Mold-Masters Dura PLUS User Manual Download Page 3

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Dura+ User Manual

Contents

Section 1 - Introduction ...................................................1-1

1.1 Intended Use ......................................................................................................1-1

1.2 Documentation ...................................................................................................1-1

1.3 Release Details ..................................................................................................1-1

1.4 Warranty .............................................................................................................1-1

1.5 Returned Goods Policy .......................................................................................1-2

1.6 Movement or Resale of Mold-Masters Products or Systems .............................1-2

1.7 Copyright ............................................................................................................1-2

1.8 Units of Measure and Conversion Factors .........................................................1-3

Section 2 - Global Support ..............................................2-1

2.1 Corporate Offices

................................................................................................2-1

2.2 International Representatives .............................................................................2-2

Section 3 - Safety..............................................................3-1

3.1 Safety Hazards ...................................................................................................3-2

3.2 Operational Hazards ...........................................................................................3-5

3.3 General Safety Symbols .....................................................................................3-7

3.4 Wiring Check ......................................................................................................3-8

3.5 Lockout Safety ....................................................................................................3-9

3.5.1 Electrical Lockout .....................................................................................3-10

3.5.2 Energy Forms and Lockout Guidelines....................................................3-11

3.6 Disposal ............................................................................................................3-12

3.7 Dura Plus Safety Hazards ................................................................................3-13

Section 4 - Preparation ....................................................4-1

4.1 Tools Required ....................................................................................................4-1

4.2 Screw Lengths ....................................................................................................4-2

4.3 Unpacking ...........................................................................................................4-2

4.4 Cleaning .............................................................................................................4-3

Section 5 - Assembly .......................................................5-1

5.1 Typical Dura Plus System ...................................................................................5-1

5.2 Pre-Assembly Checks of Gate Seals and Nozzle ..............................................5-2

5.3 Assembly of Gate Seals to Nozzle .....................................................................5-3

5.4 Thermocouple Installation for 01 Nozzle ............................................................5-4

5.4.1 Nozzle Flange Assembly ...........................................................................5-6

5.5 Sub-Manifold Assembly for Drop-In System .......................................................5-9

5.5.1 Install Valve Disk (Valve Disk Design) .......................................................5-9

5.5.2 Pneumatic System Installation .................................................................5-12

5.5.3 Hydraulic System Installation ...................................................................5-15

5.6 Actuator Assembly ............................................................................................5-20

5.6.1 Install Pneumatic Actuator Assembly .......................................................5-20

5.6.2 Install Hydraulic Actuator Assembly .........................................................5-24

5.7 Install Sub-Manifold Heater Plates (Option) .....................................................5-30

Summary of Contents for Dura PLUS

Page 1: ...version 2 Dura User Manual Original Instructions User Manual...

Page 2: ......

Page 3: ...ical Lockout 3 10 3 5 2 Energy Forms and Lockout Guidelines 3 11 3 6 Disposal 3 12 3 7 Dura Plus Safety Hazards 3 13 Section 4 Preparation 4 1 4 1 Tools Required 4 1 4 2 Screw Lengths 4 2 4 3 Unpackin...

Page 4: ...tuator 6 1 6 1 Introduction 6 1 6 2 SeVG Plus Actuator Models 6 1 6 3 SeVG Plus Actuator in Dura Plus Systems 6 1 6 4 SeVG Plus Model Options 6 2 6 4 1 SE40 20 Actuator Non Cooled 6 2 6 4 2 SE40 20C A...

Page 5: ...Dowel 9 2 9 2 4 Install Bridge Assembly 9 3 9 2 5 Final Installation Steps 9 4 Section 10 System Startup and Shutdown 10 1 10 1 Pre Startup 10 1 10 2 Startup 10 2 10 2 1 Standard Hot Runner Systems 10...

Page 7: ...s of 3 phase supplies They should know how to take appropriate measures to avoid any danger from electrical supplies 1 2 Documentation This manual is part of the documentation package for your order a...

Page 8: ...at any time without giving notice 1 6 Movement or Resale of Mold Masters Products or Systems This documentation is intended for use in the country of destination for which the product or system was p...

