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20.6 Troubleshooting Typical Problems

20.6.1 Dark Specks

The finished product contains dark specks. Usually occurs when transparent 

resins are used. 

 

Probable Cause:

1.  Molding Machine

• 

Off-line for extended period

• 

Barrel off-line for extended period

•  Barrel improperly purged

•  Contamination in plasticizer

•  Wrong nozzle

•  Use of wrong screw

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):

1.  Purge system with appropriate material
2.  Trace source of contamination and repair, remove or discard
3.  Adjust melt temperature if necessary
4. 

Inspect for dead spots: gates, runners, nozzle, back flow valve

5.  Inspect feed screw for degradation

20-5

TROUBLESHOOTING 

Hot Runner User Manual 

© 2020 Mold-Masters (2007) Limited. All Rights Reserved. 

Summary of Contents for Hot Runner

Page 1: ...Hot Runner User Manual Hot Runner User Manual version 31 Original Instructions...

Page 2: ......

Page 3: ...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 Hot Runner Safety Haz...

Page 4: ...3 Valve Bushings 5 28 5 13 1 Types of Valve Bushings 5 28 5 13 2 Valve Bushing Installation 5 28 5 14 Mount the Manifold 5 30 5 14 1 Manifold Locator 5 31 5 14 2 Manifold Locating Dowel Pin 5 32 5 14...

Page 5: ...ng 6 5 Section 7 Hot Half Assembly 7 1 7 1 Hot Half Assembly 7 1 7 2 Stack Mold Cavity Plate Installation 7 3 Section 8 System Startup and Shutdown 8 1 8 1 Pre Startup 8 1 8 2 Startup 8 2 8 2 1 Standa...

Page 6: ...r 5500 Series 6X00 Series and 7100 Series 10 20 10 13 1 For Oil Systems 10 21 10 13 2 For Pneumatic Systems 10 21 10 14 Extraction Tools for Hydraulic and Pneumatic Actuators 10 22 Section 11 Slimstac...

Page 7: ...cating Ring 13 12 13 3 13 Perform E Drive Controller Checks 13 13 13 3 14 Install the Hot Half into the Mold 13 13 13 4 First Time Installation or Replacement of the Belt 13 13 13 5 Check for Misalign...

Page 8: ...ean Nozzle Insulator Cap 15 18 15 8 Installing Nozzle Insulator Cap 15 18 15 9 Valve Actuator Maintenance 15 19 15 10 Check Nozzle Tip Height 15 19 15 11 Latches 15 20 15 12 Latch the Cavity Plate to...

Page 9: ...embly after Maintenance 18 15 Section 19 Melt CUBE Systems 19 1 19 1 Identify Your Melt CUBE Design 19 2 19 1 1 The Melt CUBE Design A 19 2 19 1 2 The Melt CUBE Design B 19 2 19 2 Example of a Melt CU...

Page 10: ...e Contamination 20 1 20 1 2 Resin Drying Issues 20 2 20 1 3 Importance of Pre Drying Resin 20 2 20 2 Pre Molding Precautions 20 2 20 2 1 History 20 2 20 2 2 Material 20 2 20 2 3 Hardware 20 3 20 2 4 S...

Page 11: ...Section 21 Glossary of Terms 21 1 Index I ix Hot Runner User Manual 2020 Mold Masters 2007 Limited All Rights Reserved...

Page 12: ...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 following documents included in the package Th...

Page 13: ...continuous 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 inte...

Page 14: ...tion 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 force 4 448 N lbf in Pound force inch 0 113 Nm min Minute mm Millimete...

Page 15: ...palayam Rathinapuri Post Coimbatore T N 641027 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...

Page 16: ...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 Promcomplect Sharangovicha 13 220...

Page 17: ...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 a face shield and heat resistant glo...

Page 18: ...chine 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 mechanism a...

Page 19: ...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 Over pressurizatio...

Page 20: ...3 1 area 9 Whipping action 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...

Page 21: ...otective 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 machine i...

Page 22: ...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 prevent slips trips an...

Page 23: ...e Accumulator 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 Surfac...

Page 24: ...sure that the power and thermocouple connections have not been wired incorrectly Communications Interface and Control Sequence It is the customer s responsibility to verify functionality of any custom...

Page 25: ...ance to avoid potential risk of electrical shock Often power sources are inadvertently turned on or valves are opened mistakenly before maintenance work is completed resulting in serious injuries and...

Page 26: ...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 prio...

Page 27: ...ut 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 object or materials Moving object may be po...

Page 28: ...n 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 environmental friendly and d...

Page 29: ...r 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 recommendations Review their material safety d...

Page 30: ...ine 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 hydraulic and air lines as well...

Page 31: ...ith 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 to avoid overheating and...

Page 32: ...ibitors Calibrated torque wrench for consistent screw pressure throughout the system Pliers for general assembly work Circlip pliers to remove and install circlip in valve systems Micrometer 0 150 mm...

Page 33: ...length of each screw size CAUTION The use of an incorrect size length and grade screw could cause the screw to shear fatigue or stretch beyond its yield point resulting in expensive downtime of the H...

Page 34: ...on the packing slip were supplied 2 Check that all mold base dimensions are correct and correspond to Mold Masters General Assembly drawings 4 4 Cleaning 1 All nozzles manifolds and Hot Runner compone...

Page 35: ...s mentioned within the manual for additional information 4 5 1 System With Cast in Heater Element Figure 4 3 Cast in heater element 1 2 3 4 5 6 7 8 9 14 13 12 11 10 1 Insulation board 2 Leader pins 3...

Page 36: ...s 3 Top clamp plate 4 Hydraulic plate 5 Valve disks 6 Manifold locator 7 Electrical box 8 Leader bushing 9 Name plate 10 Manifold plate 11 Wire retainer 12 Nozzle 13 Manifold 14 Inlet extension 15 Pip...

Page 37: ...d 2 Top clamp plate 3 Hydraulic plate 4 Bridge 5 Step 6 Electrical box 7 Name plate 8 Manifold plate 9 Nozzle 10 Manifold 11 Valve disks 12 Hydraulic pneumatic actuators 13 Backplate 14 Locating ring...

Page 38: ...technology and thermal gating 2 3 4 1 5 6 7 8 15 14 13 12 11 10 9 1 Insulation board 2 Locating ring 3 Top clamp plate 4 Center heater 5 Manifold 6 Nozzle 7 Electrical box 8 Manifold plate 9 Name plat...

Page 39: ...nsulation board 2 Leader pin 3 Hydraulic plate 4 Valve disk 5 Manifold 6 Nozzle 7 Disc spring 8 Hardened washer 9 Leader bushings 10 Name plate 11 Manifold plate 12 Jiffy plugs 13 Manifold locator 14...

Page 40: ...two halves valve side and non valve side The terminology associated with the various components and features are listed below Figure 5 1 Cutaway cast in system Valved 12 2 7 3 6 4 9 5 11 1 8 10 Non V...

Page 41: ...tures are listed below Valved Non Valved Hot Half Bolt In Arrangement 3 5 6 1 10 11 9 7 2 8 4 1 Manifold locating cam 2 Bolt in manifold 3 Gate seal gate insert 4 Heater plate 5 Inlet extension 6 Loca...

Page 42: ...igure 5 3 Cutaway of a MasterSHIELD cast in system Valved 1 2 3 4 5 6 7 Non valved 8 9 10 11 12 13 5 4 Gate Seal Finishing Most nozzles are supplied with the gate seal installed except when the seal r...

Page 43: ...n of the nozzle must be taken into consideration Check the chart on the General Assembly drawings for the length and contact height required See contact length H on table below Always refer to the Gen...

Page 44: ...well and nozzle well details 2 Finish to final height and to correct guiding diameter if required Refer to your system drawing for details 3 Clean the insert seating bore 4 Install O rings onto the wa...

