User Manual - Mold
Contents
1. 6 2 Mag Pin Activation 7 DeactlVallORi cus ocu ceied cuta ed Ua a a s Vi vesperum ae a dad Bru R CORE 6 2 FRC Ale ID LL 2 MERE TE Eom 6 3 PAS SSUES UNIAN RENI m 6 4 PXSSOMIONY 010101010101 6 4 2 1 0000000070000 6 7 Section 7 Maintenance eene P HCE OCCU OP AAP EEEE E A E E E E E EE E E E E E E ET 1 1 Recommended Maintenant asssexebutbxpXxxXXXDUS texte be QERTA RENes Dict UE adr ER T UU 1 1 Lubrication of Ball Screw Assembly en 7 1 inspection of tne TIMING BON ERUNT REUS 1 1 Replacement of BeanngS ireren R m em 1 1 Assembly Disassembly of Top Plate sss nnn nnn 7 2 MOOK Index i E Drive User Manual Revision 10 ffe fud Not under documentation control if printed May be revised without notice 03 2013 Masters Electronic version is available at www moldmasters com E Drmnmve Introduction Section 1 Introduction We would like to take this opportunity to thank you for purchasing a Mold Masters E Drive system The purpose of this manual is to assist users in the integration operation and maintenance of their E Drive sys tem This manual also provides information related to the Mag Pin Magnetic Valve Pin Holder option Symbols Used in the Manual GENERAL DESCRIPTION OF SYMBOL WARNING2. ing the manifold reaches temperature Assembly to the synchro plate r Screws 2 Extract the Mag Pin Assemblies individually Do not lift the whole synchro plate while Mag Pin Assem blies are installed i E Drive User Manual Revision 10 Mold Not under documentation control if printed May be revised without notice 003 2013 Masters Electronic version is available at www moldmasters com 6 7 E Drive AE ZXLL ILLIZE 3 1 Extraction Option 1 Use Extraction Tool EX TOOL13A with a M8 screw Place Extraction Tool EXTOOL13A on top of valve pin holder Couple Ex traction Tool EXTOOLASO 1 with a M8 screw and M8 washer WASHERM8 1 and extract Mag Pin Assembly M8 Screw EXTOOL13A 3 2 Extraction Option 2 Place Extraction Tool EXTOOL13A on top of valve pin holder Couple Extraction Tool EXTOOLASO with EXTOOL13B and extract Mag Pin Assembly EXTOOL13B EXTOOL13A E Drive User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com If the valve pin gets stuck and the mechanism or detaches from the magnet interface you may follow one of the options given below b Early disengagement of valve pin 4 1 Option 1 Extract the valve pin and holder with a M5 screw or other adaptor with a M5 thread in front A x 4 2 Option 2 Extract the valve pin and holder using Extraction Tool EXTOOLASO 1 with Extracti
3. 10 MIold 603 2013 Maste ba ers E Drive AEN ITIN Section 5 Assembly eene MOUGU ON ENTER cere c Sen eee ener er nee nen ere eee res ee M en errs 5 1 5 1 e Complete Assembly 3D VIEW 5 1 Complete Assembly Center Section m m 5 2 8 AsSSemDIYy SUMMA errea 5 2 ED O ASSEN DIY DELA E O E 5 9 First Time Installation or Replacement of the Belt e a 5 10 aban a a vu Checking for Misalignment Section 6 Mag Pin Option 6 1 HTO vile p 6 1 Mag Pin Assembly 3D VICW n 6 1 Mag Pin Application CautionsS
4. Loosen motor mount screws just enough to be Using tool KEY BPHEXTKEY5 0 place the M6 able to slide them screws that connect the ball nut flange to the 7 6 2 Release the locknut on the tensioning screw synchro plate and slightly tighten them Use an other hex key tool with stronger tip to fully tighten 7 6 3 Rotate the tensioning screw clockwise to loosen the belt the screws Tensioning screw amp lock nut Motor mount screws 8 Prepare top plate assembly before lowering Tighten 12 screws evenly on both sides Note belt must be without tension 8 1 Belt should be loose tension free 8 2 Both flange nuts should be at proper orientation and same level before top plate is lowered down for assembly Tool KEY BPHEXTKEY5 0 Gauge Block 9 1 With the belt still loose evenly rotate both ball screws clockwise until the synchro plate hits the top stop buttons and is level on each side Evenly rotate both ball screws clockwise belt is still loose b E Drive User Manual Revision 10 Mold Not under documentation control if printed May be revised without notice 03 2013 Masters Electronic version is available at www moldmasters com 5 6 E Drive A 10 Tighten the belt 12 Assemble the special clamping plate optional 10 1 Loosen motor mount screws just enough to be able to slide them 10 2 Release the locknut on the tensioning screw 10 3 Rotate the tensioning scre
5. Manual Revision 10 Bf Bull i Not under documentation control if printed May be revised without notice 003 2013 Wlas e Electronic version is available at www moldmasters com 5 1 E Drive A 2 Assembly Summary Assemble the hot runner system 8 Prepare top plate assembly before lowering 2 Assemble the hot runner system to manifold Attach the synchro plate to top plate assembly plate 10 Tighten the belt if first time installation of belt or 3 Assemble the interface plate replacing belt refer to Replacing the Belt or First Time llati f the Belt 4 Assemble the synchro plate E PU 5 11 lleli plate 5 Drop the synchro plate to place specepatetele morae 12 A le th ial cl i if exists 6 Assemble the valve pin holders pipe SIE MPs 13 A le the insulation plate amp locating ring 7 Assemble all top plate items ball screw assem Bec ESSE USO ISIN UTOR bly needs to be filled with proper grease before 14 E Drive controller checks shipping see Lubrication of Ball Screw Assem 15 Preparation for shipping bly Assembly Detail 1 Assemble the hot runner system 2 Assemble the hot runner system to the manifold E Drive User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 5 2 plate i Revision 10 Meg Bd i i 60205 Masters E Drive lt S
