Hot Runner User Manual - Mold
Contents
1. 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 1 3 Mire Introduction MPET Nozzle Assembly MPET V2 Valve Bushing and Nozzle Tip Piston Assembly e Nozzle Nozzle mam Valve Pin Band Heater Nozzle Tip ee Insulator Cap 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 1 4 ECC TM GE Global Support Section 2 Global Support MasterPET MPET System Offices GLOBAL HEADQUARTERS MPET N America Mold Masters 2007 Limited 233 Armstrong Avenue Georgetown Ontario Canada L7G 4X5 tel 1 905 877 0185 fax 1 905 873 2818 info moldmasters com SOUTH AMERICAN HEADQUARTERS MPET S America Mold Masters do Brasil Ltda Rua Hum 1106 e 1126 Jd Manchester Nova Veneza Sumare Sao Paulo Brasil CEP 13178 440 tel 55 19 3922 4265 fax 55 19 3922 4266 vendas moldmasters com br MPET MEXICO MM Hot Runner Injection Mexico S A de C V Av San Carlos No 4 Nave 2 Parque Industrial Lerma Lerma Estado de Mexico 52000 Mexico tel 52 728 282 48 33 fax 52 728 282 47 77 mexico moldmasters com EUROPEAN HEADQUARTERS MPET Europe 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 europe moldmasters com MPET FRANCE Mold Masters Franc2. Piston Removal 2 Tighten the M6 screws Piston removal is done at cold condition 1 Install piston wrench 3 2 While holding piston wrench loosen and remove M6 SHCS 4 Using appropriate wrench pull valve stem IMPORTANT 1 If valve stem resists movement the front of the valve stem can be lightly tapped with a brass hammer to loosen any hardened plastic 3 Remove piston Valve Stem Removal Valve stem removal is done at cold condition 1 Install piston adapter 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 8 2 PNE TM z Mie Maintenance Procedures Re Installing the Piston 1 Using Piston Installation Tool slide the valve stem into the valve bushing New Seal Installation Remove old seals 2 Using Seal Stretch Tool install Viton O ring onto piston N Tap lightly on the centre of the piston to bottom it into the valve bushing CAUTION E Tap on the center of the piston only other wise the valve stem may be bent 3 Using Seal Stretch Tool install Outer Seal onto piston 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 8 3 Tu Mir 8 Nozzle Tip Maintenance 1 Reasons for Nozzle Tip Maintenance e Tip damage e Obstruction to melt flow e Tip
3. The shoulder pins are secure and do not rotate or come loose shoulder pin body bushing SGEN RIGHT WRONG RIGHT WRONG 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 3 11 Laying Down Plates or Molds 1 Align a wooden block under the plate or mold at As required insert wooden blocks under plates or the side opposite to where the plate or mold is to mold to prevent any damage to components on under be laid down side and to ensure stable horizontal orientation 2 Slowly lower the plate or mold onto the wooden block Wooden Block 3 Slowly lower the plate or mold downward onto the work bench or surface Picking Up Plates or Molds 4 Move the crane so that the chain or sling maintains WARNING a vertical orientation A Use a block of wood when raising the plates or mold to prevent the load from tipping over the opposite way which could cause bodily harm Lift the plate or mold slowly off the wooden block to minimize any swinging or pendulum motion that could cause bodily harm Align a wooden block under edge of plate or mold 2 Lift the plate or mold off the workbench onto the wooden block 3 Slowly lift the plates or mold off the bench 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 3 12 1 Latching Introduction There are two reasons latches are used in a mold e o tie the mold halves
4. U R 5 2 Electrical Testing 1 Thermocouple Wiring Guide lines e Thermocouples are Type J ungrounded and color coded to ASA standards White Red e The tip must not be truncated or squeezed and must touch the bottom of the bore in order to mea sure the correct temperature e Each heat source should have its own closed loop temperature control in order to achieve accurate control e If there are not enough control zones heat sourc es that have the same wattage and affect the same environment may be grouped together CAUTION E Exceeding controller zone amperage will cause controller fuses to blow Functional Test with a Temper ature Controller The functions of the electrical equipment must be checked This test is carried out with an appropriate temperature control device e Monitor the initial heating of the system to mini mize risk 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 Re testing Where a portion of the electrical equipment is changed or modified that portion must be re verified and re tested aS appropriate 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 5 3 ECC TM GE 1 Hot Half Assembly section 6 Hot Half Assembly Assembling the Hot Half 1 Check that the nozzle well depth L in the cavi
5. fix to the disconnect switch Each person working on the equipment must follow this step The lock of the person doing the work or in charge must be installed first remain throughout and be removed last Test the main disconnect switch and make sure it cannot be moved to the on position 4 Try to start the machine using the normal operation controls and point of operation switches to make sure that the power has been disconnected NOTE In some instances there may be more than one power source feeding equipment and steps must be taken to ensure that all sources are ef fectively locked out 5 Other sources of energy that could create a hazard while working on the equipment must also be de energized and appropriately locked out This can include gravity compressed air hydraulics steam and other pressurized or hazardous liquids and gases see table below 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 3 8 When the work is completed prior to removing the last lock make sure the operational controls are in the off position so that the main discon nect switching is done under no load Ensure all blocks tools and other foreign materials are removed from machine Also ensure that all per sonnel that may be affected are informed that the lock s will be removed Remove lock and tag and close the main discon nect switch if permission has been given When the work has
6. Establish and follow a program of periodic and regular inspections of material handling equipment to ensure they are in safe operating condition e Ensure all material handling equipment including cranes chains slings eye bolts and lift rings are rated to the required load General Safety When Lifting a Load 1 Define the Load Path the path and orientation the item will move in while it is being lifted and the location and orientation where it will be set down 2 Choose lift equipment that is rated for the prescribed load 3 ldentify the characteristics center of gravity physical dimensions weight lifting points etc of the object s being lifted 4 Know the rigging requirements before the lift is performed If unsure of the rigging require ments contact the Hoisting and Rigging Inspec tor or Plant Engineering Rigging Supervisors 5 ldentify and avoid potential pinch points where an individual or a component of the lifting equipment or load may be caught between two surfaces 6 Consider load balance load configuration dimensions and attachment points 7 Never replace or modify a manufactured lifting component for example a shackle pin with a bolt in an eyebolt assembly 8 Keep shackles straight for maximum capacity In effect prevent the load as applied to the shackle from creating an eccentric force or bending moment on the shackle body Under certain conditions this type of loading m
7. Screws 8 7 Troubleshooting Matrix 9 1 U Unpacking 4 1 V Valve Stem Removal 8 2 W Warranty and Documentation 1 1 Wiring Check 5 1
8. V2 Valve Bushing Piston Assembly EE 8 1 PISTON ROMON EE 8 2 Valve Stem SEENEN eegen 8 2 New Seal VE 8 3 Ie Instramenme TIS 8 3 Nozze MAMEN QING EE 8 4 NOZZE TID une UE 8 4 Nozze WSFA e BEE 8 4 Nozzle Band Heater Removal EE 8 5 Cleaning Nozzle Jee gege Ehe 8 6 Checking Nozzle Te Lu 8 6 Nozzle Band Heater Installation EE 8 6 Spare Manifold ThermoCOUpIES sss 8 7 SYSTEM Screw le EE 8 7 Ora GO ee E E 8 7 Recommended Inspection el 8 9 Preventative Maintenance and Heturbsbment anae eee 8 10 Section 9 Troubleshooting 9 1 dele areae MaX ERREUR 9 1 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 IM BH F 4 Introduction 1 Section 1 Introduction This manual is intended to provide information for operating and maintaining the MasterPET MPET V2 Valve Bushing Hot Runner manufactured by Mold Masters 2007 Ltd For additional information please contact your representative or a MPET office Symbols Used in the Manual GENERAL DESCRIPTION OF SYMBOL WARNING Indicates an immediate or potentially hazardous situation which if not avoid ed could result in a serious injury or death CAUTION Failure to follow instructions may damage equipment IMPORTANT Indicates additional information or used as a reminder Warran
