Mold-Masters Fusion G2 User Manual Download Page 6

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Section 11 - Maintenance ...............................................11-1

11.1 Recommended Torque Settings ......................................................................11-1

11.2 Tubular Heater Installation and Replacement .................................................11-3

11.2.1 Storage ..................................................................................................11-3

11.2.2 Removing a Heater Element ..................................................................11-3

11.2.3 Installing a New Heater Element ............................................................11-3

11.2.4 New Heater Startup ...............................................................................11-6

11.3 Solenoid Valve Bank .......................................................................................11-6

11.3.1 Hydraulic Solenoid Valve Bank ..............................................................11-6

11.3.2 Components of a Hydraulic Solenoid Valve Bank ..................................11-7

11.3.3 Pneumatic Solenoid Valve Bank ............................................................11-9

11.3.4 Components of a Hydraulic Solenoid Valve Bank ..................................11-9

11.4 Recommended Spare Parts .........................................................................11-13

Section 12 - Troubleshooting ....................................... 12-1

12.1 Introduction .....................................................................................................12-1

12.2 Moisture Related Issues .................................................................................12-2

12.2.1 Resin Moisture Contamination ...............................................................12-2

12.2.2 Resin Drying Issues ...............................................................................12-2

12.2.3 Importance of Pre-Drying Resin ............................................................12-2

12.3 Pre-Molding Precautions ................................................................................12-3

12.4 Establishing Root Cause ................................................................................12-4

12.4.1 Fault Identification

..................................................................................12-4

12.5 Troubleshooting Typical Problems ..................................................................12-5

12.5.1 Dark Specks ..........................................................................................12-5

12.5.2 Blisters or Bubbles .................................................................................12-6

12.5.3 Flow Marks ............................................................................................12-7

12.5.4 Burn Marks ............................................................................................12-8

12.5.5 Delaminating Parts ................................................................................12-9

12.5.6 Dimensional Irregularities ....................................................................12-10

12.5.7 Discolored Parts ..................................................................................12-11

12.5.8 Flash ....................................................................................................12-12

12.5.9 Jetting ..................................................................................................12-13

12.5.10 Pitted Parts ........................................................................................12-14

12.5.11 Rough Surface ...................................................................................12-15

12.5.12 Parts Sticking to Cavity ......................................................................12-16

12.5.13 Parts Sticking to Core ........................................................................12-17

12.5.14 Short Parts .........................................................................................12-18

12.5.15 Sinks or Voids ....................................................................................12-19

12.5.16 Splay ..................................................................................................12-20

12.5.17 Streaks ...............................................................................................12-21

12.5.18 Stringing .............................................................................................12-22

12.5.19 Warped Parts .....................................................................................12-23

12.5.20 Weld Lines .........................................................................................12-24

Index ......................................................................................I
Section 13 - Index .................................................................I

FSG2 User Manual

Summary of Contents for Fusion G2

Page 1: ...version 14 User Manual Original Instructions...

Page 2: ......

Page 3: ...1 4 1 Tools Required 4 1 4 2 Screw Lengths 4 1 4 3 Unpacking 4 2 4 4 Cleaning 4 2 4 5 Hydraulic Cylinder Assembly 4 3 4 6 Pneumatic Cylinder Assembly 4 9 4 7 Waterless Hydraulic Actuator Assembly 4 14...

Page 4: ...5 8 2 Assemble Gate Seals to Nozzle 5 20 5 9 Install Manifold Locator 5 21 5 10 Install Support Bushings 5 21 5 11 Install Manifold Thermocouple 5 23 5 12 Install Inlet 5 24 5 12 1 Install Inlet Therm...

Page 5: ...upply 7 2 7 3 4 Verification of Continuity of Protective Bonding Circuit 7 2 7 3 5 Verification of Fault Loop Impedance 7 3 7 4 Thermocouple Continuity Test 7 3 7 5 Pinch Point Test 7 3 7 6 Heating El...

Page 6: ...esin Drying Issues 12 2 12 2 3 Importance of Pre Drying Resin 12 2 12 3 Pre Molding Precautions 12 3 12 4 Establishing Root Cause 12 4 12 4 1 Fault Identification 12 4 12 5 Troubleshooting Typical Pro...

Page 7: ...ral Lockout Guidelines 3 11 Table 4 1 Valve Pin and Spacer Combinations 4 16 Table 5 1 Typical Contact Length 5 4 Table 6 1 SEVG Plus Actuator Models 6 1 Table 6 2 FUSION SERIES Systems SeVG Plus Actu...

Page 8: ...assembled cylinder 4 25 Figure 5 1 FUSION SERIES G2 system with thread nozzle 5 1 Figure 5 2 FUSION SERIES G2 flange nozzle 5 1 Figure 5 3 FUSION SERIES G2 hydraulic system 5 2 Figure 5 4 FUSION SERI...

Page 9: ...ponents 6 9 Figure 6 9 Motor locating spigot 6 9 Figure 6 10 Insert the screws to fasten the assembly 6 10 Figure 6 11 Place cables into insulated sheath 6 10 Figure 6 12 Attach cables to wiring chann...

Page 10: ......

Page 11: ...ow 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 and should be referenced along with the f...

Page 12: ...inuous improvement and we reserve the right to alter product specifications at any time without giving notice 1 6 Movement or Resale of Mold Masters Products or Systems This documentation is intended...

