Section 12 - Maintenance Procedures - Mold
Contents
1. Crimping Tool Chart Figure 12 11 CRIMPDIE03 1 8 2 0mm Heater Element Mates with CRIMPPUNCHO3 CRIMPPUNCHO3 1 8 2 0mm Heater Element Mates with CRIMPDIE03 CRIMPREMOVEBO01 Bottom Crimp Removal Insert for shearing HE crimps Mates with CRIMPREMOVET01 CRIMPREMOVETO0O1 Top Crimp Removal Insert for shearing HE crimps Mates with CRIMPREMOVEBO01 NOTE The above tools along with the lead wire replacement kit are available through Mold Masters Spare Parts Department at 1 800 387 2483 E 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 12 4 Maintenance Procedures Master l Heater Plate Power Lead Replacement Removal 1 Remove the set screws 2 Remove the power leads NOTE VY Do not remove the ceramic sleeve Installation Figure 12 12 Terminal Ends Assembly 1 Power Leads 2 Ceramic Sleeve 3 Set Screws 4 Heater Plate 1 Push the replacement leads into the holes in the ceramic sleeve Check that the leads make contact with the terminal ends gt Tighten the set screws on the ceramic sleeve until they make contact with the wire Turn the screws an additional 1 4 turn to fasten the power leads to the terminal ends Gate Seal Maintenance Reasons for Gate Seal Maintenance e Tip damage e Obstruction to melt flow e Gate seal damage e Tip we2. to the controller and machine manufac turers documentation for procedures 4 Allow the mold to cool to room temperature Continue to circu late the mold cooling water in all plates to cool the mold faster Figure 12 18 Latch Cavity Plate to Manifold Plate 1 Latches 2 Manifold Plate 3 Cavity Plate 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 i F p Hot Runner User Manual Revision 12 Wiolgd T e n F _ i Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwe moldmasters com 1 2 8 MY F Viaka lalclaleri i adgeo T12 Miaster 5 Ifthe mold has no leader pins attach a crane that is rated to adequately support the weight of the cav ity plate WARNING Install latches before removing the cavity plate mounting screws Failure to do so may lead to serious Injury or death Latch the cavity plate to the manifold or manifold backing plate Check that the cavity plate hoses are long enough to allow the cavity plate to be latched over to the core half cold half without damaging the hoses Remove all cavity plate mounting screws 9 Remove lockout tagged out 10 Place the machine in Mold Set mode 11 Close the mold slowly WARNING Make sure the machine has been locked out and Figure 12 19 Cavity Plate to Core Plat
3. Maintenance Procedures Master Section 12 Maintenance Procedures Introduction This chapter is a guide to maintaining selective components Repairs that should be performed by Mold Masters personnel are not included If you need an item repaired that is not included in this section please call Mold Masters support The phone number and system identifier is located on the mold Valve Disk Removal Some valve disks may be difficult to remove use the following procedure to extract the valve disk from the manifold i NOTE Vy Check that the manifold is secure For Cast in Systems secure the mani fold with clamps to prevent movement Never heat up the system without first clamping the main manifold especially if the nozzles are not secured with the hot half This prevents resin from leak ing between the nozzle and hot half Figure 12 1 Manifold Clamps WARNING A All maintenance on Mold Masters products should be performed by properly trained personnel based on local law or regulation requirements Electrical products may not be grounded when removed from the assembled or normal operating condition Assure proper grounding of all electrical products before performing any maintenance to avoid potential risk of electrical shock To avoid serious burns wear safety clothing consisting of a protective heat resistant coat and heat resistant gloves Use adequate ventilation for fumes Failure to do so can result i
4. ar Multi Cavity Systems It is advisable to heat the system to ensure the temperature condi tion is met to remove the gate seals D IMPORTANT Use the socket supplied in the Mold Masters tool kit to loosen the gate seal It is recommended to use a temperature controller for this procedure If a temperature controller is not available contact your nearest Mold Masters Service Department For gate seal installation and torquing procedures refer to Gate Seal Replacement section e Hot Runner User Manual Revision 12 Whole Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwv moldmasters com 1 9 5 Master Maintenance Procedures Gate Seal Removal The following procedure applies to all gate seals including carbide with threads larger than an M6 Excluding TIT Edge NOTE LA If the cavity plate is easily removed you can access the nozzle seals while still in the system Hot runner systems must be within 100 F 55 C before the cavity plate can be removed It is recom mended the nozzle be removed from the system before removing the gate seal CAUTION Se Seals and liners for Accu Valve EX amp CX are a sub assembly utilizing a manufactured interference fit Disassembly of this sub assembly may affect align Figure 12 14 Penetrating Lubricant ment of the valve pin to the gate causing wear a IMPORTANT W Use the socket suppli