Page 9: ...tely after the S I units Table 1 2 Units of Measure and Conversion Factors Unit Abbreviation Conversion value bar Bar 14 5 psi in Inch 25 4 mm kg Kilogram 2 205 lb kPa Kilopascal 0 145 psi lb Pound 0...

Page 10: ...INDIAN HEADQUARTERS INDIA Milacron India PVT Ltd Mold Masters Div 3B Gandhiji Salai Nallampalayam Rathinapuri Post Coimbatore T N 641027 tel 91 422 423 4888 fax 91 422 423 4800 india moldmasters com U...

Page 11: ...nd Sweden Israel ASAF Industries Ltd 29 Habanai Street PO Box 5598 Holon 58154 Israel tel 972 3 5581290 fax 972 3 5581293 sales asaf com Russia System LLC Prkt Marshala Zhukova 4 123308 Moscow Russia...

Page 12: ...standards It is the responsibility of the employer to Properly train and instruct its personnel in the safe operation of equipment including the use of all the safety devices Provide its personnel wit...

Page 13: ...n reading the Table 3 1 Safety Hazards on page 3 3 Figure 3 1 Injection molding machine hazard areas Top view with guards removed Front view with guards removed 2 10 5 3 Top View with Guards Removed 2...

Page 14: ...ng shearing hazards and or impact hazards caused by Forward movement of the plasticizing and or injection unit including nozzle Movements of parts of the power operated nozzle shutoff and their drives...

Page 15: ...rial released from through the mold Hoses See Figure 3 1 area 9 Whipping action caused by hose assembly failure Possible release of fluid under pressure that can cause injury Thermal hazards associate...

Page 16: ...ing Use proper personal protective equipment All operators should wear personal protective equipment such as face shields and use heat resistant gloves when working around the feed inlet purging the m...

Page 17: ...rns to someone touching it The barrel barrel head nozzle heater bands and mold components are hot surfaces which could result in burns Keep flammable liquids or dust away from the hot surfaces as they...

Page 18: ...vere burns Discharge pressure before disconnecting water lines Warning High Pressure Accumulator Sudden release of high pressure gas or oil can cause death or serious injury Discharge all gas and hydr...

Page 19: ...hermocouple connections ensure that the power cables are never connected to the thermocouple connectors and vice versa For mixed power and thermocouple connections ensure that the power and thermocoup...

Page 20: ...Ensure proper grounding of all electrical components before performing any maintenance to avoid potential risk of electrical shock Often power sources are inadvertently turned on or valves are opened...

Page 21: ...es of energy that could create a hazard while working on the equipment must also be de energized and appropriately locked out This can include gravity compressed air hydraulics steam and other pressur...

Page 22: ...chains built in lockout devices or lockout attachments and tag valves Bleed off excess air If pressure cannot be relieved block any possible movement of machinery Kinetic Energy Energy of a moving ob...

Page 23: ...disposed of is free from fluids In the case of hydraulic needle valve systems drain the oil from the lines and cylinders and dispose it in an environmentally responsible manner 3 The electrical compo...

Page 24: ...y cooled Purgings may appear solid but may still be hot and cause serious injury The equipment supplied is subjected to high injection pressures and high temperatures Ensure that extreme caution is ob...

Page 25: ...ed to adequately support the weight of the plate s Failure to do so can cause a serious injury All maintenance on Mold Masters products should be performed by properly trained personnel based on local...

Page 26: ...stem using correctly installed J type thermocouples connected to a reliable temperature controller with soft start protection Avoid running the system for long periods on manual control Use caution wh...

Page 27: ...d alcohol for removal of rust inhibitors Calibrated torque wrench for consistent screw pressure throughout the system Pliers for general assembly work Circlip pliers to remove and install circlip in v...

Page 28: ...ht Failure to do so can cause a serious injury Make sure the machine has been locked out and tagged out in accordance to the machines documented procedures Failure to do so may lead to serious injury...

Page 29: ...mponents must be free of the rust inhibitor applied at the factory 1 Remove protective covers from all gate seals 2 Clean all surfaces and dowel holes ensuring that no debris burrs shavings dust dirt...

Page 30: ...ctions at the end of the section will be helpful for assembling the system See Section 9 System Installation for instructions on installing your Dura Plus Hot Runner into an existing manifold plate sy...