Page 13: ...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 4536 kg lbf Pound...

Page 14: ...1 6074191 6077067 6079972 6095790 6099780 6113381 6135751 6162043 6162044 6176700 6196826 6203310 6230384 6270711 6274075 6286751 6302680 6318990 6323465 6348171 6350401 6394784 6398537 6405785 644035...

Page 15: ...baba Colony Coimbatore T N India 641 011 tel 91 422 423 4888 fax 91 422 423 4800 india moldmasters com USA Mold Masters Injectioneering LLC 29111 Stephenson Highway Madison Heights MI 48071 USA tel 1...

Page 16: ...Holon 58154 Israel tel 972 3 5581290 fax 972 3 5581293 sales asaf com Russia System LLC Prkt Marshala Zhukova 4 123308 Moscow Russia tel 7 495 199 14 51 moldmasters system com ru Belarus HP Promcompl...

Page 17: ...and instruct its personnel in the safe operation of equipment including the use of all the safety devices Provide its personnel with all necessary protective clothing including such items as a face sh...

Page 18: ...ing machine hazard areas Top view with guards removed Front view with guards removed 2 10 5 3 Top View with Guards Removed 2 5 9 1 4 7 6 9 8 Front View with Guards Removed 1 Mold area 2 Clamping mecha...

Page 19: ...sticizing and or injection unit including nozzle Movements of parts of the power operated nozzle shutoff and their drives Over pressurization in the nozzle Thermal Hazards Burns and or scalds due to o...

Page 20: ...caused by hose assembly failure Possible release of fluid under pressure that can cause injury Thermal hazards associated with hot fluid Area Inside the Guards and Outside the Mold Area See Figure 3...

Page 21: ...protective equipment such as face shields and use heat resistant gloves when working around the feed inlet purging the machine or cleaning the gates of the mold Remove purged material from the machin...

Page 22: ...components are hot surfaces which could result in burns Keep flammable liquids or dust away from the hot surfaces as they could ignite Follow good housekeeping procedures and keep floors clean to prev...

Page 23: ...ccumulator Sudden release of high pressure gas or oil can cause death or serious injury Discharge all gas and hydraulic pressure before disconnecting or disassembling accumulator Warning Hot Surfaces...

Page 24: ...ouple connections ensure that the power and thermocouple connections have not been wired incorrectly Communications Interface and Control Sequence It is the customer s responsibility to verify functio...

Page 25: ...trical components before performing any maintenance to avoid potential risk of electrical shock Often power sources are inadvertently turned on or valves are opened mistakenly before maintenance work...

Page 26: ...be de energized and appropriately locked out This can include gravity compressed air hydraulics steam and other pressurized or hazardous liquids and gases See Table 3 3 6 When the work is completed p...

Page 27: ...ff excess air If pressure cannot be relieved block any possible movement of machinery Kinetic Energy Energy of a moving object or materials Moving object may be powered or coasting Blades Flywheels Ma...

Page 28: ...rain the oil from the lines and cylinders and dispose it in an environmentally responsible manner 3 The electrical components are to be dismantled separating them accordingly as environmentally friend...

Page 29: ...e completely cooled Purgings may appear solid but may still be hot and cause serious injury Some plastics develop gases that may be dangerous to personal health Follow the plastics supplier s recommen...

Page 30: ...shock Make sure the machine has been locked out and tagged out in accordance to the machine s documented procedures Failure to do so may lead to serious injury or death Check that all coolant hydrauli...

Page 31: ...temperature controller with soft start protection Avoid running the system for long periods on manual control Use caution when applying power in manual mode Use minimum heat required for the process t...

Page 32: ...rs Calibrated torque wrench for consistent screw pressure throughout the system Depth micrometer to check bore depths Die spotting blue compound for checking face contact Sockets Plastic face hammer 4...

Page 33: ...pares packages and set aside 2 After removing all restraints attach the crane to the hoist and carefully remove the system from the shipping crate 3 Check that all mold base dimensions are correct and...

Page 34: ...eals 9 Retaining ring 10 Rod seal 11 Cooling channel 12 Support spacer 13 Valve pin anti rotation collar Hydraulic cylinder section view 4 5 Hydraulic Cylinder Assembly 3 10 7 8 2 1 12 9 4 6 4 8 9 10...

Page 35: ...the pocket of the cylinder body 2 Press the seals into the housing 3 Install the rod seal retainer clip 4 Place pipe sealant on threads of the water circuit pipe plug Install the water circuit pipe p...

Page 36: ...continued 5 Install the piston seals 3 pieces 1 Piston seal 2 O ring 3 Split retainer ring 6 Install the O ring 7 Install the piston seal 1 2 3 4 5 2020 Mold Masters 2007 Limited All Rights Reserved P...

Page 37: ...er Assembly continued 8 Install the split retainer ring 9 Install the valve pin 10 Install the spring pack 11 Install the piston top 4 6 2020 Mold Masters 2007 Limited All Rights Reserved PREPARATION...

Page 38: ...e piston top NOTE Use a soft jaw vise with the piston body to prevent damage to the part 13 Install the cylinder top seal 14 Install the piston into the cylinder body 4 7 2020 Mold Masters 2007 Limite...

Page 39: ...mbly continued 15 Assemble the cylinder top to the cylinder body 16 Apply anti seize compound to the screws Install the cylinder top screws 4 8 2020 Mold Masters 2007 Limited All Rights Reserved PREPA...

