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Hot Runner User Manual - Mold

1. e Incompatible color dye e High percentage of recycled material Solution e Melt temperature increased e Mold temperature increased e Injection speed decreased e Contamination eliminated e Regrind ratio adjusted e Resin moisture content adjusted changed e System purged e Sharp corners at gate reduced Electronic version is available at www moldmasters com 1 7 8 Troubleshooting Ma aster Parts have Dimensional Irregularities The finished product is of a different dimensional value than originally designed or previous production Probable Cause Molding Machine ae e Low injection pressure ju e Short hold pressure time e Damaged back flow check ring valve e Short cycle time e Cylinder clearance too big e Nozzle heaters malfunctioning Mold e Temperature setting is too high e Small gate size resulting in wrong pressure e Incorrect gate location e Incorrect mold configuration size Material e Generally not a material related issue unless excessive regrind is used Solution e Increase the injection pressure e Increase the cooling time e Increase the mold temperature e Ensure cycle time is consistent e Monitor molding machine for irregularities e Balance regrind ratio e Increase gate size e Decrease gate land length e Balance the runner and or gate system e Decrease cavity quantity Hot R User M I a Revision 16 SRE May be revised without notice 05 2013 jase E
2. Hexagon pin holder Figure 11 9 Pin Installation 55 mm E VG VPHolder14 1 Place the pin in the pin holder 2 Install the clip to hold the pin in place 3 Apply high strength thread locking compound to the pin holder and insert it into the E VG unit 4 Screw the valve pin holder onto the E VG unit Figure 11 10 Removing E VG Unit from Hot Half 1 Unscrew and remove the wire harness cover plate Figure 11 11 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Electric Actuators 2 Remove the wires from the wiring harness Figure 11 12 3 Loosen and remove the BLACK mounting screws CAUTION gt DO NOT remove the SILVER screws Black Mounting Screw Remove Silver Screw Do Not Remove Figure 11 13 4 Carefully slide the E VG unit valve pin out of the valve bushing Figure 11 14 Revision 16 Fea iid 005 2013 Masters Electric Actuators Master series Installing E VG Unit into Hot Half 1 Insert the valve pin into the valve bushing Figure 11 18 5 Install wiring harness cover plate Figure 11 15 2 Insert the BLACK mounting screws Figure 11 19 Figure 11 16 3 Tighten the BLACK mounting screws to the torque setting indicated on the assembly drawing Figure 11 17 4 Complete wiring per assembly drawing
3. gm Not under documentation control if printed May be pevised without notice 05 20133 WMWlastersg Electronic version is available at www moldmasters c vill CIT Vaster Section 1 Introduction We would like to take this opportunity to thank you for purchasing a Mold Masters hot runner The purpose of this manual is to assist users in the integration operation and maintenance of Mold Masters sys tems Intended Use Mold Masters Hot Runners and Systems have been built to process thermoplastic material at the required tempera ture for injection molding and must not be used for any other purpose This manual is designed to cover most system configurations If you need additional information specific to your system or information in another language please contact your representative or a Mold Masters office Operator Training and Safety It is the obligation of the employer to properly train and instruct its personnel in the safe operation of equipment in cluding maintenance and the 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 maintenance of equipment does not in any way absolve the employer from fulfilling these obligations and Mold Masters disclaims liability for injury to personnel using equip ment suppl
4. Transfer Seal Torpedo Tip r Melt Disk Locator Figure 15 1 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 1 5 2 Specialty Systems Melt Disk Nozzle Wire Retainer Melt Transfer Link Transfer Seal e gt r Torpedo Tip e gt gt i gt 5 Melt Disk a gt Locator n Foam Revision 16 Wiolgd 005 2013 Masters Specialty Systems Melt Disk Nelt Disk Preparation Clean 5 Insert the pointed end of the tips torpedoes into ing the threaded end of the gate seal All nozzles manifolds and components must be free of the rust inhibitor applied at the factory 1 Disassemble the Melt Disk assembly 2 Wipe down the Melt Disk 3 Remove the part and wipe clean If necessary use a cotton swab to clean narrow interior surfaces or screw threads For larger surfaces such as mold plates use thinner in spray form to clean channels and recesses Figure 15 2 Clean Parts Figure 15 4 Assembling Gate Seal 4 Anti seize the threads of the gate seals using Mold Masters supplied compound 6 Thread the gate seal assembly into the Melt Disk Secure the Melt Disk in a soft vice and torque gate seals in the cold condition to value specified below or in the General Assembly Drawings Do not over tighten the vice Ensure none of
5. Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 5 4 Master 6 Install the clip over the terminal end Dura Line Thermocouple Instal lation This page only applies to Legacy Dura Nozzles Mold Masters Dura systems are supplied with an ap propriate bending tool Any questions regarding bend ing tools please contact your Mold Masters represen tative Make sure that correct bending tool is used Each different type of Dura nozzle requires a different bending tool The correct bending tool was supplied with your hot runner Figure 5 10 7 Use heat resistant tape to secure the nozzle wires 1 Clean nozzle thermocouple bore and thermocouple wires just above or below the insulator pod D it Figure 5 12 2 Place thermocouple through the flange of the Master Series Thermocouple nozzle Removal for non front mounted thermocouples CAUTION gt Removing thermocouples will damage them and is not recommended unless replacing a damaged thermocouple with a replacement one 1 Remove the thermocouple from the electrical box and wire channels Remove the nozzle from the manifold plate Figure 5 13 Remove the thermocouple retaining clips Remove the thermocouple 3 Place the end of the bending tool all the way over the end of the thermocouple While supporting the thermocouple create a 180 fi
6. Tm a 3 ma E a Le En Number of Cavities Figure 9 1 Efficient Color Change Range Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 9 2 13 14 15 16 17 18 19 20 Bring machine barrel back in Fill the hot runner with natural color resin to coat the melt channels with a neutral color 1 2 shots Introduce the new color Leave mold in open position and set the shot size to maximum possible Purge the entire shot through the hot runner and out the gates into the exposed cavity at the highest injection rate possible Repeat this several times Tip It may be advisable to put a protective shield over the core side to prevent plastic from injecting and cooling on the core side Set the shot size back to normal levels and begin processing parts with increased injection speeds and mold temperature Continue processing while resetting hot runner system temperatures and injection speed back to normal Return all settings to normal and confirm accept able part quality i Revision 16 Mold 005 2013 Masters 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 Actuat
7. 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 2209 aenleS Figure 10 10a 1 Install the cylinder where applicable and piston 1 Nozzle Flange Bore 2 Machined bottom without the pin and piston top into the Bushing for Center Alignment hydraulic plate 3 Tapered Angled Valve Pin 4 Nozzle Well Bore 5 Cavity 2 Measure the distance AD and AC NOTE Heat expansion difference to be removed from pin head be removed from pin head o v c e a x v o v difference to Figure 10 10b Land Location 1 Land Area 2 Cavity Face DE 0 10 or as per customer specification Figure 10 9 Measure Distance b a Hot Runner User Manual Revision 16 H e Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 4 0 3 Master Valve Actuators 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 3 Cut pin to calculated length L L AC 36 35 HE 0 3 CD 4 Grind the
8. Run parts until color has completely flushed through Continue processing while resetting hot runner system temperatures and injection speed back to normal Return all settings to normal and confirm accept able part quality k F pa Miold Masters Revision 16 05 2013 Master Color Change Procedure B More Comprehen sive 1 Empty hopper of existing color and clean thor oughly 2 Increase hot runner system temperature on all zones 30 40 F 20 C above processing tempera tures On Mold Masters controllers simply push the boost button to increase temperatures for a pre determined time and temperature 3 Back off the machine barrel introduce the appro priate purge compound and purge until previous material is cleaned then introduce new color In crease barrel extruder heats to help flush previ ous color see machine maker recommendations 4 Increase injection speed to help flush previous material 5 Use hot runner purging compound e g ASACLEAN Dyna Purge at recommended temperatures to further reduce color change time Run 10 15 shots with natural material 7 Back off the injection unit and switch off all heat on the hot runner 8 Allow the hot runner system to cool down Latch over cavity plate 10 Remove and clean gate bubbles 11 Latch back cavity plate 12 Turn on the hot runner system and heat to pro cessing temperature Efficient Color Change A
9. e Degraded resin Solution e Dry resin according to procedure check drying equipment for functionality e Reduce nozzle temperature N e Reduce material temperature 1 lower cylinder temperature 2 reduce screw speed 3 reduce back pressure e Decrease injection speed e Increase mold temperature e Decrease or eliminate screw decompression e Reduce cycle time e Check for drooling e Check for contamination in mold cavity e Open gates e Try mold in smaller shot size press Hot R User M I r n Revision 16 Electronic version is available at www moldmasters com 1 7 1 9 Master Troubleshooting series Parts are Streaked The finished product has large dull and laminate appearance areas on the surface Probable Cause Molding Machine oO e Back flow valve ring damaged Mold e Hot spots e Material trapped in certain areas Material e Contamination of resin or machine a e f pattern is identical cause may be the machine e f pattern is erratic cause may be the material or coloring Edi e Degraded or unstable material Solution 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 F p Hot Runner User Manual Revision 16 M am Mold Not under documentation control if printed May be revised without n
10. MTLO15A Melt Transfer Link Deci Top Half to nozzle MTLO16A Melt Transfer Link Centi Top Half to nozzle MTLO15B Melt Transfer Link Deci Bottom Half to Melt Cube l MTLO16B Melt Transfer Link Figure 16 13 Centi Bottom Half to Melt Cube Figure 16 18 ban Hot Runner User Manual Revision 16 Mold Not under documentation control if printed May be revised without notice 05 2013 Masti r Electronic version is available at www moldmasters com 16 6 4 C aster series 5 Install cavity inserts if applicable aligning hole 9 with cavity Figure 16 19 6 Install cavity side retainer anti rotation dowel us ing SHCS Repeat for all cavities Figure 16 20 11 7 Prepare gate seal assembly a Ensure transfer seal and torpedo are clean b Install torpedo into transfer seal Figure 16 21 8 Ensure outside of transfer seal is clean Slide fit transfer seal into cavity insert hole Figure 16 22 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 16 7 Install wedge dowel pins for locating melt wedges j T i Figure 16 23 10 Ensure all melt wedge surfaces are clean Figure 16 24 Place melt wedge on pin Apply anti seize to two SHCS M4X20 Insert melt wedge and hand tighten less than 5 LB in or 0 56 Nm until head of screw bottoms Repeat for op
11. Hot Runner User Manual Revision 16 Wiold 2 Not under documentation control if printed May be revised without notice 7 7 o Masters Electronic version is available at www moldmasters com 4 6 4 Master i oy series Melt Cube Components Load Wedge jes Gate Seal Melt Wedge e gt Assembly A Melt Cube Manifold Melee Melt Cube Anti rotation a Dowel enter Locator example custom Cavity side Retainer Cavity Insert Anti rotation Dowel Retainer Retainer Clamp Clamp Wedge Dowel Pin Cavity Insert Cayvity side Gate Seal Assembly Gate Seal Assemb a a oe example Retainer l Transfer Seal gt 4 Anti rotation _ Dowel Torpedo e _ _ gt i ead a d Figure 16 1 Not supplied by Mold Masers Hot Runner User Manual Revision 16 IWI Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 1 6 2 C aster series Example Melt Cube System _ lt e Insulation Plate Locating Ring Leader Pins Top Clamp Plate SEE SECTION 5 ASSEMBLY FOR ASSEMBLY DETAILS Inlet Bridge Manifold Nozzle Heater Nozzle Electrical Box Manifold Plate a D Melt Cube e gt Sr T Electrical Box RE Wire Channel Cavity Backing Lt Plate Cavity Plate Melt Cube Assembly R SN Melt Cube Cavit
12. rN Attach a crane that is rated to adequately support the weight of the cavity plate Check that all wires are in the retainer groves Protect the gate seal before installing the cavity plate to the manifold plate 4 1 Leave the hot half in a horizontal position 4 2 Prepare the cavity plate for assembly CAUTION IMPORTANT Heat up all manifolds to 356 F 180 C This expands the system slightly to elimi nate the cold clearance and ensures the nozzle stays straight ahead for correct alignment to the gate insert Do not lose too much time before continuing to install the cavity plate Damage may occur if the nozzle temperature becomes more than 100 F 55 C hotter than the cavity plate Install the cavity plate to the manifold plate If the plates are not assembling easily remove the cav ity plate and check for interference Install the mounting screws and torque to required specifications i Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 7 1 Master Hot Half Assembly 7 Attach a crane that is rated to adequately support the weight of the mold cold half 8 Latch the hot half to the cold half WARNING A 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 9 Refer to machin
13. Secure the ground wire with the screw I Figure 16 6 Assemble Melt Transfer Link to Melt Cube 1 Anti seize the threads of the Melt Transfer Link Top half and bottom half Figure 16 7 2 Thread the Melt Transfer Link bottom half into the Melt Cube and the Melt Transfer Link top half into the nozzle Figure 16 8 3 Torque the Melt Transfer Link COLD to the value specified in the torque chart see Figure 16 15 or the general assembly diagram m Revision 16 Vio l d 005 2013 Masters 16 4 R aster Optional Quick Disconnect Terminal Ends Optional quick disconnect terminal end kits are avail able on request The kit consists of e QDISC CRIMP Tool e TERMCONO9 Power e TERMCON 10 Thermocouple Figure 16 10 Thermocouple Quick Disconnect Terminal Ends Crimper Ratchet Disengaged Backof Jaws Tool Wire Stop ka N Slot In Contact jf Y a 4 q Wire Stop Wire Size Markings Figure 16 11 QDISC CRIMP Tool Crimping the Quick Disconnects Select the appropriate loose piece contact and identify the crimp cavity according to the wire size markings on the tool 1 Hold tool so wire side is facing you Make sure ratchet is released Squeeze tool handles together and allow them to open fully 2 Grasp locator and simultaneously move locator to ward anvil jaws and push locator slide into crimper jaws Spring tension will hold
14. b Hot Runner User Manual ae Revision 16 J Mold Not under documentation control if printed May be revised without notice 05 2013 MWlastersg Electronic version is available at www moldmasters com Maintenance Procedures 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 Mold Mas ters support The phone number 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 manifold CAUTION 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 between the nozzle and hot half Figure 12 1 Manifold Clamps A WARNING All maintenance on Mold Masters products should be performed by properly trained personnel based on local law or regula tion 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 mainte nance to avoid p
15. beyond its yield point resulting in expensive downtime of the hot runner _ WARNING Be aware of warnings placed on the assem bly drawings When the manifold is heated the metal expands stretching the mounting screws if screw lengths are shortened there is a possibility of shearing The expansion factor is calculated into the length of each screw size WARNING DO NOT SHORTEN SCREW S H C S M12 X 130 ISO GRADE 12 90 OR 13 X 4 75 ASTM A574 NOT SUPPLIED BY Mold Masters Bel m i Figure 4 2 Revision 16 Mold 052013 Masters 4 1 Master i Unpacking Cleaning All nozzles manifolds and hot runner components 1 Carefully remove all components from the ship A i must be free of the rust inhibitor applied at the factory ping box and check that all components listed on the packing slip were supplied 1 Disassemble the system 2 Check that all mold base dimensions are correct 2 Wipe down the nozzle body and correspond to Mold Masters general assem 3 Remove the part and wipe clean bly drawings 4 If necessary use a cotton swab to clean nar row interior surfaces or screw threads For large surfaces such as mold plates use thinner in spray form to clean channels and recesses Figure 4 3 Figure 4 4 E F p Hot Runner User Manual Revision 16 Mold Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is avai
16. tool 2 Use the M5 hex key KEY BPHEXTKEY5 to turn the adjusting screw clockwise to move the pin for ward or counter clockwise to move the pin back 3 When the pin is in the correct position hold the screw with the hex key and tighten the lock nut Lock nut Adjusting screw Figure 11 6 Pin Removal from 75 mm E VG VPHolder13 1 Remove the E VG unit 2 Loosen the hexagon pin holder 3 Anchor the unit in a vice and use the M5 hex key KEY BPHEXTKEY5 to remove the set screw 4 Pull the set screw out Remove the dowel pin 6 Pull the pin out Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Dowel pin Pin Hexagon pin holder Set screw a Figure 11 7 Pin Installation into 75 mm E VG VPHolder13 1 Place the pin in the pin holder 2 Apply high strength thread locking compound to the dowel pin and insert it into the pin holder 3 Apply high strength thread locking compound to the set screw and tighten set screw into the pin holder 4 Screw the set screw back into the E VG unit Figure 11 8 Pin Removal 55 mm E VG VP Holder14 1 Remove the E VG unit 2 Unthread the hexagon valve pin holder from the EVG 3 Use pliers to remove the holder clip 4 Remove the pin b F pa Revision 16 Fes ici 05 203 Masters 11 5 Master Holder clip
17. 213 Masters 16 5 Master i oy Assemble Melt Cube into Cav ity Block Center Locator a a Tii ji M g 7 ie 2 Turn on cooling to the rest of plates especially the 5 ta SETI cavity plates Supports If the system has been running 1 Make sure water to the cover plate is off then remove the cover plate e NOTE DD Mold Masters recommends a separate Figure 16 14 cooling circuit for the cover plate to be 4 Apply anti seize to the clamp SHCS s Install the able to assemble and disassemble it with proper SHCS into each retainer clamp Install out affecting other cooling circuits clamps over Melt Cube at locations shown in GA drawing Torque as specified in Clamp Screw Torque Chart see Figure 16 17 Melt Cube Assembly at cold condition Assembly at cold condition as follows Note For clar ity an example 8 cavity demo system is shown 1 Install Melt Cube anti rotation dowel in each end of the Melt Cube Component Torque Value LB ft Nm CLAMP16 7 5 10 Figure 16 12 CLAMP 17 12 16 2 Install Melt Cube center locator and spacing sup 15 20 ports into the back of the cavity block Figure 16 17 3 Insert Melt Cube into the cavity block Align the Melt Transfer Link Torque Chart anti rotation dowels with the slots in the cavity Bat ee aT are Spa block while also aligning the Melt Cube to the ere p ae Size Melt Cube center locator and spacing supports LB ft Nm mm
18. 3 Moving Platen 4 Core Plate 5 Cavity Plate Hot Runner User Manual Revision 16 Wiolgd E aa Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 1 DA 0 Maintenance Procedures Latching the Cavity Plate to the Manifold Plate Hot Half oS oN S N 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 serious injury or death CAUTION gt 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 position 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 Check the machine has been locked out tagged out Refer to the controller and machine manufac turers documentation for procedures Remove the latches on both sides of the mold Latch the cavity plate to manifold plate or manifold backing plate Remove lock out tag out Open the mold Check the machine has been locked out tagged out Refer to the controller and machine manufac turers documentation for procedures Install and torque the cavity pla
19. 4 Allow to heat soak at least 5 minutes 5 Fill system under low pressure extrude using screw rotation 6 Set nozzle temperature 10 F 6 C lower than Melt Cube Shutdown 1 Reduce Melt Cube temperatures to 300 F 150 C 2 Reduce Nozzle temperatures to 300 F 150 C 3 Turn off all zones Maintenance Replacing a Tip WARNING Potential burn hazard Use socket exten sion and heat resistant gloves e NOTE QD Before shutting down the molding machine and mold use maximum screw decom pression to remove as much molten plastic from the hot runner system as possible 1 Make sure the Melt Cube and related nozzle are at the temperature that the plastic is soft enough to be able to detach runners at gate area 2 Drain water inside cooling lines of the cover plate of the cavities and then remove the cover plate 9 3 Loosen and take out the SCHC M5X20 at the cen ter of the load wedge of tip to be replaced 4 Use SHCS M6X100 in the tool kit to extract re quired load wedge Figure 16 30 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 4 6 9 10 Loosen and take out the two SCHC M4X20 on the melt wedge Use the two SHCS M5X100 in the tool kit to ex tract related melt wedge j la j a n OoOO O m ry Figure 16 31 Let the system cool down to almost room tempera ture
