Mold-Masters Hot Runner

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6. Thread the gate seal assembly into the Melt-Disk. Secure the Melt-Disk in

a soft vice and torque gate seals in the cold condition to value specied

below or in 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 processing temperature as

specied in the General Assembly drawing.

18-4

MELT-DISK SYSTEM

Hot Runner User Manual

Main Page

Default Chapter3
- Table of Contents3
Section 1 - Introduction12
- Intended Use12
- Documentation12
- Release Details12
- Returned Goods Policy13
- Movement or Resale of Mold-Masters Products or Systems13
- Copyright13
- Units of Measure and Conversion Factors14
Section 2 - Global Support15
- Corporate Offices15
Section 3 - Safety17
- Safety Hazards18
- Operational Hazards21
- General Safety Symbols23
- Wiring Check24
- Lockout Safety25
  - Electrical Lockout26
  - Energy Forms and Lockout Guidelines27
- Disposal28
- Hot Runner Safety Hazards29
Section 4 - Preparation32
- Tools Required32
- Screw Lengths33
- Unpacking34
- Cleaning34
- Establish Your System Type35
Section 5 - Assembly40
- Cutaway of a Cast-In System40
- Cutaway of a Bolt-In System41
- Cutaway of a Mastershield System42
- Gate Seal Finishing42
- Hot Valve / Hot Sprue / F Type43
- Water-Cooled Gate Insert Installation (Optional)44
- Thermocouple Installation45
- Thermocouple Removal for Non-Front Mounted Thermocouples47
- Dura Line Thermocouple Installation48
- Nozzle Insertion51
  - Nozzle Insertion for Master-Series and Dura Lines51
  - Step Installation52
  - Nozzle Insertion-Thinpak Centi and Deci53
  - Nozzle Insertion-Mastershield Centi, Deci, and Pico55
  - Nozzle Insertion-Mastershield Femto58
- Nozzle Wire Layout62
  - Back Mounted Thermocouples62
  - Front Mounted Thermocouples62
- Emergency Heater Sleeve63
  - Installation of Emergency Heater Sleeve63
  - Removal of Emergency Heater Sleeve66
- Valve Bushings67
  - Types of Valve Bushings67
  - Valve Bushing Installation67
- Mount the Manifold69
  - Manifold Locator70
  - Manifold Locating Dowel Pin71
  - Manifold and Slot Locator71
- Manifold Thermocouple Installation72
- Main Manifolds73
  - Inlet Seal Installation - Without Step73
  - Inlet Seal Installation - with Step74
- Pressure Disk / Valve Disk Installation74
  - Pressure Disk: Final Grinding Required75
  - Pressure Disk Installation77
  - Pressure Disk: Final Grinding Not Required77
  - Ecodisk Installation78
  - Valve Disk - Final Grinding Required79
- Support Bushing Installation for Systems with Mastershield81
- Valve Disk Installation for Systems with Mastershield82
- Heater Plates Installation83
- Inlet Components Installation85
  - Back Plate Installation85
  - Center Heater Installation86
  - Three Piece Center Heater Installation86
  - Inlet Extension Installation87
  - Inlet Extension with Pressure Sleeve88
Section 6 - Electrical Testing90
- Safety90
- Electrical Wiring Check91
- Electrical Safety Testing91
- Thermocouple Wiring Guidelines94
- Functional Test with a Temperature Controller94
- Re-Testing94
Section 7 - Hot Half Assembly96
- Hot Half Assembly96
- Stack Mold Cavity Plate Installation98
Section 8 - System Startup and Shutdown100
- Pre-Startup100
- Startup101
  - Standard Hot Runner Systems101
  - Stack Mold Systems102
- Shutdown102
  - Standard Hot Runner Systems103
  - Stack Mold System103
Section 9 - Color Change104
- General Tips104
- Procedure A: Simple and Effective104
- Procedure B: more Comprehensive105
Section 10 - Hydraulic / Pneumatic Actuators107
- Valve Actuator Installation and Assembly107
- Pre-Installation108
- Cylinder Bottom Assembly108
- Piston Assembly109
  - 5500 Series Only109
  - 6X00 Series and 7100 Series109
- Cylinder Top Assembly110
- Valve Pin Finishing of Tip110
- Valve Pin Lapping Procedure for Tapered Valve Pins116
  - 5500 Series and 6X00 Series116
- Valve Pin Finishing of Head117
  - 5500 Series117
- Valve Pin Assembly118
- Install the Valve Actuator to the Hydraulic Plate121
  - 5500 Series and 6X00 Series121
  - Hydraulic Limit Switch Option (6500 Series and 6600 Series)123
