Section 10 - Hydraulic / Pneumatic Actuators - Mold
Contents
1. 9 Soak the pin in the hot runner system for 10 minutes to achieve 7100 Series 2 9 20 08 as the maximum heat expansion of the pin at the processing tem SPECIFICATION perature Mold cooling should be running Figure 10 12 Measure Distance 10 Measure the distance CD in the heated condition Check that the head of the pin is seated 11 Calculate the dimension to be ground L2 L2 CD measure ment CD specified 12 Grind the pin end to remove L2 finish cut i NOTE When the gate vestige is critical it is recommended to mold sample parts and measure samples to adjust the final pin length _ Hot Runner User Manual Revision 14 Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 1 0 4 Valve Actuators Master Steel quality in the gating area must have e High grade of toughness H13 1 2344 e Hardness of HRc 46 48 e No nitration e chrome plating The bottom of the nozzle well in the gate area must be free of stress caused by e Rough EDM e Rough machining e Sharp corners JIG grinding is recommended Valve Pin Lapping Procedure for Tapered Valve Pins 5500 and 6X00 Series If the shut off between the valve pin and gate area is not satisfactory lapping of the valve pin into the gate will be required A support bushing that fits into the nozzle flange area should be manufactured with the pi2. Series 1 Heat the hot runner system to the processing temperature 2 Allow the pin to soak in the hot runner system for 10 minutes to achieve the maximum heat expansion of the pin at processing temperature Mold cool ing must be running WARNING Extreme heat Avoid contact with heated surfaces Use appropriate protective clothing Failure to do so can cause seri ous injury 3 Measure the distance AB in heated condition NOTE Ly Heat expansion difference to be removed from pin head be removed from pin head difference to 4 Check that the tip of the pin is fitted correctly into the land 5 The heat expansion difference between the mold and hot runner is removed by grinding the back of the pinhead HED AC AB 3 05 0 02 preload HED heat expansion difference per customer 3 05 head of pin 0 02 pressure preload Figure 10 14 Measure Distance 7 Continue re assemble the actuator assembly The maximum pin preload in the land under full heat expansion must not exceed 0 02mm NOTE The standard stroke of the HY550 A E is 4 0mm This can be in creased to maximum of 8 0mm by removing material from the piston top The stroke of the HY550 C F is 8 0mm and cannot be altered y Valve Pin Assembly 5500 Series 1 Check the valve pin length Refer to Valve Pin Finishing of Tip Valve Pin Finishing of Head 2 Sli
3. 1 doj uo jsid VOIOOLXA 5 01 1100054 STOOL NOILOVYLXA NOLSId STOOL NOILOVYLXS YACNI IAD SNIGNLSLXA LOIOOLLOOOSd vOIOOLXA d00E IOOLXA XOO0ECNd A quiassyy joo UOWWUOZ LOSVIOOLXA BANIGNLSLXS 90O1IOOLXA vOAAN 3 a V 0OSSAH S1001 NOILOVYELXA NOLSId STOOL NOILOVYLXS YACNI IAD B8NIGNLSLXA vOAA 901IOOLXA d0099 1001X4 X0099AH rs vr 9 7p 1 S lt Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com
4. Valve Actuators Master Section 10 Hydraulic Pneumatic Actuators Introduction This section explains how to assemble and install the valve actuator for e 5500 Series e 6500 6600 and 6700 Series e 7100 Series Installation and Assembly of the Valve Actuator The following procedure explains how to assemble and install the valve actuator on a bench NOTE These procedures require certain parts to be lubricated or greased Valve Actuator Components 1 Screw Cylinder Locating Dowel Cylinder Top O Rings 2 3 4 5 Small O Ring 6 Piston Top 7 O Ring 8 Circlip 9 HY6X00 Spring Assembly 10 HY6X00 Stud 11 HY7100 Spacer 12 Outer Seal 13 Piston 14 Inner Viton O Ring 15 Outer Viton O Ring 16 Rod Seal 17 Cylinder 18 Cylinder Bottom O Rings 19 Valve Pin 5500 Series 6X00 Series 7100 Series Figure 10 1 Hot Runner User Manual Revision 14 J Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 1 0 1 Master j Valve Actuators Pre Installation 1 Prior to installing the actuator unit check that all fluid lines in the mold plate are de burred and do not have any metal chips Remove all rust inhibitor from the exterior of each part prior to installation Use denatured alcohol to remove the rust inhibitor compound from each part Do not clean the interior of the cylinde