20. Bushing Figure 5 27 Locator Surface N L f 4 IN N V IN ji ILN F 2 Blue the manifold locator into the bore to ensure Mounting the Manifold proper seating Introduction 3 Install the locating cam dowel pin Install the locating cam onto the dowel pin There are three methods used to locate the manifold l WARNING 1 Manifold Locator Make sure the lifting eyebolt chain and 2 Dowel Pin Locator crane can support the weight of the mani 3 Manifold and Slot Locator fold Failure to do so may cause serious injury 5 If required attach a crane of sufficient lifting ca pacity to the manifold NOTE 6 Check for correct seating and height W Check GA drawing for information for your 7 system Manifold Locator Check that there are no pinched wires Manifold Locating Dowel Pin Manifold Locating Dowel Pin Manifold Locator Figure 5 26 Manifold with a Locator Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Master i ooo T Install the dowel pin into the mold Check that the dowel pin does not touch the top of the manifold Install the locating cam dowel pin Install the manifold locating cam onto the dowel pin If required attach a crane of sufficient lifting capacity to the manifold Place the manifold on top of the nozzles and locat ing dowel Check fo
21. Edge gated systems are supplied with gate seals that The following procedure applies to TIT Edge nozzles are oversize They must be ground prior to install only The gate seal have an M6 thread ing the nozzle into the nozzle well bore Minus heat expansion Removing the Gate Seal a NOTE i NOTE Exception gate seals supplied without the gate The gate must be placed into gate seal after the seal is ground to the final dimension Refer to gate detail on the general assembly drawing a NOTE DV Heat expansion of the nozzle must also be taken in to consideration Figure 13 1 TIT Edge Gated Sys tem Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 4 3 4 W If the cavity plate is easily removed you can access the nozzle seals while still in the system Hot runner systems must be cold before the cavity plate can be re moved Apply penetrating oil to the threads Heat the nozzle to processing temperature to melt any residual plastic that may be in the gate seal area When the nozzle approaches set temperature use Mold Masters supplied socket to remove the seal a NOTE DV Cylindrically ground gate seals cannot be reinstalled Figure 13 2 TIT Edge Gate Seal i Specialty Systems Accu Line Accu Line Accu Line Body Assembly 1 Socket Head Cap Screw 2 Actuator C
22. S cccccccseccseeceeceeeceeeceeccuecaeecaeeceesaeeceeeeeeseesaeess 17 9 Pan Ale DISCO OO asserenar eer eee E E ER E EE OEO SEEN AEN NR 17 10 ANS CONANA S e n E E T 17 11 Pants S race NaS Jelling 25 x lt pcncezercussasssiecterehersansesienbachenceacavasndensddeeevandssecassesebiedsnetaneseudt 17 12 Fe AN AC 1S FOU sca a E E EE 17 14 Hot Runner User Manual Revision 16 Wield Not under documentation control if printed May be revised without notice 7 ooo Masters Electronic version is available at www moldmasters com vii ivi A amp e Fr carac series Table of Contents Parts are Sticking t0 Cavily ercer erreren aeae AEEA a e apii 17 15 Parts are Sticking to COMre cccccccccccceeccseeeceeeceeeceseceeceaeesaeesaeesaeeseuessueseueeseeeseeseeesaneseas 17 16 FLSA RO an E E E EE 17 17 Parts have SINKS OF VY OLAS arseoatecsceoaacdece sentation pasactensiecousne betetebinestectrsaousier selves eeaentad ences 17 18 FATS AN EFA rare atic ce one eve oe ana O 17 20 PTE lilo eeren ene ele ee ee 17 21 FES AS VV AOS GB seca espns E panacea area E E E EE E A 17 22 Parts have Weld ETC Scere pcs eset nes odciendiessesteaiapemiee eneuerdeetesteiceanosaeouncsoneblacerseoiencaieceseed 17 23 Hot Runner User Manual Revision 16 Wold lt lt lt lt lt lt lt KK lt IKIEE gt gt k 7_ _ _ lt gt _ lt _ lt gt gt _ gt _ LL_EI_I _ gt
23. Seal Installation with step Manifolds that use inlet seals with a step 1 Install the step inlet seal to the manifold 2 Install the dowel pin into the seal and manifold 3 Lower the main manifold into position 4 Install manifold mounting screws and torque to required settings 5 Refer to your general assembly drawing for speci fications 6 Install the manifold thermocouples Refer to n Stalling the Manifold Thermocouple NOTE W On bridge manifold systems mounting screws should be torqued 1 3 higher than specified on general assembly drawings Figure 5 33 Inlet Seal with Step 1 Sub Manifold 2 Inlet Seal 3 Locating Dowel Installing the Pressure Disk Valve Disk Review your parts list and general assembly drawing to determine the feature installed in your system e Pressure Disk is compressed by thermal ex pansive forces to form part of the plastic sealing mechanism This also helps to reduce thermal transfer to a minimum These may or may not require grinding e Valve Disk is compressed by thermal expansive forces to form part of the plastic sealing mecha nism It s high tolerance bore allows the valve pin to shift through it without plastic leakage and part of it enters the melt stream and helps guide the plastic flow without stagnation These may or may not require grinding For additional information please refer to Establishing Your System Type i Revision 16 Mold 005 213
24. Secure the thermocouple with the screw from 1 PITE Figure 15 9 b Revision 16 Mold 005 2013 Masters Specialty Systems Melt Disk 5 Use heat resistant tape to secure the nozzle wires and thermocouple wires just above the insulator pod Figure 15 10 6 Prepare all remaining Melt Disks the same way and set aside Figure 15 11 Optional Quick Disconnect Terminal Ends Optional quick disconnect terminal end kits are avail able on request The kit consists of e QDISC CRIMP Tool e TERMCONO9 Power e TERMCON 10 Thermocouple Figure 15 13 Thermocouple Quick Disconnect Terminal Ends Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Crimper PA y Jaws a Locator Ratchet Locator 7 Disengaged Slide fe N Anvil Back of Jaws Tool _ Wire Stop Slot In Contact r Wire Size Markings Wire Stop Figure 15 14 QDISC CRIMP Tool Crimping the Quick Disconnects Select the appropriate loose piece contact and identify the crimp cavity according to the wire size markings on the tool 1 Hold tool so wire side is facing you Make sure ratchet is released Squeeze tool handles together and allow them to open fully 2 Grasp locator and simultaneously move locator to ward anvil jaws and push locator slide into crimper jaws Spring tension wi
25. Take out the transfer seal and related torpedo as sembly from the cavity plate You may use proper pliers with soft tips brass and suitable hole or may use screw drivers with soft tip brass to pry transfer seal at the groove close to its wider diam eter Figure 16 32 Clean the parts and interfaces gently and replace needed parts usually the torpedo CAUTION The flat sealing interfaces of the removed melt wedges should be treated very gently Any rough scratch may become a source of leakage To clean the sealing surfaces of the removed melt wedges it is recommended to use soft sandpa per 500 grit placed on a completely flat surface ground flat surface or proper granite measure ment base Rub the surfaces gently with a few strokes on the sand paper Master gi TS series Figure 16 33 11 Loosen SHCS on opposite side of the melt wedge to have only 5 Ib in torque as well 12 Reassemble following steps in section titled Melt Cube Assembly at cold condition Complete these steps for any two sets of seals that are a mirror of one another and have been loosened to have balanced forces on interfaces of both sides during reassembly b Hot Runner User Manual Revision 16 j Mold Not under documentation control if printed May be revised without notice 05 2013 Wlasters Electronic version is available at www moldmasters com 1 6 1 0 R Master Section 17 Troubleshooting Introduction
26. Tape wires for each zone together 9 Install the wires into the wire channels and secure with wire retainers 10 Feed the wires back through the wire channel in the mold base to the electrical box Figure 5 30a Thermocouple Installation 1 Thermocouple 2 Screw 3 Washer 4 Assembly Figure 5 30b b Revision 16 VMold e623 Masters 5 10 CE aster Main Manifolds Manifolds distribute melt from the inlet component to one or more sub manifolds If you have a sub manifold configuration follow these instructions This system will have one of two configurations for inlet seals Refer to the general assembly drawing to determine which applies e Inlet seal without step e Inlet seal with step L iab g Figure 5 31 Install Main Manifold 1 Mounting Screws 2 Main Manifold 3 Dowel Pin 4 Inlet Seal Inlet Seal Installation without step Manifolds that use a seal without a step 1 Place the inlet seal into all sub manifold inlets 2 Check that the inlet seal orientation is chamfer down 3 Check that all inlet seal heights are at the same level 4 Install the manifold locators Refer to Mounting the Manifold 5 Check that all components are free of debris Figure 5 32 Inlet Seal without Step 1 Inlet Seal 2 Sub Manifold Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Inlet
27. 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 symp tom 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 a DL 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 resistant coat and heat resistant gloves Use adequate ventilation for fumes Failure to do so can result in a seri ous 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 NOTE Hot Runner User Manual 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
28. 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 specifi cations Figure 12 14 Penetrating Lubricant Revision 16 Mold i t 05 203 Masters Master Maintenance Procedures 2 Leave the nozzle in the mold or remove it to a vice 3 Check the bottom face of the nozzle counterbore and clamp carefully 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 3 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 4 While the nozzle is still hot apply a loosening pressure to the gate using the socket to remove the seal Figure 12 17 4 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 Figure 12 15 Remove Gate Seal both faces 5 Turn off the controller and wait for 5 minutes 6 Remove the gate seals Gate Seal Replacement 1 Clean the nozzle especially the thread and run ner 2 Clean all residual plas
29. Wlasters 5 11 Master series Pressure Disk Final Grinding Required This type of pressure disk is supplied oversize in height and requires grinding to dimensions specified on the general assembly drawing Pressure disk or valve disk height Pocket depth Manifold thickness Nozzle flange Air gap air gap disk height manifold thickness nozzle flange Figure 5 34 Calculating Pressure Disk Valve Disk Height Calculate Pressure Disk Height 1 Calculate the following dimensions at ambient room temperature a Measure the depth of the nozzle bore a from the top of the manifold plate to the nozzle support base 7 7 Figure 5 35 Calculating Nozzle Bore Depth a Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com b Measure the top section of the nozzle flange b Figure 5 36 Calculating Nozzle Flange Height b c Measure the manifold thickness c Figure 5 37 Calculating Manifold Thickness c 05 2013 e F a Revision 16 j Mold _ Masters CE aster 2 Calculate Pressure Disk height d a b c 5 Install the pressure disk spring dowel to the mani air gap fold This is the value d that is required for correct 6 Install the pressure disk to the manifold assembly Refer to the general assembly drawing for referenc
30. a E E E 16 2 Example Melt Cube System cccccccccccscccsseceeeeeeeeseeeeeeeceeeceeeceueeseeesaeesaeeseeeseeesaeeeseeeeaees 16 3 Assemble Melt Cube into Cavity BIOCK cccccccccsceceeeceseceeeseeeseeeseeeseeesseesseesageeneeesaees 16 6 Starup and SNUGOWI et ot ne ee 16 9 Maintenance Replacing a UND serseri iinr reuse nga NN EAE 16 9 Section 17 Troubleshooting ccceeeeeeeeeeeeeeeeeees 17 1 MOGUCOM eea E E E E E E E S 17 1 Moisture Related 1SSUCS cerais ie e a eE irna AEAT EEES 17 1 Pre Molding PRECAUTIONS siesroerrrcesererorer tis Eestise R N ie i EEEE ESEAS ESTEE E EATE ROPRET E NEARS 17 2 mE 16 1g 1G 6 hl 0 0 CAUSE erae S 17 2 UI NOTING AMOM cers csaccs tana sncusascececascnastescuceersesadesarceateueeacnnsdaicctetnsscesedcoseaceacdaedeastceasceneeee 17 2 Defect Types Causes and Remedies INdeX ccceccecceeeeeeeeeeeeeeeeeeteeeeeeeeeteeeteeeeseteeess 17 3 Parts Dave Dark DOCKS siicsanccscosneisnascansasnakeenteesauaniageindasanaaecanndansdcaniaancisesanserednnagactantanienens 17 4 Parts have Blisters and or Bubbles c ccccccccsecccececeeeceeeceeeseueeeaeecaeesaeesauecsuesageeseeesaees 17 5 Pans Nave FOW IVIAUK S acdveciagencncossaecccanssarexssescooscedsetaedanesacdessaceeeerespnaesaanvasseqeesaacdenondesyecaeeds 17 6 FAR TIS BUN MAKS eea E E E E O 17 7 Pasare DClAMIN QUING erriertan erorar E EARN ie EE E REEERE E EEE R ONARE ROPERS STEERS 17 8 Parts have Dimensional IrreQularitie
31. 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 maintenance 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 Notices Notices throughout this manual indicate additional information that must be performed or observed WARNING Safety warning indicates a potentially hazardous situation which if not avoided could result in serious injury or death oe CAUTION Ww Caution indicates that damage to equipment is possible e NOTE DL Important indicates useful additional information or is used as a reminder for important informa tion Hot Runner User Manual Revision 16 Piy nha Mold Not under documentation control if printed May be revised without notice 05 2013 MWlastersg Electronic version is available at www moldmasters com 4 5 4 Master lat att mY a Sem fh 1 Gd amp series System with cast in heater element Insulation Board Leader Pins Top Clamp Plate Center Heater Electrical Box Leader Bushing aapa 4 lt lt Melt Transfer Link on Nozzle e _ gt I MTL14A Melt Transfer Link on Melt Disk MTL14B
32. available at www moldmasters com 3 1 Remove purgings from the machine immedi ately Never touch or inspect the timing belt when power is on and motor and controller are connected Unplug the controller before any maintenance Always cover belt area with proper protecting sheet before any bench test or in mold testing High voltage and amperage cables are connected to the controller 220VAC There is also a high voltage cable connection between the servo motor and controller b Revision 16 Mold 005 213 Wlasters Unplug the controller before perform ing any maintenance work Hoses fitted to the mold will contain high or low temperature fluids or air under high pressure The operator must shut down and lockout these systems as well as relieving any pressure before per forming any work with these hoses Never perform any work on the mold unless the hydraulic pump has been stopped High voltage and amperage cables are connected to the mold Electric power must be shut off prior to install ing or removing any cables Water and or hydraulics on the mold may be in close proximity to electrical connections and equipment Water leakage may cause an electrical short circuit Hydraulic fluid leakage may cause a fire hazard Always keep water and or hydraulic hoses and fit tings in good condition to avoid leaks All maintenance on Mold Masters products should be performed by properly trained personnel based on local law
33. documentation control if printed May be revised without notice 05 2013 MWlastersg Electronic version is available at www moldmasters com 4 2 8 Maintenance Procedures mA aster Checking Nozzle Tip Height 1 Correct nozzle tip height and nozzle reference point is found on the gate detail of the general as sembly drawing 2 Assemble spacer blocks to same value as correct nozzle tip height 3 Zero indicator to spacer blocks Figure 12 27 4 Move indicator to correct reference point on nozzle tip per drawing 5 Check that nozzle height is within drawing specifi cation 6 Repeat for each nozzle Figure 12 28 Checking Nozzle Tip Height Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 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 opera tion Latches are always used in pairs mounted on diago nally 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 as
34. into position and PJUT using your fingers carefully push it into the groove Apply small amount of lubrication to O ring and 2 Put cylinder backup washer and O ring the inner side of the hard ring to help assembly into cylinder body groove Bend the cyl CAUTION inder hard ring into a kidney shape and insert into position in cylinder body ORO A O ay Cane overstretching of the hard ring Figure 14 3 Figure 14 6 3 Carefully push the protruding segment of the hard ring into the groove and reshape it using your finger Make sure it seats firmly in the groove 6 Insert piston with seals and guide ring into the cylinder body with seal and guide ring Apply a small amount of lubrication to all outside faces of seals prior to this step to help assembly r amp Figure 14 4 E P Hot Runner User Manual Revision 16 Wiolgd 2 Not under documentation control if printed May be revised without notice 05 2013 WMWlastersg Electronic version is available at www moldmasters com 1 4 2 Specialty Systems Accu Line 9 Insert O ring into cylinder top and assemble it to cylinder body Figure 14 7 Figure 14 10 7 Ensure that timing marks on both components are aligned 10 Torque fasteners to specifications detailed in GA drawings Figure 14 8 Figure 14 11 11 Turn assembled unit over and attach actuator con nection hose fittings to the supply ports Tighten to 8 Make sure installed
35. is available at www moldmasters com 8 2 System Start Up amp Shut Down E Revision 16 Wliolgd 005 2013 Masters CT em Master Section 9 Color Change Although it is not possible to make a generic color change procedure that will give the best performance in all circumstances because the flow characteristics of the plastic polymers in use can influence color changes there are specific procedures which work to enhance color changes General Tips e Always process a natural clear color for the first shot on an empty hot runner system to coat the melt channel walls and gate bubbles with a neutral color e Ensure the hopper and conveying system are free of all contamination from the previous production color Many times the previous color will hang up in the hopper or conveying system and be slowly released into the mold resulting in contaminated parts Also make sure there is no contamination in the resin being used in production e Schedule color changes from light to progressively darker e Understand the economics of your color change to decide if it is economically better to take the time to latch over the cavity plate and clean out the gate bubbles or just run scrap parts slightly longer to clean out the gate bubble area e Use purge compounds for color change in the machine barrel and hot runner Procedure A Simple amp Effec tive 1 Empty hopper of existing color and clean thor oughly Incre
36. mold female side Probable Cause Molding Machine f e High injection pressure ms lt e Long holding time e High injection speed e High material feed Mold e Hot cavity e Cold mold e Defective mold surface Material e Melt too hot Solution e Confirm cycle time for cooling e Reduce injection pressure e Reduce injection hold time e Reduce injection speed e Reduce injection time e Adjust feed e Inspect mold finish e Increase mold opening cycle e Lower mold temperature e Adjust differential temperatures e Inspect for appropriate mold release Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 1 7 1 5 Revision 16 RA Mold 05 2013 Master series E F gm Masters Master Troubleshooting Parts are Sticking to Core The finished product does not properly release from the mold male side Probable Cause Molding Machine a e High injection pressure Mold e Improper mold temperature e Bending of core e Presence of vacuum Material e Wrong resin selection aa n Solution e Confirm cycle time for cooling e Reduce injection pressure e Reduce injection hold time e Reduce injection time e Adjust feed e Reduce mold closed time e Increase core temperature e Decrease nozzle temperature e Inspect mold for undercuts and or improper draft e Verify mol
37. nozzle well bore o NOTE W A hot sprue also requires completion of the gate detail Refer to the nozzle well detail drawing Heat expansion of the nozzle must be taken into consideration Check the chart on the general assembly drawings for the length and contact height required See contact length H on table below CAUTION Ensure the thermocouple is not damaged during machining TYPICAL CONTACT LENGTH Polymer Structure Contact Length H Amorphous Filled or Reinforced 3 00 Note Always refer to the General Assembly drawing to confirm the contact length Semi crystalline Filled or Rein forced Crystalline Filled or Reinforced Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 216 0 INT PI 6 0 MIN ail 2 CUT OFF LENGTH 41 0 SUPPLIED TO BE FINISHE ve BY MOLD MAKER OS 00 0 00 Figure 5 3 Hot Valve Hot Sprue Gated System Water cooled Gate insert in stallation Option Your system may not include a water cooled gate insert Refer to your general assembly drawing The water cooled gate insert will require final machin ing 1 Machine the water cooled gate insert to final height and then add the gate detail Refer to your system drawing for details Clean the insert seatin
