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HPS-III-Heißkanalsystem_Servicehinweise_Außerbetriebnahme_BA_V-2-0_EN

7.7 Instructions for service and repair

•

Only genuine spare parts must be used.

•

When ordering spare parts please use the specifications given in the spare-parts lists.

•

In case of service requests please always have the serial number, order number and type of the used hot runner system

ready.

•

Service

www.ewikon.com in the "Contact" menue, submenue "Sales network", "Your contact at EWIKON", "Service department"

E-Mail: [email protected]

Instructions for service and repair

Summary of Contents for L2X

Page 1: ...L2X Drop in hot runner system Operating manual Valid for L2X Drop in systems L2X Drop in valve gate systems Version 2 0...

Page 2: ......

Page 3: ...nd safety measures 12 2 7 Electrical equipment 14 2 8 Spare and wear parts auxiliary and operating materials 14 2 9 Limitation of liability 14 2 10 Warranty terms 15 2 11 Standards and directives 15 3...

Page 4: ...ith 2 control zones 49 5 6 6 Wiring of 6 drop hot runner systems manifold with 2 control zones 50 5 6 7 Wiring of 8 drop hot runner systems manifold with 2 control zones 51 5 6 8 Wiring of 8 drop hot...

Page 5: ...6 2 Electric drive unit deinstallation and exchange of valve pins 76 7 7 Instructions for service and repair 77 8 Decommissioning 78 8 1 Safety instructions 78 8 2 Instructions for disposal 79 9 Tigh...

Page 6: ...6 HPS III L2X Hei kanalsystem_Inhalt_BA_V 2 0_EN...

Page 7: ...n com 1 3 Formal information on the operating manual Person in charge of documentation Henning Becker Item number not specified Version 2 0 Printing date 21 04 2020 Language German original operating...

Page 8: ...Manifold height top pressure pad H3 Manifold height pressure pad with centering top pressure pad H4 Manifold height top pressure pad bottom pressure pad P Height of nozzle retainer frame plate B Heig...

Page 9: ...and maintenance Safety instructions must be followed to prevent accidents personal injury or material damage Warnings Protect against possible personal injury and material damage when followed Classif...

Page 10: ...AUTION indicates a potentially hazardous situation which if not avoided will result in minor injury or material damage NOTE indicates useful additional information and tips to promote trouble free ope...

Page 11: ...0 bar The resin used has to be processed according to the guidelines of the material manufacturer Use of the HPS III hot runner system Use the HPS III exclusively for its intended use and in perfect c...

Page 12: ...company operating the system must comply with the statutory obligations on occupational safety In addition to the safety instructions of this manual the safety accident prevention and environment prot...

Page 13: ...ulations Injection moulding machine and hot run ner systems have to be grounded Risk of physical injuries by suspended heavy loads Only trained staff is authorised to operate lifting devices and forkl...

Page 14: ...Maintenance work must be carried out by qualified and trained staff or maintenance staff Never use the HPS III hot runner system with faulty or inoperable electrical connections In case of energy supp...

Page 15: ...ccordance with our general terms and conditions of sale and payment as well as the extended warranty conditions These are available on our homepage www ewikon com The statutory provisions prevailing a...

Page 16: ...ity size approx Unit Voltage 230 V Frequency 50 Hz Chart 4 Electrical data only valid within the EU 3 3 Hydraulic pneumatic specifications drive units Description Quantity size approx Unit Maximum hyd...

Page 17: ...can considerably enhance this resistance 3 5 Type plate Picture 1 Type plate The system type plate is to be displayed prominently on the operator side of the mould Hot halves are delivered with the t...

Page 18: ...ould half ejector side Pos 1 2 Fixed mould half nozzle side Pos 1 3 Hot half nozzle side without contour plate Pos 2 Locating ring Pos 3 Sprue bush Pos 4 Hot runner manifold Pos 5 Hot runner nozzles P...

Page 19: ...e injection phase with a continued usually pressu re regulated melt transport into the cavity compare picture 3 After the moulded part has solidified to such an extent that no new material can enter t...

Page 20: ...fting devices Exercise greatest caution when transporting the HPS III hot runner system Handle with care Pendular motion while lifting the hot runner systems with a lifting device e g overhead crane D...

Page 21: ...8 with metal tag acc to DIN 685 The octagonal red metal tags should show information about load capacities for usual modes of assembly see PPicture 7 Webbing slings see PPicture 8 and round slings se...

Page 22: ...must be checked in the following order 1 How heavy is the load The weight of single components systems or hot halves is indicated on the EWIKON note of delivery net weight without packaging If this in...

Page 23: ...least 2 attachment points are necessary to lift manifolds or L2X systems as otherwise it will not be possible to lift the load in a directed way This is often absolutely necessary when carrying out in...

