4/16 Energy connections

4.1.2 External supply

WARNING!
The fusing of the external supply is matter of the customer! Under all
circumstances the local regulations are applicable!

Installed load, see chapter 2 "Technical data"

Cooling unit

Terminals for
driving motor

Connection for
machine cables
DDDDDDDD

Terminals for
GEB-1 0906.01
external supply

4.1.3 Driving motor

Installed load, see chapter 2 ,Technical data"

Note
Cables for the driving motor and the external supply must be provided by the
customer

©Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil 14-9906-000-AA 105

 Energy connections 5/16

4.1.4 Laying cables

CAUTION!
Wrongly laid cables will lead to faults which can be eliminated only by difficult
and elaborate fault finding!

Cable ducts are to be provided for:

• control cables of the DCM 1)

• control cables of the peripheral units 2)

• power supply for the control system and motors 3)

2) 3)

'···· ··' ,.......!

The control cables of the DCM and those of the peripheral units can be laid together
when inside the ducts, a space is left between these groups.

min 30 em

min 5 em

GEB_13940

14-9906-000-AA105 © Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil

 6/ 16 Energy connections

Terminal boxes on the DCM

- I-

Injection unit
F' !=
J
~
~
ri>
r-
~

i3

Fixed platen A
~ ,rr/f=j~ '- ;.,1
~ ~ ~
I

'

Stress platen

[
t;=
v

Electric motor driven Electric motor driven

safety gate safety gate

Driving unit

© Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil 14-9906-000-AA 105

 Energy connections 7/ 16

Machine cables

The signal cables from the control cabinet to the machine are part of the scope of
delivery.

The machine cables are installed directly from the control cabinet to the corresponding
terminal boxes. This should be considered when making the foundation to ensure a
neat installation of the cables.

Note
Following symbol is used to mark the feed-through points of the machine cables
on the foundation drawing:

When the machine is shipped the machine cables are connected to the various
terminal boxes at the machine at one end and are equipped with an attachment
flange and Metrimate plug at the other end.

<33313950

Terminal box Attachment flange Metrimate plug

( 100 x 50 x 5 mm) (56 x 28 x 28 mm)

Note
Plan the dimensions of the cable ducts or pipes in such a way to enable the
installation of the cables with the plugs attached. Otherwise substantial extra
costs will have to be considered.

14-9906-000-AA 105 © Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil

 8/16 Energy connections

©Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil 14-9906-000-AA 105

 Energy connections 9/16

4.2 Water cooling

4.2.1 Important directions

Service water

CAUTION!
Service water becomes contaminated by substances that are harmful to the
environment and health , such as hydraulic fluids, spraying agents etc. !

Application:

• for cooling of hydraulic fluid

• for cooling of die and shot unit

• for spraying the die

Measures to be taken:

• Use a closed-circuit service water system with water treatment unit.

• Service water only to be drained after passing a treatment installation.

Regulations: observe the local regulations.

4.2.2 Cooling water systems

The DCM can be equipt with the following cooling water systems:

• cooling of the hydraulic fluid

• cooling of the die on the moving platen

• cooling of the die on the fixed platen Option

• cooling of the shot unit

14-9906-000-AA105 © Copyright 1999 Buhler Druckguss AG , CH-9240 Uzwil

 10/16 Energy connections

4.2.3 Types of cooling water

Following types of water can be used for cooling:

• well water

• fresh water

• industrial service water

4.2.4 Quality of cooling water

• The total contents of sulphate (S0" 4), nitrate (N0'3 ), chloride (CI') must not
exceed 70 mg/1.

• The total hardness degree must not exceed 6 dH 0 • 1 dH 0 (German degree of

hardness) is equivalent to 1.25 eHo (English hardness degrees) or 1.79 fHo
(French hardness degrees).

Note
If the cooling water does not have the required quality we recommend to install
a water treatment plant in the cooling system!

