Section 12 - Maintenance Procedures - Mold
Contents
1. Femto Centi Gating Lite Method ft lb Nm ft lb E Type Torpedo 25 28 47 54 35 40 Ext E Type Torpedo a a ae ae Hot Sprue 39 40 Extended Hot Sprue 35 40 Bi Metallic Cylindrical 16 18 12 13 27 30 20 22 34 38 25 28 E Valve Accu Valve TIT Edge Multi Tip Horizontal Hot Tip C Sprue C Valve a ae ee eee eee ee eee NOTE Gate seals are torqued at ambient room temperature 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 Hot Runner User Manual Revision 14 Fm Not under documentation control if printed May be revised without notice 06 2001 Mlasters Electronic version is available at www moldmasters com 4 2 14 Maintenance Procedures Master 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 Setting Torque Setting M8 Exception to the above bridge manifold mounting screws should be torqued 1 3 higher then specified on general assembly drawings Torque Chart for Plate Assembly Screws 10 Nm 7 ft Ibs 10 32 9 Nm 6 ft Ibs 16 Nm 12 ft Ibs 1 4 20 22 Nm 16 ft Ibs 39 Nm 29 ft Ibs 5 16 18 48 Nm 35 ft Ibs 77 Nm 57 ft Ibs 3 8 16 85 Nm 63 ft Ibs 135 Nm 100 ft Ibs 1 2 13 209 Nm 154 ft Ibs 330 Nm 243 ft Ibs 5 8 11 384 Nm 283 ft Ibs 650 Nm 479 f2. Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 12 6 Maintenance Procedures Master series Gate Seal Replacement 1 Clean the nozzle especially the thread and runner 2 Clean all residual plastic from the threads and counter bore of the gate seal WARNING Ensure nozzles have cooled to room temperature Failure to do SO may Cause serious injury CAUTION gt It is critical that seal surface is perfectly clean Failure to clean properly may result in nozzle and seal damage and leakage 3 Check the bottom face of the nozzle counterbore for damage If damaged CONG NC 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 4 After lapping is complete blue the liner to the nozzle to ensure proper mat ing If the liner is making good contact clean the bluing compound off both faces 5 Apply anti seize nickel based to the gate seal threads ONLY CAUTION gt Carefully apply anti seize to threads of the gate seal Any anti seize that enters the internal runner must be removed to prevent contamination of melt 6 Using a socket wrench re install the gate seal being careful not to damage it 7 Torque the gate seal to the appropriate value Refer to Gate Seal Torque Settings WARNING A High
3. 5 Apply nickel based anti seize to the gate seal threads ONLY 6 Install gate seal liner into nozzle using 6 point socket provided Torque gate seal to 25 28 ft Ib 34 38 Nm Figure 12 23 Torquing gate seal onto nozzle Cleaning Nozzle Insulator Cap 1 Heat cap with heat gun 2 Remove molten plastic and wipe remainder from insulator cap Figure 12 24 Cleaning Insulator Cap Installing Nozzle Insulator Cap 1 Press fit insulator cap onto liner by hand Figure 12 25 Installing Insulator Cap E ne Hot Runner User Manual Revision 14 J Hom Mold Not under documentation control if printed May be revised without notice 06 201 MWlastersg Electronic version is available at www moldmasters com 1 9 9 l Master Maintenance Procedures series Checking Nozzle Tip Height 1 Correct nozzle tip height and nozzle reference point is found on the gate detail of General Assembly Drawing 2 Assemble spacer blocks to same value as correct nozzle tip height 3 Zero vernier to spacer blocks 4 Move vernier to correct reference point on nozzle tip per drawing 5 Check that nozzle height is within drawing specification 6 Repeat for each nozzle i a Figure 12 26 Checking Nozzle Tip Height Hot Runner User Manual Revision 14 IWI NRE old _ Not under documentation control if printed May be revised without notice 06 201
4. Figure 12 28 Cavity Plate to Core Plate cedures Failure to do so may lead to serious injury or 1 Stationary Platen 2 Latches death 3 Moving Platen 4 Core Plate 5 Cavity Plate 12 Apply lockout tagged out Refer to machine manufacturers docu mentation for procedures 13 Remove the latches 14 Latch the cavity plate to the core plate or cold half 15 Remove lockout tagged out 16 Check the machine is in Mold Set mode 17 Open the mold moving the cavity plate away from the manifold plate 18 Apply lockout tagged out Refer to the controller and machine manufacturers documentation for procedures Figure 12 29 Latch Cavity Plate to Core Plate CAUTION 1 Stationary Platen 2 Cavity Plate oe The nozzles must be within 100 F 55 C of mold 3 Moving Platen 4 Core Plate temperature to prevent damage to hot runner and mold components For cylindrical valve gated systems valve pins should be in the open position prior to removal of the cavity plate to prevent damage Hot Runner User Manual Revision 14 Wiolgd Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 1 21 2 Maintenance Procedures Master Latching the Cavity Plate to the Manifold Plate Hot Half WARNING Make sure the machine has been locked out and tagged out in accordance to the machines documented procedures Failure to do so could lead to serio
