Initial Startup & Functional Check
Pre-Power Checks
Before applying power for the first time:
| System | Check |
|---|---|
| Electrical | Main breaker OFF. All sub-breakers OFF. E-stop pressed. Control transformer primary voltage matches supply. |
| Grounding | Ground connection verified (≤ 4Ω). All panels bonded. |
| Cooling water | Water supply ON, flow verified, no leaks. |
| Hydraulic | Oil level at 3/4 of sight glass. All ball valves OPEN. Tank breather installed. |
| Mechanical | No shipping braces remaining. All guards installed. Tie bar nuts at correct position. Injection unit at full retract. |
| Safety | All E-stop buttons wired and functional. Safety door switches connected. |
| Mold | If mold installed: verify it fits within tie bar space, weight within platen capacity, center height matches nozzle. |
First Power-On Sequence
Close main breaker
Energize the machine. The controller will start up (60–90 seconds). Observe the HMI for startup diagnostics.
Check control voltage
Measure 24 VDC supply at the controller power input. It must be 23.5–25.0 VDC.
Close servo breaker
Energize the servo drive. Observe the drive display for normal status (typically “rdy” or “RUN”). No fault codes should appear.
Reset E-stop
Release all E-stop buttons and close all safety doors. The safety circuit should reset.
Close heater breaker
Energize heater circuits. Start barrel heating. Set temperature to 140–160°C for drying (if material is loaded) or to 50°C for warm-up only.
Start hydraulic pump (hydraulic machines only)
Press the pump start button. Listen for abnormal noise. Monitor oil pressure:
- Low-pressure idle: 5–15 bar
- After warm-up, high-pressure standby: system pressure (typically 140–175 bar)
On first startup, if the hydraulic pump motor phase sequence is reversed, the pump will rotate backward. This can damage the pump within seconds. Verify phase sequence BEFORE starting the pump or listen for abnormal sound and stop immediately if the pump does not build pressure.
Functional Testing
Clamp Unit
| Test | Procedure | Acceptance |
|---|---|---|
| Open/close at low speed | Set speed to 20%, full stroke open and close | Smooth motion, no binding or unusual noise |
| Clamp force build | Increase to 50% rated force | Pressure holds steady, all tie bars load evenly |
| Mold safety / low-pressure protection | With mold 500 mm open, close at low speed | System detects no resistance (with no mold on small machines, may need to adjust threshold) |
Injection Unit
| Test | Procedure | Acceptance |
|---|---|---|
| Carriage forward/retract | Full stroke at low speed | Smooth, no hesitation |
| Injection (no material) | Screw forward at 10% speed for max 3 seconds | Smooth motion |
| Screw rotation (no material) | Rotate at 20 RPM for 5 seconds | Smooth rotation, no grinding |
Ejector Unit
| Test | Procedure | Acceptance |
|---|---|---|
| Ejector advance/retreat | Full stroke forward and back, repeat 5 times | Smooth motion, correct position feedback |
| Ejector stroke setting | Adjust stroke to 80% and cycle | Stops at correct position |
Temperature Control
| Test | Procedure | Acceptance |
|---|---|---|
| All zones heating | Set all zones to 180°C | All zones reach setpoint within 30 minutes |
| Thermocouple check | Compare HMI reading with independent thermocouple | All zones within ±5°C |
| SSR operation | Check each zone current draw | Each zone draws expected current |
Safety System
| Test | Procedure | Acceptance |
|---|---|---|
| Emergency stop (each button) | Press E-stop during clamp close | Immediate stop, servo de-energize, pump stop |
| Safety door (front) | Open during automatic cycle | Cycle stops immediately |
| Safety door (rear) | Open during automatic cycle | Cycle stops immediately |
| Low-pressure mold protection | Place a 3 mm thick soft material (cardboard) on mold face, close mold | Mold stops and reverses |
| Light curtain (if equipped) | Break light curtain during clamp close | Immediate stop |
First Cycle
- Set temperature to process parameters for the material being used.
- Allow 20–30 minutes soak time after reaching setpoint.
- Load material into the hopper.
- Purge 5–10 shots of material to stabilize temperature.
- Set injection parameters to conservative values (mid-range speed and pressure).
- Execute one complete semi-automatic cycle.
- Inspect the part — check for short shots, flash, sticking, or other defects.
- Adjust parameters gradually (one change at a time) until the part is acceptable.
- Run 20 continuous cycles and check shot weight repeatability.
During the first 100 cycles, pay close attention to oil temperature, vibration, and unusual sounds. This is the machine’s “break-in” period. Small adjustments to leveling, lubrication, or parameters are normal.