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HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN

Installation

CAUTION!

Control of the given tolerances while checking important dimensions

All given tolerances must be checked before initial installation. Failure to do so may result in leakage during

operation, damage to nozzles and other components of the mould and severe injuries to persons such as burns

caused by leaking plastic melt.

Machining the tip sealing area in the contour plate

The tip sealing areas should be ground or milled to fit but not eroded; otherwise leakage may be possible during

operation.

Cleanliness of sealing surfaces

Prevent sealing surfaces from being damaged by dirt or unsuitable cleaning tools. Failure to do so may result in

leakage during operation or damage to the sealing surfaces during installation.

NOTE!

Intended use

Damage to the HPS III hot runner system and/or components of the surrounding injection mould.

•

The HPS III hot runner system must only be installed in a matching injection mould.

Recommended auxiliary materials (tools) and operating materials for the following installation steps

The use of non-approved assembly tools may result in damage to the hot runner system (for recommended

auxiliary and operating materials please see chapter „5.3 Technical Requirements“).

Ambient conditions during installation

Make sure that the hot runner components are protected from direct humidity during assembly.

Dimensional check (for details please also see chapter „5.4 Checks before installation“)

Check of the given installation dimensions, fit sizes, form and location tolerances

of the mould plates surround-

ing the hot runner system (for information please see the current catalogues in the download section on www.

ewikon.com). The following dimensions have to be checked in particular:

•

Mould plate dimensions.

•

Height dimensions (e.g. X dimension).

•

Fit sizes (e.g. in the tip sealing area).

•

Gap dimensions.

Cleaning

•

Clean the installation space.

•

Make sure the sealing surfaces (contour plate/tip insert, nozzle/manifold) are clean. If necessary clean

sealing surfaces with suitable cleaning tools (brass brush or brass scraper). Prevent sealing surfaces from

being damaged by dirt or unsuitable cleaning tools. You have to heat up the HPS III-MH nozzles (processing

temperatures) before cleaning them. Failure to do so may result in leakage during operation or damage to

the sealing surfaces during installation.

Pay attention to temperatures during installation

The HPS III hot runner system has to be installed when it is cold (room temperature) (exception: L2X systems).

Excessive temperatures during installation may result in damage to the melt sealing area and thus leakage

during operation.

Mechanical stress of cable ends

The cable ends must not be subject to tensile stress.

Содержание L2X

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

Страница 2: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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