Page 45: ...n a pin vise NOTE For front mounted thermocouples skip step 2 and go straight to step 3 Insert the thermocouple through the flange bore 2 Manually bend the thermocouple tip against your thumb to appro...

Page 46: ...p of the nozzle to keep the thermocouple inside the bore This is especially important when thermocouples are assembled from the front 4 Install the terminal end retaining clip Check that the thermocou...

Page 47: ...damage them and is not recommended unless replacing a damaged thermocouple with a replacement one CAUTION 1 Remove the thermocouple from the electrical box and wire channels 2 Remove the nozzle from...

Page 48: ...pe of Dura nozzle requires a different bending tool The correct bending tool would be supplied with your Hot Runner 1 Clean nozzle thermocouple bore 2 Place thermocouple through the flange of the nozz...

Page 49: ...e bending the thermocouple at the flange 6 Press thermocouple downwards to sit against terminal end and secure to side of terminal end with heat resistant tape to ensure it does not become pinched bet...

Page 50: ...ermocouple wires just above or below the insulator pod The nozzle is ready for assembly with the thermocouple fully installed Dura Line Thermocouple installation continued 5 11 ASSEMBLY Hot Runner Use...

Page 51: ...vity In these cases care is needed to prevent damage to the sharp edge of the gate seal and gate seal receiving bore CAUTION NOTE Prior to commencing assembly verify manifold and nozzle cutouts in mol...

Page 52: ...e compound to the thread of each screw 3 Lower the manifold into position on top of the step 4 Install the screws through the manifold and the step into the nozzle 5 Torque screws to the value specifi...

Page 53: ...wel 4 Nozzle Figure 5 7 ThinPAK and MasterSHIELD nozzle and components 1 Clean the nozzle well seating bore 2 Install the hardened washer 3 Apply high temperature grease to the spring and install the...

Page 54: ...s in the slot cutout in the manifold plate Top view Side view Anti rotation dowel 5 Check that the nozzle sits squarely in the nozzle well bore 5 15 ASSEMBLY Hot Runner User Manual 2020 Mold Masters 2...

Page 55: ...s 4 3 2 1 Figure 5 8 Master Series Pico nozzle with optional MasterSHIELD components 1 Hardened washer 2 Disc spring 3 Nozzle retainer 4 Nozzle 1 Clean the seating bore of the nozzle well 2 Install th...

Page 56: ...ring in the correct orientation 5 Install the top hardened washer Install the nozzle retainer 6 Install the nozzle For anti rotation use the bolts between the manifold and nozzle 5 17 ASSEMBLY Hot Run...

Page 57: ...7 Make sure that the nozzle sits correctly in the nozzle well bore 5 18 2020 Mold Masters 2007 Limited All Rights Reserved ASSEMBLY Hot Runner User Manual...

Page 58: ...asterSHIELD components 1 Hardened washers 2 Disc springs 3 Nozzle retainer 4 Nozzle 1 Clean the seating bore of the nozzle well 2 Install the bottom hardened washer 3 Apply high temperature grease to...

Page 59: ...a different orientation from that of other MasterSHIELD systems 5 Install the top spring NOTE The top spring has a different orientation to that of the bottom spring 5 20 2020 Mold Masters 2007 Limit...

Page 60: ...washer 7 Install the nozzle retainer 8 Install the nozzle For the anti rotation version use the bolts between the manifold and the nozzle 5 21 ASSEMBLY Hot Runner User Manual 2020 Mold Masters 2007 L...

Page 61: ...9 Make sure that the nozzle sits correctly in the nozzle well bore 5 22 2020 Mold Masters 2007 Limited All Rights Reserved ASSEMBLY Hot Runner User Manual...

Page 62: ...ront Mounted Thermocouples 1 Place a zone number on each wire and thermocouple 2 Try to organize and tape wires by zone and plug 3 Install the wires into the wire channels and secure with wire retaine...

Page 63: ...ented from November 2019 onward The cutout needs to be requested when ordering so that it can be machined into the hot half during manufacturing The sleeve is shipped installed over an assembly tube T...

Page 64: ...the heater element is pointing away from the nozzle Figure 5 13 Installed heater sleeve and tube assembly 2 Make sure that the nozzle is positioned within its cutout so that the heater element exit i...

Page 65: ...ap in the heater sleeve You may have to disassemble and re assemble the nozzle 4 Make sure that the emergency heater is aligned with the end of the chamfer on the nozzle body 5 26 2020 Mold Masters 20...

Page 66: ...ion 5 11 2 5 12 2 Removal of Emergency Heater Sleeve Equipment that can be used to do this procedure snap ring pliers 1 Open the emergency heater sleeve 2 Use the slots on the emergency heater sleeve...

Page 67: ...do so may cause serious injury Do not shorten the screw length This procedure applies to valve gated systems that are bolt in design Refer to the parts lists and the General Assembly drawing to deter...

Page 68: ...flange seal level Refer to the General Assembly drawings for correct screw size 7 Torque screws to value indicated on the General Assembly drawings and secure manifold to the manifold plate NOTE On br...

Page 69: ...nifold locator 2 Manifold locating dowel pin 3 Manifold and slot locator Manifold Locator Manifold Locating Cam Figure 5 19 Manifold with a locator SURFACE A SURFACE B FACE Y X Figure 5 20 Locator sur...

Page 70: ...allow SURFACE A and SURFACE B to be at the same level in the cold condition or as specified on the General Assembly drawing FINAL GRINDING NOT REQUIRED In other systems the manifold locator does not r...

Page 71: ...hed wires 5 14 3 Manifold and Slot Locator 1 Apply die spotting blue compound to the manifold locator into the bore to ensure proper seating 2 Install the slot locator into the mold IMPORTANT Ensure s...

Page 72: ...e 4 Press down on the thermocouple and gently bend the thermocouple sheath through 90 5 Check that the thermocouple sits in the manifold cutout 6 Install the thermocouple washer and screw 7 Install a...

Page 73: ...Step 3 2 1 4 1 Mounting screws 2 Main manifold 3 Dowel pin 4 Inlet seal Figure 5 23 Install main manifold Manifolds that use a seal without a step 1 Place the inlet seal into all submanifold inlets 2...

Page 74: ...re not used within ThinPAK Series systems Please see Support Bushing Installation for Systems with MasterSHIELD on page 5 42 Review your parts list and General Assembly drawing to determine the featur...

Page 75: ...ght pocket depth air gap Figure 5 26 Calculating pressure disk valve disk height Calculate Pressure Disk Height 1 Calculate the following dimensions at ambient room temperature a Measure the depth of...

Page 76: ...ample Calculations Nozzle pocket depth a 91 39 mm 3 60 in Nozzle flange height b 43 16 mm 1 70 in Manifold thickness c 43 16 mm 1 70 in Air gap as noted on drawing 0 05 mm 0 002 in Pressure disk heigh...

Page 77: ...the pressure disk to the manifold Grind equal amounts Stone sharp corners 5 17 3 Pressure Disk Final Grinding Not Required Figure 5 30 Optional pressure disk mounting detail Alternate Method Air gap a...

Page 78: ...amic disk is facing upwards and will contact the pressure disk when assembled 3 Secure the EcoDisk with an M5 flat head screw uniformly following the plate assembly specification 4 Repeat for all EcoD...

Page 79: ...Figure 5 32 Manifold to nozzle mounting 3 Install the manifold to the nozzle 4 For 1 piece valve disk Install the valve disk in appropriate orientation For 2 piece valve disk Insert valve stem into t...

Page 80: ...e nozzle into the manifold plate 3 Install the manifold to the nozzle 4 Refer to the General Assembly drawing for valve disk locations 5 Measure the gap between the top of the manifold plate and the t...

Page 81: ...ort bushings are supplied to final dimensions No final grinding is required Refer to the General Assembly drawing for more information 1 Install the manifold into the plate and ensure that it sits on...

Page 82: ...wel Valve disk Manifold plate Nozzle Figure 5 36 MasterSHIELD system with a valve disk 1 Install the manifold into the plate and ensure that it sits on the nozzles NOTE Refer to the General Assembly d...

