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USER MANUAL - Mold

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1. to t manifold 9 Check that the thermocouple sits in the sub mani LS fold cutout Figure 5 41 i Figure 5 45 Revision 01 Mold Not under documentation control if printed May be revised without notice 02 2012 r documentatior Masters Electronic version is available at www moldmasters com 5 8 Assembly Figure 5 46 Finsihed sub manifold assembly Bridge Assembly Installing Heater Plate Thermocou ple These procedures apply to systems with external heat er plates Refer to the general assembly drawing to determine which heater plate applies to your system NOTE 3 Heater plates on the sub manifold use controlling thermocouples in the manifold Installation of the thermocouple in the heater plate is only required for heater plates on the main manifold bridge NOTE D Current bronze heater plates are directly interchangeable with previous copper or aluminum based plates that may exist on your Mold Masters system However when multiple heater plates are controlled by one thermocouple these heater plates must be made of the same material of equal voltage and located in similar ther mal environments 1 Insert the thermocouple into the bore Ensure the thermocouple is touching the bottom of the bore hole 2 Press down on the thermocouple and gently bend to 90 Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is avai
2. h A gt Be e l Figure 5 37 Apply Loctite Locktite 2422 recommended to the SHCS M8 Bolt and torque screws in a cross pattern gradually increasing torque to specified value Figure 5 38 Revision01 MiolId y om Aa 002 2012 Masters Vision User Manual Visi n Assembly Install Sub Manifold Heater Plates 6 Apply anti seize to the screw and install the ther mocouple washer and screw 1 Apply anti seize to the SHCS M6 2 Bolt and torque screws in a cross pattern gradually increasing torque to specified value Figure 5 42 7 Label the zone number on each wire and thermo couple 8 Tape wires for each zone together Figure 5 39 Install Sub Manifold Wire Armor Install Sub Manifold Thermocouple CAUTION 2 This is a pinch point area Use caution when installing Failure to do so could result in damage to the thermocouple 1 Apply anti seize to SHCS M6 Clean the thermocouple bore 2 Although not necessary a thermal compound may be applied to the thermocouple tip to ensure a good contact Figure 5 43 3 Insert the thermocouple into either one of the two 2 Install mounting tab to wire armor with SHCS bores Check that the thermocouple is touching lockwasher and nut the bottom of the hole Figure 5 40 Figure 5 44 4 Press down on the thermocouple and gently bend 3 only anti seize to second SHCS M6 the thermocouple through 90 dl ee he cub
3. 49 7221 50990 fax 49 7221 53093 europe moldmasters com INDIA Mold Masters Technologies Private Limited 247 Alagesan Road Shiv Building Saibaba Colony Coimbatore T N India 641 011 tel 91 422 423 4888 fax 91 422 423 4800 mmtplinfo moldmasters com U S A Mold Masters Injectioneering LLC 103 Peyerk Court Romeo MI 48065 USA tel 1 800 450 2270 USA only tel 1 586 752 6551 fax 1 586 752 6552 mmi ing moldmasters com CZECH REPUBLIC Mold Masters Europa GmbH Hlavni 823 75654 Zubri Czech Republic tel 420 571 619 017 fax 420 571 619 018 cz moldmasters com MEXICO MM Hot Runner Injection Mexico S A de C V Av San Carlos No 4 Nave 2 Parque Industrial Lerma Lerma Estado de Mexico 52000 Mexico tel 52 728 282 48 33 fax 52 728 282 47 77 mexico moldmasters com 2 1 ASIAN HEADQUARTERS CHINA HONG KONG TAIWAN Mold Masters KunShan Co Ltd Zhao Tian Rd Lu Jia Town KunShan City Jiang Su Province People s Republic of China tel 86 512 86162882 fax 86 512 86162883 mmc sales moldmasters com JAPAN Mold Masters K K 1 4 17 Kurikidai Asaoku Kawasaki Kanagawa Japan 215 0032 tel 81 44 986 2101 fax 81 44 986 3145 info mmkk co jp FRANCE Mold Masters France Z la Marini re 2 Rue Bernard Palissy 91070 Bondoufle tel 33 1 82 05 00 80 fax 33 1 82 05 00 83 fr moldmasters com POLAND Mold Masters Europa GmbH Skr Pocztowa 59 00 908 Wars
4. Vision User Manual Revision 01 Mo al m Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 9 6 Visi n Troubleshooting Section 10 Troubleshooting Introduction This troubleshooting information assumes that the hot runner has been operational Basic rules for troubleshooting are e Define the problem what is seen is only a symptom of the underlying problem e Develop a method to isolate the problem e Test one item at a time to verify results e Monitor the final solution to verify that the problem has been solved Repeat occurrences of the same symptom may indicate other problems e Document the solution so that a repeat occurrence can be solved quickly e Consult other resources to augment the trouble shooting information in this manual One of the best resources may be your resin supplier NOTE Refer back to Section 3 Safety for proper procedures to be followed WARNING Extreme heat Avoid contact with heated surfaces To avoid serious burns wear safety clothing consisting of a protective heat re sistant coat and heat resistant gloves Use adequate ventilation for fumes Failure to do so can result in a serious injury Make sure the machine has been locked out and tagged out in accordance to the ma chines documented procedures Failure to do so may lead to serious injury or death Vision User Manual
5. As 6 Remove valve nut insert and inlet seal and verify sembly blue on all surfaces 7 Clean bluing from all components 1 Blue valve insert valve nut and nozzle inlet seal i 8 Install and torque in crossing pattern as follows pu hand tighten 1 3 torque 2 3 torque then full torque Figure 5 19 2 Install valve insert into valve nut an o S gi Figure 5 23 9 Install valve pin to verify fit Figure 5 20 3 Install inlet seal in nozzle side of sub manifold and valve nut valve insert into other side of sub manifold Figure 5 24 NOTE p Ensure nozzle terminal end is in the direction noted on the GA drawing Figure 5 21 4 Apply anti seize to SHCS 5 Install SHCS in a crossing pattern to nozzle through the manifold Figure 5 25 Figure 5 22 Vision User Manual Revision 01 Mold Not under documentation control if printed May be revised without notice 002 2012 Masters Electronic version is available at www moldmasters com 5 5 Visi n Assembly Install Support Bushing 2 Apply die blue to the pneumatic cylinder cooling plate legs and check die blue has tranferred to 1 Apply anti seize to SHCS sub manifold 2 Install support bushing to sub manifold and torque SHCS to specified value lt de gt o gt a a I u a Sy PR gt Ai Figure 5 29 Figure 5 26 3 Install pneumatic cylinder coolin
6. WARNING To avoid serious burns wear safety clothing consisting of a protective heat resistant coat heat resistant gloves and a full face shield over safety glasses Use adequate ventilation for fumes Contact with heated components may cause serious burns Use a sign in a vis ble location indicating Danger Do Not Touch Before performing any electrical work Check that the hot runner is suitably grounded Turn off the temperature controller and disconnect all electrical wires leading from the mold Failure to do so could result in a serious injury or death Wiring Check D NOTE Ensure that a qualified electrician per forms all wiring 1 Check that each wire and thermocouple has a zone number 2 Check that wires are organized and taped togeth er by zone and plug 3 Check all wires are secured in wire channels Connect all power leads and thermocouple wires to mold plugs 5 The electricity mains should only be connected to the injection mold when all electrical connections are grounded and the mold is closed A WARNING A disassembled nozzle should only be connected to an electrical supply when the nozzle has been grounded or a safety isolating transformer is used Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 6 1 1 Use an ohm meter to check for continuity between the Mold Po
7. a reliable temperature controller that includes soft start protection All Mold Masters heated components are manufactured to standards that ensure safe and reliable operation provided that the following precautions are met e Always operate the system using correctly installed J type thermocouples connected to a reliable temperature controller with soft start protection e Avoid running the system for long periods on manual control e Use caution when applying power in manual mode Use minimum heat required for the pro cess to avoid overheating and possible damage to components e Always replace pinched or damaged thermocouples e When grouping heated components together and controlling more than one load from a single thermocouple make sure that the components are of similar material wattage size and are exposed to the same thermal conditions e When replacing heater plates or other heated components always replace with genuine Mold Masters components of the same type and install as originally specified on Mold Masters general assembly drawings gt vo Vision User Manual Revision 01 Mold Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 3 2 Ci Section 4 Preparation Introduction The following section is a step by step guide to preparing your Mold Masters system for use S
