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Mold-Masters Master Series User Manual
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Mold-Masters Master Series User Manual

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Summary of Contents for Mold-Masters Master Series

  • Page 1 Hot Runner User Manual Original Instructions...
  • Page 3 Table of Contents ® Table of Contents Section 1 - Introduction ...........1-1 Intended Use ........................Operator Training and Safety ....................Warranty ..........................Documentation ........................Release Details ........................Trademarks and Patents ..................... Section 2 - Global Support ..........2-1 Manufacturing Facilities ....................... Regional Offices ........................
  • Page 4 Table of Contents ® Section 5 - Assembly ............5-1 Introduction .......................... Gate Seal Finishing ......................Hot Valve / Hot Sprue / F Type .................... Water-cooled Gate Insert Installation (Option) ..............Master-Series Thermocouple Installation ................Master-Series Thermocouple Removal ................Dura Line Thermocouple Installation ................... Nozzle Insertion ........................
  • Page 5 Table of Contents ® Section 8 - System Start Up & Shut Down .....8-1 Introduction ......................... Pre-Start up ......................... Shut Down .......................... Section 9 - Color Change ..........9-1 General Tips ........................Procedure A: Simple & Effective ..................Procedure B: More Comprehensive ..................Section 10 - Hydraulic / Pneumatic Actuators .................10-1 Installation and Assembly of the Valve Actuator ..............
  • Page 6 Table of Contents ® Checking Nozzle Tip Height ....................11-9 Latching the Cavity Plate to the Manifold Plate (Hot Half)..........11-11 Torque Settings......................... 11-12 Section 12 - TIT Edge Gated System ......12-1 Introduction ......................... 12-1 TIT Edge Gated System ..................... 12-1 TIT Edge Gate Seals ......................
  • Page 7 Table of Contents ® Section 16 - Troubleshooting ........16-1 Introduction ......................... 16-1 Moisture Related Issues ..................... 16-1 Pre-Molding Precautions ....................16-2 Establishing Root Cause ....................16-2 Fault Identification ......................16-2 Defect Types, Causes and Remedies Index ..............16-3 Parts have Dark Specks ..................... 16-4 Parts have Blisters and/or Bubbles ..................
  • Page 9 We would like to take this opportunity to thank you for purchasing a Mold-Masters hot runner. The purpose of this manual is to assist users in the integration, operation and maintenance of Mold-Masters sys- tems. This manual is designed to cover most system configurations. If you need additional information specific to your system, or information in another language, please contact your representative or a Mold-Masters office.
  • Page 10 Information contained herein is, to our best knowledge, true and accurate, but all recommendations or sugges- tions 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 herein. No person is authorized to make any statement or recommendation not contained herein, and any such statement or recom- mendation so made shall not bind Mold-Masters.
  • Page 11 GERMANY / SWITZERLAND CHINA/HONG KONG/TAIWAN CANADA GERMANY / SWITZERLAND CHINA/HONG KONG/TAIWAN Mold-Masters (2007) Limited Mold-Masters Europa GmbH Mold-Masters (KunShan) Co, Ltd Mold-Masters (2007) Limited Mold-Masters Europa GmbH Mold-Masters (KunShan) Co, Ltd 233 Armstrong Avenue Postfach/P.O. Box 19 01 45 Zhao Tian Rd 233 Armstrong Avenue Postfach/P.O.
  • Page 12 Mold-Masters Europa GmbH Serennia Business Center Merkezi Almanya Türkiye İstanbul Şubesi Serennia Business Center Merkezi Almanya Türkiye İstanbul Şubesi Mold-Masters Singapore PTE. Ltd. Mold-Masters Singapore PTE. Ltd. Buenos Aires 37-29 Alanaldı Caddesi Bahçelerarası No 48 Toh Guan Road East Buenos Aires 37-29 Alanaldı...
  • Page 13 Section 3 - Safety Introduction Please be aware that the safety information provided by Mold-Masters does not absolve the integrator and employer from understanding and following international and local standards for safety of machinery. It is the responsibility of the end integrator to integrate the final system, provide necessary e-stop connections, safety interlocks and guarding, to select the appropriate electrical cable for the region of use and to ensure compliance with all relevant standards.