Page 83: ...of the same material be of equal wattage and be located in similar thermal environments These procedures apply to systems with external heater plates Refer to the General Assembly drawing to determin...

Page 84: ...e a zone number on each wire and thermocouple 6 Tape wires for each zone together 7 Install the wires into wire channels and secure with wire retainers 8 Feed the wires back through the wire channel i...

Page 85: ...e seating on the bottom face of the back plate and manifold 3 Install the back plate onto the manifold 4 Install M8 mounting screws through the back plate to the manifold using anti seize compound on...

Page 86: ...annels and secure with wire retainers 8 Feed wires back through the wire channel in the mold base to the electrical box 5 21 3 Three Piece Center Heater Installation 1 Install the back plate on the ma...

Page 87: ...ire and thermocouple 5 Tape wires for each zone together 6 Install the wires into the wire channels and secure with wire retainers Feed the wires back through the wire channel in the mold base to the...

Page 88: ...ired height NOTE A pressure sleeve is supplied oversize in length Refer to General Assembly drawing to determine length of pressure sleeve 1 2 3 4 5 6 7 1 Extension 2 Inlet extension 3 Thermocouple 4...

Page 89: ...rical checks refer to Section 6 Electrical Testing 1 Inlet extension 2 Manifold 3 Extension tip 4 Pressure sleeve 1 2 3 4 Figure 5 43 Inlet extension with sleeve Inlet Extension with Pressure Sleeve c...

Page 90: ...Mold Masters components and systems 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 s...

Page 91: ...rlier in the introduction are the final authority 6 3 1 Verify Equipment to its Technical Documentation First verify that the electrical equipment complies with its technical documentation 6 3 2 Insul...

Page 92: ...with a current between at least 0 2 A and approximately 10 A derived from an electrically separated supply source for example SELV see 413 1 of IEC 60364 4 41 having a maximum no load voltage of 24 V...

Page 93: ...he Hot Runner 2 Connect a temperature control device to read the temperature 3 Immerse the sheath of the thermocouple in boiling water to the point where the thermocouple reads the temperature A good...

Page 94: ...to ASA standards White Red The tip must not be truncated or squeezed and must touch the bottom of the bore in order to measure the correct temperature Each heat source should have its own closed loop...

Page 95: ......

Page 96: ...ut the machine according to the documented procedures Failure to do so may result in serious injury or death CAUTION Do not assemble disassemble the cavity plate with the valve pins forward Valve pins...

Page 97: ...install the cavity plate on a cold manifold 7 When the manifolds reach 180 C 365 F install the cavity plate on the manifold plate If the plate does not assemble easily remove the cavity plate and chec...

Page 98: ...pending on the stack mold design The following instructions should be considered as guidelines only 1 Check that the nozzle well depth L in the cavity plate is to Mold Masters specifications See Figur...

Page 99: ...Chart for System Assembly Screws on page 15 26 9 Attach a crane that is rated to support the weight of the mold 10 Lock out and tag out the machine according to the documented procedures 11 Latch the...

Page 100: ...heck 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 systems...

Page 101: ...ION IMPORTANT When running thermally sensitive materials use a thermally stable material as recommended by the material supplier for the initial startup 1 Turn on the machine barrel and mold cooling s...

Page 102: ...erial as recommended by the material supplier for the initial startup 1 Heat up all Hot Runner manifolds submanifolds bridges sub bridges and inlets excluding the nozzles to processing temperature 2 A...

Page 103: ...perature is within 55 C 130 F of the mold temperature 8 3 2 Stack Mold System CAUTION Failure to follow this procedure may result in leakage damage occurring in the Hot Runner CAUTION IMPORTANT Therma...

Page 104: ...ter to take the time to latch over the cavity plate and clean out the gate bubbles or just run scrap parts slightly longer to clean out the gate bubble area Use purge compounds for color change in the...

Page 105: ...ghly 2 Increase Hot Runner system temperature on all zones 20 C 68 F above processing temperatures On Mold Masters controllers simply push the boost button to increase temperatures for a pre determine...

Page 106: ...njection rate possible Repeat this several times NOTE It may be advisable to put a protective shield over the core side to prevent plastic from injecting and cooling on the core side 18 Set the shot s...

Page 107: ...1 Screw 2 Cylinder top 3 Locating dowel 4 Cylinder top O rings 5 Small O ring 6 Piston top 7 O ring 8 Circlip 9 Spring assembly 10 Stud 11 HY7100 spacer 12 Outer seal 13 Piston 14 Inner Viton O ring 1...

Page 108: ...cylinder 6X00 Series and 7100 Series only 2 Press the rod seal into position 3 Install the circlip with sharp edges facing up 4 Lubricate the bottom cylinder external O rings and install 1 Circlip 2 R...

Page 109: ...g An installation tool is available PS0003TOOL02 for installing the seal 4 Once all 3 rings have been assembled place installation tool PS0003TOOL01 over assembly as shown and allow rings to settle 1...

Page 110: ...r top 4 Locating dowel Figure 10 8 Typical cylinder top 10 6 Valve Pin Finishing of Tip 10 6 1 5500 Series 1 Install the cylinder where applicable and piston bottom without the pin and piston top into...

Page 111: ...n in the gate area using a lapping guide bushing or valve bushing as a lapping guide We recommend 400 600 grit lapping paste 1 2 3 4 5 1 Nozzle flange bore 2 Machined bushing for center alignment 3 No...

Page 112: ...eral Assembly drawing or Gate Detail drawing for grinding specifications 5 Lap the tip of the pin into the land area steel section in the gate area using a lapping guide bushing or valve bushing as a...

Page 113: ...sure the distance CD in the heated condition Check that the head of the pin is seated 11 Calculate the dimension to be ground L2 L2 CD measurement CD specified 12 Grind the pin end to remove L2 finish...

Page 114: ...36 35 1 43 HE CD mm in HY8700 L AC 59 70 2 35 HE CD mm in HY8800 L AC 59 70 2 35 HE CD mm in 7 Grind the valve pin tip to fit the cylindrical gate Refer to the system gate detail 8 Assemble the hydra...

Page 115: ...C 6 Calculate the heat expansion factor Fh Processing temperature Mold temperature C x 0 000012 7 Calculate the heat expansion of the valve pin HE distance BC x heat expansion factor BC x Fh 8 Cut pin...

Page 116: ...the pin diameter 2 Insert the valve pin through the bushing 3 Add 400 grit lapping paste to the tapered area of the pin and lap into the gate Verify the shut off with die spotting blue compound 4 Be s...

Page 117: ...nce 4 Check that the tip of the pin is fitted correctly into the land 5 The heat expansion difference between the mold and Hot Runner is removed by grinding the back of the pinhead 6 HED AC AB 3 05 0...

Page 118: ...pin length Refer Valve Pin Finishing of Tip on page 10 4 2 Slide the valve pin into position 3 Assemble the disk springs to the spring retainer stud a Check for the correct orientation of the disk sp...

Page 119: ...ud a Check for the correct orientation of the disk springs when installing b 6500 Series align the springs in five alternating groups of five convex and concave c 6600 Series align the springs in eigh...

Page 120: ...to the spacer s threaded end it allows for simple extraction of the spacer 4 Grease and install the O ring 5 Install piston top and tighten to recommended torque setting 20 27 Nm 15 20 ft Ib Figure 10...

Page 121: ...the cylinder into the bore of the actuator plate with a nylon mallet 4 Position the piston installation tool PS0003TOOL01 on top of the cylinder 5 Install the valve pin and piston into the cylinder b...

Page 122: ...PORTANT EXTOOLAS10 replaces EXTOOL5500A EXTOOL6500A EXTOOLAS01 Figure 10 22 Cylinder extraction tool 1 EXTOOLAS10 2 Cylinder extraction tool 3 Cylinder 1 3 2 10 16 2020 Mold Masters 2007 Limited All R...

