Section 16 - Melt-Cube System - Mold
Contents
1. 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 Hot Runner User Manual Revision 15 Mold Not under documentation control if printed May berevisedwithoutnotice 05 2012 Maste IN Electronic version is available at www moldmasters com 1 6 1 Master A series Melt Cube Components Load Wedge Y e Cate Seal Melt Wedge e Assembly Melt Cube d Manifold Melt Cube Anti rotation Dowel Melt Cube Center Locator example custom Cavity side Retainer Cavity Insert Anti rotation Dowel Retainer Retainer _Clamp Clamp Wedge Dowel Pin Gate Seal Assembly Melt Cavity Insert Cavity side a example Retainer Transfer Seal i Wedge Ani Toto i Dowel Torpedo e _ _ gt ig ia p Figure 16 1 Not supplied by Mold Masers Hot Runner User Manual Revision 15 Wold M k _ Not under documentation control if printed May be revised without notice 05 2012 Masters Electronic version is available at www moldmasters com 1 6 2 Ci aster series Example Melt Cube System _ lt t e Insulation Plate Locating Ring Leader Pins Top Clamp Plate SEE SECTION 5 H ASSEMBLY FOR ASSEMBLY DETAILS a L Inlet t pyan Bridge Manifold Nozzle Heater Nozzle Electrical Box Manifold Plat2. is soft enough to be able to detach runners at gate area Drain water inside cooling lines of the cover plate of the cavities and then remove the cover plate Loosen and take out the SCHC M5X20 at the cen ter of the load wedge of tip to be replaced Use SHCS M6X100 in the tool kit to extract re quired load wedge Figure 16 27 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 Figure 16 28 Let the system cool down to almost room tempera ture Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 8 10 11 12 16 8 Master 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 29 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 grani
3. 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 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 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
4. e j P Wire Channel Melt Cube e gt Electrical Box Cavity Backing Plate Cavity Plate Melt Cube Assembly Melt Cube Center Locator Cavity Inserts Cavity Block Melt ae T a Transfer are Ss _ Cavity Inserts Link Melt Cube iy _ tt Melt Cube Spacing ge Assembly Supports Cavity Block elt Cover Plate Wedge Clamp Wo I Figure 16 2 Hot Runner User Manual Revision 15 Wiold Not under documentation control if printed May be revised without notice 05 2012 MViasters Electronic version is available at www moldmasters com 1 6 3 Master i 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 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 Figure 16 5 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic v
5. e cavity block 3 Insert Melt Cube into the cavity block Align the anti rotation dowels with the slots in the cavity block while also aligning the Melt Cube to the Melt Cube center locator and spacing supports Figure 16 10 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Center Locator Spacing Supports Figure 16 11 4 Apply anti seize to the clamp SHCS s Install the proper SHCS into each retainer clamp Install clamps over Melt Cube at locations shown in GA drawing Torque as specified in Clamp Screw Torque Chart see Figure 16 14 Torque Value LB ft Nm 7 5 10 12 16 15 20 CLAMP 16 CLAMP 17 CLAMP 18 Figure 16 14 Melt Transfer Link Torque Chart Part Description Torque Socket Number Value Size LB ft Nm m 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 MTLO16B Melt Transfer Link Centi Bottom Half to Melt Cube Figure 16 15 Revision 15 Mold 05 2012 16 5 Masters Master lt i ors series 5 Install cavity inserts if applicable aligning hole with cavity Figure 16 16 6 Install cavity side retainer anti rotation dowel us ing SHCS Repeat for all cavities Figure 16 17 T Prepar
6. e gate seal assembly a Ensure transfer seal and torpedo are clean b Install torpedo into transfer seal Figure 16 18 8 Ensure outside of transfer seal is clean Slide fit transfer seal into cavity insert hole E 4 4 Figure 16 19 Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 9 10 11 12 13 14 16 6 Install wedge dowel pins for locating melt wedges Figure 16 20 Ensure all melt wedge surfaces are clean Figure 16 21 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 opposite cavity melt wedge pm Wi Figure 16 22 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 Then loosen load wedge SHCS one full turn CCW to assure no engagement Repeat for all load wedges 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 E Revision 15 Mold 005 212 Masters i i Vaster CAUTION Failure to re tighten wedge screws at pro cess t
7. emperature could cause leakage Figure 16 23 Figure 16 26 Retighten Wedge Screws at Hot Condi 4 ighten all melt wedge SHCS M4x20 in two tion stages CAUTION a First tighten all to 15 LB in 1 69 Nm torque os Wedge screws must be tightened once the b Then tighten all to 30 LB in 3 38 Nm torque system is heated to processing tempera as shown in Figure 16 25 ture Failure to do so could cause leakage 5 Assemble cavity block cover plate and connect Do not over torque screws Use proper proper cooling lines 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 7 Fill system under low pressure extrude using screw rotation 6 Allow all hot runner components to reach process ing temperature 1 Set temperature of all hot runner components to processing temperature according to start up 8 Set nozzle temperature 10 F 6 C lower than melt procedure Make sure all cooling lines other than cube cover plate are connected properly CAUTION 2 After reaching the processing temperature in Melt oe If the processing temperature is changed by more than 54 F 30 C then all wedge Cube let it soak for at least 5 minutes screws should be loosened at cold condi 3 Tighten the SHCS M5X20 at the center of load tion and the assembly process repeated at wedge to the proper torque shown in Figure 16 24 cold and process tempera
8. ersion is available at www moldmasters com Assemble Ground Wire 1 Apply anti seize to the retaining screw Secure the ground wire with the screw f 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 E Revision 15 Vio l d 005 2012 Masters 16 4 R aster Assemble Melt Cube into Cav ity Block If the system has been running 1 Make sure water to the cover plate is off then remove the cover plate 2 Turn on cooling to the rest of plates especially the cavity plates NOTE aD Mold Masters recommends a separate cooling circuit for the cover plate to be able to assemble and disassemble it with out affecting other cooling circuits 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 W Eo E G E a Tat at i Bee eS ee ee ee oe ee bh Figure 16 9 2 Install Melt Cube center locator and spacing sup ports into the back of th
9. te measure ment base Rub the surfaces gently with a few strokes on the sand paper Figure 16 30 Loosen SHCS on opposite side of the melt wedge to have only 5 Ib in torque as well 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 P Revision 15 e Mold 05 20122 Miasters
10. ture as ex WARNING plained above A Potential burn hazard Use socket exten sion and heat resistant gloves Startup and Shutdown Startup Load Wedge Screw Torque Chart SHCS Tip Angle Temperature Torque Value Ib in Nm Heat bridge and inlet to processing temperature Heat nozzles to processing temperature 0 Process Temp 306A 29 3 3 a Fill system under low pressure extrude using eee screw rotation M5x20 60 Process Temp LAU 6 Set nozzle temperature 10 F 6 C lower than Melt Figure 16 24 Cube Melt Wedge Screw Torque Chart Shutdown SHCS Temperature Torque Value 1 Reduce Melt Cube temperatures to 300 F 150 C C Ib in Nm 2 Reduce Nozzle temperatures to 300 F 150 C M4X20 30 3 4 S Timati dizones Figure 16 25 Heat Melt Cube to processing temperature Allow to heat soak at least 5 minutes ee 7 P Hot Runner User Manual Revision 15 i Not under documentation control if printed May be revised without notice 05 2012 Masters Electronic version is available at www moldmasters com 4 6 7 Maintenance Replacing a Tip WARNING Potential burn hazard Use socket exten sion and heat resistant gloves NOTE 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 A D Make sure the Melt Cube and related nozzle are at the temperature that the plastic
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