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Mold-Masters Hot Runner User Manual
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Hot Runner User Manual
Hot Runner
User Manual
ver
sion 31
Original Instrucons
2
Table of Contents
Default Chapter
3
Table of Contents
3
Section 1 - Introduction
12
Intended Use
12
Documentation
12
Release Details
12
Returned Goods Policy
13
Movement or Resale of Mold-Masters Products or Systems
13
Copyright
13
Units of Measure and Conversion Factors
14
Section 2 - Global Support
15
Corporate Offices
15
Section 3 - Safety
17
Safety Hazards
18
Operational Hazards
21
General Safety Symbols
23
Wiring Check
24
Lockout Safety
25
Electrical Lockout
26
Energy Forms and Lockout Guidelines
27
Disposal
28
Hot Runner Safety Hazards
29
Section 4 - Preparation
32
Tools Required
32
Screw Lengths
33
Unpacking
34
Cleaning
34
Establish Your System Type
35
System with Cast-In Heater Element
35
System with Hydraulic or Pneumatic Units
36
System with Bridged Hydraulic Pneumatic System
37
Centi or Deci System with Mastershield Technology
38
Section 5 - Assembly
40
Cutaway of a Cast-In System
40
Cutaway of a Bolt-In System
41
Cutaway of a Mastershield System
42
Gate Seal Finishing
42
Hot Valve / Hot Sprue / F Type
43
Water-Cooled Gate Insert Installation (Optional)
44
Thermocouple Installation
45
Thermocouple Removal for Non-Front Mounted Thermocouples
47
Dura Line Thermocouple Installation
48
Nozzle Insertion
51
Nozzle Insertion for Master-Series and Dura Lines
51
Step Installation
52
Nozzle Insertion-Thinpak Centi and Deci
53
Nozzle Insertion-Mastershield Centi, Deci, and Pico
55
Nozzle Insertion-Mastershield Femto
58
Nozzle Wire Layout
62
Back Mounted Thermocouples
62
Front Mounted Thermocouples
62
Emergency Heater Sleeve
63
Installation of Emergency Heater Sleeve
63
Removal of Emergency Heater Sleeve
66
Valve Bushings
67
Types of Valve Bushings
67
Valve Bushing Installation
67
Mount the Manifold
69
Manifold Locator
70
Manifold Locating Dowel Pin
71
Manifold and Slot Locator
71
Manifold Thermocouple Installation
72
Main Manifolds
73
Inlet Seal Installation - Without Step
73
Inlet Seal Installation - with Step
74
Pressure Disk / Valve Disk Installation
74
Pressure Disk: Final Grinding Required
75
Pressure Disk Installation
77
Pressure Disk: Final Grinding Not Required
77
Ecodisk Installation
78
Valve Disk - Final Grinding Required
79
Support Bushing Installation for Systems with Mastershield
81
Valve Disk Installation for Systems with Mastershield
82
Heater Plates Installation
83
Inlet Components Installation
85
Back Plate Installation
85
Center Heater Installation
86
Three Piece Center Heater Installation
86
Inlet Extension Installation
87
Inlet Extension with Pressure Sleeve
88
Section 6 - Electrical Testing
90
Safety
90
Electrical Wiring Check
91
Electrical Safety Testing
91
Verify Equipment to Its Technical Documentation
91
Insulation Resistance Test
91
Verification of Conditions for Protection by Automatic Disconnection of Supply
92
Verification of Continuity of Protective Bonding Circuit
92
Verification of Fault Loop Impedance
92
Thermocouple Continuity Test
93
Pinch Point Test
93
Heating Element Check
93
Ungrounded Thermocouple Continuity Test
94
Thermocouple Wiring Guidelines
94
Functional Test with a Temperature Controller
94
Re-Testing
94
Section 7 - Hot Half Assembly
96
Hot Half Assembly
96
Stack Mold Cavity Plate Installation
98
Section 8 - System Startup and Shutdown
100
Pre-Startup
100
Startup
101
Standard Hot Runner Systems
101
Stack Mold Systems
102
Shutdown
102
Standard Hot Runner Systems
103
Stack Mold System
103
Section 9 - Color Change
104
General Tips
104
Procedure A: Simple and Effective
104
Procedure B: more Comprehensive
105
Section 10 - Hydraulic / Pneumatic Actuators
107
Valve Actuator Installation and Assembly
107
Pre-Installation