9. and is usually set such that the protective conductor resistance between the grounding conductor connection and all of the protec tive earth conductor connected parts is Maximum 0 3 TY In TN systems the following two checks must be made Test 1 Verifies the continuity of the protective bonding circuit The purpose of this test is to check whether all relevant touchable conductive parts are properly grounded See the relevant requirements of the standard DIN EN 60204 1 NFPA79 The protective conductor resistance is measured with a special instrument with a current between at least 0 2 A and approximately 10 A derived from an electrically separated supply source for example SELV see 413 1 of IEC 60364 4 41 having a maximum no load voltage of 24 V AC or DC The resistance should be within the expected range Test 2 Fault loop impedance verification and suitability of the associated overcurrent protective device The power supply connections and incoming external grounding connections to the hot runner system usu ally through a temperature control device must be verified by inspection The conditions for protection by automatic disconnec tion of supply must be checked by both 1 Checking the impedance of the fault loop by calcu laton or measurement 2 Confirming that the setting and characteristics of the associated overcurrent protective device are in accor dance with the requirements of the standar
10. area between the barrel and the sprue bushing See Figure 3 1 area 4 Plasticizing and or injection unit area Area from the adaptor barrelhead end cap to the extruder motor above the sled including the carriage cylinders See Figure 3 1 area 5 Mechanical Hazards Crushing and or shearing and or impact hazards caused by e Movement of the platen Movements of the injection barrel s into the mold area Movements of cores and ejectors and their drive mechanisms e Tie bar motion Thermal Hazards e Burns and or scalds due to operating temperature of e The mold heating elements of the molds e Plasticized material released from through the mold Mechanical Hazards Crushing and or shearing and or impact hazards caused by e Movement of the platen e Movement of the drive mechanism of the platen e Movement of the core and ejector drive mechanism Mechanical Hazards Mechanical hazards of crushing shearing and or impact caused by the movements of e Core and ejector drive mechanisms Mechanical Hazards Crushing shearing hazards and or impact hazards caused by e Forward movement of the plasticizing and or injection unit including nozzle e Movements of parts of the power operated nozzle shutoff and their drives e Over pressurization in the nozzle Thermal Hazards Burns and or scalds due to operating temperature of e nozzle e Plasticized material discharging from the nozzle Mechanical Hazards Cru
11. ensure that all motions are stopped Block material from moving into area of work blank as required Energy Forms Energy Sources and General Lockout Guidelines Stored energy that an object If possible lower all suspended has the potential to release due parts and loads to the lowers Potential Energy to its position springs e g in rest position block parts that air brake cylinders actuators might be moved by gravity counterweights raised loads release or block spring energy top or movable part of a press or lifting device Supply lines Thermal Energy Shut off lock with chains built in lockout devices or lockout Storage tanks and vessels attachments and tag valves bleed off excess liquids or gases blank lines as necessary Electrical Lockout Employers must provide an effective Lockout Tagout program 6 NIE Refer to all machine manuals and local L regulations and codes 1 Shut down machine using normal operational shut down procedure and controls This should be done by or in consultation with the machine operator 2 After ensuring that the machinery has been f completely shut down and all controls in the off position open the main disconnect switch located in the field 8 3 Using your own personal padlock one assigned by your supervisor lock the disconnect switch in the off position Do not lock only the box Remove the key and retain Complete a lockout tag and af
12. equipment to ensure they are in safe operating condition and proper adjustment Ensure that no modifications repairs or rebuild of portions are made to the equipment that reduces the level of safety existing at time of manufacture or remanufacture Safety Hazards The following safety hazards are most commonly associated with plastic injection molding equipment see European Standard EN201 or American Standard ANSI SPI B151 1 WARNING Also refer to all machine manuals and local regulations and codes for safety information 1 Mold area 2 Clamping mechanism area 3 Area of movement of core and ejector drive mechanisms outside areas 1 amp 2 4 Nozzle area 5 Plasticizing and or injection unit area 6 Feed opening area 7 Area of the heater bands of the plasticiz ing and or injection cylinders 8 Parts discharge area 9 Hoses 10 Area inside the guards and outside the mold area Figure 3 1 Injection molding machine HIMM with hori zontal clamping unit and horizontal injection unit shown without guards for illustration clarity 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 3 1 Mold Area Area between the plat ens See Figure 3 1 item 1 Clamping Mechanism Area See Figure 3 1 area 2 Movement of drive mechanisms outside the mold area and outside the clamping mechanism area See Figure 3 1 area 3 Nozzle area The nozzle area is the
13. installed removed or machine to be stopped before the bypassed worker can reach into the danger area Never purposefully reach around under or over guards into hazardous areas It is important to ensure that Do not remove alter or attempt to other Safety guards are tested and inspected regularly wise bypass a safety interlock for correct operation Never access the mold cavity via the e Operators and maintenance workers are trained operator s gate and do not remove a fixed in location of equipment safeguards how they guard during normal operation provide protection and what hazards they protect against Never rely on interlocks rather than lock e Operators and maintenance workers are trained in out tagout procedures how and under what circumstances guards can be removed e Operators and maintenance workers are trained in the location of emergency stops 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 3 9 T meum TM o Handling Safety A WARNING The use of improper material handling equipment can cause injury or death Ensure all equipment including cranes chains slings eye bolts and lift rings are rated to the required load It is the responsibility of the employer to e Ensure the original and continuing competence of personnel operating material handling equipment including rigging inspecting and using equipment e
14. not been completed on the first shift the next operator should install a personal lock and tag before the first operator removes the original lock and tag If the next operator is de layed a lock and tag could be installed by the next supervisor Lockout procedures should indicate how the transfer is to be conducted It is important that for their personal protection each worker and or foreperson working in or on a machine places his her own safety lock on the disconnect switch Use tags to spotlight work in progress and give details of work being done see figure 2 Only when the work is completed and the work permit signed off may each worker remove his her lock The last lock to be removed should be that of the person supervising the lockout and this responsibility should not be delegated Industrial Accident Prevention Association 2008 8 Safety Guards and Interlocks Plastic injection machines require guards to protect Types of Guards employees from nip points numerous moving parts Method TE ET TEE and exposure to high voltage and high temperature 9 9 1 Fixed Not Provides a barrier AN WARNING Interlocked Serious injuries including fatalities ampu Moveable Shuts off or disengages power and tations avulsions burns cuts and bruises Interlocked prevents starting of machine when can occur during operation if guards are guard is open should require the missing improperly