8. and correspond to Mold Masters general assem bly drawings Cleaning All nozzles manifolds and hot runner components must be free of the rust inhibitor applied at the factory 1 Remove protective covers from all gate seals 2 Clean all surfaces and dowel holes ensuring that no debris burrs shavings dust dirt or other for eign material which could interfere with measure ments exists Ream holes out if necessary 3 Remove tape from inlet and clean Revision Miold y om 002 2012 Masters Vision Section 5 Assembly Introduction Vision systems are designed as pre assembled drop in systems for easy installation quick start ups and user friendly maintenance However depending on the type of system ordered some systems may be supplied minus certain optional components or features Please reference your GA drawing for details on the system ordered The following detailed assembly instructions are Optional Components Features largely for reference purposes The wiring and een plumbing instructions at the end of the section will be P al lll helpful for those systems ordered without the pre e Optional water cooling nozzle jacket wired and pre plumbed feature See Section 7 System Installation for instructions on installing your Vision hot runner into an existing manifold plate system or spacer block system Typical Vision System An example Vision system is provided below to illustrate the vari
9. any appropriate Mold Masters Temperature Controller User Manual gt Vision User Manual Revision 01 faa Mold Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com dice Visi n Introduction Trademarks and Patents ACCU VALVE DURA FLEX DURA FLEX SERIES FUSION SERIES HOT EDGE INJECTIONEER ING MASTERPROBE MASTER SHOT MOLD MASTERS MELT DISK MOLD MASTERS ACADE MY MASTER SERIES MASTERSOLUTION MASTERSPEED MERLIN MOLD MASTERS SYSTEM MPET SCAN MASTER STACK LINK are the registered trademarks of MOLD MASTERS 2007 LIMITED Information contained herein is to our best knowledge true and accurate but all recommendations or sug gestions are made without guarantee Since the conditions of use are beyond our control Mold Masters disclaims any liability incurred in connection with the use of our products and information contained here in No person is authorized to make any statement or recommendation not contained herein and any such statement or recommendation so made shall not bind Mold Masters Furthermore nothing contained herein shall be construed as a recommendation to use any product in conflict with existing patents cover ing any products or its use and no license implied or in fact granted herein under the claims of any patents Nopartofthispublicationmaybereproducedortransmittedinanyformorbyanymeans electronicormechanica
10. blue to bottom of inlet Figure 5 56 2 Apply anti seize to SHCS and install inlet to mani fold Figure 5 57 3 Torque screws in a crossing pattern gradually increasing torque to specified value Figure 5 58 4 Remove inlet to verify blued surfaces Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 9 12 Assembly Clean the die blue from the inlet and manifold Figure 5 59 Re install inlet Torque screws in a crossing pattern gradually increasing torque to specified value Figure 5 60 Blue the inlet seal and verify blued surfaces to check fit of seal in the inlet y i Figure 5 61 Clean blue from inlet seal and inlet Figure 5 62 Revision0 Mold ZA pm 002 2012 Masters Assembly 9 Install inlet heaters and sleeves per specified 13 Bend 180 degrees drawing Figure 5 63 Figure 5 67 10 Apply anti seize to threads and install inlet seal to 14 Install thermocouple clip inlet a Figure 5 68 Install Bridge Wire Armor 1 Apply anti seize to button head cap screws BHCS l 2 Install BHCS screws through appropriate slot in eee wire armor 12 Install thermocouple into slot until bottoms out 3 Add spacer Install wire armor assembly to manifold Figure 5 66 Figure 5 69 Vision User Manual Revision 01 Mold Not under documentation
11. control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 1 0 1 1 www moldmasters com Mold Masters and the Mold Masters logo are registered trademarks of Mold Masters 2007 Limited 2012 VSUMENO1XX E 3 gt a 2 E E T o E 4 iSO 9001 CERTIFIED n Mold Masters performance delivered
12. control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 5 1 3 Visi n Assembly Sub Manifold Wiring CAUTION All wires close to a heat source re quire high temperature sheathing Power Wiring 1 Run all the power wires to the bridge and locate a position for quick connector sitting cut the wires to a proper length 2 Label the wires and install high temperature sheathing 3 Crimp all heater plates and nozzle power wires with female contacts 4 Insert the power wires contacts into the male plug of quick connector 1P per wiring schematic in GA 5 Insert the coding pin to the male plug as per wiring schematic if applicable 6 Get six spare wires crimped with male contacts in one end insert into the female plug of quick connect 1P label the wires according to the male side 7 Snap 1P plugs together Run the open end of the wires to the electrical plugs Cut the wires to the proper length and crimp them Install high tem perature sheathing if needed 8 Install the power wires into electric plugs per wir ing schematic in the GA drawing 9 Repeat above for each zone Name connector number according to drop number Be sure to locate the connectors inside the wire armor Thermocouple Wiring 1 Run all the thermocouple wires to the bridge wire armor and locate a position for quick connector sitting cut the wires to a pr
13. in the same location e Review past history logs for similar oc currences and resolutions Review the machine settings to ensure that there is no variation from the original set up which was producing standard parts injection speed melt heating screw speed locking melt temperature cushion back pressure mold heating For a more thorough analysis of the defect refer to the Troubleshooting Section in the following pages Revision Mold ZA 0222 Masters 10 2 Visi n Troubleshooting Defect types causes and remedies index Parts have dark specks Page 10 4 Parts have blisters and or bubbles Page 10 5 Parts have burn marks Page 10 6 Parts surface has jetting Page 10 7 Parts are short Page 10 8 Parts have sink marks or voids Page 10 9 Parts display splay Page 10 10 Parts are streaked Page 10 11 Vision User Manual Revision 0 Miold a Not under documentation control if printed Mayberevisedwithoutnotice co Masters Electronic version is available at www moldmasters com 1 0 3 Visi n Troubleshooting Parts have dark specks The finished product contains dark particles When transparent resins are usually used Probable Cause Molding Machine e Off line for extended period e Barrel offline for extended period e Barrel improperly purged e Contamination in plasticizer e Wrong nozzle e Use of wrong screw e Gate and or runner has dead spots Material e Physical contamination of r
14. trols ACAL wat temperature cannot NOTE exceed 85 F 29 4 C For hot runner systems using heater plates allow 20 minutes of soak time after 4 Test the pin actuation only once the hot runner is the system reaches processing tempera at processing temperature ture 5 Connect all electrical components CAUTION Start up gt Failure to follow the above procedure may result in leakage damage occurring in the WARNING hot Assume the system is pressurized and hot runner at all times Failure to do so can result ina serious injury or death Shut Down G NOTE 1 Turn OFF all heat to the system Y When running thermally sensitive materi 2 Leave the mold cooling system ON including als use a thermally stable material as recommended by the material supplier for the initial start up 1 Turn ON the machine barrel and mold cooling system 2 Prior to start up ensure the e Vision Valve Gate Actuator water is on e Maximum inlet water temperature does not exceed 85 F 29 4 C Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 8 1 valve actuator water until the hot runner system temperature is within 100 F 37 7 C of the mold temperature A NOTE A Thermally sensitive materials should be purged from the hot runner system prior to shut down using a thermally stable mate rial with a similar processing temperature For exam
15. 002 2012 Masters Electronic version is available at www moldmasters com 1 4 Section 2 Global Support Manufacturing Facilities GLOBAL HEADQUARTERS CANADA Mold Masters 2007 Limited 233 Armstrong Avenue Georgetown Ontario Canada L7G 4X5 tel 1 905 877 0185 fax 1 905 873 2818 info moldmasters com SOUTH AMERICAN HEADQUARTERS BRAZIL Mold Masters do Brasil Ltda Rua Hum 1106 e 1126 Jd Manchester Nova Veneza Sumare Sao Paulo Brasil CEP 13178 440 tel 55 19 3922 4265 fax 55 19 3922 4266 vendas moldmasters com br UNITED KINGDOM Mold Masters UK Ltd Netherwood Road Rotherwas Ind Est Hereford HR2 6JU United Kingdom tel 44 1432 265768 fax 44 1432 263782 uk moldmasters com Regional Offices AUSTRIA East and South East Europe Mold Masters Handelsges m b H Pyhrnstrasse 16 A 4553 Schlierbach Austria tel 43 7582 51877 fax 43 7582 51877 18 at moldmasters com KOREA Mold Masters Korea Ltd 708 Byucksan Digital Valley 5 Cha 60 73 Gasan dong Geumcheon gu Seoul 153 788 South Korea Tel 82 2 2082 4755 Fax 82 2 2082 4756 mmkr sales moldmasters com Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com EUROPEAN HEADQUARTERS GERMANY SWITZERLAND Mold Masters Europa GmbH Postfach P O Box 19 01 45 76503 Baden Baden Germany Neumattring 1 76532 Baden Baden Germany tel
16. 61 8 8374 4633 fax 61 8 8299 0892 bparrington comtecipe com Finland Oy Scalar Ltd Viertolantie 12 11120 Riihimaki Finland tel 358 19 783 191 fax 358 19 783 190 info scalar fi Italy Commerciale Isola SPA Via G B Tiepolo 3 35010 Cadoneghe Padova Italy tel 39 49 706600 fax 39 49 8874231 info com isola it Turkey MMG Consulting amp Engineering Yesil esme Sok No 30 3 iftehavuzlar 81060 Istanbul Turkey tel 90 216 357 0783 fax 90 216 385 0656 mmgevrek superonline com Bulgaria Mold Trade OOD 62 Aleksandrovska St Ruse City Bulgaria tel 359 82 821 054 fax 359 82 821 054 contact mold trade com Ireland Bray Engineering Services Mr Liam Shortt Unit F3 Network Enterprise Business Park Kilcoole Co Wicklow Ireland tel 353 1 201 5088 fax 353 1 201 5099 info BrayEngineeringServices com Portugal Gecim LDA Rua Fonte Dos Ingleses No 2 Engenho 2430 130 Marinha Grande Portugal tel 351 244 575600 fax 351 244 575601 gecim gecim pt Vietnam Lotus Chemical Technology 393 Dien Bien Phu St Ward 4 Dist 3 Ho ChiMinh City Vietnam tel 84 8 832 7605 fax 84 8 832 7730 dieuphuoc nguyen lotusfirma com i ICi P Far Vision User Manual Revision01 Miold i 2202 Masters Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 2 2 Section 3 Safety High injection pre