38. one cavity and producing only one finished part per cycle Sprue Bushing A hardened steel insert in the mold that accepts the Screw nozzle and provides an opening for transferring the melt Sprue Gate A passageway through which melt flows from the nozzle to the mold cavity Sprue The feed opening provided in injection molding between the nozzle and cavity or runner system Stationary Platen The large front plate of an injec tion molding press to which the front plate of the mold is secured This platen does not move during normal operation Thermoplastic A polymer which melts or flows when heated Thermoplastic polymers are usually not highly cross linked and act much like molecular solids low melting and boiling points high ductile strength Thermoset A polymer that doesn t melt when heated Thermoset polymers set into a given shape when first made and afterwards do not flow or melt but rather decompose upon heating They are often highly cross linked polymers with properties similar to those of net work covalent solids i e hard and strong Valve Disk Manifold component designed to be com pressed by thermal expansive forces to form part of the plastic sealing mechanism It s high tolerance bore allows the valve pin to shift through it without plastic leakage and part of it enters the melt stream and helps guide the plastic flow without stagnation Valve Gating An injection molding method that uses a mechani
39. pages i Revision 16 Mold 005 213 Wlasters 17 1 Master 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 e Review any documentation associated with your batch job regarding the recipe using the mold molding machine thermoplastic resin environ mental setting etc e Review comments notes logbooks blogs and anything other resource material that pertains to the batch job e Verify that all settings such as all time tempera ture pressure material etc are correct Material e 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 e Verify that the pigment dye to be used meets manufacturers specifications and is compatible with the resin molding machine mold e Verify the correct recycle ratio and adjust settings accordingly Hardware e Make sure the mold has been properly stored and is dry clean free of rust dirt moisture residual resin pigment and any protective coating e Check that the temperature controller meets re quirements and is fully tested and operational e The injection molding machine has been properly maintained cleaned lubricated tolerances and dimensions verified e Make sure that the nozzles cylinders v
40. point on the thermocouple is immersed in water Heating Element Check Measure the resistance between each pair of heater power wires at the mold power connector Compare your reading with your general assembly drawing p _U Where R resistance U voltage P power i Revision 16 Mold 005 2013 Masters Electrical Testing Master Thermocouple Wiring Guide lines e Thermocouples are Type J ungrounded and color coded to ASA standards White Red e The tip must not be truncated or squeezed and must touch the bottom of the bore in order to mea sure the correct temperature e Each heat source should have its own closed loop temperature control in order to achieve accurate control e If there are not enough control zones heat sourc es that have the same wattage and affect the same environment may be grouped together CAUTION oe Exceeding controller zone amperage will cause controller fuses to blow Functional Test with a Temper ature Controller The functions of the electrical equipment must be checked This test is carried out with an appropriate temperature control device e Monitor the initial heating of the system to mini mize risk 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 Re testing Where a portion of the electrical equipment is changed or modified that portion must be re ver
41. required attach a crane of sufficient lifting capacity to the manifold Make sure the lifting eyebolt chain and crane can support the weight of the manifold Failure to do somay cause serious injury Figure 5 24 Valve Bushing 1 Valve Bushing 2 Nozzle 3 Locating Dowel 3 Apply anti seize on the threads of each screw 4 Lower the manifold into position WARNING Ensure the dowels are in the correct posi tions Install screws through the manifold and into the manifold plate the mounting screw thread must start at the flange seal level Refer to the GA drawings for correct screw size Torque screws to value indicated on the general assembly drawing and secure manifold to the manifold plate i NOTE On bridge manifold systems main to sub manifold screws should be torqued 1 3 higher than specified on general assembly drawings WARNING Do not shorten the screw length A Revision 16 Mold 005 2013 Masters CE aster 1 For some systems locators are supplied oversize X 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 This will al low SURFACE A and SURFACE B to be at the same level in the cold condition However check the GA drawing for exception notations SURFACE A SURFACE B Figure 5 25 Valve Bushing Installation o W te Me 1 Mounting Screw 2 Manifold i e a S e e 3 Nozzle 4 Valve
42. size 75mm stroke 8mm LS0003A ES7510008A DOUBLE ACTING LINEAR SOLENOID PACKAGE w VP HOLDER13 amp 3 0mm PIN 10 LG 8mm STROKE 48VDC LSO003B ES7510008A DOUBLE ACTING LINEAR SOLENOID PACKAGE w VP HOLDER13 amp 3 0mm PIN 14 LG 8mm STROKE 48VDC LS0003x ES7510008A DOUBLE ACTING LINEAR SOLENOID PACKAGE w VP HOLDER13 w o 3 0mm PIN 8mm STROKE 48VDC i Hot Runner User Manual Revision 16 Wiolgd Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 4 4 _4 Master Electric Actuators ES Solenoids ES Solenoids are precision engineered actuators with integrated permanent magnets Inside the actuator a mov ing armature is guided by linear bearings The armature can take two end positions and is solidly held at these positions by permanent magnets Switching between both end positions is accomplished by energising the coils CAUTION l Switching between both end positions of the armature must only take place by means of apply ing an electric current to the coils Any switching with external mechanical means may lead to the destruction of the ES solenoid Safety Warnings This product contains permanent magnets e The ES solenoid must be mechanically A which generate a magnetic field even if the coil fixed before operating is not energised This magnetic field is also E The latest standards and regulations such as the Low Vo
43. soft start protection 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 thermo couples e When grouping heated components together and controlling more than one load from a sin gle thermocouple make sure that the compo nents 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 Mold Masters components of the same type and install as Originally specified on Mold Masters general assembly drawings i Hot Runner User Manual Revision 16 Flea ied G i _ Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com SD CE Vaster Section 4 Preparation Introduction The following section is a step by step guide to preparing your Mold Masters system for use 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 Depending on system set o
44. thermally sensitive materi als use a thermally stable material as recomended 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 Machine barrel is up to processing tempera ture e Mold cooling is on and at cooling temperature 3 Heat manifold zones and Inlet to processing tem perature Heat Melt Disks to processing temperature Heat nozzles to processing temperature A small amount of material may weep at this stage Allow to heat soak at least 10 minutes Fill system under low pressure extrude using screw rotation 8 Set Melt Disk temperature at least 10 F lower than nozzles NOTE W For hot runner systems using heater plates allow 10 minutes of soak time after the system reaches processing tempera ture CAUTION Failure to follow the above procedure may result in leakage damage occurring in the hot runner Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Master i WARNING A N When the mold is open never inject mate rial through hot runner system under high pressure Failure to do so can result in serious injury or death Shut Down NOTE For horizontal tips refer to the controller operating manual 1 Maximize decompression stroke prior to shut down This will minimize drool at start up whe
45. without notice 05 2013 MWlastersg Electronic version is available at www moldmasters com 5 1 5 Master gy ooo 4 Center Heater Installation The center heater may require the machine nozzle radius to be added 1 2 Figure 5 44 Center Heater Assembly 1 Thermocouple 2 Center Heater 3 Screw Install M8 mounting screws through the back plate Three Piece Center Heater Installation to the manifold using anti seize on threads Torque screws to value indicated on the GA draw 1 Install the back plate on the manifold ing in a cross pattern in 5 ft lb increments 2 Mount the center heater on back plate e NOTE 3 Although not necessary a thermal compound may DPD The machine nozzle bore should be no be applied to the thermocouple tip to ensure a smaller than 1 0mm 0 040 smaller than good contact the back plate bore and no larger than the the th le back plate bore Install the thermocouple Install the cover plate 6 Install M8 mounting screws through the cover plate into the tapped holes of the manifold Use anti Sseize on screws 7 Torque screws to values indicated on the general Place the center heater on the manifold assembly drawing Rotate the center heater to align with the tapped holes in the manifold and align terminals with cut out Install mounting screws through the center heater into the tapped holes of the manifold Use anti seize on the screws Torque screws to values indicated on t
46. 0 2 Cylinder Top Assembly 10 2 Maintenance Procedure 10 7 Valve Pin Finishing of Tip 10 3 5500 Series 10 3 7100 Series 10 4 Valve Bushings 5 8 Valve Disk 5 11 5 14 Valve Disk Removal 12 1 Valve Pin Assembly 10 6 Valve Pin Finishing of Head 10 5 Valve Pin Lapping Procedure for Tapered Valve Pins 10 5 W Warping 17 22 Warranty and Documentation 1 1 Water Cooled Gate Insert Installation 5 3 Weld Lines 17 23 Wiring Check 6 1 i Revision 16 Mold 005 2013 Masters 19 Ii NOTE TO MOLD MAKER This detailed user manual has been prepared to assist in the integration processing and troubleshooting of your Mold Masters System When this hot runner system has been integrated into the mold please ensure that this user manual is for warded to the molder end user together with the mold www moldmasters com i Mold BN g E Mold Masters and the Mold Masters logo are registered trademarks of AY t m CERTIFIED Mold Masters 2007 Limited 2013 HRUM EN XX V16 rs k ee performance delivered
47. 07380 7410353 7410354 7413432 7416402 7438551 7462030 74620371 7462314 7465165 7470122 7507081 7510392 7513771 7513772 7517214 7524183 7527490 7544056 7547208 7553150 7559760 7559762 7565221 7581944 7611349 7614869 7614872 7618253 7658605 7658606 7671304 7678320 7686603 7703188 7713046 7722351 7731489 7753676 7766646 7766647 7175788 7780433 7780434 7794228 7802983 7803306 7806681 7824163 7845936 7850442 7874833 7877163 7891969 7918660 7918663 7931455 7963762 7988445 7998390 8062025 8066506 8113812 8142182 8152513 8167608 8202082 8206145 8210842 8241032 8280544 8282386 8308475 8308476 8328546 D525592 RE38265 RE38396 RE38920 RE39935 RE40478 RE40952 RE41536E RE41648E Pending 2013 MOLD MASTERS 2007 LIMITED ALL RIGHTS RESERVED k Hot Runner User Manual Revision 16 Wiolg Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 1 2 em Master 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 426
48. 5 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 Hot Runner User Manual 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 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 inq 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
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50. 7 1 Nozzle Insulator Cap Cleaning 12 8 Nozzle Insulator Cap Installing 12 8 Nozzle Tip Height Checking 12 9 Nozzle Wire Layout 5 7 P Pinch Point Test 6 2 Pitted 17 13 Pitting 17 13 Pre Drying Resin 17 1 Pre Molding Precautions 17 2 Preparation 4 1 Pressure Disk 5 11 5 13 Removing EVG Unit 11 6 Resin Drying Issues 17 1 Resin Moisture Contamination 17 1 S SAFETY WARNINGS General 3 1 Short parts 17 17 Sinks or Voids 17 18 Solenoids Safety 11 2 Splay 17 19 Sprint Gate Seal Maintenance 12 7 Sprint Nozzle Tip Installation 12 8 Sprint Nozzle Tip Removal 12 7 Sticking to Cavity 17 15 Sticking to Core 17 16 Streaking 17 20 Stringing 17 21 Surface rough 17 14 System Screw Torques 12 12 System Start Up amp Shut Down 8 1 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com T Terminal Assembly 12 3 Terminal End Removal and Installation 12 2 Thermocouple Continuity Test 6 1 Thermocouple Installation 5 4 Thermocouple Installation Dura Line 5 5 Thermocouple Installation Master Series 5 4 Thermocouple Removal 5 5 Thermocouple Wiring Guidelines 6 2 Three Piece Center Heater Installation 5 16 TIT Edge Gated System 13 1 Torque 12 12 Torques 12 13 Torque Settings 12 12 Troubleshooting 17 1 U Unpacking 4 2 V valve actuator 10 1 Valve Actuator 10 1 Valve Actuators Cylinder Bottom Assembly 1
51. 902 Hospitalet de Llobregat Barcelona Spain tel 34 93 802 36 01 fax 34 93 802 49 08 es moldmasters com Turkey Mold Masters Europa GmbH Merkezi Almanya Turkiye Istanbul Subesi Alanaldi Caddesi Bahcelerarasi Sokak No 31 D 1 erenk y Atasehir ISTANBUL Tel 90 216 577 32 44 Fax 90 216 577 32 45 turkey 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 Finland Oy Scalar Ltd Viertolantie 12 11120 Riihimaki Finland tel 358 10 387 2955 fax 358 10 387 2950 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 Hot Runner User Manual Australia Comtec PE 1084 South Road Edwardstown South Australia 5039 PO Box 338 Magill South Australia 5072 tel 61 8 8374 4633 fax 61 8 8299 0892 bparrington comtecipe com Greece lonian Chemicals S A 21 Pentelis Ave 15235 Vrilissia Athens Greece tel 30 210 6836918 9 fax 30 210 6828881 m pavlou ionianchemicals gr 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 Not under documentation control if printed May be revised without notice Electronic version is availab
52. A after grinding Figure 5 40a Manifold to Nozzle Mounting 1 Spring Dowel 2 Nozzle 3 Manifold 4 Valve Disk 3 Install the manifold to the nozzle For 1 Pc Valve Disk Install the valve disk in ap propriate orientation For 2 Pc Valve Disk Insert valve stem into the manifold in appropriate orientation Slide valve flange over the stem See Figure 5 33b Figure 5 40b 2 Pc Valve Disk 1 Valve Disk Flange 2 Valve Disk Stem Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 5 Ensure correct air gap between the valve disk and the top plate as specified in the GA drawing 6 For information on removal refer to Valve Disk Removal within the Maintenance Procedures section Alternate Method Air gap adjustment from top clamp or hydraulic plate 1 Calculate and machine the nozzle bore seat with additional air gap value Example Flange height Manifold height Valve disk height Air gap value 2 Install the nozzle into the manifold plate Install the manifold to the nozzle Refer to the general assembly drawing for valve disk locations 5 Measure the gap between the top of the manifold plate and the top of the valve disk Ensure that it matches the air gap value on the general assem bly drawing Installing Heater Plates These procedures apply to systems with external heat er plates Refer to t
53. DIEO3 CRIMPREMOVEBO01 Bottom Crimp Removal Insert for shearing HE crimps Mates with CRIMPREMOVET01 CRIMPREMOVET01 Top Crimp Removal Insert for shearing HE crimps Mates with CRIMPREMOVEB01 T Slide the ceramic insulator and silicon seal into place i a v E 3 Remove the power leads using crimp removal tool Heater Plate Power Lead Replacement Removal 1 Remove the set screws 2 Slide ceramic sleeve off Figure 12 10 8 Complete the repair by screwing the element sleeve into position CAUTION Keep an eye on the silicon seal It should not rotate with the sleeve or the wires may break Figure 12 12 Terminal Ends Assembly 1 Power Leads 2 Ceramic Sleeve 3 Set Screws 4 Heater Plate Figure 12 11 k Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 12 4 Hot Runner User Manual Revision 16 Wiolgd Maintenance Procedures Mast Yr Installation 1 Push the replacement leads into the holes in the ceramic sleeve Gate Seal Removal The following procedure applies to all gate seals in cluding carbide with threads larger than an M6 2 Crimp the leads to the terminal ends Slide ceramic sleeve over the terminal end 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
54. Hot Runner User Manual om Mold a Masters performance delivered Table of Contents Master Table of Contents Section 1 Introduction cccsceeecesseeesceeseeeeeeeeeneeeeseeees 1 1 Ee a D E E A E E E E eee E eee eee 1 1 Operator Training and Safely ssosierprisen ietie n RRR ie EEEE Ee R ERIS EE 1 1 Y AW e E E EEE E E EEE T E 1 1 DOCUM MA OIT E E E E E E soatessesneanacoee 1 1 Kolase DCA eraa eE E E OT 1 1 Trademarks and Ir ALCS sercensennne ene ET 1 2 Section 2 Global Support cccceessseeseeesceeeeceeeeeeeees 2 1 Man factuning FacilUGS saser E E 2 1 Redional OCES resepsi EEEE E ee ee 2 1 International REpresentatives ccccccccceecsecceeceeeeeeceeseeeaeeceeseeeaeeceeseeeaeeeseceeeeessueeeeseeseeeeaes 2 2 Section 3 Safety nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnn 3 1 Jeligele ci IO E E E ee ee ee a eee 3 1 DON SS cass esate cg E NE 3 1 General Safety Warnings cccscccsscceecceecececeeseecaeecusecaeeeeaeesseesanesauecauecaueeceeeseeesseesagesaes 3 1 Section 4 Preparation cccccceececseeeeeeeeeeeeeceeeneeseeeeeeees 4 1 IAU OCIEIG HOI oee E E N EE E 4 1 SOW ESTI a n E E E E E E E E eee tenonaueadenete 4 1 TOOTS PS S De A E E E EAE 4 1 VADAC UNG eee E E E E 4 2 cleanin eee E ee E E eee 4 2 Establishing Your System Type cccccccccseccececeseeseecececeeeseseseeeseueeseessaeeseesaeeseeesaeeeseeees 4 3 system With Cast In Heater EIOMe
55. Hot Runner Injection Mexico S A de C V Av San Carlos No 4 Nave 2 Parque Industrial Lerma Lerma Estado de M xico 52000 M xico tel 52 728 282 48 33 fax 52 728 282 47 77 mexico moldmasters com Not under documentation control if printed May be revised without notice Electronic version is available at www 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 Warszawa Poland tel 48 0 66 91 80 888 fax 48 0 66 91 80 208 pl moldmasters com i Revision 16 Mold c5 23 Masters Miaster 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 08
56. K 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 sugges tions 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 herein No person is autho rized to make any statement or recommendation not contained herein and any such statement or recommenda tion so made shall not bind Mold Masters Furthermore nothing contained herein shall be construed as a recom mendation to use any product in conflict with existing patents covering any products or its use and no license implied or in fact granted herein under the claims of any patents No part of this publication may be reproduced or transmitted in any form or by any means electronic or mechani cal including photocopy recording or any information storage and retrieval system without permission in writing from the publisher All details standards and specifications may be altered in accordance with technical develop ment without prior notification May be manufactured under one or more of the following U S Patents 9284436 5299928 5312242 5326251 5334008 5334010 5346388 5366369 5366370 5387099 5405258 9421716 5427519 5429491 5437093 5441197 5443381 5460510 5474440 5494433 5496168 5507635 9507636 5536165 5591465
57. May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 14 4 Specialty Systems Accu Line Figure 14 20 20 Ensure that the nozzle terminal end is correctly oriented Figure 14 21 21 Secure the valve pin holder to piston Tighten to specifications detailed in the GA drawing Figure 14 22 22 Assemble inside mold and verify assembly and all connections for accuracy Figure 14 23 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 1 4 5 Revision 16 VMiold 05 2013 m pm Masters Specialty Systems Melt Disk Master Section 15 Melt Disk System MVielt Disk Introduction We would like to take this opportunity to thank you for purchasing a Mold Masters Melt Disk system The purpose of this manual is to assist users in the integration operation and maintenance of Mold Masters systems This manual is designed to cover most system configurations For additional information please contact your representative or a Mold Masters office Safety Please see Section 3 for important safety information The responsibility for 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
58. ace Probable Cause Molding Machine e Improper or worn out feed screw e Low melt temperature e Low injection speed Mold e Gating shear e Sharp corners Material e Resin used is not homogeneous e External contamination Solution e Reduce shear e Reduce back pressure e Reduce injection speed e Modify temperature e Modify regrind ratio e Modify shot size e Inspect hot runner and nozzles i Hot Runner User Manual Revision 16 WWiold Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 17 1 3 j Master Troubleshooting Parts Surface is Rough The finished product exhibits patterns on the surface similar to grooves on a record due to rapid cooling of the melt as it nears mold surface followed over and over again by fresh melt Probable Cause Molding Machine e Low injection speed e Low injection pressure Mold e Cold mold e Irregularities in mold surface defective polishing Material e Cold melt Solution e Increase injection speed e Increase injection pressure e Increase melt temperature e Increase mold temperature e Inspect mold surface Hot R User M I Oo unner User Manua Revision 16 i Se aS a a a ea Electronic version is available at www moldmasters com 1 7 1 4 Troubleshooting Parts are Sticking to Cavity The finished product does not properly release from the