Page 40: ...l 8 Rod wiper seal 9 Cooling plate 10 Valve pin anti rotation collar 11 Support spacer 12 Valve pin Pneumatic cylinder components 1 2 11 5 8 7 10 3 4 9 Pneumatic cylinder section view Figure 4 3 Pneum...

Page 41: ...2 pieces 2 Use the piston to push the seal into position 3 Install the wiper seal 2 pieces 4 Use the piston to push the seal into position 4 10 2020 Mold Masters 2007 Limited All Rights Reserved PREPA...

Page 42: ...ston top 7 Using a soft jaw vise tighten the piston top to a torque of 10 N m 7 lb ft NOTE Use soft vise jaws with cutout for piston body to prevent damage to the part 4 11 2020 Mold Masters 2007 Limi...

Page 43: ...tall the piston into the cylinder body 9 Install the cylinder top seal 10 Assemble the cylinder top to the cylinder body 4 12 2020 Mold Masters 2007 Limited All Rights Reserved PREPARATION FSG2 User M...

Page 44: ...seize compound to the screws 12 Install the cylinder top screws 13 Install the piston collar on the cylinder body Piston collar 4 13 2020 Mold Masters 2007 Limited All Rights Reserved PREPARATION FSG...

Page 45: ...ion view 2 13 11 12 14 15 1 Cylinder top 2 Cylinder top seal 3 Cylinder body 4 Piston top 5 Piston seal 6 Retaining ring 7 Rod seal 8 Spring package 9 Piston bottom 10 Valve pin 11 Shoulder screw 12 D...

Page 46: ...d for this procedure a soft jaw vise 1 Examine the piston seal and make sure that it is in good condition 2 Install the piston seal 3 Install the valve pin 4 Install the solid spacer or spring pack 4...

Page 47: ...vise when tightening the piston top to prevent damage to the piston assembly CAUTION 6 Using a soft jaw vise tighten the piston top to a torque of 10 N m 7 lb ft 4 16 2020 Mold Masters 2007 Limited A...

Page 48: ...this procedure snap ring pliers and a 12 0 mm 0 5 in diameter rod 1 Insert the die spring into the cylinder bore hole 2 Insert the washer into the bore hole 3 Compress the clip and press it into the...

Page 49: ...clip with a 12 0 mm 0 5 in diameter rod 5 Install the spacer and the rod seal 6 Use snap ring pliers to install the retaining ring 4 18 2020 Mold Masters 2007 Limited All Rights Reserved PREPARATION F...

Page 50: ...the cylinder 2 Install the assembled piston in the cylinder housing 3 Install the spacer in the cylinder top 10 mm stroke 4 Attach the cylinder top to the cylinder bottom 5 Apply anti seize compound t...

Page 51: ...f 16 N m 11 8 ft lb 4 7 4 Assemble the Anti Rotation Waterless Hydraulic Actuator Figure 4 5 Piston collar dowel pin and screws 1 Install the piston collar in the bottom of the cylinder 4 20 2020 Mold...

Page 52: ...iston bottom 5 Piston seal 6 Piston guide ring 7 Piston top 8 Rod seal 9 Wiper seal 10 Spacers for pin adjustment 11 Valve pin 12 Shoulder bolt 13 Die spring 14 Spacers for pin adjustment 15 Washer 16...

Page 53: ...pin spacers thickness 2 1 mm and 2 2 mm into the piston bore 3 Insert valve pin 4 Install the remaining two valve pin spacers thickness 2 0 mm and 2 3 mm on top of the valve pin See Figure 4 8 Valve...

Page 54: ...C 50 F and 104 F and remove valve pin from piston 9 Refer to Table 4 1 to choose the correct spacer combination for the length adjustment Table 4 1 Valve Pin and Spacer Combinations Valve Pin Length V...

Page 55: ...Actuator 1 Insert die spring into cylinder body bore hole 2 Insert washer into bore hole 3 Assemble spiral retaining ring a Deform the clip and press into bore hole 4 24 2020 Mold Masters 2007 Limite...

Page 56: ...ll the O ring for the rod seal See Figure 4 9 Figure 4 9 Install O ring for rod seal 5 Install the rod seal See Figure 4 10 Figure 4 10 Install rod seal 4 25 2020 Mold Masters 2007 Limited All Rights...

Page 57: ...Use the piston to push the seal into position 7 Install the O ring for the wiper seal See Figure 4 12 Figure 4 12 Install O ring for wiper seal 8 Install the wiper seal See Figure 4 13 Figure 4 13 In...

Page 58: ...ion See Figure 4 14 for an image of the rod seal and wiper seal assemblies Rod seal assembly Wiper seal assembly Figure 4 14 Rod seal and wiper seal assemblies 4 27 2020 Mold Masters 2007 Limited All...

Page 59: ...sert the piston into the cylinder body See Figure 4 15 Figure 4 15 Install the piston 2 Install the cylinder top seal See Figure 4 16 Top seal Figure 4 16 Install the top seal 4 28 2020 Mold Masters 2...

Page 60: ...are on the same face See Figure 4 17 Figure 4 17 Assembled cylinder note ports 4 Apply anti seize compound to the screws 5 Install the cylinder top screws 6 Torque to 16 Nm 11 8 ft lbs 4 29 2020 Mold...