15. tip per drawing 2 Use Allen key to secure with small SHCS on band heater SHCS 5 Check that nozzle tip height is within drawing speci fication 6 Repeat for each nozzle 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 8 6 ECC BC TM Bag IM s f Spare Manifold Thermocouples 1 In the case of a manifold thermocouple failure spare thermocouples for each manifold zone are wired and labeled as spares and located within the respective manifold connector 1 2 Refer to the wiring diagram for further information Spare thermocouples located inside electrical box behind these manifold connectors System Screw Torques Quality and length of screws must be as specified on General Assembly drawings Torque Settings for Assembly Screws Imperial Metric Torque Setting Torque Setting 10 Nm 7 ft lb 16 Nm 12 ft Ib 39 Nm 29 ft Ib 77 Nm 57 ft lb 9 Nm 6 ft lb 22 Nm 16 ft lb 48 Nm 35 ft lb 85 Nm 63 ft lb M12 135 Nm 100 ft Ib 209 Nm 154 ft lb M16 330 Nm 243 ft Ib M30 2250 Nm 1658 ft lb 1 8 1411 Nm 1042 ft lb 3850 Nm 2842 ft lb 1 1 4 7 2820 Nm 2083 ft lb Torque Settings for Nozzle Tip 30 lb 41 e IMPORTANT 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
16. together for transportation and handling e To gain access between two mold plates which are screwed together during normal mold opera tion Latches are always used in pairs mounted on diago nally opposite sides of the mold to provide equal pull on the plates The latches are located on e The operator s side e side of the mold or e 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 Make sure the machine has been locked out and tagged out in accor dance to the machine s documented procedures Failure to do so may lead to serious injury or death Open the mold 2 Check the machine and hot runner controller has been locked out and tagged out Refer to the con troller and machine manufacturers documentation for procedures 3 Apply lockout tagged out to the machine power source and hot runner controller Refer to the con troller and machine manufacturers documentation for procedures 4 Allow the mold to coo
17. 1 Stationary Platen 2 Latches 3 Moving Platen 4 Core Plate 5 Cavity Plate Latch Cavity Plate to Core Plate 1 Stationary Platen 2 Cavity Plate 3 Moving Platen 4 Core Plate Remove lockout tagout Open the mold Check the machine has been locked out tagged out Refer to the controller and machine manufac turers documentation for procedures Install and torque the cavity plate mounting bolts Torque to required specifications refer to assem bly drawings for required torque settings Install hoses if required Remove latches from both sides of the mold 1 Section 5 Preparation ae El Introduction The following section is a step by step guide to preparing your MPET System for use Screw Specifications 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 ex pands stretching the mounting screws if screw lengths are shortened there is a possibility of shear ing The expansion factor is calculated into the length of each screw size Tools Depending on the size and complexity of your MPET 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 impe
18. 13 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 Electrical Safety Testing Electrical safety tests shall be performed according tO DIN EN 60204 1 paragraph 18 and NFPA79 Testing guidelines are given below however the standards identified earlier in the introduction are the final author ity Verify Equipment to its Technical Documenta tion First verify that the electrical equipment complies with its technical documentation Insulation Resistance Test Measure the insulation resistance between each pin of the MPET power connector in particular the heating circuit and ground The insulation resistance is measured at a DC voltage of 500V The insulation resistance must not be less than 1 MQ If this value is not reached when heating the cause is often moisture inside the heating element which should be removed using a control unit equipped with this function Where a mold has not been in use for several weeks or months it should be re tested Verification of Conditions for Protection by Automatic Disconnection of Supply WARNING AN The user is responsible to take protective measures against shock by indirect con tact while performing the tests ee Benn MP i 5 1 Tu Mir 8 The conditions for automatic shutdown of the supply is set at the MasterPET facility
19. Hot Runner User Manual with V2 Valve Bushing SS 1 KK sa e j s se E dh amp Co 8 2 uj Ze ee 8 Z sa 0 22 ef 151 vi 4 5 609 97 2 09 16 6 8 W 9 s ANO 7 e Ze Ze 4 4 49 E ASTI www moldmasters com Mold Masters the Mold Masters logo MasterPET and are either trademarks or registered trademarks of Mold Masters 2007 Limited 2013 All rights reserved pum Table of Contents 4 Table of Contents T m Section 1 Introduction 1 1 Symbols Used in the Riz PNE E 1 1 Warranty Documentation sass 1 1 PREIS ASS RE 1 1 MPE T System Overview 1 2 MPET System Overview e 1 3 MPET Nozzle Assembly Nozzle Tip sss 1 4 MPET V2 Valve Bushing PAS OMD E 1 4 Section 2 Global Support eee 2 1 MasterPET MPET System Re 2 1 Section 3 EE eas ex REX eave REXESE TEE UNE DINE KM EFERIERDnEEE 3 1 MOUCINA EE E S E 3 1 ee LS OY gm 2 A eet 3 1 Safety Symbols Typical to Injection Molding 3 4 General Safety Warnings 3 5 LOCO AN SY ee ete sa
20. Latch the cavity plate to the core plate or cold half Remove lockout tagged out Check the machine is in Mold Set mode Open the mold moving the cavity plate away from the manifold plate Apply lockout tagged out Refer to the controller and machine manufacturers documentation for procedures Latching the Cavity Plate to the Mani fold Plate Hot Half IA ls WARNING Make sure the machine has been locked out and tagged out in accor dance to the machines documented proce dures Failure to do so may lead to serious injury or death CAUTION The nozzles must be within 300 F 150 C of mold temperature to pre vent 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 e Check the machine is locked out tagged out Lubricate the guide pins on the hot half Remove lockout tagout Check the machine is in slow speed Mold Set mode Slowly close the mold Check the machine has been locked out tagged out Refer to the controller and machine manufac turers documentation for procedures Remove the latches on both sides of the mold Latch the cavity plate to manifold plate or manifold backing plate 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 10 11 12 13 14 3 14 Cavity Plate to Core Plate
21. M10 384 Nm 283 ft Ib 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 8 7 Maintenance Procedures Mold Storage Corrosion Protection An unprotected mold will oxidize rust especially in environments with any moisture or salt in the air Before a mold is placed in storage it should be thoroughly cleaned and sprayed with a protective coating Do not wrap the mold in plastic wrap as this may trap condensation The mold can be further pro tected by vacuum sealing in a polyethylene bag with a silicate absorbent The coating should offer good protection from mois ture mild acids and alkaline conditions It should not contain chlorinated solvents or silicone Mold Mas ters Ltd recommends LPS 26 Heavy Duty Lubricant or LPS 3 Premier Rust Inhibitor or equivalent see below Heavy Duty Lubricant Non drying oily film for long lasting lubrication Loosens rusted and frozen parts Protects against corrosion on steel parts indoors for up to one year Displaces moisture Excellent protection for hand machine tools Does not contain chlorinated solvents or silicones Non conductive Safe on most surfaces Meets NSF requirements for H2 Registration category H2 129026 Aerosol 059848 Bulk Canadian Food Inspection Agency Category n1 or equivalent Rust Inhibitor Forms a transparent soft waxy film for protection and lubrication Inhibits rust and corrosion protects steel parts indoors for