59. ack pressure e Damaged backflow valve check ring Mold e Mold not at required temperature e Small gate leading to early freezing e Gate land length too long e Incorrect rib wall dimensions e Material flow incorrect e Thick wall part Material e Hot material he e Material wrong grade for application a i x here yh Solution e Adjust injection speed e Increase injection hold time e Increase injection pressure e Adjust melt temperature e Adjust mold temperature e Inspect for hot spots e Enlarge and or add vents to mold parting line e Increase sprue or runner size e Increase gate size reduce gate land length e Relocate gate closer to heavy thicker areas e If possible core out heavy wall sections b Hot Runner User Manual Revision 16 Wiolgd z Not under documentation control if printed May be revised without notice 05 20133 WMWlastersg Electronic version is available at www moldmasters com 1 7 1 8 Troubleshooting Master Parts Display Splay The finished product display splay splash marks and or silver streaks Probable Cause e Resin degraded from overheating _ ee e Cylinder contains hot spots e Material trapped at nozzle tip e Wrong injection pressure e Wrong injection speed e Low back pressure Mold e Friction related burning in gate nozzle or hot runner e Trapped volatile compounds Material e Hot melt _ e Contaminated resin moisture dirt organics
60. al should sit on top of the inner Viton O ring An installation tool is avail Press the rod seal into position able PSOO03TOOLO2 for installing the seal Install the circlip with sharp edges facing up 4 Once all 3 rings have been assembled place Lubricate the bottom cylinder external O rings and installation tool PSO003TOOLO1 over assembly as install shown and allow rings to settle Figure 10 6 Outer Seal Assembly 3 Outer Seal 4 Installa Figure 10 5 Piston tion Tool PSOOO3TOOLO2 Assembly 1 Back Up Ring 2 Inner Viton O Ring Figure 10 2 6X00 and 7100 Figure 10 3 6X00 and Bottom Cylinder 7100 Bottom Cylinder 1 Circlip 2 Rod Seal O Rings Figure 10 4 Seal Kit PS0003 Figure 10 7 Piston 1 Back Up Ring 2 Inner Viton O Ring 3 Outer Seal Assembly 1 Piston Bottom 2 Installation Tool PS0003TOOLO1 Hot Runner User Manual Revision 16 rear a NO Electronic version is available at www moldmasters com 1 0 2 Valve Actuators Master Cylinder Top Assembly 3 Cut pin to calculated length L L AD AC DE 3 05 0 02 On the inside face of the cylinder top 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 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 We recommend 400 600 grit lapping paste
61. alculating the pres value sure valve disk height 2 Install the nozzle into the manifold plate 3 Grind equal amounts from each side of the pres 3 Install the manifold to the nozzle sure disk to give 0 00 to 0 025mm cold clearance and retain maximum strength of the V form Some systems require a larger air gap refer to the general assembly drawing 5 Measure the gap between the top of the manifold plate and the top of the pressure disk Ensure that it matches the air gap value on the general assem Refer to the general assembly drawing for pres sure disk locations 4 Remove the sharp corners after grinding and clean the disk well to ensure no grinding dust bly drawing remains on the disk y J Grind Stone Equal Sharp Amounts Corners DS Figure 5 38 b Hot Runner User Manual Revision 16 I Hot Runner User Manual 00000000000 I I M Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 5 1 3 Master gy ooo Valve Disk Final Grinding Required These valve disks are supplied oversize in height and require grinding to dimensions specified on the gen eral assembly drawing before calculating the pressure valve disk height 1 Grind the valve disk on top side only 2 Remove sharp corners after grinding and clean the valve disk especially inside the valve pin bore Ensure correct Clean bore air gap per G
62. alves gates and any other variable that is appropriate for the batch job has been chosen Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Settings Ensure that all batch job parameters are correct e Temperatures e Pressures e Injection Speed e Back Pressure 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 in the same location e Review past history logs for similar occurrences and resolutions Review the machine settings to ensure that there is no variation from the original set up which was producing standard parts injection spe
63. ase hot runner system temperature on all zones 30 40 F 20 C above processing tem peratures On Mold Masters controllers simply push the boost button on the controller to increase temperatures for a pre determined time and tem perature Back off the machine barrel introduce the appro priate purge compound and purge until previous material is cleaned then introduce new color In crease barrel extruder heats to help flush previ ous color see machine maker recommendations Increase injection speed to help flush previous material Use hot runner purging compound e g ASACLEAN Dyna Purge at recommended temperatures to further reduce color change time Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 9 1 WARNINGS To avoid serious burns when purg ing 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 Some plastics develop gases that may be dangerous to personal health Follow the plastics supplier s recommendations Do not look directly into the feed throat of a hopper use a mirror Unexpected release of resin may cause serious burns Never handle plastic purgings or drool until they have completely cooled Purgings may appear solid but may still be hot and cause serious injury
64. ase injection hold time e Increase cooling time e Adjust injection pressure e Adjust mold temperature set sequential temperatures based on part geometry e Check gate dimensions quantities and locations e Re design part if necessary k Hot Runner User Manual Revision 16 Wliold Not under documentation control if printed May be revised without notice 05 20133 WMWlastersg Electronic version is available at www moldmasters com 1 7 22 Troubleshooting Master Parts have Weld Lines The finished product has lines where two flow fronts meet and have not fused creating the possibility of weak areas and stress fractures Probable Cause Molding Machine Solution Low injection speed Low injection pressure Short injection time forward Low mold temperature Poor venting Back flow valve check ring malfunctioning Gates too far apart Redesign part Cold melt Material wrong grade for application Increase injection pressure Increase injection holding time Increase injection speed Increase cylinder temperature Increase mold temperature Check for venting Provide an overflow well adjacent to the weld area Modify the gate location Decrease gate land length Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 1 7 23 E Revision 16 Mold 005 213 Masters Glossary of Terms Ma
65. ave stalling valve pins c HY6600 and 6700 series Align the springs in 8 alternating groups of 6 convex and concave 5500 Series 4 Install the disk spring assembly on top of the valve 1 Check the valve pin length Refer to pin Valve Pin Finishing of Tip Valve Pin Finishing of Head 5 Grease and install the O ring Install piston top and tighten recommended Slide the valve pin into the piston torque setting 15 20 ft Ibs 20 27 Nm Grease and install the O ring Install the piston top and tighten torque setting 15 20 ft Ibs 20 27 Nm Figure 10 15 8 X 5 Disk Spring Assembly 1 Cylinder Top 2 Valve Pin 3 Spring Retainer Stud 4 Disk Springs Figure 10 16 Piston Spacer Installation 1 Actuator Spacer 2 O Ring 3 Spacer Threads Up 4 Piston 5 Piston Top k Hot Runner User Manual Revision 16 pr _ gpm Mold Not under documentation control if printed May be revised without notice 05 2013 Maste Electronic version is available at www moldmasters com 4 0 6 Master VEW TE e a te series 7100 Series Check the valve pin length Slide the valve pin into the piston 3 Install the actuator spacer with the threaded side 2 facing towards the piston top NOTE 3 DPD The threaded side is used for removal or installation use By installing a screw into A the spacer s threaded end it allows for simple extraction of the spacer Grease and install the O ring 5 Insta
66. break or splinter Turn off a defective solenoid immediately and disconnect it from its power supply Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 4 1 E gt Damage to the solenoid is possible if the follow ing cautions are not followed e Any switching with external mechanical means may lead to the destruction of the ES solenoid e Oiling or greasing the moving parts of the solenoid may lead to a total failure of the ES solenoid e Applying an improper voltage to the coils or exceeding the nominal switch on period may damage or thermally destroy the sole noid by overheating e Any mechanical damage of the surfaces may lead to corrosion e Exposing the unit to hard shocks during installation may interfere with the function of the ES solenoid e All wire leads and electrical contacts need to be protected against mechanical dam ages e Exposure to high temperatures will irrepara bly damage the permanent magnets e Prevent magnetisable particles such as iron cuttings from getting close to the prod uct j Revision 16 Fea iid 005 2013 Masters Electric Actuators AY aster e Exposing the ES solenoid to dust particles will reduce the life cycle of the bearings guiding the armature e Modifications of the ES solenoid may limit its function or lead to its total failure e The ES solenoid shou
67. c cccececnctcesencrccsecesacadecerceatcesdeedaaendiastdetasendasciashdeieathaneaeoredenesasteds 5 13 HSN FIC tel lr VCS eer E 5 14 Installation of Inlet Components cccecceccceecceeeeseceeecaeteeeceeecaeesseceeeseeeeueeseeneeeeeeeeeteeeas 5 15 Section 6 Electrical TeSting cccccseeeeeeeeeeeeeeeeeeeee 6 1 HUVEC UO aecscs retort oe E eee span pene eee E Seeman senses cseeesasesaeweees 6 1 MIEN 2 TS OK seror anna aero va cele taps ciae nse ae an ag acm eee cen acta ses one geneece ane cusaeseseeennouceat te 6 1 Electrical Safety TeES UNg ee or ene eee ee E eee eet ee eee eee 6 1 Thermo o ple Wiring Guidelines ascus ccorceresemcapaeesssdyaneancelesiguodare sdansiededentugesseeosas saceceeouse 6 3 Functional Test with a Temperature Controller ccccccccccceeceeeeeeeteeeteeeeseeeeeteeenseseseeseenes 6 3 EEEN E EAEE eee eee ne ee ee ee ee ee ee 6 3 Section 7 Hot Half Assembly ccccseeeeeeeeeeeeeeees 7 1 MOGUC UO ox4 cranscanesesstteesratncsecaaeawonssnceateaetaasecanel et his e verdes edaedessteesesenaenedatneactestoncaaesede aieaeacoes 7 1 PASSE MMIONING NE FHOCHANN E 7 1 Section 8 System Start Up amp Shut Down 8 1 MOGUCU gera n E E E ss saeegeec eden 8 1 Pree D a E A E E E ee 8 1 SAUL DONN ee E E ee eee ee 8 2 Hot Runner User Manual Revision 16 Wiold Not under documentation control if printed May be revised without notice 05 203 Miasters Electronic version i
68. cal shut off to open and close the gate orifice Vent A shallow channel or opening cut in the cavity to allow air or gases to escape as the melt fills the cavity Some glossary content DRM Associates 2008 Protomold 1999 2009 k D Hot Runner User Manual Revision 16 Wia Hm Mold Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 18 3 CE aster index A Accu Line System 14 1 Actuators 10 1 Assembly 5 1 Back Up Ring 10 2 Blisters 17 5 Bridged Hydraulic Pneumatic System 4 5 Bridge Manifold Systems mounting screws 5 11 Bubbles 17 5 Burn Marks 17 7 C cast in heater element 4 3 Cast in Heater Element System 4 3 Center Heater Installation 5 16 Checking Nozzle Tip Height 12 9 Cleaning 4 2 Cleaning Nozzle Insulator Cap 12 8 Crimping Tool Chart 12 4 Dark Specks 17 4 Defect Types Causes and Remedies 17 3 Delaminating 17 8 Dimensional Irregularities 17 9 Discolored 17 10 Electric Actuators 11 1 Pin Height Adjustment 11 3 Pin Removal 55 mm EVG VPHolder14 11 5 Removing EVG Unit 11 6 Electrical Testing 6 1 External heater plates 5 14 F Flash 17 11 Flow Marks 17 6 Front Mounted Thermocouples 5 7 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com G Gate Seal Finishing 5 3 5 4 Hot Va
69. cess to complete one set of moldings The cycle is taken at a point in the operation and ends when this point is again reached and moving platens of the clamp unit in the fully open position Cycle Time The time required by an injection molding system to mold a part Dwell A pause in the applied pressure to a mold during the injection cycle just before the mold is completely closed This dwell allows any gases formed or present to escape from the molding material Ejector Pins Pins that are pushed into a mold cavity from the rear as the mold opens to force the finished part out of the mold Also called knockout pins Ejector Return Pins Projections that push the ejector assembly back as the mold closes Also called surface pins or return pins Ejector Rod A bar that actuates the ejector assembly when the mold opens Family Mold A multi cavity mold where each of the cavi ties forms one of the component parts of an assembled finished part Fill The packing of the cavity or cavities of the mold as required to give a complete part or parts that are free of flash Flow A qualitative description of the fluidity of a plastic material during the process of molding A measure of its moldability generally expressed as melt flow rate or melt index Gate An orifice through which the melt enters the mold cavity Hot Tip Gate An injection molding method that uses a heated gate on the A side of the part to eliminate the creatio
70. cesseeeeeseeeeeeeees 15 1 MOGUC UO enee e E E E E E acer 15 1 NS EPEE E EEE E E E E E E E 15 1 System with cast in heater ClEMeEN ccccceccceccceeeceeeceeeeceeecceceeeseuecsueesaeeseeeseeeseeeeseeees 15 2 Melt Disk Preparation CICANING cccccccseccececeeeeseeceeeseeecsseceueceueesaeeseeseeseeeseeeneeesaees 15 3 INOZZIe TNETMOCOUDIE ASSEMDIY aciccisetsndcastucacwecesncdmeubdconeseudlescceiariedonelndeutncutastesensdaneetetencd 15 4 Hot Runner User Manual Revision 16 Wiold Not under documentation control if printed May be revised without notice 05 203 WMiasters Electronic version is available at www moldmasters com Vi Table of Contents Master Melt Disk Thermocouple Assembly ccccccccsccseeceecceeceeeceeeceeceeeceeceeeeeesaeeseeseuesaeesaeess 15 4 Anti seize the threads of the 1pc Melt link using Mold Masters supplied compound 15 6 Melt Disk System Start Up amp Shut Down ccc eccccccceecceeceeeceeeecaeeseeesaeeceeesegeeseeeeaees 15 7 Disassembly for Maintenance cccccccsecceseceeeceseececcececeeeseeeseueeeaeesaeeseesaueseeesaeeeseeesaees 15 7 Melt Disk Reassembly after Maintenance cccccccceccceccceeeceeeeeeeeseeeceeeseeessueeaneeseeeeeees 15 7 Section 16 Melt Cube System ccccceeeeeeeeeeeeees 16 1 WR OG ICT ODN cst e a E ia cy ecsesaeeete T estes sootenceaes 16 1 Oye S A i ee ere nee ee eee ee ee ee ee ee ee 16 1 VU CS COMPONE ce
71. condition Check that the head of the pin is seated 11 Calculate the dimension to be ground L2 L2 CD measurement CD specified 12 Grind the pin end to remove L2 finish cut g NOTE W When the gate vestige is critical it is recommended to mold sample parts and measure samples to adjust the final pin length 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 No 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 i Revision 16 WwWiolg 05213 Masters 10 4 Valve Actuators Master Valve Pin Finishing of Head 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 pin 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 bush ing as a lapping guide 1 Install the machined bushing with the center hole matching the pin diameter Insert the valve pin through the bushing Add 400 grit lapping paste to the tapered area of the pin and lapp into the gate Verify the sh
72. d bending ratio Hot Runner User Manual Revision 16 Wiolgd Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 1 7 1 6 Troubleshooting Master Parts are Short The finished product is not completely formed Probable Cause Molding Machine e Feed system issue e Low injection pressure e Low injection speed e Short injection time e Back flow valve or check ring faulty e Improper venting Mold e Insufficient venting e Cold mold Material e Low melt temperature e Viscous material e Check venting 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 e Inspect for restrictions e Increase gate size of sprue and runner system m Hot Runner User Manual Revision 16 F Haml Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 1 7 1 7 Master 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 E e Low injection pressure EL e Short injection time e Insufficient material in cavity e High injection speed e Low b
73. d without notice Electronic version is available at www moldmasters com b Revision 16 Mold 6 203 Masters 4 4 CE Vaster System with Bridged Hydraulic Pneumatic System Insulation Board Bridge Step Tae Electrical Box e gt gt Name Plate Figure 4 7 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 4 5 Locating Ring Backplate Hydraulic Pneumatic Actuators Valve Disks Manifold Nozzle Manifold Plate b Revision 16 Mold 05 213 Masters em Master Section 5 Assembly Introduction This section is a step by step guide to assembling your Mold Masters hot runner system Cutaway of a cast in system This illustration of a typical Mo ld Masters cast in hot runner system is divided into two halves valve side and non valve side The terminology associated with the various components and features are listed below Figure 5 1 Valved 1 airgap 2 inlet extension 3 locating ring 4 machine nozzle pad backplate 5 manifold locating cam 6 manifold locator 7 cast in manifold 8 nozzle Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Non Valved 9 pressure disk 10 gate seal 11 valve actuator 12 valve disk
74. de are drafted with equal and opposite draft the wall thickness will be constant Cycle Time The time it takes to make one part includ ing the closing of the mold the injection of the resin the solidification of the part the opening of the mold and the ejection of the part Cavity The space inside a mold into which material is injected Clamp The part of an injection molding machine incor porating the platens that provides the force necessary to hold the mold closed during injection of the molten resin and open the mold to eject the molded part Clamping Plate A plate fitted to a mold and used to fasten the mold to a platen Clamping Pressure The pressure applied to the mold to keep it closed during a cycle usually expressed in tons Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Closed loop Control System for monitoring complete injection molding process conditions of temperature pressure and time and automatically making any changes required to keep part production within preset tolerances Cooling Channels Channels located within the body of a mold through which a cooling medium is circulated to control the mold surface temperature Cushion Extra material left in barrel during cycle to try and ensure that the part is packed out during the hold time Cycle The complete sequence of operations in a pro
75. e Channel 2 Retainers b Revision 16 Mold o 203 Masters 5 7 Master gy ooo Front Mounted Thermocouples 1 Place a zone number on each wire and thermo couple Try to organize and tape wires by zone and plug 3 Install the wires into the wire channels and secure with wire retainers 4 Feed the wires back through the wire channel in the mold base to the mold plug Do not cut the wires too short Leave sufficient wire for future maintenance and ease of access Figure 5 22 Thermocouple Layout Side View 1 Thermocouple 2 Wire Retainer 3 Manifold 4 Manifold Backing Plate 5 Power Wire 6 Mold Plug 7 Electrical Box 8 Manifold Plate Valve Bushings Types of Valve Bushings Heated Non Heated Figure 5 23 Valve Bushing Types 1 Non Heated 2 Heated Valve Bushing Installation This procedure applies to valve gated systems that are bolt in design Refer to the parts lists and your general assembly drawing to determine if your system has a valve bushing Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 5 8 2 1 Mount the valve bushing on top of the nozzle NOTE The valve bushing for Accu Valve has a locating dowel pin with the mold W Install the locating dowel Ensure the dowel pin is not too long as this will effect the seal between the nozzle and the manifold WARNING If
76. e Obstruction to melt flow e Gate seal damage e Tip wear Figure 12 13 Gate Seals Multi Cavity Systems It is advisable to heat the system to ensure the tem perature condition is met to remove the gate seals 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 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 12 5 1 W W Excluding TIT Edge 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 CAUTION Seals and liners for MEX Accu Valve EX amp CX are a sub assembly utilizing a manu factured interference fit Disassembly of this sub assembly may affect alignment of the valve pin to the gate causing wear NOTE Use the socket supplied in the Mold Mas ters tool kit to loosen the gate seal Apply penetrating lubricant to gate seal area A
77. e manufacturers documentation for procedures 10 Install the mold into the molding machine 11 Torque the mold mounting screws to required specifications 12 Connect wire lines hydraulic pneumatic and elec trical components 13 Remove latches b F p Hot Runner User Manual Revision 16 m Mold Not under documentation control if printed May be revised without notice 05 2013 Mlasters Electronic version is available at www moldmasters com 7 2 em Master Section 8 System Start Up amp Shut Down Introduction This chapter explains how to start up and shut down your hot runner system o NOTE See Section 15 Melt Disk System and Section 16 Melt Cube System for start up and shut down procedures for those products Pre Start up 1 Install the mold into the molding machine i NOTE The machine nozzle bore should be no smaller than 1 0mm 0 040 smaller than the back plate bore and no larger than the back plate bore 1 Connect all water lines and test to ensure there are no leaks and that the required flow is achieved in all water circuits 2 Connect all hydraulic pneumatic lines if appli cable NOTE JW After the hot runner system is installed in the molding machine make sure to bleed all the air out of the hydraulic lines if appli cable Failure to do so could result in high gate vestige CAUTION valve pins Failure to do so could cause damage t