4.2.5 Cooling water filters

We recomend to include a central filter into the cooling water system.

Note
Buhler-cooling water systems are equipt with filters standardly

4.2.6 Shut-off devices

All energy connections must have the appropriate shut-off devices which can
interrupted from the DCA or DCI.

4.2.7 Peripheral units

The connected loads of the peripheral units can be taken from the relevant instruction
manuals.

©Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil 14-9906-000-AA 105

 Energy connections 11 /16

4.2.8 Cooling of the hydraulik fluid

Hydraulik tank

/(
GEB-13396-00

Partial flow pump

Heat exchanger

Low pressure filter

Technical data
• Operating pressure: .. .... ............... ............. ........ .......... ........ ... 3 - 10 bar
• Temperature supply line: .. .................. .......... ........ .................. 5 - 30 oc
• Consumption, see chapter 2 ,Technical data"

Heat exchanger

Solenoid valve
Filter

Outlet G 1"

GES -13405

lntlet G 1"

14-9906-000-AA 105 ©Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil

 12/16 Energy connections

4.2.9 Cooling of the die and injection unit

Distributor bloc Distributor bloc

moving platen fixed platen

Flow regulator Connection plate Connection plate

moving platen fixed paten

Note
The connection to the inlet and outlet of the flow regulator must be done by the
customer and is not part of the delivery.

Technical data

• Operating pressure: .......... ................... ........ ... ............. ... .... ... 3 - 10 bar

• Temperature supply line: ........................................................ 5 - 30 oc

Consumption

• Since the wall thicknesses of the casting vary it is practically impossible to

determine the cooling water consumption for the dies accurately.

• According to a rule of the thumb the die and the shot unit require about four
times the amount of cooling water of the hydraulics-cooling system.

• Flow ratio of one cooling circuit = 0 ... 201/min.

• Flow ratio of the flow regulator with a water pressure of 5 bar= 2001/min.

© Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil 14-9906-000-AA105

 Energy connections 13/ 16

Flow regulator

The flow regulator controls the independent cooling systems:

• die cooling of the moving platen (Wmob =max. 18 cooling circuits)

• die cooling of the fixed platen (Wfix =max. 15 cooling circuits)
• cooling of the injection unit (WI =max. 3 cooling circuits)

_B OIOIOb) IOIOIO 3_ ¢::I

,--, ~ ,.-- ~
T T T T
QD VV\u)

~ IOIO OIOIO ~
~ to E
--r
.(r:l
Die cooling
'n
0 ==:-- r'--' ~ moving platen
'I IJ t. I
I
I IT
f!in
Q~ w
QD"""
lii

Outlet G 2"
0
~ I'
-- ~
Die cooling
fixed platen
Inlet G 2"

~
0
9_A~ }=~
H [] [
a[[;~
I.
/
~~
I'
t] ..... Clll =[.'=? :X
Cooling casting
~ ~/
------- outfit

Solenoid valve
/ ~ Hose assembly
inside 0 25 mm
Hose assembly
inside 0 13 mm

Note
For the connection between the flow regulator and the machine the delivery
contains:
Hose inside 0 13 mm 50 m
Hose inside 0 25mm 15 m

14-9906-000-AA105 © Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil

 14/ 16 Energy connections

Connecting plate moving platen

Hose assembly Hose assembly

inside 0 13 mm inside 0 25 mm

G 3/8" G 1"
GEB13412

013mm 025mm t
Distributer bloc moving platen

~
@
~ Hose coupling

@ HASCO
Coupling = ZS0/13
~ Nippel = Z8 11 / 13/R3/8

.A.A.A..

