Additional Manuals

Additional copies of this manual and other documentation can be purchased through your
nearest Husky Regional Service and Sales office.

iv Ordering Additional Manuals

Operator Manual v 2.6 — April 2012 Table of Contents

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Telephone Support Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Ordering Additional Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Purpose of the Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Restrictions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5.1 Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5.2 Drawings and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.3 Safety Alert Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Machine Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Chapter 2: Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Safety Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.1 Mechanical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.2 High Pressure Leak Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.3 Burn Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.4 High Pressure Explosion Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.5 Electrical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.6 Noise Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.7 Gas, Vapor and Dust Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.8 Slip, Trip or Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.9 Lifting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Safety Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Guards and Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6.1 Performing Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6.2 Removing Locks and Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 Personal Protective Equipment and Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7.1 Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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 v 2.6 — April 2012 HyPET Injection Molding Machine

2.7.2 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.8 Material Safety Data Sheet (MSDS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.9 Materials, Parts and Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.10 Safety Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.10.1 Warning Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.10.2 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.10.3 Product Handling Gate Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.10.4 Safety Gates and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.10.5 Mechanical Safety Device (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.10.6 CEN Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.10.7 Automatic Dump Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.10.8 Manual Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.10.9 Purge Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.10.10 Electrical Cabinet Door Interlocks and Override (UL only) . . . . . . . . . . . . . . . . . . 25

Chapter 3: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Chapter 4: Human Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4.1 Access Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Default User Name and Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Logging On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3.1 Logging On With a Datakey. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3.2 Logging On With a Username and Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4 Logging Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5 General Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5.1 Sidebar Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5.1.1 Accessing the Function Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5.1.2 Standard Sidebar Function Groups and Sidebar Icons . . . . . . . . . . . . . . . . . 35
4.5.1.3 Function Group, Function and Process Value Icons Explained . . . . . . . . . 37
4.5.2 Cycle Mode Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.5.3 Robot Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.5.4 Pump Motor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.5.5 Main Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5.6 Screen Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5.7 Manual Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5.8 Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.5.9 Common Screen Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.5.9.1 Alphanumeric Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.5.9.2 Numeric Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.5.9.3 Common Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.6 Setting the Machine Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.7 Generating On-Demand and Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.7.1 Report Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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4.7.2 Generating On-Demand Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.7.3 Enabling Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.7.4 Viewing Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.7.5 Printing Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.7.5.1 Printing On-Demand Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.7.5.2 Printing Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.7.6 Saving Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.7.6.1 Saving On-Demand Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.7.6.2 Saving Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.8 Graphing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.8.1 Common Graphing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.8.2 Generating a Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.9 Assigning Reasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.10 Enabling/Disabling the Booster Cylinders (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . 57

Chapter 5: Starting the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.1 Inspecting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.2 Powering Up the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.3 Logging On to the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.4 Checking the Safety Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.5 Checking the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.6 Checking and Resetting the Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.7 Warming the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.8 Checking the Machine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.9 Checking the Product Handling Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.10 Checking/Enabling the Mold Related Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.11 Cycling the Machine and Product Handling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.12 Turning On the Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.12.1 Turning on the Machine, Mold and Nozzle Tip Heats (RS80/80). . . . . . . . . . . . . 68
5.12.1.1 Turning on the Machine Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.12.1.2 Turning on the Mold Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.12.1.3 Turning on the Nozzle Tip Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.12.2 Turning on the Machine, Mold and Nozzle Tip Heats (P85/95E85 to
P155/150E155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.12.3 Enabling Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.12.4 Configuring the Temperature Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.12.4.1 Configuring an Individual Temperature Setpoint for a Machine or
Mold Heat Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.12.4.2 Configuring Individual Temperature Setpoints for Nozzle Tip Heat
Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.12.4.3 Configuring a Global Temperature Setpoint for Machine or Mold
Heat Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.12.4.4 Configuring a Global Temperature Setpoint for Nozzle Tip Heat Zones 82

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5.13 Preparing the Process Material Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

5.13.1 Opening the Process Material Feed Manual Shutoff (If Equipped) . . . . . . . . . . 84
5.13.2 Opening the Process Material Feed Auto-Shutoff (If Equipped). . . . . . . . . . . . . 84
5.13.3 Opening the Magnet Drawer (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.14 Purging the Injection Unit Before Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.15 Cleaning the Injection Nozzle Tip, Purge Guard and Stationary Platen. . . . . . . . . . . 86
5.16 Inspecting the Mold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.17 Precharging the Hot Runner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.18 Producing Test Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.19 Setting Up SmartStart (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.20 Setting Up SmartStop (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.20.1 Stopping on a Critical Machine Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.20.2 Stopping After Producing Extra Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.20.3 Stopping After Completing Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.20.4 Stopping on a Specific Day and Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.21 Starting Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.21.1 Starting Production Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.21.2 Starting Production with SmartStart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Chapter 6: Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