78. e values such as the air gap 3 The actual height thickness of the supplied pres Pressure Disk Final Grinding Not Re sure disk e will be of a value that s higher than quired the value d Calculate the difference and then divide by 2 This is the value that will need to be ground from each side of the pressure disk Example Calculations Nozzle pocket depth a 91 39 mm Nozzle flange height b 43 16 mm Manifold thickness c 43 16 mm Air gap as noted on drawing 00 05 mm Pressure disk height d 91 39 43 16 43 16 0 05 5 02 mm Supplied pressure disk e 5 10 mm Difference between supplied pressure disk e and required pressure disk d 5 10 mm 5 02 mm 0 08 mm Material to be removed from each side of the pres PRESSURE DISK sure disk 0 08mm 2 0 04 mm Figure 5 39 Optional Pressure Disk Mounting Detail With Nozzle bores and pressure disks must be within out Final Grinding tolerances specified in the general assembly Grawing Alternate Method Air gap adjustment from top clamp or hydraulic plate Pressure Disk Installation 1 Calculate and machine the nozzle bore seat with 1 Install the manifold to the nozzle additional air gap value Example Flange height 2 Refer to the general assembly drawing for pres Manifold height Pressure disk height Air gap sure disk dimensions before c
79. ed 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 j Revision 16 Fea cd 005 2013 Masters 17 2 Troubleshooting ri aster a Defect Types Causes and Remedies Index Parts have dark specks Parts have blisters and or bubbles Parts have flow marks Parts have burn marks Parts are delaminating Parts have dimensional irregularities Parts are discolored Parts contain flash Parts surface has jetting Parts are pitted Parts surface is rough Parts are sticking to cavity Parts are sticking to core Parts are short Parts have sink marks or voids Parts display splay Parts are streaked Parts are stringing Parts are warped Parts have weld lines Hot Runner User Manual Not under documentation control if printed May be revised without notice 05 2013 Electronic version is available at www moldmasters com 17 3 Revision 16 Via cl 17 4 17 5 17 6 17 7 Page 17 12 Page 17 13 Page 17 14 Page 17 15 Page 17 16 Page 17 17 Page 17 18 Page 17 19 Page 17 20 Page 17 21 Page 17 22 Page 17 23 i a t Maste _ rs Master Troubleshooting Parts have Dark Specks The finished product contains dark particles When transparent resins are usually used Probable Cause Molding Machine e Offline for extended period e Barrel offline for e
80. eeesuetseeeseseuetseeeeeeaeeeaess 12 7 SPL NOZZE MO Removal sen EE acetate 12 7 Cleaning Nozzle Insulator Cap c cccccecccscccececeeeceeeceeeeeeeseeeseeesuecsueseueeseeeseeseeesseeseaeeas 12 8 IS CaF Nozzle Insulator CAD eesse ae e E EEAS 12 8 Valve Actuator Maintenance cccccccecceeeceeeceecnecueeseeceeesuuecaeecseseuesaeesaesauesaeeseesaeesaeess 12 8 SPM INOZZ1C TMO MNS UIA ON e e EE AE 12 8 EACAN reee E cee E E E E eee 12 9 Checking Nozze TiO HEIM oee EET 12 9 Latching the Cavity Plate to the Manifold Plate Hot Hallf cc cccceeeeeeeeeeeeeeeeees 12 11 TUe S 11 0 lt meta eee E E ee ee ee 12 12 Section 13 TIT Edge Gated System eee 13 1 HERO CUICIION crazcnacsccducezanedtoneaccsenaadsauacererakenseeedeaamseenossieneeaectaneqesssestesetdecataresacecsisncesostecnceadanes 13 1 fA Bro 0 ek CF eTe Bo o 1 4 eee ee ee eee ere eee eee ee ee eee eee 13 1 M EQ OS CIO SOAS era ceccacecescasecaseioesancvecsrersaascscecescnauarsentescaveesasecuspeatescetobsesaqucnsanaceceeoeate 13 1 Section 14 Accu Line System cccsceseeeeeseeeeeeeees 14 1 ACCU LING Body ASSECIMDIY aisicesdececc auc tececsccnnesesesarnennaedeensdarcnesenenenmsdarnaensdenncetaeemuadoassnesiactenes 14 1 By on Ao 1010 oeren a eee eee ee eee 14 2 Accu Line Assembly ProCeCUre ccccceccscececcceeceseceeeceeceuecueeceeeceesaeesaeecaecaeesaeseunsaeeseess 14 2 Section 15 Melt Disk System ccc
81. ell seating bore 2 Install the nozzle Figure 5 19 Nozzle Well Cleaning CAUTION Systems with gate seals that are not ac cessible when fully assembled require the gate seals to be torqued hot prior to instal lation The mold plate needs to be in horizontal position when inserting nozzles Care must be taken when handling the nozzles For liner systems damage to the tip of a nozzle can result in gate vestige Special care must be take with F type Hot Sprue and Hot Valve gating styles where the transfer seal goes up into the part cavity In these cases care is needed to prevent damage to the sharp edge of the gate seal and gate seal receiving bore Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 3 Check that Face 1 is at the same level for all drops relative to the mold plate split line Figure 5 20 4 Check that nozzle sits squarely in nozzle well bore Nozzle Wire Layout Back Mounted Thermocouples 1 Place a zone number on each wire and thermo couple Try to organize and tape wires by zone and plug 3 Install the wires into the wire channels and secure with wire retainers 4 Feed the wires back through the wire channel in the mold base to the electrical box Do not cut the wires until the remaining components are installed Figure 5 21 Wiring Layout 1 Wir
82. er is responsible to take protective measures against shock by indirect con tact while performing the tests i Master Electrical Testing The conditions for automatic shutdown of the supply is set at Mold Masters and is usually set such that the protective conductor resistance between the ground ing conductor connection and all of the protective earth conductor connected parts is Maximum 0 3 Q In TN systems the following two checks must be made Test 1 Verifies the continuity of the protective bonding circuit The purpose of this test is to check whether all rel evant touchable conductive parts are properly ground ed See the relevant requirements of the standard DIN EN 60204 1 NFPA79 The protective conductor resistance is measured with a special instrument with a current between at least 0 2 A and approximately 10 A derived from an electri cally separated supply source for example SELV see 413 1 of IEC 60364 4 41 having a maximum no load voltage of 24 V AC or DC The resistance should be within the expected range Test 2 Fault loop impedance verification and suitability of the associated overcurrent protective device The power supply connections and incoming external grounding connections to the hot runner system usu ally through a temperature control device must be verified by inspection The conditions for protection by automatic disconnec tion of supply must be checked by both 1 Checking the i
83. f met ric or imperial size keys for use On cap screws 4 5 6 8 and 10 mm or imperial equivalent 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 0 6 and 0 150 mm to check system part and plate thickness e Depth micrometer to check bore depths e Slot head screw driver used in installing ther mocouples and ground wires e Slot head screw driver small used in fasten ing electrical wires to connectors e Crimping tool for fastening connector pins when necessary 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 Proper actuator installation extraction tools Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Figure 4 1 Screw Lengths The use of an incorrect size length and grade screw could cause the screw to shear fatigue or stretch
84. ff heaters after gate seal removal i Revision 16 Ailes lcd 05 2013 ae Masters Master Maintenance Procedures Sprint Nozzle Tip Installation Cleaning Nozzle Insulator Cap 1 Clean all residual plastic from the nozzle threads 1 Heat cap with heat gun and the torpedo nozzle sealing surface 2 Remove molten plastic and wipe remainder from 2 Check the torpedo nozzle sealing surface for dam insulator cap age If damaged lap the torpedo nozzle sealing surface in a circular fashion with a hardened tool and 300 grit lapping compound 3 After a smooth torpedo nozzle contact surface is established blue the torpedo to the nozzle surface to ensure proper mating Figure 12 25 Cleaning Insulator Cap Installing Nozzle Insulator Cap 1 Press fit insulator cap onto torpedo by hand Figure 12 23 Applying blue to torpedo surface 4 After ensuring good contact clean bluing off both surfaces 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 at process temperature Figure 12 26 Installing Insulator Cap Valve Actuator Maintenance Please see Section 10 Valve Actuators Figure 12 24 Torquing gate seal onto nozzle WARNING Failure to torque the gate seals at processing temperatures may result in leakage b Hot Runner User Manual Revision 16 Wiolgi a Not under
85. from pin head nce to E re w 4 v v gt V oo E oc LS E 2a Heat expansion v he v wa w D specification Figure 10 14 Measure Distance Check that the tip of the pin is fitted correctly into the land 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 3 05 head of pin 0 02 pressure preload Continue to re assemble the actuator assembly The maximum pin preload in the land under full heat expansion must not exceed 0 02mm i Master Valve Actuators e NOTE 6X00 Series IW The standard stroke of the HY550 A E is 1 4 0mm This can be increased to maxi l mum of 8 0mm by removing material from the piston top 2 Slide the valve pin into position The stroke of the HY550 C F is 8 0mm CAUTION and cannot be altered Failure to install the disk springs in the cor rect order will cause damage to the gate Check the valve pin length Refer to Valve Pin Finishing of Tip Valve Pin Assembly 3 Assemble the disk springs to the spring retainer stud CAUTION a Check for the correct orientation of the disk For systems with MEX Accu Valve EX springs when installing or Accu Valve CX Gate Seals b HY6500 series Align the springs in 5 alternat Gate seals must be removed prior to in ing groups of 5 convex and conc
86. g bore Install O rings onto the water cooled gate insert Figure 5 4 Water cooled Gate Insert 1 O Rings 2 Seating Bore i F pa Revision 16 VMold o0s 203 Masters 5 3 Master gy ooo series Master Series Thermocouple Installation 1 Clean the nozzle thermocouple bore e For 1mm thermocouples use a 58 drill in a pin vise e For 1 5mm thermocouples use a 1 16 inch drill in a pin vise Figure 5 a Figure 5 7b 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 Figure 5 5 2 Insert the thermocouple through the flange bore Figure 5 8 5 Install the terminal end retaining clip Check that the thermocouple fits into the recess of the clip CAUTION Ensure the terminal end of the thermo couple stays fully engaged in the slot while Figure 5 6a Figure 5 6b bending the thermocouple at the nozzle flange area 3 Manually bend the thermocouple tip against your thumb to approximately a 90 angle ensuring s bend length is sufficient to reach the bottom of the e termocouple bore A l Figure 5 9 Hot Runner User Manual Ravician 1R E
87. gate detail Extrude material through the hot runner system using 500 PSI 34 4 bar of back pressure The purpose is to fill the Visco Seal at low pressure This prevents any possibility of leakage past the nozzle seal Start up for systems filled with material Purge intended shot size twice from the barrel prior to bringing the machine barrel forward to the hot run ner interface F Revision 16 Mold 005 213 Wlasters 5 Set injection time and pressure in coordination to part size gate size and material WV NOTE For hot runner systems using heater plates allow 10 minutes of soak time after the system reaches processing tempera ture CAUTION Failure to follow the above procedure may result in leakage damage occurring in the hot runner Shut Down W NOTE For Melt Disk refer to the accompanying Mold Masters Controller operating manual Turn off all heat to the system 2 Leave the mold cooling system on until the hot runner system temperature is within 100 F 55 C of the mold temperature W NOTE 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 example a system running PVC should be initially started and subsequent ly shut down on LDPE Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version
88. he general assembly drawing Place zone number on each wire and thermo couple Tape wires for each zone together Install the wires into the wire channels and secure with wire retainers Feed wires back through the wire channel in the mold base to the electrical box Figure 5 45 3 Piece Assembly 1 Screw 2 Center Heater 3 Back Plate 4 Manifold 5 Ground Wire 6 Thermocouple 7 Cover Plate 8 Set Screw i F p Hot Runner User Manual Revision 16 Hm Mold Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 5 16 CE Master Inlet Extension Installation Inlet Extension with Pressure Sleeve CAUTION oe Always install the inlet extension pressure sleeve clamp plate and locating ring with the mold plates in the horizontal position 3 Torque screws to manifold using anti seize on Failure to do so could result in damage to threads the components and cause material leak age Place the inlet extension on the manifold 2 Install mounting screws through the nozzle flange and into the manifold 4 Place a zone number on each wire and thermo couple Tape wires for each zone together Place the inlet extension on the manifold 2 Apressure sleeve is supplied oversize in length Refer to general assembly drawing to determine length of pressure sleeve 6 Install the wires into the wire channels and secure with
89. he general assembly drawing to determine which heater plate applies to your system g NOTE LD 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 wattage and are located in similar thermal environments CAUTION ore Heater plates are controlled by a thermo couple located in the heater plate Do not control the heater plate from a thermo couple in the manifold 1 Clean the thermocouple bore Suggestion for 1 5 mm thermocouples is to use a 1 16 inch drill in a pin vise 2 Insert the thermocouple into the bore Ensure the thermocouple is touching the bottom of the bore hole 3 Press down on the thermocouple and gently bend to 90 b Revision 16 VMold e523 Masters 5 14 CE aster 6 The heater plates are supplied with the power wires connected Place a zone number on each wire and thermocouple Tape wires for each zone together Install the wires into the wire channels and secure with wire retainers 9 Feed the wires back through the wire channel in the mold base to the electrical box Installation of Inlet Compo nents The following procedures refer to different system configurations Refer to your parts list and general as sembly drawings to determine your system ty
90. he same for nozzle terminal ends NOTE LD Please contact Mold Masters Spare Parts Department to ensure you have the cor Figure 12 6 rect repair kit and crimping tool The tools along with the lead wire replacement kit are available through the Mold Masters Spare Parts Department 4 Slide crimps onto leads Stranded wire should extend beyond the crimp Terminal Assembly 1 Assemble the repair kit components Figure 12 7 5 Spread the wire strands and insert the lead wire onto the terminal posts Figure 12 4 2 Ensure the terminal end is clean Figure 12 8 Figure 12 5 E Hot Runner User Manual Revision 16 Wiolgd Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 12 3 Master Maintenance Procedures 6 Grasp the crimp with the crimping tool slide the Crimping Tool Chart crimp into position over the terminal post and Beoduephamea PUNCHHANDLEO Ratchet tool for securing crimp to terminal end assemblies CRIMPDIEO1 4 0mm Heater Element Mates with CRIMPPUNCHO1 CRIMPPUNCHO1 4 0mm Heater Element Mates with CRIMPDIEO1 CRIMPDIEO2 2 5 3 0mm Heater Element Mates with CRIMPPUNCHO2 CRIMPPUNCHO2 2 5 3 0mm Heater Element Mates with CRIMPDIEO2 crimp the connection CRIMPDIEO3 1 8 2 0mm Heater Element Mates with CRIMPPUNCHO3 CRIMPPUNCHO3 1 8 2 0mm Heater Element Mates with CRIMP
91. hout notice Electronic version is available at www moldmasters com EXTOOL5500P Cylinder Extraction Head KEY04 EXTSTUDM8 Piston Extraction Head EXTOOL06 EXTOOL2300P Cylinder Extraction Head PS0001TOOL01 Piston Extraction Head EXTOOL04 Piston Top EXTSTUDM6 Piston EXTOOL2300P Cylinder Extraction Head KEYO5 EXTSTUDM8 Piston Extraction EXTOOLO1 Piston Top EXTOOLO5 Piston Installation Tools PS0003TOOL01 Piston Assy PSO003TOOLO2 Seal Assy Revision 16 Mold 05 203 Miasters Coa Master Section 11 Electric Actuators Electric Valve Actuator Selection Chart Part Name Part Description ES5510003A Solenoid size 55mm stroke 3mm LSOO01A ES5510003A DOUBLE ACTING LINEAR SOLENOID PACKAGE w VP HOLDER14 amp 3 0mm PIN 10 LG 3mm STROKE 48VDC LS0001B ES5510003A DOUBLE ACTING LINEAR SOLENOID PACKAGE w VP HOLDER14 amp 3 0mm PIN 14 LG 3mm STROKE 48VDC LS0001x ES5510003A DOUBLE ACTING LINEAR SOLENOID PACKAGE w VP HOLDER14 w o 3 0mm PIN 3mm STROKE 48VDC ES7510003A Solenoid size 75mm stroke 3mm LSO002A ES7510003A DOUBLE ACTING LINEAR SOLENOID PACKAGE w VP HOLDER13 amp 3 0mm PIN 10 LG 3mm STROKE 48VDC LSO002B ES7510003A DOUBLE ACTING LINEAR SOLENOID PACKAGE w VP HOLDER13 amp 3 0mm PIN 14 LG 3mm STROKE 48VDC LS0002x ES7510003A DOUBLE ACTING LINEAR SOLENOID PACKAGE w VP HOLDER13 w o 3 0mm PIN 3mm STROKE 48VDC ES7510008A Solenoid
92. i Master gy ooo Cutaway of a bolt in system This illustration of a typical Mold Masters bolt in hot runner system is divided into two halves valve side and non valve side The terminology associated with the various components and features are listed below Figure 5 2 Valved Non Valved 1 manifold locating cam 8 manifold locator 2 bolt in manifold 9 nozzle 3 gate seal gate insert 10 valve actuator 4 heater plate 11 valve bushing 5 inlet extension 6 locating ring 7 machine nozzle pad backplate i Pa Hot Runner User Manual Revision 16 Mold Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 5 2 C aster Gate Seal Finishing Most nozzles are supplied with the gate seal installed except when the seal requires final machining by a toolmaker such as the hot valve or hot sprue e NOTE W The gate seals supplied with your system may need to be adjusted to tolerances based on the material grade and cooling in the cavity Refer to your Mold Masters General Assembly Gate Detail drawing to determine if gate seal finishing is required Refer to the general assembly drawing to determine which gating method applies Hot Valve Hot Sprue F Type Hot valve and hot sprue gated systems are supplied with gate seals that are oversize in length They must be machined prior to installing the nozzle into the
93. ied Warranty 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 The documentation package provided with your hot runner system will include any or all of the following e EC declaration of conformity e Parts list containing all system components Together with the general assembly drawing the parts list should be referenced when ordering spare parts e General assembly drawing used to integrate your hot runner system into the mold e Hot half drawing used to integrate hot half to cavity plate a NOTE This manual should also be used in conjunction with other relevant manuals e g Temperature Con troller E Drive or E Multi manual When ordering this manual please reference the document number below Release Details Release Date Version HRUM EN XX V16 May 2013 i B Pam Hot Runner User Manual Revision 16 i Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 1 1 Master x od Trademarks and Patents ACCU VALVE DURA FLEX DURA FLEX SERIES FUSION SERIES HOT EDGE INJECTIONEERING MAS TERPROBE MASTER SHOT MOLD MASTERS MELT DISK MOLD MASTERS ACADEMY MASTER SERIES MASTERSOLUTION MASTERSPEED MERLIN MOLD MASTERS SYSTEM MPET SCAN MASTER STAC
94. ified and re tested as appropriate k Hot Runner User Manual Revision 16 Mold Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 6 3 em Master Section 7 Hot Half Assembly Introduction The following section is a step by step guide to assembling your Mo d Masters hot runner system Figure 7 1 Nozzle Depth 1 Nozzle Well Depth L 2 Cavity Plate 3 Manifold Plate Assembling the Hot Half 1 Check that the nozzle well depth L in the cavity plate is to Mold Masters specifications See Figure 7 1 e NOTE DL For valved systems the hot half is pro vided with valve pins already installed Refer to the general assembly drawings for instructions For valve assembly details refer to the Valve Actuator Section 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 Do not assem ble disassemble cavity plate with the valve pins forward Valve pins must be retracted prior to cavity plate installation CAUTION Potential pinch point Ensure that all wires are in the retainer grooves Failure to do SO can cause lost production due to hot runner down time For valve gated sys tems it is recommended to have the pins in the open position to reduce the possibil ity of damage
95. igure 16 27 WARNING Potential burn hazard Use socket exten sion and heat resistant gloves Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com SHCS Torque Value Ib in Nm msx20 0 Process Temp 306A msx20 60 Process Temp 16 1 8 Figure 16 27 Melt Wedge Screw Torque Chart SHCS Tip Angle Temperature Torque Value Ib in Nm 4X20 30 3 4 Figure 16 28 Figure 16 29 4 Tighten all melt wedge SHCS M4x20 in two stages a First tighten all to 15 LB in 1 69 Nm torque b Then tighten all to 30 LB in 3 38 Nm torque as shown in Figure 16 28 5 Assemble cavity block cover plate and connect proper cooling lines 6 Allow all hot runner components to reach process ing temperature 7 Fill system under low pressure extrude using screw rotation 8 Set nozzle temperature 10 F 6 C lower than melt cube CAUTION E If the processing temperature is changed by more than 54 F 30 C then all wedge screws should be loosened at cold condi tion and the assembly process repeated at cold and process temperature as ex plained above j Revision 16 Fea iid 6 203 Masters 16 8 R aster Startup and Shutdown 5 Startup 6 1 Heat bridge and inlet to processing temperature 2 Heat nozzles to processing temperature 3 Heat Melt Cube to processing temperature
