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Mold-Masters Master Series User Manual
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iginal Instr
uct
ions
Hot Runner
Us
er Manual
2
Table of Contents
Section 1 - Introduction
9
Intended Use
9
Operator Training and Safety
9
Warranty
9
Documentation
9
Release Details
9
Trademarks and Patents
10
Section 2 - Global Support
11
Manufacturing Facilities
11
Regional Offices
11
International Representatives
12
Section 3 - Safety
13
Introduction
13
Common Injection Molding Safety Hazards
13
Safety Symbols Typical to Injection Molding Machines
16
Hot Runner Safety Warnings
17
Section 4 - Preparation
19
Introduction
19
Screw Lengths
19
Tools Required
19
Unpacking
20
Cleaning
20
Establishing Your System Type
21
System With Cast In Heater Element
21
System With Hydraulic or Pneumatic Units
22
System with Bridged Hydraulic Pneumatic System
23
Section 5 - Assembly
25
Introduction
25
Gate Seal Finishing
27
Hot Valve / Hot Sprue / F Type
27
Water-cooled Gate Insert Installation (Option)
27
Master-Series Thermocouple Installation
28
Master-Series Thermocouple Removal
29
Dura Line Thermocouple Installation
29
Nozzle Insertion
31
Nozzle Wire Layout
31
Valve Bushings
32
Mounting the Manifold
33
Main Manifolds
35
Pressure Disk Installation
37
EcoDisk Installation
38
Installing Heater Plates
39
Installation of Inlet Components
40
Section 6 - Electrical Testing
43
Introduction
43
Wiring Check
43
Electrical Safety Testing
43
Thermocouple Wiring Guidelines
45
Functional Test with a Temperature Controller
45
Re-testing
45
Section 7 - Hot Half Assembly
47
Introduction
47
Assembling the Hot Half
47
Stack Mold Cavity Plate Installation
48
Section 8 - System Start Up & Shut Down
49
Introduction
49
Pre-Start up
49
Shut Down
50
Section 9 - Color Change
51
General Tips
51
Procedure A: Simple & Effective
51
Procedure B: More Comprehensive
52
Section 10 - Hydraulic / Pneumatic Actuators
53
Installation and Assembly of the Valve Actuator
53
Valve Pin Lapping Procedure for Tapered Valve Pins
57
Valve Pin Finishing of Head
57
Valve Pin Assembly
58
Installing the Valve Actuator to the Hydraulic Plate
59
Maintenance Procedure
60
Extraction Tools for Hydraulic Units & Pistons
61
Section 11 - Maintenance Procedures
63
Introduction
63
Valve Disk Removal
63
Gate Seal Maintenance
67
Gate Seal Removal
67
Gate Seal Replacement
68
Sprint Gate Seal Maintenance
69
Sprint Nozzle Tip Removal
69
Cleaning Nozzle Insulator Cap
70
Installing Nozzle Insulator Cap
70
Valve Actuator Maintenance
70
Sprint Nozzle Tip Installation
70
Latching
71
Checking Nozzle Tip Height
71
Latching the Cavity Plate to the Manifold Plate (Hot Half)
73
Torque Settings
74
Section 12 - TIT Edge Gated System
77
Introduction
77
TIT Edge Gated System
77
TIT Edge Gate Seals
77
Section 13 - Accu-Line System
79
Accu-Line Body Assembly
79
Pre-Assembly
80
Accu-Line Assembly Procedure
80
Section 14 - Melt-Disk System
85
Introduction
85
Safety
85
System with cast in heater element
86
Melt-Disk Preparation / Cleaning
87
Nozzle Thermocouple Assembly
88
Melt-Disk Thermocouple Assembly
88
Assembly of Melt Disk to the Nozzle
90
Melt-Disk System Start Up & Shut Down
91
Disassembly for Maintenance
91
Melt-Disk Reassembly after Maintenance
91
Section 15 - Melt-Cube System
93
Introduction
93
Safety
93
Melt-Cube Components
94
Example Melt-Cube System
95
Assemble Melt-Cube into Cavity Block
98
Startup and Shutdown
101
Maintenance - Replacing a Tip
101
Section 16 - Troubleshooting
103
Introduction
103
Moisture Related Issues
103
Pre-Molding Precautions
104
Establishing Root Cause
104
Fault Identification
104
Defect Types, Causes and Remedies Index
105
Parts have Dark Specks
106
Parts have Blisters and/or Bubbles
107
Parts have Flow Marks
108
Parts have Burn Marks
109
Parts are Delaminating
110
Parts have Dimensional Irregularities
111
Parts are Discolored
112
Parts Contain Flash
113
Parts Surface has Jetting
114
Parts Surface is Rough
116
Parts are Sticking to Cavity
117
Parts are Sticking to Core
118
Parts are Short
119
Parts have Sinks or Voids
120
Parts are Streaked
122
Parts are Stringing
123
Parts are Warped
124
Parts have Weld Lines
125
Section 17 - Glossary of Terms
127
Index
131
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Mold-Masters Master Series Specifications
General
Brand
Mold-Masters
Model
Master Series
Category
Industrial Equipment
Language
English
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