Page 24: ...der reduced load capacity of attachment swivels For the installation work described below the attachment swivels are loaded at changing inclination angles Depending on the manufacturer and design of t...

Page 25: ...o upright vertical position z362 10 100 load capacity 50 load capacity Putting hot runner assemblies hot halves mould plates manifolds or L2X systems from upright vertical into lying horizontal positi...

Page 26: ...ring installation Injuries caused by flying parts or whipping hoses Injuries to eyes caused by escaping pressurised liquids NOTE Pay attention to system characteristics The work steps described just s...

Page 27: ...t conditions during installation Make sure that the hot runner components are protected from direct humidity during assembly Dimensional check for details please also see chapter 5 4 Checks before ins...

Page 28: ...sibly resulting in leakage during operation When screwing in nozzle tips gaps between sealing surfaces may be possible this may also lead to leakage during operation Unless otherwise indicated only us...

Page 29: ...g to DIN 685 Clamping device Maintenance of HPS III MHR nozzles Cordless screwdriver Exchange of valve pin seal of valve gate systems Copper drift Exchange of HPS III MH thermocouples Crimping tool At...

Page 30: ...l changes Preferably side cutter for electronics Snap ring pliers Deinstallation of snap rings of drive units Soft face hammer Maintenance work Spacer bolt for swivel eye bolt Lifting and moving of ho...

Page 31: ...Ciric A Molyduval GmbH Collapsible tube 100g Operation temperature up to 1200 C 17363 Fully synthetic High performance grease Lubrication of components in injection moulds such as ejectors sliders an...

Page 32: ...ing torques compare chapter 9 Tightening torques must be adhered to Standard part Valid standard Invalid old standard Hexagon socket head cap screw DIN EN ISO 4762 ISO 4762 DIN 912 Hexagon socket head...

Page 33: ...Actual value of the gap dimension S Thickness of the clamping plate If pressure pads are installed in the clamping plate they also have to be measured and considered when calculating the gap dimensio...

Page 34: ...kanalsystem_Vorspann Pr fma e L2X_BA_V 2 0_EN 5 4 3 Dimensions to be checked for a L2X Drop in hot runner system Picture 22 Example Dimensions to be checked for a L2X Drop in hot runner system z349 0...

Page 35: ...Pos 53 Contour plate BR Installation space for EWIKON parts H1 Manifold height H2 Manifold height top pressure pad H3 Manifold height pressure pad with centering top pressure pad H4 Manifold height to...

Page 36: ...36 HPS III L2X Hei kanalsystem_Montage_BA_V 2 0_EN...

Page 37: ...valve gate version includes the complete piping for the drive units as well as a connector block for the supply lines Connector block for valve gate supply lines Electrical connector box Read operatin...

Page 38: ...kg loading capacity for 0 see chapter 5 3 1 Tools and operating materials Distance bolts with appropriate length item number see EWIKON L2X catalogue may be used in exceptional cases only Please pay...

Page 39: ...hten with matching torque See chapter 9 2 Tightening torques for manifold screw connections and retaining screws Before installation apply high temperature installation paste see chapter 5 3 1 Tools a...

Page 40: ...torque See chapter 9 Tightening torques 5 For valve gate systems connect the supply lines to the connector block 6 In order to clearly identify the hot runner system attach the type plate included in...

Page 41: ...ere injuries due to live components The HPS III hot runner system the single tip the hot half and the mould have to be disconnected from the voltage source during installation Insufficient protective...

Page 42: ...e connection cables All connecting cables have to secured in such a way that they do not get pinched when they are installed in the mould use cable binders and or covering plates for the recesses Adhe...

Page 43: ...used Please make sure that the voltage applied corresponds to this specification The heaters are connected to the plug according to the arrangement given in the wiring diagram of the respec tive hot r...

Page 44: ...s respectively A sufficient protective earthing of the hot runner system must be ensured Furthermore thermocouples type J Fe CuNi are used The hot runner controller used must be designed to work with...

Page 45: ...by line from top left to bottom right according to the scheme shown below If the manifold has multiple heaters the same numbering scheme is applied The power and thermo collective plugs are numbered...

Page 46: ...ndard system configurations are shown on the following pages z218 09 Cable colour black white type J Option green white type K Cable colour green yellow Cable colour brown L Cable colour brown L Cable...

Page 47: ...Z Plug 230 V 10 pin No X Contact L N Plug thermo 10 pin No X Contact Z 01 X 1 1 H 01 1 6 X 1 2 T 01 1 6 Z 02 X 1 1 M 01 2 7 X 1 2 T 02 2 7 Z 03 X 1 1 CN 01 3 8 X 1 2 T 03 3 8 X 1 2 5 4 3 2 1 10 9 8 7...

