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The purpose of this manual is to assist users in the integration, operation

and maintenance of

Mold-Masters

systems. This manual is designed to

cover most system configurations. If you need additional information specific

to your system, or information in another language, please contact your

representative or a

Mold-Masters

office.

1.1 Intended Use

FUSION SERIES

G2 systems have been built to process thermoplastic

material at the required temperature for injection molding and must not be

used for any other purpose.
This manual is written for use by skilled persons who are familiar with

injection molding machinery and their terminology. Operators should be

familiar with plastic injection molding machines and the controls of such

equipment. Maintenance persons should have sufficient understanding of

electrical safety to appreciate the dangers of 3-phase supplies. They should

know how to take appropriate measures to avoid any danger from electrical

supplies.

1.2 Documentation

This manual is part of the documentation package for your order and should

be referenced along with the following documents included in the package:
• The Bill of Materials (BOM). Together with the General Assembly drawing,

the Bill of Materials should be referenced when ordering spare parts.

• General Assembly drawing used to integrate your Hot Runner system into

the mold.

• Hot Half drawing used to integrate Hot Half to cavity plate.
• CE declaration of conformity and declaration of incorporation (EU only)

NOTE

This manual should also be used in conjunction with other relevant

manuals, e.g. Mold Machine Manual and Controller Manual.

1.3 Release Details

Table 1-1 Release Details

Document Number

Release Date

Version

FSG2-UM-EN-00-13-2

July 2019

13-2

FSG2-UM-EN-00-13-3

January 2020

13-3

FSG2-UM-EN-00-13-4

June 2020

13-4

FSG2-UM-EN-00-14

July 2020

FSG2-UM-EN-00-14-1

September 2020

14-1

Section 1 - Introduction

1-1

INTRODUCTION

FSG2 User Manual

Содержание Fusion G2

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 10: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 64: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 151: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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