Machine Installation and Commissioning Step-by-Step

Prepare the machine foundation before the SPV5 machine arrives. The foundation must support the static machine weight (15-28 tons depending on model) plus dynamic forces generated during the 3.5-6 second high-speed injection cycles. Pour a reinforced concrete foundation pad with minimum 300mm thickness, 35 MPa compressive strength, and steel reinforcement mesh. The foundation dimensions should exceed the machine footprint by 200mm on each side: for the HMD 380M8-SPV (7.5x1.9m machine), the foundation should be 7.9x2.3m. Level the foundation surface to within 0.3mm per meter using a precision leveling compound. Install M24 or M30 anchor bolts at the factory-specified positions before concrete pouring—HWAMDA provides a foundation drawing with exact bolt locations for each model. Allow the concrete to cure for minimum 21 days before machine placement. Verify floor loading capacity: the point load under each machine foot is 3-7 tons, requiring a floor rated for minimum 5 tons per square meter. Prepare utility connections within 3 meters of the machine: 3-phase electrical supply (380V/50Hz or 400V/50Hz, 200-350A depending on model), cooling water supply and return (DN32-DN50, 3-5 bar), compressed air (DN15, 6-8 bar), and floor drain for cooling water overflow.

Electrical installation must be performed by a licensed electrician familiar with industrial machinery. Connect the 3-phase power supply to the machine's main disconnect switch using cable sized for the machine's rated current: HMD 270M8-SPV requires 200A (95mm2 cable), HMD 380M8-SPV requires 250A (120mm2 cable), and HMD 600M8-SPV requires 350A (185mm2 cable). Verify the supply voltage at the main disconnect: 380V plus or minus 10% between each phase pair, with phase-to-phase balance within 2%. Connect the protective earth conductor to the machine frame ground stud using a green/yellow cable of equal cross-section to the phase conductors. Measure earth ground resistance: must be below 4 ohms per IEC 60204-1. Before first power-up, verify that all electrical cabinet connections are tight by performing a torque check on all terminal blocks. Confirm the phase rotation is correct (R-S-T sequence) using a phase rotation meter—incorrect rotation will cause the hydraulic pump to run backward, which can damage the pump within seconds. Power up the main disconnect and verify the INOVA controller boots to the home screen. Check that all heater zones display the correct resistance on the INOVA diagnostics screen. Perform an insulation resistance test on the pump motors (minimum 1 megaohm at 500V DC). Activate the hydraulic pump for 2 seconds only to confirm rotation direction by observing the pressure gauge response.

Fill the hydraulic tank with ISO VG 46 anti-wear hydraulic oil through the tank-top fill port using a filter cart equipped with a 3-micron filter element. For the HMD 380M8-SPV with a 480-liter tank, filling takes approximately 45 minutes at a typical filter cart flow rate of 15 liters per minute. Fill to the upper sight glass mark with all cylinders retracted. Charge the accumulator bladders with dry nitrogen to the specified pre-charge pressure (typically 60-70% of system pressure, or 10.5-12.25 MPa for the 17.5 MPa system). Never use compressed air or oxygen for accumulator charging. Run the hydraulic pump at idle (low pressure, approximately 3-5 MPa) for 30 minutes to circulate oil through all circuits and purge air from the system. During this period, manually cycle all machine movements at slow speed: mold open/close, injection forward/back, screw rotation, ejector forward/back. Air trapped in cylinders causes jerky motion and audible popping. Bleed air from the highest points in the hydraulic circuit using the bleed screws on the injection cylinder and clamping cylinder. After 30 minutes of circulation, check the return line filter differential pressure indicator—replace the filter if the indicator has tripped. Check the oil level again (it will have dropped as oil fills cylinders and manifolds) and top up to the mark.

Begin process optimization by molding 50-100 setup shots at conservative parameters (80% of target injection speed, 110% of target cooling time). Gradually increase injection speed in 5% increments while inspecting parts for flash, short shots, and weld line strength. Use the INOVA controller's cavity pressure monitoring (if equipped) or visual part inspection to identify the optimal switchover point from velocity control to pressure control—this occurs when the cavity is 95-98% filled. Fine-tune holding pressure in 2 MPa increments to achieve target part weight within plus or minus 2%. Optimize cooling time by reducing in 0.2-second increments until the ejected part shows acceptable temperature (below 60°C surface temperature measured with IR thermometer) and no deformation. Document the final optimized parameters as the production recipe in the INOVA controller. Run a 2-hour trial production at full speed to verify process stability—monitor part weight, dimensions, and visual quality every 15 minutes. Calculate the process capability index (Cpk) for part weight: target Cpk above 1.33 for production release. After successful trial production, provide operator training covering startup procedure, parameter adjustment within approved ranges, quality inspection methods, and basic troubleshooting. The complete commissioning takes 7-14 days depending on mold complexity and operator experience level. HWAMDA engineers provide on-site commissioning support for $350-500 per day.