user manual - Mold
Contents
1. Determine the frequency Is the problem random or in the same location 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 pro ducing standard parts injection speed e 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 gt T Updates are available online at www moldmasters com Mold E 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 10 4 Masters Fusion Troubleshooting Defect types causes and remedies index Parts have dark specks Page 10 6 Parts have blisters and or bubbles Page 10 7 Parts have flow marks Page 10 8 Parts have burn marks Page 10 9 Parts are delaminating Page 10 10 Parts have dimensional irregularities Page 10 11 Parts are discolored Page 10 12 Parts contain flash Page 10 13 Parts surface has jetting Page 10 14 Parts are pitted Page 10 15 Parts surface is rough Page 10 16 Parts are sticking to cavity Page 10 17 Parts are sticking to core Page 10 18 Parts are short Page 10 19 Parts have sink marks or voids Page 10 20 Parts display splay Page 10 21 Parts are streaked Page 10 22 Parts are stringing Page 10 23 Parts are warped Page 10 24 Parts have weld lines Page 10 25 gt e Update2. Fusion on 32 user manual performance delivered Fusion Table of Contents Table of Contents Section 1 Introduction ME 1 1 Warranty and Documentation EEN 1 1 Release Details ea cuaiyityasaeseucyuayatuaieavutety 1 1 Trademarks and E 1 2 Section 2 Global S ppori EE 2 1 Manufacturing Facilities NNN 2 1 PVE OOM al TNC RTT TTE m 2 1 International Hepresentatives nenne 2 2 SEENEN 3 1 SIR E ie E ue Io IE IE TTE TT 3 1 Operating the Mold WEE 3 1 INQ GC EE 3 1 CAUTO MNT Dmm 3 2 Heater Elemen E e TT 3 2 Section PVC ARAN MEER 4 1 COV nie un EE 4 1 TOONS RETUO O ETE S Et e m 4 2 Diare e e lee NDERIT TERT TETTE Emm 4 3 Brio 4 3 Establishing Your System Type ENN 4 3 Wc yS nn Ee TE 4 4 HY8300 Hydraulic Actuator Typical CGomponente nennen nnn nnn nnns 4 5 HY8300 Hydraulic Actuator Typical CGomponente 4 6 PY8300 Pneumatic Actuator Typical Components s ssessssosnsrrernsnrnnrsrrnrrnrrerrnrrnrrnnrnnrnnrnrrnrrnnennnne 4 7 PY8300 Pneumatic Actuator Typical Components s ss ssssosnsnrernsrrnnrsrrnrrnrrsrrnrrnrrnnrnrrnnrnrrnnrnnrnnnne 4 8 Section 5 JASsSeImbly sosasisamivddiditqgesivbdiaxe pepe ete citi eed ERE C KK tne MUS NM Dad Mb us CIS NEU DUNS 5 1 Comer Mig Bnet 5 3 Thermocouple MIS LAILALIOU TEE 5 4 Actuator Installation Hydraulic seeeeseseeseeeeeeeee nenn
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4. 7189071 7192268 7192270 7198740 7201335 7210917 7223092 7238019 724418 7252498 7255555 7258536 7270538 7303720 7306454 7306455 7314367 7320588 7320589 7320590 7326049 7344372 7347684 7364425 7364426 73704177377768 7381050 7396226 7407379 7407380 7410353 7410354 7413432 7416402 7438551 7462030 7462031 7462314 7465165 7470122 7507081 7510392 7513771 7513772 7517214 7524183 7527490 7544056 7547208 7553150 7559760 7559762 7565221 D525592 RE38265 RE38396 RE38920 RE39935 RE40478 Pending 2010 MOLD MASTERS 2007 LIMITED ALL RIGHTS RESERVED gt e Updates are available online at www moldmasters com Mold Za 6 2010 Mold Masters 2007 Limited All Rights Reserved a3 e Revised April 2010 v 2 0 1 2 IVI ters performance delivered Fusion Global Support Section 2 Global Support Mold Masters contacts worldwide visit us online at www moldmasters com Manufacturing Facilities GLOBAL HEADQUARTER CANADA Mold Masters Limited 233 Armstrong Avenue Georgetown Ontario Canada L7G 4X5 tel 1 905 877 0185 fax 1 905 873 2818 info moldmasters com SOUTH AMERICAN HEADQUARTER BRAZIL Mold Masters do Brasil Ltda Rua Hum 1106 e 1126 Jd Manchester Nova Veneza SumarE S o Paulo Brasil CEP 13178 440 tel 55 19 3922 4265 fax 55 19 3922 4266 moldmasters moldmasters com br UNITED KINGDOM Mold Masters UK Netherwood Road Rotherwas Hereford HR2 6JU t
5. Asaoku Kawasaki Kanagawa Japan 215 0032 tel 81 44 986 2101 fax 81 44 986 3145 info mmkk co jp 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 Mold Miasters performance delivered Fusion Regional Offices Con t MEXICO Mold Masters Mexico Av Palmira 407 Villas Palmira Lomas del Marques Queretaro Qro Mexico 76146 Tel 52 442 2456378 egarrido moldmasters com UNITED KINGDOM Mold Masters UK Limited Unit 28 The Gateway Birmingham Airport Birmingham B26 3QD United Kingdom tel 44 121 781 7800 fax 44 121 782 4604 mmuk all moldmasters co uk 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 CZECH REPUBLIC Mold Masters Europa GmbH Hlavni 823 75654 Zubri Czech Republic tel 420 571 619 017 fax 420 571 619 018 cz moldmasters eu International Representatives 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 Finland Oy Scalar Ltd Mestarintie 5 SF 12100 Oitti Finland tel 358 19 783 191 fax 358 19 783 190
6. Revised April 2010 v 2 0 10 1 Masters performance delivered Fusion Troubleshooting Moisture Related Issues Many common molding issues can be directly attributed to moisture contamination of the pro duction resin Generally manufacturing resin is supplied from the manufacturer in ready to process pellets that are in sealed airtight containers Follow manufacturers storage instructions keeping con tainers sealed until ready to use Prior to using pellets follow the drying instructions as provided by the resin supplier and mold ing machine manufacturer if applicable Resin Moisture Contamination Moisture can be introduced into the resin in many ways during transportation environmental exposure aging malfunctioning heater dryer extreme humidity in atmosphere inadequate or malfunctioning facility HVAC Resin Drying Issues During the drying stage of the resin if applicable ensure that the resin pellets are not overpacked adequate air circulation is present 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 sec tion Recyc
7. Reserved 3 1 MI Revised April 2010 v 2 0 performance delivered Fusion GENERAL SAFETY WARNINGS Con t 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 performing 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 installing 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 fittings in good condition to avoid leaks E 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 sufficient length so that they will not strain or pinch when the mold halves separate GENERAL CAUTIONS 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 thermocoup
8. When this hot runner system has been integrated into the mold please ensure that this user manual is forvvarded to the molder end user together with the mold wvvvw moldmasters com Mold Masters and the Mold Masters logo are registered trademarks of an aste g Mold Masters 2007 Limited 2010 MMFSUMO1 performance delivered A iSO 9001 CERTIFIED
9. a time amp check that the temperature responds accord ingly when the set temperature is adjusted Pinch Point Test 1 Ifthere is a suspected pinch point on the thermocouple re move the thermocouple from the hot runner 2 Connect a controller to read the temperature Figure 6 1 Mold Plug 1 Mold Power Connector 3 Immerse the sheath of the thermocouple in boiling water at 2 Thermocouple Connector the point that 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 reading until the pinch point on the thermocouple is immersed in water Heater Continuity Measure the resistance between each pair of heater power wires at the Mold Power Connector Compare your reading with your general assembly drawing Where R resistance V voltage P power ix P Thermocouple Wiring Guidelines e The thermocouples are type J grounded and are color coded to ASA standards White Red e The tip must not be cut or crimped and must touch the bottom of the bore in order to measure the cor rect temperature e Each heat source should have its own closed loop temperature control in order to achieve accurate control e fthere are not enough control zones heat sources that have the same wattage and effect the same environment may be gr
10. at the end of the runner system e Use hot sprue bushing e identify and eliminate dead pockets sections gt ey Updates are available online at www moldmasters com Mold Ee E 2010 Mold Masters 2007 Limited All Rights Reserved Wi p Revised April 2010 v 2 0 10 8 lasters Fusio m C 3 9 Troubleshooting Parts Have Burn Marks The finished product display brown 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 High injection speed Backflow check ring valve malfunctioning High back pressure Mold e rapped or volatile gas e Burning due to friction e ncorrect sprue diameter Material Overheated underheated melt possible shear Solution In sequence 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 gt e Updates are available online at www moldmasters com Mold is 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 10 9 Masters performance delivered Fusion G 2 Troubleshooting Parts are Delaminating The finished product is separating into layers that can be peeled off surface layers are flaking off Insuf
11. at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 10 1 7 Masters Fusion Troubleshooting Parts are sticking to core The finished product does not properly release from the mold male side Probable Cause Molding Machine e Hot core e Bending of core e Presence of vacuum Material _ Generally not a material related issue Solution In sequence 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 Verify mold bending ratio gt T Updates are available online at www moldmasters com Mold Za E o 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 10 1 8 Masters Fusion G 2 Troubleshooting Parts are short The finished product is not completely formed Probable Cause Molding Machine e Bad feed e Low injection pressure e Low injection speed e Short injection time e Back flow valve check ring faulty e Improper venting Insufficient venting Cold mold Material e Low melt temperature e Viscous material Solution In sequence e Increase feed e Increase injection pressure e Increase feed temperature by increasing cylinder temperature e Increase
12. 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 polishil Material 1 e Cold melt Solution In sequence e ncrease injection speed e Increase injection pressure e ncrease melt temperature e Increase mold temperature e Inspect mold surface gt T Updates are available online at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved G Revised April 2010 v 2 0 10 1 6 Masters Fusion 237 Troubleshooting Parts are sticking to cavity The finished product does not properly release from the mold female side Probable Cause Molding Machine e High injection pressure e High injection speed e Long holding time e High material feed Mold e Hot cavity Cold mold e Defective mold surface Material e Melt too hot Solution In sequence 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 gt e Updates are available online
13. gate land length e Wrong gate location Material e Cold melt Solution In sequence e Decrease injection speed e Verify nozzle temperature e Increase mold temperature e ncrease melt temperature e Increase gate size e Modify gate location gt ey Updates are available online at www moldmasters com Mold e 2010 Mold ee ao Limited All Rights Reserved Wi Revised April 2010 v 2 10 14 laste ors Fusion G 2 Troubleshooting Parts are Pitted The finished product contains unmelted particles or small holes on the surface 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 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 gt e Updates are available online at www moldmasters com Mold e M O KM M o M e Sc pm 2010 Mold Masters 2007 Limited All Rights Reserved MI S Revised April 2010 v 2 0 10 1 5 lasters Fusion G 2 Troubleshooting Parts surface is Rough The
14. info scalar fi 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 Turkey MMG Consulting amp Engineering Yesil Gesme Sok No 30 3 Ciftehavuzlar 81060 Istanbul Turkey tel 90 216 357 0783 fax 90 216 385 0656 mmgevrek superonline com Bulgaria Mold Trade OOD 62 Aleksandrovska St Ruse City Bulgaria tel 359 82 821 054 fax 359 82 821 054 contact mold trade com Israel ASAF INDUSTRIES Ltd 29 Habanai Street PO Box 5598 Holon 58154 Israel tel 972 3 5581290 fax 972 3 5581293 sales asaf com Romania International Mold Trade Co SRL Str Constantin Aricescu Nr 21 BI 20 Sc 2 Apt 20 Bucharest Sector 1 Romania tel 4021 230 60 51 fax 4 021 231 78 43 contact matritehightech ro Vietnam Lotus Chemical Technology 393 Dien Bien Phu St Ward 4 Dist 3 HoChiMinh City Vietnam tel 84 8 832 7605 fax 84 8 832 7730 dieuphuoc nguyen lotusfirma com Updates are available online at www moldmasters com 2010 Mold Masters 2007 Limited All Rights Reserved 2 0 Revised April 2010 v 2 0 Global Support SPAIN Mold Masters Espana Serennia Business Center Buenos Aires 37 29 08902 Hospitalet de Llobregat Barcelona Spain tel 34 93 802 36 01 fax 34 93 802 49 08 spain moldmasters eu POLAND Mold Masters Europa GmbH Skr Pocztowa 59 00 908 Warszawa Poland tel
15. injection time e Increase mold temperature e Increase nozzle diameter e Inspect for restrictions e Increase gate size of sprue and runner system a e Updates are available online at www moldmasters com Mold zz uM M M Y V M OO M M QM M M Bo c X pm 2010 Mold Masters 2007 Limited All Rights Reserved MI S Revised April 2010 v 2 0 10 1 9 lasters Fusion 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 Low injection pressure e Short injection time e Insufficient material in cavity e High injection speed e Low back pressure e Damaged backflow valve check ring e Mold not at required temperature e Small gate leading to early freezing e Gate land length too long e ncorrect rib wall dimensions e Material flow incorrect e Thick wall part Material e Hot material e Material wrong grade for application Solution In sequence e Adjust injection speed e ncrease injection hold time e ncrease injection pressure e Adjust melt temperature e Adjust mold temperature e nspect for hot spots e Enlarge and or add vents to mold parting
16. of important information e gt E GENERAL SAFETY WARNINGS A SCH 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 e 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 e Never disable or bypass a safety device e tis highly recommended that all operators wear face shields and use heat resistant gloves when working around the feed throat purging the machine or cleaning the gates of the mold e Check frequently for possible oil leaks water leaks Stop the machine and make repairs e Remove purgings from the machine immediately e Never touch or inspect the timing belt when power is on and motor and controller are connected Unplug the controller before any maintenance e Always cover belt area with proper protecting sheet before any bench test or in mold testing e High Voltage and amperage cables are connected to the controller 220VAC There is also a high voltage cable connection between servo motor and controller e Unplug the controller before performing any maintenance work gt Updates are available online at www moldmasters com Mold a pm 2010 Mold Masters 2007 Limited All Rights
17. 10 24 lasters Fusion G 2 Troubleshooting 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 e Low injection speed e Low injection pressure e Short injection time forward e Low mold temperature e Poor venting e Back flow valve check ring malfunctioning e Gates too far apart e Redesign part Material e Cold melt e Material wrong grade for application Solution In sequence e ncrease injection pressure e Increase injection holding time e ncrease injection speed e ncrease cylinder temperature e Increase mold temperature e Check for venting e Provide an overflow well adjacent to the weld area e Modify the gate location e Decrease gate land length gt e Updates are available online at www moldmasters com Mold e M M M O O B c eee pm 2010 Mold Masters 2007 Limited All Rights Reserved MI S Revised April 2010 v 2 0 10 25 lasters NOTE TO MOLD MAKER This detailed user manual has been prepared to assist in the integration processing and troubleshooting of your Mold Masters System
18. 48 0 66 91 80 888 fax 48 0 66 91 80 208 pl moldmasters eu 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 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 Russia OOO Portmold Gefsimanskie prudy 4 office 2 141312 Russian Federation Moscow region Sergiev Posad tel 007 495 743 48 65 fax 007 496 549 25 26 moldmasters portmold ru E Mold ez Masters performance delivered Section 3 Safety 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 safety procedures and checks not included here in the hot runner specific manual Notices To make the manual easier to use we ve included notices throughout that highlight important information See below SAFETY WARNING Safety warning indicates a potentially hazardous 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 IMPORTANT Important indicates useful additional information or is used as a reminder
19. 7 Limited All Rights Reserved MI S Revised April 2010 v 2 0 7 5 lasters Fusion System Start Up Section 8 System Start Up amp Shut Introduction This chapter explains how to start up and shut down your Fusion Series hot runner system Pre Start up 1 Install the mold into the molding machine NOTE A Ensure the machine nozzle orifice matches or at most is 1 0 mm 0 040 smaller than melt entrance for the hot runner system 2 Connect all water lines and test Water temperature is not to exceed 85 F Water to Fusion Valve Actuators must be turned on before heating is activated 3 Connect all hydraulic pneumatic lines if applicable NOTE Kei After the hot runner system is installed in the molding machine make sure to bleed all the air e out of the hydraulic lines Possible high gate vestige could occur CAUTION Check that the system is heated to processing temperature Failure to do so could cause damage to the valve pins Water must be turned on for Fusion Actuation before turning on temperature controls Actuator water temperature cannot exceed 85 F 4 Test the pin actuation if applicable only if the hot runner is at processing temperature 5 Connect all electrical components Start up WARNING A Assume the system is pressurized and hot at all times Failure to do so can result in a serious injury or death gt e Updates are available online at www moldmasters com Mold e 2010 Mold Mas
20. 738 Pneumatic Cylinder Assembly 1 Install the rod seal RODSEALOS Two Piece De sign 2 Install the piston forming the seal into position 3 Install the wiper seal WS0002 Two Piece Design 4 Install the piston forming the seal into position gt T Updates are available online at www moldmasters com Mold Ee 2010 Mold Masters 2007 Limited All Rights Reserved Wi s Revised April 2010 v 2 0 4 8 lasters on G2 5 Install the piston seals PS0012 Two Piece Design 6 Install the piston top HHPL6HP50N S 7 Torque the piston top 8 Assemble the piston into the cylinder bottom gt T Updates are available online at www moldmasters com Mold Zz pm 2010 Mold Masters 2007 Limited All Rights Reserved MI Revised April 2010 v 2 0 4 9 lasters Fusion 2 A 9 Install the cylinder top seal PNOR2 038 10 Assemble cylinder top to the cylinder bottom 11 Apply anti seize to the SHCS s 12 Install the cylinder top SHCS s 13 Install the Piston Collar to the Mounting Base gt Updates are available online at www moldmasters com Mold a F 2010 Mold Masters 2007 Limited All Rights Reserved G Revised April 2010 v 2 0 4 10 Masters Fusion 52 Series 14 Assemble the cylinder mounting base to the manifold 15 Apply anti seize to the SHCS s 16 Tighten all SHCS s in a crossing pattern 17 Torque all SHCS s in a crossing pattern Upd
21. EE 10 3 Klee 10 3 EE 10 3 Establishing Root Cause ENEE 10 4 FUN EVISTA CVT Ce EVO EE 10 4 Defect types causes and remedies index ENN 10 5 gt T Updates are available online at www moldmasters com Mold T 2010 Mold Masters 2007 Limited All Rights Reserved ii Ma r Revised April 2010 v 2 0 performance delivered Fusion Top wgolo ULezuLo g Section 1 Introduction We would like to take this opportunity to thank you for purchasing a Mold Masters Fusion G2 hot runner 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 Please note that 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 in cluding 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 W
22. Mold Mast 2007 Limited All Rights R d 9 Revised April 2010 v 2 0 id A 9 2 Masters Fusion Troubleshooting Section 10 Troubleshooting Introduction 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 symptom of the underlying problem e Develop a method to isolate the problem Test one item at a time to verify results Monitor the final solution to verify that the problem has been solved Repeat occurrences of the same symptom may indicate other problems Document the solution so that a repeat occurrence can be solved quickly Consult other resources to augment the troubleshooting information in this manual One of the best resources may be your resin supplier NOTE La 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 cloth ing consisting of a protective heat resistant coat and heat resistant gloves Use adequate ventilation for fumes Failure to do so can result in a serious 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 gt e Updates are available online at www moldmasters com Mold e pm 2010 Mold Masters 2007 Limited All Rights Reserved Ana
23. and general assembly drawings Record values for future reference right on the mold is sug gested using a Sharpie style marker 2 Verify centres depth tolerances radii against general assem bly drawings Install Manifold Locator Dowel 1 Using a depth micrometer verify the dimensions of the manifold locator pocket to those specified on print 2 Apply anti seize paste to SHCS 3 Install manifold locator dowel a e Updates are available online at www moldmasters com Mold to 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 7 3 Masters Fusion Eh 9 System Installation System installation Carefully install system into mold ensuring manifold remains level to avoid damage to nozzle wiring Lower system and check system is completed seated with tool 2 Remove installation tool lift bar etc 3 Apply anti seize to system screws and install SCrews 4 Torque system screws in a crossing pattern gradually increasing torque to specified value T Updates are available online at www moldmasters com Mold 2010 Mold ee ao Limited All Rights Reserved Revised April 2010 v 2 7 4 Maste ers Fusion G 2 System Installation 5 Install socket cap srews to secure electrical and solenoid interface to exterior of mold base 6 Install clamp plate gt e Updates are available online at www moldmasters com Mold e 2010 Mold Masters 200
24. arranty and Documentation 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 will include any or all of the following a e Parts list containing all system components Together with the general assembly drawing the D parts list should be referenced when ordering spare parts e General assembly drawing used to integrate your hot runner system into mold e Hot half drawing used to integrate hot half to cavity plate When ordering this manual please reference document number MMFSUM Release Details Release Date Version MMFSUMO2 April 2010 This document has been reviewed by Mold Masters Application Engineering Design Engineering Sales and Marketing Service a This manual should be used in conjunction with any appropriate TempMasterTemperature Controller User Manual gt Updates are available online at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved 1 1 ivi Revised April 2010 v 2 0 performance delivered Fusion Introduction 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 SCAN MASTER STACK LINK are the reg
25. ates are available online at www moldmasters com 2010 Mold Masters 2007 Limited All Rights Reserved 4 11 Revised April 2010 v 2 0 Preparation ws Mold e Mas Taste rss Fusion 2 A 18 Assemble the cylinder to the mounting base 19 Apply anti seize to the SHCS s 20 Tighten all SHCS s in a crossing pattern 21 Torque all SHCS s in a crossing pattern gt e Updates are available online at www moldmasters com Mold Ee d es 2010 Mold Masters 2007 Limited All Rights Reserved Wi p Revised April 2010 v 2 0 4 1 2 lasters Fusion Section 5 Assembly Introduction This section is a step by step guide to assembling your Mold Masters Fusion G2 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 t Heat expa
26. dates are available online at www moldmasters com Mold e 2010 Mold ee ao Limited All Rights Reserved Wi Revised April 2010 v 2 10 1 2 laste ars Fusion gt L Troubleshooting 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 nadequate mold supports e Low clamping force e Damaged mold e Projected area too large for machine capacity Material Low melt viscosity High melt temperature Solution In sequence e Reduce the injection speed e Reduce the injection pressure e Reduce the injection time e ncrease clamping force e nspect the mold for irregularities e Reduce the melt temperature e nspect vent depth e Switch to higher tonnage clamping machine e Establish correct transfer position e Reduce hold pressure gt Updates are available online at www moldmasters com Mold e o 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 10 1 3 Masters Fusion G 2 Troubleshooting Parts surface has Jetting The finished product exhibits serpentine flow patterns on the surface as a result of the melt cooling prior to complete filling of the mold Probable Cause Molding Machine e High injection speed Mold e Cold mold e Small gate e Wrong
27. e gt e Updates are available online at www moldmasters com Mold e uM M M Y D P IO MM O OM S eee pm 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 10 23 Masters Fusion G 2 Troubleshooting Parts are warped The finished product has pressure differences stress on its surface causing the part to be disfigured Probable Cause Molding Machine eWrong cooling time e High injection pressure 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 In sequence 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 ncrease 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 gt ey Updates are available online at www moldmasters com Mold Ee 2010 Mold Masters 2007 Limited All Rights Reserved Wi p Revised April 2010 v 2 0
28. e 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 gt e Updates are available online at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved e Revised April 2010 v 2 0 7 1 Masters Fusion System Installation Manifold Installation Unpacking Carefully open the shipping crate and inspect contents Secure loose items and check for any damage Remove any documentation or spares packages and set aside 2 After removing all restraints attach the sling to the hoist and carefully remove the manifold assembly from the shipping crate 3 Verify all dimensions and tolerances and prepare mani fold for insertion into the mold cavity 4 Prepare mold cavity for Fusion G2 Series manifold insertion Mold type illustrated can be a Spacer Block System or a Manifold Cavity System 5 Clean all surfaces and dowel holes ensuring that no de bris burrs shavings dust dirt or other foreign material which could interfere with measurements exists Ream holes out if necessary mu T Updates are available online at www moldmasters com Miold i 2010 Mold Masters 2007 Limited All Rights Reserved Wi 9 Revised April 2010 v 2 0 7 2 lasters Fusion er System Installation Pre Installation 1 Verify all dimensions tolerances angles taps chamfers etc of the mold against the engineering
29. ed WARNING A A disassembled nozzle should only be connected to an electrical supply when the nozzle has been grounded or a safety isolating transformer is used Ground Shorts Test 1 Use an ohm meter to check for continuity between the Mold Power Connector ground pin metal tabs on side and the manifold steel The ohm reading should be zero 2 Measure the resistance between each pin of the Mold Power Connector See Figure 6 1 and ground mold base The reading should be infinity Occasionally the electric heaters accumulate moisture which can reduce the resistance value to between 100 KQ to 10 MQ The controller should be designed to remove this moisture during start up Never apply full power to a heater if the insulation resistance reading is below 300 KQ Heater resistance above 500 KQ is acceptable Also check this if the mold has not been in use for a number of weeks months 3 f necessary remove excess moisture before placing the heater under full current gt e Updates are available online at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved e Revised April 2010 v 2 0 6 1 Masters Fusion Electrical Testing Thermocouple Continuity Test 1 Measure the resistance between each pair of thermocouple wires on the mold s Thermocouple Connector See Figure 6 1 The resistance should be between 2 5 Q and 25 Q 2 To verify alignment of thermocouple to heater turn ON one zone at
30. ed air in feed e Feed error Mold e Trapped or volatile gas e Low mold temperature e Poor thin thick transition phase e Inadequate venting Material e Overheating of resin Solution In sequence e Verify control and or holding pressure e ncrease back pressure e ncrease mold temperature e nspect back flow valve e Ensure proper venting e Increase gate size e Decrease vent land length gt Updates are available online at www moldmasters com Mold e pm 2010 Mold Masters 2007 Limited All Rights Reserved amn 00 0 0 00 Revised April 2010 v 2 0 10 7 Masters performance delivered Fusion 2 Troubleshooting Parts Have Flow Marks The finished product exhibits blush and flow marks due to variations in material temperature from gradi ents between the machine nozzle and mold sprue bushing 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 and length of gate is too long e ncorrect hot runner system Material e Melt temperature is too low Solution In sequence e Adjust injection speed e Adda large cold slug area e Add cold wells
31. el 44 1432 265768 fax 44 1432 263782 pms pmssystems com Regional Offices AUSTRIA HUNGARY Mold Masters Handelsges m b H Pyhrnstrasse 16 A 4553 Schlierbach Austria tel 43 7582 51877 fax 43 7582 51877 18 office moldmasters at EUROPEAN HEADQUARTER 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 info moldmasters de INDIA Mold Masters Technologies Private Limited 247 Alagesan Road Shiv Building Saibaba Colony Coimbatore T N India 641 011 tel 91 422 423 4888 20 fax 91 422 423 4800 mmiplinfo moldmasters com U S A Mold Masters Injectioneering LLC 103 Peyerk Court Romeo MI 48065 tel 1 800 450 2270 USA tel 1 586 752 6551 fax 1 586 752 6552 info moldmasters com FRANCE Mold Masters France Zl la Marini re 2 Rue Bernard Palissy 91070 Bondoufle tel 33 1 82 05 00 80 fax 33 1 82 05 00 83 mmf info moldmasters eu Updates are available online at www moldmasters com 2010 Mold Masters 2007 Limited All Rights Reserved 2 1 Revised April 2010 v 2 0 ASIAN HEADQUARTER 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
32. electrical box Plumbing cylinders 1 Install hoses per drawing schematic gt y T Updates are available online at www moldmasters com Mold t o 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 5 20 Masters Fusion Electrical Testing Section 6 Electrical Testing Introduction This section contains electrical test procedures for your Mold Masters hot runner system WARNING A To avoid serious burns 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 Contact with heated components may cause serious burns Use a sign in a visible location indi cating Danger Do Not Touch Before performing any electrical work Check that the hot runner is suitably grounded off the temperature controller and disconnect all electrical wires leading from the mold Failure to do so could result in a serious injury or death Wiring Check 2 IMPORTANT JU Ensure that a qualified electrician performs all wiring Check that each wire and thermocouple has a zone number 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 E a P um The electricity mains should only be connected to the injection mold when all electrical connections are grounded and the mold is clos
33. en nennen nnnm nnne nnn nn nnn nnns 5 7 Valve Fm MSTA el METTE 5 9 Aluminum Channel Assembly s ssasnennsnnunnennnnsnnrrnrnrrnnrnnrnrrnrrnrrrrnnrrnrenrenrnrrenrnrrnnrenrnnrnnrnnrnnrnnrnnrnnnnnne 5 11 Section 6 Electrical Testing E 6 1 WIO Bue 6 1 Ground SOS RE 6 1 Thermocouple Continuity Jeer 6 2 PVC tO UT E 6 2 Heater GCOMUNMUILY EE 6 2 gt Cee ce ola a e Bauen AH apNO 20 E Limited All Rights Reserved i Masters Fusion Table of Contents Section 7 System Installation eeeseeeeseeeeseee eene nennen nnne nnn nnn nn nnn nnn nn nnne nna nns 7 1 Assembling the Fusion Series Hor Halt 7 1 Manifold Installation Unpacking nennen nennen nnne nnne nnn nnne nnne nn nnns 7 2 Mold Cavity Preparation secnismcssetr cat isct uve et sues cece Ia Ever e CUIR Or NEOS EIC e Ioa CE Y CUR Du FoU TES EPA TIE E TENE naii 7 3 Section 8 System Start Up amp Shut Down esseeeseseeeeeee nennen nnne nn nnn nnn nnns 8 1 Section 9 Color e Te LE 9 1 Color Change for e Ree NEE WEE 9 1 Color Change for Valve Gate System E 9 2 Locating source of contamination enne nenne nnne nnne nnna nna sana asas asas asa sanae sae nns 9 1 Section 10 TFOUDICSINOO CHING DEE 10 1 Moisture Related leeues AE 10 2 Resin Moisture Contamination enne nennen nnne nnne nein nui rau r aes r series r sean se sna sane sanas 10 2 Resin Ple eM cii EEN 10 2 InmpornanesorFre Drad ROS E 10 2 Pre Molding Precautions EE 10 3 SLOTY EN 10 3 Mig
34. ficient 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 Material _ e Physical contamination of raw material e Chemical contamination of raw material i e Melt too hot poor melt e Incompatible color dye e High percentage of recycled material Solution In sequence 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 gt e Updates are available online at www moldmasters com Mold Ee 2010 Mold Masters 2007 Limited All Rights Reserved Wi p Revised April 2010 v 2 0 10 10 lasters Fusion Troubleshooting Parts Have Dimensional Irregularities The finished product is of a different dimensional value than originally designed or previous production Probable Cause Molding Machine e Low injection pressure 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 e Temperature setting too high e Small gate size resulting in wrong pressure e Incorrect gate location e Incorrect mold configuration size Material e Generally not a mater
35. ge occurring in the hot runner Shut Down 1 Turn OFF all heat to the system 2 Leave the mold cooling system ON including valve actuator water until the hot runner sys tem temperature is within 100 F 377 C of the mold temperature NOTE ke Thermally sensitive materials should be purged from the hot runner system prior to shut down using a thermally stable material with a similar processing temperature For example a system running PVC should be initially started and subsequently shut down on LDPE zz T Updates are available online at www moldmasters com Mold zz 2010 Mold Mast 2007 Limited All Rights R d 9 Revised April 2010 20 heme Lu d 8 2 Masters Fusion eT oJ 0 M Change Section 9 Color Change Introduction This chapter explains how to process your Fusion Series hot runner system Color Change In order to change from one color to another it is necessary to remove all traces of the first color from the injection molding system Refer to the following procedures to assist in performing the color change Before commencing color change review the following warnings WARNING A To avoid serious burns when purging 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 WARNING A N Do not look directly into the feed throat of a hopper Unexpected release of resin may cause serious burns Use a mi
36. ial related issue unless excessive regrind is used Solution In sequence 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 Ch Updates are available online at www moldmasters com Mold e 62010 Mold Masters 2007 Limited AllRights Reserved 40 1201 Masters Revised April 2010 v 2 0 performance delivered f a o 37 Troubleshooting Fusion c Seri ies 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 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 In sequence 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 ncrease mold venting gt T Up
37. istered trademarks of MOLD MASTERS 2007 LIMITED Information contained herein is to our best knowledge true and accurate but all recommendations or suggestions are made without guarantee Since the conditions of use are beyond our control Mold Mas ters disclaims any liability incurred in connection with the use of our products and information contained herein No person is authorized to make any statement or recommendation not contained herein and any such statement or recommendation so made shall not bind Mold Masters Furthermore nothing con tained herein shall be construed as a recommendation 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 mechanical 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 accor dance with technical development without prior notification May be manufactured under one or more of the following U S Patents 4941249 4945630 4981431 5000675 5002480 5007821 5015170 5022846 5028227 5030084 5046942 5049062 5061174 5094603 5106291 5118279 5118280 5122050 5125827 5135377 5142126 5148594 5206040 5217730 5223275 5227596 5227181 5235737
38. ith high temperatures e Solvents denatured alcohol For removal of rust inhibitors Calibrated torque wrench For consistent screw pressure throughout the system Depth micrometer To check bore depths Bluing Compound For checking face contact Sockets e Plastic face hammer Unpacking 1 Carefully remove the system from the shipping box and check that the system is received in good condition and no damage occurred during shipment 2 Check that all mold base dimensions are correct and correspond to Mold Masters general assembly drawings Cleaning All nozzles manifolds and hot runner components must be free of the rust inhibitor applied at the factory 1 Remove protective covers from all gate seals 2 Remove tape from inlet and clean gt T Updates are available online at www moldmasters com Mold E 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 4 2 Masters Hydraulic Cylinder Assembly 1 Install the rod seal RODSEALO6 Two Piece Design 2 Press the seals into the housing e Updates are available online at www moldmasters com 2010 Mold Masters 2007 Limited All Rights Reserved 4 3 Revised April 2010 v 2 0 i Preparation Masters performance delivered on G2 3 Install the rod seal retainer clip RGN130029 4 Install the water circuit pipe plug PP1 16 27 Use pipe sealant on threads 5 Install the piston
39. le 180 degrees 3 Install thermocouple retainer clip Install Heater Retaining Clip 1 Using snap ring pliers expand the clip and install into snap ring groove on nozzle core T Updates are available online at www moldmasters com 2010 Mold Masters 2007 Limited All Rights Reserved Revised April 2010 v 2 0 Mold 5 6 Masters performance delivered Fusion 32 Assembly System Assembly Assembly of Nozzle to Manifold 1 Follow pre assembly checks mentioned ear lier in the section 2 Apply anti seize to nozzle threads 3 Assemble nozzle to manifold Torque nozzles to specified value Manifold Locator Installation 1 Apply anti seize to socket head cap screws SHCS 2 Install manifold locator to manifold and torque SHCS to specified value gt e Updates are available online at www moldmasters com Mold e TE OM M A dM O o o EIE X 1 pm 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 5 7 Masters P Ci Fusion 52 ies s e n mm ay Assembly 3 Verify height of manifold locator to specified print di mension Install Support Bushings 1 Apply anti seize to SHCS 2 Install support bushing to manifold and torque SHCS to specified value 3 Repeat for other suppo
40. le extension cables They are not designed to carry the power load or list accurate temperature readings in each other s application To maximize heater element and component life the temperature must be controlled and maintained within safe operating limits Mold Masters strongly recommends individual control of each heated component including heater plates with a reliable temperature con troller that includes soft start protection All Mold Masters heated components are manufactured to standards that ensure safe and reliable operation provided that the following precautions are met Always operate the system using correctly installed J type thermocouples connected to a reliable temperature controller with soft start protection Avoid running the system for long periods on manual control Use caution when applying power in manual mode Use minimum heat required for the process to avoid overheating and possible damage to components Always replace pinched or damaged thermocouples When grouping heated components together and controlling more than one load from a single thermocouple make sure that the components are of similar material wattage size and are exposed to the same thermal conditions When replacing heater plates or other heated components always replace with genuine Mold Masters components of the same type and install as originally specified on Mold Masters general assembly drawings gt T h Update
41. led resins can have higher hygroscopic properties 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 pages gt T Updates are available online at www moldmasters com Mold e E 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 10 2 Masters Fusion 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 production History Review any documentation associated with your batch job regarding the recipe using the mold molding machine thermoplastic resin environmental setting etc Review comments notes logbooks blogs and anything other resource material that per tains to the batch job Verify that all settings such as all time temperature pressure material etc are correct Material 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 Verify that the pigment dye to be used meets manufacturers specifications and is compatible with the resin molding machine mold Verify the correct recycle ratio and adjust settings accordingly Hardware Make sure the mold has been properly stored and is dry clean free of rust dirt moisture resid
42. line e Increase sprue or runner size e Increase gate size reduce gate land length e Relocate gate closer to heavy thicker areas e f possible core out heavy wall sections gt T Updates are available online at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 10 20 Masters Fusion Troubleshooting Parts display splay The finished product display splay splash marks and or silver streaks Probable Cause Molding Machine Material Ps e Resin degraded from overheating e Cylinder contains hot spots e Material trapped at nozzle tip e Wrong injection pressure e Wrong injection speed e Low back pressure e Friction related burning in gate nozzle or hot runner e Trapped volatile compounds e Hot melt e Contaminated resin moisture dirt organics e Degraded resin Solution In sequence e Dry resin according to procedure check drying equipment for functionality e Reduce nozzle temperature 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 gt e Updates are available online at www moldmasters com Mold e 2010 Mold Mas
43. ng pattern gradually increasing torque to specified value gt e Updates are available online at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 5 17 Masters Wiring Attach Wire Armor to Side of Manifold 1 Apply anti seize to button head cap screws bhcs 2 Install bhcs screws through appropriate slot in wire armor 3 Add spacer 4 Install assembly to manifold Wiring 1 Group thermocouple and heater wires for a single zone together and install high temp wire sheathing 2 Label all heater and thermocouple zones gt T Updates are available online at www moldmasters com Mold Ee 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 5 1 8 Masters 3 Use heat resistant tape to tape group thermocou ple heater zones together to avoid losing labels 4 Repeat for all zones Electrical Routing into Electrical Box 1 Install thermocouple and heater wires into electri cal plugs per wiring schematic 2 Install plugs into electrical box a e Updates are available online at vvvvv moldmasters com Miold 2010 Mold Masters 2007 Limited All Rights Reserved Wi 9 Revised April 2010 v 2 0 5 19 lasters 4 4 N h n b v mn UI SION J Assembly Solenoid Valve Wiring 1 Install solenoid coil wires into electrical plugs per wiring schematic 2 Install plugs into
44. nlet and manifold 6 Re install inlet Torque screws in a crossing pattern gradually increasing torque to specified value 7 Blue the inlet seal and verify blued surfaces to check fit of seal in the inlet a e Updates are available online at www moldmasters com Mold to 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 5 11 Masters gs m aa RU ii m e D c Series 8 Clean blue from inlet seal and inlet 9 Install inlet heaters and sleeves per specified drawing 10 Apply anti seize to threads and install inlet seal to inlet 11 Torque to specified value gt T Updates are available online at www moldmasters com Mold a 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 5 12 Masters Fusion CS 2 Assembly Install inlet thermocouple 1 Install thermocouple into slot until bottoms out 2 Bend 180 degrees 3 Install thermocouple clip Install valve bushing 1 Blue valve insert a e Updates are available online at www moldmasters com Mold zz uM M M M M HMM PH D A o EEE E pm 2010 Mold Masters 2007 Limited All Rights Reserved MI S Revised April 2010 v 2 0 5 1 3 lasters Fusion G 2 Assembly 2 Install
45. nsion of the nozzle must also TS a be taken into consideration 566 0 MIN Contour of gate seal should be done at process temperature E 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 Figure 5 1 Hot Valve Hot Sprue Gated System Polymer Structure Contact Length H Amorphous Filled or Reinforced Semi crystalline Filled or Reinforced 3 00 Crystalline Filled or Reinforced 2 00 gt e Updates are available online at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved e Revised April 2010 v 2 0 5 1 Masters Fusion C gp P Assembly Pre Assembly Checks of Gate Seals amp Nozzle Blue off the gate seal and liner if relevant to ensure a proper contact on sealing surface Note the following example shows gate seal with a liner 1 Apply die blue to the gate seal and gate seal liner if rel evant 2 Torque the gate seal to specified value 3 Remove gate seal and verify transfer of die blue from gate to the liner Verify transfer of die blue to nozzle core If not 100 blue on face contact your Mold Masters repre sentative 4 Clean die blue from components T Updates are available online at www moldmasters com 2010 Mold Masters 2007 Limited All Righ
46. ouped together Heating Test with a Temperature Controller 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 e Stay with the system and monitor the initial heating to minimize risk gt T Updates are available online at www moldmasters com Mold e Tee RR E SSS a a EE 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 6 2 Masters Fusion System Installation Section 7 System Installation Introduction The following section is a step by step guide to install your Mold Masters Fusion G2 Series hot runner into the existing Manifold Plate System or Spacer Block System Assembling the Fusion G2 Series System NOTE iu Refer to the general assembly drawings for instructions Ke il 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 1 Attach a crane that is rated to adequately support the weight of the cavity plate 2 Check that all wires are retained CAUTION Do not assemble 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 groves Failure to do so can cause lost production due to hot runner down time WARNING Make sure the machin
47. r back off the injection unit purge and introduce the new color zi Start molding the new color until the majority of old color has been removed from the hot runner system 3 Back off the injection unit and switch off all heats on the hot runner system CAUTION Do not activate the valve gate while purging or feeding the barrel unless the hot runner sys tem has reached normal processing temperature 4 Allow the hot runner system to cool down Leave mold water cooling actuator cooling on This pulls old material away from the runner walls and allows new and old color to mix 5 Heat up the system and start molding Locating the Source of Contamination by a Previous Color 1 Purge the original color from the machine following the instructions in Color Change for a HotTip Sprue System Color Change for a Valve Gate System 2 Load the hopper with a 2nd color different from the intended color 3 Continue to purge until no trace of the 1st color appears 4 Shut off the hopper and continue to remove the 2nd color following the instructions above 5 Load the hopper with the 3rd and final intended color 6 Purge the 3rd color through the injection unit to clean the injection unit of the 2nd color Continue to purge until no trace of the first color appears 7 If the 2nd color appears in the molded product then the problem is in the injection unit T Updates are available online at www moldmasters com Mold zz 2010
48. rror Failure to do so may cause serious injury A WARNING Never handle plastic purgings or drool until they have completely cooled Purgings may ap pear solid but may still be hot and cause serious injury Color Change for a HotTip Sprue System 1 System is up amp running with one color 2 Back off machine barrel purge and introduce new color 3i Increase hot runner system temperature on all zones 30 40 F above processing tempera tures 4 Increase injection speed 5 Run 10 15 shots 6 Back off injection unit and switch off all heat on the hot runner Leave Mold cooling on 7 Allow hot runner system to cool down This pulls old material away from runner walls 8 Turn ON the hot runner system and heat to processing temperature 9 Bring machine barrel back in 10 Increase injection speed and mold temperature until color change is acceptable 11 Continue processing while resetting hot runner system temperatures and injection speed 7 Updates are available online at www moldmasters com Mold 1 EE Limited All Rights Reserved 9 1 Masters Fusion eo 0 M Change WARNING A Some plastics develop gases that may be dangerous to personal health Follow the plastics supplier s recommendations Review their material safety data sheet Ensure the molding area Is well ventilated Failure to do so can result in a serious injury or death Color Change for a Valve Gate System 1 When the system is up and running with one colo
49. rt bushings typical application will require 1 support bushing per nozzle Revised April 2010 v 2 Updates are available online at wwws emoldmasters com 2010 Mold ee ao Limited All Rights Reserved 5 8 Mold Z Mas ers performance delivered Fusion Assembly 4 Verify height of support bushing and manifold locator to print specifications Install Manifold Thermocouple 1 Ensure thermocouple holes in manifold are clean and free of blockage 2 Install manifold thermocouple into manifold thermo couple hole until it bottoms out in the hole 3 Bend thermocouples into slot gt e Updates are available online at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved e Revised April 2010 v 2 0 5 9 Masters Fusion 52 Assembly 4 Install manifold ground strap and thermocouple reten tion screw combination Install Inlet 1 Apply die blue to bottom of inlet 2 Apply anti seize to SHC screws and install inlet to mani fold 3 Torque screws in a crossing pattern gradually increas ing torque to specified value mu T Updates are available online at www moldmasters com Miold 2010 Mold Masters 2007 Limited All Rights Reserved Wi 9 Revised April 2010 v 2 0 5 10 lasters Fusion j Assembly 4 Remove inlet to verify blued surfaces If not 100 blue on face contact your Mold Masters representative 5 Clean the die blue from the i
50. s are available online at www moldmasters com Mold KA 2010 Mold Masters 2007 Limited All Rights Reserved 3 2 MI Revised April 2010 v 2 0 E performance delivered Fusion Section 4 Preparation Introduction The following section is a step by step guide to preparing your Mold Masters system for use Screw Lengths A WARNING The use of an incorrect size length and grade screw could cause the screw to shear fatigue or stretch beyond its yield point resulting in expensive downtime of the hot runner Be aware of warnings placed on the assembly drawings When the manifold is heated the metal expands stretching the mounting screws if screw lengths are shortened there is a pos sibility of shearing The expansion factor is calculated into the length of each screw size WARNING DO NOT SHORTEN SCREW S H C S M10 ISO GRADE 12 90 ASTM A574 NOT SUPPLIED B MOLD MAST amp R gt e Updates are available online at www moldmasters com Mold e oo 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 4 1 Masters Fusion Tools Required Depending on the size and complexity of your hot runner system you will require most of the tools and materials listed below Allen keys Set of imperial size keys and metric sizes for use on both imperial and metric cap screws depending on system Anti seize compound To prevent oxidation of screw threads that could cause screws to seize w
51. s are available online at www moldmasters com c e ers 2010 Mold Masters 2007 Limited All Rights Reserved 40 5 z Revised April 2010 v 2 10 5 Mas rs erforma t er red Fusion G 2 Troubleshooting Parts Have Dark Specks The finished product contains dark particles When transparent resins are usually used Probable Cause Molding Machine e Off line for extended period e Barrel offline for extended period e Barrel improperly purged e Contamination in plasticizer e Wrong nozzle e Use of wrong screw 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 In sequence e Purge system with appropriate material e race source of contamination and repair remove or discard e Adjust melt temperature if necessary e nspect for dead spots gates runners nozzle back flow valve e nspect feed screw for degradation gt e Updates are available online at www moldmasters com Mold Ee 2010 Mold Masters 2007 Limited All Rights Reserved Wi p Revised April 2010 v 2 0 10 6 lasters Fusion Troubleshooting Parts Have Blisters and or Bubbles The finished product contains small gas or air filled pockets or cooling voids Probable Cause Molding Machine e Low Injection Pressure e Back flow valve malfunctioning e Suck back cycle too long e Rapid plasticizing e Trapp
52. seals P50003 Three Piece Design Z T Updates are available online at www moldmasters com Miold 2010 Mold Masters 2007 Limited All Rights Reserved Wi 9 Revised April 2010 v 2 0 4 4 lasters Fusion 22 A 6 Install the valve pin 7 Install the valve pin spacer SPACER42 8 Install the piston top HHPL6HP50N S 9 Torque the piston top gt p E Updates are available online at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved e Revised April 2010 v 2 0 4 5 Masters Fusion 52 10 Install the cylinder top seal PNOR2 129 11 Install the cylinder bleeder valve NIP PLEMS8X1 12 Assemble the piston into the cylinder bottom 13 Assemble cylinder top to the cylinder bottom 14 Apply anti seize to the SHCS s gt T Updates are available online at www moldmasters com Mold Ee E 2010 Mold Masters 2007 Limited All Rights Reserved Wi s Revised April 2010 v 2 0 4 6 lasters on G2 15 Install the cylinder top SHCS s 16 Assemble the cylinder to the manifold 17 Apply anti seize to the SHCS s 18 Tighten and torque all SHCS s in a crossing pattern Fusion G2 Pneumatic Cylinder Components w Anti Rotation gt T Updates are available online at www moldmasters com Mold a pm 2010 Mold Masters 2007 Limited All Rights Reserved MI s Revised April 2010 v 2 0 4 7 lasters Fusion 2 TT 777777
53. ters 2007 Limited All Rights Reserved e Revised April 2010 v 2 0 10 21 Masters Fusion G 2 Troubleshooting Parts are streaked The finished product has large dull and laminate appearance areas on the surface Probable Cause Molding Machine e Back flow valve ring damaged e Hot spots e Material trapped in certain areas Material e Contamination of resin or machine If pattern is identical cause may be the machine If pattern is erratic cause may be the material or Degraded or unstable material Solution In sequence e Check for contamination e Check barrel purging e Inspect back flow ring for wear or cracks e nspect feed screw for wear and tear e Inspect screw barrel for tolerances e Verify heater operation e Verify thermocouple operation gt T Updates are available online at www moldmasters com Mold e 2010 Mold ee ao Limited All Rights Reserved Wi 9 Revised April 2010v2 10 22 laste c S Fusion 27 Troubleshooting Parts are stringing The finished product have thin plastic strings attached to the sprue Probable Cause Molding Machine e High back pressure e High nozzle temperature e Incorrect sprue Material Ee e Melt strength inadequate Solution In sequence 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 gat
54. ters 2007 Limited All Rights Reserved e Revised April 2010 v 2 0 8 1 Masters Fusion System Start Up NOTE 1 When running thermally sensitive materials use a thermally stable material as recommend ed 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 Fusion Valve Gate Actuator water must be on Maximum inlet water temperature not to exceed 85 F Machine barrel is up to processing temperature Mold cooling is on and at cooling temperature 3 Heat up the hot runner system to processing temperature Wait until ALL heating zones reach processing temperature before continuing t WARNING amp When the mold is open never inject material through hot runner system under high pressure Failure to do so can result in serious injury or death 4 Start up only for empty hot runner system Extrude material through the hot runner system using 200 PSI 14 bar of back pressure 5 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 runner interface 6 Set injection time and pressure in coordination to part size gate size and material NOTE a For hot runner systems using heater plates allow 20 minutes of soak time after the system reaches processing temperature CAUTION E Failure to follow the above procedure may result in leakage dama
55. ts Reserved 5 Revised April 2010 v 2 0 T Mold e Masters performance delivered Fusion I Assembly Blue off nozzle core to manifold 1 Inspect threads for burrs 2 Apply die blue to nozzle core 3 Apply anti seize to threads 4 Assemble nozzle to manifold and torque to specified value gt Updates are available online at www moldmasters com Mold e p 2010 Mold Masters 2007 Limited All Rights Reserved mp 99 0 0 0 0 0 Revised April 2010 v 2 0 5 3 Masters performance delivered 5 Verify transfer of die blue from nozzle core to manifold 6 Clean die blue from components Assembly of Gate Seals to Nozzle 1 Apply anti seize paste to all threaded interfaces 2 Ensure all sealing surfaces are clean and dry gt Updates are available online at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved O Revised April 2010 v 2 5 4 Masters performance delivered Fusion 32 Assembly 3 Install gate seal and liner 4 Torque to specified values Nozzle Assembly Install nozzle heaters and sleeves 1 Install heaters and sleeves per specified drawings Install thermocouple 1 Insert thermocouple into slot until bottoms out gt e Updates are available online at www moldmasters com Mold e 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 5 5 Masters 2 Bend thermocoup
56. ual resin pigment and any protective coating Check that the temperature controller meets requirements and is fully tested and operation al The injection molding machine has been properly maintained cleaned lubricated tolerances and dimensions verified Make sure that the nozzles cylinders valves gates and any other variable that is appropriate for the batch job has been chosen Settings Ensure that all batch job parameters are correct Temperatures Pressures Injection Speed Back Pressure gt e Updates are available online at www moldmasters com Mold Zz GE E Limited All Rights Reserved 10 3 Masters Fusion Troubleshooting 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 specifications A sudden change in any parameter indicates a possible fault Rather than modify other settings to compensate for this variation it is advisable to determine which of the original settings has changed Fault Identification The operator will need to evaluate all the possible conditions which may have caused the defect Identify the problem
57. valve insert into valve nut 3 Apply anti seize to the SHCS s 4 Install the SHCS s in a crossing pattern 5 Remove valve bushing and verify blue on all surfaces 6 Clean bluing from all components 7 Install and torque in a crossing pattern 8 Install valve pin to verify fit gt e Updates are available online at vvvvw moldmasters com Mold e ee E E SS SSS EE As 2010 Mold ee ao Limited All Rights Reserved Wi p Revised April 2010 v 2 5 14 laste aed DPA Assembly Install Cylinder to Manifold Pneumatic 1 Install pneumatic cylinder mounting plate to mani fold 2 Apply anti seize paste to SHCS 3 Torque screws in a crossing pattern gradually in creasing torque to specified value 4 Place cylinder housing onto cylinder mounting plate e Updates are available online at www moldmasters com Mold t 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 5 1 5 Masters Fusion 32 Assembly 5 Insert valve pin into piston 6 Apply anti seize paste to piston top 7 Install piston top into piston 8 Install piston into cylinder housing gt T Updates are available online at www moldmasters com Mold 2010 Mold Masters 2007 Limited All Rights Reserved 9 Revised April 2010 v 2 0 5 1 6 Masters 9 Install cylinder top o ring 10 Install cylinder top 11 Apply anti seize paste to SHCS and torque screws in a crossi
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