Page 61: ...eals Figure 4 18 Install piston seals and guide ring 8 Install valve pin spacers thickness 2 1mm and 2 2 mm into the piston bore 9 Insert valve pin 10 Install the anti rotation dowel to prevent rotati...

Page 62: ...e 4 20 Install valve pin and spacers 12 Install the piston top NOTE Ensure that the O ring is in good condition 13 Insert the piston with the anti rotation dowel into the cylinder body See Figure 4 21...

Page 63: ...dowel in the piston aligned with the anti rotation slot NOTE Ensure the ports are on the same face See Figure 4 23 Figure 4 23 Anti rotation version assembled cylinder 16 Apply anti seize compound to...

Page 64: ......

Page 65: ...ead nozzle Figure 5 2 FUSION SERIES G2 flange nozzle 1 Locating ring 2 Inlet extension 3 Insulation bridge 4 Enclosed wire channels 5 FUSION SERIES G2 manifold 6 System screw 7 Support bushing 8 Manif...

Page 66: ...5 Wire harness 6 Manifold 7 Manifold locator 4 5 6 1 2 3 9 8 7 10 11 12 8 Flange 9 FUSION SERIES G2 nozzle 10 Nozzle protective sleeve assembly 11 Centering ring 12 Snap ring 13 Gate seal 13 Figure 5...

Page 67: ...actuator oil air hoses Adapter plates for external fitting connection Optional solenoid valvebank connection 5 1 2 FUSION SERIES G2 Lite System Hot Runner system will be pre assembled however No wire...

Page 68: ...expansion of the nozzle must also be taken into consideration Contour of gate seal should be done at process temperature Always refer to the General Assembly drawing to confirm the contact length Hot...

Page 69: ...the start up procedure 2 Make sure all cooling lines other than the cover plate are connected properly 3 After reaching the processing temperature let the system soak at that temperature for at least...

Page 70: ...que to specified value 9 Verify transfer of die spotting blue compound from nozzle core to manifold 10 Clean die spotting blue compound from components Check Nozzle Core to Manifold Fit continued 5 6...

Page 71: ...reads 12 Assemble the nozzle to the manifold 13 Torque the nozzles to value on the General Assembly drawing IMPORTANT Remember to re torque at process temperature when system assembly is complete 5 7...

Page 72: ...tems without protective sleeves please see 5 7 Nozzle Assembly for Systems without Protective Sleeves on page 5 13 14 Install the bottom end cap of the protective sleeve onto the coredel 15 Install an...

Page 73: ...hrough the cut on the bottom end cap Cutout in bottom end cap 18 Install all other heated or unheated sleeves if applicable Nozzle Assembly for Systems with Protective Sleeves continued 5 9 2020 Mold...

Page 74: ...ver the protective sleeve NOTE Ensure proper seating of the top end cap Move the thermocouple clip down if necessary Nozzle Assembly for Systems with Protective Sleeves continued 5 10 2020 Mold Master...

Page 75: ...TANT Systems with protective sleeves require the use of a center guiding ring 21 Install the center guiding ring 22 Using snap ring pliers expand the clip and install it into the snap ring groove on t...

Page 76: ...for completed protective sleeve assembly Figure 5 7 Completed protective sleeve assembly Heater Retaining Clip Installation continued 5 12 2020 Mold Masters 2007 Limited All Rights Reserved ASSEMBLY F...

Page 77: ...tall heaters and sleeves per specified drawings 5 7 2 Install Thermocouple 2 Insert the thermocouple into the thermocouple slot until it bottoms out Bend the thermocouple 180 degrees 3 Install the the...

Page 78: ...ouple hole on nozzle body until it bottoms out 2 Slide front heater onto the nozzle body and line up the slot on the heater with thermocouple 3 Bend the thermocouple 180 degrees and then install the r...

Page 79: ...e mounted thermocouples These thermocouples are mounted on heater sleeves 1 Insert the thermocouple into the thermocouple slot until it reaches the bottom of the slot 2 Bend the thermocouple along the...

Page 80: ...expand the clip and install it into the snap ring groove on the nozzle core NOTE Installation of a guiding ring is an option for systems without protective sleeves Please see Figure 5 8 Nozzle center...

Page 81: ...plunger top surface is lower than the flange top surface by at least 0 08 mm 0 003 in 0 08mm 3 Apply anti seize compound to the nozzle threads and then thread the nozzle into the flange Torque nozzles...

Page 82: ...assembly to the manifold by lining up the two ball plungers to the dimples on manifold bottom surface Make sure the balls sit completely inside the dimple 6 Torque the two M5 shoulder bolts to 9 5 Nm...

Page 83: ...eal to specified value 3 Remove gate seal and verify transfer of die spotting blue compound from gate to the liner Verify transfer of die spotting blue compound to nozzle core If not 100 blue on face...

Page 84: ...nterfaces 6 Ensure all sealing surfaces are clean and dry 7 Install the gate seal and liner 8 Torque to specified values Remember to re torque at process temperature when system assembly is complete 5...

Page 85: ...the screw to the specified value See 11 1 Recommended Torque Settings on page 11 1 3 Verify the height of the manifold locator to the dimension specified on the General Assembly drawing 5 10 Install...

Page 86: ...rt bushings Typical application will require one support bushing per nozzle 7 Verify the height of the support bushing and the manifold locator to the specification on the General Assembly drawing Ins...