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18. NING High temperature on the nozzle Wear safety clothing such as heat resistant coat and heat resistant gloves Failure to do so may cause serious injury CAUTION The terminal end is a sensitive area and can easily break if not handled to specifi cations Revision Mold pa 002 2012 Masters isn Leave the nozzle in the mold or remove it to a vice and clamp carefully Using the temperature controller heat the nozzle body until all residual plastic is melted from the gate area If the nozzle is inside the mold heat up the whole system and turn on the cooling or remove all O rings While the nozzle is still hot apply a loosening pressure to the gate using the socket to remove the seal Turn off the controller and wait for 5 minutes Remove the gate seals Figure 12 5 Gate Seal Replacement 1 Clean the nozzle especially the thread and run ner Clean all residual plastic from the threads and counter bore of the gate seal in Le p A Remove Plastic A WARNING Ensure nozzles have cooled to room temperature Failure to do so may cause serious injury Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 9 3 CAUTION It is critical that seal surface is perfectly clean Failure to clean properly may result in nozzle and seal damage and leakage Check the bottom face of t
19. Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Moisture Related Issues Many common molding issues can be directly attrib uted to moisture contamination of the production resin Generally manufacturing resin is supplied from the manufacturer in ready to process pellets that are in sealed airtight containers Follow manufacturers stor age instructions keeping containers sealed until ready to use Prior to using pellets follow the drying instructions as provided by the resin supplier and molding machine manufacturer if applicable Resin Moisture Contamination Moisture can be introduced into the resin in many ways e during transportation e environmental exposure aging e malfunctioning heater dryer e extreme humidity in atmosphere e inadequate or malfunctioning facility HVAC Resin Drying Issues During the drying stage of the resin if applicable ensure that e the resin pellets are not overpacked e adequate air circulation is present e the drying system is properly sealed ac cording to manufacturers instructions Importance of Pre Drying Resin Thermoplastic resins can be hygroscopic able to absorb moisture from the air Under normal processing conditions this can lead to degradation of the polymer during molding Breakage of polymer chains changes the properties resulting in possible blisters streaks splay or other defec
20. USER MANUAL Mold A Masters performance delivered Wisin Table of Contents Section 1 Introduction u uuuununnununnunununnunnann 171 ACC FEAT ee ee A 1 1 IYDICAL APDICAU ON Se een 1 1 SOY BEE ee ee ee ne een nen EE er 1 1 o ee a A ee 1 3 Warranty and DOCUMENT lO zen ae ee ren 1 3 RELEASE Bc rc ee ne os ee ee 1 3 Trademarks and Palenls mine ned 1 4 Section 2 Global Support uu uunnunnnnnnnnnnnnnnnnnn 2 1 Manufacturing Facille S sent seen ee 2 1 REAONAL OMICOS crs acs ee orina 2 1 International RepreSsentatiVES sauren san na rear 2 2 Section 3 Safety uuuunnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 9 1 A PA 3 1 General Safety Warnings ccooccoconcconnconnnocnononocanonononannnnnnonnnonanonanonnnnnnnnonnnonannnaninnnnnnnns 3 1 SPAIN tHe Moll astra 3 2 a rasen E ee a ee ne ee 3 2 IO Ma Bee ee ee eer ore ne ee 4 1 NS se er ee nee ee 4 1 An e SR ee 4 1 Ole le Je e o o A 4 1 cc a 4 1 ot Zs Vision User Manual Revision 01 MioId Az Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com Visi n Table of Contents Section 5 Assembly iccccccccccccoccc 9 1 1 are arer A ee renee E E te eter eee ee eet eee 9 1 DICA MISION yS IN ee ee ee ee nee 5 1 Pre Assembly Checks of Gate Seals amp Nozzle occoocccconccocccocncocncocnocanocancnncncnanonono 5 2 Assembly of Gate Seals t
21. asters 9 14 Visi n Assembly Preparing to Wire the Bridge 2 Install plugs into electrical box CAUTION All wires close to a heat source re quire high temperature sheathing 1 Group thermocouple and heater wires for a single zone together and install high temperature wire sheathing Label all heater and thermcouple zones Use heat resistant tape to group thermocouple heater zones together and to avoid losing labels Figure 5 73 4 Repeat for all zones Bridge Wiring 1 Run the wires through the wire armor to the electri Plumbing Cylinders cal plugs 2 Install the thermocouple and heater wires into 1 Install hoses per schematic in GA drawings electrical plugs per wiring schematic in GA draw Ings a Electrical Box 1 Install plugs into electrical box Figure 5 74 3 Tie plumbing on top of the wire channel using high temperature cable ties Figure 5 71 Pc Solenoid Valve Wiring 1 Install solenoid coil wires into electrical plugs per wiring schematic in GA drawings Figure 5 75 Figure 5 72 Vision User Manual Revision 01 Mold Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 5 1 5 Visi n Electrical Testing Section 6 Electrical Testing Ground Shorts Test Introduction This section contains electrical test procedures for your Mold Masters Vision system A
22. at www moldmasters com 7 2 Section 8 System Start Up amp Shut Down Pre Start up 1 Install the mold into the molding machine e Machine barrel is up to processing tempera ture e Mold cooling is on and at cooling temperature 3 Heat up the hot runner system to processing y NOTE temperature Wait until ALL heating zones reach Y Ensure the machine nozzle orifice match processing temperature before continuing es or at most is 1 0 mm 0 040 smaller than melt entrance for the hot runner WARNING system When the mold is open never inject mate rial through hot runner system under high 2 Connect all water lines and test Water tempera pressure This can result in serious injury ture is not to exceed 85 F Water to Valve Actua or death tors must be turned on before heating is activated 4 Start up only for empty hot runner system Ex 3 Connect all hydraulic pneumatic lines if appli trude material through the hot runner system using cable 200 PSI 14 bar of back pressure 5 Start up for systems filled with material Purge CAUTION intended shot size twice from the barrel prior to gt Check that the system is heated to pro bringing the machine barrel forward to the hot run cessing temperature Failure to do so ner interface nn a me nn Pu 6 Set injection time and pressure in coordination to ater must be turne on for Vision actua part size gate size and material tion before turning on temperature con
23. aw material e Chemical contamination of raw material e Particulate contamination from machine barrel Solution In sequence e Purge system with appropriate material e Trace source of contamination and repair remove or discard e Adjust melt temperature if necessary e Inspect for dead spots gates runners nozzle back flow valve e Inspect feed screw for degradation gt Vision User Manual Revision01 IMi En Not under documentation control if printed May be revised without notice 2202 Masters Electronic version is available at www moldmasters com 1 0 A Visi n Troubleshooting Parts have blisters and or bubbles The finished product contains small gas or air filled pockets or cooling voids Probable Cause Molding Machine e Low Injection Pressure e Back flow valve malfunctioning e Suck back cycle too long e Rapid plasticizing e Trapped air in feed e Feed error e Trapped or volatile gas e Low mold temperature e Poor thin thick transition phase e Inadequate venting Material e Overheating of resin Solution In sequence e Verify control and or holding pressure e Increase back pressure e Increase mold temperature e Inspect back flow valve e Ensure proper venting e Increase gate size e Decrease vent land length gt Vision User Manual Revision 01 an Mold Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at w
24. crew Lengths When the manifold is heated the metal expands stretching the mounting screws if screw lengths are shortened there is a possibility of shearing Be aware of warnings placed on the assembly drawings The expansion factor is calculated into the length of each screw size WARNING DO NOT SHORTEN SCREW R A Y s H c s 14 V ISO GRADE 42 90 ASIMAS74 NOT S PPLIED BY lt y MOLD MASTERS WARNING The use of an incorrect size length and grade screw could cause the screw to shear fatigue or stretch beyond its yield point resulting in expensive downtime of the hot runner Tools Required Depending on the size and complexity of your hot runner system you will require most of the tools and materials listed below e Allen keys Set of imperial size keys and metric sizes for use on both imperial and metric cap screws depending on system e Nickel based anti seize compound To prevent oxidation of screw threads that could cause screws to seize with high temperatures e Solvents denatured alcohol For removal of rust inhibitors e Calibrated torque wrench For consistent screw pressure throughout the system e Pliers For general assembly work e Circlip pliers To remove and install Circlip in valve systems e Micrometer sizes O 6 and O 150 mm to check system part and plate thickness e Depth micrometer To check bore depths e Slot head screw driver Used in installing thermo couple