22. al threads ONLY WARNING A The hot runner system must be turned off and cooled to below 38 C 100 F before cavity plate is removed The cavity plate can then be removed to expose the nozzle band heaters 1 After band heaters are exposed by removing the cavity plate use Allen key to loosen small SHCS on nozzle band heater 5 Install nozzle tip into nozzle and torque using 12 point 14mm socket Torque nozzle tip to 30 ft Ib 41 Nm SHCS 2 Use needle nose pliers to grasp the band heater clamp and remove the band heater 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 HEN dili TM Mie Maintenance Procedures 3 Remove band heater wire from the wire channel and 3 Route band heater wire through the wire channel electrical connection and make relevant electrical connection Cleaning Nozzle Insulator Cap 1 Heat cap with heat gun 2 Wipe material from cap Nozzle Band Heater Installation 1 Slide nozzle band heater onto the nozzle housing until it bottoms Checking Nozzle Tip Height 1 Correct nozzle tip height and nozzle reference point is found on the gate detail of General Assembly Drawing 2 Assemble spacer blocks to same value as correct nozzle tip height Zero indicator to spacer blocks Move indicator to correct reference point on nozzle
23. are removed Mold is securely crated and crate is strapped and labelled clearly 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 8 8 Maintenance Procedures e Mie Maintenance Procedures Recommended Inspection Schedule Task Interval Record any cavities that are not making preforms and why Visual inspection of preforms noting any issues Walk around the machine listening for any unusual sounds Knocking Check for rubbing hoses and cables Check for water and air leaks Check for unusual wear on leader pins and bushings Re hang mold if necessary Check for loose machine opening stroke limiters Check for loose machine ejector rods Check for loose cam followers Review the process and cycle time noting any changes from standard Remove and replace grease from leader pins and bushings Remove and replace grease from cavity taper and parting line Check amperage draw on all manifold zones Inspect nozzle tips and insulators for wear and damage see component replacement schedule Inspect valve stem tips and gate holes for wear see compo nent replacement schedule Remove and inspect valve seals see component replace ment schedule Remove and inspect nozzle insulators and tips see compo nent replacement schedule Remove and inspect valve stems see component replace ment schedule Check mold mounting screws for cracks and wear Check mold lift ba
24. ay cause the legs of the shackle to open up 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 WARNING Please inform MPET Systems immedi ately if interfacing an other than supplied mold cold half or hot half as this will impact the weight of the mold and therefore lift bars latches and mold mounting ECC mE Mi i 3 10 Mi BH wW Safety Hoist Ring and Eyebolt Safety Always inspect hoist ring before use Make sure Ensure hoist rings and eyebolts are used at correct lift angle see examples below Secure and balance the load in the chain or lifting Minimize swinging by bringing the hook over the Stand clear of the suspended load at all times 1 Know the intended use of the eyebolts when they are supplied as part of the equipment It is pos lifting sible that they may only have intended to lift part of eyebolt the mold equipment lift bar device before it is lifted more than a few inches load appropriately Use shoulder eyebolts only and de rate them accordingly depending on the angle angle of the load path of the corresponding connecting sling or wire rope bail The screw is tightened to recommended torque The bushing sits flush against object being lifted Hoist ring is free to swivel and pivot in evey direction There are no signs of corrosion wear or cracks especially on the screw shoulder pins and bail
25. channel for any contamination back stroke and pullback dwell time to reduce the pressure in the preform e Cooling rate too high in the tip area Lower cooling rate at preform tip e Increase mold manifold temperature to favour the valve stem closing e Reduce hold pressure time to reduce the cooling rate and melt pressure in the tip area e Increase or decrease nozzle tip temperature e Increase nozzle tip temperature to increase the melt in the tip area e Increase decompression to reduce the cooling rate the tip area e Increase the cooling time to increase the dome solidification and break gate vestige during mold opening e Check valve gate compressed air is not below 110 psi 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 9 2 Symptoms amp Cause Formation of long nub during mold opening Solution Check water cooling temperature and flow Reduce the mold break to zero Increase mold opening speed Increase the last hold pressure to favor the cool ing Reduce nozzle tip temperature Increase cooling time Decrease decompression by decreasing the pullback stroke and pullback dwell time to prevent melt drawn away 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Troubleshooting PIN HOLES GATE VOIDS Symptoms amp Cause Small hole on the gate nub or just below the gate nub Plastic i
26. d For more information see the text of the EN 60204 1 NFPA79 standards Thermocouple Continuity Test 1 Measure the resistance between each pair of thermocouple wires and the mold s thermocouple connector See Figure 6 1 The resistance should 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Electrical Testing Figure 6 1 Mold Plug 1 Mold Power Connector 2 Thermocouple Connector be between 2 5 and 25 Q To verify alignment of thermocouple in the heating element turn on one zone after the other and check that the temperature responds accordingly if the set temperature is adjusted Pinch Point Test 1 If there is a suspected pinch point on the thermocou ple remove the thermocouple from the hot runner Connect a temperature control device to read the temperature Immerse the sheath of the thermocouple in boiling water to the point where the thermocouple reads the temperature 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 Heating Element Check Measure the resistance between each pair of heater power wires at the mold power connector Compare your reading with your general assembly draw ing Where R resistance U voltage power
27. e Zl la Marini re 2 Rue Bernard Palissy 91070 Bondoufle tel 33 1 82 05 00 80 fax 33 1 82 05 00 83 fr moldmasters com MPET INDIA Mold Masters Technologies Private Limited 247 Alagesan Road Shiv Building Saibaba Colony Coimbatore India 641 011 tel 91 422 423 4888 fax 91 422 423 4800 mmiplinfo moldmasters com ASIAN HEADQUARTERS MPET Asia 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 MPET JAPAN Mold Masters K K 1 4 17 Kurikidai Asaoku Kawasaki Kanagawa Japan 215 0032 tel 81 44 986 2101 fax 81 44 986 3145 info mmkk co jp 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 2 1 gm um Tu Bag EG Section 3 Safety 1 Introduction Any instructional material provided by MPET Systems for the operation and maintenance of equipment does not in any way absolve the employer from fulfilling the following obligations and MPET Systems disclaims li ability for injury to personnel using equipment supplied It is the responsibility of the employer to Ensure the original and continuing competence of personnel caring for setting up inspecting and maintain ing injection molding equipment Establish and follow a program of periodic and regular inspections of injection molding
28. en x Thermocouple stom open or cose delay Nozzetipteme Waid opening speed X cowewe x mewone 1 BR HR m ES m E We SC m E x m Ee l WW AE m 1 ES 2013 Mold Masters 2007 Limited Rights Reserved Revised 4 April 2013 9 1 Troubleshooting LONG GATE NUBS Symptoms amp Cause Symptoms amp Cause A torn section on the external surface of the preform Long injection point due to the valve stem not starting from the gate nub extending outward toward closing properly the hemispherical area The torn section sticks on the molding surface of the gate insert and can remain for Solution several cycles e Check for foreign matter in the nozzle Solution e Check for damaged valve stem or valve stem e Check the gate insert nozzle tip insulator stem piston seals and nozzle tips for any wear damage and e Check for proper valve gate air pressure and clean replace if necessary the filter e Check the clearance between valve stem and e Check for damaged nozzle tip insulator gate insert e Reduce hold pressure time to reduce the cooling Check for oval gate hole rate and melt pressure in the tip area e Check water cooling and flow e Increase decompression by increasing the pull Check water
