Page 5-12 - Mold
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1. Manifold Locator 2 Locating Cam 3 Dowel Pin i Hot Runner User Manual Revision 12 Wiolgd p_a t Fa 7 Not under documentation control if printed May be revised without notice 05 200 WIlasters Electronic version is available at wwwe moldmasters com 5 8 CT em Master WARNING Make sure the lifting eyebolt chain and crane can support the weight of the mani fold Failure to do so may cause serious injury 5 If required attach a crane of sufficient lifting ca pacity to the manifold 6 Check for correct seating and height 7 Check that there are no pinched wires Dowel Pin Locator 1 Install the dowel pin into the mold 2 Check that the dowel pin does not touch the top of the manifold 3 Install 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 5 Place the manifold on top of the nozzles and locating dowel Check for correct seating and height Check that there are no pinched wires Manifold and Slot Locator 1 Blue the manifold locator into the bore to en sure proper seating 2 Install the slot locator into the mold Ensure sufficient gap between the slot locator and the manifold slot top surface Under no circum stances should they touch 3 Place the manifold on top of the nozzles and manifold locator 4 If required attach a crane of sufficient lifting capacity to the ma2. Failure to do so could result in damage to the components and cause material leakage 1 Place the inlet extension on the manifold 2 A pressure sleeve is supplied oversize in length Refer to general assembly drawing to determine length of pres sure sleeve 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 thermocouple Tape wires for each zone together a a 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 i f Figure 5 40 Inlet Extension with Sleeve 9 For electrical checks refer to the Electrical Testing section 1 inlet Petension 2 Manifold 3 Extension Tip 4 Pressure Sleeve E Hot Runner User Manual Revision 12 Wiolgd Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwv moldmasters com 5 1 7
3. Make sure the thermocouple is fully engaged in the nozzle body while bending the thermocouple at the flange Figure 5 13a Figure 5 13b 5 Press thermocouple downwards to sit against terminal end and secure to side of terminal end with heat resistant tape to ensure it does not become pinched between nozzle and manifold Figure 5 14 6 Use heat resistant tape to secure the nozzle wires and thermo couple wires just above or below the insulator pod The nozzle is ready for assembly with thermocouple fully installed Figure 5 15 b Revision 12 Moid 05 2010 Masters Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at wwwv moldmasters com 5 5 Master gy OT Nozzle Insertion NOTE YA Prior to commencing assembly verify mani fold and nozzle cutouts in mold plates are to specification to ensure proper clearance to hot runner Improper clearance will affect system performance 1 Clean the nozzle well seating bore 2 Install the nozzle CAUTIONS E Systems with gate seals that are not acces sible when fully assembled require the gate seals to be torqued hot prior to installation 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 typ
4. Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Figure 5 28 Inlet Seal without Step 1 Inlet Seal 2 Sub Manifold Figure 5 29 Inlet Seal with Step 1 Sub Manifold 2 Inlet Seal 3 Locating Dowel H ia ie Figure 5 30 Install Main Manifold 1 Mounting Screws 2 Main Manifold 3 Dowel Pin 4 Inlet Seal i Revision 12 Wliolgd 0520 Masters 5 11 Master gy OT 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 ls compressed by thermal expansive forces to form part of the plastic sealing mecha nism Also helps to reduce thermal transfer to a minimum e Valve Disk ls compressed 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 For additional information refer to Establishing Your System Type Pressure Disks and Valve Disks are supplied oversize in height and require grinding to dimensions speci fied on the general assembly drawing Pressure Disk or Valve Disk Height Pocket Depth Manifold Thickness Nozzle Flange Air Gap air gap disk height manifold pocket thickness depth no
5. Runner User Manual Revision 12 Whole eee E F _ Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwv moldmasters com 5 3 Master A Dura Line Thermocouple installation This page only applies to legacy Dura nozzles Mold Masters Dura systems are supplied with an appropriate bending tool Any questions regarding bend ing tools please contact your Mold Masters representative Make sure that correct bending tool is used Each different type of Dura Nozzle requires a different bending tool The correct bending tool was sup plied with your hot runner 1 Clean nozzle thermocouple bore Place thermocouple through flange of nozzle Figure 5 10a Figure 5 10b 2 Place the end of the bending tool all the way over the end of the thermocouple While supporting the thermocouple create a 180 fish hook with the tool Make sure the bending tool is snug up eden the thermocouple Figure 5 11a Figure 5 11b 3 Insert the bent thermocouple end into the nozzle mating hole and make sure it is fully engaged Figure 5 12 e F p Hot Runner User Manual Revision 12 Wiold p_i G 7 Not under documentation control if printed May be revised without notice 05 200 MIasters Electronic version is available at wwwv moldmasters com 5 4 Assembly Master Dura Line Thermocouple Installation con t 4