  • Page 14 Safety ® Hazard Area Potential Hazards 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 See Figure 3-1 item 1 area Movements of cores and ejectors and their drive mechanisms.
  • Page 15 Safety ® Hazard Area Potential Hazards 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- • The plasticizing and/or injection unit.
  • Page 16 Safety ® Safety Symbols Typical to Injection Molding Machines GENERAL DESCRIPTION OF SYMBOL 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.
  • Page 17 • All maintenance on Mold-Masters products should be performed by properly trained personnel based on local law or regulation requirements. Electrical products may not be grounded when removed from the assembled or normal operating condition.
  • Page 18 Safety ® CAUTIONS CAUTION All Mold-Masters heated components are manufactured to standards that ensure safe and reliable operation provided that the following precautions are met: • To maximize heater element and component life, the temperature must be controlled and maintained within safe operating limits.
  • Page 19 ® Section 4 - Preparation Introduction The following section is a step-by-step guide to preparing your Mold-Masters system for use. Tools Required Depending on the size and complexity of your hot runner system, you will require most of the tools and materials listed below.
  • Page 20 1. Disassemble the system. 2. Check that all mold base dimensions are correct 2. Wipe down the nozzle body. and correspond to Mold-Masters general assem- 3. Remove the part and wipe clean. bly drawings. 4. If necessary, use a cotton swab to clean nar- row interior surfaces or screw threads.
  • Page 21 Preparation ® 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 component lists. If your system does not match these systems, please refer to other specialty systems mentioned within the manual for additional information.
  • Page 22 Preparation ® System With Hydraulic or Pneumatic Units Insulation Board Leader Pins Locating Ring Top Clamp Plate Jiffy Plugs Hydraulic / Pneumatic Actuators Hydraulic Plate Pipe Plugs Inlet Extension Valve Disks Manifold Nozzle Manifold Locator Electrical Box Leader Bushing Wire Retainer Manifold Plate Name Plate Figure 4-6...
  • Page 23 Preparation ® System with Bridged Hydraulic Pneumatic System Insulation Board Locating Ring Top Clamp Plate Hydraulic Plate Backplate Hydraulic / Bridge Step Pneumatic Actuators Valve Disks Manifold Nozzle Electrical Box Manifold Plate Name Plate Figure 4-7 Hot Runner User Manual Revision 18 Not under documentation control if printed.
  • Page 25 This section is a step-by-step guide to assembling your Mold-Masters hot runner system. Cutaway of a “cast-in” system This illustration of a typical Mold-Masters “cast-in” hot runner system is divided into two halves (valve side and non-valve side). The terminology associated with the various components and features are listed below.
  • Page 26 ® Cutaway of a “bolt-in” system This illustration of a typical Mold-Masters “bolt-in” hot runner system is divided into two halves (valve side and non- valve side). The terminology associated with the various components and features are listed below. Hot Half - Bolt In Arrangement...
  • Page 27 The gate seals supplied with your system may need to be adjusted to tolerances based on the material grade and cooling in the cavity. Refer to your Mold-Masters General Assembly Gate Detail drawing to determine if gate seal finishing is required.
  • Page 28 Assembly ® Master-Series Thermocouple Installation 1. Clean the nozzle thermocouple bore. • For 1 mm thermocouples use a #58 drill in a pin vise. • For 1.5 mm thermocouples use a 1/16 inch drill in a pin vise. Figure 5-7a Figure 5-7b 4.
  • Page 29 6. Install the clip over the terminal end. lation This page only applies to Legacy Dura Nozzles. Mold-Masters Dura systems are supplied with an ap- propriate bending tool. Any questions regarding bend- ing tools, please contact your Mold-Masters represen- tative. Make sure that correct bending tool is used.
  • Page 30 Assembly ® 6. Press thermocouple downwards to sit against ter- minal end and secure to side of terminal end with heat resistant tape to ensure it does not become pinched between the nozzle and the manifold. Figure 5-14 4. Insert the bent thermocouple end into the nozzle Figure 5-17 mating hole and make sure it is fully engaged.
  • Page 31 Assembly ® Nozzle Insertion 3. Check that Face 1 is at the same level for all nozzles relative to the mold plate split line. NOTE Face 1 Prior to commencing assembly verify manifold and nozzle cutouts in mold plates are to specification to ensure proper clear- ance to hot runner.