Page 87: ...ifold thermocouple into the manifold thermocouple hole until it bottoms out in the hole Repeat for all manifold thermocouples 3 Bend the thermocouples into the slot 4 Install the manifold ground strap...

Page 88: ...g blue compound to the bottom of the inlet 7 Apply anti seize compound to the screw and install the inlet to the manifold 8 Torque screws in a crossing pattern gradually increasing torque to the speci...

Page 89: ...t and the manifold 11 Re install the inlet Torque screws in a crossing pattern gradually increasing the torque to the specified value 12 Install the inlet heater and sleeve to the inlet Ensure the ter...

Page 90: ...hermocouple 180 degrees Install the thermocouple clip 5 12 2 Install Inlet Extension Tip 15 Apply die spotting blue compound to the inlet extension tip and install it into the inlet Verify blued surfa...

Page 91: ...ip and the inlet 17 Apply anti seize compound to the threads and install the inlet extension tip to the inlet 18 Torque to the specified value Install Inlet Extension Tip continued 5 27 2020 Mold Mast...

Page 92: ...the valve nut and four M6 bolts 1 Valve insert 2 Valve nut 2 1 19 Verify the height of the valve insert and the depth of manifold bore to the dimension specified on the General Assembly drawing 20 App...

Page 93: ...a crossing pattern 23 Remove the valve insert and verify blue on all surfaces 24 Clean die spotting blue compound from all components Install Valve Insert Valve Insert Design continued 5 29 2020 Mold...

Page 94: ...ll and torque in a crossing pattern 26 Install the valve pin to verify fit Install Valve Insert Valve Insert Design continued 5 30 2020 Mold Masters 2007 Limited All Rights Reserved ASSEMBLY FSG2 User...

Page 95: ...ly die spotting blue compound to the valve disk stem 2 Install the valve disk stem into the manifold hole 3 Install the valve disk flange on top of the valve disk stem 5 31 2020 Mold Masters 2007 Limi...

Page 96: ...surface 6 Clean die spotting blue compound from all components 7 Re install the valve disk stem and valve disk flange Torque in a crossing pattern 8 Install the valve pin to verify fit Install Valve D...

Page 97: ...AUTION Use a soft jaw vise with the piston body to prevent damage to the part CAUTION 1 Install the spacers on top of the manifold or valve disk flange 2 Locate the pneumatic cylinder cooling plate on...

Page 98: ...ross pattern gradually increasing the torque 5 Place the cylinder housing onto the cylinder cooling plate 6 Insert the valve pin into the piston 5 34 2020 Mold Masters 2007 Limited All Rights Reserved...

Page 99: ...p 8 Install the piston top in the piston Using a soft jaw vise tighten the piston top to a torque of 10 N m 7 lb ft 9 Install the piston into the cylinder housing 5 35 2020 Mold Masters 2007 Limited A...

Page 100: ...1 Install the cylinder top 12 Apply anti seize compound to the threads of the screws Tighten the screws in a cross pattern gradually increasing the torque 5 36 2020 Mold Masters 2007 Limited All Right...

Page 102: ...t the actuator on the top of the valve disk flange 1 Install the spacers on top of the manifold or valve disk flange 2 Locate actuator on top of the spacers 3 Apply anti seize compound to the screws 5...

Page 103: ...e screws in a cross pattern gradually increasing the torque 5 Connect hydraulic and cooling water hoses as per the system design 5 39 2020 Mold Masters 2007 Limited All Rights Reserved ASSEMBLY FSG2 U...

Page 104: ...ot runner assembly during high temperature oven cleaning This could cause permanent damage to the actuators components CAUTION Valve insert design Valve disk design Figure 5 9 Waterless actuator model...

Page 105: ...stall support pillars b For the valve disk design install the support pillars on top of the valve disk flange See Figure 5 12 Support pillars Figure 5 12 Valve disk design install support pillars 3 To...

Page 106: ...ly Figure 5 13 Screw shoulder bolts into support pillar NOTE Ensure the bolts are fully seated in the support pillars See Figure 5 13 7 Torque the shoulder bolts in a crossing pattern Gradually increa...

Page 107: ...ments as shown on the General Assembly drawing See Figure 5 15 L1 L2 L2 distance from manifold plate to top of mounting plate pocket L1 distance from manifold plate pocket to cylinder top Note The act...

Page 108: ...late to the mounting plate Note gap now closed Figure 5 16 Bolt clamp plate This action should press the cylinder down to close the gap See Figure 5 16 11 Torque the bolts to the value specified on th...

Page 109: ...on on the manifold 2 Apply anti seize compound to the button head cap screws BHCS Using the BHCS screws install the bracket over the insulation plate in the appropriate location s on the manifold 3 Mo...

Page 110: ...rough the wire armor and install the wire armor channel caps 6 Repeat for all zones 5 16 3 Electrical Routing into Electrical Box 7 Install thermocouple and heater wires into the electrical plugs acco...

Page 111: ...ring 1 Install the solenoid coil wires into the electrical plugs according to the wiring schematic 2 Install the plugs into the electrical box 5 47 2020 Mold Masters 2007 Limited All Rights Reserved A...

Page 112: ...For ease of hose assembly the actuator has three optional plumbing cylinders 1 Connect the hoses to the actuators 2 Label and group the hoses 5 48 2020 Mold Masters 2007 Limited All Rights Reserved AS...