5. temperature on the nozzle Wear safety clothing such as heat resistant coat and heat resistant gloves Failure to do so may cause serious injury 8 Check that the seal has bottomed out heat nozzle to process temperature and re torque seal WARNING A Failure to torque the gate seals at processing temperatures may result in leakage E F Hot Runner User Manual Revision 14 J 2 Not under documentation control if printed May be revised without notice 06 2011 MWlastersg Electronic version is available at www moldmasters com 1 2 7 we Ta ste r 5 CO a ala eicilo VI IO O Sprint Gate Seal Maintenance Reasons for Gate Seal Maintenance e Tip damage e Obstruction to melt flow e Gate seal damage e Tip wear It is advisable to heat the nozzle to ensure the tem perature condition is met to remove the gate seal CAUTION gt Use the socket supplied in the tool kit to loosen the gate seal Sprint Nozzle Tip Removal IMPORTANT IW The hot runner system must be turned off and cooled to below 38 C 100 F before cavity plate is removed The cavity plate can then be removed to expose the nozzle tips Maintenance Procedures Assembled Nozzle Tip Liner Gate Seal Insulator Cap Figure 12 18 Sprint Gate Seal Components 1 After gate seals are exposed by removing the cavity plate heat nozzles only to 290 C 550 F if nozzle thermocouples are present or set nozzle to 2
6. 0 power until plastic softens in gate area 2 Apply loosening torque to the gate seal using 6 point socket provided 16mm socket If the seal starts to loosen but starts to bind apply some Pro Long super lubricant to remove the gate seal more easily 3 The gate seal liner and insulator cap should come off the nozzle as an assembly Ifthe liner remains in the nozzle after the gate seal is removed raise the nozzle temperature by 15 C 25 F or 5 power and remove the liner using soft jawed pliers 4 Turn off heaters after gate seal removal Sprint Nozzle Tip Installation 1 Clean all residual plastic from the nozzle threads and the liner nozzle sealing surface 2 Check the liner nozzle sealing surface for damage If damaged lap the liner nozzle sealing surface in a circular fashion with a hardened tool and 300 grit lapping compound 3 After a smooth liner nozzle contact surface is established blue the liner to the nozzle surface to ensure proper mating Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Figure 12 19 Tool Kit for Gate Seal Maintenance MPS Figure 1 2 20 Loosening Gate Seal Fd Figure 12 21 Applying blue to liner surface e Revision 14 Mold 06 201 Masters 12 8 Maintenance Procedures Master series 4 After ensuring good contact clean bluing off both surfaces
7. 1 Masters Electronic version is available at www moldmasters com 1 2 1 0 Maintenance Procedures Master Latching Introduction There are two reasons latches are used in a mold e To tie the mold halves together for transportation and handling e To gain access between two mold plates which are screwed together during normal mold operation Latches are always used in pairs mounted on diagonally opposite sides of the mold to provide equal pull on the plates The latches are located on e The operator s side e Non operator s side of the mold e Top and bottom of the mold Under no circumstances are plates to be pulled or handled with only one latch attached Latch locations are shown on the assembly drawings During mold operation the latches must be removed from the mold and stored elsewhere Latching the Cavity Plate to the Core Half Cold Half Use this procedure for reference purposes only For latch locations refer to the assembly drawings For additional instructions on latching in the machine refer to the machine manufacturers manual WARNING Make sure the machine has been locked out and tagged out in accordance to the machines docu mented procedures Failure to do so may lead to serious injury or death Open the mold 2 Ensure that the machine and hot runner controller has been locked out and tagged out 3 Apply lock out tag out to the machine power source and hot runner controller Refer to the cont