  • Page 32 Assembly ® Front Mounted Thermocouples 1. Mount the valve bushing on top of the nozzle. NOTE 1. Place a zone number on each wire and thermo- couple. The valve bushing for Accu-Valve has a locating dowel pin with the mold. 2.
  • Page 33 Assembly ® SURFACE A SURFACE B FACE Y Figure 5-27 Locator Surface Manifold Locator 1. Depending on your system, the manifold locator may require final grinding. NOTE Figure 5-25 Valve Bushing Installation Refer to the GA drawing for details of your 1.
  • Page 34 Assembly ® Manifold Locating Dowel Pin Installing the Manifold Thermocouple 1. Install the dowel pin into the mold. This procedure only applies to integrated systems. 2. Check that the manifold locating dowel pin does 1. Although not necessary, a thermal compound may not touch the top of the manifold.
  • Page 35 Assembly ® Main Manifolds Inlet Seal Installation (with step) Manifolds that use inlet seals with a step: Manifolds distribute melt from the inlet component to one or more sub-manifolds. If you have a sub manifold 1. Install the step inlet seal to the manifold. configuration, follow these instructions.
  • Page 36 Assembly ® Pressure Disk - Final Grinding Required b. Measure the top section of the nozzle flange “b”. This type of pressure disk is supplied oversize in height and requires grinding to dimensions specified on the general assembly drawing. Pressure disk or valve disk height = Pocket depth - (Manifold thickness + Nozzle flange + Air gap) air gap disk height...
  • Page 37 Assembly ® Pressure Disk - Final Grinding Not 3. The actual height (thickness) of the supplied pres- sure disk “e” will be of a value that’s higher than Required the value “d”. Calculate the difference, and then divide by 2. This is the value that will need to be ground from each side of the pressure disk.
  • Page 38 Assembly ® EcoDisk Installation Valve Disk - Final Grinding Required These valve disks are supplied oversize in height and EcoDisks are present on all Sprint systems and require grinding to dimensions specified on the gen- optional on others. They are installed directly onto eral assembly drawing before calculating the pressure the clamp plate and will align with the pressure disks valve disk height.
  • Page 39 4. Secure the heater plate to the manifold. Refer to on your Mold-Masters system. However, the general assembly drawing for location. Use when multiple heater plates are controlled anti-seize compound on the threads.
  • Page 40 Assembly ® Installation of Inlet NOTE Heater plates mounted on the side of the Components manifold may require heater plate holders. See the diagram below if applicable. The following procedures refer to different system configurations. Refer to your parts list and general as- sembly drawings to determine your system type.
  • Page 41 Assembly ® Center Heater Installation Inlet Extension Installation The center heater may require the machine nozzle radius to be added. 1. Place the inlet extension on the manifold. 1. Place the center heater on the manifold. 2. Install mounting screws through the nozzle flange and into the manifold.
  • Page 42 Assembly ® Inlet Extension with Pressure Sleeve 4. Chamfer the outside edge of the pressure sleeve. 5. Place zone number on each wire and thermo- CAUTION couple. Always install the inlet extension, pressure 6. Tape wires for each zone together. sleeve, clamp plate and locating ring with the mold plates in the horizontal position.
  • Page 43 Section 6 - Electrical Testing Introduction This section contains guidelines for electrical testing of your Mold-Masters hot runner 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...
  • Page 44 Electrical Testing ® The conditions for automatic shutdown of the supply is set at Mold-Masters and is usually set such that the protective conductor resistance between the ground- ing conductor connection and all of the protective Ω earth conductor connected parts, is Maximum 0.3...
  • Page 45 Electrical Testing ® Thermocouple Wiring Guide- lines • Thermocouples are Type "J" ungrounded and color coded to ASA standards. (White “+”/Red “- “). • The tip must not be truncated or squeezed and must touch the bottom of the bore in order to mea- sure the correct temperature.
  • Page 47 Section 7 - Hot Half Assembly Introduction The following section is a step-by-step guide to assembling your Mold-Masters hot runner system. Figure 7-1 Nozzle Depth; 1. Nozzle Well Depth (L) 2. Cavity Plate 3. Manifold Plate Assembling the Hot Half 6.