96. ision 16 Wliold a 005 203 Masters Master Valve Actuators Actuator units should be inspected every 12 months or per pre determined maintenance schedule The following procedures are performed on a bench For Oil Systems 1 Remove oil from system 2 Remove the cylinder top with tool in upright posi tion to prevent oil from entering the system 3 Heat up the system required to remove the valve pin Figure 10 20 HY5500 Series For Pneumatic Systems Cylinder Extraction Tool Kit l 1 Remove the cylinder top for every zone 2 Heat up the system required to remove the valve pin A WARNING Extreme Heat Avoid contact with heated surfaces Use appropriate protective clothing Fail ure 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 h 10 29 h Drain the oil before removing the pin from yinaer Extraction fool Al the hydraulics 3 Install the cylinder extraction tool to assist with the Maintenance Procedure removal of the cylinder HY5500 HY6X00 and HY7100 Series 4 Disassemble the system CAUTION 5 t ts oe Heat sensitive materials should be purged ad ae ana j pS from the system prior to maintenance 6 Replace O rings O ring replacement kit is Failure to do so may result in degradation OR550P1 for 5500 series and OR650P2 for 6X00 of material in the system and 7100 series When heating the ho
97. lable at www moldmasters com 4 2 l CE Master Establishing Your System Type The following pages are to be used as a general guide to assist in identifying components Refer to your general assembly drawings for specific component lists If your system does not match these systems please refer to other specialty systems mentioned within the manual for additional information System With Cast In Heater Element Insulation Board Leader Pins ocating Ring Top Clamp Plate e gt Jiffy Plugs Center Heater Pressure Disk Manifold Electrical Box Nozzle Name Plate Figure 4 5 k i Pa Hot Runner User Manual Revision 16 JW old Not under documentation control if printed May be revised without notice 05 2013 r documentatior Masters Electronic version is available at www moldmasters com 4 3 Master i To System With Hydraulic or Pneumatic Units Insulation Board Locating Ring Top Clamp Plate e gt lt t Jiffy Plugs Vaa l Hydraulic Pneumatic l A Actuators Hydraulic Plate e gt Inlet Extension Valve Disks Manifold Manifold Nozzle Locator Electrical Box gt Leader Bushing SZ f J If Figure 4 6 Wire Retainer Hot Runner User Manual Not under documentation control if printed May be revise
98. ld be installed at a clean location e Only use the mounting holes provided to attach the unit e Use screws to mechanically attach the ES solenoid and tighten them with an appro priate torque before connecting the unit electrically e To apply the supply voltage only use leads with a sufficient cross section and insula tion e Solvents such as Acetone or Benzine can influence the function of the ES solenoid You may safely remove metal cuttings stuck to the solenoid by means of an adhesive tape e Store in a dry location at the required stor age temperature Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Additional Tools Required The following tools are required in addition to those listed in Section 4 e Valve pin pulling tool e Long M5 hex key with T handle and snap ring in tip Mold Masters item number KEY BPHEXTKEY5 0 e Grease Castrol Longtime PD2 Mola Masters item number 104L1105l e Proper Valve Pin extraction tools Specifications Input power 230 V Actuator stack height 100mm 35mm mounting plate Stroke length e for 55mm solenoid 3mm e for 75mm solenoid 3mm and 8mm Minimum pitch e for 55mm solenoid gt 58mm e for 75mm solenoid gt 78mm Available gating styles any cylindrical valve gate Number of cavities 2 8 Resins commodity resins ABS PA Maximum va
99. le at www moldmasters com 2 2 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 Romania Tehnic Mold Trade SRL Str W A Mozart nr 17 Sect 2 020251 Bucharesti Romania tel 4 021 230 60 51 fax 4 021 231 05 86 contact matritehightech ro 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 Vietnam 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 i Revision 16 Fea cd 05 2013 Ase Masters Cem Master section 3 Safety Introduction High injection pressures 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 safe
100. lectronic version is available at www moldmasters com 4 7 9 Master Troubleshooting Parts are Discolored The finished product varies in color on different surfaces Probable Cause Molding Machine e Contamination e Incorrect sprue diameter e Inadequate venting Material x e Physical contamination of raw material e Chemical contamination of raw material e Melt too hot poor melt e Incompatible color dye e Residence time too high Solution e Heating cylinder purged e Resin temperature lowered by a reducing cylinder temperature b reducing screw speed c reducing back pressure e Nozzle temperature decreased e Residence time adjusted e Regrind ratio adjusted e Cycle time adjusted e Check for external contamination sources e Ensure proper cooling in all areas e Increase mold venting Hot Runner User Manual Revision 16 Wliold Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 17 1 0 Troubleshooting Master Parts Contain Flash Also known as Fins or Spew The finished product contains a thin film of material attached at the mold parting line Probable Cause Molding Machine e Low clamping pressure e High injection pressure e High injection speed Mold e Inadequate mold supports e Low clamping force e Damaged mold a e Projected area too large for machine capacity Mate
101. ll hold locator position against crimper jaws 3 Insert contact mating end into appropriate hole in locator slide Orient contact so wire barrel and in sulation barrel are facing crimper jaws wire size markings CAUTION gt Do not attempt to close tool handles when locator slide is positioned between crimp ing jaws damage to the tool jaws and or locator slide may result 4 Pull locator slide out of crimping jaws Spring ten sion will pull locator down and allow wire stop to enter the slot between barrel and contact shoulder CAUTION gt Make sure both sides of the insulation bar rel are started evenly into the crimper jaws do not attempt to crimp an improperly positioned contact 5 Squeeze tool handles together until ratchet engag es Do not deform insulation barrel or wire barrel 6 Insert properly stripped wire contact into the wire barrel until wire butts against the wire stop m Revision 16 VMiold lt _ 005 203 Masters t 15 5 Master series 7 Holding wire in place squeeze tool handles togeth er until ratchet releases Allow tool handles to open fully Move locator toward anvil jaws and remove crimped contact Assembling the System with Quick Discon nects 1 When assembling the system connect female and male connector pins 2 Then screw male sleeve into female sleeve Assembly of Melt Disk to the Nozzle Two piece Melt Link 1 Anti seize the threads
102. ll piston top and tighten recommended torque setting 15 20 ft lbs 20 27 Nm Figure 10 17 Cylinder Installation Installing the Valve Actuator to the Hydraulic Plate Figure 10 18 Valve Pin and Piston Installation 1 Valve Pin and Piston 2 Installation Tool The following procedure is for new systems 1 Lubricate the sides of the actuator cylinder before installing into the hydraulic plate Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 10 7 CAUTION Check for sharp edges before installing the cylinder Failure to do so could dam age O rings Tap the cylinder into the bore of the actuator plate with a nylon mallet Position the piston installation tool PS0003TOOLO01 on top of the cylinder Install the valve pin and piston into the cylinder bottom Figure 10 19 Cylinder Top 1 Cylinder Top 2 Mounting Screws 3 Hydraulic Plate Press the valve pin into position using a nylon mallet to finish seating the valve pin into the as sembly CAUTION Heat sensitive materials should be purged with a compatible less sensitive material If the system is not purged material in the manifold could 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 Rev
103. locator position against crimper jaws Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 3 Insert contact mating end into appropriate hole in locator slide Orient contact so wire barrel and in sulation barrel are facing crimper jaws wire size markings CAUTION Do not attempt to close tool handles when locator slide is positioned between crimp ing jaws damage to the tool jaws and or locator slide may result 4 Pull locator slide out of crimping jaws Spring ten sion will pull locator down and allow wire stop to enter the slot between barrel and contact shoulder CAUTION Make sure both sides of the insulation bar rel are started evenly into the crimper jaws do not attempt to crimp an improperly positioned contact rN 5 Squeeze tool handles together until ratchet engag es Do not deform insulation barrel or wire barrel 6 Insert properly stripped wire contact into the wire barrel until wire butts against the wire stop 7 Holding wire in place squeeze tool handles togeth er until ratchet releases Allow tool handles to open fully Move locator toward anvil jaws and remove crimped contact Assembling the System with Quick Discon nects 1 When assembling the system connect female and male connector pins 2 Then screw male sleeve into female sleeve b Revision 16 Mold E gm 05
104. ltage Directive need to be observed when installing the ES sole noid In addition any technical information effective outside of the product The following warnings indicate a potentially hazardous situation which if not avoided could result in serious injury or death printed on the label and the packaging must Magnetic fields can erase data stored on be observed magnetic media They can also influence or even destroy electronic and mechanic Cautions components such as pacemakers For this reason the required safety distances need to be observed Certain magnetic materials are toxic and or easily soluble and therefore represent a safety hazard Destruction and disintegra tion can be caused by corrosion chemical influences other magnetic fields high tem peratures etc Direct contact with magnetic materials may result in allergic reactions For shipping via airfreight a dangerous goods declaration is required Permanent magnets may not be exposed to radioactive emissions During its operation the ES solenoid may develop considerable heat Physical con tact with the solenoid during operation may result in burns Loud noises can be caused during opera tion Wearing hearing protection is strongly recommended Activating the ES solenoid manually with external mechanical tools may lead to seri ous physical harm When applying mechanical forces please take into consideration that the material may
105. lve Hot Sprue F Type 5 3 Gate Seal Maintenance 12 5 12 7 Gate Seal Removal 12 5 Glossary of Terms 18 1 Ground Shorts Test 6 1 Heater Continuity 6 2 Hot Half Assembly 7 1 Hydraulic or Pneumatic System 4 4 Hydraulic Pneumatic 10 1 Inlet Extension Installation 5 17 Inlet Extension With Pressure Sleeve 5 17 Inlet Seal Installation without step 5 11 Inlet Seal Installation with step 5 11 Installation 10 1 Installation and Assembly of the Valve Actuator 10 1 Installing Heater Plates 5 14 Installing Nozzle Insulator Cap 12 8 Installing the Manifold Thermocouple 5 10 Installing the Pressure Disk Valve Disk 5 11 J Jetting 17 12 L Latching 12 9 Main Manifolds 5 10 Manifold and Slot Locator 5 10 Manifold Locator 5 9 Melt Cube Assemble Melt Cube into Cavity Block 16 5 Clamp Screw Torque Chart 16 5 Example Melt Cube System 16 3 Maintenance 16 8 Melt Cube Components 16 2 Melt Transfer Link Torque Chart 16 5 Preparation 16 4 Startup and Shutdown 16 7 i 19 i Master gos Wedge Screw Torque Chart 16 7 Melt Disk Assembly of Melt Disk to Nozzle 15 5 Assembly of Melt link to Nozzle 15 5 Melt Disk Reassembly after Maintenance 15 6 Melt Disk Thermocouple Assembly 15 4 Nozzle Thermocouple Assembly 15 4 Preparation Cleaning 15 3 Pressure Disk Details 5 13 Start Up amp Shut Down 15 6 System Start Up amp Shut Down 15 6 System with cast in heater element 15 2 Melt Link 15 5 16 4 Moisture Related Issues 1
106. lve pin diameter e for 55mm solenoid 3 2mm e for 75mm solenoid e with 3mm stroke 5 2mm e with 8mm stroke 3 2mm mS F pa Revision 16 Vio l ai F 05 203 Masters 11 3 Master Electric Actuators Be eo E VG solenoids plate j Insulator plate Manifold plate Figure 11 1 Example 6 Cavity hot half with E VG units Figure 11 2 Example 2 Cavity Accu Valve Stack for high mold temperature gt 122 F 50 C CX hot half and 75 mm and 55 mm EVG Stack for low mold temperature lt 122 F 50 C Figure 11 3 75 mm E VG with VP Holder14 Figure 11 4 55 mm E VG with VPHolder13 Figure 11 5 E VG with Valve Pin Assembled b Hot Runner User Manual Revision 16 J Mold Not under documentation control if printed May be revised without notice 05 2013 MWlastersg Electronic version is available at www moldmasters com 1 1 4 Electric Actuators AY aster Pin Height Adjustment The following procedure is for adjusting the pin height The pin height can be adjusted 1 mm in each direction forward or back NOTE IW Pin height adjustments need to be done when the system is hot in order for the pin to be a true length in operating con ditions Failure to do so could result in damage to the gate CAUTION Water circulating in the holder space plate should be 25 C or below 1 Open the lock nut using the supplied lock nut
107. m a part Mold Frame Aseries of steel plates which contain mold components including cavities cores runner system cooling system ejection system etc Mold Temperature Control Unit Auxiliary equipment used to control Hot Runner temperature Some units can both heat and cool the mold Others called chillers only cool the mold Moving Platen The platen of an injection molding ma chine that is moved by a hydraulic ram or mechanical toggle Multi Cavity Mold A mold having two or more impres sions for forming finished items in one machine cycle Multi Material Molding The injection of two or more materials in sequence into a single mold during a single molding cycle The injection molding machine is equipped with two or more plasticators See also co injection Nest Plate A retainer plate in the mold with a depressed area for cavity blocks Non Fill See short shot Non Return Valve Screw tip that allows for material to flow in one direction and closes to prevent back flow and inject material into the mold Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Machine Nozzle The hollow cored metal nose screwed into the injection end of a plasticator The nozzle matches the depression in the mold This nozzle allows transfer of the melt from the plasticator to the runner system and cavities Packing The filli
108. mentation for procedures 13 Remove the latches 14 Latch the cavity plate to the core plate or cold half Figure 12 29 15 Remove lockout tagged out o Ee MARNIC LAIO AY 16 Check the machine is in Mold Set mode 17 Open the mold moving the cavity plate away from the manifold plate 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 6 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 Plate Remove all cavity plate mounting screws 1 Stationary Platen 2 Cavity Plate 3 Moving Platen 4 Core Plate 9 Remove lockout tagged out 10 Place the machine in Mold Set mode 18 Apply lockout tagged out Refer to the controller and machine manufacturers documentation for procedures CAUTION oe 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 position prior to removal of the cavity plate to prevent 11 Close the mold slowly damage Figure 12 30 Cavity Plate to Core Plate 1 Stationary Platen 2 Latches
109. mpedance of the fault loop by calcu laton or measurement 2 Confirming that the setting and characteristics of the associated overcurrent protective device are in ac cordance with the requirements of the standard For more information see the text of the EN 60204 1 NFPA79 standards Thermocouple Continuity Test 1 Measure the resistance between each pair of ther mocouple wires on the mold s thermocouple con nector See Figure 6 1 The resistance should be between 2 5 Q and 25 Q Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 6 2 Figure 6 1 Mold Plug 1 Mold Power Connector 2 Thermocouple Connector To verify alignment of thermocouple in the heat ing element turn on one zone after the other and check that the temperature responds accordingly if the set temperature is adjusted Pinch Point Test 1 Ifthere is a suspected pinch point on the thermo couple remove the thermocouple from the hot runner 2 Connect a temperature control device to read the temperature 3 Immerse the sheath of the thermocouple in boiling water to the point where 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
110. n there is limited gate cooling 2 Reduce nozzle temperatures to 300 F 150 C Reduce Melt Disk temperatures to 300 F 150 C 4 Turn off all zones 2 NOTE y 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 example a system running PVC should be initially started and subsequent ly shut down on LDPE Disassembly for Maintenance NOTE Before shutting down the molding machine i and mold use maximum screw decom pression to remove as much molten plastic from the hot runner system as possible 1 Disassemble mold to expose the Melt Disk Plate insert removal to be done with all components in the cold condition 2 Melt Disks should be heated to 250 280 F before removal The Melt Disk should be removed as soon as it reaches set point The EXTOOLAS01 can be used to assist with the Melt Disk removal Melt Disk Reassembly after Maintenance 1 All sealing surfaces are to be clean and inspected for defects 2 The inside bore of the Melt Disk is to be free of material so that when it is installed to the Melt link there is no interference 3 The Melt Disk is to be installed cold onto a cold Melt link F 15 7 CT Master Section 16 Melt Cube System VMieitsCUBE Introduction We would like to take this opportunity to thank you for purchasing a Mold Masters Melt Cube sys
111. n of any runner or sprue The gate vestige will be a small sharp bump that can be trimmed if necessary i 18 1 Master Glossary of Terms Hot Runner Mold A mold in which the runners are insulated from the chilled cavities and are kept hot Hot runner molds make parts that have no scrap Injection The process of forcing melted resin into a mold Injection Pressure The pressure on the face of the injection screw or ram when injecting material into the mold usually expressed in PSI OR BAR Knockout Pins A rod or device for knocking a finished part out of a mold L D Ratio A term used to help define an injection screw This is the screw length to diameter ratio Manifolds distribute melt from the inlet component to one or more sub manifolds WITHIN AHOT RUNNER Melt Flow Rate A measure of the molten viscosity of a polymer determined by the weight of polymer extruded through an orifice under specified conditions of pressure and temperature Particular conditions are dependent upon the type of polymer being tested MFR usually is reported in grams per 10 minutes Melt flow rate defines the flow of a polypropylene resin An extrusion weight of 2160 grams at 446 F 230 C is used Melt Flow Index Term that defines the melt flow rate of a polyethylene resin An extrusion weight of 2160 grams at 310 F 190 C is used Mold Aseries of machined steel plates containing cavi ties into which plastic resin is injected to for
112. ng of the mold cavity or cavities as full as possible without causing undue stress on the molds or causing flash to appear on the finished parts Over or under packing results in less than optimum fill PET Polyethylene Terephthalate a type of polyester and a leading recyclable plastic material Pinpoint Gate A restricted gate of 0 030 in or less in diameter this gate is common on hot runner molds Platens The mounting plates of a press on which the mold halves are attached Preform A plastic test tube shaped part produced by injection molding systems in the first step of a two stage injection molding and blow molding process used to produce PET bottles or containers The perform is sub sequently re heated and stretch blown through a blow molding process into the final container shape Pressure Disk Manifold component designed to be compressed by thermal expansive forces to form part of the plastic sealing mechanism Also helps to reduce thermal transfer to a minimum Process The injection molding environment consisting of input variables such as temperature pressure injec tion rates and time that are controlled to fill the mold while optimizing the trade offs between cosmetics and dimensional accuracy Ram The forward motion of the screw in the barrel that forces the melt into the mold cavity Recovery Time The length of time for the screw to rotate and create a shot Restricted Gate A very small orifice between