6.1 Stopping the Machine in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.2 Pausing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
6.3 Stopping the Machine in a Controlled Manner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
6.3.1 Stopping Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
6.3.2 Shutting Off the Process Material Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
6.3.3 Purging the Injection Unit After Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
6.3.4 Turning Off All the Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
6.3.4.1 Turning Off the Machine, Mold and Nozzle Tip Heats (RS80/80) . . . . . .107
6.3.4.1.1 Turning Off the Machine Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
6.3.4.1.2 Turning Off the Mold Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
6.3.4.1.3 Turning Off the Nozzle Tip Heats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
6.3.4.2 Turning Off the Machine, Mold and Nozzle Tip Heats (P85/95E85 to
P155/150E155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
6.3.5 Cleaning the Injection Nozzle Tip, Purge Guard and Stationary Platen . . . . .110
6.3.6 Emptying the Hopper/Direct Feed Tube (Optional) . . . . . . . . . . . . . . . . . . . . . . .110
6.3.7 Cleaning the Mold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
6.3.8 Turning Off Mold Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
6.3.9 Turning Off the Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
6.3.10 Powering Down the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
6.4 Unexpected Machine Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Chapter 7: Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

7.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

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7.1.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

7.1.2 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
7.1.3 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
7.2 Draining the Air Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
7.3 Cleaning the Nozzle Tip, Stationary Platen and Purge Guard . . . . . . . . . . . . . . . . . . .123
7.4 Checking the Safety Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
7.4.1 Checking the Emergency Stop Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
7.4.2 Checking the Safety Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
7.4.3 Checking the Mechanical Safety Device (If Equipped) . . . . . . . . . . . . . . . . . . . . .127
7.4.4 Checking the Automatic Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
7.4.5 Checking the Purge Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
7.4.6 Checking the CEN Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
7.5 Cleaning the Machine and HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
7.6 Checking the Hydraulic Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
7.7 Purging the Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
7.7.1 Manually Purging the Injection Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
7.7.2 Auto Purging the Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
7.8 Changing the Resin Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

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Operator Manual v 2.6 — April 2012 Introduction

Chapter 1 Introduction

This chapter describes the machine, training opportunities, and the available equipment
manuals.

1.1 Purpose of the Equipment

Husky equipment and systems are designed for injection molding applications only, using
approved materials and operating within design guidelines.
Contact your nearest Husky Regional Service and Sales office if you plan to use a Husky
product for anything other than its intended use.

1.2 Restrictions of Use

Husky injection molding equipment must never be:

• used for any purpose other than that described in Section 1.1, unless otherwise
approved by Husky
• used to extrude metal or food compounds
• operated or serviced by personnel unfamiliar with the inherent risks and necessary
precautions related to injection molding equipment
• operated at temperatures higher than the maximum presumable temperature for
plasticizing
• operated by more than one person

1.3 Unauthorized Modifications

Unauthorized modifications or reconstruction of any Husky injection molding system is

strictly prohibited. Modifications, such as the substitution or removal of components, can be
unsafe and/or void warranty.
Contact your nearest Husky Regional Service and Sales office to discuss modifications or
requirements for Husky systems.

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 v 2.6 — April 2012 HyPET Injection Molding Machine

1.4 Auxiliary Equipment

Husky is only responsible for the interaction of Husky equipment and systems with auxiliary
equipment when Husky is the system integrator. If auxiliary equipment is removed, proper
safeguards must be installed.
For information about integrating non-Husky auxiliary equipment, contact your nearest
Husky Regional Service and Sales office.

1.5 Documentation

Each Husky machine is delivered with a Documentation CD that contains a full set of
manuals, drawings, certificates and other documentation needed by operators and service
technicians. Documentation is also available online through www.husky.ca.
Printed manuals and drawings from the Original Equipment Manufacturers (OEMs) are also
provided with the machine when available.

IMPORTANT!
If a Husky mold is equipped, refer to the separate Documentation CD provided with the mold
for operation, installation and service information.

IMPORTANT!
Keep all CDs and printed documentation in a convenient location for future reference.