Page 31: ...ent material leakage from the gate seal CAUTION 1 Apply die spotting blue compound to the gate seal and liner if used to ensure a proper contact on sealing surface 2 Torque the gate seal to specified...

Page 32: ...Gate Seals to Nozzle 1 Apply anti seize compound to all threaded interfaces 2 Ensure all sealing surfaces are clean and dry 3 Install gate seal and liner 4 Torque to specified values Refer to the Gene...

Page 33: ...the nozzle For 2 mm thermocouples we suggest using a 2 1 mm drill in a pin vise 2 Insert the thermocouple through the flange bore 3 Manually bend the thermocouple tip against your thumb to approximat...

Page 34: ...de the bore This is especially important when thermocouples are assembled from the front 5 Install the terminal end retaining clip Check that the thermocouple is seated in the recess of the terminal e...

Page 35: ...erature to the torque value specified to prevent material leakage CAUTION 1 Apply anti seize compound to the ball plunger threads 2 Install the ball plunger into the flange with a 2 5 mm 0 10 in hex w...

Page 36: ...lange Torque nozzles to the following values For Hecto Nozzles torque value is 135Nm 100 ft lb For Mega Nozzles torque value is 183Nm 135 ft lb Remember to re torque at process temperature when system...

Page 37: ...Reserved Nozzle Flange Assembly continued 6 Locate the nozzle assembly to the manifold by lining up the two ball plungers to the dimples on manifold bottom surface Make sure the balls sit completely i...

Page 38: ...anifold Assembly for Drop In System 5 5 1 Install Valve Disk Valve Disk Design 1 Apply die spotting blue compound to the valve disk stem Apply die spotting blue compound here 2 Line up the valve disk...

Page 39: ...ue compound is continuous on valve disk stem or manifold contact surfaces 6 Clean die spotting blue compound from all components 7 Apply anti seize compound to screws reinstall the valve disk stem and...

Page 40: ...All Rights Reserved Dura User Manual 9 Install screws in a crossing pattern to nozzle through the manifold NOTE Ensure nozzle terminal end is in the direction noted on the General Assembly drawing In...

Page 41: ...e spacers on top of the manifold or valve disk flange 2 Locate the pneumatic cylinder cooling plate onto the spacers Make sure to align the fitting ports in the appropriate direction 3 Apply anti seiz...

Page 42: ...Torque screws in a crossing pattern gradually increasing torque to the specified value Refer to the General Assembly drawing for torque values 5 Place the cylinder housing onto the cylinder cooling p...

Page 43: ...hts Reserved 7 Apply anti seize compound to the piston top 8 Install the piston top into the piston NOTE Use soft vise jaws with cutout for piston body to prevent damage to the part 9 Install the pist...

Page 44: ...top 12 Apply anti seize compound to the screws and torque the screws in a crossing pattern gradually increasing torque to the specified value Refer to the General Assembly drawing for torque values 5...

Page 45: ...of the spacers Make sure to align the fitting ports in the appropriate direction 3 Apply anti seize compound to the screws 4 Torque screws in a crossing pattern gradually increasing torque to the spec...

Page 46: ...ves 1 Place sub manifold on nozzle with heater sleeves install the screws and torque to the specified value Refer to the General Assembly drawing for torque values NOTE Heater plates are not shown in...

Page 47: ...sk with Nozzle with Heater Sleeves continued 4 Line up the valve disk stem into the manifold hole Install and confirm sealing contact 5 Install valve disk flange on top of valve disk stem 6 Install th...

Page 48: ...fold contact surfaces Verify die spotting blue continuity 8 Clean die spotting blue compound from all components 9 Apply anti seize compound to the screws and reinstall the valve disk stem and valve d...

Page 49: ...der body 4 Piston bottom 5 Piston seal 6 Piston top 7 Rod seal 8 Rod wiper seal 9 Cooling plate 10 Valve pin anti rotation collar 11 Support spacer 12 Valve pin Pneumatic cylinder components Pneumatic...

Page 50: ...l Rights Reserved Dura User Manual Install Pneumatic Actuator Assembly continued 1 Install the rod seal 2 pieces 2 Use the piston to push the seal into position 3 Install the rod wiper seal 2 pieces 4...