6. on the valve disk corresponds to the direction of the melt flow Ensure correct air gap between the valve disk and the top plate as specified in the GA drawing 5 For information on removal refer to Valve Disk Removal within the Maintenance Procedures section Figure 5 33 Manifold to Nozzle Mounting 1 Spring Dowel 2 Nozzle 3 Manifold 4 Pressure Disk 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 Pressure or Valve Disk height Air Gap Value 2 Install the nozzle into the Manifold Plate 3 Install the Manifold to the Nozzle 4 Refer to the General Assembly drawing for Pressure Valve Disk locations 5 Measure the gap between the top of the Manifold Plate and the top of the Pressure Valve Disk Ensure that it matches the air gap value on the General Assembly drawing Hot Runner User Manual Revision12 Wiolgd Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwv moldmasters com 5 1 3 Master gy eT Installing Heater Plates These procedures apply to systems with exter nal heater plates Refer to the general assembly drawing to determine which heater plate applies to your system NOTE L gt Current bronze heater plates are di rectly interchangeable with previous copper or aluminum ba
7. revised without notice 05 2010 Was rs Electronic version is available at wwwv moldmasters com 5 2 Assembly Master Master Series Thermocouple Installation con t 4 Dress thermocouple carefully alongside nozzle body and install retaining clip s Check parts list for recom mended number of clips for the nozzle type Check that the thermocouple fits into the recess of the clip It is im portant that one retainer clip is at the top of the nozzle to keep the thermocouple inside the bore This is espe cially important when thermocouples are assembled from the front 5 Install the terminal end retaining clip Check that the thermocouple fits into the recess of the clip IMPORTANT Ensure the terminal end of the thermo couple stays fully engaged in the slot while bending the thermocouple at the nozzle flange area Figure 5 7 6 Install the clip over the terminal end 7 Use heat resistant tape to secure the nozzle wires and Figure 5 8 thermocouple wires just above or below the insulator pod Master Series Thermocouple Removal for non front mounted thermocouples Figure 5 9 IMPORTANT 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 2 Remove the nozzle from the manifold plate 3 Remove the thermocouple retaining clips 4 Remove the thermocouple ke Hot
8. Ce Master Section 5 Assembly Introduction This section is a step by step guide to assembling your Mold Masters hot runner system 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 Hot Sprue NOTE _ The gate seals supplied with your system may need to be adjusted to tolerances based on the ma terial 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 FType 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 nozzle well bore NOTE _ Hot sprue also requires completion of the gate detail Refer to the nozzle well detail drawing ie sae p se Q MIN NOTE a Heat expansion of the nozzle must also 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 a CAUTION TO BE FINISHED Ensure the thermocouple is not BY MOLD MAKER damaged during machining E o EEG Pa Figure 5 1 Hot Valve Hot Sprue Gated System Polymer Structure Contact Length H Amorphous Filled or Reinforced Sem
9. ater plates are supplied with the power wires connect k _ Hot Runner User Manual Revision 12 Wiolgd F Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at www moldmasters com 5 14 rT Vaster ed Place a zone number on each wire and thermocouple 5 Tape wires for each zone together 6 Install the wires into the wire channels and secure with wire retainers 7 Feed the wires back through the wire channel in the mold base to the electrical box Installation of Inlet Components The following procedures refer to different system configurations Refer to your parts list and general as sembly drawings to determine your system type CAUTION For all inlet components it is important that the mold locating ring is touching the inlet compo oe nent just enough for sealing the area This should be doubled checked with the system draw Ings e Back Plate Installation e Center Heater Installation e Three Piece Center Heater Installation e Inlet Extension Installation e Inlet Extension With Pressure Sleeve 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 Install M8 mounting screws through the back plate to the manifold using anti seize on threads 5 Torque screws to value indicated on the GA draw ing in acros
10. ation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwe moldmasters com 5 10 em Master Main Manifolds Manifolds distribute melt from the inlet component to one or more sub manifolds If you have a sub mani fold 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 Inlet seal without step Inlet seal with step Inlet Seal Installation without step Manifolds that use a seal without a step l 2 Place the inlet seal into all sub manifold inlets Check that the inlet seal orientation is chamfer down Check that all inlet seal heights are at the same level Install the manifold locators Refer to Mounting the Manifold Check that all components are free of debris Inlet Seal Installation with step Manifolds that use inlet seals with a step l 2 3 4 Install the step inlet seal to the manifold Install the dowel pin into the seal and manifold Lower the main manifold into position Install manifold mounting screws and torque to required settings Refer to your general assembly drawing for specifications Install the manifold thermocouples Refer to Installing the Manifold Thermocouple NOTE On Bridge Manifold Systems mounting screws should be torqued 1 3 higher than specified on general assembly drawings Hot