1.5.1 Manuals
Husky manuals aid in the safe and proper use of Husky products. Where applicable, the
manuals provide instructions on installation, operation and maintenance.
Personnel should thoroughly review all manuals provided with their Husky equipment prior
to performing any tasks. Proceed with tasks only if all instructions are understood and always
follow applicable workplace safety requirements.
The following manuals are provided with each Husky machine upon delivery:

Site Preparation Manual Describes preparing the site and receiving/handling the machine

Operator Manual Describes operator controls, startup and shutdown procedures,

production controls, and daily maintenance requirements

Service Manual Includes specifications and requirements, installation procedures,

scheduled maintenance procedures, corrective maintenance procedures
and troubleshooting

2 Auxiliary Equipment
Operator Manual v 2.6 — April 2012 Introduction

IMPORTANT!
Some manuals may contain addendums that detail new or updated information. Before
reading a manual, make sure to review all available addendums located at the end of the
manual.

1.5.2 Drawings and Schematics

Each Husky machine is provided with a set of drawings and schematics specific to the
machine. These are used for troubleshooting the machine and ordering spare parts.
NOTE: Each drawing and schematic is specific to the machine it is provided with.

1.5.3 Safety Alert Conventions

Safety alerts highlight hazardous conditions that may arise during installation, operation or
maintenance and describe methods for avoiding personal injury and/or property damage.
Depending on the severity of the hazard, safety alerts start with one of the following signal
words: Danger, Warning or Caution.

DANGER!
The DANGER safety alert indicates an imminently hazardous situation that, if not
avoided, will result in death or serious injury.

WARNING!
The WARNING safety alert indicates a potentially hazardous situation that, if not
avoided, could result in death or serious injury.

CAUTION!
The CAUTION safety alert indicates a potentially hazardous situation that, if not
avoided, could result in property damage.

Other non-safety related alert types used in the manuals highlight important information
needed by the user to install, operate or maintain the machine properly. They may also, in
some cases, describe best practices, offer an expanded explanation, or reference a related
section in the manual.
Non-safety related alerts start with one of the following signal words: Note, Important, or
Reminder.
NOTE: The NOTE alert is used to add information to a subject that does not fit within the
general flow of the document.

Drawings and Schematics 3

 v 2.6 — April 2012 HyPET Injection Molding Machine

IMPORTANT!
The IMPORTANT alert is used to highlight important steps, conditions, or considerations
related to the subject.

1.6 Training

All designated operators and maintenance personnel must be fully trained before using or
servicing Husky injection molding systems.
If training is required, visit www.husky.ca or contact your nearest Husky Regional Service and
Sales office to learn more about Husky’s training solutions.

IMPORTANT!
It is the obligation of the employer to properly train and instruct all personnel in safe
methods of operation and maintenance. Manuals and other reference material, which have
been prepared by Husky for the operation and maintenance of Husky equipment, do not in
any way absolve the employer from fulfilling these obligations and Husky disclaims liability
for injury to personnel which is attributable to the employer's failure to do so.

1.7 Machine Layout

Throughout this manual and other documentation provided with the machine, references
will be made to specific areas of the machine. The illustration below describes these areas
and the standard terminology used to reference them.

4 Training
Operator Manual v 2.6 — April 2012 Introduction

5 6

Figure 1-1 Machine Orientation (Typical)

1. Clamp End 2. Non-Operator Side 3. Injection End 4. Operator Side 5. Clamp Unit and
Product Handling Area 6. Injection Unit 7. Operator Work Area

Machine Layout 5
 v 2.6 — April 2012 HyPET Injection Molding Machine

6 Machine Layout
Operator Manual v 2.6 — April 2012 Safety Summary

Chapter 2 Safety Summary

This chapter describes the general requirements and conditions for safe operation of the
machine.

IMPORTANT!
Personnel must read, understand and follow all safety precautions.

IMPORTANT!
Personnel must follow applicable industry and regulatory safety requirements for safe
installation, operation and maintenance of equipment.

2.1 Qualified Personnel

Only fully trained and qualified personnel should be permitted to operate equipment.
Qualified personnel must have demonstrated skills and knowledge related to injection
molding equipment, as well as training to recognize potential hazards.