108
Cylinder Bottom Assembly
108
Piston Assembly
109
5500 Series Only
109
6X00 Series and 7100 Series
109
Cylinder Top Assembly
110
Valve Pin Finishing of Tip
110
5500 Series
110
6X00 Series
112
7100 Series
112
8X00 Series
114
8600 - AR Series
115
Valve Pin Lapping Procedure for Tapered Valve Pins
116
5500 Series and 6X00 Series
116
Valve Pin Finishing of Head
117
5500 Series
117
Valve Pin Assembly
118
5500 Series
118
6X00 Series
118
Hydraulic Limit Switch Option (6500 Series and 6600 Series)
119
7100 Series
120
Install the Valve Actuator to the Hydraulic Plate
121
5500 Series and 6X00 Series
121
Hydraulic Limit Switch Option (6500 Series and 6600 Series)
123
Proximity Sensor Installation for Hydraulic Limit Switch Option
124
Cutout Options Based on Stroke
125
Test the Proximity Sensor for Hydraulic Limit Switch Option
126
Maintenance Procedures for 5500 Series, 6X00 Series and 7100 Series
126
For Oil Systems
127
For Pneumatic Systems
127
Extraction Tools for Hydraulic and Pneumatic Actuators
128
Section 11 - Slimstack Actuator
130
Introduction
130
Slimstack Actuator Assembly
131
Assembly Procedure
132
Installation
142
Section 12 - Sevg Plus Actuator
146
Introduction
146
Sevg Plus Actuator Models
146
Sevg Plus Actuator in Hot Runner Systems
146
Sevg Plus Model Options
147
SE40-20 Actuator - Non Cooled
147
SE40-20C Actuator - Cooled
148
SE20-15 Actuator - Non Cooled
149
Sevg Plus in Plate Mounted Systems
150
SE40-20 Model
150
SE20-15 Model
150
Assembly and Installation
151
Attach the Water Lines (Cooled Models Only)
152
Assemble and Install the Valve Pin Holder
153
Install the Motor and Valve Pin Assembly
153
Disassembly
156
SE40-20 and SE40-20C Models
156
SE20-15 Model
157
Section 13 - E-Drive
158
Typical E-Drive System
158
E-Drive Components
160
E-Drive Safety
161
Assembly
162
Assembly Detail
163
Hot Runner Assembly
163
Interface Plate Assembly
163
Synchro-Plate Assembly
164
Ball-Screw Preparation
165
Ball-Screw Lubrication
165
Ball-Screw Assembly
166
Ball-Screw Maintenance
167
Top Plate Assembly
167
Attach the Synchro-Plate to Top Plate Assembly
167
Tension Belt Assembly
167
Inspect Parallelism of the Synchro-Plate
169
Assemble the Insulation Plate and Locating Ring
169
Perform E-Drive Controller Checks
170
Install the Hot Half into the Mold
170
First Time Installation or Replacement of the Belt
170
Check for Misalignment
172
Section 14 - Mag-Pin Option
173
Mag-Pin Assembly (3D View)
174
Mag-Pin Safety
174
Mag-Pin Operation
175
Handling Magnets
177
Assembly Summary
178
Assembly Details
178
Place the Magnet on Top of Magnet Retainer
179
Polarity Check
179
Clean the Magnet Holder
179
Assemble the Magnetic Retainer to Magnet Holder
180
Place the Magnet Holder and Magnet into the Housing
180
Assemble the Nut and Lock Magnet Holder
181
Assemble the Valve Pin into the Valve Pin Holder
181
O-Ring Installation into Valve Pin Holder
182
Assemble Valve Pin into Housing Assembly
182
Install Mag-Pin Assembly into the Synchro-Plate
183
Mag-Pin Extraction
184
Section 15 - Maintenance
188
Valve Disk Removal
188
Extraction of 1-Piece Valve Disk
189
Extraction of 2-Piece Valve Disk
191
Valve Disk Extraction Tool Overview
193
Terminal End Removal and Installation
195
Terminal End Removal
195
Terminal Installation
195
Terminal Assembly
196
Heater Plate Power Lead Removal
198
Installation
199
Gate Seal Maintenance
199
Multi-Cavity Systems
199
Gate Seal Removal
200
Gate Seal Replacement
201
Sprint Gate Seal Maintenance
203
Sprint Nozzle Tip Removal
203
Sprint Nozzle Tip Installation
204
Clean Nozzle Insulator Cap
205
Installing Nozzle Insulator Cap
205
Valve Actuator Maintenance
206
Check Nozzle Tip Height
206
Latches
207
Latch the Cavity Plate to the Core Half (Cold Half)
207
Latch the Cavity Plate to the Manifold Plate (Hot Half)
209
Torque Settings
211
Torque Settings of Dura-Plus Gate Seals