  • Page 48 If the plates 1. Check that the nozzle well depth (L) in the cavity do not assemble easily, remove the cavity plates plate is to Mold-Masters specifications. See Figure and check for interference. Be careful to not dam- 7-1.
  • Page 49 System Start Up & Shut Down ® Section 8 - System Start Up & Shut Down Introduction This chapter explains how to start up and shut down your hot runner system. NOTE See "Section 14 - Melt-Disk System" and "Section 15 - Melt-Cube System" for start up and shut down procedures for those products.
  • Page 50 Shut Down NOTE For Melt-Disk, refer to the accompanying Mold-Masters Controller operating manual. 1. Turn off all heat to the system. 2. Leave the mold cooling system on, until the hot runner system temperature is within 55°C (100°F) of the mold temperature.
  • Page 51 20°C (30-40°F) above processing tem- normal. peratures. On Mold-Masters controllers, simply push the boost button on the controller to increase 8. Return all settings to normal and confirm accept- temperatures for a pre-determined time and tem- able part quality.
  • Page 52 (1-2 shots) zones 20°C (30-40°F) above processing tempera- 15. Introduce the new color. tures. On Mold-Masters controllers, simply push 16. Leave mold in open position and set the shot size the boost button to increase temperatures for a to maximum possible.
  • Page 53 Hydraulic / Pneumatic Actuators ® Section 10 - Hydraulic / Pneumatic Actuators Introduction This section explains how to assemble and install the valve actuator for: • 5500 Series • 6500, 6600, and 6700 Series • 7100 Series Installation and Assembly of the Valve Actuator The following procedure explains how to assemble and install the valve actuator on a bench.
  • Page 54 Hydraulic / Pneumatic Actuators ® Pre-Installation Piston Assembly 5500 Only 1. Prior to installing the actuator unit, check that all fluid lines in the mold plate are de-burred and 1. Lightly use silicone grease and install the O-ring clean. on the piston. 2.
  • Page 55 Hydraulic / Pneumatic Actuators ® Cylinder Top Assembly 3. Cut pin to calculated length “L”. (L = AD - AC + DE + 3.05*+0.02** [mm]) On the inside face of the cylinder top: L = overall length from tip to top of pin head * 3.05 = head of pin 1.
  • Page 56 Hydraulic / Pneumatic Actuators ® 6X00 Series 2. Measure the distance AC and BC. 3. Calculate the heat expansion factor. 1. Calculate the heat expansion factor. Fh = (Processing temperature - Mold temperature) Fh = (Processing temperature - Mold temperature) °C x 0.000012.
  • Page 57 Hydraulic / Pneumatic Actuators ® Valve Pin Lapping Procedure Valve Pin Finishing of Head for Tapered Valve Pins 5500 Series 5500 and 6X00 Series 1. Heat the hot runner system to the processing tem- perature. If the shut off between the valve pin and gate area is 2.
  • Page 58 Hydraulic / Pneumatic Actuators ® NOTE 6X00 Series The standard stroke of the HY550* A/E is 1. Check the valve pin length. Refer to "Valve Pin 4.0mm. This can be increased to maxi- Finishing of Tip". mum of 8.0mm by removing material from 2.
  • Page 59 Hydraulic / Pneumatic Actuators ® 7100 Series CAUTION Check for sharp edges before installing CAUTION 1. Check the valve pin length. the cylinder. Failure to do so could dam- age O-rings. 2. Slide the valve pin into the piston. 2. Tap the cylinder into the bore of the actuator plate 3.
  • Page 60 Hydraulic / Pneumatic Actuators ® Actuator units should be inspected every 12 months or per pre-determined maintenance schedule. The following procedures are performed on a bench. For Oil Systems: 1. Remove oil from system. 2. Remove the cylinder top with tool in upright posi- tion to prevent oil from entering the system.
  • Page 61 Hydraulic / Pneumatic Actuators ® Extraction Tools for Hydraulic Units & Pistons EXTOOL5500P Cylinder Extraction Head EXTOOLAS01 - KEY04 Common HY5500X - EXTSTUDM8 Extraction Tool Assembly Piston Extraction Head - EXTOOL06 EXTOOL2300P EXTOOLAS01 Replaces EXTOOL5500A, EXTOOLAS01 Piston Extraction Head EXTOOL6500A on newer Common systems - EXTOOL04...