5. de the valve pin into the piston 3 Grease and install the O ring 4 Install the piston top and tighten torque setting 15 20 ft Ibs 20 27 Nm Hot Runner User Manual Revision 14 Mold Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 1 0 6 Valve Actuators AY a ster 6X00 Series 1 Check the valve pin length Refer to Valve Pin Finishing of Tip 2 Slide the valve pin into position lt CAUTION Failure to install the disk springs in the correct order will cause damage to the gate 3 Assemble the disk springs to the spring retainer stud a Check for the correct orientation of the disk springs when installing b HY6500 series Align the springs in 5 alternating groups of 5 convex and concave c HY6600 and 6700 series Align the springs in 8 alternating groups of 6 convex and concave 4 Install the disk spring assembly on top of the valve pin 5 Grease and install the O ring 6 Install piston top and tighten recommended torque setting 15 20 ft lbs 20 27 Nm Figure 10 15 8 X 5 Disk Spring Assembly 1 Cylinder Top 2 Valve Pin 3 Spring Retainer Stud 4 Disk 7100 Series Springs 1 Check the valve pin length 2 Slide the valve pin into the piston 3 Install the actuator spacer with the threaded side facing towards the piston top i NOTE The threaded side is used for removal
6. hydraulics Install the cylinder extraction tool to assist with the removal of the cylinder Disassemble the system Inspect components Replace O rings O ring replacement kit is OR550P1 for 5500 series and OR650P2 for 6X00 and 7100 series When installing the rod seal check that the rod seal is seated to the base of the cylinder and is secured in place with the circlip To complete the assembly refer to Cylinder Bottom Assembly Piston Assembly Cylinder Top Assembly Figure Valve Pin Assembly Installing the Valve Actuator to the Hydraulic Plate oanoo Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 1 0 9 Figure 10 20 HY5500 Series Cylinder Extraction Tool Kit Figure 10 21 HY6 7 00 Series Cylinder Extraction Tool Kit Figure 10 22 Valve Disk Extraction Tool b Revision 14 Vio 6 201 Masters N 5 es 0 lt Extraction Tool Assembly doj uo jsid LOIOOLX4A UO SIq GOIOOLX3 B8ANIGNLSLXA GOAA STOOL NOILOVYLXA STOOL NOILOVYLXA NOLSId YACNI TAO BSAIGNLSLXA 9043 CO 1IOOLE000Sd LOIOOLEO00Sd GO 1OOLXA LO 1IOOLXA d0099 IOOLXA X00 x ZAH X00 x9AH Ajquiassy e s 1 00054 1 LOTOOLE000Sd S1001 NOILVTIVLSNI 401514 QNIGNLSLXA
7. n diameter in the center of the support bushing to properly align the pin with the gate area see below Or use the nozzle well diameter of the cavity for the support bushing as a lapping guide 1 Install the machined bushing with the center hole matching the pin diam eter Insert the valve pin through the bushing 3 Add 400 grit lapping paste to the tapered area of the pin and lapp into the gate Verify the shut off with bluing compound 4 sure to remove all lapping paste from the valve pin and cavity before continuing with actuator assembly Figure 10 13 Bushing for Pin Lapping 1 Nozzle Flange Bore 2 Machined Bushing for Center Alignment Tapered Angled Valve Pin 4 Nozzle Well Bore 5 Cavity NOTE i Do not permit the lapping paste to enter the valve bushing bore A WARNING Avoid skin contact with decomposing O rings Use appropriate protective clothing Failure to do so can cause serious injury NOTE Viton O rings used for the valve actuators are rated for operation below 200 C 400 F Always turn ON the plate cooling prior to heating the hot runner system Refer to the warning if O rings have been subjected to higher than rated temperatures b Hot Runner User Manual Revision 14 Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 1 0 5 Master Valve Pin Finishing of Head 5500
8. on 14 Wioldgd TE Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 1 0 3 Master 6X00 Series 1 Calculate the heat expansion factor Fh Processing temperature Mold temperature C x 0 000012 2 Calculate the heat expansion of the valve pin HE distance BC x heat expansion factor BC x Fh Cut to calculated length L L AC 36 35 HE 0 3 CD Grind the valve pin tip to an angle of 20 per side 40 inclusive Refer to Figure 10 7 5 Lap the tip of the pin into the land area steel section in the gate area using a lapping guide bushing or valve bushing as a lapping guide Recommended lapping paste 400 600 grit 6X00 Series SPEC CATIC IF 7100 Series 1 Install the cylinder where applicable and piston bottom without the pin and piston top into the hydraulic plate Measure the distance AC and BC Calculate the heat expansion factor Fh Processing temperature Mold temperature C x 0 000012 4 Calculate the heat expansion of the valve pin HE distance BC x heat expansion factor BC x Fh 5 Cut pin to calculated length 1 L AC 36 35 HE CD 6 Grind the valve pin tip to fit the cylindrical gate Refer to the sys tem gate detail T Assemble the hydraulic unit Heat the hot runner system to processing temperature