6. 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 UNITED KINGDOM Mold Masters UK Ltd Netherwood Road Rotherwas Ind Est Hereford HR2 6JU United Kingdom tel 44 1432 265768 fax 44 1432 263782 uk moldmasters com Regional Offices AUSTRIA East and South East Europe Mold Masters Handelsges m b H Pyhrnstrasse 16 A 4553 Schlierbach Austria tel 43 7582 51877 fax 43 7582 51877 18 at moldmasters com KOREA Mold Masters Korea Ltd 708 Byucksan Digital Valley 5 Cha 60 73 Gasan dong Geumcheon gu Seoul 153 788 South Korea Tel 82 2 2082 4755 Fax 82 2 2082 4756 mmkr sales moldmasters com E Drive User Manual EUROPEAN HEADQUARTERS GERMANY SWITZERLAND Mold Masters Europa GmbH Postfach P O Box 19 01 45 76503 Baden Baden Germany Neumattring 1 76532 Baden Baden Germany tel 49 7221 50990 fax 49 7221 53093 europe moldmasters com INDIA Mold Masters Technologies Private Limited 247 Alagesan Road Shiv Building Saibaba Colony Coimbatore T N India 641 011 tel 91 422 423 4888 fax 91 422 423 4800 mmitplinfo moldmasters com U S A Mold Masters Injectioneering LLC 103 Peyerk Court Romeo MI 48065 USA tel 1 800 450 2270 USA only tel 1 586 752 6551 fax 1 586 752 6552 mmi ingq moldmasters com CZECH REPUBLIC Mold Master
7. before plugging in the cables of the motor Otherwise it can cause damage to the motor do not hot plug the motor Carefully read the instructions before operat ing the equipment If in doubt contact Mold Masters for clarification E Drive components are rated to operate at temperatures less than 70 C 158 F Do not heat the hot runner system without connecting a proper cooling system In addition if in your application mold temperature needs to be set above 70 C 158 F use proper mold design for high temperatures In high temperature applications an additional insulation plate and support plate need to be installed above the manifold plate See E Drive Catalogue Pages In addition plates above manifold plate need to be cooled with separate cooling line set at lower temperatures recommended tempera ture is below 50 C E Drive User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 3 4 A e WARNING When the E Drive system is equipped with a magnetic valve pin holder in the synchro plate it is equipped with very strong magnets Be care ful of potential pinch hazards when handling the magnets CAUTION Assembly of the magnetic valve pin holder parts must be done in a clean area that is free of metal chips Ensure parts are clean of metal before assembly Do not place the magnets close to other mag nets or other ferr
8. in tip Mold Masters item number KEY BPHEXTKEY5 0 Grease Castrol Longtime PD2 Mold Masters part number 104L11051 e Proper Valve Pin extraction tools E Drive User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 4 2 Unpacking 1 Carefully remove all components from the ship ping box and check that all components listed on the parts list were supplied 2 Check that all mold base dimensions are correct and correspond to Mold Masters general assembly drawings Cleaning All nozzles manifolds and hot runner components must be free of the rust inhibitor applied at the factory Disassemble the system Wipe down nozzle body Remove the part and wipe clean pe S JS If necessary use a cotton swab to clean narrow interior surfaces or screw threads For larger sur faces such as mold plates use thinner in spray form to clean channels and recesses Establishing Your System Type The following pages are to be used as a general guide to assist in identifying components Refer to your general assembly drawings for specific compo nent lists i Revision 10 Mff Ed 60205 Masters E Drive ZEN Typical E Drive System Locating Ring Insulation Plate Top Plate Servo Motor Interface Plate E Tensioning Screw Gear Head S Lock Nut Idler Pulley without teeth 2 Drive and Tensioning Pulley Ball Sc
9. 1 7182591 7182893 7189071 7192268 7192270 7198740 7201335 7210917 7223092 7238019 724418 7252498 7255555 7258536 7270538 7303720 7306454 7306455 7314367 7320588 7320589 7320590 7326049 7344372 7347684 7364425 7364426 7370417 7377768 7381050 7396226 7407379 7407380 7410353 7410354 7413432 7416402 7438551 7462030 74620371 7462314 7465165 7470122 7507081 7510392 7513771 7513772 7517214 7524183 7527490 7544056 7947208 7553150 7559760 7559762 7565221 7581944 7611349 7614869 7614872 7618253 7658605 7658606 7671304 7678320 7686603 7703188 7713046 7722351 7731489 7753676 7766646 7766647 7775788 7780433 7780434 7794228 7802983 7803306 7806681 7824163 7845936 7850442 7874833 7877163 7891969 7918660 7918663 7931455 7963762 7988445 7998390 8062025 8066506 D525592 RE38265 RE38396 RE38920 RE39935 RE40478 RE40952 RE41536E RE41648E Pending 2012 MOLD MASTERS 2007 LIMITED ALL RIGHTS RESERVED b Revision 10 IVloldud 003 2013 Masters E Drive User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com E Drive EBEN 7 7773 Manufacturing Facilities GLOBAL HEADQUARTERS CANADA 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 BRAZIL Mold
10. 2 Trademarks and Patents 1 2 U Unpacking 4 2 V Valve pin holders 5 2 W Warranty and Documentation 1 1 b Revision 0 Meg Bd 602205 Masters Index i www moldmasters com Mold Masters and the Mold Masters logo are registered trademarks of an P ste g Mold Masters 2007 Limited 2013 EMMEDUM10 performance delivered A ISO 9001 CERTIFIED
11. 3 Assemble the interface plate 5 Drop the synchro plate into place Check for smooth up down movement of the synchro plate e Main leader pins e Synchro plate leader pins e Bearing and retainers e Fastening screws between plates 4 Assemble the synchro plate without ball nut 6 Assemble the valve pin holders Top stop buttons Valve pin holders if needed Ball nut flange Guide bushings with top bottom retainers Bottom stop buttons i E Drive User Manual Revision 10 Not under documentation control if printed May be revised without notice 03 2013 Masters Electronic version is available at www moldmasters com 5 3 7 Assemble all top plate items 7 2 Assemble the ball screw to the top plate Assemble the ball screw assemblies pulley assem blies motor mount assembly guide bushes and belt details follow 7 2 1 Check dimension of fixed bearing bores in top plate before assembly Flange Nut 71 Prepare the ball screw 7 1 1 Assemble the ball screw and fixed bearing 7 1 2 Torque the ball screw nut M20 x 1 0 to 19Nm 14 Ft Ib 7 1 3 Make sure the bearing is properly seated 1512 a umma 7 2 2 Insert the ball screw and fixed bearing into top plate press fit Bearing will protrude 0 10mm to seal with the cover 7 3 Fasten cover plate into position i x E Drive User Manual Revision 10 en Mold A Not under documentation control if printed