  • Page 63 Section 11 - Maintenance Procedures Introduction This chapter is a guide to maintaining selective components. Repairs that should be performed by Mold-Masters personnel are not included. If you need an item repaired that is not included in this section, please call Mold-Masters support.
  • Page 64 Maintenance Procedures ® 3. For 2-Pc Valve Disk: EXTRACTION TOOLS a) Remove the Valve Flange prior to installing Part Number Where Used extraction tool. 1-Pc Inverted b) Attach the extraction tool to the Valve Stem and Valve Style with remove the stem. 5mm x .8 thread;...
  • Page 65 Terminal Installation Although this procedure shows a manifold, the process is the same for nozzle terminal ends. NOTE Please contact Mold-Masters Spare Parts Department to ensure you have the cor- Figure 11-6 rect repair kit and crimping tool.The tools, along with the lead wire replacement kit, Slide crimps onto leads.
  • Page 66 Maintenance Procedures ® Crimping Tool Chart Grasp the crimp with the crimping tool, slide the crimp into position over the terminal post and Product Name Description crimp the connection. PUNCHHANDLE01 Ratchet tool for securing crimp to terminal end assemblies CRIMPDIE01 4.0mm Heater Element (Mates with CRIMPPUNCH01) CRIMPPUNCH01...
  • Page 67 It is recommended to use a temperature controller for this procedure. If a temperature controller is not available, contact your nearest Mold-Masters Service Department. Figure 11-14 Penetrating Lubricant For gate seal installation and torquing procedures refer to "Gate Seal Replacement"...
  • Page 68 Maintenance Procedures ® 2. Leave the nozzle in the mold or remove it to a vice 3. Check the bottom face of the nozzle counterbore and clamp carefully. for damage. If damaged, lap the bottom face of the nozzle in a circular fashion with a hardened 3.
  • Page 69 Maintenance Procedures ® Figure 11-21 Tool Kit for Gate Seal Maintenance It is advisable to heat the nozzle to ensure the tem- perature condition is met to remove the gate seal. CAUTION Figure 11-19 Use the socket supplied in the tool kit to CAUTION loosen the gate seal.
  • Page 70 Maintenance Procedures ® Sprint Nozzle Tip Installation Cleaning Nozzle Insulator Cap 1. Clean all residual plastic from the nozzle threads 1. Heat cap with heat gun. and the torpedo/nozzle sealing surface. 2. Remove molten plastic and wipe remainder from 2. Check the torpedo/nozzle sealing surface for dam- insulator cap.
  • Page 71 Maintenance Procedures ® Checking Nozzle Tip Height Latching Introduction 1. Correct nozzle tip height and nozzle reference There are two reasons latches are used in a mold: point is found on the gate detail of the general as- • To tie the mold halves together for transportation sembly drawing.
  • Page 72 Maintenance Procedures ® WARNING Make sure the machine has been locked out and tagged out in accordance to the machines documented procedures. Failure to do so may lead to serious injury or death. 12. Apply lockout / tagged out. Refer to machine manufacturers documentation for procedures.
  • Page 73 Maintenance Procedures ® Latching the Cavity Plate to the Manifold Plate (Hot Half) WARNING Make sure the machine has been locked out and tagged out in accordance to the machines documented procedures. Failure to do so could lead to serious injury or death.
  • Page 74 Maintenance Procedures ® Torque Settings Gate Seal Torque Settings Seal Torque Settings Femto- Femto Pico Centi Deci Hecto Lite Gating Method ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb E-Type Torpedo 16-18 12-13 27-30 20-22 34-38 25-28 47-54 35-40 Ext. E-Type Torpedo F-Type Torpedo 16-18 12-13 27-30 20-22 34-38 25-28 47-54 35-40 Hot Sprue...
  • Page 75 Maintenance Procedures ® System and Plate Screw Torques Quality and length of screws must be as specified on Mold-Masters general assem- bly drawings. Torque Chart for System Assembly Screws Metric Torque Setting Imperial Torque Setting 7 Nm #10-32 5 ft lbs...
  • Page 77 3. When the nozzle approaches set temperature, use Mold-Masters supplied socket to remove the seal. NOTE Cylindrically ground gate seals cannot be reinstalled. Figure 12-1 TIT Edge Gated System...