29. erly trained personnel based on local law or regulation requirements Electrical products may not be grounded when removed from the assembled or normal operating condition m TM m 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 3 5 MIFE i AC Ensure proper grounding of all electrical products before performing any maintenance to avoid potential risk of electrical shock Do not mix electrical power cables with thermocouple extension cables They are not designed to carry the power load or list accurate temperature readings in each other s application 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 Regularly inspect and replace all flexible hoses and restraints Never perform any work on the mold machine unless the hydraulic pump has been stopped 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 Check frequently for possible oil leaks water leaks Stop the machine and make repairs Ensure that mold lifting equipment eyebolts fork lift truck cra
30. evel 9 4 Air Hooks Streaks 9 7 B Black Specs 9 4 Bubble 9 5 Burn Marks 9 6 C Cleaning 4 1 Color Streaks 9 6 Connections 5 1 E Electrical Testing 5 1 F Flash 9 7 G Gate depressions 9 8 Gate voids 9 3 Global Support 2 1 Ground Shorts Test 5 1 H Handling Safety 3 2 Hoist Ring and Eyebolt Safety 3 3 Hot Half Assembly 6 1 L Latching 3 5 Latching the Cavity Plate to the Core Half Cold Half 3 5 Latching the Cavity Plate to the Manifold Plate Hot Half 3 7 Laying Down Plates or Molds 3 4 Lifting a Load 3 2 Long Gate Nub 9 2 Maintenance Schedule 8 9 Manifold Thermocouples Backup 8 7 Mold Storage 8 7 N Nozzle Assembly and Nozzle Tip 8 1 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Nozzle Band Heater Installation 8 6 Nozzle Band Heater Removal 8 5 Nozzle Insulator Cap Cleaning 8 6 Nozzle Tip Height Checking 8 6 Nozzle Tip Installation 8 4 Nozzle Tip Removal 8 4 P Peeling 9 2 Picking Up Plates or Molds 3 4 Pin Holes 9 3 Pin Holes Gate Voids 9 3 Piston Assembly 1 4 8 1 Piston Removal 8 2 Preparation 4 1 Tools Required 4 1 Pull Gate Nub 9 3 S Safety Handling 3 2 Safety Warnings 3 1 Screw Specifications 4 1 Seal Installation 8 3 Spare Manifold Thermocouples 8 7 Storage 8 7 Stringing 9 8 Symbols Used in the Manual 1 1 System Screw Torques 8 7 System Start Up amp Shut Down 7 1 T Thermocouple Continuity Test 5 1 Torques System
31. i Do not increase the manifold temperatures above 285 C 10 C 545 F 50 F and any time Failure to do so can result in deg radation of the PET which can lead to burnt material in the part and or damage to the hot runner components EC we lt TM n Ua Maintenance Procedures Section 8 Maintenance Procedures Introduction MPET V2 Valve Bushing This chapter is a guide to maintaining selective hot run Piston Assembly ner components 1 Seal and Valve Pin Stem Maintenance e Seal 2 Nozzle Tip and Band Heater Maintenance 3 Manifold Thermocouples All other maintenance or repairs should be performed with the assistance of MasterPET MPET service 44 e Screws personnel or at MPET service depot A recommended preventative maintenance schedule is supplied at the end of this section gt Piston CAUTION Ei Always use the correct tool during disas sembly and assembly If a part resists removal ensure you are using the correct 4t e Spacer tool and procedure Use penetrating oil and heat cool parts as required MPET Nozzle Assembly and Nozzle Tip Assembled Nozzle Valve Pin Nozzle Tip d 1 Insulator x Cap 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 8 1 0 EC Sen TM SC Maintenance Procedures T
32. l to room temperature Continue to circulate the mold cooling water in all plates to cool the mold faster 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 3 13 10 11 AE WARNING Make sure the lifting eyebolt lifting chain and crane are rated to ad equately support the weight of the plate s Failure to do so can cause a serious injury If the mold has no leader pins attach a crane that is rated to adequately support the weight of the cavity plate N 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 Latch Cavity Plate to Manifold Plate 1 Latches 2 Manifold Plate 3 Cavity 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 Remove lockout tagged out Place the machine in Mold Set mode Close the mold slowly WARNING Make sure the machine has been locked out and tagged out in accor dance to the machines documented procedures Failure to do so may lead to serious injury or death p Sg VO ZE Tu o 1 Apply lockout tagged out Refer to machine manufacturers documentation for procedures Remove the latches
33. me e Increase transition point e Increase valve stem open delay time to ensure valve gates are not opening too early e Ensure there is no debris in the mold e Check cooling time and flow e Reduce hold pressure Reduce injection pressure by reducing the injec tion speed e Stack mold alignment e Check for any part interference during closing ton nage block leader pin taper lock bolt etc e Check for any part damage taper wear etc e Increase clamp force do not exceed max allow able clamp tonnage e Modify extruder temperature according to the PET characteristic e Check for parting line damage i e if mold has been flashed 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 9 7 gt IM o VUn GATE DEPRESSIONS TY Symptoms amp Cause Flash is located at the parting line and forms a burr Solution e Check water cooling temperature and flow e Increase preform cooling time e Reduce hold time e Increase transition point 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Troubleshooting STRINGING Symptoms amp Cause Flash is located at the parting line and forms a burr Solution e Check water cooling temperature and flow e Increase preform cooling time e Reduce hold time e Check nozzle tip heat settings 9 8 gm um Tu Bag GC T Index A AA l
34. n the vestige was not properly formed or solidi fied Solution 9 3 Check water cooling temperature and flow Check for any wear or damage on the valve stem gate insert nozzle or nozzle tip insulator Reduce mold break Increase the last hold pressure time to favor the cooling Reduce increase nozzle tips temperature Increase cooling time Decrease decompression by decreasing the pullback stroke and pullback dwell time to prevent melt draw away Reduce valve stem close delay Increase manifold temperature to favor the valve stem closing Check all temperature readings and correct if necessary Check valve gate compressed air TM Mir 8 Y AA LEVEL Symptoms amp Cause Thermal degradation due to an excessive melt temperature and residence time during processing The most significant contributor of AA in a preform is the machine amp dryer Ensure proper residence time and processing in dryer and screw Solution Check thermocouple on mold extruder and dryer Check resin quality Reduce dryer temperature Reduce residence time in the dryer Increase dew point by reducing the air flow in the dryer Check extruder throat cooling Reduce extruder temperature Check nozzle tip heat settings Reduce if neces sary Reduce back pressure Reduce screw speed Reduce manifold temperature Reduce the transfer speed and transfer cushion Reduce re
35. nes etc will have sufficient capacity to handle mold and hot runner weight 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 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 water hydraulic fluid The nozzles may short out or become damaged 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 3 6 gm um Tu Bag 1 Lockout Safety Often power sources are inadvertently turned on valves opened mistakenly before the work is completed resulting in serious injuries and fatalities Therefore it is important not only to ensure that all energies are properly locked out but also that they remain locked out until the work is completed If a lockout is not performed uncontrolled energies could cause e Electrocution contact with live circuits e Cuts bruises crushing amputations death resulting from entanglement with belts chains conveyors rollers shafts impellers e Burns contact with hot parts materials or equipment such as furnaces e Fires and explosions e Chemical exposures gases o