12. 3 1 area 7 Parts Discharge Area See Figure 3 1 area 8 Hoses See Figure 3 1 area 9 Area Inside the Guards and Outside the Mold Area See Figure 3 1 area 10 Electrical Hazards Hydraulic Accumulators Pinching and crushing between injection screw movement and housing Burns and or scalds due to operating temperature of e The plasticizing and or injection unit e The heating elements e g heater bands e The plasticized material and or vapors discharging from the vent opening feed throat or hopper Mechanical Hazards Accessible Through the Discharge Area Crushing shearing and or impact hazards caused by e Closing movement of the platen Movements 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 Whipping action caused by hose assembly failure Possible release of fluid under pressure that can cause injury Thermal hazards associated with hot fluid Crushing and or shearing and or impact hazards caused by Movement of the platen Movement of the drive mechanism of the platen Movement of the core and ejector drive mechanism Clamp opening movement Electric shock or burns due to contact with live conductive parts Electrical or electromagnetic disturbance generated by the motor control unit Electrical or elec
13. 676 9282735 9405258 9507635 5700499 5935615 6074191 6203310 6398537 6655945 6789745 6921257 7018197 7022278 7025585 7025586 7029269 7040378 7044191 7044728 7048532 5284436 5299928 5312242 5326251 5334008 5334010 5346388 5366369 5421716 5427519 5429491 5437093 5441197 5443381 5460510 5474440 0007636 5536165 5591465 5599567 5614233 5641526 5644835 5652003 5704113 5705202 5707664 5720995 5792493 5795599 5820899 5843361 5935616 5935621 5942257 5952016 5980236 6009616 6017209 6030198 6077067 6079972 6095790 6099780 6113381 6135751 6162043 6162044 6230384 6270711 6274075 6286751 6302680 6318990 6323465 6348171 6405785 6440350 6454558 6447283 6488881 6561789 6575731 6625873 6675055 6688875 6701997 6739863 6752618 6755641 6761557 6769901 6830447 6835060 6840758 6852265 6860732 6869276 6884061 6887418 6921259 6936199 6945767 6945768 6955534 6962492 6971869 6988883 9366370 9494433 9658604 9849343 6030202 6176700 6350401 6638053 6776600 6890473 6992269 7086852 5387099 5496168 5695793 5853777 6062841 6196826 6394784 6648622 6780003 6893249 7014455 7105123 7108502 7108503 7115226 7118703 7118704 7122145 7125242 7125243 7128566 7131832 7131833 7131834 7134868 7137806 7137807 7143496 7156648 7160100 7160101 7165965 7168941 7168943 7172409 7172411 7175419 7175420 717908
14. 93 fax 65 6261 8378 mmsinfo moldmasters com SPAIN Mold Masters Espana Serennia Business Center Buenos Aires 37 29 08902 Hospitalet de Llobregat Barcelona Spain tel 34 93 802 36 01 fax 34 93 802 49 08 es moldmasters com International Representatives Argentina Sollwert S R L La Pampa 2849 B C1428EAY Buenos Aires Argentinia tel 54 11 4786 5978 fax 54 11 4786 5978 Ext 35 sollwert fibertel com ar Denmark Norway Sweden Englmayer A S Skenkelsoevej 9 Postbox 35 DK 3650 Oelstykke Denmark tel 45 46 733847 fax 45 46 733859 support englmayer dk Israel ASAF INDUSTRIES Ltd 29 Habanai Street PO Box 5598 Holon 58154 Israel tel 972 3 5581290 fax 972 3 5581293 sales asaf com Romania International Mold Trade Co SRL Str Constantin Aricescu Nr 21 Bl 20 Sc 2 Apt 20 Bucharest Sector 1 Romania tel 4021 230 60 51 fax 4 021 231 78 43 contact matritehightech ro E Drive User Manual Australia Comtec P E 1084 South Road Edwardstown South Australia 5039 PO Box 338 Magill South Australia 5072 tel 61 8 8374 4633 fax 61 8 8299 0892 bparrington comtecipe com Finland Oy Scalar Ltd Viertolantie 12 11120 Riihimaki Finland tel 358 19 783 191 fax 358 19 783 190 info scalar fi Italy Commerciale Isola SPA Via G B Tiepolo 3 35010 Cadoneghe Padova Italy tel 39 49 706600 fax 39 49 8874231 info com isola it Turkey MMG Consulting a
15. Indicates an immediate or potentially hazardous situation which if not avoided could result in a serious injury or death CAUTION Failure to follow instructions may damage equipment NOTE Indicates additional information or used as a reminder Warranty and Documentation Please check with your original order documentation for warranty details NOTE W Please do not return any parts to Mold Masters without prior pre authorization and a return authorization number supplied by Mold Masters 2007 Limited Documentation will include one or more of the following e Information on the Mold Masters E Drive system in general and information on the Mag Pin Magnetic Valve Pin Holder option e Parts list contains all system components Together with the general assembly drawing the parts list should be referenced when ordering spare parts e General assembly drawing used to integrate your E Drive system into the mold WARNING This manual must be used in conjunction with any appropriate Machine Hot Runner and Tem b perature Controller User Manual Release Details EMMEDUM10 25 March 2013 E Drive User Manual Revision 10 Ji Mold Not under documentation control if printed May be revised without notice 003 2013 Masters Electronic version is available at www moldmasters com 1 1 E Drive Wa Trademarks and Patents ACCU VALVE DURA FLEX DURA FLEX SERIES FUSION SERIES HOT EDGE INJECTIONEER ING MASTERPR
16. May be revised without notice 03 2013 Masters Electronic version is available at www moldmasters com 5 4 E Drive lt S 7 5 Assemble ball screw and ball nut 7 5 1 The nut is to be mounted as follows Remove the rubber ring from one end of the mounting arbor 7 4 Assemble ball nut on ball screw Ball screw mounting kit EDRIVEBSMNTKITP is supplied with the system CAUTION Do not disassemble the arbor from ball nut before getting ready for as sembling it into the ball screw 7 5 2 Push the mounting arbor with nut until it bears against the end of the thread The arbor must make contact with no axial clearance Arbor needs to be placed properly against ball screw when rotating the ball screw Failure to do so may result in balls falling out of assembly It would be very difficult to reassemble the balls and unit may have to be Carefully turn the nut unit onto the thread ap 7 5 3 Keep the arbor and rubber rings in plying only slight thrust Remove the arbor only a safe place You will need them for when the nut unit is fully located on the screw disassembly of the ball screw from thread ball nut i E Drive User Manual Revision 10 Mold Not under documentation control if printed May be revised without notice 003 2013 Masters Electronic version is available at www moldmasters com 5 5 7 6 Release the tension of the belt 9 Attach the synchro plate to top plate assembly 7 6 1