  • Page 79 Specialty Systems - Accu-Line ® Section 13 - Accu-Line System Accu-Line Body Assembly 1 - Socket Head Cap Screw 2 - Actuator Cylinder Top 3 - O-Ring, Viton 4 - O-Ring, Viton 5 - Guide Ring 6 - O-Ring, Viton 7 - Guide Ring 8 - Actuator Piston 9 - Outer Cylinder Housing...
  • Page 80 Specialty Systems - Accu-Line ® Pre-Assembly 4. Repeat steps 1 - 3 to install inner seal into the piston. 1. Cut pin to calculated length, as specified in the general assembly drawing. Refer to "Valve Pin Finishing of Tip". Accu-Line Assembly Procedure 1.
  • Page 81 Specialty Systems - Accu-Line ® 9. Insert O-ring into cylinder top and assemble it to cylinder body. Figure 13-7 Figure 13-10 Ensure that timing marks on both components are 10. Torque fasteners to specifications detailed in GA aligned. drawings. Figure 13-11 Figure 13-8 11.
  • Page 82 Specialty Systems - Accu-Line ® 16. Place the heater body over the assembly. Install the heater body thermocouple as follows: a. Remove the body wire retainer. b. Fully insert the end of the thermo- couple into the mating hole and bend it into the thermocouple groove.
  • Page 83 Specialty Systems - Accu-Line ® Figure 13-20 20. Ensure that the nozzle terminal end is correctly oriented. Figure 13-21 21. Secure the valve pin holder to piston. Tighten to specifications detailed in the GA drawing. Figure 13-22 22. Assemble inside mold and verify assembly and all connections for accuracy.
  • Page 85 We would like to take this opportunity to thank you for purchasing a Mold-Masters Melt-Disk system. The purpose of this manual is to assist users in the integration, operation and maintenance of Mold-Masters systems. This manual is designed to cover most system configurations. For additional information, please contact your representative or a Mold-Masters office.
  • Page 86 Specialty Systems - Melt-Disk ® System with cast in heater element Insulation Board Leader Pins Locating Ring Top Clamp Plate Jiffy Plugs Pressure Disk Center Heater Manifold Electrical Box Nozzle Leader Bushing Wire Retainer Manifold Plate Name Plate Melt Disk Melt Transfer Link on Nozzle MTL14A)
  • Page 87 Figure 14-2 Clean Parts Figure 14-4 Assembling Gate Seal 4. Anti-seize the threads of the gate seals, using Mold-Masters supplied compound. 6. Thread the gate seal assembly into the Melt-Disk. Secure the Melt-Disk in a soft vice and torque gate seals in the cold condition to value specified below or in the General Assembly Drawings.
  • Page 88 Specialty Systems - Melt-Disk ® Torque gate seals in heated condition at process- 2. Insert the thermocouple tip into the thermocouple ing temperature as specified in the general assem- hole. Thermocouple must bottom out in the hole. bly drawings. CAUTION CAUTION Failure to torque the gate seals at pro- cessing temperatures may result in leak-...
  • Page 89 Specialty Systems - Melt-Disk ® 5. Use heat resistant tape to secure the nozzle wires Crimper and thermocouple wires just above the insulator Jaws pod. Locator Ratchet Disengaged Locator Slide Anvil Back of Jaws Tool Wire Stop Slot (In Contact) Wire Stop Wire Size Figure 14-10...
  • Page 90 1. Anti-seize the threads of the Melt link using Mold- One-piece Melt Link Masters supplied compound. 1. Anti-seize the threads of the 1pc Melt link, using Mold-Masters supplied compound. Figure 14-15 2. Thread Melt link MTL14A into the nozzle and Melt Link MTL14B into the Melt-Disk.
  • Page 91 Specialty Systems - Melt-Disk ® WARNING When the mold is open never inject mate- rial through hot runner system under high pressure. Failure to do so can result in serious injury or death. Shut Down Do not damage NOTE sharp edge For horizontal tips, refer to the controller operating manual.
  • Page 93 We would like to take this opportunity to thank you for purchasing a Mold-Masters Melt-Cube system. The purpose of this manual is to assist users in the integration, operation and maintenance of Mold-Masters systems. This manual is designed to cover most system configurations. For additional information, please contact your representative or a Mold-Masters office.