Page 113: ...hoses on top of the wire armor and secure with ties 4 Connect the hoses to the adapter plate according to the drawing schematic 5 49 2020 Mold Masters 2007 Limited All Rights Reserved ASSEMBLY FSG2 U...

Page 114: ...LOSE to the port on the top of the cylinder White G1 Close hoses go to the upper ports 4 Route the hose on top of the wire channel and secure with high temperature cable ties 5 Connect the other end o...

Page 115: ...the hose on top of the wire channel and secure with high temperature cable ties 4 Connect the other end of the hose to the port of the designated valve unit 5 Repeat above steps to connect each hose...

Page 116: ...t the valve pin opening speed of the connected actuator It has no effect on the closing speed 2 Install all fittings onto the mounting plate 3 Install the flow control valve onto mounting plate using...

Page 117: ...ve continued Solenoid Valve Unit Hydraulic Cylinder Adapter Plate PORT B CONTROL ELEMENT PORT A VP OPEN PORT LOWER VP CLOSE PORT TOP VP OPEN PORT VP CLOSE PORT Figure 5 17 Hydraulic flow control valve...

Page 118: ...It can also be used for system troubleshooting NOTE Figure 5 19 shows the additional components for a system which includes an actuator position sensor For a list of components for standard actuators...

Page 119: ...iston bottom See BOM list for new components 4 Install the piston assembly into the cylinder body assembly 5 Install the O ring rod seal and the retainer ring into the cylinder top Make sure that the...

Page 120: ...nto mounting slot Make sure that the sensor body sits on the bottom of the slot and the sensor top stop by the ring 9 Install the locker to hold sensor into place and lock the nuts Install Actuator Po...

Page 121: ...Flush 1 2 3 4 1 SCHSM5 2 Sensor 3 Dowel pin 4 Sensor bracket Figure 5 18 Top sensor mounting assembly installation 11 Run the sensor wires into the wire channel and route the sensor amplifier to the e...

Page 122: ...M12 nuts 1 Amplifier 2 LED light 1 2 13 Connect the wires to the connectors according to the wiring schematic Z BK 4 output PNP BN 1 Vs 0v BU 3 14 Follow the similar procedure to assemble the pneumati...

Page 123: ...in accordance with Mold Masters General Assembly drawings CAUTION IMPORTANT Water cooled gate inserts cannot be used in systems with protective sleeves 1 Install O rings to the gate insert 2 Install...

Page 124: ...g exit slot to the correct direction 6 Tighten the screws 4XSHCSM10 evenly to press the gate insert into correct position completely Tighten it with the required torque See torque table for torque spe...

Page 125: ...rform 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 SeVG Plus Actuator Models The SeVG...

Page 126: ...at the SeVG Plus actuator is not dropped at any time as damage to its connectors and internal parts may lead to the failure of the actuator CAUTION 1 Valve pin 2 Valve pin holder bottom 3 Valve pin ho...

Page 127: ...may lead to the failure of the actuator CAUTION IMPORTANT Mold Masters assumes no responsibility for connection monitoring and or maintenance of any cooling system associated with an SeVG Plus system...

Page 128: ...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 plate 14 Assembly screw 1 2...

Page 129: ...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 plate 14 Assembly screw 15 Quick connections for motor coo...

Page 130: ...6 6 SeVG Plus in Manifold Mounted Systems Figure 6 5 SE40 20 actuator in a manifold mounted system 6 6 2020 Mold Masters 2007 Limited All Rights Reserved SEVG PLUS ACTUATOR FSG2 User Manual...

Page 131: ...n serious injury or death Ensure the wires between the controller and the motors do not touch any heated components A non conductive plate is supplied with every SeVG Plus system For systems supplied...

Page 132: ...stic to become soft before the assembly is installed See Warning hot surfaces on page 6 7 Ensure that the cooling system is connected NOTE For systems with the water cooled model of the SeVG actuator...

Page 133: ...ssembly onto the motor Torque to 8 to 10 Nm 6 to 7 ft lbs See Figure 6 8 1 2 3 1 Motor rod 2 Valve pin holder top 3 Valve pin holder bottom 4 Valve pin 4 Figure 6 8 Valve pin holder components 9 Place...

Page 134: ...90 2 Motor mount flange 3 Valve disk flange 1 2 3 Figure 6 10 Insert the screws to fasten the assembly 11 Attach the water hoses 12 Place the cables in an insulated sheath with a heat rating of 280 C...

Page 135: ...ecurely to the wiring channel See Figure 6 12 Figure 6 12 Attach cables to wiring channel IMPORTANT The cables must not be allowed to touch the manifold or other heated components 14 Continue assembly...

Page 136: ...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 actuator may be perma...

Page 137: ...re is access to the valve pin holder Use a suitable wrench to open the valve pin holder to disconnect the pin and then remove the motor valve pin holder assembly If there is not access to the valve pi...

Page 138: ...system is securely grounded Turn the temperature control off and disconnect all electric wires coming from the mold Failure to follow any of these steps may lead to serious injury or death Ensure that...

Page 139: ...y Automatic Disconnection of Supply WARNING The user is responsible to take protective measures against shock by indirect contact while performing the tests The conditions for automatic shutdown of th...