17. OBE MASTER SHOT MOLD MASTERS MELT DISK MOLD MASTERS ACADE MY MASTER SERIES MASTERSOLUTION MASTERSPEED MERLIN MOLD MASTERS SYSTEM MPET SCAN MASTER STACK LINK are the registered trademarks of MOLD MASTERS 2007 LIMITED Information contained herein is to our best knowledge true and accurate but all recommendations or sug gestions are made without guarantee Since the conditions of use are beyond our control Mold Masters disclaims any liability incurred in connection with the use of our products and information contained here in No person is authorized to make any statement or recommendation not contained herein and any such statement or recommendation so made shall not bind Mold Masters Furthermore nothing contained herein shall be construed as a recommendation to use any product in conflict with existing patents cover ing any products or its use and no license implied or in fact granted herein under the claims of any patents Nopartofthispublicationmaybereproducedortransmittedinanyformorbyanymeans electronicormechanical including photocopy recording orany information storage and retrieval systemwithoutpermission in writing from the publisher All details standards and specifications may be altered in accordance with technical development without prior notification May be manufactured under one or more of the following U S Patents 0148594 5206040 5217730 5223275 5227596 5227181 5235737 5238378 5238391 5268184 5269
18. User Manual Mold AUERS e performance delivered E Drive AEEEEEEEEEEENK T1773 Table of Contents Section 1 Introduction Symbols Used in the Manual Warranty and Release Details We a a Trademarks and Patents ccccccceccececcccccecececececceteneaeeceneueateneneatsteneananenenears Section 2 Global Support Manufacturing FacCilitieS ssssssssss aieo RGgsIlc International RepresentatiV S sss Section 3 Safety OOC WON cr SY AZ A c E Drive Safety VVAthilids asse o ca iaa a E o Tie zB uec M TAG FP US Section 4 Preparation 111110016 11 o Pc Screw pro tg MERO oe eer a Tools 216 0 80 M arene ce e RIM AG diuo 010 EEE e ERA 010 Establishing Your System Type sss Typical E Drive System sss E Drive 1 1 1 aa nk E Drive User Manual Not under documentation control if printed May be jm without notice Electronic version is available at www moldmasters c Revision
19. alve pin height after final assembly into synchro plate at heated condition Re adjust as required to ensure proper valve pin height 0 50mm E Drive User Manual Revision 10 z Not under documentation control if printed May be revised without notice 03 2013 Mias rg Electronic version is available at www moldmasters com 6 5 E Drive AEN ZXLL ILLIZEM 8 Lubricate O ring PNOR2 017 with a thin layer of high temperature grease and place it into the relat ed groove on the valve pin holder VPHOLDER12 Clean excessive grease from top and side faces 9 Place the valve pin into the valve pin holder slot and then gently place the assembly into the housing as sembly avoid impact forces on the magnet 10 The Mag Pin is now ready for assembly into the synchro plate Heat up the system and complete final valve pin height adjustment if valve pin protru sion is not correct i E Drive User Manual Revision 10 Mold Not under documentation control if printed May be revised without notice 003 2013 Masters Electronic version is available at www moldmasters com 6 6 E Drive S Mag Pin Extraction NOTE JJ For this procedure Mold Masters recom mends using Extraction Tool MM Part EXTOOL13 see below with Extraction Tool MM Part EXTOOLASO1 _ EXTOOL13B M8 Thread M5 Thread EXTOOL13A 1 Heatthe system to processing temperature ensur 3 Remove the M5 screws securing the Mag Pin
20. aper bushing set screws on top of both ball screw pulleys 1 4 20 UNC NOTE use another standard 74 20 socket head cap screw to jack the pulley until it releases make sure synchro plate remains all the way up and seated flat Replace the belt Put back the idler without teeth and tighten the nuts E Drive User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com f 10 11 12 13 14 Install the taper bushing allowing the pulley to still rotate not gripping yet Apply slight tension to engage two pulleys check elevation of pulleys Time both ball screw pulleys to engage in same Way Tighten the taper bushing set screws on top of ball screw pulleys make sure the pulleys are at proper elevation and synchro plate remains flat and seated Do not apply more than 80 Ib in torque to the set screws Apply proper tension to belt Tighten the motor mount screws Tighten the locknut on tensioning pulley Check belt height all around and make sure it is in middle of all pulleys and not rubbing on sides measure depth of belt at various places and check alignments If possible while system is heated do a few dry cycles using 24 VDC manual trigger and check movement and noise Double check the position of belt within all pulleys See E Drive Controller Operating Manual Idler tensioning screw Tensioning idler
21. ch with lots of metal chips or grinding powder Always use new and clean rags with no metal chips to clean the parts before assembly Handle the magnets in a safe and thick plastic container Do not place the magnets close to a ferromagnetic part or close to another magnet Their light weight and high magnetic strength can cause a powerful collision force that may cause the magnet faces to chip or even break due to impact 1 Clean the top surface and side wall of the magnet with alcohol based cleaner recommend Dena tured Alcohol DA 2A and let it completely dry about 15 minutes c En Clean with Alcohol E Drive User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 7 Assemble the nut and lock magnet holder do not disrupt adhesive bonding perform within 15 min or after 24 hours Lubricate O ring with a thin layer of high tempera ture grease and place it into the related groove on the valve pin holder Clean excessive grease from top and side faces Place the valve pin into valve pin holder slot and then gently place the assembly into the housing as sembly Avoid impact forces on magnet 10 The Mag Pin is now ready for assembly into the synchro plate Heat up the system and complete final valve pin height adjustment if valve pin protru sion is not correct Clean and inspect the magnet hold