~
G)@
@@)
@@ p 013mm
G)@
@@)
@@ p
0 0
GEB 13413

©Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil 14-9906-000-AA 105

 Energy connections 15/16

Connecting plate fixed platen

Metal braided
hose

CEB13414

t t
Distributor bloc fixed platen

t
14-9906-000-AA 105 © Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil
 16/ 16 Energy connections

4.3 Enclosures
Ch ecklist

Foundation plan

© Copyright 1999 BOhler Druckg uss AG, CH-9240 Uzwil 14-9906-000-AA 105
 Checklist page 1/ 1

Check list for preparation of power connections

Check following points according to check list: OK= V'

• Is the location for the control unit suitable [J

• Is the required quantity of energy available [J

• Are safety systems included in the external supply [J

• Is the safety system of the external supply selective [J

• Are cable ducts and lead-throughs available [J

• The water quality meets the requirements [J

• Cleaning and disposal of service water is ensured [J

• The required supply of cooling water is available [J

• The required supply of compressed air is available [J

• The necessary shut-off devices are available [J

• The necessary material has been provided [J

• The preparations for peripheral units have been made [J

Notes

Date: .......................... .. . Signature: ............................................. .

G EB-17002-en 18.04.96 a Buhler AG

 Operating materials 1/ 16

5 Operating materials HFC

Contents
5.1 Instructions for application and maintenance of flame-resistant
hydraulic fluids Type HFC ................................ .. .................................... 3
5.1.1 Introduction .......................................... ..................................... 3
5.1 .2 Instructions on the use of HFC fluids ........................................ 3
5.1.3 Operating conditions ................. ................................................ 5
5.1.4 Requirements for HFC fluids ... ......... ................................ .. ....... 6
5.1 .5 Instructions for maintenance .. ..... .............................................. 7
5.1 .6 Changing types of fluids ............... ................... .......................... 8
5.2 Instructions on application and maintenance of
lubricating oil for central lubricating systems ......................................... 9
5.2.1 Manufacturers of oil for central lubrication ......... ................. ...... 9
5.2.2 Operating conditions ...... .... ......... ............................................ 11
5.2.3 Application of other products ................................................... 11
5.2.4 Directions on maintenance ..... .. ............................................... 11
5 .3 Lubricants for plunger lubricating unit .................. .. .... .... .. ....... .. .. ...... ... 12
5.4 Lubricating grease for Buhler die casting machines ............................ 13
5.5 Lubricating grease for electric motors ....... .. .................. .. ..................... 14
5.6 Nitrogen N2 •.••••••••••••••••••••••••• .• •••••••• ••• •• • •• ••••••• •••• •..•••• •• ••• •••••• •• •••• • •••••••.•• 15
5.7 Die spraying agents ...................... .. ..................................................... 16
5.8 Disposal of operating materials .. ............. .............. ............................... 16

15-001 0-000-AAOO ©Copyri ght 1999 BOhler Druckguss AG, CH-9240 Uzwil
 2/16 Operating materials

Software
Page Maker 6.5

©Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil 15-001 0-000-AAOO

 Operating materials 3/16

5.1 Instructions for application and maintenance of

flame-resistant hydraulic fluids Type HFC

5.1.1 Introduction
In order to take into account the requirements for accident-free and safe die-casting
plants we recommend the use of flame-resistant hydraulic fluids of the HFC type.

HFC fluids are safety fluids on water-glycol basis.

The proportion of water of 35 to 50% in HFC flu ids avoids quick ignition of residues
of fluid at hot areas (e.g. at the molten metal). Spreading of the flames from these
areas is prevented.

Liquid emitting under pressure from a leak (jet) is not ignited by flames .

The hydraulic system of every Buhler die-casting machine is designed in such a

manner that, when using high quality HFC fluids as are normally available on the
market and which are conform to the current Report of Luxembourg, fail-safe operation
is granted (provided correct maintenance as described under Paragraph 5.1.6 is
executed).