Page 51: ...ts Reserved Install Pneumatic Actuator Assembly continued 5 Install the piston seals 2 pieces 6 Install the piston top 7 Tighten the piston top NOTE Use soft vise jaws with cutout for piston body to p...

Page 52: ...anual Install Pneumatic Actuator Assembly continued 9 Install the cylinder top seal 10 Assemble the cylinder top to the cylinder body 11 Apply anti seize compound to the screws 12 Install the cylinder...

Page 53: ...assembly components Hydraulic cylinder components 1 7 12 6 2 4 3 8 10 9 Hydraulic cylinder section view 1 2 7 3 12 5 8 9 10 11 13 4 6 1 Cylinder top 2 Cylinder body 3 Piston bottom 4 Piston top 5 Valv...

Page 54: ...ted All Rights Reserved Dura User Manual Install Hydraulic Actuator Assembly continued 1 Place the two pieces that make the rod seal into the pocket of the cylinder body 2 Press the seals into the hou...

Page 55: ...All Rights Reserved Install Hydraulic Actuator Assembly continued 4 Place pipe sealant on threads of the water circuit pipe plug Install the water circuit pipe plug 5 Install the piston seals 3 piece...

Page 56: ...SSEMBLY 2020 Mold Masters 2007 Limited All Rights Reserved Dura User Manual Install Hydraulic Actuator Assembly continued 7 Install the piston seal 8 Install the split retainer ring 9 Install the valv...

Page 57: ...All Rights Reserved Install Hydraulic Actuator Assembly continued 10 Install the spring pack 11 Install the piston top 12 Tighten the piston top NOTE Use soft vise jaws with cutout for piston body to...

Page 58: ...Rights Reserved Dura User Manual 14 Assemble the piston into the cylinder body 15 Assemble the cylinder top to the cylinder body 16 Apply anti seize compound to the screws Install the cylinder top scr...

Page 59: ...ter plates Refer to the General Assembly drawing to determine which heater plate applies to your system NOTE The controlling thermocouple for the heater plates is located in the heater plates The cont...

Page 60: ...Assembly drawing for the correct torque values It is recommended that the heater plate wires be isolated and grouped so that they do not have to be disconnected if the manifold needs to be dismantled...

Page 61: ...eld replacement of flexible heater elements only We do not recommend field replacement of heater elements that are brazed or pasted into the manifold For these types of heater elements please contact...

Page 62: ...troller Use a plastic nylon mallet only A regular soft rubber hammer will not work A smaller head size is preferred Do not use a metal hammer It will damage the heater and the manifold surface CAUTION...

Page 63: ...groove pre bend the heater element manually before hammering it into the groove This will prevent the shielding from being damaged by the groove edge 7 Make sure the heater element is completely seat...

Page 64: ...r Manual 9 Crimp the wire with the proper size crimper pin Connect it to the heater threaded pin with the ceramic terminal connector 10 After all connections are finished test the electrical connectio...

Page 65: ...refer to different system configurations Refer to your parts list and General Assembly drawings to determine your system type 5 10 2 Heated Back Plate Installation The center heater may require the m...

Page 66: ...wires for each zone together 10 Install the wires into the wire channels and secure with high temperature cable ties 11 Feed wires back through the wire channel in the mold base to the electrical box...

Page 67: ...Torque screws in a crossing pattern gradually increasing torque to specified value Refer to the General Assembly drawing for torque values 4 Remove inlet to verify blue surfaces 5 Clean the die spotti...

Page 68: ...continued 7 Apply die spotting blue compound to the inlet seal and verify these surfaces to check fit of seal in the inlet 8 Clean die spotting blue compound from inlet seal and inlet 9 Install inlet...

Page 69: ...ted All Rights Reserved Inlet Extension with Heater Sleeves continued 11 Torque to specified value Refer to the General Assembly drawing for torque values 12 Install thermocouple into slot until it bo...

Page 70: ...onents All wires for power and control are collected in an intermediate space and it routes the hoses for control and cooling above the wiring channel for protection All wire channels are custom desig...

Page 71: ...ngth and the hollow space inside allows wires for power thermocouple and controls 6 Bolt 3 used to mount the wiring channel body and U shaped bracket 7 Bolt 1 used to mount the U shaped bracket and Ho...