22. er VPMAG HOLDERO 1 Make sure the interface with the magnet has no grease burrs or dust Clean the mating surfaces of the magnet holder with alcohol based cleaner Let it dry for 15 minutes Apply a thin layer of LOCTITE 620 to the mating faces of the magnet holder as shown below Wipe off any excess adhesive a thin uniform layer pro vides the best adhesive performance Clean with alcohol Once dry apply adhesive to mating faces i Revision 10 Mff Ed 03 2013 Masters 6 4 E Drmie Magnetic Valve Pin Option 4 Forease of assembly place the magnet holder on 6 Immediately place the magnet holder and magnet top of assembly Place the magnet into the magnet into the housing VPMAGHOUSING071 holder Rotate the magnet holder counter clockwise with a omm hex key until threaded portion protrudes In order to not disturb the set of the adhesive any further steps must be done within 15 min utes of bonding the magnet or after the adhe sive has cured for 24 hours 5 Detach the valve pin holder from the magnet holder slide to the side Make sure the magnet is completely seated in the magnet holder and wipe off any excess adhesive from surfaces 7 Assemble the nut and lock magnet holder 7 1 Assemble the jam nut M12 1 00 NUTLM12F 01 as shown Note pitch of thread is 1 00mm per turn 7 2 Adjust the heights to have 0 50mm gap as shown default setting for adjustability 0 50mm Re examine v
23. ion 3 000 000 cycles Replacement of Bearings After 1 5 million 1 500 000 cycles replace Fixed and Floating Bearings Identified on page 5 1 Mold Master Part Number Fixed Bearing LBSF BO01 2 per Synchro plate Floating Bearing FBSB61904 2RS1 2 per Synchro plate i P 5 E Drive User Manual Revision 10 Mold Not under documentation control if printed May be revised without notice 03 2013 Masters Electronic version is available at www moldmasters com 7 1 Maintenance E Drive Assembly Disassembly of Top Plate Assembled 5 Remove tension from belt and remove ball nut System holder screws Loosen 12 screws attached Remove to ball screw nut using a tension from hex key tool with strong belt hex tip Remove plates up to top plate Remove 12 screws attached to ball screw nut Remove locating ring and any clamp plate plates with KEY BPHEXTKEYS5 0 Remove insulation plate oN 5 Remove all screws on top plate 6 Lift the top plate assembly carefully to have access to grease lines grease lines CAUTION Be very careful with ball nuts Make sure both CAUTION ball nuts remain in proper orientation and The system must be heated before manu at same elevation If any of the ball nuts get ally rotating the belt if the taper locks are rotated without having proper arbor at the end engaged with ball screw pulleys of ball screws balls may fall o
24. mp Engineering Yesil esme Sok No 30 3 iftehavuzlar 81060 Istanbul Turkey tel 90 216 357 0783 fax 90 216 385 0656 mmgevrek superonline com Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 2 2 Bulgaria Mold Trade OOD 62 Aleksandrovska St Ruse City Bulgaria tel 359 82 821 054 fax 359 82 821 054 contact mold trade com Ireland Bray Engineering Services Mr Liam Shortt Unit F3 Network Enterprise Business Park Kilcoole Co Wicklow Ireland tel 353 1 201 5088 fax 353 1 201 5099 info BrayEngineeringServices com Portugal Gecim LDA Rua Fonte Dos Ingleses No 2 Engenho 2430 130 Marinha Grande Portugal tel 351 244 575600 fax 351 244 575601 gecim gecim pt Vietnam Lotus Chemical Technology 393 Dien Bien Phu St Ward 4 Dist 3 Ho ChiMinh City Vietnam tel 84 8 832 7605 fax 84 8 832 7730 dieuphuoc nguyen lotusfirma com E Revision 0 Mff Ed 60205 Masters E Drive lt E Section 3 Safety Introduction Any instructional material provided by Mold Masters for the operation and maintenance of equipment does not in any way absolve the employer from fulfilling the following obligations and Mold Masters disclaims liability 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 set
25. omagnetic parts Their light weight and high magnetic strength can cause a powerful collision force that may cause the magnet to chip or break due to impact i Revision 10 Mfg Ed 602205 Masters E Drive Preparation Section 4 Preparation Introduction The following section is a step by step guide to preparing your Mold Masters E Drive system for use Screw Lengths 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 shearing The expansion factor is calculated into the length of each screw size WARNING DO NOT SHORTEN SCREW S H C S M12 X 130 ISO GRADE 12 90 OR 13 X 4 75 ASTM A574 NOT SUPPLIED BY MOLD MASTERS H B 3 She d 8 T ESE 1831 2 SOCHIT HEAD DAP SIFET 5675 18 X 1 001 a ee Se ST CAD DAP OR Psled3 a zHCSAoB T1X4 0 ST MEAD DAP SOPDW S B 1 x a4 DO i 3 E Drive User Manual Revision 10 Mold Not under documentation control if printed May be revised without notice 003 2013 Mas
26. on Tool EXTOOL13B using M5 thread end for extraction of valve pin M5 Screw M8 Thread EXTOOL13B M5 Thread i 8 Revision 10 Mold 003 2013 Masters 6 8 E Drive ZEE 77773 Section 7 Maintenance Introduction This chapter is a guide to maintaining the Mo d Masters E Drive system See the Mold Masters Hot Runner User Manual for other maintenance procedures Repairs that should be performed by Mold Masters personnel are not included f 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 Recommended Maintenance Every 6 months or 250 000 cycles whichever comes first Lubrication of Ball Screw Assembly Recommended grease is Castrol Longtime PD2 MM Part 104L11051 e For first time assembly use 4g 4cc per ball nut e For 6 month or 250 000 cycles maintenance whichever comes first use 2g 2cc per ball nut See Assembly Disassembly of Top Plate on following page Inspection of the Timing Belt If the timing belt becomes too loose and needs to Grease line on ball nuts be tensioned follow instructions Tightening the ball screws not shown Belt If the timing belt is worn out or shows signs of cracking replace it following the instructions for First Time Installation or Replacement of the Belt It is recommended replacing the belt after 3 mill