5.1.2 Instructions on the use of HFC fluids

When selecting your HFC fluid make sure that a product is used which

a) grants extensively low-risk operation of Buhler die-casting plants and

b) based upon good experience, has been applied in die-casting plants more than
once previously

Furthermore, we recommend to negotiate a guarantee agreement with the suppliers

of the fluid . The guarantee should embrace faultless operation of all hydraul ic
components of the system, such as for example, pumps, solenoid valves etc ..

15-0010-000-AAOO © Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil

 4/16 Operating materials

Viscosity-temperature diagram

mm 2/s (eSt) 20 50 55 6)
~

GEB-13260-00
2000
1500
1000
800
700
600
"" "' ''

500
"
"
-
400

'"
-
300
1) 250
200 -
'
150

100
=
-
-
-
-
- ""'' 9)
"'
-
9) 90 - ~
80 -
70
60
-
~
50 ~
~
45
40
35
' ~

30
7)
'--
25
=
-
-
"
~

2) 20
18
16
---

-
-
' 1\.
5)
~

'"''--
14
13
12
11
3)
10

-20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 oc

ooF 100°F
4) .. 8) Temp.

© Copyright 1999 Buhler Druckguss AG , CH-9240 Uzwil 15-0010-000-AAOO

 Operating materials 5/16

5.1.3 Operating conditions

Legend to the viscosity-temperature diagram

In the viscosity-temperature diagram the viscosity-temperature line is entered for an

HFC fluid which meets the requirements as given under Par. 5.1.4.

By means of this line the different temperature points can be determined. The critical
viscosity limits 20 eSt and 250 eSt are pre-determined by the used components in
the hydraulic system.
1) Absolute maximum permissible viscosity
2) Absolute minimum permissible viscosity
3) Minimal cold-starting temperature based upon the maximum permissible
viscosity (250 eSt)
4) Liquid must be pre-heated (external heating system)
5) Theoretical maximum liquid temperature based upon the minimum permissible
viscosity (20 eSt)
6) Maximum permissible liquid temperature of the HFC fluids
7) Optimal range of the operating viscosity
8) Optimal range of the operating temperature
9) Machine ready for operation (approx. 80 eSt - 100 eSt) .

Optimal operating conditions

In order to obtain optimal operating conditions the correct operating viscosity or

operating temperature has to be maintained; factors of influence are:
• intake temperature of the cooling water
• quantity of cooling water
• ambient temperature of the machine
• average performance level (number of cycles) of the machine

All temperature points are permanently programmed in the machine control unit, for
the ISO viscosity class ISO VG 46.

Note
In case due to local conditions (high ambient temperatures, poor cooling
conditions etc.), other hydraulic fluids, for example of the ISO viscosity class
VG 68, are used, the temperature points are programmed accordingly.

Changing from one viscosity class to another must not be done without previously
consulting our customer service.

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 6/ 16 Operating materials

Optimal efficiency

In order to obtain the optimal efficiency of the hydraulic elements (pumps, hydraulic
motors etc.) the installation should be operated within the most favourable operating
viscosity of 32 - 47 eSt. The absolute maximum and maximally permissible minimum
viscosity must not be exceeded.

Minimal cold-starting temperature

If the temperature of the flu id drops below the minimum cold-starting value, the
hydraulic fluid has to be heated up to the laid down cold-starting temperature by
means of an external heating system . When heating up w ith an external heating
system only such is to be used as is designed specifically for the purpose (hence, no
immersion heater, heating rods, etc.) .

5.1.4 Requirements for HFC fluids

The hydraulic fluid not only has the purpose of transferring pressure in hydraulic
systems, it also acts as a lubricant and anti-corrosive agent. Furthermore, the hydraulic
fluid must fulfil a high safety function regarding fire resistance.