5. at www moldmasters com 1 2 11 Miaster MY F Viaka lalclalex e adao 0 g System Screw Torques Quality and length of screws must be as specified on Mold Masters General Assembly drawings Torque Chart for System Assembly Screws Metric Torque Setting Torque Setting vE 6 ve Torque Chart for Plate Assembly Screws Component Torque Settings Valve Actuator Series 5500 6500 6600 and 6700 Torque Setting Exception to the above bridge manifold mounting screws should be torqued 1 3 higher then specified on general assembly drawings NOTE LA Torque sequence and step torquing It is recommended that system screws be torqued in a standard bolt pattern and that the specified torque is achieved in 2 steps half torque full torque k Parm Hot Runner User Manual Revision 12 Wiolgd gm Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at www moldmasters com 1 2 1 2
6. e 5 Remove the power leads Terminal Installation Although this procedure shows a manifold the process is the same for nozzle terminal ends Please contact Mold Masters Spare Parts Department to ensure you have the correct repair kit 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 1 2 2 Maintenance Procedures Master Terminal Assembly 1 Assemble the repair kit components 2 Ensure the terminal end is clean 3 Slide the element sleeve silicon seal and ce ramic insulator onto the wires 4 Slide crimps onto leads Stranded wire should extend beyond the crimp 5 Spread the wire strands and insert the lead wire onto the terminal posts Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 1 2 3 Figure 12 7 Figure 12 8 b Revision 12 VMiold m 0520 Masters Master MET at a 1al adao 01g 6 Grasp the crimp with crimping tool slide crimp into position over the terminal post crimp connection 7 Slide the ceramic insulator and silicon seal into place 8 Complete the repair by screwing the element sleeve into position CAUTION oe Keep an eye on the silicon seal It should not rotate with the sleeve or the wires may break
7. e tagged out in accordance to the machines document 1 Stationary Platen 2 Latches ed procedures Failure to do so may lead to serious 3 Moving Platen injury or death 4 Core Plate 5 Cavity Plate 12 Apply lockout tagged out Refer to machine manufacturers documentation for procedures 13 Remove the latches 14 Latch the cavity plate to the core plate or cold half 15 Remove lockout tagged out 16 Check the machine is in Mold Set mode 17 Open the mold moving the cavity plate away from the manifold plate 18 Apply lockout tagged out Refer to the controller and machine aad gg i Figure 12 20 Latch Cavity Plate to Core manufacturers documentation for procedures Plate 1 Stationary Platen 2 Cavity Plate 3 Moving Platen 4 Core Plate CAUTION The nozzles must be within 100 F 55 C of mold temperature to prevent damage to hot runner and mold components For cylindrical valve gated systems valve pins should be in the open position prior to removal of the cavity plate to prevent damage Hot Runner User Manual Revision12 Wiolgd Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwv moldmasters com 1 2 9 Master MY F Viaka lalclaler i adao 0 d Latching the Cavity Plate to the Manifold Plate Hot Half WARNING Make sure the machine has been locked out and tagged out in accordance to the machines documented procedures Failure to do so
8. ed in the Mold Masters tool kit to loosen the gate seal 1 Apply penetrating lubricant to gate seal area A WARNING High temperature on the nozzle Wear safety cloth ing such as heat resistant coat and heat resistant gloves Failure to do so may cause serious injury CAUTION The terminal end is a sensitive area and can easily break if not handled to specifications 2 Leave the nozzle in the mold or remove it to a vice and clamp carefully 3 Using the temperature controller heat the nozzle body until all residual plastic is melted from the gate area If the nozzle is inside the mold heat up the whole system and turn on the cooling or remove all O rings Figure 12 15 Remove Gate Seal 4 While the nozzle is still hot apply a loosening pressure to the gate using the socket to remove the seal Turn off the controller and wait for 5 minutes Remove the gate seals _ Hot Runner User Manual Revision 12 Wiolg Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at wwwe moldmasters com 1 2 6 Maintenance Procedures Master l Gate Seal Replacement 1 Clean the nozzle especially the thread and runner 2 Clean all residual plastic from the threads and counter bore of the gate seal WARNING Ensure nozzles have cooled to room temperature Failure to do so may cause serious injury 3 Check the bottom face of the nozzle c
9. ings Seal Torque Settings KOO Gating Lite Method rE TypeTorpedo s9 67 s9 67 16 18 1213 2730 20 22 34 96 25 28 27 54 35 40 ee eres er ee Fiypetorpedo 89 67 69 67 1618 12 13 27 90 20 22 94 38 26 28 47 54 3540 Horse so 67 tens 12 13 27 30 20 22 28 25 28 47 54 3540 TextendeaHotsprue hene 12 13 27 30 20 22 94 38 26 28 arsa 95 40 Hovas eo e7 iens 12 19 27 90 20 22 94 98 25 28 a754 35 00 rsiMetalicc Spe rens i273 2730 20 20 34 38 25 28 47 54 36 40 Bi Metallic Cylindrical te 16 18 12 13 27 30 20 22 34 38 25 28 os Valve reimetalicCvave rer 12 13 27 00 20 20 0 08 2520 ar54 35 40 Spirano rere iz 27 20 20 22 sae 25 28 47 54 35 40 Taccu valves ee 7 iers 1213 2730 2022 sea8 as2e mmea id OT i ta e rats on oars pon muro _ espasar THorizontalotte ss nas rete nal csoue eo o se exme elo 1 i 1 Note Gate Seals are torqued at ambient room temperature at Mold Masters Please torque each seal at processing temperature to the torque value specified This is to prevent material leakage from the Gate Seal Hot Runner User Manual Revision 12 Mold nee el Not under documentation control if printed May be revised without notice 05 2010 Maste rs Electronic version is available