27. rew Pulley 2 Timing Belt Tensioning Idler Pulley Tensioning Idler Screw E Drive User Manual Revision 10 J Mold Not under documentation control if printed May be revised without notice 003 2013 Masters Electronic version is available at www moldmasters com 4 3 E Drive ZEN LL oynchro Plate Inlet Extension Tensioning Idler Assembly oynchro Plate Valve Pin Holder Ball Screw Assembly Valve Pin oynchro Plate Guiding E Drive User Manual Revision 10 mg Not under documentation control if printed May be revised without notice 003 2013 Masters Electronic version is available at www moldmasters com 4 4 E Drive lt E Drive Components Tensioning Idler Assembly E Drive Motor Mount exploded view Fix Idler without eeth E Drive User Manual Revision 10 Mold Not under documentation control if printed May be revised without notice 03 2013 Masters Electronic version is available at www moldmasters com A 5 E Drive lt Section 5 Assembly Introduction Your Mold Masters E Drive system is shipped pre assembled and requires minimal pre installation assembly The following details the assembly installation procedures for various components of the E Drive Complete Assembly 3D View Optional Custom Clamp Plate Shown Ballscrew Fixed Bearing Angular Contact Bar Bearing Floating Bearing Ball Bearing b E Drive User
28. ronic version is available at www moldmasters com 5 1 0 E Drive ANNE TL AZZLIEIZE Section 6 Mag Pin Option Introduction The following provides details for the assembly installation of the Mag Pin Magnetic Valve Pin Holder which is an optional component of the E Drive This mechanism allows the deactivation of any individual valve pin in the synchro plate design at press without need to open up mold plates A deactivated valve pin will remain at the closed position This provides the ability to selectively shut down any cavity in a synchro plate design Mag Pin Assembly 3D View NUTLM12F 01 locking nut VPMAGHOLDERO1 Adjustable magnet holder VPMAGNETO 1 ES magnet N SHCSM5X15 recommended screws for attachment to synchro plate PNOR2 017 O ring for dust protection VPMAGHOUSINGO1 VPHOLDER12 main holder body Valve pin Holder Valve pin STD 2 5 or 3 mm b E Drive User Manual Revision 10 F Not under documentation control if printed May be revised without notice 603 2013 Masters Electronic version is available at www moldmasters com 6 1 E Drive AEN ZXLL LLIZN Mag Pin Application Cautions This product is not suitable for all material and hot The following conditions are not recommended for Mag runner applications Please contact Mold Masters Pin application regarding your application Molding very soft and elastic materials with Durom Fac
29. s Europa GmbH Hlavni 823 75654 Zubri Czech Republic tel 420 571 619 017 fax 420 571 619 018 cz moldmasters com MEXICO MM Hot Runner Injection Mexico S A de C V Av San Carlos No 4 Nave 2 Parque Industrial Lerma Lerma Estado de M xico 52000 M xico tel 52 728 282 48 33 fax 52 728 282 47 77 mexico moldmasters com Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com ASIAN HEADQUARTERS CHINA HONG KONG TAIWAN Mold Masters KunShan Co Ltd Zhao Tian Rd Lu Jia Town KunShan City Jiang Su Province People s Republic of China tel 86 512 86162882 fax 86 512 86162883 mmc sales moldmasters com JAPAN Mold Masters K K 1 4 17 Kurikidai Asaoku Kawasaki Kanagawa Japan 215 0032 tel 81 44 986 2101 fax 81 44 986 3145 info mmkk co jp FRANCE Mold Masters France Zl la Marini re 2 Rue Bernard Palissy 91070 Bondoufle tel 33 1 82 05 00 80 fax 33 1 82 05 00 83 fre moldmasters com POLAND Mold Masters Europa GmbH Skr Pocztowa 59 00 908 Warszawa Poland tel 48 0 66 91 80 888 fax 48 0 66 91 80 208 pl moldmasters com Revision 10 Mff lcd 602205 Masters E Drive ZEE E7778 Regional Offices Con t SINGAPORE MALAYSIA INDONESIA THAILAND Mold Masters Singapore PTE Ltd No 48 Toh Guan Road East 206 140 Enterprise Hub Singapore 608586 Republic of Singapore tel 65 6261 77
30. screws Taper bushing screws Use standard 1 4 20 socket head cap screw to jack taper lock Idler nut amp pulley without teeth Motor mount screws Tensioning screw amp locknut Revision 10 Mold 003 2013 Mat E Drive A 2 Checking for Misalignment During belt installation and drive alignment two types of misalignment can occur e Parallel misalignment is when driveR and driveN shafts are parallel but the two pulleys lie in differ ent planes e Angular misalignment is when the two shafts are not parallel A fleeting angle is the angle at which the belt enters and exits the pulleys and equals the sum of the parallel and angular misalignments Any degree of pulley misalignment will result in some reduction of belt life which is not accounted for in the normal drive design procedure Misalignment of all positive belt drives should not exceed 1 4 or 5 mm per metre of centre distance Misalignment should be checked with a good straight edge tool The tool should be applied from driveR to driveN and from driveN to driveR so that the effect of parallel and angular misalignment is taken into account Parallel Misalignment fleeting angle driveR driveN Angular Misalignment fleeting angle driveR i ran E Drive User Manual Revision 10 Rf m Mold Not under documentation control if printed May be revised without notice 003 2013 Masters Elect