- Proximity Sensor Installation for Hydraulic Limit Switch Option124
  - Cutout Options Based on Stroke125
- Test the Proximity Sensor for Hydraulic Limit Switch Option126
- Maintenance Procedures for 5500 Series, 6X00 Series and 7100 Series126
  - For Oil Systems127
  - For Pneumatic Systems127
- Extraction Tools for Hydraulic and Pneumatic Actuators128
Section 11 - Slimstack Actuator130
- Introduction130
- Slimstack Actuator Assembly131
- Assembly Procedure132
- Installation142
Section 12 - Sevg Plus Actuator146
- Introduction146
- Sevg Plus Actuator Models146
- Sevg Plus Actuator in Hot Runner Systems146
- Sevg Plus Model Options147
- Sevg Plus in Plate Mounted Systems150
- SE40-20 Model150
  - SE20-15 Model150
- Assembly and Installation151
- Disassembly156
  - SE40-20 and SE40-20C Models156
  - SE20-15 Model157
Section 13 - E-Drive158
- Typical E-Drive System158
  - E-Drive Components160
  - E-Drive Safety161
- Assembly162
- Assembly Detail163
- First Time Installation or Replacement of the Belt170
- Check for Misalignment172
Section 14 - Mag-Pin Option173
- Mag-Pin Assembly (3D View)174
- Mag-Pin Safety174
- Mag-Pin Operation175
- Handling Magnets177
- Assembly Summary178
- Assembly Details178
- Mag-Pin Extraction184
Section 15 - Maintenance188
- Valve Disk Removal188
  - Extraction of 1-Piece Valve Disk189
  - Extraction of 2-Piece Valve Disk191
- Valve Disk Extraction Tool Overview193
- Terminal End Removal and Installation195
- Heater Plate Power Lead Removal198
  - Installation199
- Gate Seal Maintenance199
- Sprint Gate Seal Maintenance203
  - Sprint Nozzle Tip Removal203
  - Sprint Nozzle Tip Installation204
- Clean Nozzle Insulator Cap205
- Installing Nozzle Insulator Cap205
- Valve Actuator Maintenance206
- Check Nozzle Tip Height206
- Latches207
- Latch the Cavity Plate to the Core Half (Cold Half)207
- Latch the Cavity Plate to the Manifold Plate (Hot Half)209
- Torque Settings211
Section 16 - TIT Edge Gated System214
- TIT Edge Gated System214
- TIT Edge Gate Seals215
  - Remove the Gate Seal215
Section 17 - Accu-Line216
- Accu-Line™ with Valve Bushing216
  - Accu-Line™ with Valve Bushing217
  - Pre-Assembly217
- Accu-Line™ with Valve Bushing - Assembly217
- Accu-Line™ with Valve Insert224
  - Pre-Assembly of Accu-Line™ with Valve Insert225
- Assembly of Accu-Line™ with Valve Insert226
Section 18 - Melt-Disk System237
- Reverse Melt-Link Identification237
- System with Cast-In Heater Element238
- Melt-Disk Preparation / Cleaning239
- Nozzle Thermocouple Assembly241
- Melt-Disk Thermocouple Assembly241
- Optional Quick Disconnect Terminal Ends243
  - Crimp the Quick Disconnects244
  - Assemble the System with Quick Disconnects244
- Assembly of Melt Disk to the Nozzle245
  - Reverse Two-Piece Melt-Link245
  - One-Piece Melt-Link246
- Melt-Disk System Startup247
  - Startup - Melt Link247
  - Startup - Reverse Melt Link ONLY248
- Melt-Disk System Shutdown249
  - Shutdown - Melt Link249
  - Shutdown - Reverse Melt Link ONLY250
- Disassembly for Maintenance250
  - For Melt Link250
  - For Reverse Melt Link250
- Melt-Disk Reassembly after Maintenance251
Section 19 - Melt-CUBE Systems252
- Identify Your Melt-CUBE Design253
  - The Melt-CUBE Design a253
  - The Melt-CUBE Design B253
- Example of a Melt-CUBE System254
- Melt-CUBE Design a255
- Melt-CUBE Design B270
- Melt-CUBE Design B: Install the Thermocouple273
- Melt-CUBE Design B: Attach the Ground Wire274
- Melt-CUBE Design B: Install the Melt Transfer Link274
- Melt-CUBE Design B: Assemble the Melt-CUBE276
- Melt-CUBE Design B: Install Gate Seals and Cavity Inserts279
- Melt-CUBE Design B: Install Melt Block280
- Melt-CUBE Design B: Disassembly of Transfer Seal / Torpedo and Melt Block282
- Optional Quick Disconnect Terminal Ends283
- Startup and Shutdown285
  - Startup285
  - Shutdown285
Section 20 - Troubleshooting287
- Moisture Related Issues287
- Pre-Molding Precautions288
- Establishing Root Cause289
- Fault Identification289
- Defect Types, Causes and Remedies Index290
- Troubleshooting Typical Problems291

Mold-Masters Hot Runner - Page 240

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