25. e sleeve or the wires may Remove the seal break Remove the set screw from the ceramic sleeve Remove the power leads a NOTE D Please contact Mold Masters Spare Parts Department 1 800 387 2483 to ensure you have the correct repair kit and crimp ing tools Available tools along with the lead wire replacement kit are shown Figure 12 1 Nozzle Terminal Assembly below 1 Nozzle Flange 2 Ceramic Insert 3 Ceramic Sleeve 4 Seal 5 Element Sleeve Crimping Tool Chart CRIMPDIEO3 1 8 2 0mm Heater Element Mates with CRIMPPUNCHO3 CRIMPPUNCHO3 1 8 2 0mm Heater Element Mates with CRIMPDIEO3 CRIMPREMOVEBO1 Bottom Crimp Removal Insert for shearing HE crimps Mates with CRIMPREMOVET01 CRIMPREMOVETDO1 Top Crimp Removal Insert for shearing HE crimps Mates with CRIMPREMOVEB01 gt Vision User Manual Revision 01 a Mold Not under documentation control if printed May be revised without notice 002 2012 Masters Electronic version is available at www moldmasters com 9 1 isn Heater Plate Power Lead Re placement Removal 1 Remove the set screws 2 Slide ceramic sleeve off 3 Remove the power leads using crimp removal tool Installation 1 Push the replacement leads into the holes in the ceramic sleeve Crimp the leads to the terminal ends Slide ceramic sleeve over the terminal end Tighten the set screws on the ceramic sleeve to secure the terminal assembly Figure 12 2 Terminal Ends A
26. ed throat purging the machine or cleaning the gates of the mold e Check frequently for possible oil leaks water leaks Stop the machine and make repairs e Remove purgings from the machine immediately e Never touch or inspect the timing belt when power is on and motor and controller are con nected Unplug the controller before any maintenance e Always cover belt area with proper protecting sheet before any bench test or in mold testing e High voltage and amperage cables are connected to the controller 220VAC There is also a high voltage cable connection between servo motor and controller e Unplug the controller before performing any maintenance work gt Vision User Manual Revision 01 Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 3 1 Vision General Safety Warnings Con t e Hoses fitted to the mold will contain high or low temperature fluids or air under high pressure A The operator must shut down and lockout these systems as well as relieving any pressure before performing any work with these hoses e Never perform any work on the mold unless the hydraulic pump has been stopped e High voltage and amperage cables are connected to the mold Electric power must be shut off prior to installing or removing any cables e Water and or hydraulics on the mold may be in close proximity to electrical connections and equip
27. g plate to sub manifold Install Sub Manifold Anti Rotation Dow el Pin 1 Install anti rotation dowel pin into manifold until it bottoms out y Figure 5 30 4 Apply Loctite Locktite 2422 recommended to VPHOLDER17 and install into cylinder piston rod Figure 5 27 Install Pnuematic Cylinder 1 Apply teflon tape and install pneumatic fittings to the pneumatic cylinder cooling plate Figure 5 31 5 Place valve pin into VPHOLDER18 pocket Figure 5 28 Figure 5 32 gt E Vega Vision User Manual Revision 01 Mold Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 5 6 Visi n 6 Apply Loctite Locktite 2422 recommended to shoulder bolt SHSS M6 Figure 5 33 7 Insert VPHOLDER18 into VPHOLDER17 then thread shoulder bolt to lock together Figure 5 34 VPHOLDER17 psy Fi Ti Shoulder bolt VPHOLDER18 Figure 5 35 8 Drop the cylinder assembly onto the cooling plate making sure the shoulder bolt aligns to the side slot on the cooling plate Figure 5 36 Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 5 7 10 11 Assembly 9 Check to make sure the valve pin can freely move up and down aS al TT s di H p m APA TG le Rz
28. he nozzle counterbore for damage If damaged lap the bottom face of the nozzle in a circular fashion with a hardened tool and 300 grit lapping compound If the nozzle counterbore is free of damage proceed to step 5 Figure 12 7 After lapping is complete blue the liner to the nozzle to ensure proper mating If the liner is mak ing good contact clean the bluing compound off both faces Figure 12 8 Apply anti seize nickel based to the gate seal threads ONLY Figure 12 9 CAUTION Carefully apply anti seize to threads of the gate seal Any anti seize that enters the in ternal runner must be removed to prevent contamination of melt Revision 01 Mold y om 02 2012 Masters isn 6 Using a socket wrench re install the gate seal be 5 Check that nozzle height is within drawing specifi ing careful not to damage it cation 7 Torque the gate seal to the appropriate value 6 Repeat for each nozzle Refer to Gate Seal Torque Settings WARNING Replacing Pneumatic Cylinder High temperature on the nozzle Wear Seal and Gasket safety clothing such as heat resistant coat and heat resistant gloves Failure to do so may cause serious injury 1 Use snap retaining tool to remove retainer ring 8 Check that the seal has bottomed out heat nozzle 2 Slowly pull out the piston to process temperature and re torque seal 3 Remove any damaged seals and or gasket WARNING 4 Carefully install the new sea
29. ient material in cavity High injection speed Low back pressure Damaged backflow valve check ring Mold not at required temperature Small gate leading to early freezing Gate land length too long Incorrect rib wall dimensions Material flow incorrect Thick wall part Hot material Material wrong grade for application Solution In sequence Adjust injection speed Increase injection hold time Increase injection pressure Adjust melt temperature Adjust mold temperature Inspect for hot spots Enlarge and or add vents to mold parting line Increase sprue or runner size Increase gate size reduce gate land length Relocate gate closer to heavy thicker areas If possible core out heavy wall sections Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Revision 01 Mold gt Pa vn Yan o02 2012 Masters 10 9 Visi n Troubleshooting Parts display splay The finished product display splay splash marks and or silver streaks Probable Cause Molding Machine e Resin degraded from overheating Material e Cylinder contains hot spots Material trapped at nozzle tip Wrong injection pressure Wrong injection speed Low back pressure Friction related burning in gate nozzle or hot runner Trapped volatile compounds Hot melt Contaminated resin moisture dirt organics Degraded resin Sol
30. ifold locator into the bore to ensure Install Bridge Assembly proper seating 4 Install the anti rotation dowel into the mold En CAUTION sure sufficient gap between the dowel and the Match drop s stamped on wedge and manifold slot top surface Under no circum bridge during assembly stances should they touch NOTE lt lt Bridge Bridge mounting screws should be torqued 1 3 higher than specified on GA drawings 1 Measure and confirm locator height as specified Anti rotation SALE dowel 2 Align bridge to sub manifold wedges and locate on manifold locator Take care not to pinch the wires Remove any installation tools used Apply anti seize to the bridge screws a S Torque bridge screws in a crossing pattern gradu ally increasing torque to specified value Mold plate 7 Measure and confirm drop height as specified on GA drawing 8 Repeat for each drop Figure 722 Final Installation Steps 1 Connect the sub manifold power wires to the bridge using quick connectors if applicable En sure quick connectors are locked as shown below 2 Connect all the plumbing air and water hoses to the sub manifold unit 3 Install SHCS to secure electrical and solenoid interface to exterior of mold base 4 Install clamp plate gt Vision User Manual Revision 01 Mold Not under documentation control if printed May be revised without notice oo2 2012 Masters Electronic version is available
31. ision 01 Mold Not under documentation control if printed May be revised without notice oo2 2012 Masters Electronic version is available at www moldmasters com 5 3 Visi n Assembly Sub Manifold Assembly 7 Blue top and bottom faces of wedge inlet seal Install Wedge 1 Install wedge anti rotation dowel pin into sub manifold Figure 5 17 8 Insert inlet seal into wedge inlet bore Figure 5 14 2 Blue top and bottom faces of inlet seal 3 Insert inlet seal into sub manifold inlet bore Figure 5 18 9 Apply anti seize to SHCS M12 and install to bridge 10 Remove screws and inlet seal and verify blue on all surfaces Figure 5 15 4 Apply anti seize to the SHCS M16 and install from sub manifold to wedge and torque to check fit 11 Clean bluing from all components and keep for system installation NOTE Bridge and wedge mounting screws should be torqued 1 3 higher than speci fied on GA drawings Figure 5 16 NOTE Use 1 3 of specified torque value for bluing 5 Remove screws and verify blue on top and bottom surfaces of the inlet seal 6 Clean bluing from all components install screws and torque to specified value gt Vision User Manual Revision 01 Mold Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 5 4 Visi n Assembly Install Valve Nut Insert and Nozzle