31. terial around valve pin releases the pin and magnet gets engaged at interface once actuation starts Handling Magnets 1 M Deactivated Activated Gate Gate Close Position Open Position Use supplied plastic spacers Part WASHER3 7 between magnets to prevent them from colliding with each other during handling and storage In addition keep groups of magnets in a thick plastic container to avoid impact with other parts or tools Plastic Spacer WASHER37 Magnet WARNING Be careful of potential pinch hazards when handling the magnets E Drive User Manual Revision 10 Mold Not under documentation control if printed May be revised without notice 03 203 Masters Electronic version is available at www moldmasters com 6 3 E Drive AEN ZXLLL LLIZEM Assembly Summary 1 Clean the top and side surface with alcohol Let dry 15 minutes Clean the magnet holder with alcohol Make sure there are no burrs Let dry 15 minutes Apply thin layer Loctite adhesive to mating sur faces of magnet holder Wipe excess adhesive Place magnet into the magnet holder Detach the valve pin holder from the magnet holder slide to side Place the magnet holder and magnet into the housing Assembly Details WARNING e Be careful of potential pinch hazards when handling the magnets CAUTION Assembly must be done on a clean workbench Do not start the assembly on a workben
32. ters Electronic version is available at www moldmasters com 4 1 E Drive AE 77778 Tools Required Depending on the size and complexity of your hot runner system you will require most of the tools and materials listed below e Allen keys Set of imperial size keys and metric sizes 4 5 6 8 and 10 mm for use on both imperial and metric cap screws depend ing on system e Anti seize compound To prevent oxidation of screw threads that could cause screws to seize with high temperatures e Solvents denatured alcohol For removal of rust inhibitors e Calibrated torque wrench For consistent screw pressure throughout the system e Pliers For general assembly work e Circlip pliers To remove and install Circlip in valve systems e Micrometer sizes 0 6 and 0 150 mm To check system part and plate thickness e Depth micrometer To check bore depths e Slot head screw driver Used in installing thermocouples and ground wires e Slot head screw driver small Used in fastening electrical wires to connectors e Crimping tool For fastening connector pins when necessary Wire strippers For preparing wires Utility knife For cutting tape wires etc Glass tape Used for grouping wires into zones e Bluing Compound For checking face contact e Sockets e Lapping compound for valve gate systems e Plastic face hammer e Valve pin pulling tool Long M5 hex key with T handle and snap ring
33. ting up inspecting and maintaining injection molding equipment e Establish and follow a program of periodic and regular inspections of injection molding equipment to ensure they are in safe operating condition and proper adjustment e 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 From the American National Standard for Plastics Machinery Horizontal Injection Molding Machines ANSI SPI B151 1 2007 WARNING For Safety Information also refer to all machine manuals and local regulations and codes 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 2 9 Hoses 10 Area inside the guards and outside the NI E j mold area j 1 Figure 3 1 Injection molding machine HIMM with horizontal clamping unit and horizontal injec tion unit Shown without guards for illustration clarity Front View with Guards Removed T E Drive User Manual Revision 10 m P aem Mold Not under documentation con
34. tors that need to be considered are eter Hardness Style A less than 90 especially for Plastic material very short length nozzles e Molding very viscous materials with very long e Nozzle length nozzles e Valve pin size only for 2 5 and 3 mm diameter valve pins e Accu Valve CX gating style e Gating style Mag Pin Activation Deactivation Regular operation Nozzle is at processing temperature and gate is active Force of magnet is high enough to hold the valve pin attached to synchro plate during opening cycle Deactivated gate Nozzle is turned off and colder plastic all around valve pin holds the pin at close position Therefore valve pin can be detached from synchro plate at magnet interface Close Position Both activated amp Open Position Activated gate 8mm stroke deactivated shown conditions Synchro Plate Open Position Deactivated gate 8mm Stroke shown E Drive User Manual Revision 10 ma Moll Not under documentation control if printed May be revised without notice 03 2013 Masters Electronic version is available at www moldmasters com 6 2 E Drive ABE 7X77I7I773 Deactivation After turning the nozzle off for 5 to 10 minutes depending on material plastic material around valve pin holds the pin in place and decoupling hap pens at magnet interface Activation After turning the nozzle on for 4 to 8 minutes depending on material plastic ma
35. trol if printed May be revised without notice 03 2013 Masters Electronic version is available at www moldmasters com 3 1 E Drive lt Mold Area Mechanical Hazards Area between the plat Crushing and or shearing and or impact hazards caused by ens Movement of the platen Movements of the injection barrel s into the mold area See Figure 3 1 item 1 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 Clamping Mechanism Mechanical Hazards Area Crushing and or shearing and or impact hazards caused by See Figure 3 1 area 2 Movement of the platen e Movement of the drive mechanism of the platen e Movement of the core and ejector drive mechanism Movement of drive Mechanical Hazards mechanisms outside Mechanical hazards of crushing shearing and or impact caused by the movements the mold area and of outside the clamping Core and ejector drive mechanisms mechanism area See Figure 3 1 area 3 Nozzle area Mechanical Hazards The nozzle area is the Crushing shearing hazards and or impact hazards caused by area between the barrel Forward movement of the plasticizing and or injection unit including nozzle and the sprue bushing Movements of parts of the power operated nozzle shutoff and their drives See Fig