Page 123: ...pin and piston into the cylinder bottom 6 Press the valve pin into position using a nylon mallet to finish seating the valve pin into the assembly 7 Remove the installation tool 8 Check that the cyli...

Page 124: ...gure 10 23 Single sensor bracket assembly on page 10 18 Insert one proximity sensor into the metal bracket hole Lock the position of the proximity sensor with the lock nuts See 10 11 1 Cutout Options...

Page 125: ...out Options Based on Stroke For 9 8 mm Stroke For 19 8 mm Stroke Option 1 For 19 8 mm Stroke Option 2 10 19 HYDRAULIC PNEUMATIC ACTUATORS Hot Runner User Manual 2020 Mold Masters 2007 Limited All Righ...

Page 126: ...lock nuts until the sensor detects the trigger ring after which the LED light will turn on 5 Operate the hydraulic actuator until the piston top is in the open position Stop the hydraulic actuator at...

Page 127: ...a bench 10 13 1 For Oil Systems 1 Remove oil from system 2 Remove the cylinder top with tool in upright position to prevent oil from entering the system 3 Heat up the system required to remove the va...

Page 128: ...oller bearing 4 External retaining ring 5 Sleeve 6 Socket head cap screw M5X16 7 Rod 8 Socket head cap screw M6 X 12 9 Flange 10 Holder 11 Set screw M4X8 12 Set screw M5X16 13 Puller base M5 screws 14...

Page 129: ...0 N A HY6500x HY6500xAR HY650Xx HY650XxAR HY650XxL HY650XxLAR HY6600x HY6600xAR HY6700x HY6700xAR HY7100x HY7100xAR HY710X x HY710XxAR HY710XxL HY710XxLAR HY8700x VPAC0008 VPAC0009 VPAC0010 VPAC0011 E...

Page 130: ...tion provides the information for the assembly and installation of a Slimstack actuator Refer to the General Assembly drawings for part names sizes and quantities for any components See Figure 11 1 Sl...

Page 131: ...ead cap screw 15 Titanium locating ring 16 Outer body 17 Dowel pin 18 O rings 19 Valve pin holder 20 Ungrounded thermocouple 21 Set screw 22 Ground wire 23 Dowel pin 24 Valve pin 25 O ring 26 O ring 2...

Page 132: ...head cap screw Outer body Custom support plate Thermocouple wire left Heated body Piston bottom Valve pin Valve pin guide Flat head cap screw Inlet seal Dowel Set screw Pressure plug Valve pin holder...

Page 133: ...l Assembly drawing install the O rings into the grooves on the piston top and the piston bottom Carefully push the O rings into the grooves using your finger Ensure the O rings are firmly seated in th...

Page 134: ...d of the ground wire is completely within the mating hole 4 Lock the ground wire using a set screw See Figure 11 5 1 Thermocouple 2 Ground wire 3 Set screw 2 3 1 Figure 11 5 Install ground wire and th...

Page 135: ...ted body 1 2 3 Figure 11 6 Install valve pin and valve pin guide 6 Insert the valve pin holder into the heated body slot and over the head of the valve pin Valve pin holder Valve pin head Figure 11 7...

Page 136: ...of valve pin into keyhole slot 8 Slide the valve pin holder to locate the valve pin head in the narrowed portion of the slot See Figure 11 9 Narrowed portion Figure 11 9 Locate the valve pin head in t...

Page 137: ...o piston bottom IMPORTANT For step 10 the valve pin holder slot on the piston top must be facing downwards towards the nozzle This slot is shown in Figure 11 11 Valve pin holder slot Figure 11 11 Slot...

Page 138: ...s the nozzle Slide the piston assembly over the heated body and seat the valve pin holder into the piston top slot See Figure 11 12 and Figure 11 13 Figure 11 12 Install piston assembly onto heated bo...

Page 139: ...piston assembly and valve pin holder 12 Carefully place the valve bushing on the nozzle NOTE Ensure that the slot on the valve bushing and the thermocouple groove on the nozzle are on the same side T...

Page 140: ...ft lb See Figure 11 16 1 2 1 Retainer 2 SHCSM4X50 2X Figure 11 16 Attach retainer to valve bushing 16 Position the dowel on the valve bushing to align with the slot on the heated body Carefully attach...

Page 141: ...of the seals prior to O ring installation will make the procedure easier 18 As shown in the General Assembly drawing install the O rings into the grooves on the outer body Carefully push the O rings...

Page 142: ...plate and the O ring is in place on the outer body See Figure 11 20 1 Attach the outer body to the manifold plate using socket head cap screws Torque to 15 Nm 11 ft lb See Figure 11 20 11 4 Installati...

Page 143: ...Turn the manifold plate and carefully install the Slimstack unit into the manifold plate using screws with washers See Figure 11 23 IMPORTANT Ensure that the nozzle and the heated body terminal end a...

Page 144: ...24 Stack disc springs in series 6 Attach the custom support plate to the manifold plate with four socket head cap screws Torque to 72 Nm 53 ft lb See Figure 11 25 Figure 11 25 Attach custom support pl...

Page 145: ...ge 5 1 7 Mount the nozzle thermocouple on the front of the nozzle See Figure 11 26 Figure 11 26 Mount nozzle thermocouple 8 After turning the manifold plate attach the inlet seal to the heated body Ch...

Page 146: ...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 12 2 SeVG Plus Actuator M...

Page 147: ...hat 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 h...

Page 148: ...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 1 Valve p...

Page 149: ...VG 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 2 1 3 4 5 7 1 Valve pin 2 Valve pin holder bottom 3 Valve pin...

Page 150: ...4 1 Note non cooled model shown Figure 12 4 SE40 20 actuator in a Hot Runner system 12 6 1 SE20 15 Model 1 2 3 4 1 SeVG Plus actuator 2 Frame plate 3 Actuator plate 4 Manifold plate Figure 12 5 SE20 1...

Page 151: ...rious 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 with...

Page 152: ...ge 12 6 Make sure that the cooling system is also connected 12 7 1 Attach the Water Lines Cooled Models Only CAUTION Ensure that excess force is not exerted on the interface between the fitting and th...

Page 153: ...ve pin holder assembly cross section Figure 12 3 Valve pin holder assembly 12 7 3 Install the Motor and Valve Pin Assembly 1 Hold the motor rod to prevent rotation See Caution on page 12 7 2 Install t...

Page 154: ...e with four SHCSM6X25 screws Torque to 18 Nm 13 ft lbs See Figure 12 5 and Figure 12 6 Figure 12 5 Install the SE40 20 actuator Figure 12 6 Install the 40 20C actuator Install the Motor and Valve Pin...

Page 155: ...p of the assembly Use the SHCSM5X155 mounting screws DO NOT use the two assembly screws marked with the dye spotting blue compound to attach the actuator See Figure 12 8 Figure 12 7 Install the SE20 1...

Page 156: ...drive to retract or extract the rod until the system reaches the internal hard stop position or the actuator may be permanently damaged Ensure that any cables or attachments do not become damaged duri...

Page 157: ...move the valve pin 3 Remove the two SHCSM5X155 mounting screws See Figure 12 10 Figure 12 10 Remove the two mounting screws 4 Pull motor up until the valve pin is free to disengage 12 12 2020 Mold Mas...

Page 158: ...1 E Drive system 2 3 4 5 7 8 6 1 1 Insulation plate 2 Locating ring 3 Gear box 4 Servo motor 5 Gear mount 6 Interface plate 7 Top plate 8 Fixed idler 9 10 12 13 14 11 9 Drive pulley 10 Idler pulley 1...

Page 159: ...ssembly 5 Synchro plate 6 Valve pin holder 7 Valve pin 1 2 3 1 Synchro plate 2 Inlet extension 3 Tensioning idler assembly 5 6 7 4 Typical E Drive System continued 13 2 2020 Mold Masters 2007 Limited...