32. l including photocopy recording oranyinformationstorage andretrievalsystemwithoutpermission in writingfromthe publisher All details standards and specifications may be alteredinaccordancewithtechnicaldevelopmentwithoutpriornotification May be manufactured under one or more of the following U S Patents 9148594 5206040 5217730 5223275 5227596 5227181 5235737 5238378 5238391 5268184 5269676 9282735 5284436 5299928 5312242 5326251 5334008 5334010 5346388 5366369 5366370 5387099 9405258 5421716 5427519 5429491 5437093 5441197 5443381 5460510 5474440 5494433 5496168 9507635 5507636 5536165 5591465 5599567 5614233 5641526 5644835 5652003 5658604 5695793 5700499 5704113 5705202 5707664 5720995 5792493 5795599 5820899 5843361 5849343 5853777 9935615 5935616 5935621 5942257 5952016 5980236 6009616 6017209 6030198 6030202 6062841 6074191 6077067 6079972 6095790 6099780 6113381 6135751 6162043 6162044 6176700 6196826 6203310 6230384 6270711 6274075 6286751 6302680 6318990 6323465 6348171 6350401 6394784 6398537 6405785 6440350 6454558 6447283 6488881 6561789 6575731 6625873 6638053 6648622 6655945 6675055 6688875 6701997 6739863 6752618 6755641 6761557 6769901 6776600 6780003 6789745 6830447 6835060 6840758 6852265 6860732 6869276 6884061 6887418 6890473 6893249 6921257 6921259 6936199 6945767 6945768 6955534 6962492 6971869 6988883
33. l if printed May be revised without notice 02 2012 Maste S Electronic version is available at www moldmasters com 6 2 Visi n Section 7 System Installation Introduction The following section is a step by step guide to install your Mold Masters Vision hot runner into the existing mani fold plate system or spacer block system Prior to Assembly 1 Please unpack and clean the system as outlined in Section 4 Preparation N WARNING Make sure the lifting eyebolt lifting chain and crane are rated to adequately support the weight of the plate s Failure to do so can cause a serious injury Make sure the machine has been locked out and tagged out in accordance to the machines documented procedures Failure to do so may lead to serious injury or death CAUTION Do not assemble disassemble cavity plate with the valve pins forward Valve pins must be retracted prior to cavity plate installation Potential pinch point Ensure that all wires are retained NOTE Refer to the general assembly GA draw ings for instructions g System installation Water Cooling Nozzle Jacket Assembly Please note your system may not include the water cooling nozzle jacket option Refer to your general as sembly drawing for details 1 2 Clean the insert seating bore Install O rings onto the water cooling nozzle jacket Insert water cooling nozzle jacket assembly into seating bore Fasten the water c
34. lable at www moldmasters com Figure 5 47 Install Heater Plates 1 5 9 Install the heater plate to the manifold Refer to the general assembly drawing for location Use anti seize on threads Bolt and torque screws in a cross pattern gradually increasing torque to specified value CAUTION This is a pinch point area Use caution when installing the heater plate to the manifold plate Failure to do so could result in damage to the thermocouple Figure 5 48 CAUTION Do not over tighten the mounting screws This could result in the heater plate los ing contact with the manifold plate Refer to the general assembly drawing for the correct torque values It is recommended that the heater plate wires be isolated and grouped so that they do not have to be disconnected if the manifold needs to be dismantled for repair The heater plates are supplied with the power wires connected Place a zone number on each wire and thermocouple Revision0 Mold 00202 Masters Visi n Assembly Install Step Installation of Inlet Components If using step instead of wedge The following procedures refer to different system 1 Blue bottom of step configurations Refer to your parts list and general as sembly drawings to determine your system type CAUTION For all inlet components it is important that the mold locating ring is touching the inlet component just enough for sealing the area Thi
35. le Thermocouple Removal Torque Chart for Plate Assembly Screws ea NOTE Torque Setting Torque Setting 0 Removing thermocouples will damage 10Nm 7ftibs 10 32 9 Nm 6 ft Ibs them and is not recommended unless replacing a damaged thermocouple with a 16 Nm 12 ft 1 4 20 22 Nm 16 ft lbs replacement one lbs 1 Remove the thermocouple from the electrical box 2 ur eo ale en ote and wire channels M10 77 Nm 57 ft 3 8 16 85 Nm 63 ft lbs Remove the nozzle from the manifold plate lbs Remove the thermocouple retaining clips M12 135 Nm 100 1 2 13 209 Nm 154 ft lbs ft Ibs 4 Remove the thermocouple 330Nm 243 5 8 11 384 Nm 283 ft lbs ft Ibs Torque Settings 650 Nm 479 3 4 10 678 Nm 500 ft lbs ft lbs Gate Seal Torque Settings Gating Method ft Ib Bi Metallic C Valve 25 28 47 54 35 40 Bi Metallic Extended C Valve 25 28 47 54 35 40 NOTE D Gate seals are torqued at ambient room tem perature at Mold Masters Please torque each seal at processing temperature to the torque value specified This is to prevent material leakage from the gate seal System Screw Torques Quality and length of screws must be as specified on Mold Masters general assembly drawings Torque Chart for System Assembly Screws Metric Torque Set Imperial Torque Set ting ting Exception to the above bridge manifold mounting screws should be torqued 1 3 higher then specified on general assembly drawings gt
36. ls or gasket into the Failure to torque the gate seals at pro piston and or collar cessing temperatures may result in leak 5 Apply lubricating grease when needed age Install piston and collar back into the cylinder tube Checking Nozzle Tip Height 7 Use retaining ring pliers to install the retaining ring making sure it is seated properly 1 Correct nozzle tip height and nozzle reference point is found on the gate detail of General As sembly Drawing 2 Assemble spacer blocks to same value as correct Cylinder Housing nozzle tip height gt a 3 Zero vernier to spacer blocks Piston Collar Figure 12 10 4 Move vernier to correct reference point on nozzle tip per drawing Snap Ring Gasket Piston Seal Figure 12 12 Pneumatic Cylinder Components Figure 12 11 gt Vision User Manual Revision 01 Mold Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 9 4 Visi n Maintenance CYLINDER HOUSING PISTON PISTON SEAL BUSHING GASKET COLLAR RETAINER RING ROD SEAL PISTON ROD Figure 12 13 Pneumatic Cylinder Section Figure 12 14 Pneumatic Cylinder Assembled y Vision User Manual Revision 01 Mold Not under documentation control if printed May be revised without notice 02 2012 Maste S Electronic version is available at www moldmasters com 9 5 Wisin Nozz
37. maintenance Key Features Key Benefits e Specially engineered angled step e Ability to meet a variety of angles for optimal e Pre assembled and pre wired with drop in gate locations functionality and quick disconnects Simplified mold plate machining TA ai components including e Greater tool integrity due to minimal machining for system interface Quick actuator disassembly to release Simplified cooling circuit design requirements valve pin e Optional dual thermocouples e Quick easy system maintenance e Optional water cooling nozzle jacket e Rapid 2D and 3D designs resulting in e Extended Bi Metallic C Valve gives expedited system delivery improved steel condition at the gate e Reduced installation times e Valve pin orientation option available for textured or contoured surfaces 2 Drop Vision System Extended Bi Metallic C Valve gives improved steel condition at the gate Quick connections be tween sub manifold and main bridge Typical Applications Headlights Dipped and main Marker and Tail lights E beam Lights signal lights z Vision User Manual R 01 iin evision0 _ Mold Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 1 4 Visi n Introduction Standard Vision System Drop in Connect amp Go e Pre wired and plumbed for easy Drop in Connect amp Go installation e Ma
38. ment Water leakage may cause an electrical short circuit Hydraulic fluid leakage may cause a fire hazard Always keep water and or hydraulic hoses and fittings in good condition to avoid leaks e All maintenance on Mold Masters products should be performed by properly trained personnel based on local law or regulation requirements The electrical products need to be grounded before performing any maintenance to avoid potential risk of electrical shock Operating the Mold moving parts of the mold machine or robot The lines must be of sufficient length so that they will gt Check that all coolant hydraulic and air lines as well as electrical cables will not interfere with the not strain or pinch when the mold halves separate e For water cooling nozzle jacket coolant must be maintained with the proper mixture to prevent corrosion and circuit blockage e Care must be taken to ensure the nozzle terminal ends do not come in contact with the hydrau lic fluid The nozzles may short out or become damaged e Do not mix electrical power cables with thermocouple extension cables They are not designed to carry the power load or list accurate temperature readings in each other s application Heater Element To maximize heater element and component life the temperature must be controlled and maintained within safe operating limits Mold Masters strongly recommends individual control of each heated gt component including heater plates with