  • Page 94 Melt-Cube ® Melt-Cube Components M4 Screw (SHCSM4X20) M6 Screw (SHCSM6X25) Load Wedge Melt Wedge Gate Seal Assembly Melt-Cube Melt-Cube Anti-rotation Manifold Dowel Cavity Insert Retainer Clamp Retainer Clamp Cavity Insert Wedge Dowel (example) Not supplied by Mold-Masers Melt Cube Maintenance Toolkit (MCKIT01P) Gate Seal Assembly Inseal Melt Wedge...
  • Page 95 Melt-Cube ® Example Melt-Cube System Insulation Plate Locating Ring Leader Pins Top Clamp Plate SEE SECTION 5 "ASSEMBLY" FOR ASSEMBLY DETAILS Inlet Bridge/Manifold Nozzle Heater, Nozzle, Electrical Box Manifold Plate Wire Channel Melt-Cube Electrical Box Cavity Backing Plate Cavity Plate Melt-Cube Assembly Melt-Cube Center Locator...
  • Page 96 Melt-Cube ® Preparation Assemble Ground Wire Inspection 1. Apply anti-seize compound to the retaining screw. Secure the ground wire with the screw. 1. Inspect critical dimensions for cavity cutout to ensure it matches the general assembly drawing and catalogue pages. Clean Melt-Cube 1.
  • Page 97 Melt-Cube ® Optional Quick Disconnect Terminal 3. Insert contact mating end into appropriate hole in Ends locator slide. Orient contact so wire barrel and in- sulation barrel are facing crimper jaws (wire size Optional quick disconnect terminal end kits are avail- markings).
  • Page 98 Supports NOTE Figure 15-14 Mold-Masters recommends a separate 4. Apply anti-seize compound to the clamp SHCS's. cooling circuit for the cover plate, to be Install the proper SHCS into each retainer clamp. able to assemble and disassemble it with- Install clamps over Melt-Cube at locations shown out affecting other cooling circuits.
  • Page 99 Melt-Cube ® 5. Install cavity inserts (if applicable), aligning hole 9. Install wedge dowel pins for locating melt wedges. with cavity. Figure 15-19 Figure 15-23 6. Any cavity alignment features, such as dowels or 10. Ensure all melt wedge surfaces and inseals are cams, must be properly inserted at this time.
  • Page 100 Melt-Cube ® 14. Once the system is assembled, melt wedge and Load Wedge Screw Torque Chart load wedge screws must be re-tightened at pro- SHCS Tip Angle Temperature Torque Value cess temperature. See "Retighten Wedge Screws (°) Nm (in-lb) at Hot Condition". M6X25 0°...
  • Page 101 Melt-Cube ® Startup and Shutdown 5. Loosen and take out the two SCHC M4X20 on the melt wedge. Startup 6. Use two spare M5 screws to extract related melt wedge. 1. Heat bridge and inlet to processing temperature. 2. Heat nozzles to processing temperature. 3.
  • Page 102 Melt-Cube ® Figure 15-33 Remove the Inseal from the Melt-Wedge using the Inseal extraction tool (EXTOOL20) 10. Clean the parts and interfaces gently and replace needed parts (usually the torpedo). The Inseal can be cleaned with an abrasive cloth (e.g. Scotch- brite).
  • Page 103 Troubleshooting ® Section 16 - Troubleshooting Introduction Moisture Related Issues This troubleshooting information assumes that the hot Many common molding issues can be directly attrib- runner has been operational. uted to moisture contamination of the production resin. Generally, manufacturing resin is supplied from the Basic rules for troubleshooting are: manufacturer in ready to process pellets that are in sealed, airtight containers.
  • Page 104 Troubleshooting ® Pre-Molding Precautions Settings Ensure that all batch job parameters are correct: Prior to commencing production, ensure that the following conditions have been met. This will greatly • Temperatures reduce any future need to troubleshoot defective pro- • Pressures duction.
  • Page 105 Troubleshooting ® Defect Types, Causes and Remedies Index Parts have dark specks ........................Page 16-4 Parts have blisters and/or bubbles ...................... Page 16-5 Parts have flow marks ......................... Page 16-6 Parts have burn marks ........................Page 16-7 Parts are delaminating......................... Page 16-8 Parts have dimensional irregularities....................