11. correct positions 5 Install screws through the manifold and into the manifold plate Mounting screw thread must start at the flange seal level Refer to the GA drawing s for correct screw size 6 Torque screws to value indicated on the general assembly ge an E itt a drawing and secure manifold to the manifold plate Rae rere eae NOTE LA On Bridge Manifold Systems main to sub manifold screws should be torqued 1 3 higher than specified on general assembly drawings A WARNING ma E Do not shorten the screw length Figure 5 22 Valve Bushing Installation 1 Mounting Screw 2 Manifold 3 Nozzle 4 Valve Bushing Mounting the Manifold introduction There are 3 methods used to locate the manifold 1 Manifold Locator SURFACE A SURFACE B 2 Dowel Pin Locator _ 3 Manifold and Slot Locator Manifold Locator NOTE gt Check GA drawing for information for your system 1 Forsome 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 allow SURFACE A and SURFACE B to be at the same level in the cold condition However check the GA drawing for exception notations 2 Blue the manifold locator into the bore to ensure proper seating 3 Install the locating cam dowel pin 4 Install the locating cam onto the dowel pin Figure 5 24 Manifold with a Locator 1
12. d to the thermocouple tip to ensure a good contact 4 Install the thermocouple 5 Install the cover plate 6 Install M8 mounting screws through the cover plate into the tapped holes of the manifold Use anti seize on screws 7 Torque screws to values indicated on the general as sembly drawing Figure 5 38 3 Piece Assembly 1 Screw 2 Center Heater 3 Back Plate 4 Manifold 5 Ground Wire 6 Thermocouple Z Cover Plate i as Hot Runner User Manual Revision 12 Wiolg Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwe moldmasters com 5 1 6 em Master Inlet Extension Installation 1 Place the inlet extension on the manifold 2 Install mounting screws through the nozzle flange and into the manifold 3 Torque screws to manifold using anti seize on threads 4 Place a zone number on each wire and thermocouple 5 Tape wires for each zone together 6 Install the wires into the wire channels and secure with wire retainers Feed the wires back through the wire channel in the mold base to the electrical box Figure 5 39 Inlet Extension 1 Extension Tip 2 Inlet Extension 3 Thermocouple n n 4 Manifold 5 Nozzle Flange 6 Screw Inlet Extension with Pressure Sleeve J CAUTION ED Always install the inlet extension pressure sleeve clamp plate and locating ring with the mold plates in the horizontal position
13. e 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 Figure 5 17 3 Check that Face 1 is at the same level for all drops relative to the mold plate split line 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 18 Wiring Layout 1 Wire Channel 2 Retainers i as Hot Runner User Manual Revision 12 Wiolg Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwe moldmasters com 5 6 Ee Vaster 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 mainte nance and ease of acce
14. i crystalline Filled or Reinforced 3 00 Crystalline Filled or Reinforced 2 00 b F pa Hot Runner User Manual Revision 12 Fy H Not under documentation control if printed May be revised without notice 05 200 MWlasters Electronic version is available at www moldmasters com 5 1 Master gx eT Water Cooled Gate Insert Installation Option Your system may not include a water cooled gate insert Refer Fi 1 to your general assembly drawing Me The water cooled gate insert will require final machining 1 Machine the water cooled gate insert to final height and NS then add the gate detail Refer to your system drawing for SSS details SSN ANNS 2 Clean the insert seating bore Figure 5 2 Water Cooled Gate Insert 3 Install O rings onto the water cooled gate insert 1 O Rings 2 Seating Bore Master Series Thermocouple Installation 1 Clean the nozzle thermocouple bore Suggestion for e 1mm thermocouples use a 58 drill in a pin vise e 1 5mm thermocouples use a 1 16 inch drill in a pin vise 2 Insert the thermocouple through the flange bore CA Figure 5 4b 3 Manually bend the thermocouple tip against i p your thumb to approximately a 90 angle ensuring bend length is sufficient to reach the K bottom of the termocouple bore Figure 5 5a Figure 5 5b k F p Hot Runner User Manual Revision 12 Wiold Hams p s t Not under documentation control if printed May be
15. nifold Check for correct seating and height 6 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 Figure 5 25 Manifold Locating with a Dowel Pin 1 Manifold Locating Dowel 2 Locating Cam 3 Dowel Pin Slot Locator TIN oe iz Figure 5 26 Manifold with Slot Locator b Revision 12 VMiold on20 Masters Master Assembly Installing the Manifold Thermocouple This procedure only applies to integrated systems only 1 Although not necessary a thermal compound may be applied to the thermocouple tip to ensure a good contact 2 Insert the thermocouple into the bore Check that the thermocouple is touching the bottom of the hole 3 Press down on the thermocouple and gently bend the thermocouple sheath through 90 4 Check that the thermocouple sits in the manifold cutout 5 Install the thermocouple washer and screw 6 Install a zone number on each wire and thermo couple 7 Tape wires for each zone together Figure 5 27 Thermocouple Installation 1 Thermocouple 2 Screw 3 Washer 8 Install the wires into the wire channels and secure 4 Assembly with wire retainers 9 Feed the wires back through the wire channel in the mold base to the electrical box Hot Runner User Manual Revisi 2 am evision 12 Mold Not under document
16. s pattern in 5 ft lb increments NOTE The machine nozzle bore should be 1 0mm m cai 0 040 smaller than the back plate bore Figure 5 36 Nozzle Pad Installation 1 Mounting Screw 2 Nozzle Radius 3 Back Plate 4 Manifold 5 Bottom Face b a ae Hot Runner User Manual Revision 12 Hamm Mold Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at www moldmasters com 5 1 5 Master A 07 Center Heater installation The center heater may require the machine nozzle radius to be added 1 Place the center heater on the manifold 2 Rotate the center heater to align with the tapped holes in the manifold and align terminals with cut out 3 Install mounting screws through the center heater into the tapped holes of the manifold Use anti seize on the screws 4 Torque screws to values indicated on the general as sembly drawing 5 Place zone number on each wire and thermocouple 6 Tape wires for each zone together 7 Install the wires into the wire channels and secure Figure 5 37 Center Heater Assembly with wire retainers 1 Thermocouple 2 Center Heater 3 Screw 8 Feed wires back through the wire channel in the mold base to the electrical box Three Piece Center Heater Installation 1 Install the back plate on the manifold Mount the center heater on back plate 3 Although not necessary a thermal compound may be applie
17. sed plates that Figure 5 34 Heater Plate and Thermocouple 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 volt age and are located in similar thermal environments CAUTION Heater plates are controlled by a thermocouple E located in the heater plate Do not control the heater plate from a thermocouple in the manifold 1 Insert the thermocouple into the bore Ensure the thermo couple is touching the bottom of the bore hole Press down on the thermocouple and gently bend to 90 3 Install the heater plate to the manifold Refer to general assembly drawing for location CAUTION This is a pinch point area Use caution when os installing the heater plate to the manifold plate Failure to do so could result in damage to the thermocouple 4 Secure the heater plate to the manifold Use anti seize on Figure 5 35 T C Installation threads 1 Thermocouple 2 Manifold 3 Mounting Screw 4 Heater Plate 5 Thermocouple Bore Hole Plate CAUTION j Do not over tighten the mounting screws This E could result in the heater plate losing 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 The he
18. ss Figure 5 19 Thermocouple Layout Side View 1 Thermocouple 2 Wire Retainer 3 Manifold 4 Manifold Backing Plate 5 Power Wire 6 Mold Plug Z Electrical Box 8 Manifold Plate Valve Bushings Types of Valve Bushings e Heated e Non Heated Valve Bushing Installation This procedure applies to valve gated systems that are bolt in design Refer to the parts lists and your general Figure 5 20 Valve Bushing lypes assembly drawing to determine if your system has a 1 Non Heated 2 Heated valve bushing 1 Mount the valve bushing on top of the nozzle NOTE Y The valve bushing for Accu Valve has a locating dowel pin with the mold 2 Install the locating dowel Ensure the dowel pin is not too long as this will effect the seal between the nozzle and the manifold NOTE LA If required attach a crane of sufficient lifting capacity to the manifold Figure 5 21 Valve Bushing 1 Valve Bushing 2 Nozzle 3 Locating Dowel WARNING Make sure the lifting eyebolt chain and crane can support the weight of the manifold Failure to do so may cause serious injury ke Hot Runner User Manual Revision 12 Wiolgd Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwv moldmasters com 5 7 Master A 3 Apply anti size on the threads of each screw 4 Lower the manifold into position WARNING Ensure the dowels are in the
19. zzle flange Pressure Disk Figure 5 31 Calculating 1 Install the manifold to the nozzle Pressure Disk Valve Disk Height 2 Refer to the general assembly drawing for pressure disk dimensions before calculating the pressure valve disk height 3 Pressure disks are supplied oversize in height grind equal amounts from each side 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 Grind equal at NS amounts Stone sharp corners Figure 5 32 Pressure Disk 4 Remove the sharp corners after grinding 5 Install the pressure disk spring dowel to the manifold 6 Install the pressure disk to the manifold i F p Hot Runner User Manual Revision 12 Wiolgd p s MMMM t _ z Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwe moldmasters com 5 1 2 waster Valve Disk Valve disks are supplied oversize in height and require grind Ensure correct Clean bore ing to dimensions specified on the general assembly drawing air gap per GA after grinding 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 3 Install the manifold to the nozzle 4 Install the valve disk Check that the arrow engraved
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