36. njury or death Refer to machine manufacturers documentation for operating procedures Install the mold into the molding machine Torque the mold mounting screws to required speci fications Connect wire lines hydraulic pneumatic and electri cal components Remove latches ECC TM GE 1 System Start Up amp Shut Down section 7 System Start Up amp Shut Down Introduction This procedure explains how to start up and shut down your MasterPET MPET System IMPORTANT Ensure the machine nozzle orifice matches or at most is 1 0 mm 0 040 smaller than melt entrance for the hot runner system CAUTION Check that the system is heated to process ing temperature before actuating the valve pins Failure to do so could cause damage to the valve pins Start up WARNING A Take appropriate safety precautions by as suming the system is pressurized and hot at all times Failure to do so can result in a serious injury or death 2 1 Turn on the mold cooling and ensure flow is correct 2 Ensure all mold surfaces are clean and free of plas tic debris 3 3 Ensure the correct valve gate air pressure is pres ent Turn on all manifold heats to 280 C 550 F When the manifold heats have reached their set point turn nozzles on to 45 power Wait 4 6 min utes for the tips to come up to temperature CAUTION Begin processing within 4 6 minutes of turn ing on the n
37. nst shock by indirect contact protective earth conductors and automatic disconnection of supply MPET nents and systems are either equipped with a protective earth conductor or there is a connector for this purpose WARNING To avoid serious burns wear safety cloth ing 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 vis ible location indicating Danger Do Not Touch Before you carry out electrical work make sure that the hot runner system is securely grounded Turn the temperature control off and disconnect all electric wires coming from the mold Failure to follow of these steps may lead to serious injury or death Wiring Check AN WARNING Ensure that all wiring and connection work is performed by a qualified electrician ac cording to DIN EN 60204 1 NFPA79 1 Check that each wire and thermocouple has a zone number 2 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 5 The electricity mains should only be connected to the injection mold when all electrical connections are grounded and the mold is closed 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 20
38. on Molding Machines General Warning Indicates an immediate or potentially hazardous situation which if not avoid ed could result in a serious injury or death Warning Barrel cover grounding strap Lockout Tagout procedures must be followed before removing the barrel cover Barrel cover can become energized upon removal of grounding straps and contact can result in death or serious injury Grounding straps must be reconnected before reconnecting power to machine Warning Crushing and or impact points Contact with moving parts can cause serious crushing injury Always keep guards in place Warning Crush hazard closing mold Warning Hazardous voltage Contact with hazardous voltages will cause death or serious injury Turn off power and review electrical schematics before servicing equipment May contain more than one live circuit Test all circuits before handling to make sure circuits have been de energized Warning High pressure Overheated fluids may cause severe burns Discharge pressure before disconnecting water lines Warning High pressure accumulator Sudden release of high pressure gas or oil can cause death or serious injury Discharge all gas and hydraulic pressure before disconnecting or disassem bling accumulator Warning Hot surfaces Contact with exposed hot surfaces will cause serious burn injury Wear protec tive gloves when working near these areas Mandatory Lock
39. out Tagout Ensure that all energies are properly locked out and remain locked out until the service work is completed Servicing equipment without disabling all internal and external power sources can cause death or serious injury De energize all internal and external power sources electrical hydraulic pneumatic kinetic potential and thermal Warning Molten material and or high pressure gas Molten material or high pressure gas can cause death or severe burns Wear personal protective equipment while servicing the feed throat nozzle mold areas and when purging the injection unit 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 3 4 Warning Read manual before operation Personnel should read and understand all instructions in the manuals before working on equipment Only properly trained personnel should operate the equipment Warning Slip Trip or Fall Hazard Do not climb on equipment surfaces Serious slip trip or fall injuries can result from personnel climbing on equipment surfaces Caution Failure to follow instructions may damage equipment Important Indicates additional information or used as a reminder General Safety Warnings Ensure that extreme caution is observed in the operation and maintenance of the injection molding machines 1 The equipment supplied is subjected to high injection pressures and high temperatures e Only fully trained personnel sho
40. ozzles 6 Use machine screen to determine when the all heats have reached their set points from the mold test then proceed with mold start up 7 Reduce the mold heats and nozzle tip heats to specified temperatures see chart 8 Check to ensure all preform quality is acceptable for production 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 7 1 CAUTION Failure to follow the above procedure may result in leakage damage occurring in the hot runner CAUTION If for any reason plastic has not been injected for 20 minutes the Manifold Heats should be put in Stand by Mode 180 C 350 F manifold and nozzles at 22 power Failure to do so can result in deg radation of the PET which can lead to burnt material in the parts and or damage to the hot runner system Shut Down Shift pins to closed position If system downtime is expected to be less than half an hour switch mold heats to stand by mode 180 C 350 F Set nozzles to 20 power If system downtime is expected to be more than half an hour turn all manifold and nozzles Off When the Hot Runner temperature is below 100 C 212 F turn off mold cooling and or chiller CAUTION Ei Do not increase nozzle temperatures above 65 power at any time Failure to do so can result in degradation of the PET which can lead to burnt material in the parts and or mechanical damage to the hot runner components CAUTION E
41. r e Decrease transition point e Reduce extruder temperature 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 9 5 BURN MARKS Symptoms amp Cause Black marks and streaks in the gate area caused by degraded material Solution e Check all temperature readings e Check thermocouple on the extruder and mold e Reduce extruder temperature e Reduce manifold temperature e Reduce nozzle tip temperature Check water cooling temperature and flow e Reduce screw speed and back pressure e Reduce injection speed e Reduce temperature during extruder stand by 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Troubleshooting COLOR STREAKS Symptoms amp Cause Colorant is not mixed properly Solution e Ensure color feeder is dosing color properly e Ensure no clogging has occurred e Increase transfer cushion by increasing extruder position e Increase screw speed and back pressure e Increase extruder temperature e sure that the color mixer is rotating continu ously 9 6 Symptoms amp Cause Flash is located at the parting line and forms a burr Troubleshooting AIR HOOKS STREAKS Symptoms amp Cause Small curving or hooked streaks on the surface Solution Solution e Reduce shot size e Check nozzle tip heat settings e Increase injection time e Increase injection ti
42. r for cracks and damage Check latch for cracks and damage 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 8 9 Every time used ECC BC IM 8 Maintenance Procedures T Preventative Maintenance and Refurbishment MPET offer an outstanding preventative maintenance and refurbishment program that is designed to minimize unplanned downtime costs Contact any MPET office for further information Our recommended preventative maintenance and refurbishment program is outlined below Tier 1 Preventative Maintenance This program is designed to tune up a hot runner by replacing all high wear components Typically this should be done once a year to prevent forced downtime due to bad gates and air leaks Tier 2 Intermediate Refurbishment This program is designed to restore a hot runner to production wor thy condition by eliminating all air and plastic leaks Tier 3 Comprehensive Refurbishment This program will restore the hot runner to like new condition All moving and wear components are replaced with new 1 5 M 3M 4 5 M 6M 7 5 M 9 M Cvcles 10 5 M 12M Cycles Cycles Cycles Cycles Cycles y Cycles Cycles X X X Piston Seals Valve Stems Nozzle Tips Nozzle Tip Insulators Back up Insulators Sprue T C Clean Manifold pocket Nozzle Band Heaters Nozzle Housings Manifold center locating Insulators Manifold Thermocouples Manifold Inserts BeCu Elect