39. mmerse the sheath of the thermocouple in boiling water at the point that the thermocouple reads the temperature 4 A good thermocouple will show a temperature rise as soon as the tip of the thermocouple is immersed in water If there is a pinch point in the thermocouple there will be no change in the read ing until the pinch point on the thermocouple is immersed in water Heater Continuity Measure the resistance between each pair of heater power wires at the Mold Power Connector Compare your reading with your general assembly drawing where R resistance V voltage P power 2 R P Thermocouple Wiring Guidelines e The thermocouples are type J grounded and are color coded to ASA standards White Red e The tip must not be cut or crimped and must touch the bottom of the bore in order to measure the correct temperature e Each heat source should have its own closed loop temperature control in or der to achieve accurate control e If there are not enough control zones heat sources that have the same wattage and effect the same environment may be grouped together Heating Test with a Temperature Controller e Never start the heating with more than 40 of power e Stay a minimum of 5 minutes at 212 F 100 C before increasing heat e Stay with the system and monitor the initial heating to minimize risk gt Vision User Manual Revision 01 mo Mold Not under documentation contro
40. ncaronnonanenns 9 2 Gate Seal MaintenaNCE nee ea re doce 9 2 Gate Seal REMOVAL ASA 9 2 Checking Nozzle Tip Height torera iaa 9 4 Replacing Pneumatic Cylinder Seal and Gasket oooccocccconccocccocnocononanocanocannoncnonanenono 9 4 Nozzle Thermocouple Removal css Ren 9 6 POROUS 556 UNS E A T E E E ATEN E EA 9 6 Section 10 Troubleshooting 2222 10 1 MOUCHO AMA E E E E een 10 1 Moisture Related ls SS Sen ee a ee ee 10 1 P CMON FS CANNOT NG serrer ae ee er 10 2 Establishing Root O Einen ste nenne ns an 10 2 Defect types causes and remedies index 2 u0220222020002n00nnn anne nnnennnnnne nenne nne nennen 10 3 Pans pave GANG A eee EE A AS 10 4 Parts have Dlisters and or DUI DIG S estresante ee 10 5 Pans Have DUNN MAKS corset 10 6 PAS Surface Has An sided 10 7 Fans Ale Mera 10 8 Pa s Have SITUS OF VOLS nen ee ee aia 10 9 Ras CIS DIAS DI lila loa ta 10 10 Parts are streaked eemocccrin ardid 10 11 Vision User Manual Revision 1 Miold a Not under documentation control if printed May be revised withoutnotice Tr Masters Electronic version is available at www moldmasters com Visi n Introduction Section 1 Introduction Visio DROP IN CONNECT GO THE CLEAR CHOICE FOR LENSES With standard components and drop in features the Vision system is a clear choice for automotive lens or housing applications Vision ensures faster delivery time easy installation quick start ups and user friendly
41. nifold mounted wire armor that protects and routes electrical and thermocouple wires while providing a stable mounting platform for the plumbing e Integrated electrical panel that houses and protects all electrical connections including solenoid plugs e Quick connection between sub manifold and bridge e All wire contact pins and required high temperature sheathing installed e Stainless steel braided plumbing hoses with high temp TFE liner Vision Lite System Complete your own wiring and plumbing e Basic assembled sub manifold and bridge without pre wiring or plumbing e Does not include e Quick connections between sub manifold and bridge e Wire contact pins or high temperature sheathing e Wire armor electrical boxes mounting plate plumbing interface or valve solenoid mounting gt vo Vision User Manual Revision 01 Mold Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 1 2 Visi n Introduction Introduction We would like to take this opportunity to thank you for purchasing a Mold Masters Vision hot runner The purpose of this manual is to assist users in the integration operation and maintenance of Mold Masters sys tems This manual is designed to cover most system configurations For additional information please contact your representative or a Mold Masters office Please note that the responsibility f
42. o NOZZIE un een era aia 5 2 Nozzle Thermocouple Installation u 5 3 gt UD MANIIOI PRS SO ante EE 5 4 A A o A 5 9 Installing Heater Plate Thermocouple u ee 5 9 Installation of Inlet Components sinusitis ca 5 10 EIN VV enyqPP RPQ e 5 14 PIDIO OVINOS eee gec an ateaeccseceancessaceoesencasececesente octet acecucceusensaetaeess E 5 15 POO WIIG ee a E snvqonas pugedetenstsosucagecu rer 9 15 Section 6 Electrical Testing uuuunuunuuununnnn 6 1 MVC OCT ION ee een en ea en ee ae een 6 1 BUILD SIE An 6 1 Thermocouple Continuity OS veresseeeeeensee 6 1 PINOA FONT AA o OOO ae 6 2 sn a 6 2 Thermocouple Wiring Guidelines serra ercer ee re 6 2 Heating Test with a Temperature Controller ooocooccoccncconoconococncocnnonnonanoconocarocannnnoos 6 2 Section 7 System Installation uuuuuuuunnnnnnnn 2 1 io ASS e AA 7 1 FMF LO ASS SED een ae ee ae a en en ee ee 7 1 SA Pe EA een 7 1 Section 8 System Start Up amp Shut Down 8 1 cn e RE TI ee ee RR 8 1 o N rn Eee Eee 8 1 Vision User Manual Revision 01 a evision Mold A Not under documentation control if printed May be revised without notice 002 2012 Maste S Electronic version is available at www moldmasters com Visi n Table of Contents Section 9 Maintenance Procedures u I91 o ee 9 1 e E PA 9 1 Cil A A A 9 1 Heater Plate Power Lead Replacement ccocccoccconcociccnconcononcncoccononnnonnnononnonnnna
43. ooling nozzle jacket to the mold plate with the supplied button head cap screw and washer Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Install Sub manifold Assembly 8 CAUTION Match drop s stamped on wedge and bridge during assembly Measure and confirm height as specified on GA drawing Insert nozzle into seating bore or water cooling nozzle jacket ensuring that the anti rotation dowel is engaged in the slot Take care not to pinch the wires Remove any installation tools used Apply anti seize to the four system screws and install Torque system screws in a crossing pattern gradu ally increasing torque to specified value Measure and confirm wedge height as specified on GA drawing Repeat for each drop Install Manifold Locator and Anti Rota tion Dowel 7 1 Q NOTE e Check GA drawing for information for your system For some systems locators are supplied oversize and must be ground to the same level as the top of the nozzles Remove the material from the bottom face of the locator FACE Y However check the GA drawing for exception notations Figure 7 1 Locator Surface Using a depth micrometer verify the dimensions of the manifold pocket to those specified on the print Revision Wiold Mn 002 2012 Masters Visi n System Installation 3 Blue the man
44. oper length 2 Label the wires and install high temperature sheathing Crimp all thermocouple wires with male contacts Insert the thermocouple wire contacts into the female plug of quick connector 1T per wiring schematic in GA 5 Get six spare wires crimped with female contacts in one end insert into the male plug of quick con nect 1T label the wires accordingly to the female side 6 Insert the coding pin to the male plug as per wiring schematic if applicable 7 Snap 1T plugs together run the open end of the wires to the electrical plugs cut the wires to the proper length and crimp them install high tem perature sheathing if needed 8 Install all the thermocouple wires into electric plugs per wiring schematic drawing in the GA 9 Repeat above for each zone Name connector number according to drop number Be sure to locate the connectors inside the wire armor SUB MANIFOLD SECURE IN ELECTRICAL BOXES BRIDGE WIRE ARMOR Male xP Quick Female xP Quick Connect Plug Connect Plug Power Sub Manifold Power Wiring Power Wires m E a ME si ME Electric Plugs TC Sub Manifold y T C Electric Wiring T C Wires mm O E Plugs Female xT Quick aa Connect Plug Male xT Quick Connect Plug Figure 5 70 Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Revision0 Mold ZA pm 002 2012 M
45. or the safety of personnel remains exclusively with the employer It is the obligation of the employer to properly train and instruct its personnel in the safe operation of equipment including maintenance and the purpose and proper use of all the safety devices In addition the employer must provide its personnel with all necessary protective clothing including such items as a face shield and heat resistant gloves Any instructional material provided by Mold Masters for the operation and mainte nance of equipment does not in any way absolve the employer from fulfilling these obligations and Mold Masters disclaims liability for injury to personnel using equipment supplied Warranty and Documentation Your original system documentation contains warranty details If for any reason parts must be returned to Mold Masters it is essential to obtain prior pre authorization and a return authorization number Documentation will include any or all of the following e Parts list containing all system components Together with the general assem D bly drawing the parts list should be referenced when ordering spare parts e General assembly drawing used to integrate your hot runner system into mold e Hot half drawing used to integrate hot half to cavity plate When ordering this manual please reference document number VSUMENO1 XX Release Details Release Date Version February 2012 e This manual should be used in conjunction with
46. ot under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 5 2 Visi n Assembly Nozzle Thermocouple Installation 4 Dress thermocouple carefully alongside nozzle body and install retaining clip s Check parts list for recommended number of clips for the nozzle type Check that the thermocouple fits into the recess of the clip It is important that one retainer clip is at the top of the nozzle to keep the thermo couple inside the bore This is especially important when thermocouples are assembled from the front 1 Clean the nozzle thermocouple bore For 1 5 mm thermocouples we suggest using a 1 16 inch drill in a pin vise Figure 5 8 2 Insert the thermocouple through the flange bore Figure 5 11 5 Install the terminal end retaining clip Check that the thermocouple is seated in the recess of the terminal end clip Figure 5 9 3 Manually bend the thermocouple tip against your thumb to approximately a 90 angle ensuring bend length is sufficient to reach the bottom of the thermocouple bore Figure 5 12 CAUTION Ensure the terminal end of the thermo couple stays fully engaged in the slot while bending the thermocouple at the nozzle flange area 6 Use heat resistant tape to secure the nozzle wires and thermocouple wires just above or below the insulator pod o Figure 5 13 Vision User Manual Rev