10. may lead to serious injury or death CAUTION E The nozzles must be within 100 F 55 C of mold temperature to prevent damage to hot run ner and mold components For cylindrical valve gated systems valve pins should be in the open position prior to removal of the cavity plate to prevent damage Check the machine is locked out tagged out Lubricate the guide pins on the hot half Remove lockout tagged out Check the machine is in Mold Set mode Slowly close the mold Ao R WN Check the machine has been locked out tagged out Refer to the controller and machine manufacturers documentation for procedures N Remove the latches on both sides of the mold Latch the cavity plate to manifold plate or manifold backing plate Remove locked out tagged out 10 Open the mold 11 Check the machine has been locked out tagged out Refer to the controller and machine manufacturers documentation for procedures 12 Install and torque the cavity plate mounting screws Torque to required specifications refer to assembly drawings for required torque settings 13 Install hoses if required 14 Remove latches from both sides of the mold i F p Hot Runner User Manual Revision 12 H Mold Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at www moldmasters com 12 1 0 Maintenance Procedures Master Torque Settings Gate Seal Torque Sett
11. n serious injury A 1 Heat the manifold to allow any plastic still in the system to become soft 2 Attach the valve disk extraction tool to the Valve Disk 3 Attach the extraction tool to the main assembly tool Refer to the Extraction Tool Chart on next page 4 Extract the valve disk Hot Runner User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 12 1 Figure 12 2 Valve Disk Extracted 1 Valve Disk Extraction Tool 2 Valve Disk b Revision 12 Wiolgd 05200 Masters Master MY F Viaka lalclaleri Me adao 0 g EXTRACTIONTOOLS EXTRACTION TOOLS Where Used Where Used Part Number Valve Disk Part Number Nozzle Type Do EXTOOL10P ied 049 VD0027 VD0031 VD0032 Terminal End Removal and installation Although this procedure shows a nozzle terminal end the process is the same for manifold terminal ends Terminal End Removal 1 Ifthe terminal end is covered with plastic warm the terminal end prior to removing the element sleeve E CAUTION Care must be taken when removing the element sleeve as not to damage the ceramic sleeve or terminal nut Figure 12 3 Nozzle Terminal Assembly 2 Grip the element sleeve at the threaded area and turn 1 Nozzle Flange 2 Ceramic Insert counter clockwise 3 Ceramic Sleeve 4 Seal 5 Element Sleeve 3 Remove the seal 4 Remove the set screw from the ceramic sleev
12. ounterbore for damage If dam nM aged lap the bottom face of the nozzle in a circular fashion with a hard Figure 12 16 Cleaning Location ened tool and 300 grit lapping compound If nozzle counterbore is free of 1 Remove Plastic damage proceed to step 5 4 After lapping is complete blue the liner to the nozzle to ensure proper mating If the liner is making good contact clean the bluing compound off both faces 5 Apply anti seize nickel based to gate seal threads ONLY CAUTION E Carefully apply anti seize to threads of gate seal Any anti seize that enters the internal runner must be removed to prevent contamination of melt 6 Using a socket wrench re install the gate seal being careful not to dam age it 7 Torque the gate seal to the appropriate value Refer to Gate Seal Torque Settings WARNING A High temperature on the nozzle Wear safety clothing such as heat resistant coat and heat resistant gloves Failure to do so may cause serious injury 8 Check that the nozzle has bottomed out heat nozzle to process tempera ture and re torque seal WARNING A Failure to torque the gate seals at processing temperatures may result in leakage Figure 12 17 Nozzle Preparation E F Hot Runner User Manual Revision 12 FF a Mold Not under documentation control if printed May be revised without notice 05 2010 Masters Electronic version is available at www moldmasters com 12 7 l Miaste
13. r MY F Viaka lalclalex ie adaeler tel lat Latching Introduction There are two reasons latches are used in a mold e To tie the mold halves together for transportation and handling e To gain access between two mold plates which are screwed together during normal mold operation Latches are always used in pairs mounted on diagonally opposite sides of the mold to provide equal pull on the plates The latches are located on e The operator s side e Non operator s side of the mold or e Top and bottom of the mold Under no circumstances are plates to be pulled or handled with only one latch attached Latch locations are shown on the assembly drawings During mold operation the latches must be removed from the mold and stored elsewhere Latching the Cavity Plate to the Core Half Cold Half Use this procedure for reference purposes only For latch locations refer to the assembly drawings For additional instructions on latching in the machine refer to the machine manufacturers manual WARNING A Make sure the machine has been locked out and tagged out in accordance to the machines documented procedures Failure to do so may lead to serious injury or death 1 Open the mold 2 Check the machine and hot runner controller has been locked out and tagged out Refer to the controller and machine manufactur ers documentation for procedures 3 Apply lockout tagged out to the machine power source and hot runner controller Refer
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