43. r liquids released from pipelines Energy Forms Energy Sources and General Lockout Guidelines Electrical Energy Hydraulic Energy Pneumatic Energy Kinetic Energy 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Power transmission lines Machine power cords Motors Solenoids Capacitors stored electrical energy Hydraulic systems e g hy draulic presses rams cylinders hammers Pneumatic systems eg Ines pressure reservoirs accumula tors air surge tanks rams cylinders Energy of a moving object or materials moving object may be powered or coasting Blades Flywheels Materials in supply lines 3 Turn off power at machine first e at point of operation switch and then at the main disconnect switch for the machine lock and tag main disconnect switch Fully discharge all capacitative systems e g cycle machine to drain power from capacitors according to manufacturer s instructions Shut off lock with chains built in lockout devices or lockout attachments and tag valves bleed off and blank lines as necessary Shut off lock with chains built in lockout devices or lockout attachments and tag valves bleed off excess air if pressure cannot be relieved block any possible movement of machinery Stop and block machine parts e g stop flywheels and ensure that they do not recycle review entire cycle of mechanical mo tion
44. rial and metric cap screws de pending on system Anti seize compound To prevent oxidation of screw threads that could cause screws to seize with high temperatures Calibrated torque wrench and adjustable wrenches Hex head socket driver Pry Bars Feeler Gauges Bluing Compound For checking face contact Sockets Plastic brass face hammer Brass bristle wire brush Brass scrapers Grease gun Flashlight Eyebolt Inspection mirror Recommended Equipment Must meet weight requirements Work Bench Crane Test controller suited for mold requirements 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 4 1 Preparation Tu Mir 8 Unpacking TY 1 Carefully remove components from the shipping container and check that all components listed on the packing slip were supplied 2 Check that all mold base dimensions are correct and correspond to MPET Systems general as sembly drawings Cleaning 1 Carefully remove any rust inhibitor that has been applied to the system to avoid contamination of food packaging mold Machine Checks 1 Check machine is level and if necessary adjust per machine manual 2 With mold open and leader pin not engaged check machine parallelism and if necessary adjust per machine manual 3 With mold closed but not in clamp up check machine parallelism and if necessary adjust per machine manual CAUTION Failure to en
45. rical Connector Inserts Sprue Band Heater Bake Manifolds Clean Clean out all manifold plate water lines Clean out all manifold backing plate air and water lines Pistons Spacers Valve Bushings Locating Ring Electrical Connector Housings Hardware 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 8 1 0 Section 9 Troubleshooting Troubleshooting Matrix Troubleshooting VW m Defects Es o gt Problem Related to Pull Gate Pin Hole Gate Black Specks Bubbles Color Streaks Depressions 0 x 0 5 qe lt Peeling Long Gate Nubs AA Level arose Txt LI NAE ERE Waterfowtempicontaminaton x x x xP Boegen overresideneime xl Resincontamnaton pm ee L Reese seasainn SSES ES EES ES o pP IE Eo ame x x x VER RE Ee eer Giearance bw Grand stem x Noze pmsmo x x x x Pese x L emere Back pressure idx Shot size eustiony Screw speed x x Decompression stroke ard ime X X X Hold pressurestime x X X injection speed ll L mew npom x x Mentg
46. shing shearing and or drawn into hazards caused by Unintentional gravity movements e g for machines with plasticizing and or injec tion unit positioned above the mold area The movements of the screw and or the injection plunger in the cylinder acces sible through the feed opening Movement of the carriage unit Thermal Hazards Burns and or scalds due to operating temperature of e plasticizing and or injection unit e The heating elements e g heater bands plasticized material and or vapors discharging from the vent opening feed throat or hopper Mechanical and or Thermal Hazard Hazards due to reduction in mechanical strength of the plasticizing and or injection cylinder due to overheating 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 3 2 Feed Opening Pinching and crushing between injection screw movement and housing See Figure 3 1 area 6 Area of the heater Burns and or scalds due to operating temperature of bands of the plasticiz plasticizing and or injection unit ing and or injection e The heating elements e g heater bands cylinders e plasticized material and or vapors discharging from the vent opening feed See Figure 3 1 area 7 throat or hopper Parts Discharge Area Mechanical Hazards See Figure 3 1 area 8 Accessible Through the Discharge Area Crushing shearing and or impact hazards caused by e Closing movement of the platen Movemen
47. sidence time in the extruder by reducing cycle time 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Troubleshooting BLACK SPECKS Symptoms amp Cause Black particles occurs randomly in the preform caused by degraded material Solution e Check thermocouple on mold extruder and dryer e Check the dryer condition e Check the resin quality Reduce extruder temperature Reduce manifold temperature Reduce nozzle tip temperature Reduce screw speed and back pressure Check injection time and adjust speed if neces Sary Reduce temperature during extruder stand by 9 4 IMib 4 Troubleshooting BUBBLES Symptoms amp Cause Symptoms amp Cause Body sink Bubble in any part of the preform Solution Bubble trapped in the melt during plasticizing process e Check the mold cooling temperature and flow Solution Check valve stem motion Increase extruder temperature e Check valve gate compressed air is adequate Increase screw speed and back pressure e Check resin for temperature and residence time Check dryer for residence time and temperature e Decrease decompression by decreasing the pull Increase hold time pressure back stroke and pullback dwell time e Check feeding zone the resin flow must be con e Increase cooling time but not too much stant e Reduce injection speed e Maintain a cushion of 5 8mm on plunge
48. sure machine is level and parallel could result in damage to mold or machine e 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Clamp Area Preparation Removing Temporary Components Any temporary components that are needed for mov ing and lifting latches lift bars etc are all marked in YELLOW and must be removed before using the hot runner for production CAUTION E Failure to remove these temporary components before production will damage the mold or machine WARNING A Any components marked in red are es sential safety components that MUST NOT be removed Check Machine Level 6 checks 9 2 Mold Area 3 Check Machine Parallel 4 checks 4 2 T Electrical Testing section 5 Electrical Testing Introduction This section contains guidelines for electrical testing of your MasterPET MPET System system The testing is based on the following European and North American standards EN 60204 1 DIN EN 60204 1 IEC 60204 1 modified Safety of machinery electrical equipment of machines NFPA 79 Electrical Standard for Industrial Machinery The standards themselves are the final authority for testing requirements also any additional testing requirements from any national standards where the hot runner is in use WARNING A The user is responsible to ensure protec tion agai
