Mold-Masters Hot Runner

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4. Attach the thermocouple with the thermocouple retaining 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

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

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