Page 48: ...V Thermo Control zone Z Plug 230 V 10 pin No X Contact L N Plug thermo 10 pin No X Contact Z 01 X 1 1 H 01 1 6 X 1 2 T 01 1 6 Z 02 X 1 1 H 02 2 7 X 1 2 T 02 2 7 Z 03 X 1 1 M 01 3 8 X 1 2 T 03 3 8 Z 0...

Page 49: ...r L Phase conductor N Neutral conductor male female 230 V Thermo Control zone Z Plug 230 V 16 pin No X Contact L N Plug thermo 16 pin No X Contact Z 01 X 1 1 H 01 1 9 X 1 2 T 01 1 9 Z 02 X 1 1 H 02 2...

Page 50: ...4 3 2 1 16 15 14 13 12 11 10 9 24 23 22 21 20 19 18 17 32 31 30 29 28 27 26 25 N 20 19 18 17 16 15 14 13 L 8 7 6 5 4 3 2 1 21 9 22 10 23 11 24 12 X 1 1 230 V Thermo Control zone Z Plug 230 V 24 pin No...

Page 51: ...21 20 19 18 17 32 31 30 29 28 27 26 25 N 20 19 18 17 16 15 14 13 L 8 7 6 5 4 3 2 1 21 9 22 10 23 11 24 12 X 1 1 230 V Thermo Control zone Z Plug 230 V 24 pin No X Contact L N Plug thermo 32 pin No X...

Page 52: ...X 1 1 H 03 3 15 X 1 2 T 03 3 11 Z 04 X 1 1 H 04 4 16 X 1 2 T 04 4 12 Z 05 X 1 1 H 05 5 17 X 1 2 T 05 5 13 Z 06 X 1 1 H 06 6 18 X 1 2 T 06 6 14 Z 07 X 1 1 H 07 7 19 X 1 2 T 07 7 15 Z 08 X 1 1 H 08 8 20...

Page 53: ...re can be automatically carried out by using the diagnosis function To be checked in heated condition operating temperature Leak tightness and function of drive units hydraulic fluid pressurised air b...

Page 54: ...e injuries due to live components The operator must ensure that during startup of hot runner single tips or hot runner systems all electrical system components have been wired to to the protective con...

Page 55: ...er to avoid damage to hot runner components Each hot runner system is individually designed for the material to be processed Therefore the specified operating temperatures must be observed The tempera...

Page 56: ...o the mould during cycle Connect power cable thermocouple collective cable and ground cable Check if the thermocouple and power connections are allocated correctly by heating up each zone separately f...

Page 57: ...0 C for approx 10 minutes sequential start compound heating mode of the controller Set processing temperature and heat system for 3 5 minutes sequential start compound heating mode so that the preload...

Page 58: ...a valve gate system is used 6 Remaining material residues at the nozzle tip can be removed by using a wire brush soft wire see chapter 5 3 1 Tools and operating materials 7 Switch off the hot runner L...

Page 59: ...rops 1000 liters of compressed air Hydraulic drive To prevent thermal decomposition of the hydraulic oil the drive unit is equipped with a direct screwed on drive unit or indirect e g cooling channels...

Page 60: ...erial in the system Adhere to the specified heat up times When processing sensitive materials e g POM purge with a neutral material natural material not coloured e g polypropylene before shutting down...

Page 61: ...ouple indicates wrong tempera ture value Wrong type of thermocouple allocated in the controller Thermocouple indicates value zero Thermocouple reverse poled check thermocouple circuit Burns on part in...

Page 62: ...eased wear on single components of the HPS III hot runner system Maintenance work must be carried out according to the maintenance schedule completely and within the indicated time intervals Specific...

Page 63: ...to sealing surfaces during installation Threads and sealing surfaces must be checked on cleanliness and free movement Clean sealing surfaces and threads by using suitable cleaning tools best directly...

Page 64: ...ber example pos 1 7 pos 1 8 or pos 1 9 Two piece nozzle tips Two piece nozzle tips consist of the nozzle tip pos 1 3 and another component like for example a nosepiece pos 1 4 screw on gate bushes pos...

Page 65: ...e tube with thread G and fits P Pos 1 2 Protective tube Pos 1 3 Nozzle tip Pos 1 4 Mouthpiece Pos 1 5 Screw on gate bush Pos 1 6 Extended screw on gate bush Pos 1 7 Nozzle tip with sealing ring one pi...

Page 66: ...or the thermocouple may be teared off Attention When HPS III S nozzles with flow channel 3 and 4 5 mm for standard installation are used the installation of a dowel pin is not possible Thus the nozzl...

Page 67: ...os 1 9 thoroughly by using a brass wire brush see chapter 5 3 1 Tools and operating materials If necessary use a hot air gun with a maxi mum temperature of 460 C 860 F 5 Check all surfaces for cleanli...