Page 160: ...mponents Figure 13 3 E Drive components Ball screw assembly Tensioning idler assembly Fix idler E Drive motor mount exploded view 13 3 E DRIVE Hot Runner User Manual 2020 Mold Masters 2007 Limited All...

Page 161: ...r between the controller and the mold Combination Hazards Failure Disorder of Control System Mixed up connections of the motor power cables on dual motor units may result in an out of control or unexp...

Page 162: ...ed and requires minimal pre installation assembly The following details the assembly installation procedures for various components of the E Drive 1 Top plate 2 Fixed bearing angular contact ball bear...

Page 163: ...e Hot Runner system to the manifold plate 13 3 2 Interface Plate Assembly 1 Assemble the interface plate to the manifold plate Install the fastening screws between the plates 13 6 2020 Mold Masters 20...

Page 164: ...interface plate 1 Top stop buttons 2 Ball nut flange seating area 3 Guide bushings with top bottom retainers 4 Bottom stop buttons 1 2 3 4 2 Assemble the valve pin holders into the synchro plate Valve...

Page 165: ...the lubrication It may damage the part We recommend to use Dynalub 510 as a lubricant Do not use grease based graphite or MoS2 It will reduce the life time of the ball screws CAUTION 1 Move the ball...

Page 166: ...004 in to seal with the cover 2 Install the cover plate into position 3 Assemble ball nut on ball screw with a torque of 43 45 Nm 31 7 to 33 1 lbf ft NOTE Ball screw mounting kit EDRIVEBSMNTKITP is s...

Page 167: ...with the ball screw to the synchro plate 3 Install the motor and the gearbox to the unit 4 Install the tension idler pulleys to the top plate 13 3 9 Attach the Synchro Plate to Top Plate Assembly 1 U...

Page 168: ...sity width and span length to the Sonic tension meter Refer the name plate for the required information Belt density M 004 7 g m fixed value Belt width W 012 0 mm R fixed value Span length S Variable...

Page 169: ...e depth gauge tools and inspect the parallelism with the help of the measuring holes provided in the system Measuring holes Enlarged view 2 Once the parallelism is confirmed tighten the screws 2 Nos i...

Page 170: ...e valve pins are at the open position before shipping CAUTION 13 4 First Time Installation or Replacement of the Belt Figure 13 5 Installation or replacement of the belt 1 Idler nut and pulley 2 Tensi...

Page 171: ...ley to still rotate not gripping yet 8 Apply slight tension to engage two pulleys check elevation of pulleys 9 Time both ball screw pulleys to engage in same way 10 Tighten the taper bushing set screw...

Page 172: ...ignment will result in some reduction of belt life which is not accounted for in the normal drive design procedure Misalignment of all positive belt drives should not exceed 1 4 or 5 mm per metre of c...

Page 173: ...and shut down any cavity in a synchro plate design NOTE Deactivation of the magnets must be only used as a temporary solution Engaged Disengaged Do not use the Mag Pin option for the conditions that f...

Page 174: ...02 Main holder body 10 VALVE PIN STD 2 5 or 3 mm 14 2 Mag Pin Safety WARNING STRONG MAGNETIC FIELD HAZARDS Persons with pacemakers or other metallic electronic magnetic implants devices or objects sha...

Page 175: ...ose position decrease the temperature until the plastic material is frozen This low temperature plastic around the valve pin holds the pin in the closed position The valve pin separates from the synch...

Page 176: ...the nozzle is turned on the plastic material around the valve pin releases the pin and the magnet is engaged at the interface when the actuation starts Mag Pin Operation continued Figure 6 3 Mag Pin a...

Page 177: ...etween the magnets to prevent the contact between them when you handle and store the magnets Make sure that you keep the groups of magnets in a thick plastic container to avoid impact with other parts...

Page 178: ...age 14 10 10 Install Mag Pin Assembly into the Synchro Plate on page 14 11 14 6 Assembly Details WARNING Be careful of the possible pinch hazards when you handle the magnets Store the magnets in a saf...

Page 179: ...nets before assembly Flip the magnet if the polarity shown on the magnet is wrong Correct setup Wrong setup Flip the magnet 14 6 3 Clean the Magnet Holder 1 Clean and inspect the magnet holder 2 Make...

Page 180: ...with a torque of 27 to 30 Nm 20 to 22 lbf ft 14 6 5 Place the Magnet Holder and Magnet into the Housing 1 Install the magnet holder and magnet into the housing 2 Use a 5 mm 0 2 in hex key and rotate t...

Page 181: ...plate in heated condition and examine the valve pin height 5 Adjust if required and ensure the correct valve pin height 0 50mm Figure 14 4 Jam nut assembly 14 6 7 Assemble the Valve Pin into the Valve...

Page 182: ...e on the valve pin holder 3 Use a cloth and clean the excessive grease from the top and side faces 14 6 9 Assemble Valve Pin into Housing Assembly 1 Carefully assemble the valve pin into the housing a...

Page 183: ...the system and adjust the valve pin height if the valve pin protrusion is not correct 2 The Mag Pin assembly at this condition can be installed into the synchro plate 14 11 MAG PIN OPTION Hot Runner...

Page 184: ...S10 1 EXTOOL13B 2 EXTOOL13A 3 M8 thread 4 M5 thread 1 Heat the system to the processing temperature 2 Make sure that the manifold reaches the required temperature 3 Extract the Mag Pin assemblies one...

Page 185: ...ool EXTOOL13A on top of the valve pin holder b Couple the extraction tool with the M8 screw and M8 washer and extract the Mag Pin assembly 1 M8 screw 2 EXTOOL13A 3 M6 screw Mag Pin Extraction continue...

Page 186: ...L13B 2 EXTOOL13A If the valve pin gets stuck in the mechanism or if it detaches from the magnet interface choose one of the methods that follow a Method 1 Extract the valve pin and holder with a M5 sc...

Page 187: ...ool EXTOOLAS10 with extraction tool EXTOOL13B Use the M5 thread end for extraction of valve pin 1 M8 thread 2 EXTOOL13B 3 M5 thread Mag Pin Extraction continued 1 2 3 14 15 MAG PIN OPTION Hot Runner U...

Page 188: ...maintenance to avoid potential risk of electrical shock To avoid serious burns wear safety clothing consisting of a protective heat resistant coat and heat resistant gloves Use adequate ventilation f...

Page 189: ...Attach the valve disk extraction tool to the valve disk 3 Attach the EXTOOLAS10 tool to the valve disk extraction tool 4 Extract the valve disk from the manifold IMPORTANT Ensure that the pulling dir...

Page 190: ...sk extraction tool to the valve disk 4 Attach EXTOOLAS10 to the valve disk extraction tool 5 Extract the valve disk from the manifold IMPORTANT Ensure that the pulling direction is perpendicular to th...

Page 191: ...OOLAS10 2 LHCSM4X16 2x 3 Spacer 4 Extraction tool for threaded models 5 Valve disk stem 5 Figure 15 4 For valve disks with threads For valve disk stems with continuous grooves b Attach the valve disk...

Page 192: ...alve disk stem NOTE For close pitch conditions use EXTOOLAS10 with a spacer 5 Extract the valve disk from the manifold IMPORTANT Ensure that the pulling direction is perpendicular to the manifold surf...

Page 193: ...erted Style 7 74 2 1 EXTOOL26P 2 piece Extended Inverted Style 10 74 EXTOOL27P 2 piece Extended Inverted Style 15 74 EXTOOL35P 2 piece Extended Inverted Style with 6 7 groove 2 1 EXTOOL36P 2 piece Ext...

Page 194: ...OLAS 10 EXTOOL28 35 mm Valve Disks Non Inverted Design EXTOOL29 39 mm Valve Disks Non Inverted Design EXTOOL30 42 mm Valve Disks Non Inverted Design EXTOOL31 49 mm Valve Disks Non Inverted Design 1 F...