113. nnected to the injection mold when all electrical connections are grounded and the mold is closed Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 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 A Electrical Safety Testing Electrical safety tests shall be performed according to DIN EN 60204 1 paragraph 18 and NFPA79 Testing guidelines are given below however the standards identified earlier in the introduction are the final author ity Verify Equipment to its Technical Docu mentation First verify that the electrical equipment complies with its technical documentation Insulation Resistance Test Measure the insulation resistance between each pin of the Mold Masters power connector in particular the heating circuit and ground The insulation resistance is measured at a DC voltage of 500V The insulation resistance must not be less than 1 MQ If this value is not reached when heating the cause is often moisture inside the heating element which should be removed using a control unit equipped with this function Where a mold has not been in use for several weeks or months it should be re tested Verification of Conditions for Protection by Automatic Disconnection of Supply A WARNING The us
114. nt ccc ccccceecceeeeeeeeee cece eeseeeceeeeeeeseeeseeesaeetseeeaes 4 3 system With Hydraulic or Pneumatic Units ccc cccccseceseeeceeeceeeeseeeeeeeseeeseeeseeeseeeeees 4 4 system with Bridged Hydraulic Pneumatic SySteM ccccccc cece eecceeeeeeeeseeeeeeeseeeeeeeseeeeaes 4 5 Hot Runner User Manual Revision 16 Wield Not under documentation control if printed May be revised without notice 7 ooo Masters Electronic version is available at www moldmasters com Master Table of Contents Section 5 Assembly cccccecceceeeeeeeeeeeeeneneenseneensensens 5 1 VEO GUC OM e E E E A E 5 1 Gae Gal FM SINNG senene e ERE E ESAE T EE EEE E 5 3 Hot valve Rot Spr e F TYPE va aatacdasicacxsascedswnintinicoacasanenansmiatigneiactanteeesentiicidireianaaeledheaniadste 5 3 Master Series Thermocouple Installation ccccccccccsecceeeseeeeeeeeeeteeeaeeeeeeeeeteeessesseeteeenes 5 4 Master Series Thermocouple Removal cccccceecceeceeteeeceeeeeeeeeeteeeeeeeeeeteeeteeeeuetseetaeenas 5 5 Dura Line Thermocouple Installation cccccccecceeceeeseeteeceeeeeeeeeseeeeeseeseecseeneeeeeeeeeseeaess 5 5 NOZZIC IN OON een a ER E E E ET 5 7 INOZZI Wiro LAV OUD c c25tceccnsrcasecavenaadastonatcosenededasmansdrateneheadeeantientachenestcaveaedase EEES 5 7 VANG BUSING S eeepc cece E E E E E E E ecaceteann 5 8 IOUT UNG Me MINIO eses E E E E E ENR 5 9 Ka MANOS erea E E 5 11 Press re DISK JINSIANQUON 2 1
115. o the valve pins 3 Connect all electrical components and monitor to ensure that all Zones are receiving heat and all thermocouples are reacting appropriately 4 If applicable test the valve pin actuation but only if the hot runner is at processing temperature see Caution above Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Check that the system is heated to pro cessing temperature before actuating the 8 1 Start up A WARNING Take appropriate safety precautions by as suming the system is pressurized and hot at all times Failure to do so could result in a serious injury or death NOTE JW When running thermally sensitive materi als use a thermally stable material as recommended by the material supplier for the initial start up Turn on the machine barrel and mold cooling system Prior to start up ensure the e Machine barrel is up to processing tempera ture e Mold cooling is on and at cooling temperature Heat up the hot runner system to processing temperature Wait until ALL heating zones have reached processing temperature for 5 minutes before continuing WARNING A When the mold is open never inject mate rial through hot runner system under high pressure Failure to do so can result in serious injury or death Start up for empty systems or where there is no material in the
116. of the Melt link using Mold Masters supplied compound Figure 15 15 2 Thread Melt link MTL14A into the nozzle and Melt Link MTL14B into the Melt Disk Figure 15 16 3 Torque COLD to 20 22 Ft Ibs 27 30 Nm Assemble Melt Disks onto the nozzles according to mold design via the Melt link Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Specialty Systems Melt Disk 5 Ensure the sharp edge of the melt link does not get damaged when pushing the two halves to gether MTL014A threaded into Nozzle CA MTL014B threaded into Melt Disk Do not damage sharp edge Figure 15 17 One piece Melt Link 1 Anti seize the threads of the 1pc Melt link using Mold Masters supplied compound Figure 15 18 2 Thread the Melt link into the nozzle Figure 15 19 3 Torque the Melt link COLD to the value specified in the general assembly diagram 4 Assemble Melt Disks onto the nozzles according to mold design 5 Ensure the sharp edge of the melt link does not et damaged b g g Revision 16 VMiold 005 2013 Masters 15 6 Specialty Systems Melt Disk Do not damage sharp edge Figure 5 20 Melt Disk System Start Up amp Shut Down Also refer to Section 8 System Start Up amp Shut Down and the controller manual Start Up NOTE When running
117. or The following procedure explains how to assemble and install the valve actuator on a bench NOTE JW These procedures require certain parts to be lubricated or greased Valve Actuator Components 1 Screw Cylinder Top 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 16 J _ Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 4 0 4 Master Valve Actuators Pre Installation Piston Assembly 1 Prior to installing the actuator unit check that all 5500 Only fluid lines in the mold plate are de burred and 1 Lightly use silicone grease and install the O ring clean on the piston 2 Use denatured alcohol to remove the rust inhibi tor compound from each part Do not clean the interior of the cylinder 6X00 and 7100 Series 1 Using silicone grease lightly grease and install the Cylinder Bottom Assembly inner Viton O ring on the piston Install the back up ring 1 Insert the rod seal support disk into the cylinder 6X00 and 7100 only Install the outer seal The se
118. or regulation requirements Electrical products may not be grounded when removed from the as sembled or normal operating condition Ensure proper grounding of all electrical products before performing any maintenance to avoid potential risk of electrical shock Check that all coolant hydraulic and air lines as well as electrical cables will not interfere with the moving parts of the mold machine or robot The lines must be of suf ficient length so that they will not strain or pinch when the mold halves separate For water cooled gate inserts coolant must be maintained with the proper mixture to prevent corrosion and circuit blockage Care must be taken to ensure the nozzle terminal ends do not come in contact with the hydraulic fluid The nozzles may short out or become damaged 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 Master gE oe CAUTIONS All Mold Masters heated components are manu factured to standards that ensure safe and reliable operation provided that the following precautions are met e To maximize heater element and component life the temperature must be controlled and maintained within safe operating limits Mold Masters strongly recommends individual con trol of each heated component including heater plates with a reliable temperature controller that includes
119. otential risk of electrical shock To avoid serious burns wear safety cloth ing consisting of a protective heat resis tant coat and heat resistant gloves Use adequate ventilation for fumes Failure to do so can result in serious injury Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 1 2 1 1 Heat the manifold to allow any plastic still in the system to become soft For 1 Pc Valve Disk a Attach the valve disk extraction tool to the valve disk b Attach the EXTOOLAS0 1 tool to the valve disk extraction tool c Extract the valve disk Figure 12 2a 1 Pc Valve Disk Extraction 1 EXTOOLASO1 2 Valve Disk Extraction Tool 3 Valve Disk 1 pc b Revision 16 Wio l ai 05 203 Masters t Master 3 For 2 Pc Valve Disk a Remove the Valve Flange prior to installing extraction tool b Attach the extraction tool to the Valve Stem and remove the stem Remove Valve Disk Flange prior to installing extraction tool Extraction assembly tool Extrac tion tool package Valve Disk Stem Figure 12 2b 2 Pc Valve Disk Extraction Tool EXTRACTION TOOLS 35mm Valve Disks EXTOOLO7 Non Inverted Design O39mm Valve Disks Non Inverted Design O49mm Valve Disks Non Inverted Design EXTOOLO08 EXTOOL12 Hot Runner User Manual Not under documentation control if printed Ma
120. otice 05 2013 MWlastersg Electronic version is available at www moldmasters com 1 7 20 Troubleshooting Mi aster series Parts are Stringing The finished product has thin plastic strings attached to the sprue Probable Cause Molding Machine O e High back pressure Eu e High nozzle temperature gt Mold e Incorrect sprue Material om e Melt strength inadequate a i iy Solution e Reduce back pressure e Modify nozzle temperature e Modify temperature profile e Eliminate sprue breaks e Increase cooling time e Decrease mold temperature at the gate b Hot Runner User Manual Revision 16 Wiold eit _ Not under documentation control if printed May be revised without notice 05 2013 Maste E Electronic version is available at www moldmasters com 1 7 21 Master Troubleshooting Parts are Warped The finished product has pressure differences stress on its surface causing the part to be disfigured Probable Cause Molding Machine e Wrong cooling time e High injection pressure Mold e Gate located in wrong area e Undercuts too big e Cavity too hot e Part is wrong design or too heavy Material e Fillers have wrong orientation e Incorrect material Solution e Ensure temperature in both mold halves is equal e Monitor part ejection from mold for uniformity e Monitor part handling following ejection e Verify part weight following ejection e Incre
121. pe CAUTION For all inlet components it is important that the mold locating ring is touching the inlet component just enough for sealing the area This should be doubled checked with the system drawings Back Plate Installation 1 Check the machine nozzle radius 2 Check the seating on the bottom face of the back plate and manifold 3 Install the back plate onto the manifold Figure 5 42 T C Installation 1 Thermocouple 2 Manifold 3 Mounting Screw 4 Heater Plate 5 Thermocouple Bore Hole Plate 4 Install the heater plate to the manifold Refer to the general assembly drawing for location CAUTION oe This is a pinch point area Use caution when installing the heater plate to the manifold plate Failure to do so could re sult in damage to the thermocouple 5 Secure the heater plate to the manifold Use anti seize on threads CAUTION oe 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 torques 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 Figure 5 43 Back Plate Installation 1 Mounting Screw 2 Nozzle Radius 3 Back Plate 4 Manifold 5 Bottom Face b Hot Runner User Manual Revision 16 Mold Not under documentation control if printed May be revised
122. posite cavity melt wedge Figure 16 25 E Revision 16 Moid o0 Masters Master ga Load Wedge Screw Torque Chart Temperature 12 Install load wedge between melt wedges Apply anti seize to SHCS M5X20 and hand tighten to about 7 LB in or 0 79 Nm torque to make sure all components are in proper contact condition 13 Then loosen load wedge SHCS one full turn CCW to assure no engagement Repeat for all load wedges 14 Once the system is assembled melt wedge and load wedge screws must be re tightened at pro cess temperature See Retighten Wedge Screws at Hot Condition amp CAUTION Failure to re tighten wedge screws at pro cess temperature could cause leakage Figure 16 26 Retighten Wedge Screws at Hot Condi tion CAUTION oe Wedge screws must be tightened once the system is heated to processing tempera ture Failure to do so could cause leakage Do not over torque screws Use proper torque wrench for LB in or fraction of Nm scale Do not use torque wrenches with LB ft or large scale Nm for tightening the M4 and M5 screws 1 Set temperature of all hot runner components to processing temperature according to start up procedure Make sure all cooling lines other than cover plate are connected properly 2 After reaching the processing temperature in Melt Cube let it soak for at least 5 minutes 3 Tighten the SHCS M5X20 at the center of load wedge to the proper torque shown in F
123. r correct seating and height Check that there are no pinched wires Manifold and Slot Locator HHH Slot Locator Figure 5 29 Manifold with Slot Locator Blue the manifold locator into the bore to ensure proper seating Install the slot locator into the mold Ensure suffi cient gap between the slot locator and the mani fold slot top surface Under no circumstances should they touch If required attach a crane of sufficient lifting ca pacity to the manifold Place the manifold on top of the nozzles and manifold locator Check for correct seating and height Check that there are no pinched wires Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Installing the Manifold Thermocouple This procedure only applies to integrated systems 1 Although not necessary a thermal compound may be applied to the thermocouple tip to ensure a good contact 2 Clean the thermocouple bore Suggestion for 1 5 mm thermocouples is to use a 1 16 inch drill in a pin vise 3 Insert the thermocouple into the bore Check that the thermocouple is touching the bottom of the hole 4 Press down on the thermocouple and gently bend the thermocouple sheath through 90 5 Check that the thermocouple sits in the manifold cutout Install the thermocouple washer and screw Install a Zone number on each wire and thermo couple
124. rcusoneates E E E 11 2 GAUOS ar E E E E A E E E E 11 2 Additional Tools Required aannnnanonnannnnannnoannnnnnnnnnnnnrnrnrrnrnrrnrnrnnrnrnnrnrnnrnrnnrnrnnrnrnrrnrnnrnrnene 11 3 SPEC CA OMS or e E A E 11 3 FU ACIONCAGIUSTA ON serer E E E E 11 5 Pin Removal from 75 mm E VG VPHolder13 0 0 0 ccceccceccceeeeeeeeeeeeceeeteeeeeeesaeeeseeeseesaes 11 5 Pin Installation into 75 mm E VG VPHolIder13 cece ccccseeeeeeeaeeeceeeseeeseeeseeeseeeseesaes 11 5 Pin Removal 55 mm E VG VPHoIder14 0 cccecccccccsecceeeeeeeese cece eeeeeeseueeeeeseeeseeeseeensues 11 5 Pin Installation 55 mm E VG VPHoIder14 cc cccccccceecceeeeeeeeeeeeseeeseesceeeeeeeseeeseeeseesaees 11 6 installing E VG UNIT into OU AN ocseccccaseesedocsectexeecensasaadenecesersaneaeseaenedsoepeenyeeuscenssehedeuere ceeds 11 7 Hot Runner User Manual Revision 16 Wield Not under documentation control if printed May be revised without notice 7 ooo Masters Electronic version is available at www moldmasters com Master Table of Contents Section 12 Maintenance Procedures 0000 12 1 MOGUC UOI eee r E E E esos 12 1 VAlIVO DISK ROMOVA ee EE REEE EEEREN ee 12 1 Gale Sedl Mantena GO ssesisrrrerre raran era eO Ea 12 5 Gate Seal Removal een en eee ee ee ee a 12 5 Gate Seal Replacement srsstictsseats ce eater punters soe reset ined anione reste SE EA EE EEE 12 6 Sprint Gate Seal Maintenance cccccccecceseceeeteeeteeeeseteeeseeeeetee
125. rease gate size Decrease vent land length Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 4 7 5 mS F pa Revision 16 Fes ici 05 2013 Mas t _ ters Master Troubleshooting Parts have Flow Marks The finished product exhibits blush and flow marks due to variations in material temperature from gradients between the machine nozzle and mold sprue bush ing Cold material in the nozzle tip section results in a halo around the direct sprue Probable Cause Molding Machine e Wrong injection speed e Wrong injection pressure e Hold pressure too long Mold e Insufficient mold cooling e Temperature of mold too high around the gate e Temperature of mold too cool e Gate size is too small e Gate is in wrong location e Land length of gate is too long Material e Melt temperature is too low bed in j Solution e Adjust injection speed e Add a large cold slug area e Add cold wells at the end of the runner system e Use hot sprue bushing e Identify and eliminate dead pockets or sections F Hot Runner User Manual Revision 16 Wilolgd Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 1 7 6 Troubleshooting Master Parts have Burn Marks The finished product display bro
126. 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 instruc tions 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 according 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 defects 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
127. rial e Low melt viscosity e High melt temperature Solution e Reduce the injection speed e Reduce the injection pressure e Reduce the injection time e Increase clamping force e Inspect the mold for irregularities e Reduce the melt temperature e Inspect vent depth e Switch to higher tonnage clamping machine e Establish correct transfer position e Reduce hold pressure Hot Runner User Manual Revision 16 Wiold m Not under documentation control if printed May be revised without notice 05 203 MWlasters Electronic version is available at www moldmasters com 1 7 1 1 Master 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 Mold e Cold mold e Small gate e Wrong gate land length e Wrong gate location Material e Cold melt Solution e Decrease injection speed e Verify nozzle temperature e Increase mold temperature e Increase melt temperature e Increase gate size e Modify gate location k Hot Runner User Manual Revision 16 Wliold ez Not under documentation control if printed May be revised without notice 05 20133 Wilasters Electronic version is available at www moldmasters com 1 7 1 2 Troubleshooting Master Parts are Pitted The finished product contains unmelted particles or small holes on the surf
128. runner and cavity in an injection mold When the part is ejected this gate readily breaks free of the runner system Gen erally the part drops through one chute and the runner system through another leading to a granulator and scrap reclaim system Retainer Plate The plate on which demountable pieces such as mold cavities ejector pins guide pins and bush ings are mounted during molding Ring Gate Used on some cylindrical shapes This gate encircles the core to permit the melt to first move around the core before filling the cavity Runner The channel that connects the sprue with the gate for transferring the melt to the cavities Runnerless Molding See hot runner mold b Revision 16 Mold e203 Masters 18 2 Glossary of Terms Master Screw Travel The distance the screw travels forward when filling the mold cavity Shear The force between layers of resin as they slide against each other or the surface of the mold The result ing friction causes some heating of the resin Short Shot Failure to completely fill the part or cavities of the mold Edges may appear melted Shot The complete amount of melt injected during a molding cycle including that which fills the runner system Shot Capacity Generally based on polystyrene this is the maximum weight of plastic that can be displaced or injected by a single injection stroke Generally expressed as ounces of polystyrene Single Cavity Mold A mold having only
129. s available at www moldmasters com Table of Contents Master Section 9 Color Change c ccsscsscssscsscesccsecnsenscnseesees 9 1 RS ST E e e E A E cer E A E E A E E 9 1 Procedure A Simple amp Effective cccccccecssccsseeeeteeeeeeeseteeeteeesseteeeteeessetegetaeeseetsgenseeeas 9 1 Procedure B More Comprehensive ccccecceeceeteeceeeceeeteeeteeeegeteeeteeeseeteseteeeseetseeseeeas 9 2 Section 10 Hydraulic Pneumatic PRC OS aen Eai 10 1 Installation and Assembly of the Valve Actuator ccccccccccsecceeeeseeeceeeseeeeseeseeeeseeeseeeaes 10 1 Valve Pin Lapping Procedure for Tapered Valve PINS ccceccsseeeeeeeeseeeeeteeeteeeeseenees 10 5 Valve PIN FINISHING OF HEaAd orini n ee Ea aa e EEE OE ERRERA 10 5 VAVE FINAS SMD e eeen EE EE E E EEE 10 6 Installing the Valve Actuator to the Hydraulic Plate 0 0 0 0 ccccccccecceeeceeeseeeeeeeeeeaeeeaeeeaess 10 7 Maintenance FPOCC UNS aircscrecsnsdsandcuniidumeniekcsteendmapndtladioamenatiatntummanneaeeeteadedenhareineassecnagdnedacnsnes 10 8 Extraction Tools for Hydraulic Units amp PIStONS cece cece sececeeeceeeseeeceeeseeeseeeseeeseeenaues 10 9 Section 11 Electric Actuators ccccceeeeeeeeeeneeneees 11 1 Electric Valve Actuator Selection Chart ccccccccccscccseeceseceeeeceeeseeesaueceueseueeeeeeeeeesseesaees 11 1 Ste ee 6 219 6 0 eee ee ete eee ee ee ee ee eee eee 11 2 ISL VV CLRIIINI Sar dscttesenecaeseateta
130. seals engage into guiding specifications detailed in the GA drawing chamfer Press piston smoothly and gently apply ing even force Figure 14 12 Figure 14 9 12 Attach gate seal and liner to nozzle Tighten to specs detailed in the GA drawings Attach nozzle thermocouple b Hot Runner User Manual Revision 16 AN pn m Mold Not under documentation control if printed May be revised without notice 05 2013 MWlastersg Electronic version is available at www moldmasters com 4 4 3 Specialty Systems Accu Line 16 Attach the heater body over the assembly Tight en to specifications detailed in the GA drawing The thermocouple can be inserted by removing the wire retainer holding terminal end and bending into the thermocouple groove Figure 14 13 13 Attach valve bushing Tighten to specifications detailed in the GA drawing N Figure 14 17 17 Slide the valve pin holder into the heater body slot and over the valve pin head Figure 14 14 14 Slide the valve pin into the nozzle assembly Figure 14 18 18 The valve pin holder should be locked with and move together with the valve pin Figure 14 15 15 Attach the 2 hollow sleeves to the valve bushings Hecto nozzles only i Figure 14 19 19 Carefully place the nozzle assembly into the hy draulic unit as shown Figure 14 16 E Hot Runner User Manual Revision 16 Wiolg Not under documentation control if printed
131. sembly 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 documented 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 con troller and machine manufacturers documentation 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 WARNING A 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 Revision 16 Wliolg nae 05 203 Masters 12 9 Master Maintenance Procedures WARNING 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 12 Apply lockout tagged out Refer to machine manufacturers docu