47. ous components valve actuator actuator cooling valve nut amp insert wedge heater plate bridge inlet locating ring bridge anti rotation 10 air gap 11 bridge locator 12 wire armor option 13 sub manifold anti rotation 14 support bushing gate liner 16 gate seal 17 water cooling nozzle jacket option 18 nozzle 19 sub manifold YO S O OO M OCONOARARWNDN a 9 6 Sd 9 9 4D Figure 5 1 gt Vision User Manual Revision 01 o Mold Not under documentation control if printed May be revised without notice oo2 2012 Masters Electronic version is available at www moldmasters com 5 1 Visi n Assembly Pre Assembly Checks of Gate Seals Assembly of Gate Seals to Nozzle amp Nozzle 1 Apply anti seize paste to all threaded interfaces 1 Blue off the gate seal and liner if relevant to en sure a proper contact on sealing surface Figure 5 5 Figure 5 2 2 Ensure all sealing surfaces are clean and dry 2 Torque the gate seal to specified value 3 Install gate seal and liner ae eae di Figure 5 3 Figure 5 6 3 Remove gate seal and verify transfer of die blue from gate to the liner Verify transfer of die blue to nozzle If not 100 blue on the face contact your Mold Masters representative 4 Torque to specified values Figure 5 7 Figure 5 4 4 Clean die blue from components Vision User Manual Revision 01 Mold N
48. ple a system running PVC should be initially started and subsequent ly shut down on LDPE Revision 01 Mold y om 02202 Masters isn Section 9 Maintenance Procedures Introduction Terminal Assembly This chapter is a guide to maintaining selective compo 1 Assemble the repair kit components nents 2 Ensure the terminal end is clean Repairs that should be performed by Mold Masters u personnel are not included If you need an item re 3 Slide the element sleeve silicon seal and ceramic paired that is not included in this section please call insulator onto the wires Mold Masters support 4 Slide crimps onto leads Stranded wire should extend beyond the crimp 7 9 Spread the wire strands and insert the lead wire Terminal End Removal onto the terminal posts 6 Grasp the crimp with the crimping tool slide the crimp into position over the terminal post and crimp the connection 1 Ifthe terminal end is covered with plastic warm the terminal end prior to removing the element sleeve CAUTION T e ceramic insulator and silicon seal into Care must be taken when removing the l element sleeve to not damage the ceramic 8 Complete the repair by screwing the element sleeve or terminal nut sleeve into position 2 Grip the element sleeve at the threaded area and CAUTION turn counter clockwise If the wires rotate with the Keep an eye on the silicon seal It should sleeve damage may result not rotate with th
49. rature controller meets require ments and is fully tested and operational The injection molding machine has been properly maintained cleaned lubricated tolerances and dimen sions verified Make sure that the nozzles cylinders valves gates and any other variable that is appropriate for the batch job has been chosen Settings Ensure that all batch job parameters are correct e Temperatures e Pressures e Injection Speed e Back Pressure Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Establishing Root Cause This section is to be used as a reference tool only When a system that has been set up according to specification and was functioning normally suddenly produces sub standard parts the data in the following pages may be used to determine the possible cause but only should be used as a guide A correct set up procedure that has been proven in will produce parts that meet design tolerances and speci fications A sudden change in any parameter indicates a possible fault Rather than modify other settings to compensate for this variation it is advisable to deter mine which of the original settings has changed Fault Identification The operator will need to evaluate all the possible con ditions which may have caused the defect e Identify the problem e Determine the frequency e Is the problem random or
50. s and ground wires e Slot head screw driver small Used in fastening electrical wires to connectors e Crimping tool For fastening connector pins when necessary Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com e Wire strippers For preparing wires e Utility knife For cutting tape wires etc e Glass tape Used for grouping wires into zones e Bluing Compound For checking face contact e Sockets e Lapping compound for valve gate systems e Plastic face hammer e Retaining ring pliers for bore diameter bigger than 65mm e Removal tool for crimp contacts when necessary Unpacking the System 1 Carefully open the shipping crate and inspect contents Secure loose items and check that the system is received in good condition and no damage occurred during shipment Remove any documentation or spares packages and set aside 2 After removing all restraints attach the crane to the hoist and carefully remove the system from the shipping crate WARNING Make sure the lifting eyebolt lifting chain and crane are rated to adequately support the weight Failure to do so can cause a serious injury Make sure the machine has been locked out and tagged out in accordance to the machines documented procedures Failure to do so may lead to serious injury or death 3 Check that all mold base dimensions are correct
51. s should be double checked with the system drawings i NOTE The machine nozzle bore should be no Figure 5 49 smaller than 1 0mm 0 040 smaller than the back plate bore and no larger than the back plate bore 2 Apply anti seize to SHCS and install step to sub manifold Heated Back Plate Installation The center heater may require the machine nozzle radius to be added 1 Check the machine nozzle radius 2 Check the seating on the bottom face of the back Figure 5 50 3 Torque screws in a crossing pattern gradually increasing torque to specified value 4 Remove step to verify blued surfaces 5 Clean blue from all components 6 Re install step Figure 5 51 7 Torque screws in a crossing pattern gradually Clean bluing off all components increasing torque to specified value o Place the center heater on the manifold NOTE 5 Rotate the center heater to align with the tapped Bridge and wedge mounting screws holes in the manifold and align terminals with cut should be torqued 1 3 higher than speci out fied on GA drawings u 6 Install mounting screws through the center heater Use 1 3 of specified torque value for into the tapped holes of the manifold Use anti bluing seize on the screws Figure 5 52 gt Vision User Manual Revision01 Wield ez Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 5 1 0 Vi
52. si n Assembly 7 Torque screws to values indicated on the general Inlet Extension Installation assembly drawing Er 1 Check the machine nozzle radius 2 Check the seating on the bottom face of the back plate and manifold using bluing compound 3 Clean bluing off all components Place the inlet extension on the manifold Install mounting screws through the nozzle flange and into the manifold 6 Torque screws to manifold using anti seize on Figure 5 53 threads 7 Place a zone number on each wire and thermo 8 Place zone number on each wire and thermo couple couple 9 Tape wires for each zone together Tape WESTOP SEEN ZONE OENE Install the wires into the wire channels and secure with wire retainers Feed the wires back through the wire channel in the mold base to the electrical 10 Install the wires into the wire channels and secure with high temperature cable ties 11 Feed wires back through the wire channel in the mold base to the electrical box Figure 5 54 Back Plate Heated 1 Thermocouple 2 Center Heater 3 Screw Figure 5 55 Inlet Extension 1 Extension Tip 2 Inlet Extension 3 Thermocouple 4 Manifold 5 Flange 6 Screw gt Vision User Manual Revision 01 an Mold Not under documentation control if printed May be revised without notice 02 2012 Masters Electronic version is available at www moldmasters com 5 1 1 Inlet Extension with Heater Sleeves 1 Apply die
53. ssembly 1 Power Leads 2 Ceramic Sleeve 3 Set Screws 4 Heater Plate Gate Seal Maintenance Reasons for Gate Seal Maintenance e Tip damage e Obstruction to melt flow e Gate seal damage e Tip wear Multi Cavity Systems It is advisable to heat the system to ensure the tem perature condition is met to remove the gate seals y NOTE Use the socket supplied in the Mold Mas ters tool kit to loosen the gate seal It is recommended to use a temperature controller for this procedure If a temperature controller is not available contact your nearest Mold Masters Service Department For gate seal installation and torquing procedures refer to Gate Seal Replacement section Vision User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 9 2 Gate Seal Removal The following procedure applies to all gate seals in cluding carbide with threads larger than an M6 Figure 12 3 D NOTE If the cavity plate is easily removed you can access the nozzle seals while still in the system Hot runner systems must be within 70 F 40 C of mold temperature before the cavity plate can be removed It is recom mended the nozzle be removed from the system before removing the gate seal Use the socket supplied in the Mold Mas ters tool kit to loosen the gate seal Apply penetrating lubricant to gate seal area Figure 12 4 WAR