From this ensue the requirements listed below:

• hydraulic fluid sprayed under pressure must not ignite.
• the minimum water content should be 35%.
• the density at 15°C must be under 1,1 kg/dm3.
• the pour-point temperature must lie under the lowest application temperature.
Usually the pour-point temperature is :-:; - 25°C.
• The shear stability (measured ace. to DIN 51382) must be sufficient. At+ 20°C
and + 50°C the viscosity may not drop more than 15%. Moreover, the water
content may not decrease more than 8% and the pH-value not more than one
unit.
• The pH value should be at the maximum 10 and at the minimum 9. When the
pH value exceeds 10 it becomes difficult to handle the fluid because by then it
is already quite aggressive to the skin. When the pH value drops below 8.8
there is a great risk that the anti-corrosive effect, particularly in the vapour
phase, is drastically reduced .
• The tendency for foaming should not be higher than with mineral oil.
• The air release property should be as big as possible. The limit value of 20
minutes at 50°C at the maximum, should not be exceeded. Measured according
to DIN 51381.
• A high ageing stability and good wearing properties are a precondition also at
pressures above 140 bar.
The wearing resistance is measured with the Vickers pump test, or if only a
small amount of fluid is available with the VKA test (400 N, 1 h).

©Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil 15-0010-000-AAOO

 Operating materials 7116

• The product should have no, or only an extremely low toxicity and should be
free of nitrite and morpholine.
• The hydraulic fluid should have good anti-corrosive properties in the liquid as
well as in the vapour phase. No significant corrosive marks should appear. This
related in particular to: -steel I cadmium- copper I zinc- aluminium I zinc and
-steel I aluminium. The change of weight is measured at defined test plates.
• The swelling behaviour and changing of hardness of various sealing materials
should be extremely low and be proved.
• It should be able to mix hydraulic fluids of the HFC type from different
manufacturers, when they are fresh and have not yet been used. (which,
however, is not to be recommended) .
It should be possible to mix used and unused HFC-type fluids of the same
manufacturer.
• Good biological degradability should be proven.

5.1.5 Instructions for maintenance

The hydraulic fluid in the tank of the machine must never sink below the marked
minimum level. The level of the fluid should be checked at regular intervals, also on
machines with automatic level control; in particular every time after servicing and
repairs.

HFC fluids usually have a long service life when the instructions of the manufacturer
on application and maintenance are adhered to. Most manufacturers of HFC fluids
have their own testing service, which however, is not granted in all countries. Make
sure these service facilities are available in your country.

Note
We recommend to make an agreement with your suppliers on regular testing
and maintenance of the hydraulic fluid.

At regular intervals (about every 6 months, under unfavourable operating conditions

possibly at shorter intervals, according to manufacturer, independent of the number
of operating hours) a sample of approx. 1 litre should be taken and tested in the
laboratories of the manufacturers. The results of the test and eventual measures to
be taken are laid down in a test report.

The sample is tested upon :

• water content
• pH value
• density
• viscosity
• anti-corrosive behaviour
• solids and liquids contamination, etc.
15-001 0-000-AAOO ©Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil
 8/16 Operating materials

Every time when the fluid is changed (the same product) the tank has to be cleaned.

Note
In the event of a replacement of liquid because of inadmissible changes (e.g.
drop of pH-value) the tank has to be cleaned and the machine additionally
flushed. Contact the supplier of the liquid for the correct procedure.

With all maintenance work strictly observe cleanliness.

Carry out maintenance of the filters according to instructions; maintenance instructions

are given in Manual 2 of the DCM documentation.

In the event of breakdown the filter elements must be replaced immediately (see
Manual 2, Chapter "Maintenance").

5.1.6 Changing types of fluids

Different types of fluid must not be mixed together, for example mineral oil with HFC
fluid, or HFC fluids of different manufacturers, or HFD fluid (synthetic fluids on
phosphate-ester basis) with HFC fluids etc. Contamination with different types of
fluids within the hydraulic system can lead to serious break-downs and damage.

Note
When changing to a different type of fluid such as from mineral oil to HFC fluid
etc., request the necessary instructions on the procedure from your suppliers
and follow these carefully. As a principle, in such cases the entire hydraulic
system has to be rinsed out.

© Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil 15-001 0-000-AAOO

 Operating materials 9/16
...
5.2 Instructions on application and maintenance of
lubricating oil for central lubricating systems

5.2.1 Manufacturers of oil for central lubrication

Manufacturer Product Viskosity mm2/s (eSt) at

2ooc 40°C

ARAL ARAL DEGOL BG 150 500 150

ARAL ARAL DEGOL BG 220 850 220

ASEOL ASEOL MIPRESS 11-311 600 150

ASEOL ASEOL MIPRESS 11-318 800 220

BP ENERGOL GR-XP 250 490 140

BP ENERGOL GR-XP 220 830 210

ESSO SPARTAN EP 150 520 140

ESSO SPARTAN EP 220 800 210

Kluber LAMORA 150 540 150

Kluber LAMORA 220 820 220

MOBIL MOBILGEAR 629 510 143

MOBIL MOBILGEAR 630 800 209

SHELL OMALA 150 535 150

('"'~ ~SHEL_S) OMALA 220 820 220

VALVOLINE VALVOLINE EPG-150 500 148

VALVOLINE VALVOLINE EPG-220 800 223

GEB 15000-en

15-001 0-000-AAOO ©Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil

 10/ 16 Operating materials

Viscosity-temperature diagram

mm 2/s (eSt)

GEB-13180-00
1) 2000
\ I\. ~
1500 ~
A)'- ~)
~
1000
800 '
"' "" "'
700
4) 600
500

'
-
400
'
'' ' '
-
300
250 ...
200
150
=
=
-
""' " '

"'
--

' ''"
- I\.
100 - ~
90 -

9)
80
70
- ." \ " ~-
-
r\. '\
60
1\
50
45
40
35
~

'"'
30
=
25 =
-
---
20
18 -
16
-
14
13
12
11
10 ~

I
-20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 oc
ooF 100°F
I
J
Temp.
2)
3)
..1 I
6)
7) I

Manufacturer Product Viskosity mm2/s (eSt) at

20°C 40°C

A)ARAL ARAL DEGOL BG 150 500 150

B) ARAL ARAL DEGOL BG 220 850 220

GEB 15000-en

© Copyright 1999 Buhler Druckguss AG , CH-9240 Uzwil 15-001 0-000-AAOO

 Operating materials 11 / 16

5.2.2 Operating conditions

Legend to viscosity-temperature diagram

The viscosity-temperature line of a CGLP lubricating oil (DIN 51502) which meets
the requirements as stated under Par. 6.2.3, example A), is shown in the viscosity-
temperature diagram.

By means of this line the operating-temperature range and the minimum permissible
starting temperature can be determined.
1) Absolute maximum permissible viscosity
2) Minimum permissible starting temperature at 2000 eSt for VG68
3) Maximum operating viscosity
4) Minimum operating viscosity
5) Operating-temperature range for VG68

5.2.3 Application of other products

If, due to local conditions, priority is given to other products the central lubricating oil
must fulfil following requirements:
• CGLP lubricating oil, viscosity class ISO-VG68 for an operating temperature
range of approx .. 2°C to 65°C.
• Compatibility with metal: lubricating oils and their decomposition products may
not cause corrosion of metal (e.g. of steel, bronze, aluminium).
• The lubricating oil must not contain any substances which attack the usual
sealing materials.

5.2.4 Directions on maintenance

The level of the lubricating oil in the tank must never drop below the minimum.

Check the level of the lubricating oil at regular intervals, also when the tank is fitted
with automatic level control.

Particularly every time after servicing and repairs check the level of the lubricating
oil.

Before initial starting up and then once every year clean the lubricating oil tank.

Always when servicing observe utmost cleanliness.

Note
Always use the same brand of lubricating oil with the same quality. Lubricating
oils of different brands and quality must not be mixed.

15-001 0-000-AAOO © Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil