Section 15 - Melt-Disk System - Mold
Contents
1. Figure 5 26 Securing the Cover Plate 4 Flip assembled hot half over Use appropriate sized wooden blocks to rest hot half to prevent damage to nozzles and other components WARNING Make sure the lifting eyebolt chain and crane can support the weight of the manifold Fail ure to do SO may Cause serious Injury 5 Attach connector pins ends to each wire and crimp Configure electrical connector as specified in engi neering print Figure 5 27 Electrical Connector Assembly Assemble Melt Disk to Nozzle 1 Assemble Melt Disks onto the nozzles according to mold design 2 Ensure the sharp edge of the melt link does not get damaged Figure 5 28 n P Hot Runner User Manual Revision 12 Mold Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwv moldmasters com 1 5 1 5 Miaster Specialty Systems Melt Disk Melt Disk System Start Up amp Shut Down Also refer to Section 8 System Start Up amp Shut Down and the MZ TempMaster Series Controller manual Start Up NOTE gt When running thermally sensitive materials use a thermally stable material as recomend 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 e Machine barrel is up to processing temperature e Mold cooling is on and at cooling temperature 3 Heat Manifold2. Caution indicates that damage to equipment is possible NOTE a Important indicates useful additional information or is used as a reminder for important i information p Hot Runner User Manual Revision 12 File Mold Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwv moldmasters com 1 5 1 Master Specialty Systems Melt Disk System with cast in heater element Insulation Board Leader Pins Top Clamp Plate Jiffy Plugs ane dbe o Pressure Disk a Center Heater Manifold CF a Electrical Box Nozzle Leader Bushing P Retainer Melt Transfer m a Disk Link i Transfer Seal Torpedo Tip L jy z Melt Disk ab Locator Hot Runner User Manual Revision 12 Mold Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwe moldmasters com 1 5 2 Specialty Systems Melt Disk Hot Half Pre Assembly Melt Disk Preparation Cleaning All nozzles manifolds and components must be free of the rust inhibitor applied at the factory 1 Disassemble the Melt Disk assembly 2 Wipe down Melt Disk 3 Remove the part and wipe clean If necessary use a cotton swab to clean narrow interior surfaces or screw threads For larger surfaces such as mold plates use thinner in spra
3. May be revised without notice 05 2010 Masters Electronic version is available at wwwe moldmasters com 1 5 1 6 Specialty Systems Melt Disk Master Disassembly for Maintenance NOTE Before shutting down the molding machine and mold use maximum screw decompression to remove as much molten plastic from the hot runner system as possible 1 Disassemble mold to expose the Melt Disk Plate insert removal to be done with all components in the cold condition 2 Melt Disks should be heated to 250 280 F before removal The Melt Disk should be removed as soon as it reaches set point The EXTOOLASO1 can be used to assist with the Melt Disk removal Melt Disk Reassembly after Maintenance 1 All sealing surfaces are to be clean and inspected for defects 2 The inside bore of the Melt Disk is to be free of material so that when it is installed to the Melt Link there is no interference 3 The Melt Disk is to be installed cold onto a cold Melt Link k Pam Hot Runner User Manual Revision 12 Mold Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at www moldmasters com 15 17
4. zones amp Inlet to processing temperature 4 Heat Melt Disks to processing temperature 5 Heat Nozzles to processing temperature A small amount of material may weep at this stage 6 Allow to heat soak at least 10 minutes 7 Fill system under low pressure extrude using screw rotation 8 Set Melt Disk temperature at least 10 F lower than nozzles NOTE LA For hot runner systems using heater plates allow 10 minutes of soak time after the system reaches processing temperature CAUTION E Failure to follow the above procedure may result in leakage damage occurring in the hot runner WARNING A When the mold is open never inject material through hot runner system under high pres sure Failure to do so can result in serious injury or death Shut Down NOTE 1A For horizontal tips refer to the MZ Controller operating manual 1 Maximize decompression stroke prior to shut down This will minimize drool at start up when there is limited gate cooling 2 Reduce Nozzle temperatures to 300 F 150 C 3 Reduce Melt Disk temperatures to 300 F 150 C 4 Turn off all zones NOTE 1A 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 exam ple a system running PVC should be initially started and subsequently shut down on LDPE 5 Hot Runner User Manual Revision 12 Willd Not under documentation control if printed
5. 5 1 2 zy Specialty Systems Melt Disk Master Installing the Manifold Thermocouple 1 Although not necessary a thermal compound may be applied to the thermocouple tip to ensure a good contact Insert the thermocouple into the bore Check that the thermocouple is touching the bottom of the hole Press down on the thermocouple and gently bend the thermocouple sheath 90 Check that the thermocouple sits in the manifold cutout Install the thermocouple washer and screw Install a zone number on each wire and thermocouple Organize and tape together wires for each zone and plug O ND oO A WN Feed the wires back through the wire channel in the mold base to the electrical box and secure with wire retainers Figure 5 23 Thermocouple Installation 1 Thermocouple 2 Screw 3 Washer 4 Assembly Manifold Center Heater Optional 1 Attach Back Plate to Manifold Plate as follows a Snug up each fastener but do not tighten b Once all fasteners are snug torque each to 20 ft Ibs 2 Place the Center Heater over the Back Plate Attach the Cover plate and torque to 20 ft Ibs Run the wires through the appropriate channel into the Electrical Box Figure 5 24 Heater and Back Plate Assembly Hot Runner User Manual Revision 12 Wiolgd a b j _ Not under documentation control if printed May be revised without notice 05 2010 Mas rs Electronic version is available at www moldmasters com 1 5 1 3 Specialty Sy
6. Eas eee oe Master Section 15 Melt Disk System Vielt Disk Introduction We would like to take this opportunity to thank you for purchasing a Mold Masters Melt Disk system The purpose of this manual is to assist users in the integration operation and maintenance of Mold Mas ters systems This manual is designed to cover most system configurations For additional information please contact your representative or a Mold Masters office Safety Please see Section 3 for important safety information The responsibility for the safety of personnel remains exclusively with the employer It is the obligation of the employer to properly train and instruct its personnel in the safe operation of equipment including maintenance and the purpose and proper use of all the safety devices In addition the employer must provide its personnel with all necessary protective clothing including such items as a face shield and heat resistant gloves Any instructional material provided by Mold Masters for the operation and maintenance of equipment does not in any way absolve the employer from fulfilling these obligations and Mold Mas ters disclaims liability for injury to personnel using equipment supplied Notices Notices throughout this manual indicate additional information that must be performed or observed WARNING Safety warning indicates a potentially hazardous situation which if not avoided could result in serious injury or death CAUTION
7. er documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwe moldmasters com 1 5 8 Specialty Systems Melt Disk Master Manifold Cavity Preparation Con t 2 Calculate Pressure Disk height d a b c air gap This is the value d that s required for correct assembly Refer to the General Assembly Drawing for reference values such as the air gap 3 The actual height thickness of the supplied Pressure Disk e will be of a value that s higher than the value d Calculate the difference and then divide by 2 This is the value that will need to be ground from each side of the Pressure Disk Pressure Disk Details 1 Install the manifold to the nozzle 2 Refer to the general assembly drawing for pres sure disk dimensions before calculating the pres Grind Bae sure valve disk height Equal Sharp 3 Pressure disks are supplied oversize in height Amounts Corners grind equal amounts from each side to cold clearance and retain maximum strength of the V form Some systems require a larger air gap Refer to the General Assembly drawing 4 Remove the sharp corners after grinding and clean the disk well to ensure no grinding dust remains on the disk Figure 5 16 Pressure Disk Details 5 Install the pressure disk spring dowel to the manifold 6 Install the pressure disk to the manifold Example Calculations Nozzle Bore De
8. evel in the cold condition For other systems there Is a long distance between the manifold locator and the nozzles and the mani fold locator needs to be higher than the nozzles approximately 0 03 mm Before grinding the manifold locator it is strongly advised to check the GA drawing FE Me EN 17 ST fe a e Fi j ol aA pes ATF Ni Figure 5 18 Nozzle Insertion 3 Feed the wires back through the wire channel in the mold base to the Mold Plug Do not cut the wires until the remaining components are installed i aad 4 i 4 a a Figure 5 19 Manifold Locator Adjustment Hot Runner User Manual Revision12 Wiolg Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwes moldmasters com 1 5 1 0 Specialty Systems Melt Disk er Electrical Box Preparation 1 Use washers to offset the electrical box from manifold plate This prevents the top plate from bumping into the electrical box during assembly Feed all wires through as shown Trim the wires back noting the number tags assigned to each wire Do not cut these tags off Figure 5 20 Electrical Box Mounting Detail Final Mold Plate Assembly 1 Using appropriate tools place the Manifold into the Manifold Cavity of the Manifold Plate as shown below Ensure that no electrical or thermocouple wires are pinched frayed or bent Backplate a
9. igure 15 11 2 Thread the Melt Link into the nozzle 3 Torque Melt Link COLD to value specified in the l Figure 15 12 General Assembly Diagram 2 Hot Runner User Manual Revision 12 Wold Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwwe moldmasters com 1 5 7 Master Specialty Systems Melt Disk Manifold Cavity Preparation 1 Calculate the following dimensions at ambient room temperature a Measure the depth of the nozzle bore a from the top of the Manifold Plate to the Nozzle Sup port Base aih EN i Figure 5 13 Calculating Nozzle Bore Depth a b Measure the top section of the nozzle flange b ar a i j A i 7 T Ja 1 f a A Nor one jin o Pail a om ae 9 k 4 Pal g p y i e ATS 7 F E a _ 1 y 2 li a i T Wh Wh j i i s i Th E a z i i a s m Figure 5 14 Calculating Nozzle Flange Height b 4 LLA c Measure the Manifold thickness c Figure 5 15 Calculating Manifold Thickness c b Hot Runner User Manual Revision 12 Wiola _ T EEE eee y 7x lt L gt E __ lt gt lt gt gt gt EEEES gt gt gt gt S gt gt gt gt _ Z _ __aa z z amp gt _K amp z Ke i a eES EEE _ Not und
10. nd heater assembly shown already assembled Normally assembled at a later step 2 Secure wires to the Manifold Plate using wire retainers Figure 5 21 Inserting Manifold into Manifold Plate WARNING Make sure the lifting eyebolt chain and crane can support the weight of the manifold f Failure to do so may cause serious injury b Fa 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 1 5 11 Master Specialty Systems Melt Disk series Final Mold Plate Assembly Con t 3 If required attach a crane of sufficient lifting capacity to the manifold 4 Place the manifold on top of the nozzles and locator 5 Place Pressure Disks machined to proper thickness as detailed in section Manifold Cavity Preparation atop the Manifold 6 Connect Ground Wire and Manifold Thermocouple Figure 5 22 Manifold Preparation System Screw Torques Quality and length of screws must be as specified on Mold Masters general assembly drawings Torque Can for System SEeMHIY Screws Exception Bridge manifold mounting screws should be torqued 1 3 higher than specified on GA drawings Hot Runner User Manual Revision 12 Mold Not under documentation control if printed May be revised without notice 05 2010 MVMaste rs Electronic version is available at www moldmasters com 1
11. pth a 91 39 mm Nozzle Flange Height b 43 16 mm Manifold Thickness c 43 16 mm Air Gap as noted on drawing 00 05 mm Pressure Disk Height d 91 39 43 16 43 16 0 05 5 02 mm Supplied Pressure Disk e 5 10 mm Difference between supplied Pressure Disk e and required Pressure Disk d 5 10 mm 5 02 mm 0 08 mm Material to be removed from each side of the Pressure Disk 0 08mm 2 0 04 mm Nozzle bores and pressure disks must be within tolerances specified in the General Assembly drawing b P Hot Runner User Manual Revision 12 File Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwv moldmasters com 1 5 9 Specialty Systems Melt Disk Final Assembly of the Manifold Plate 1 Insert each prepped nozzle into the nozzle cavities Make sure the wires are not bent or pinched any where Place a zone number on each wire and thermocouple Group and tape wires for each zone and plug Feed all wires through the wire channels towards the electrical box channel EA NOTE Check GA drawing for information for your system 2 For some systems locators are supplied oversize SURFACE A SURFACE B X and must be ground to the same level as the E a a top of the nozzles Remove the material from the i SNA bottom face of the locator FACE Y This will allow SURFACE A and SURFACE B to be at the same l
12. stems Melt Disk Final Assembly 1 Rub a small amount of High Temperature Grease on the Clamp Plate guide pins and lower onto Mani fold plate Ensure no wires will be pinched WARNING Make sure the lifting eyebolt chain and crane can support the weight of the Clamp Plate Failure to do so may cause serious Injury 2 Dab anti seize compound on tip of the fasteners Tighten from the center of the plate out towards the edges Figure 5 25 Securing the Clamp Plate F Hot Runner User Manual Revision 12 Wliolag lt lt lt lt lt i i XT TTTX lt a aXK K z __ _ K E_K__K_ _ _ gt C i lt lt lt i C K z amp K amp lt lt amp lt _ _ amp amp amp amp amp amp amp lt lt lt lt lt lt amp amp gt gt gt _ O SESE gt EE E ES p p B BEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEqqx amp amp X amp YXxXXxK K K KZ Zxz XKX XY Uu KXu 65 ix E y vx_ x_ a axxX E EEX X j _ Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwe moldmasters com 1 5 14 Specialty Systems Melt Disk er j 3 Torque each fastener to value specified for Plate Assembly Screw on the General Assembly Drawings Attach the locating ring and tighten a aE oa
13. tems Melt Disk Master series Nozzle Thermocouple Assembly 1 Although not necessary a thermal compound may be applied to the tip of the thermocouple 2 Connect the thermocouple as specified in the General Assembly diagram See also Assembly Section 5 Melt Disk Thermocouple Assembly 1 Remove the thermocouple retaining screw from the Melt Disk 2 Insert the thermocouple tip into the thermocouple hole Thermocouple must bottom in hole 3 Bend the thermocouple back 90 f Figure 15 7 Hot Runner User Manual Revision 2 Wold Not under documentation control if printed May be revised without notice 05 2010 Vas ers Electronic version is available at www moldmasters com 15 5 Master Specialty Systems Melt Disk 4 Secure the thermocouple with the screw from 1 1 5 Use heat resistant tape to secure the nozzle wires and thermocouple wires just above the insulator pod 6 Prepare all remaining Melt Disks the same way Figure 15 9 and set aside Figure 15 10 F Hot Runner User Manual Revision 12 Wiold 7 C7 i 1 Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwv moldmasters com 1 5 6 Specialty Systems Melt Disk Master Assembly of Melt Link to Nozzle 1 Anti seize the threads of the Melt Link using Mold Masters supplied compound F
14. y form to clean channels and recesses Figure 15 1 Cleaning Parts 4 Anti seize the threads of the Gate Seals using Mold Masters supplied compound Figure 15 2 Anti Seize Compound Application b pm Hot Runner User Manual Revision 12 fy Haml Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwv moldmasters com 1 5 3 Specialty Systems Melt Disk 5 Insert the pointed end of the tips torpedoes into the threaded end of the Gate Seal ie z fr k iy Figure 15 3 Assembling Gate Seal 6 Thread the Gate Seal Assembly into the Melt Disk Secure the Melt Disk in a soft vice and torque Gate Seals in the cold condition to value specified below or in the General Assembly Drawings Do not over tighten vice Ensure none of the components are damaged L_ Thread size imperial Metric M9 10 11 ft Ibs 14 15 Nm 7 Torque Gate Seals in heated condition at processing temperature as specified in the General Assembly Drawings 4am CAUTION al E N Failure to torque the gate seals at processing temperatures may result in leakage co a LED t TERI 7 ae ae Ae O O i Figure 15 4 Torquing Gate Seals E F p Hot Runner User Manual Revision 12 Flea lcd Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at www moldmasters com 15 4 Specialty Sys
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