9. or installation use By installing a screw into the spacer s threaded end it allows for simple extraction of the spacer 4 Grease and install the O ring 5 Install piston top and tighten recommended torque setting 15 20 ft lbs 20 27 Nm Figure 10 16 Piston Spacer Installation 1 Threaded Side 2 O Ring 3 Spacer Installed Threads Up 4 Piston 5 Piston Top Hot Runner User Manual Revision 14 nnn nnn nnn nnn nnn nnn nn SSS I k _ Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 1 0 7 Master Valve Actuators series Installing the Valve Actuator to the Hydraulic Plate The following procedure is for new systems 1 N Lubricate the sides of the actuator cylinder before installing into the hydraulic plate CAUTION lt Check for sharp edges before installing the cylinder Failure to do so could damage O rings Tap the cylinder into the bore of the actuator plate with a nylon mal let Position the piston installation tool PSOOO3TOOLO1 on top of the cylinder Install the valve pin and piston into the cylinder bottom Press the valve pin into position using a nylon mallet to finish seat ing the valve pin into the assembly CAUTION Heat sensitive materials should be purged with a compatible lt less sensitive material If the system is not purged material in the manifold co
10. r Cylinder Bottom Assembly Insert the rod seal support disk into the cylinder 6X00 and 7100 only Press the rod seal into position Install the circlip with sharp edges facing up Lubricate the bottom cylinder external O rings and install Bottom Cylinder 1 Circlip 2 Rod Seal 1 2 Figure 10 3 6X00 and 7100 Figure 10 4 Seal Kit PSO003 Bottom Cylinder O Rings 1 Back Up Ring 2 Inner Viton O Ring 3 Outer Seal Piston Assembly Figure 10 5 Piston 5500 Only Assembly 1 Lightly use silicone grease and install the O ring on the 1 Back Up Ring 2 Inner piston Viton O Ring 3 Stud 6X00 and 7100 Series 1 Using silicone grease lightly grease and install the inner Viton O ring on the piston Figure 10 6 Piston Install the back up ring Assembly 1 Outer Seal 2 Installa Install the outer seal The seal should sit on top of tion Tool 3 Stud the inner Viton O ring An installation tool is available PSOO003TOOLOZ2 for installing the seal 4 Once all 3 rings have been assembled place installation tool PSOOO3TOOLO1 over assembly as shown and allow rings to settle 9 Figure 10 7 Piston Assembly 1 Stud 2 Installation Tool 50003 02 Hot Runner User Manual Revision 14 Aes fed E UUO a _ Not under documentation control if printed May be revised without notice 06 2001 Electronic version is available at www moldmasters com 1 0 2 Valve Actuator
11. s AY a ster Cylinder Top Assembly On the inside face of the cylinder top 1 Insert the locating dowel 2 Using silicone grease lightly grease and insert the small O ring 3 Using silicone grease lightly grease and insert the large O ring Figure 10 8 Typical Cylinder Top 1 Large O Ring 2 Small O Ring 3 Cylinder Top 4 Locating Dowel Valve Pin Finishing of Tip 5500 Series 1 Install the cylinder where applicable and piston bottom without the pin and piston top into the hydraulic plate 2 Measure the distance AD and AC Heat expansion difference to be removed from pin head be removed from pin head I difference to 3 Cut pin to calculated length L L AD DE 3 05 0 02 L overall length from tip to top of pin head 3 05 head of pin 0 02 pressure preload 4 Grind the valve pin tip an angle of 20 per side 40 inclusive DE 0 10 or as per customer specification 5 Lap the tip of the pin into the land area steel section in the gate area Refer to Figure 10 10 using a lapping guide bushing or valve bushing as a lapping guide Recommended lapping paste 400 600 grit Figure 10 10a 1 Nozzle Flange Bore 2 Machined Bushing for Center Alignment 3 Tapered Angled Valve Pin 4 Nozzle Well Bore 5 Cavity Figure 10 10b Land Location 1 Land Area 2 Cavity Face Hot Runner User Manual Revisi
12. uld degrade resulting in poor quality of product Remove the installation tool Check that the cylinder top dowel and O rings are installed Install the cylinder top Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 1 0 8 Figure 10 18 Valve Pin and Piston Installation 1 Valve Pin and Piston 2 Installation Tool Figure 10 19 Cylinder Top 1 Cylinder 2 Mounting Screws 3 Hydraulic Plate E Revision 14 Mold L 06 2011 Mlasters Valve Actuators aster Maintenance Procedure HY5500 HY6X00 and HY7100 Series Actuator units should be inspected every 12 months or per pre determined maintenance schedule The following procedure is performed on a bench For Oil Systems 1 2 3 Remove oil from system Remove the cylinder top with tool in upright position to prevent oil from entering the system Heat up the system required to remove the valve pin For Pneumatic Systems 1 2 ot Remove the cylinder top for every zone Heat up the system required to remove the valve pin WARNING A Extreme Heat Avoid contact with heated surfaces Use appropriate protective clothing Failure to do so can cause serious injury If possible keep cooling on within hot half Do not assemble new O rings if the plates are still hot Drain the oil before removing the pin from the
Download Pdf Manuals
Related Search