49. ts of cores and ejectors and their drive mechanisms Thermal Hazards Accessible Through the Discharge Area Burns and or scalds due to operating temperature of The mold Heating elements of the mold Plasticized material released from through the mold Hoses Whipping action caused by hose assembly failure See Figure 3 1 area 9 Possible release of fluid under pressure that can cause injury Thermal hazards associated with hot fluid Area Inside the Guards Crushing and or shearing and or impact hazards caused and Outside the Mold Movement of the platen Area Movement of the drive mechanism of the platen See Figure 3 1 area 10 Movement of the core and ejector drive mechanism Clamp opening movement Electrical Hazards Electric shock or burns due to contact with live conductive parts Electrical or electromagnetic disturbance generated by the motor control unit Electrical or electromagnetic disturbance that can cause failures in the machine control systems and adjacent machine controls Electrical or electromagnetic disturbance generated by the motor control unit Hydraulic High pressure discharge Accumulators Power Operated Gate Crush or impact hazards caused by the movement of the power operated gates Vapors and Gases Certain processing conditions and or resins can cause hazardous fumes or vapors 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Safety Symbols Typical to Injecti
50. ty T plate is to MasterPET MPET System specifi cations 8 i 10 ai D SL S O 2 Nozzle Depth 1 Nozzle Well Depth L 2 Cavity Plate 12 3 Manifold Plate 13 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 E CAUTION Potential pinch point Ensure that all wires are in the retainer grooves Failure to do so can cause lost production due to hot run ner down time For valve gated systems it is recommended to have the pins in the open position to reduce the possibility of damage 2 Attach a crane that is rated to adequately support the weight of the cavity plate 3 Protect the nozzle tip before installing the cavity plate to the manifold plate Prepare the cavity plate for assembly Install the cavity plate to the manifold plate If the plates are not assembling easily remove the cavity plate and check for interference 6 Install the mounting screws and torque to required specifications 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 6 1 11 Attach a crane that is rated to adequately support the weight of the mold cold half Latch the hot half to the cold half A WARNING Make sure the machine has been locked out and tagged out in accordance to the ma chines documented procedures Failure to do 50 may lead to serious i
51. ty and Documentation Please check with your original order documentation for warranty details e IMPORTANT Please do not return any parts to MPET without pre authorization and a return authorization number supplied by MPET Documentation will include one or more of the following Parts list of all system components Together with the general assembly drawing the parts list should be referenced when ordering spare parts Hot half drawing used to integrate hot half to cavity plate WARNING This manual must be used in conjunction with any appropriate Machine Mold and Temperature Controller User Manual When ordering this manual please reference document number MPTHHUM V2 02 Release Details MPTHHUM V2 02 4 April 2013 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 1 1 LL Introduction D Electric Box c EP z I kn ke be r E 5 Pin MPET System Overview Front 1 2 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Mie f Introduction MPET System Overview Back Es _ m EE m Lei SS I bee 5 1 Electric Box M Lift Holes o 4 Mounting s Bei Hole o 3 e e Be Sprue ee Bushing C C e 0 i
52. uld operate or maintain equipment Do not operate the equipment with unconfined long hair loose clothing or jewelry including name badges neckties etc These may get caught in the equipment and can cause death or serious injury e When necessary wear heat resistant personal protective equipment PPE to prevent burns from contact with hot surfaces or splatter of hot plastic and gases e It is 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 Remove purgings from the machine immediately e Ensure proper ventilation and exhaust systems are in place to help prevent inhalation of harmful gases and vapors e Consult manufacturer s Material Safety Data Sheets MSDS e Follow good housekeeping procedures and keep floors clean to prevent slips trips and falls due to spilled pellets on the work floor e Apply engineering controls or hearing conservation programs as necessary to control noise e Never disable or bypass a safety device e High voltage and amperage cables are connected to the controller 220 240 e Unplug from the controller before performing any maintenance work e High voltage and amperage cables are connected to the mold Electric power must be shut off and lockout tagout procedures followed prior to installing or removing any cables e All maintenance should be performed by prop
53. up to 2 years Inhibits exfoliation and filiform corrosion of alumi num Penetrates to displace moisture Does not contain chlorinated solvents or silicone Non conductive Safe on most surfaces Meets NSF requirements for H2 Registration 129027 aerosol 059849 bulk Canadian Food Inspection Agency Category n1 or equivalent Tu Mir 8 Protecting Mold Surfaces from Damage Extra protection is recommended for any delicate molding surfaces Mold should be stored in a clean dry environment Contaminates water spillage etc can damage the mold resulting in costly repairs If possible the mold should be stored as a complete unit If the mold is disassembled protect mold sur faces from damage and store the mold in a way that prevents tipping etc Short Term Storage up to 30 days At the end of the production run ensure Mold is thoroughly clean and dry Water lines are blown clear with compressed air Mold is sprayed with a light to medium protective coating including molding surfaces If necessary tear down mold and clean all cavity surfaces runners especially if corrosive plastics are being molded Where applicable water air electrical and hydraulic connectors are capped Mold is inspected for damage and any repairs or maintenance noted and a copy stored with the mold Long Term Storage over 30 days In addition to the above items also ensure Any lifting eyebolts
54. ves Seana pai al a E EE SDE SE EE 3 7 Salely ACSA cs sasaka wees OT 3 9 PARANG E 3 10 Laying Down Plates or MoldS E 3 12 LANG TTNG BE 3 13 Section 5 Preparation 4 1 JnjigoeWeiopt M T 4 1 Screw Specifications eege 4 1 jo 4 1 Recommended Equipment ns 4 1 E 4 2 ICANN ME 4 2 Removing Temporary leien 4 2 ee 4 2 Section 5 Electrical Testing 5 1 NONG tai nan aaa na E apan gan Kinten adan aa neka aa n a paka Jaa aaa a a eaaa aapa CHECK RE Selen TES IMU E E Thermocouple Wiring Elte En Functional Test with Temperature Controller PSC SING ebe tee EE 2013 Mod Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Mire 4 Table of Contents Section 6 Hot Half Assembly 6 1 Assembling the Hot e AUT E 6 1 Section 7 System Start Up amp Shut Down 7 1 Tee ele et PANE EN eer nen ante ae ets eee Tm 7 1 7 1 DON E A 7 1 Section 8 Maintenance Procedures 8 1 It ge al ge Le ME 8 1 MPET TIM Nozzle Assembly and Nozzle WD E 8 1 MPET
55. wear It is advisable to heat the nozzle to ensure the tempera ture condition is met to remove the Nozzle Tips CAUTION E Use the socket recommended to loosen the Nozzle Tip Assembled Nozzle 2 Nozzle Nozzle Band Heater 1 Nozzle Tip d 4 Insulator Ij Cap S Ato 2013 Mold Masters 2007 Limited All Rights Reserved Revised 4 April 2013 Maintenance Procedures Nozzle Tip Removal WARNING The hot runner system must be turned off and cooled to below 38 C 100 F before cavity plate is removed The cavity plate can then be removed to expose the nozzle tips 1 Using a 12 point 14mm socket remove tip If tip resists removal heat tip area with a propane torch being careful not to damage wires and then remove tip Nozzle Tip Installation 1 Clean all residual plastic from the nozzle threads and the tip nozzle sealing surface 2 Check the tip nozzle sealing surface for damage If damaged lap the tip nozzle sealing surface circular fashion with a hardened tool and 300 grit lapping compound 3 After a smooth tip nozzle contact surface is estab lished blue the nozzle tip to the nozzle surface to ensure proper mating After ensuring good contact clean bluing off both surfaces 8 4 PER TM 4 Mie Maintenance Procedures 4 Apply nickel based anti seize to the nozzle tip Nozzle Band Heater Remov
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