Page 72: ...wiring schematic in General Assembly drawing 5 Insert the coding pin to the male plug as per wiring schematic if applicable 6 Get six spare wires crimped with male contacts in one end insert into the...

Page 73: ...male plug of quick connect 1T and label the wires accordingly to the female side 6 Insert the coding pin to the male plug as per wiring schematic if applicable 7 Snap 1T plugs together run the open e...

Page 74: ...e using a crane of adequate capacity before commencing work Failure to support the machine can result in severe injury or death The screws securing the wiring channel to the manifold and or other acce...

Page 75: ...d Wiring Channel Installation continued 4 Unscrew the bolts and remove the side covers 5 Organize all sorted power thermocouple and other control wires to the wiring channel then install side covers 6...

Page 76: ...must not be overstretched Hoses must be held at the proper bending angle All hoses must be run through the U shaped bracket 5 11 5 Electrical Box 1 Install plugs into electrical box 5 11 6 Solenoid Va...

Page 77: ...strial grade actuator intended to perform the functions of moving the working mechanisms and providing the necessary force and speed for a given control cycle when installed in a Hot Runner system 6 2...

Page 78: ...operating temperature for the actuator plate and the top spacer plates is 80 C 175 F Ensure that the SeVG Plus actuator is not dropped at any time as damage to its connectors and internal parts may l...

Page 79: ...us actuator is not dropped at any time as damage to its connectors and internal parts may lead to the failure of the actuator CAUTION IMPORTANT Mold Masters assumes no responsibility for connection mo...

Page 80: ...temperature for the actuator plate and the top spacer plates is 80 C 175 F Ensure that the SeVG Plus actuator is not dropped at any time as damage to its connectors and internal parts may lead to the...

Page 81: ...40 20 SE40 20C ModelS 1 SeVG Plus actuator 2 Frame plate 3 Actuator plate 4 Manifold plate 2 3 4 1 Note non cooled model shown Figure 6 4 SE40 20 actuator in a Dura Plus system 6 6 1 SE20 15 Model 1 2...

Page 82: ...system is disconnected before starting the assembly procedure Failure to do so may result in serious injury or death Ensure the wires between the controller and the motors do not touch any heated comp...

Page 83: ...astic heat the system to processing temperature before the assembly is placed and see the hot surfaces warning above Make sure that the cooling system is also connected 6 7 1 Attach the Water Lines Co...

Page 84: ...valve pin holder Torque to 8 to 10 Nm 6 to 7 ft lbs See Figure 6 8 Valve pin holder assembly Valve pin holder assembly cross section Figure 6 8 Valve pin holder assembly 6 7 3 Install the Motor and Va...

Page 85: ...mbly with the valve pin downwards a For the SE40 20 and SE40 20C models Attach to the actuator plate with four SHCSM6X25 screws Torque to 18 Nm 13 ft lbs See Figure 6 10 and Figure 6 11 Figure 6 10 In...

Page 86: ...See Figure 6 12 IMPORTANT The SE20 15 model of the SeVG Plus actuator has four screws on the top of the assembly Use the SHCSM5X155 mounting screws DO NOT use the two assembly screws marked with the...

Page 87: ...tective clothing Failure to do so can cause serious injury CAUTION Do not use the linear servo drive to retract or extract the rod until the system reaches the internal hard stop position or the actua...

Page 88: ...l Rights Reserved 6 8 2 SE20 15 Model 1 Heat the system to allow any plastic to become soft 2 Remove the valve pin 3 Remove the two SHCSM5X155 mounting screws See Figure 6 15 Figure 6 15 Remove the tw...

Page 89: ...6 9 1 SE40 20 Model Figure 6 16 SE40 20 actuator 1 Motor 2 SHCSM6X90 3 Motor mount flange 4 Motor locating spigot 5 Motor rod 6 Valve pin holder top 7 Valve pin holder bottom 8 Valve disk stem 9 Valve...

Page 90: ...90 3 Motor mount flange 4 Motor locating spigot 5 Motor rod 6 Valve pin holder top 7 Valve pin holder bottom 8 Valve disk stem 9 Valve pin 10 Valve disk flange 11 Spacer 12 Water fitting 13 Cooling pl...

Page 91: ...6 15 SEVG PLUS ACTUATOR 2020 Mold Masters 2007 Limited All Rights Reserved Dura User Manual 6 10 SeVG Plus in Manifold Mounted Systems Figure 6 18 SE40 20 actuator in a manifold mounted system...