Page 68: ...ve gate nozzle tip the valve pin must be moved to position open 5 Unscrew and deinstall the nozzle tip again and check the transfer of the blue The surface T between nozzle tip pos 1 9 and pressure tu...

Page 69: ...4 thoroughly by using a brass wire brush see chapter 5 3 1 Tools and operating materials If necessary use a hot air gun The temperature must not exceed 400 C 752 F 6 Check all surfaces for cleanliness...

Page 70: ...The surfaces T between nozzle tip pos 1 3 and pressure tube pos 1 1 as well as between nosepiece pos 1 4 and nozzle tip pos 1 3 must show an even ring shaped transfer of the blue 7 Clean all surfaces...

Page 71: ...ge source during installation HAZARD Sharp edges and heavy components Cut injuries to body and extremities mainly to the hands Crushing of fingers or hand Control of live components before installatio...

Page 72: ...tighten the protec tive tube If necessary apply WD 40 penetrating oil see chapter 5 3 1 Tools and operating materials or heat moderately from the outside Picture 57 Disassemble the thermocouple 3 The...

Page 73: ...ure 61 Installation of the new thermocouple 5 Bend the thermocouple carefully and wind it along the heater At the same time slide the protective tube over the pressure tube to fix the already position...

Page 74: ...nents The hot runner system and the mould have to be disconnected from the voltage source during installation HAZARD Pressurised systems During installation all hydraulic or pneumatic supply lines mus...

Page 75: ...load only Tilting or bending caused by lateral load must be avoided Slowly push the valve pin through the manifold and the valve pin guide in the tip insert of the nozzle until the valve pin retainer...

Page 76: ...pos 17 carefully out the valve pin retainer 6 For installation of the new valve pin and the drive unit please see chapter 5 5 11 Electric drive unit 7 6 2 Electric drive unit deinstallation and exchan...

Page 77: ...pare parts please use the specifications given in the spare parts lists In case of service requests please always have the serial number order number and type of the used hot runner system ready Servi...

Page 78: ...ner components and the mould have to be disconnected from the voltage source during deins tallation WARNING PPE Hot surfaces hot material plastic melt Body burns by hot surfaces Let the HPS III hot ru...

Page 79: ...osal were agreed with EWIKON the disassembled components have to be recycled after deinstallation Scrap metallic materials Recycle plastic components and plastic waste from the production Dispose the...

Page 80: ...sation of the minimum yield strength Rp0 2 The values given are valid for socket head screws with property class 8 8 10 9 and 12 9 with internal hexagon and standard metric thread complying with DIN E...

Page 81: ...2 12 9 15 4 11 4 19 3 14 2 M7 1 0 6 8 8 14 8 10 9 18 7 13 8 10 9 21 7 16 0 27 5 20 3 12 9 25 4 18 7 32 2 23 7 M8 1 3 6 8 8 21 6 15 9 27 3 20 1 10 9 31 8 23 5 40 1 29 6 12 9 37 2 27 4 46 9 34 6 M10 1 5...

Page 82: ...ng torques for manifold screw connections and retaining screws Thread Tightening torque Lubricated high temperature installation paste see chapter 5 3 1 Tools and operating materials MA Nm MA ft lb M4...

Page 83: ...063 95093 95123 95182 HPSIII L2X NV NV95063 NV95093 NV95123 NV95182 HPSIII MV 95 3 95 4 93 3 Tightening torque Nm 3 5 3 5 13 30 50 100 Tightening torque ft lb 2 6 2 6 9 6 22 1 36 9 73 8 Chart 15 Tight...

Page 84: ...see chapter 5 3 1 Tools and operating materials MA Nm MA ft lb 6 mm Part No 95063 M18x1 5 22 50 36 88 9 mm Part No 95093 M22x1 5 27 100 73 76 12 mm Part No 95123 M30x1 5 32 200 147 51 18 mm Part No 9...

Page 85: ...g torques for drive units For drive unit Item number see drawing provided by EWIKON For item number screw in housing cover Thread Tightening torque Lubricated high temperature installation paste see c...

Page 86: ...9 8 Tightening torques for valve pin seals 9 8 1 Tightening torques for one piece valve pin seals Valve pin mm Item number Thread valve pin retainer Tightening torque Thread lubricated high temperatur...

Page 87: ...lation paste see chapter 5 3 1 Tools and operating materials Item number Thread MA Nm MA ft lb 1 7 22550 SV01 22570 22571 M9x0 75 7 5 2 22550 SV02 2 2 22552 SV01 22570 22571 M9x0 75 7 5 2 22552 SV02 3...

Page 88: ...EWIKON Hei kanalsysteme GmbH Siegener Stra e 35 35066 Frankenberg Tel 49 6451 501 0 Fax 49 6451 501 202 E Mail info ewikon com www ewikon com Technical information subject to alteration...

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