Page 195: ...Figure 15 6 Nozzle terminal assembly 2 Grip the element sleeve at the threaded area and turn counter clockwise If the wires rotate with the sleeve damage may result 3 Remove the seal 4 Remove the set...

Page 196: ...re the terminal end is clean 3 Slide the element sleeve silicon seal and ceramic insulator onto the wires 4 Slide crimps onto leads Stranded wire should extend beyond the crimp 15 9 MAINTENANCE Hot Ru...

Page 197: ...terminal post and crimp the connection 7 Slide the ceramic insulator and silicon seal into place 8 Screw the element sleeve into the position Make sure that the silicon sleeve does not rotate with th...

Page 198: ...IMPPUNCH03 CRIMPPUNCH03 1 8 2 0mm Heater Element Mates with CRIMPDIE03 CRIMPREMOVEB01 Bottom Crimp Removal Insert for shearing HE crimps Mates with CRIMPREMOVET01 CRIMPREMOVET01 Top Crimp Removal Inse...

Page 199: ...wear 15 5 1 Multi Cavity Systems 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 loo...

Page 200: ...ot Runner systems must be within 40 C 104 F of mold temperature before the cavity plate can be removed It is recommended the nozzle be removed from the system before removing the gate seal Use the soc...

Page 201: ...se serious injury CAUTION It is critical that seal surface is perfectly clean Failure to clean properly may result in nozzle and seal damage and leakage Any anti seize compound that enters the interna...

Page 202: ...t clean the die spotting blue compound off both faces 5 Apply nickel based anti seize compound to the gate seal threads ONLY Make sure that the internal runner is clean and free from anti seize compou...

Page 203: ...to heat the nozzle to ensure the temperature condition is met to remove the gate seal 15 6 1 Sprint Nozzle Tip Removal CAUTION The Hot Runner system must be turned off and cooled to below 38 C 100 F b...

Page 204: ...good contact clean die spotting blue compound off of both surfaces 5 Apply nickel based anti seize compound to the gate seal threads ONLY 2 Apply loosening torque to the gate seal using the 6 point so...

Page 205: ...7 Clean Nozzle Insulator Cap 1 Heat cap with heat gun 2 Remove molten plastic and wipe remainder from insulator cap 15 8 Installing Nozzle Insulator Cap 1 Press fit insulator cap onto torpedo by hand...

Page 206: ...e detail of the General Assembly drawing 2 Assemble spacer blocks to same value as correct nozzle tip height 3 Zero indicator to spacer blocks 4 Move indicator to correct reference point on nozzle tip...

Page 207: ...rocedures Make sure the lifting eyebolt lifting chain and crane are rated to adequately support the weight of the plate s Install latches before removing the cavity plate mounting screws Failure to do...

Page 208: ...over to the core half Cold Half without damaging the hoses 8 Remove all cavity plate mounting screws 9 Remove lockout tagged out 10 Place the machine in Mold Set mode 11 Close the mold slowly 1 2 2 3...

Page 209: ...or death CAUTION The nozzles must be within 55 C 130 F of mold temperature to prevent damage to Hot Runner and mold components For cylindrical valve gated systems valve pins should be in the open posi...

Page 210: ...l and torque the cavity plate mounting screws Torque to required specifications Refer to assembly drawings for required torque settings 13 Install hoses if required 14 Remove latches from both sides o...

Page 211: ...orque N m Dura Plus Deci 25 28 34 38 Hecto 35 40 47 54 Mega 42 48 57 65 15 14 2 Torque Settings of Master Series Gate Seals Table 15 5 Torque Settings of Master Series Gate Seals Product Line Product...

Page 212: ...35 40 47 54 Mega 35 40 47 54 Dura MTT Centi 10 12 14 16 Deci 20 22 27 30 Dura Tit Edge Centi 11 13 15 18 Deci 11 13 15 18 Pico 8 10 11 14 15 14 5 Torque Settings of ThinPAK Gate Seals Table 15 8 Torq...

Page 213: ...System Assembly Screws Metric Torque Setting Imperial Torque Setting M5 7 Nm 10 32 5 ft lbs M6 14 Nm 1 4 20 10 ft lbs M8 20 Nm 5 16 18 15 ft lbs M10 40 Nm 3 8 16 30 ft lbs M12 60 Nm 1 2 13 45 ft lbs M...

Page 214: ...rsize They must be ground prior to installing the nozzle into the nozzle well bore Minus heat expansion NOTE Exception gate seals supplied without the gate The gate must be placed into gate seal after...

Page 215: ...ems must be cold before the cavity plate can be removed 1 Apply penetrating oil to the threads 2 Heat the nozzle to processing temperature to melt any residual plastic that may be in the gate seal are...

Page 216: ...ing 8 Actuator piston 9 Outer cylinder housing 10 Socket head cap screws 11 Actuator 24 con hose with fittings 12 Actuator heated body 13 Actuator valve pin holder 14 Socket head cap screws 15 Valve p...

Page 217: ...Valve Pin Finishing of Tip on page 10 4 17 2 Accu Line with Valve Bushing Assembly CAUTION Do not use any tools to install the backup washer to prevent any overstretching of the hard ring CAUTION 1 C...

Page 218: ...he back up washer should be placed on the shorter side of the piston 6 Place one side of piston hard ring into position and carefully push it into the groove using your fingers Apply a small amount of...

Page 219: ...onents are aligned 10 Make sure installed seals engage into guiding chamfer Press piston smoothly and gently applying even force 11 Insert O ring into cylinder top and assemble it to cylinder body Acc...

Page 220: ...iled in the General Assembly drawing 14 Attach gate seal and liner to nozzle Tighten to specifications detailed in the General Assembly drawings Attach nozzle thermocouple 15 Attach valve bushing Tigh...

Page 221: ...hermocouple groove c Reinstall the wire retainer 19 Finish installing the heater body onto the nozzle assembly and torque to the specification given in the General Assembly drawing Thermocouple instal...

Page 222: ...place the nozzle assembly into the hydraulic unit as shown 22 Ensure that the nozzle terminal end is correctly oriented 23 Secure the valve pin holder to piston Tighten to specifications detailed in...

Page 223: ...mble inside mold and verify assembly and all connections for accuracy Accu Line with Valve Bushing Assembly continued 17 8 2020 Mold Masters 2007 Limited All Rights Reserved ACCU LINE Hot Runner User...

Page 224: ...16 Cooling plug 17 Dowel 18 Cooling plug 19 Jiffy plug 20 Socket head cap screw 21 Outer cylinder 22 Guide ring 23 Rod seal 24 Dowel pin 25 O ring 26 Piston seal 27 Guide ring 28 Piston 29 Guide ring...

Page 225: ...1 Accu Line with Valve Bushing on page 17 1 1 Make sure that the length of your valve pin is the same as that of the General Assembly drawing 2 Make sure that your components match those of the parts...

Page 226: ...hat both sit firmly in the grooves 22 23 22 Guide ring 23 Rod seal A Outer cylinder B Heated body C Cylinder top D Piston E Cover plate F Insulation plate G Valve pin holder H Nozzle I Adapter J Gate...

Page 227: ...within the plates In this case use the bottom ports for the cooling connections as shown in the General Assembly drawing 4 Insert the plugs into the supply ports of the cylinder and seal the lines In...

Page 228: ...ing and piston seal into the grooves in the piston Make sure that they sit firmly in the grooves 30 29 29 Guide ring 30 Rod seal 26 27 26 Piston seal 27 Guide ring 17 13 ACCU LINE Hot Runner User Manu...

Page 229: ...e that there is 37 mm between the top surfaces of the piston and the cylinder CAUTION The hole shown in the following figure has a chamfer Be careful to avoid damaging the piston seal when inserting t...

Page 230: ...the O rings sit firmly in the grooves 10 Apply grease to the O ring assembly groove in the outer surface of the cylinder top 11 Use your fingers to gently push the O ring into the outer groove of the...