Page 140: ...between each pair of thermocouple wires on the mold s thermocouple connector The resistance should be between 2 5 and 25 2 To verify alignment of thermocouple in the heating element turn on one zone...

Page 141: ...d loop temperature control in order to achieve accurate control If there are not enough control zones heat sources that have the same wattage and affect the same environment may be grouped together 7...

Page 142: ...to refer to the General Assembly drawings for full instructions 8 1 Unpacking 1 Carefully open the shipping crate and inspect the contents Secure loose items and check for any damage Remove any docum...

Page 143: ...ral Assembly drawings a support bushing with extra stock can be ordered from Mold Masters This bushing can then be machined from its bottom face to compensate for the system height difference caused b...

Page 144: ...installation CAUTION CAUTION The F3000 and F4000 nozzles are drop in systems They must be installed in a cold condition CAUTION CAUTION In systems that contain F3000 and or F4000 nozzles along with F5...

Page 145: ...t be turned on before heating is activated 16 Connect all electrical hydraulic pneumatic lines as applicable 8 4 1 Installation of a System with Flanged Nozzles 1 Inspect the flanged nozzle and if nec...

Page 146: ...ator valve pin move properly Ensure that a the valve pin moves fast and smoothly b the valve pin moves in the correct direction If not check the connection 5 If solenoid sequential control is used act...

Page 147: ...w control valve is lockable and the key can be used to unlock all valves Check to ensure the signal indication on controller screen or LED board matches the valve pin position Manually activate the ac...

Page 148: ...tige Check that the system is heated to processing temperature before actuating the valve pins Failure to do so could cause damage to the valve pins The maximum operating temperature for Hot Runner sy...

Page 149: ...nozzles to processing temperature 9 Begin nozzle heating when the manifolds and or bridges have come within 50 C of processing temperature IMPORTANT Wait until ALL heating zones have reached processin...

Page 150: ...from the FUSION SERIES G2 system prior to shutdown using a thermally stable material with a similar processing temperature 12 Turn off all heat to the system 13 Leave the mold cooling system turned on...

Page 151: ......

Page 152: ...rst color 2 Back off the machine barrel purge and introduce the new color 3 Increase the Hot Runner system temperature on all zones 15 25 C 59 77 F above processing temperature 4 Increase injection sp...

Page 153: ...system and start molding 10 4 Locating a Source of Contamination 6 Purge the original color from the machine following the instructions in 10 2 Color Change for a Hot Tip Sprue System on page 10 1 10...

Page 154: ...m the gate seal Torque sequence and step torquing Mold Masters recommends that manifold mounting screws be torqued in a standard bolt pattern and that the specified torque is achieved in 3 steps 1 3 2...

Page 155: ...450 332 Piston Top All All 8 mm 0 25 in hex key 10 7 5 Inlet Tip IE08TP IE09TP IE13TP IE14TP IE32TP F3000 F4000 F5000 F6000 36 1 41 88 65 IE29TP IE30TP IE33TP F7000 F8000 50 1 97 360 265 Actuator Moun...

Page 156: ...ere is a chance it has been exposed to high humidity during storage then the insulation resistance should be confirmed prior to installation Rmin 5 M at 500 V DC If necessary heating elements should b...

Page 157: ...ly from both sides in parallel This will help to get an equal exit length Align the center of heater element with the center of the manifold heater element path 8 Use a plastic nylon mallet to tap the...

Page 158: ...unbendable zones of the heater element This is the last 35 mm 1 4 in area on each end See below 35 mm 1 4 in 12 Crimp the wire with the proper size crimper pin Connect it to the heater threaded pin wi...

Page 159: ...ore information about hydraulic and pneumatic solenoid control valves which may assist system startup and maintenance 11 3 1 Hydraulic Solenoid Valve Bank The standard hydraulic valve bank has been co...

Page 160: ...high pressure The maximum working pressure of the PRV is 350 bar 5076 PSI and its adjusted pressure range is 28 80 bar 406 1160 PSI In other words the pump pressure to the valve bank is not the main c...

Page 161: ...ual hydraulic pressure that is driving the actuator there are two ports that can be used to install the pressure gauge Ports 3 2 1 P T Figure 11 2 Manometer mounting port Gauge Port Thread Size Pressu...

Page 162: ...DIN 43650 Form A Figure 11 3 Solenoid connector 11 3 3 Pneumatic Solenoid Valve Bank The stackable valve bank could be supplied from 2 to 12 units If reducing or adding new solenoid stations are need...

Page 163: ...external muffler to the ports 3 and 5 82 84 15 Insert the gasket and O ring into the right end plate 16 Insert the screws with your hand and assemble the end plates into the lower two tie rods Compon...

Page 164: ...to the system 18 Evenly tighten the tie rod mounting screws with a torque of 2 0 5 Nm 17 7 4 43 lbf in 19 Install solenoid connectors and hose fittings Components of a Hydraulic Solenoid Valve Bank co...

Page 165: ...itch Confirm the switch is in the right orientation O before starting production run Figure 11 4 Manual override switch b Solenoid Form C Connector Specification ISO 15217 2000 3 m 9 84 ft wire length...

Page 166: ...pare Seal Kits Actuator Type Bore Size mm in No Sensor Sensor Option Pneumatic 63 2 48 ORPNG2KIT ORPNG2KIT2 80 3 15 ORPNG2KIT1 ORPNG2KIT3 Hydraulic 41 1 61 ORHYG2KIT ORHYG2KIT1 Nozzle spring clip the...