8. Maintenance Procedures AY aster Section 12 Maintenance Procedures Introduction This chapter is a guide to maintaining selective components Repairs that should be performed by Mold Masters personnel are not included If you need an item repaired that is not included in this section please call Mo d Masters support The phone num ber and system identifier is located on the mold Valve Disk Removal Some valve disks may be difficult to remove use the following procedure to extract the valve disk from the mani fold i NOTE LA Check that the manifold is secure For Cast in Systems secure the manifold with clamps to prevent movement Never heat up the system without first clamping the main manifold especially if the nozzles are not secured with the hot half This prevents resin from leaking be Figure 12 1 Manifold Clamps tween the nozzle and hot half A WARNING All maintenance on Mold Masters products should be per formed by properly trained personnel based on local law or regulation requirements Electrical products may not be grounded when removed from the assembled or normal operating condition Assure proper grounding of all electrical products before performing any maintenance to avoid poten tial risk of electrical shock consisting of a protective heat resistant coat and heat resistant gloves Use adequate ventilation for fumes Failure to do so can result in serious injury A To avoid serious burns
9. ill 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 recommended the nozzle be removed from the system before removing the gate seal CAUTION gt Seals and liners for Accu Valve EX amp CX are a sub as sembly utilizing a manufactured interference fit Disas sembly of this sub assembly may affect alignment of Figure 12 14 Penetrating Lubricant the valve pin to the gate causing wear a NOTE IW Use the socket supplied in the Mold Masters tool kit to loosen the gate seal 1 Apply penetrating lubricant to gate seal area A WARNING 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 specifications 2 Leave the nozzle in the mold or remove it to a vice and clamp care fully 3 Using the temperature controller heat the nozzle body until all Figure 12 15 Remove Gate residual plastic is melted from the gate area If the nozzle is inside Seal the mold heat up the whole system and turn on the cooling or remove all O rings 4 While the nozzle is still hot apply a loosening pressure to the gate using the socket to remove the seal 5 Turn off the controller and wait for 5 minutes Remove the gate seals k Hot Runner User Manual Revision 14 Mold
10. ion is available at www moldmasters com 4 2 3 Master Maintenance Procedures 6 Grasp the crimp with the crimping tool slide the crimp into position over the terminal post and crimp the connection 7 Slide the ceramic insulator and silicon seal into place 8 Complete the repair by screwing the element sleeve into position CAUTION gt Keep an eye on the silicon seal It should not rotate with the sleeve or the wires may break Figure 12 11 Crimping Tool Chart CRIMPPUNCHO1 4 0mm Heater Element Mates with CRIMPDIE01 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 CRIMPREMOVET01 Top Crimp Removal Insert for shearing HE crimps Mates with CRIMPREMOVEB01 NOTE yA The above tools along with the lead wire replacement kit are available through Mold Masters Spare Parts Department at 1 800 387 2483 E a 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 4 2 A Maintenance Procedures Master Heater Plate Power Lead Replacement 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
11. n when removing the element sleeve as not to damage the ceramic sleeve or terminal nut 2 Grip the element sleeve at the threaded area and turn coun ter clockwise If the wires rotate with the sleeve damage may result Figure 12 3 Nozzle Terminal Assembly 1 Nozzle Flange 2 Ceramic Insert 3 Ceramic Sleeve 4 Seal 5 Element Sleeve 3 Remove the seal Remove the set screw from the ceramic sleeve 5 Remove the power leads Terminal Installation Although this procedure shows a manifold the process is the same for nozzle terminal ends NOTE a Please contact Mold Masters Spare Parts Department to ensure you have the correct repair kit and crimping tool b Hot Runner User Manual Revision 14 _ d Mold Not under documentation control if printed May be revised without notice 06 2011 Maste Electronic version is available at www moldmasters com 12 2 Maintenance Procedures AY aster Terminal Assembly 1 Assemble the repair kit components 2 Ensure the terminal end is clean 3 Slide the element sleeve silicon seal and ceramic insulator onto the wires 4 Slide crimps onto leads Stranded wire should extend beyond the crimp 5 Spread the wire strands and insert the lead wire onto the terminal posts Figure 12 8 b Hot Runner User Manual Revision 14 _ Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic vers