Page 92: ...system is disconnected before starting the assembly procedure Failure to do so may result in serious injury or death Ensure the wires between the controller and the motors do not touch any heated comp...

Page 93: ...occur if the proper tool is not used See Figure 6 20 Do not apply force to the motor rod CAUTION Hold the motor rod by the flats Figure 6 20 Motor rod flats IMPORTANT Heat the system to allow any pla...

Page 94: ...the top of the spacers into the counterbores on the bottom of the cooling plate 7 Hold the motor rod to prevent rotation 8 Install the valve pin holder assembly onto the motor Torque to 8 to 10 Nm 6...

Page 95: ...s not exerted on the interface between the fitting and the aluminum motor casing Follow instructions below CAUTION For systems with the SE40 20C model the water lines must be connected This timing of...

Page 96: ...ath with a heat rating of 280 C 535 F See Figure 6 24 Figure 6 24 Place cables into insulated sheath 12 Attach the sheathed cables securely to the wiring channel See Figure 6 25 Figure 6 25 Attach cab...

Page 97: ...SURFACES Extreme heat Avoid contact with heated surfaces Use appropriate protective clothing Failure to do so can cause serious injury CAUTION Do not use the linear servo drive to retract or extract t...

Page 98: ...contact with the motors 5 Detach the sheathed motor cables from the wiring channel 6 If there is access to the valve pin holder Use a suitable wrench to open the valve pin holder to disconnect the pi...

Page 99: ...oling plug 14 Socket head cap screw 15 Outer cylinder 16 O ring 17 O ring 18 Piston 19 O ring 20 Cooling plug 21 O ring 22 O ring 23 Cover plate 24 Socket head cap screw 25 Insert 26 Valve insert 27 V...

Page 100: ...ts against the parts list Outer cylinder Insulation plate Support sleeve Hose Dowel pin Valve pin Jiffy plug Valve pin holder Valve insert Socket head cap screw Inlet tip Shoulder screw Nozzle Adapter...

Page 101: ...inder 3 Use your fingers and gently push the O rings into the groove in the cylinder Make sure that the O rings seats firmly in the groove Non Front Mounted Model Front Mounted Model 4 Insert the jiff...

Page 102: ...tion of the bottom ports for cooling connections 5 Insert the plugs into the supply ports of the cylinder and seal the lines In out cooling lines from customer plate 6 Apply grease to the O ring assem...

Page 103: ...into the outer cylinder Apply even force with both hands and gently press the piston until it seats evenly NOTE Ensure that the top surface of the piston and cylinder are level with one another Non Fr...

Page 104: ...anual ACCU LINE 2020 Mold Masters 2007 Limited All Rights Reserved 9 Insert the dowel pin into the outer cylinder assembly Non Front Mounted Models Front Mounted Models Accu Line with Valve Insert Ass...

Page 105: ...ly push the O rings into the outer groove in the cylinder NOTE Ensure that the O ring seats firmly in the groove Non Front Mounted Models Front Mounted Models 11 Apply grease to the O ring assembly gr...

Page 106: ...ngs into the inner groove of the cylinder top NOTE Ensure that the O ring seats firmly in the groove CAUTION Verify the stroke height with the General Assembly drawing before and after installing the...

Page 107: ...ts Reserved Dura User Manual 15 Insert the screws and torque to 7 Nm 5 lbf ft Non Front Mounted Models Front Mounted Models 16 Place the insulation plate on the cylinder body and install the support s...

Page 108: ...nsulation plate Insert the socket head cap screws and torque to 14 Nm 10 lbf ft Non Front Mounted Models 1 Insulation plate 2 Sleeve 3 Cover plate 4 Socket head cap screw 1 2 3 4 Front Mounted Models...

Page 109: ...1 3 2 4 1 Cooling in 2 Cooling out 3 Gate open 4 Gate close Front Mounted Models 1 2 3 4 1 Cooling in 2 Cooling out 3 Gate open 4 Gate close IMPORTANT Steps 19 and 20 are optional for systems that co...

Page 110: ...rmcon assembly ground wire assembly and thermocouple assembly into the heated body 22 Insert the end of the thermocouple completely into the mating hole and bend it into the thermocouple groove 2 1 3...