2.2 Safety Guidelines

Personnel operating, installing, maintaining or servicing Husky equipment must adhere to

safe working practices that are in compliance with the following guidelines:
• Use an appropriate ladder or platform to access areas of the machine.
• Lockout and tag electrical, pneumatic and hydraulic energy sources before servicing the
machine or entering the mold area.
• Depressurize the hydraulic system using the manual dump valve before servicing any
hydraulic component.
• Do not climb over Husky equipment while the machine is in operation.
• Do not operate the machine unless all guards are in place.
• Do not operate the machine if a safety interlock is bypassed, modified or damaged.
• Do not operate the machine if any component or system is missing or damaged.

Qualified Personnel 7
 v 2.6 — April 2012 HyPET Injection Molding Machine

• Do not operate the machine if scheduled preventive maintenance has not been
performed.
• Do not use a magnetic platen without approval from Husky and the magnetic platen
supplier/manufacturer.

2.3 Safety Hazards

Some common safety hazards associated with injection molding equipment are:
• Mechanical (pinching, shearing, crushing)
• High Pressure Leak
• Burn
• Explosion
• Electrical
• Noise
• Gas, Vapor and Dust Emissions
• Slip, Trip or Fall
• Lifting

2.3.1 Mechanical Hazards

• Worn Hoses and Safety Restraints
Regularly inspect and replace all flexible hose assemblies and restraints.
• Cooling Water Hoses
Cooling water hoses degrade over time and need to be replaced on a yearly basis.
Cooling water hoses routed in the vicinity of the barrel are exposed to high
temperatures that shorten their useful life and can require more frequent replacement.
Degraded hoses become brittle and can break or separate from the fitting when
manipulated. To minimize the risk of failure, inspect the hoses regularly and replace as
required.
Make sure to wait until the machine has cooled down before servicing cooling water
hoses.
• Injection and Clamp Units
Hydraulic circuits in injection and clamp units contain high pressure accumulators.
Before servicing hydraulic systems, lock out and tag the machine to discharge all stored
energy. When servicing hydraulic systems, read the equipment manuals and refer to
hydraulic schematics for additional details.

8 Safety Hazards
Operator Manual v 2.6 — April 2012 Safety Summary

2.3.2 High Pressure Leak Hazards

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

WARNING!
High pressure spray hazard – risk of death or serious injury. High pressure hydraulic oil
spray can penetrate human tissue and cause extensive injuries. Lock out and tag the
machine before servicing any hydraulic component.

• Skin Puncture Injuries

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

2.3.3 Burn Hazards

• Hot Surfaces
The mold area, auxiliary mold equipment, and injection unit heating elements have
numerous high temperature surfaces. At normal operating temperatures, contact with
these surfaces will cause severe skin burns. These areas are clearly marked with safety
signs. Wear personal protective equipment when working in these areas.
• Molten Material
Never touch process material purged or otherwise flowing from the nozzle, mold, hot
runner or feed throat area. Molten material can appear cool on the surface, but remain
very hot on the inside. Wear personal protective equipment when handling purged
material.

2.3.4 High Pressure Explosion Hazards

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

2.3.5 Electrical Hazards

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

High Pressure Leak Hazards 9

 v 2.6 — April 2012 HyPET Injection Molding Machine

2.3.6 Noise Hazards

When the machine is at idle, the average noise level in the operator’s work area is 85 dB(A),
as measured according to DIN 45 635-T1-Class 2.
The peak noise level will vary depending on processing conditions.

WARNING!
All personnel in the machine area must wear appropriate hearing protection if noise
emission levels exceed 85 dB(A). Prolonged exposure to excessive noise levels can
cause hearing loss.
Make sure noise levels are in compliance with all applicable local regulations.

2.3.7 Gas, Vapor and Dust Emissions

Certain processed materials release harmful gas, vapors or dust. Install an exhaust system
according to local codes.

2.3.8 Slip, Trip or Fall Hazards

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

2.3.9 Lifting Hazards

When lifting equipment, use suitable lifting devices, proper balancing techniques and
designated lifting points. Refer to the installation details for handling and lifting instructions.
Do not exceed the rated capacity of the lifting equipment.

2.4 Safety Signs

Safety signs clearly mark potentially hazardous areas in or around equipment. For the safety
of personnel involved in equipment installation, operation and maintenance, use the
following guidelines:
• Verify that all signs are in the proper locations. Refer to the drawing package for details.
• Do not alter signs.
• Keep signs clean and visible.
• Order replacement signs when necessary. Refer to the drawing package for part
numbers.

10 Noise Hazards