36. troller mode of operation should be RefPinPosition Mode 14 2 Check MECHANICAL FACTOR See E Drive Controller Operating Manual f Ball screw assembly package name is EDRIVEBSASMO 1 then Mechanical Gear ing Factor needs to be set to 1 0 Hint In such cases shown diameter of the top pulley is D 62mm or 2 45 If Ball screw assembly package name is EDRIVEBSASMO 2 then Mechanical Gear ing Factor needs to be set to 1 2 Hint In such cases shown diameter of the top pulley is D 5mm or 2 95 i E Drive User Manual Revision 0 ffe Not under documentation control if printed May be revised without notice 03 2013 Masters Electronic version is available at www moldmasters com 5 8 E Drive First Time Installation or Replacement of the Belt 1 If system is new and no plastic is inside move the synchro plate to home position fully open posi tion With proper hex keys on top of ball screws rotate clockwise If system has run plastic before make sure you heat up the system before moving the synchro plate to fully open position In such case attach cooling lines to cooling system and make sure that Mold Temperature will not exceed 70 C 158 F for E Drive plates Remove tension from belt completely from both sides motor mount amp tensioning idler Loosen nuts above one idler without teeth and remove the idler pulley to allow inserting the belt in tight belt conditions Remove the t
37. tromagnetic disturbance that can cause failures in the machine control systems and adjacent machine controls Electrical or electromagnetic disturbance generated by the motor control unit High pressure discharge 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 E Drive User Manual b Revision 10 Mold 2 Not under documentation control if printed May be revised without notice 03 2013 Masters Electronic version is available at www moldmasters com 3 3 E Drive lt Mag Pin Safety E Drive Safety Warnings Never touch or inspect the timing belt when A power is on and E Drive motor and controller are connected Unplug the controller before any maintenance Do not operate the equipment with unconfined long hair loose clothing or jewellry including name badges neckties etc These may get caught by the moving belt mechanism and can cause death or serious injury Always cover belt area with proper protecting sheet before any bench test or in mold testing High Voltage and amperage cables are con nected to E Drive controller 220VAC Also there is high voltage cable connection between servo motor and controller Unplug the controller before performing any maintenance work E Drive Cautions Make sure the controller power supply is un a plugged or turned off
38. ure 3 1 area 4 e Over pressurization in the nozzle Thermal Hazards Burns and or scalds due to operating temperature of e The nozzle e Plasticized material discharging from the nozzle Plasticizing and or Mechanical Hazards injection unit area Crushing shearing and or drawn into hazards caused by Area from the adaptor Unintentional gravity movements e g for machines with plasticizing and or barrelhead end cap injection unit positioned above the mold area to the extruder motor The movements of the screw and or the injection plunger in the cylinder acces above the sled including sible through the feed opening the carriage cylinders Movement of the carriage unit See Figure 3 1 area 5 Thermal Hazards Burns and or scalds due to operating temperature of e The plasticizing and or injection unit e The heating elements e g heater bands e The 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 3 E Drive User Manual Revision 10 Mold Not under documentation control if printed May be revised without notice 003 2013 Masters Electronic version is available at www moldmasters com 3 2 ie E Drive EE 7738 Feed Opening See Figure 3 1 area 6 Area of the heater bands of the plasticiz ing and or injection cylinders See Figure
39. ut of assembly It would be very difficult to find and reassemble the balls and ball nut In such case the ball nut may need to be scrapped 5 E Drive User Manual Revision 10 amm Not under documentation control if printed May be revised without notice 008 2013 naoi E Electronic version is available at www moldmasters com 725 E Drive lt S Index A Assembly 5 1 Assembly Center Section 5 1 Ball Screw 4 5 Ball Screw Assembly 7 1 Bearings Replacement 7 1 Belt 5 9 7 1 C Clamping plate 5 2 Cleaning 4 2 Components 4 5 Controller 3 4 Documentation 1 1 E Drive System 4 3 Fr Fixed Bearing 7 1 Fix Idler 4 5 Floating Bearing 7 1 G Global Support 2 1 Grease 7 1 Hazards 3 2 3 3 Insulation plate 5 2 Interface plate 5 2 Introduction 1 1 L Leader pins 5 3 Locating ring 5 2 E Drive User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Magnets 3 4 6 3 Mag Pin 6 1 Mag Pin Extraction 6 7 Maintenance 7 1 Manifold plate 5 2 Misalignment 5 10 Motor Mount 4 5 P Parallelism 5 2 Patents 1 2 plastic spacers 6 3 Preparation 4 1 Release Details 1 1 S Safety 3 1 Safety E Drive 3 4 Safety Hazards 3 1 Safety Mag Pin 3 4 Screw Lengths 4 1 Symbols 1 1 synchro plate 5 2 System Type 4 2 T Temperatures 3 4 Tensioning Idler Assembly 4 5 Tools 4 2 Top plate 5 2 Top Plate Assembly Disassembly 7
40. w counter clockwise to tighten the belt 10 4 Tighten the motor mount screws Motor mount Screws Tensioning screw amp locknut 11 Inspect parallelism of the synchro plate If holes for inspection of synchro plate are provided check parallelism of the synchro plate with proper depth gauge tools ry Enlarged view Inspection holes i E Drive User Manual Revision 10 Mold Not under documentation control if printed May be revised without notice 003 2013 Masters Electronic version is available at www moldmasters com o E Drive A 2 13 Assemble the insulation plate and locating ring oc 14 Perform E Drive Controller Checks 15 The hot half is now ready to be installed into the Before startup of the system read E Drive Con mold troller Operating Manual i CAUTION e Make sure the synchro plate valve pins are CAUTION y alv Do not swap E Drive Controllers for at the open position before shipping different E Drive systems without checking manual as controller setup must match mechanical system 14 1 Check MODE OF OPERATION See E Drive Controller Operating Manual e f E Drive system is designed to have the synchro plate bottoming at a hard stop at close position of valve pins E Drive controller mode of operation should be EndStop Mode f E Drive system is designed to have the valve pins closing position set within a certain range usually 0 3mm E Drive con
Download Pdf Manuals
Related Search