Page 111: ...o 68 Nm 50 lbf ft 25 Attach the gate seal and liner to nozzle Attach nozzle thermocouple 26 Assemble the adapter into the nozzle 27 Insert the screws For M5 screws torque to 7 Nm 5 lbf ft For M8 screw...

Page 112: ...the nozzle assembly 30 Insert the screws and torque to 14 Nm 10 lbf ft 31 Slide the valve pin holder into the heated body slot and over the valve pin head 32 Insert the valve pin head into the keyhole...

Page 113: ...ert Assembly continued 33 In cold condition measure the N dimension in the heated body and the T dimension in the cylinder body IMPORTANT Ensure that these two measurements are equal NOTE Air gap will...

Page 114: ...007 Limited All Rights Reserved 34 Carefully place the nozzle assembly into the hydraulic unit NOTE Ensure that the nozzle terminal end is correctly oriented Non Front Mounted Models Front Mounted Mod...

Page 115: ...Limited All Rights Reserved Dura User Manual Accu Line with Valve Insert Assembly continued 35 Secure the valve pin holder to the piston with a shoulder head screw Torque to 3 Nm 2 2 lbf ft Non Front...

Page 116: ...he assembly Check all the connections and actuations for accuracy Non Front Mounted Models Front Mounted Models Front mounted Accu Line models have built in wire channel cutouts for easy connection to...

Page 117: ...ms are either equipped with a protective earth conductor or there is a connector for this purpose Before you carry out electrical work make sure that the Hot Runner system is securely grounded Turn th...

Page 118: ...ure 8 1 Mold plug and ground mold base The reading should be infinity Occasionally the electric heaters accumulate moisture which can reduce the resistance value to between 100 K to 10 M The controlle...

Page 119: ...thermocouple is immersed in water 8 6 Heater Continuity Measure the resistance between each pair of heater power wires at the mold power connector Compare your reading with your General Assembly draw...

Page 120: ...ION Never start the heating with more than 40 of power CAUTION Stay a minimum of five minutes at 212 F 100 C before increasing heat Stay with the system and monitor the initial heating to minimize ris...

Page 121: ...documented procedures Failure to do so may lead to serious injury or death CAUTION Do not assemble disassemble cavity plate with the valve pins forward Valve pins must be retracted prior to cavity pl...

Page 122: ...or torque values 7 Measure and confirm the angled sub manifold height as specified on the General Assembly drawing 8 Repeat for each drop 9 2 3 Install Manifold Locator and Anti Rotation Dowel CAUTION...

Page 123: ...y drawing 1 Measure and confirm locator height as specified on General Assembly drawing 2 Align bridge to sub manifold and locate on manifold locator 3 Take care not to pinch the wires 4 Remove any in...

Page 124: ...on Steps 1 Connect the sub manifold power wires to the bridge using quick connectors if applicable Ensure quick connectors are locked 2 Connect all the plumbing air and water hoses to the sub manifold...

Page 125: ...ure before actuating the valve pins Failure to do so could cause damage to the valve pins The maximum operating temperature for Hot Runner systems is 400 C 750 F CAUTION 1 Install the mold into the mo...

Page 126: ...ning thermally sensitive materials use a thermally stable material as recommended by the material supplier for the initial startup 1 Heat up all Hot Runner manifolds and or bridges and inlets excludin...

Page 127: ...Heat soak for 15 minutes 4 Raise nozzle temperature to setpoint 5 Heat soak for 20 minutes 10 3 Shutdown The correct shutdown procedure for your Hot Runner system depends on the type of system Standar...

Page 128: ...eakage damage occurring in the Hot Runner CAUTION IMPORTANT Thermally sensitive materials should be purged from the Hot Runner system prior to shutdown using a thermally stable material with a similar...

Page 129: ...ct repair kit and crimping tool Available tools and lead wire replacement kits are shown below See Section 2 Global Support for contact information Table 11 1 Crimping Tool Chart Product Name Descript...

Page 130: ...nut CAUTION 1 Nozzle flange 2 Ceramic insert 3 Ceramic sleeves 4 Seal 5 Element sleeve 1 2 3 4 5 Figure 11 1 Nozzle terminal assembly 1 If the terminal end is covered with plastic warm the terminal en...