Page 231: ...he support sleeves Place the cover plate on the insulation plate Insert the socket head cap screws and tighten them to a torque of 14 N m 10 lbf ft 1 Insulation plate 2 Sleeve 3 Cover plate 4 Socket h...

Page 232: ...sure that there are no leaks In out actuation lines from the plate 17 Install the termcon assembly ground wire assembly and thermocouple assembly in the heated body Insert the end of the thermocouple...

Page 233: ...orque of 68 N m 50 lbf ft 19 Install the inlet tip in the heated body and tighten to a torque of 61 N m 45 lbf ft 20 Attach the gate seal and liner to the nozzle 21 Attach the nozzle thermocouple 17 1...

Page 234: ...ghten them to a torque of 7 N m 5 lbf ft 23 Slide the valve pin into the nozzle assembly 24 Install the heated body onto the nozzle assembly Insert the screws and tighten them to a torque of 14 N m 10...

Page 235: ...dimension N of the heated body and the dimension T of the cylinder body Make sure that they are the same NOTE The air gap is determined by the flange depth of the mold plate N T 27 Carefully place the...

Page 236: ...n using shoulder head screws and tighten them to a torque of 3 N m 2 2 lbf ft 29 Install the unit in the mold Examine all the connections and actuations 17 21 ACCU LINE Hot Runner User Manual 2020 Mol...

Page 237: ...e which is located on the side of the Hot Half See Figure 18 1 Note Reverse Melt Link Figure 18 1 Reverse Melt Link plate You can also check your parts list on the General Assembly drawing for the Rev...

Page 238: ...Nozzle 11 Manifold 12 Pressure disk 13 Jiffy plugs 14 Locating ring 6 3 4 5 1 2 7 8 9 10 1 Melt transfer link on nozzle MTL14A 2 Melt transfer link on Melt Disk MTL14B 3 Transfer seal 4 Torpedo tip 5...

Page 239: ...Remove the part and wipe clean If necessary use a cotton swab to clean narrow interior surfaces or screw threads For larger surfaces such as mold plates use thinner in spray form to clean channels an...

Page 240: ...n the General Assembly drawing Do not over tighten the vice Ensure none of the components are damaged Thread size Imperial Metric M9 10 11 ft lb 14 15 Nm 7 Torque gate seals in heated condition at pro...

Page 241: ...sembly drawing See also Section 5 Assembly 18 5 Melt Disk Thermocouple Assembly 1 Remove the thermocouple retaining screw from the Melt Disk 2 Insert the thermocouple tip into the thermocouple hole un...

Page 242: ...g screw 5 Use heat resistant tape just above the insulator pod to attach the nozzle wires and thermocouple wires together 6 Set the thermocouple assembly aside 18 6 2020 Mold Masters 2007 Limited All...

Page 243: ...le quick disconnect terminal ends Locator Locator Slide Back of Tool Anvil Jaws Crimper Jaws Ratchet Disengaged Wire Stop Wire Size Markings Wire Stop Slot In Contact 1 Crimper jaws 2 Locator 3 Locato...

Page 244: ...er jaws wire size markings 4 Pull locator slide out of crimping jaws Spring tension will pull locator down and allow wire stop to enter the slot between barrel and contact shoulder 5 Make sure both si...

Page 245: ...MTL14B into the Melt Disk 3 Torque COLD to 27 30 Nm 20 22 ft lb 4 Assemble Melt Disks onto the nozzles according to mold design via the Melt Link 5 Ensure the sharp edge of the Melt Link does not get...

Page 246: ...ink into the nozzle 3 Torque the Melt Link COLD to the value specified in the General Assembly drawing 4 Assemble Melt Disks onto the nozzles according to mold design 5 Ensure the sharp edge of the Me...

Page 247: ...ure may result in leakage or damage occurring in the Hot Runner CAUTION IMPORTANT When running thermally sensitive materials use a thermally stable material as recommended by the material supplier for...

Page 248: ...tion on how to identify if your system has a Reverse Melt Link 1 Turn on the machine barrel and mold cooling system 2 Prior to start up ensure the a Machine barrel is up to processing temperature b Mo...

Page 249: ...nd your controller user manual 18 9 1 Shutdown Melt Link CAUTION Failure to follow this procedure may result in leakage or damage occurring in the Hot Runner CAUTION IMPORTANT Thermally sensitive mate...

Page 250: ...screw decompression to remove as much molten plastic from the Hot Runner system as possible 1 Disassemble mold to expose the Melt Disk Plate insertion removal to be done with all components in the col...

Page 251: ...r defects 2 The inside bore of the Melt Disk is to be free of material so that when it is installed to the Melt Link there is no interference 3 The Melt Disk is to be installed cold onto a cold Melt L...

Page 252: ...different for each design Failure to obey the correct instructions will damage the parts Ensure that the correct instructions are followed for your design of Melt CUBE CAUTION Mold Masters has differe...

Page 253: ...e Melt CUBE design A uses five screws See Figure 19 1 Note multiple screws Figure 19 1 Melt CUBE design A 19 1 2 The Melt CUBE Design B The new Melt CUBE design B uses a single screw See Figure 19 2 N...

Page 254: ...er nozzle electrical box 9 Manifold plate 10 Wire channel 11 Cavity backing plate 12 Melt CUBE electrical box 13 Cavity plate 14 Melt CUBE center locator 15 Cavity block 16 Cavity inserts 17 Melt CUBE...

Page 255: ...sters Cavity insert 1 M4 screw SHCSM4X20 2 M6 screw SHCSM6X25 3 Load wedge 4 Melt wedge 5 Melt CUBE anti rotation dowel 6 Melt CUBE manifold 7 Gate seal assembly 8 Cavity insert 9 Wedge dowel pin 10 R...

Page 256: ...Design A Maintenance Toolkit Melt CUBE inseal extraction tool EXTOOL20 2 mm 0 08 in hex wrench use for M4 set screws 3 mm 0 12 in hex wrench use for M4 screws 5 mm 0 2 in hex wrench use for M6 screws...

Page 257: ...the General Assembly drawing 19 3 5 Melt CUBE Design A Cleaning CAUTION Ensure that the critical surfaces are not damaged during the cleaning process CAUTION 1 Wipe down the Melt CUBE 2 If necessary...

Page 258: ...the thermocouple back 90 to sit in the manifold channel 3 Apply anti seize compound to the retaining screw Secure the thermocouple with the screw 19 3 7 Melt CUBE Design A Assemble Ground Wire 1 Apply...

Page 259: ...E system 3 Torque the melt transfer link to the value specified in the torque chart or the General Assembly diagram See Caution above Table 19 1 Melt CUBE Design A Melt Transfer Link Torque Chart Part...

Page 260: ...fecting other cooling circuits 19 3 10 Melt CUBE Design A Assembly Cold Condition CAUTION Failure to retighten wedge screws at process temperature could cause leakage CAUTION Assembly at cold conditio...

Page 261: ...supports NOTE For the dual nozzle Melt CUBE the center locator is bolted onto the Melt CUBE Insert the Melt CUBE into the cavity block Align the anti rotation dowels and Melt CUBE center locator with...

Page 262: ...nt Torque Value Nm ft lb M6X35 CLAMP16 10 7 5 M8X35 CLAMP17 16 12 M8X35 CLAMP18 20 15 5 Install cavity inserts if applicable aligning hole with cavity 6 Any cavity alignment features such as dowels or...

Page 263: ...r seal is clean Slide fit transfer seal into cavity insert hole 9 Install wedge dowel pins for locating melt wedges 10 Ensure all melt wedge surfaces and inseals are clean Place inseals into melt wedg...

Page 264: ...SHCSM6X25 and hand tighten to about 0 79 Nm 7 in lb torque to make sure all components are in proper contact condition 13 Loosen load wedge screw SHCSM6X25 one full turn in counter clockwise directio...

Page 265: ...w CAUTION 1 Set temperature of all Hot Runner components to processing temperature according to start up procedure Make sure all cooling lines other than cover plate are connected properly 2 After rea...