Page 167: ...Failure to do so may lead to serious injury or death This troubleshooting information assumes that the Hot Runner has been operational Basic rules for troubleshooting are Define the problem what is se...

Page 168: ...acility HVAC 12 2 2 Resin Drying Issues During the drying stage of the resin if applicable ensure that the resin pellets are not overpacked adequate air circulation is present the drying system is pro...

Page 169: ...ecifications Verify that the pigment dye to be used meets manufacturer s specifications and is compatible with the resin molding machine mold Verify the correct recycle ratio and adjust settings accor...

Page 170: ...for this variation it is advisable to determine which of the original settings has changed 12 4 1 Fault Identification The operator will need to evaluate all the possible conditions which may have cau...

Page 171: ...ew 2 Mold Gate and or runner has dead spots 3 Material Physical contamination of raw material Chemical contamination of raw material Particulate contamination from machine barrel Solution in sequence...

Page 172: ...eed Feed error 2 Mold Trapped or volatile gas Low mold temperature Poor thin thick transition phase Inadequate venting 3 Material Overheating of resin Solution in sequence 1 Verify control and or hold...

Page 173: ...e too long 2 Mold Insufficient mold cooling Temperature of mold too high around the gate Temperature of mold too cool Gate size is too small Gate is in wrong location Land length of gate is too long I...

Page 174: ...volatile gas Burning due to friction Incorrect sprue diameter 3 Material Overheated underheated melt possible shear Solution in sequence 1 Clear blocked vent channels 2 Lower injection speed 3 Lower i...

Page 175: ...causing shear heat 3 Material Physical contamination of raw material Chemical contamination of raw material Melt too hot poor melt Incompatible color dye High percentage of recycled material Solution...

Page 176: ...esulting in wrong pressure Incorrect gate location Incorrect mold configuration size 3 Material Generally not a material related issue unless excessive regrind is used Solution in sequence 1 Increase...

Page 177: ...lt Incompatible color dye Residence time too high Solution in sequence 1 Purge heating cylinder 2 Lower resin temperature by reducing cylinder temperature reducing screw speed reducing back pressure 3...

Page 178: ...a too large for machine capacity 3 Material Low melt viscosity High melt temperature Solution in sequence 1 Reduce the injection speed 2 Reduce the injection pressure 3 Reduce the injection time 4 Inc...

Page 179: ...hine High injection speed 2 Mold Cold mold Small gate Wrong gate land length Wrong gate location 3 Material Cold melt Solution in sequence 1 Decrease injection speed 2 Verify nozzle temperature 3 Incr...

Page 180: ...ow injection speed 2 Mold Gating shear Sharp corners 3 Material Resin used is not homogeneous External contamination Solution in sequence 1 Reduce shear 2 Reduce back pressure 3 Reduce injection speed...

Page 181: ...obable Cause 1 Molding Machine Low injection speed Low injection pressure 2 Mold Cold mold Irregularities in mold surface defective polishing 3 Material Cold melt Solution in sequence 1 Increase injec...

Page 182: ...ve mold surface 3 Material Melt too hot Solution in sequence 1 Confirm cycle time for cooling 2 Reduce injection pressure 3 Reduce injection hold time 4 Reduce injection speed 5 Reduce injection time...

Page 183: ...not a material related issue Solution in sequence 1 Confirm cycle time for cooling 2 Reduce injection pressure 3 Reduce injection hold time 4 Reduce injection time 5 Adjust feed 6 Reduce mold closed t...

Page 184: ...venting Cold mold 3 Material Low melt temperature Viscous material Solution in sequence 1 Increase feed 2 Increase injection pressure 3 Increase feed temperature by increasing cylinder temperature 4 I...

Page 185: ...rrect rib wall dimensions Material flow incorrect Thick wall part 3 Material Hot material Material wrong grade for application Solution in sequence 1 Adjust injection speed 2 Increase injection hold t...

Page 186: ...d resin moisture dirt organics Degraded resin Solution in sequence 1 Dry resin according to procedure check drying equipment for functionality 2 Reduce nozzle temperature 3 Reduce material temperature...

Page 187: ...is identical cause may be the machine If pattern is erratic cause may be the material or coloring Degraded or unstable material Solution in sequence 1 Check for contamination 2 Check barrel purging 3...

Page 188: ...temperature 2 Mold Incorrect sprue 3 Material Melt strength inadequate Solution in sequence 1 Reduce back pressure 2 Modify nozzle temperature 3 Modify temperature profile 4 Eliminate sprue breaks 5 I...

Page 189: ...rect material Solution in sequence 1 Ensure temperature in both mold halves is equal 2 Monitor part ejection from mold for uniformity 3 Monitor part handling following ejection 4 Verify part weight fo...

Page 190: ...alve check ring malfunctioning Gates too far apart Redesign part 3 Material Cold melt Material wrong grade for application Solution in sequence 1 Increase injection pressure 2 Increase injection holdi...

Page 191: ...Solenoid Valve Bank 11 9 Pressure Reducing and Relieving Valve 11 7 S Safety Hazard Areas 3 2 Lockout 3 10 Safety Symbols General Descriptions 3 7 Solenoid Connector 11 9 Solenoid Form C Connector 11...

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