211
Torque Settings of Master-Series Gate Seals
211
Torque Settings of Summit-Series Gate Seals
211
Torque Settings of Dura Gate Seals
212
Torque Settings of Thinpak Gate Seals
212
System and Plate Screw Torques
213
Section 16 - TIT Edge Gated System
214
TIT Edge Gated System
214
TIT Edge Gate Seals
215
Remove the Gate Seal
215
Section 17 - Accu-Line
216
Accu-Line™ with Valve Bushing
216
Accu-Line™ with Valve Bushing
217
Pre-Assembly
217
Accu-Line™ with Valve Bushing - Assembly
217
Accu-Line™ with Valve Insert
224
Pre-Assembly of Accu-Line™ with Valve Insert
225
Assembly of Accu-Line™ with Valve Insert
226
Section 18 - Melt-Disk System
237
Reverse Melt-Link Identification
237
System with Cast-In Heater Element
238
Melt-Disk Preparation / Cleaning
239
Nozzle Thermocouple Assembly
241
Melt-Disk Thermocouple Assembly
241
Optional Quick Disconnect Terminal Ends
243
Crimp the Quick Disconnects
244
Assemble the System with Quick Disconnects
244
Assembly of Melt Disk to the Nozzle
245
Reverse Two-Piece Melt-Link
245
One-Piece Melt-Link
246
Melt-Disk System Startup
247
Startup - Melt Link
247
Startup - Reverse Melt Link ONLY
248
Melt-Disk System Shutdown
249
Shutdown - Melt Link
249
Shutdown - Reverse Melt Link ONLY
250
Disassembly for Maintenance
250
For Melt Link
250
For Reverse Melt Link
250
Melt-Disk Reassembly after Maintenance
251
Section 19 - Melt-CUBE Systems
252
Identify Your Melt-CUBE Design
253
The Melt-CUBE Design a
253
The Melt-CUBE Design B
253
Example of a Melt-CUBE System
254
Melt-CUBE Design a
255
Melt-CUBE Design A: Gate Seal Assembly
256
Melt-CUBE Design A: Maintenance Toolkit
256
Melt-CUBE Design A: Dual Nozzle Assembly
257
Melt-CUBE Design A: Inspection
257
Melt-CUBE Design A: Cleaning
257
Melt-CUBE Design A: Assemble Melt-CUBE Thermocouple
258
Melt-CUBE Design A: Assemble Ground Wire
258
Melt-CUBE Design A: Assemble Melt Transfer Link to Melt-CUBE
259
Melt-CUBE Design A: Assemble into Cavity Block
260
Melt-CUBE Design A: Assembly (Cold Condition)
260
Melt-CUBE Design A: Retighten Wedge Screws (Hot Condition)
265
Melt-CUBE Design A: Replace a Transfer Seal / Torpedo
267
Melt-CUBE Design B
270
Melt-CUBE Design B: Components
270
Melt-CUBE Design B: Inspection
271
Melt-CUBE Design B: Maintenance Toolkit
271
Melt-CUBE Design B: Cleaning
272
Melt-CUBE Design B: Install the Thermocouple
273
Melt-CUBE Design B: Attach the Ground Wire
274
Melt-CUBE Design B: Install the Melt Transfer Link
274
Melt-CUBE Design B: Assemble the Melt-CUBE
276
Melt-CUBE Design B: Install Gate Seals and Cavity Inserts
279
Melt-CUBE Design B: Install Melt Block
280
Melt-CUBE Design B: Disassembly of Transfer Seal / Torpedo and Melt Block
282
Optional Quick Disconnect Terminal Ends
283
Crimp the Quick Disconnects
284
Assemble the System with Quick Disconnects
284
Assemble Melt-CUBE into Cavity Block
284
Startup and Shutdown
285
Startup
285
Shutdown
285
Section 20 - Troubleshooting
287
Moisture Related Issues
287
Resin Moisture Contamination
287
Resin Drying Issues
288
Importance of Pre-Drying Resin
288
Pre-Molding Precautions
288
History
288
Material
288
Hardware
289
Settings
289
Establishing Root Cause
289
Fault Identification
289
Defect Types, Causes and Remedies Index
290
Troubleshooting Typical Problems
291
Dark Specks
291
Blisters or Bubbles
292
Flow Marks
293
Burn Marks
294
Delaminating Parts
295
Dimensional Irregularities
296
Discolored Parts
297
Flash
298
Jetting
299
Pitted Parts
300
Rough Surface
301
Parts Sticking to Cavity
302
Parts Sticking to Core
303
Short Parts
304
Sinks or Voids
305
Splay
306
Streaks
307
Stringing
308
Warped Parts
309
Weld Lines
310
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Mold-Masters Hot Runner Specifications
General
Brand
Mold-Masters
Model
Hot Runner
Category
Industrial Equipment
Language
English
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