Page 266: ...screw in the center of the load wedge to 11 3 Nm 90 in lb to lock the load wedge in place 7 Assemble cavity block cover plate and connect proper cooling lines 8 Allow all Hot Runner components to rea...

Page 267: ...and related nozzle are at a temperature such that the plastic is soft enough to be able to detach runners at gate area 2 Drain water inside cooling lines of the cover plate of the cavities and then r...

Page 268: ...the SHCSM5X90 screws in a vice clamp to hold the melt wedge upwards b Heat the melt wedge to approximately the melting temperature of the plastic material c Adjust the inseal extraction tool to the s...

Page 269: ...osen the screws SHCSM4X20 on the other side of the melt wedge so that the torque is only 5 in lb 0 56 Nm 15 Reassemble following steps in 19 3 10 Melt CUBE Design A Assembly Cold Condition on page 19...

Page 270: ...lock bolting 2 M6 bolt manifold bolting 3 Titanium washer 4 Rectangular washer 5 Gate seal 5a Transfer seal 5b Torpedo this part is only to be used for 40mm and 50mm pitch 8 cavity Melt CUBEs Figure 1...

Page 271: ...B Inspection Inspect and document the critical dimensions for cavity cutout as shown in Figure 19 8 IMPORTANT These dimensions must match the General Assembly drawing 1 2 3 1 Distance from the bottom...

Page 272: ...gure 19 9 Clean plastic from surfaces shown here Figure 19 9 Remove plastic residue from surfaces 2 Clean the manifold interfaces with a fine grade 400 or 600 grit polishing stone See Figure 19 10 Fig...

Page 273: ...he thermocouple hole See Figure 19 12 IMPORTANT The thermocouple must touch the bottom of the hole Thermocouple Figure 19 12 Insert thermocouple tip 2 Bend the thermocouple back 90 to sit in the manif...

Page 274: ...Melt CUBE Design B Install the Thermocouple continued 19 4 7 Melt CUBE Design B Install the Melt Transfer Link CAUTION This procedure must be done with the Melt CUBE at room temperature between 10 C a...

Page 275: ...Transfer Link Torque Chart Part Number Description Torque Value Nm ft lb Socket Size mm MTL015A Melt Transfer Link Deci Top Half to nozzle 34 38 25 28 19 MTL016A Melt Transfer Link Centi Top Half to n...

Page 276: ...een 10 C and 40 C 50 F and 104 F CAUTION 1 Install the anti rotation dowel into each end of the Melt CUBE See Figure 19 17 Figure 19 17 Install the anti rotation dowel 2 Install the Melt CUBE center l...

Page 277: ...ock using M6 lifting bolts See Figure 19 20 Figure 19 20 Install Melt CUBE manifold IMPORTANT Ensure that the anti rotation dowels are inserted to the cavity block cutout as shown in Figure 19 17 Inst...

Page 278: ...0mm or a 50mm pitch a side clamp must be installed and torqued to 10 Nm 7 5 ft lb See Figure 19 22 Figure 19 22 Install side clamp specific systems only 6 Install the torpedo into the transfer seal Se...

Page 279: ...erature between 10 C and 40 C 50 F and 104 F CAUTION 1 Install the cavity insert into the cavity block Figure 19 24 Install cavity insert 2 Install the gate seal into the cavity insert See Figure 19 2...

Page 280: ...Figure 19 26 and Figure 19 27 Figure 19 26 Install with an M10 lifting bolt Figure 19 27 Install by hand 2 Insert the rectangular washer and the M8 bolt onto the melt block Torque bolt at 27 Nm 20 ft...

Page 281: ...much molten plastic from the Hot Runner system as possible IMPORTANT If hard resin was used in the system purge with a softer resin before shutting down 2 Drain the water inside the cooling lines of t...

Page 282: ...l 7 Clean the manifold interfaces on Melt CUBE using a fine polishing stone See Figure 19 10 Clean manifold interfaces on page 19 21 8 Inspect the sealing surfaces for any damage IMPORTANT If the seal...

Page 283: ...terminal ends Figure 19 33 Thermocouple quick disconnect terminal ends Locator Locator Slide Back of Tool Anvil Jaws Crimper Jaws Ratchet Disengaged Wire Stop Wire Size Markings Wire Stop Slot In Con...

Page 284: ...own and allow wire stop to enter the slot between barrel and contact shoulder 5 Make sure both sides of the insulation barrel are started evenly into the crimper jaws Do not crimp an improperly positi...

Page 285: ...o the processing temperature 2 Heat the nozzles to the set point temperature 3 Wait 10 minutes IMPORTANT The nozzle temperature must be set 6 C 10 F lower than the Melt CUBE temperature 4 Heat the Mel...

Page 286: ...NOTE The Melt CUBE must only be disassembled at room temperature 19 35 MELT CUBE SYSTEMS Hot Runner User Manual 2020 Mold Masters 2007 Limited All Rights Reserved...

Page 287: ...roblem 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 other resources to augment the...

Page 288: ...es 20 2 Pre Molding Precautions Prior to commencing production ensure that the following conditions have been met This will greatly reduce any future need to troubleshoot defective production 20 2 1 H...

Page 289: ...the possible cause but only should be used as a guide A correct set up procedure that has been proven in will produce parts that meet design tolerances and specifications A sudden change in any parame...

Page 290: ...s 19 10 Discolored 19 11 Flash 19 12 Jetting 19 13 Pitted Parts 19 14 Rough Surface 19 15 Parts Sticking to Cavity 19 16 Parts Sticking to Core 19 17 Short Parts 19 18 Sinks or Voids 19 19 Splay 19 20...

Page 291: ...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 1 P...

Page 292: ...ed 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 holdi...

Page 293: ...oo 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 Inco...

Page 294: ...atile 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 inje...

Page 295: ...using 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 in...

Page 296: ...lting 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 inj...

Page 297: ...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 De...

Page 298: ...oo 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 Increa...

Page 299: ...e 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 Increas...

Page 300: ...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 4...

Page 301: ...ble 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 injectio...

Page 302: ...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 6 A...

Page 303: ...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 time...

Page 304: ...ting 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 Incr...

Page 305: ...ct 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 time...

Page 306: ...esin 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 lo...

Page 307: ...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 Ins...

Page 308: ...perature 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 Incr...

Page 309: ...t 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 follo...

Page 310: ...e 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 holding...

Page 311: ...nter 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 side of a mold is referred to as the core side Core ca...

Page 312: ...en the mold opens Family Mold A multi cavity mold where each of the cavities forms one of the component parts of an assembled finished part Fleeting angle The angle at which the belt enters and exits...

Page 313: ...platen of an injection molding machine that is moved by a hydraulic ram or mechanical toggle Multi Cavity Mold A mold having two or more impressions for forming finished items in one machine cycle Mul...

Page 314: ...e core to permit the melt to first move around the core before filling the cavity Runner The channel that connects the sprue with the gate for transferring the melt to the cavities Runnerless Molding...

Page 315: ...ed Thermoset polymers set into a given shape when first made and afterwards do not flow or melt but rather decompose upon heating They are often highly cross linked polymers with properties similar to...

Page 316: ...lt Cube System 19 3 Maintenance 19 16 Melt Cube Components 19 4 Melt Transfer Link Torque Chart 19 8 Startup and Shutdown 19 34 Melt Disk Assembly of Melt Disk to Nozzle 18 8 Melt Disk Reassembly afte...

Page 317: ...m Assembly 10 2 Cylinder Top Assembly 10 3 Maintenance Procedure 10 20 10 21 Valve Pin Finishing of Tip 10 4 5500 Series 10 4 7100 Series 10 6 10 8 10 9 Valve Disk 5 24 5 29 Valve Disk Removal 15 1 Va...

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Page 319: ...APAN 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 e mexico moldmasters com UNITED KINGDOM tel 44 1432 265768 e uk moldmast...

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