12. roller and machine manufacturers docu mentation for procedures 4 Allow the mold to cool to room temperature Continue to circulate the mold cooling water in all plates to cool the mold more quickly Figure 12 27 Latch Cavity Plate to Manifold Plate 1 Latches 2 Manifold Plate A WARNING 3 Cavity Plate Make sure the lifting eyebolt lifting chain and crane are rated to adequately support the weight of the plate s Failure to do so could cause serious injury b a Hot Runner User Manual Revision 14 qm Mold Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 1 21 1 Master Maintenance Procedures 5 Ifthe mold has no leader pins attach a crane that is rated to adequately support the weight of the cavity plate WARNING Install latches before removing the cavity plate mounting screws Failure to do so may lead to serious injury or death Latch the cavity plate to the manifold or manifold backing plate 7 Check that the cavity plate hoses are long enough to allow the cavity plate to be latched over to the core half cold half without damaging the hoses 8 Remove all cavity plate mounting screws Remove lockout tagged out 10 Place the machine in Mold Set mode 11 Close the mold slowly WARNING A Make sure the machine has been locked out and tagged out in accordance to the machines documented pro
13. t Ibs 3 4 10 678 Nm 500 ft Ibs Component Torque Settings Valve Actuator Series 5500 6500 6600 and Torque Setting 6700 Piston Top 20 27 Nm 15 20 ft lbs NOTE Torque sequence and step torquing Li It is recommended that system screws be torqued in a standard bolt pattern and that the specified torque is achieved in 3 steps 1 3 2 3 and full torque b B Pam Hot Runner User Manual Revision 14 IWI Ai a aa a a a aaa a a aaa Oa a aa a s ss ol _ Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 4 2 4 5
14. the holes in the ceramic sleeve Figure 12 12 Terminal Ends Assembly 1 Power Leads 2 Ceramic Sleeve Slide ceramic sleeve over the terminal end 3 Set Screws 4 Heater Plate 2 Crimp the leads to the terminal ends a 4 Tighten the set screws on the ceramic sleeve to secure the terminal assembly 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 temperature condition is P D f Pt met to remove the gate seals Figure 12 13 Gate Seals NOTE i Use the socket supplied in the Mold Masters 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 b Hot Runner User Manual Revision 14 i Vio re _ Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 1 2 5 Master Maintenance Procedures Gate Seal Removal The following procedure applies to all gate seals including carbide with threads larger than an M6 Excluding TIT Edge i NOTE YA If the cavity plate is easily removed you can access the nozzle seals while st
15. us injury or death CAUTION ore The nozzles must be within 100 F 55 C of mold temperature to prevent damage to hot runner and mold components For cylindrical valve gated systems valve pins should be in the open posi tion prior to removal of the cavity plate to prevent damage Check the machine is locked out tagged out Lubricate the guide pins on the hot half Remove lock out tag out Check the machine is in Mold Set mode Slowly close the mold aN SN Check the machine has been locked out tagged out Refer to the controller and machine manufacturers documentation for procedures Remove the latches on both sides of the mold 8 Latch the cavity plate to manifold plate or manifold backing plate 9 Remove lock out tag out 10 Open the mold 11 Check the machine has been locked out tagged out Refer to the controller and machine manufacturers documentation for procedures 12 Install and torque the cavity plate mounting screws Torque to required specifications refer to assembly draw ings for required torque settings 13 Install hoses if required 14 Remove latches from both sides of the mold b 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 4 2 4 3 Master Maintenance Procedures Torque Settings Gate Seal Torque Settings Seal Torque Settings
16. wear safety clothing 1 Heat the manifold to allow any plastic still in the system to become soft 2 Attach the valve disk extraction tool to the valve disk 3 Attach the extraction tool to the main assembly tool Refer to Figure 12 2 Valve Disk Extracted the extraction tool chart on next page 1 Valve Disk Extraction Tool 4 Extract the valve disk 2 Valve Disk b Hot Runner User Manual Revision 14 7 Not under documentation control if printed May be revised without notice 06 2011 Masters Electronic version is available at www moldmasters com 1 2 1 Master Maintenance Procedures EXTRACTION TOOLS EXTRACTION TOOLS Where Used Where Used Part Number Valve Disk Nozzle Type Tee a Valve Disk Nozzle Type VD0035 VD0088B Femto ga __YD0085 VD01088 VD0089 EXTOOL10P VD0109B VD0013 VD0110B Pico sa vDoo22 Cemi 939 VD0022 Centi VD0075B Centi Femto Femto Femto Pico VD0111B Centi vpo0s4 Pico voo106B Deci vpoose Pico _vooos7B_ Femto VDo0o37 Pico EXTOOL10P1 _ VDo093B Femto EXTOOL12 aue 849 vDoo27 Centi VDoo66B Centi voooz8 Centi vpoost Deci VD0032 Deci Terminal End Removal and Installation Although this procedure shows a nozzle terminal end the process is the same for manifold terminal ends Terminal End Removal 1 If the terminal end is covered with plastic warm the terminal end prior to removing the element sleeve CAUTION Care must be take
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