Page 131: ...Assembly CAUTION Keep an eye on the silicon seal It should not rotate with the sleeve during the assembly process or the wires may break CAUTION 1 Assemble the repair kit components 2 Ensure the term...

Page 132: ...d 5 Spread the wire strands and insert the lead wire onto the terminal posts 6 Grasp the crimp with the crimping tool slide the crimp into position over the terminal post and crimp the connection 7 Sl...

Page 133: ...Limited All Rights Reserved Dura User Manual Terminal Assembly continued 9 Slide the second ceramic insulator and silicone seal into place 10 11 Complete the assembly by screwing the element sleeve i...

Page 134: ...f 3 Remove the power leads using crimp removal tool Figure 11 3 Terminal end assembly 1 3 4 2 1 Power leads 2 Set screws 3 Ceramic sleeve 4 Heater plate 11 4 2 Installation 1 Push the replacement lead...

Page 135: ...ms It is advisable to heat the system to ensure the temperature condition is met to remove the gate seals NOTE Use the socket supplied in the Mold Masters tool kit to loosen the gate seal It is recomm...

Page 136: ...in the system It is recommended the nozzle be removed from the system before removing the gate seal Use the socket supplied in the Mold Masters tool kit to loosen the gate seal The following procedure...

Page 137: ...ctly clean Failure to clean properly may result in nozzle and seal damage and leakage Any anti seize compound that enters the internal runner must be removed to prevent contamination of melt Failure t...

Page 138: ...to the liner to the nozzle to ensure proper mating If the liner is making good contact clean the die spotting blue compound off both faces 5 Apply anti seize compound nickel based to the gate seal th...

Page 139: ...zle reference point is found on the gate detail of the General Assembly drawing 2 Assemble spacer blocks to same value as correct nozzle tip height 3 Zero vernier to spacer blocks 4 Move vernier to co...

Page 140: ...l box and wire channels 2 Remove the nozzle from the manifold plate 3 Remove the thermocouple retaining clips 4 Remove the thermocouple 11 11 Torque Settings 11 11 1 Gate Seal Torque Settings CAUTION...

Page 141: ...5 ft lbs M10 40 Nm 3 8 16 30 ft lbs M12 60 Nm 1 2 13 45 ft lbs M16 145 Nm 5 8 11 107 ft lbs M20 285 Nm 3 4 10 210 ft lbs Table 11 4 Torque Chart for Plate Assembly Screws Metric Torque Setting Imperia...

Page 142: ...lution to verify that the problem has been solved Repeat occurrences of the same symptom may indicate other problems Document the solution so that a repeat occurrence can be solved quickly Consult oth...

Page 143: ...A convex feature on either side of the mold that will enter an opposing cavity when the mold is closed The void between the cavity and core is where the resin solidifies and forms the part Often the B...

Page 144: ...tor Pins Pins that are pushed into a mold cavity from the rear as the mold opens to force the finished part out of the mold Also called knockout pins Ejector Return Pins Projections that push the ejec...

Page 145: ...ing cavities into which plastic resin is injected to form a part Mold Frame Aseries of steel plates which contain mold components including cavities cores runner system cooling system ejection system...

Page 146: ...helps to reduce thermal transfer to a minimum Process The injection molding environment consisting of input variables such as temperature pressure injection rates and time that are controlled to fill...

Page 147: ...ring normal operation Thermoplastic A polymer which melts or flows when heated Thermoplastic polymers are usually not highly cross linked and act much like molecular solids low melting and boiling poi...

Page 148: ...ssary of Terms 13 1 H Hazard areas 3 2 Heater Continuity 8 3 Hot Tip Gate 13 2 I Intended Use 1 1 J Jetting 12 13 N Nozzle Tip Height Checking 11 11 P Parts Sticking to Cavity 12 16 Parts Sticking to...

Page 149: ...com ASIA CHINA Regional HQ tel 86 512 86162882 e china moldmasters com JAPAN tel 81 44 986 2101 e japan moldmasters com U S A tel 1 248 544 5710 e usa moldmasters com MEXICO tel 52 442 713 5661 sales...

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Mold-Masters Dura PLUS, User Manual, Page: 3 / 149

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