54. ssures and high temperatures are used in the operation of hot runners To protect the operator in the work place ensure that all safety devices are installed on the machine e Be aware of all warning labels attached to the mold and machine e Refer to the machine user manual for safety procedures and checks not included here in the hot runner specific manual Notices To make the manual easier to use we ve included notices throughout that highlight important information See below WARNING A safety warning indicates a potentially hazardous situation which if not avoided could result in serious injury or death CAUTION A caution indicates that damage to equipment is possible if the instruction is not followed a NOTE D A note indicates useful additional information or is used as a reminder of important information General Safety Warnings The equipment supplied is subjected to high injection pressures and high temperatures A Ensure that extreme caution is observed in the operation and maintenance of the hot runner system and the injection molding machines e Do not operate the equipment with unconfined long hair loose clothing or jewelry including name badges neckties etc These may get caught by the moving belt mechanism and can cause death or serious injury e Never disable or bypass a safety device e It is highly recommended that all operators wear face shields and use heat resistant gloves when working around the fe
55. ts described in this section Recycled resins can have higher hygroscopic proper ties due to greater surface area and should be dried separately from fresh resins If moisture issues are ruled out continue with the troubleshooting tables in the following pages Revision 01 Mold Mn 022012 Masters 10 1 Visi n Troubleshooting Pre Molding Precautions Prior to commencing production ensure that the following conditions have been met This will greatly reduce any future need to troubleshoot defective pro duction History Review any documentation associated with your batch job regarding the recipe using the mold molding ma chine thermoplastic resin environmental setting etc Review comments notes logbooks blogs and any thing other resource material that pertains to the batch job Verify that all settings such as all time temperature pressure material etc are correct Material Ensure that the thermoplastic resin to be used is the right grade and has been stored and or prepared dried etc according to manufacturers specs Verify that the pigment dye to be used meets manufac turers specifications and is compatible with the resin molding machine mold Verify the correct recycle ratio and adjust settings ac cordingly Hardware Make sure the mold has been properly stored and is dry clean free of rust dirt moisture residual resin pigment and any protective coating Check that the tempe
56. ution In sequence Vision User Manual Revision0 Wield Not under documentation control if printed May be revised without notice 02 2012 Mast Dry resin according to procedure check drying equipment for functionality Reduce nozzle temperature Reduce material temperature 1 lower cylinder temperature 2 reduce screw speed 3 reduce back pressure Decrease injection speed Increase mold temperature Decrease or eliminate screw decompression Reduce cycle time Check for drooling Check for contamination in mold cavity Open gates Try mold in smaller shot size press Sy S Electronic version is available at www moldmasters com 1 0 1 0 Visi n Troubleshooting Parts are streaked The finished product has large dull and laminate appearance areas on the surface Probable Cause Molding Machine e Back flow valve ring damaged e Hot spots e Material trapped in certain areas Material e Contamination of resin or machine e If pattern is identical cause may be the machine e If pattern is erratic cause may be the material or coloring e Degraded or unstable material Solution In sequence e Check for contamination e Check barrel purging e Inspect back flow ring for wear or cracks e Inspect feed screw for wear and tear e Inspect screw barrel for tolerances e Verify heater operation e Verify thermocouple operation gt Vision User Manual Revision 01 Mold Not under documentation
57. wer Connector ground pin metal tabs on side and the manifold steel The ohm reading should be zero Measure the resistance between each pin of the Mold Power Connector See Figure 6 1 and ground mold base The reading should be o infinity Occasionally the electric heaters accu mulate moisture which can reduce the resistance value to between 100 KQ to 10 MQ The controller should be designed to remove this moisture during start up Never apply full power to a heater if the insulation resistance reading is below 300 KQ Heater resistance above 500 KQ is acceptable Also check this if the mold has not been in use for a number of weeks months If necessary remove excess moisture before plac ing the heater under full current Thermocouple Continuity Test 1 Measure the resistance between each pair of thermocouple wires on the mold s Thermocouple Connector See Figure 6 1 The resistance should be between 2 5 Q and 250 Figure 6 1 Mold Plug 1 Mold Power Connector 2 Thermocouple Connector To verify alignment of thermocouple to heater turn ON one zone at a time amp check that the tempera ture responds accordingly when the set tempera ture is adjusted Revision01 MiolId y Aa 002 2012 Masters Visi n Electrical Testing Pinch Point Test 1 If there is a suspected pinch point on the thermo couple remove the thermocouple from the hot runner Connect a controller to read the temperature I
58. ww moldmasters com 1 0 5 Visi n Troubleshooting Parts have burn marks The finished product display brown streaks This is from the material being overheated due to trapped air diesel effect which can lighten or darken the color Probable Cause Molding Machine e High injection speed e Backflow check ring valve malfunctioning High back pressure Mold e Trapped or volatile gas e Burning due to friction e Incorrect sprue diameter Material Overheated underheated melt possible shear Solution In sequence e Clear blocked vent channels e Lower injection speed e Lower injection pressure e Check heater functionality e Check thermocouple functionality e Reduce feed screw rotation e Reduce melt temperature e Increase mold cavity venting e Enlarge gate e Change gate position and or size gt Vision User Manual Revision 01 ma Mold Not under documentation control if printed May be revised without notice oo2 2012 Masters Electronic version is available at www moldmasters com 10 6 Visi n Troubleshooting Parts surface has jetting The finished product exhibits serpentine flow patterns on the surface as a result of the melt cooling prior to com plete filling of the mold Probable Cause Molding Machine e High injection speed Cold mold Small gate e Wrong gate land length e Wrong gate location Material Cold melt Solution In sequence e Decrease injection speed e Verify no
59. zawa Poland tel 48 0 66 91 80 888 fax 48 0 66 91 80 208 pl moldmasters com Az Mold Masters Revision 01 02 2012 Visi n Global Support Regional Offices Con t SINGAPORE MALAYSIA INDONESIA THAILAND Mold Masters Singapore PTE Ltd No 48 Toh Guan Road East 06 140 Enterprise Hub Singapore 608586 Republic of Singapore tel 65 6261 7793 fax 65 6261 8378 mmsinfo moldmasters com SPAIN Mold Masters Espana Serennia Business Center Buenos Aires 37 29 08902 Hospitalet de Llobregat Barcelona Spain tel 34 93 802 36 01 fax 34 93 802 49 08 es moldmasters com International Representatives Argentina Sollwert S R L La Pampa 2849 2f B C1428EAY Buenos Aires Argentinia tel 54 11 4786 5978 fax 54 11 4786 5978 Ext 35 sollwert fibertel com ar Denmark Norway Sweden Englmayer A S Skenkelsoevej 9 Postbox 35 DK 3650 Oelstykke Denmark tel 45 46 733847 fax 45 46 733859 support englmayer dk Israel ASAF INDUSTRIES Ltd 29 Habanai Street PO Box 5598 Holon 58154 Israel tel 972 3 5581290 fax 972 3 5581293 sales asaf com Romania International Mold Trade Co SRL Str Constantin Aricescu Nr 21 Bl 20 Sc 2 Apt 20 Bucharest Sector 1 Romania tel 4 021 230 60 51 fax 4 021 231 78 43 contact matritehightech ro Australia Comtec I P E 1084 South Road Edwardstown South Australia 5039 PO Box 338 Magill South Australia 5072 tel
60. zzle temperature e Increase mold temperature e Increase melt temperature e Increase gate size e Modify gate location gt Vision User Manual Revision01 Mi En Not under documentation control if printed May be revised without notice 2202 Masters Electronic version is available at www moldmasters com 1 0 7 Visi n Troubleshooting Parts are short The finished product is not completely formed Probable Cause Molding Machine e Bad feed e Low injection pressure e Low injection speed e Short injection time e Back flow valve check ring faulty e Improper venting Insufficient venting Cold mold Material e Low melt temperature e Viscous material Solution In sequence e Increase feed e Increase injection pressure e Increase feed temperature by increasing cylinder temperature e Increase injection time e Increase mold temperature e Increase nozzle diameter Inspect for restrictions e Increase gate size of sprue and runner system gt Vision User Manual Revision01 NMiold Not under documentation control if printed May be revised without notice oo2 2012 Masters Electronic version is available at www moldmasters com 1 0 8 Visi n Troubleshooting Parts have sinks or voids The finished product has hollows and pockets in areas that do not cool sufficiently causing contraction Probable Cause Molding Machine Material Low injection pressure Short injection time Insuffic

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