132. sh hook with the tool Make sure the bending tool is snug up against the thermocouple Hot Runner User Manual Revision 16 H Not under documentation control if printed May be revised without notice 05 2013 MWlastersg Electronic version is available at www moldmasters com 5 5 Master gy ooo series 6 Press thermocouple downwards to sit against ter minal end and secure to side of terminal end with heat resistant tape to ensure it does not become pinched between the nozzle and the manifold Figure 5 14 4 Insert the bent thermocouple end into the nozzle Figure 5 17 mating hole and make sure it is fully engaged 7 Use heat resistant tape to secure the nozzle wires and thermocouple wires just above or below the insulator pod The nozzle is ready for assembly with the thermocouple fully installed Figure 5 15 5 Make sure the thermocouple is fully engaged in the nozzle body while bending the thermocouple at the flange Figure 5 18 Figure 5 16 Hot Runner User Manual Revision 16 Mold Not under documentation control if printed May be revised without notice 05 2013 Mlasters Electronic version is available at www moldmasters com 5 6 CE aster Nozzle Insertion W NOTE Prior to commencing assembly verify manifold and nozzle cutouts in mold plates are to specification to ensure proper clear ance to hot runner Improper clearance will affect system performance 1 Clean the nozzle w
133. stem Screw Torques Quality and length of screws must be as specified on Mold Masters general assem bly drawings Torque Chart for System Assembly Screws 6 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 M5 10 Nm 7 ft lbs 10 32 9 Nm 6 ft Ibs M8 39Nm 29ft Ibs 5 16 18 48 Nm 35 ft Ibs 16 Nm 12 ft Ibs 1 4 20 22 Nm 16 ft lbs 77 Nm 57 ft lbs 3 8 16 85 Nm 63 ft lbs 135 Nm 100 ft Ibs 1 2 13 209 Nm 154 ft Ibs M16 330 Nm 243 ft lbs 5 8 11 384 Nm 283 ft Ibs M20 650 Nm 479 ft lbs 3 4 10 678 Nm 500 ft Ibs M5 M8 M10 M12 M16 M20 Component Torque Settings Valve Actuator Series 5500 6500 6600 and Torque Setting 6700 Piston Top 20 27 Nm 15 20 ft lbs a NOTE W Torque sequence and step torquing 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 p Hot Runner User Manual Revision 16 Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 1 2 1 3 Specialty Systems TIT Edge Gated System Master Section 13 TIT Edge Gated System Introduction The following section contains procedures on non standard components TIT Edge Gated System TIT Edge Gate Seals
134. ster Section 18 Glossary of Terms Aspect Ratio Ratio of total flow length to average wall thickness Back Pressure The pressure applied to the plastic dur ing screw recovery By increasing back pressure mixing and plasticating are improved however screw recovery rates are reduced Backplate Inlet component to the hot runner manifold Barrel The part of the molding press where resin is melted B Side The mold half that mounts to the moving side of the injection molding press Sometimes referred to as the core side of the mold or the cold half the B Side has ejector pins to push the part out of the open mold An analysis of the part geometry determines the optimal part orientation to ensure that it will remain on the B Side when the mold is opened Clamp Force The force required to hold the mold shut so resin cannot escape during injection Contoured Pins Ejector pins with the ends shaped to match a sloping surface on the part Core A convex feature on either side of the mold that will enter an opposing cavity when the mold is closed The void between the cavity and core is where the resin solidifies and forms the part Often the B side of a mold is referred to as the core side Core cavity The design of a mold where the A side forms the outside of the part and the B side forms the inside The advantage to this approach is that the part will shrink onto the B side so it can be ejected and if the inside and outsi
135. t runner system for E When installing the rod seal check that the rod maintenance mold cooling should be on seal is seated to the base of the cylinder and is to protect seals and o rings secured in place with the circlip 8 To complete the assembly refer to CAUTION E For systems with MEX Accu Valve EX a Cylinder Bottom Assembly or Accu Valve CX Gate Seals b Piston Assembly Gate seals must be removed prior to re c Cylinder Top Assembly moving or re installing valve pins d Figure Valve Pin Assembly oe Sieve E EERO ae e Installing the Valve Actuator to the Hydraulic nozzle temperature enough to allow removal or installation of the valve pin Plate However nozzle temperature should not be high enough to allow excessive mate rial flow from the nozzle into the thread area After installing valve pins thoroughly clean the nozzle seat and thread area k oe Hot Runner User Manual Revision 16 Wiolgd i i Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 10 8 Valve Actuators Master Extraction Tools for Hydraulic Units amp Pistons EXTOOLASO1 HY5500X Porno Extraction Tool Assembly EXTOOLASO1 Common PN2300X Extraction Tool Assembly EXTOOLASO1 HY6 00X Common HY7 00X Extraction Tool Assembly Figure 10 22 Hot Runner User Manual Not under documentation control if printed May be revised wit
136. te mounting screws Torque to required specifications refer to assembly drawings for required torque settings Install hoses if required Remove latches from both sides of the mold Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Master series E F Revision 16 Wiold 005 203 Masters Master Maintenance Procedures Torque Settings Gate Seal Torque Settings Seal Torque Settings Femto Centi Gating Lite Method Nm fib N Enys Torpedo 69 er s0 67 1618 1213 2730 2022 3438 2528 a7 wem fef TT tt ft tt 25 28 a Bi Metallic Cylindrical ae E 16 18 12 13 27 30 20 22 34 38 25 28 a Valve ae ee ee Ree RS ECE ce ccuwa eo or rete 12 13 27 00 2022 46 2528 mese Oita ot feats pon paas on tite _ _ espas 7 20 2022 orzon s pa sae a esme so o se o eyw eoe 0 E e d NOTE I Gate seals are to be torqued at ambient room temperature and then re torqued at processing tem perature to the torque value specified This is to prevent material leakage from the gate seal bn Hot Runner User Manual Revision 16 Mold o_a Not under documentation control if printed May be revised without notice 05 2013 Maste rs Electronic version is available at www moldmasters com 4 2 1 2 Maintenance Procedures Master Sy
137. te seal damage e Tip wear Assembly Torpedo 4 A E Gate Seal 3 al Insulator Cap i 1 Figure 12 20 Sprint Gate Seal Components Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 12 7 gi 4 Figure 12 21 Tool Kit for Gate Seal Maintenance It is advisable to heat the nozzle to ensure the tem perature condition is met to remove the gate seal CAUTION Use the socket supplied in the tool kit to loosen the gate seal Sprint Nozzle Tip Removal CAUTION 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 After gate seals are exposed by removing the cav ity plate heat nozzles only until plastic softens in gate area temperature will depend on resin used Apply loosening torque to the gate seal using 6 point socket provided 16mm socket If the seal initially loosens but then starts to bind apply some industrial lubricant to remove the gate seal more easily ZEF a N Figure 12 22 Loosening Gate Seal The gate seal torpedo and insulator cap should come off the nozzle as an assembly If the tor pedo 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 torpedo using soft jawed pliers Turn o
138. tem The purpose of this manual is to assist users in the integration operation and maintenance of Mold Masters systems This manual is designed to cover most system configurations For additional information please contact your representative or a Mold Masters office Safety Please see Section 3 for important safety information The responsibility for 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 maintenance 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 Notices Notices throughout this manual indicate additional information that must be performed or observed WARNING Safety warning indicates a potentially hazardous situation which if not avoided could result in serious injury or death oe CAUTION Ww Caution indicates that damage to equipment is possible NOTE LD Important indicates useful additional information or is used as a reminder for important informa tion
139. the components are damaged Thread size M9 s 10 11 ft Ibs 14 15 Nm B Hot Runner User Manual Revision 16 l gm Miold i Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 15 3 Master Ar A Ce Ars Qc sel IeS 7 Torque gate seals in heated condition at process 2 ing temperature as specified in the general assem bly drawings G CAUTION Failure to torque the gate seals at pro cessing temperatures may result in leak age e a J E z p a j w ri emm g r z Pu s cy W a wit ee ae G ee T s n y Figure 15 5 Torquing Gate Seals Nozzle Thermocouple Assem bly 1 Although not necessary a thermal compound may be applied to the tip of the thermocouple 2 Connect the thermocouple a s specified in the general assembly diagram See also Section 5 Assembly Melt Disk Thermocouple As sembly 1 Remove the thermocouple retaining screw from the Melt Disk Figure 15 6 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 15 4 Specialty Systems Melt Disk Insert the thermocouple tip into the thermocouple hole Thermocouple must bottom out in the hole Figure 15 7 Bend the thermocouple back 90 Figure 15 8 4
140. tic from the threads and Figure 12 18 5 Apply anti seize nickel based to the gate seal threads ONLY CAUTION gt Carefully apply anti seize to threads of the _ R gate seal SS eee Any anti seize that enters the internal run Figure 12 16 A Cleaning Location ner must be removed to prevent contami WARNING nation of melt A 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 Hot Runner User Manual Revision 16 Wiolgi E _ Not under documentation control if printed May be revised without notice 05 2013 MWlastersg Electronic version is available at www moldmasters com 4 2 6 Figure 12 19 6 Using a socket wrench re install the gate seal be ing careful not to damage it 7 Torque the gate seal to the appropriate value Refer to Gate Seal Torque Settings 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 8 Check that the seal has bottomed out heat nozzle to process temperature and re torque seal WARNING Failure to torque the gate seals at pro 2 cessing temperatures may result in leak age Sprint Gate Seal Maintenance Reasons for Gate Seal Maintenance e Tip damage e Obstruction to melt flow e Ga
141. ty procedures and checks not included here in the hot runner specific manual Notices To make the manual easier to use we have included notices throughout that highlight important information See below WARNING A Safety warning indicates a potentially hazard ous situation which if not avoided could result in serious injury or death CAUTION Caution indicates that damage to equipment is possible if instruction is not followed a NOTE W Note indicates useful additional information or is used as a reminder of important information A General Safety Warnings The equipment supplied is subjected to high injection pressures and high temperatures Ensure that extreme caution is observed in the operation and maintenance of the hot runner system and the injection molding machines 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 Never disable or bypass a safety device It is highly recommended that all op erators wear face shields and use heat resistant gloves when working around the feed throat purging the machine or cleaning the gates of the mold Check frequently for possible oil or water leaks Stop the machine and make repairs Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is
142. ut off with bluing compound 4 Be sure to remove all lapping paste from the valve pin and cavity before continuing with actuator as sembly NOTE W Do not permit the lapping paste to enter the valve bushing bore WARNING Avoid skin contact with decomposing O rings Use appropriate protective clothing Failure to do so can cause serious injury NOTE W The Viton O rings used for the valve actua tors 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 Figure 10 13 Bushing for Pin Lapping 1 Nozzle Flange Bore 2 Machined Bushing for Center Alignment 3 Tapered Angled Valve Pin 4 Nozzle Well Bore 5 Cavity Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 5500 Series 1 10 5 Heat the hot runner system to the processing tem perature 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 cooling must be running j WARNING Extreme heat Avoid contact with heated surfaces Use appropriate protective clothing Fail ure to do so can Cause serious injury Measure the distance AB in heated condition NOTE Heat expansion difference to be removed
143. valve pin tip to an angle of 20 per side 40 inclusive Refer to Figure 10 10 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 We recommend 400 600 grit lapping paste 6X00 Series 2 43 1865 Figure 10 11 Measure Distance 7100 Series 1 Install the cylinder where applicable and piston bottom without the pin and piston top into the hydraulic plate 2 Measure the distance AC and BC 7100 Series c 9 20 oR as R OH PER CUSTOME SFECIFICAT Figure 10 12 Measure Distance Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 3 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 L L AC 36 35 HE CD 6 Grind the valve pin tip to fit the cylindrical gate Refer to the system gate detail 7 Assemble the hydraulic unit o Heat the hot runner system to processing tem perature 9 Soak the pin in the hot runner system for 10 min utes to achieve the maximum heat expansion of the pin at the processing temperature Mold cool ing should be running 10 Measure the distance CD in the heated
144. wire retainers Feed the wires back through the wire channel in the mold base to the electrical box 3 Cut the inlet extension pressure sleeve to the required height Chamfer the outside edge of the pressure sleeve Place zone number on each wire and thermo couple Tape wires for each zone together 7 Install the wires into the wire channels and secure with wire retainers 8 Feed the wires back through the wire channel in the mold base to the electrical box 9 For electrical checks refer to the Electrical Testing section Figure 5 46 Inlet Extension 1 Extension Tip 2 Inlet Extension 3 Thermo couple 4 Manifold 5 Nozzle Flange 6 Screw 7 Wire wrap Figure 5 47 Inlet Extension with Sleeve 1 Inlet Extension 2 Manifold 3 Extension Tip 4 Pressure Sleeve Hot Runner User Manual Revision 16 Mold Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 5 1 7 ER Master Section 6 Electrical Testing Introduction This section contains guidelines for electrical testing of your Mo ld Masters hot runner system The testing is based on the following European and North American standards EN 60204 1 DIN EN 60204 1 IEC 60204 1 modified Safety of machinery electrical equipment of machines NFPA 79 Electrical Standard for Industrial Machinery The standards themselves are the final authorit
145. wn 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 e High back pressure Mold e Trapped or volatile gas e Burning due to friction e Incorrect sprue diameter Material e Overheated underheated melt possible shear Solution 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 be Hot Runner User Manual Revision 16 i Mold Not under documentation control if printed May be revised without notice 05 203 WWiasters Electronic version is available at www moldmasters com 1 7 7 Master Troubleshooting Parts are Delaminating The finished product is separating into layers that can be peeled off surface layers are flaking off Insufficient layer bonding as a result of high shear stresses non homogenious material Probable Cause Molding Machine e High injection speed e Cold mold e Gate has sharp corners e Sharp corners causing shear heat e Physical contamination of raw material e Chemical contamination of raw material e Melt too hot poor melt
146. xtended period e Barrel improperly purged e Contamination in plasticizer e Wrong nozzle e Use of wrong screw Mold e Gate and or runner has dead spots Material e Physical contamination of raw material e Chemical contamination of raw material e Particulate contamination from machine barrel Solution 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 e Hot Runner User Manual Revision 16 Wliold E Not under documentation control if printed May be revised without notice 05 2013 WMWlastersg Electronic version is available at www moldmasters com 1 7 4 Troubleshooting Mi aster Parts have Blisters and or Bubbles The finished product contains small gas or air filled pockets or cooling voids Probable Cause Molding Machine pa Mold Material ha itom a D i i 5 a EE Solution Low Injection Pressure Back flow valve malfunctioning Suck back cycle too long Rapid plasticizing Trapped air in feed Feed error Trapped or volatile gas Low mold temperature Poor thin thick transition phase Inadequate venting Overheating of resin Verify control and or holding pressure Increase back pressure Increase mold temperature Inspect back flow valve Ensure proper venting Inc
147. y Center Locator Inserts Cavity Block Melt Transfer Cavity Inserts Link if Melt Cube ii m 4 Melt Cube Spacing ey i a ge Assembly Supports e j F Cavity Block Melt jj os Cover Plate Wedge Clamp 4 amp Figure 16 2 Hot Runner User Manual Revision 16 Wiold Not under documentation control if printed May be revised without notice 05 2013 Masters Electronic version is available at www moldmasters com 1 6 3 Master gE Ty series Preparation Inspection 1 Inspect critical dimensions for cavity cutout to ensure it matches the GA drawing and catalogue pages Clean Melt Cube Wipe down the Melt Cube 2 If necessary use a cotton swab to clean narrow interior surfaces or screw threads For larger sur faces such as the manifold use thinner in spray form to clean channels and recesses Figure 16 3 Assemble Melt Cube Thermocouple 1 Insert the thermocouple tip into the thermocouple hole Thermocouple must bottom out in the hole Figure 16 4 2 Bend the thermocouple back 90 to sit in the mani fold channel 3 Apply anti seize to the retaining screw Secure the thermocouple with the screw 3 SD ad Figure 16 5 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Assemble Ground Wire 1 Apply anti seize to the retaining screw
148. y be revised without notice Electronic version is available at www moldmasters com Maintenance Procedures EXTRACTION TOOLS Part Number Where Used 1 Pc Inverted Valve Style with 5mm x 8 thread EXTOOL10P 13mm centre to centre 1 Pc Inverted Valve Style with EXTOOL10P1 4mm x 7 thread 13mm centre to centre EXTRACTION TOOLS Part Number Where Used 2 Pc Inverted EXTOOL17P Style EXTOOL18P 7 74mm Terminal End Removal and In stallation Although this procedure shows a nozzle terminal end the process is the same for manifold terminal ends 2 Pc Inverted Style 10 74mm Terminal End Removal 1 Ifthe terminal end is covered with plastic warm the terminal end prior to removing the element sleeve CAUTION ee Care must be taken when removing the element sleeve to avoid damage to the ceramic sleeve or terminal nut Figure 12 3 Nozzle Terminal Assembly 1 Nozzle Flange 2 Ceramic Insert 3 Ceramic Sleeve 4 Seal 5 Element Sleeve Revision 16 Mold 005 2013 Masters 12 2 Maintenance Procedures Master 2 Grip the element sleeve at the threaded area and 3 Slide the element sleeve silicon seal and ceramic turn counter clockwise If the wires rotate with the insulator onto the wires sleeve damage may result 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 t
149. y for testing requirements also any additional testing requirements from any national standards where the hot runner is in use WARNING The user is responsible to ensure protec tion against shock by indirect contact by protective earth conductors and automatic disconnection of supply Mo d Masters components and systems are either equipped with a protective earth conductor or there is a connector for this purpose WARNING To avoid serious burns wear safety cloth ing 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 ible location indicating Danger Do Not Touch Before you carry out electrical work make sure that the hot runner system is securely grounded Turn the temperature control off and disconnect all electric wires coming from the mold Failure to follow of these steps may lead to serious injury or death Wiring Check WARNING Ensure that all wiring and connection work is performed by a qualified electrician ac cording to DIN EN 60204 1 NFPA79 1 Check that each wire and thermocouple has a zone number 2 Check that wires are organized and taped together by zone and plug 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 co
150. ylinder Top 3 O Ring Viton 4 O Ring Viton 5 Guide Ring 6 O Ring Viton 7 Guide Ring 8 Actuator Piston 9 Outer Cylinder Housing 10 Socket Head Cap Screws 11 Actuator 24 Con Hose w Fittings 12 Actuator Heated Body 13 Actuator Valve Pin Holder 14 Socket Head Cap Screws 15 Valve Pin 16 Dowel Pin 17 Socket Head Cap Screw 18 Accu Line Bushing 19 Nozzle 20 Liner 21 Gate Seal REFER TO GENERAL ASSEMBLY DRAWINGS FOR ACTUAL SIZES Piston Parts List A HYORGxx Viton o ring B PSOOxx 3 piece piston seals Each containing 1 Backup ring with split 1 Viton o ring 1 Hard ring C GUIDERINGxx Guide ring ia i Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 1 4 1 Figure 14 1 Accu Line Body Assy b Revision 16 Mold F 05 203 Masters Master Specialty Systems Accu Line series Pre Assembly 4 Repeat steps 1 3 to install inner seal into the piston 1 Cut pin to calculated length as specified in the general assembly drawing Refer to Valve Pin Finishing of Tip Accu Line Assembly Procedure 1 Check components against the parts list Figure 14 5 5 Install piston backup washer and O ring into the designated outer groove The back up washer should be placed on the shorter side of the piston Place one side of piston hard ring

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