  • Page 106 Troubleshooting ® Parts have Dark Specks The finished product contains dark particles. (When transparent resins are usually used.) Probable Cause: Molding Machine • Offline for extended period • Barrel offline for extended period • Barrel improperly purged • Contamination in plasticizer •...
  • Page 107 Troubleshooting ® Parts have Blisters and/or Bubbles The finished product contains small gas or air filled pockets or cooling voids. Probable Cause: Molding Machine • Low Injection Pressure • Back flow valve malfunctioning • Suck-back cycle too long • Rapid plasticizing •...
  • Page 108 Troubleshooting ® Parts have Flow Marks The finished product exhibits blush and flow marks, due to variations in material temperature from gradients between the machine nozzle and mold sprue bush- ing. Cold material in the nozzle tip section results in a halo around the direct sprue.
  • Page 109 Troubleshooting ® Parts have Burn Marks The finished product display brown streaks. This is from the material being overheated due to trapped air (diesel effect), which can lighten or darken the color. Probable Cause: Molding Machine • High injection speed •...
  • Page 110 Troubleshooting ® Parts are Delaminating The finished product is separating into layers that can be peeled off; surface layers are flaking off. Insufficient layer bonding as a result of high shear stresses; non-homogenious material. Probable Cause: Molding Machine • High injection speed Mold •...
  • Page 111 Troubleshooting ® Parts have Dimensional Irregularities The finished product is of a different dimensional value than originally designed, or previous production. Probable Cause: Molding Machine • Low injection pressure • Short hold pressure time • Damaged back-flow/check ring valve • Short cycle time •...
  • Page 112 Troubleshooting ® Parts are Discolored The finished product varies in color on different surfaces. Probable Cause: Molding Machine • Contamination Mold • Incorrect sprue diameter • Inadequate venting Material • Physical contamination of raw material • Chemical contamination of raw material •...
  • Page 113 Troubleshooting ® Parts Contain Flash Also known as "Fins" or "Spew". The finished product contains a thin film of material attached at the mold parting line. Probable Cause: Molding Machine • Low clamping pressure • High injection pressure • High injection speed Mold •...
  • Page 114 Troubleshooting ® Parts Surface has Jetting The finished product exhibits serpentine flow patterns on the surface as a result of the melt cooling prior to com- plete filling of the mold. Probable Cause: Molding Machine • High injection speed Mold •...
  • Page 115 Troubleshooting ® Parts are Pitted The finished product contains unmelted particles or small holes on the surface. Probable Cause: Molding Machine • Improper or worn out feed screw • Low melt temperature • Low injection speed Mold • Gating shear •...
  • Page 116 Troubleshooting ® Parts Surface is Rough The finished product exhibits patterns on the surface similar to grooves on a record, due to rapid cooling of the melt as it nears mold surface, followed over and over again by fresh melt. Probable Cause: Molding Machine •...
  • Page 117 Troubleshooting ® Parts are Sticking to Cavity The finished product does not properly release from the mold (female side). Probable Cause: Molding Machine • High injection pressure • High injection speed • Long holding time • High material feed Mold •...
  • Page 118 Troubleshooting ® Parts are Sticking to Core The finished product does not properly release from the mold (male side). Probable Cause: Molding Machine • High injection pressure Mold • Improper mold temperature • Bending of core • Presence of vacuum Material •...
  • Page 119 Troubleshooting ® Parts are Short The finished product is not completely formed. Probable Cause: Molding Machine • Feed system issue • Low injection pressure • Low injection speed • Short injection time • Back flow valve or check ring faulty •...
  • Page 120 Troubleshooting ® Parts have Sinks or Voids The finished product has hollows and pockets in areas that do not cool sufficiently, causing contraction. Probable Cause: Molding Machine • Low injection pressure • Short injection time • Insufficient material in cavity •...
  • Page 121 Troubleshooting ® Parts Display Splay The finished product display splay/splash marks and/or silver streaks. Probable Cause: Molding Machine • Resin degraded from overheating • Cylinder contains hot spots • Material trapped at nozzle tip • Wrong injection pressure • Wrong injection speed •...
  • Page 122 Troubleshooting ® Parts are Streaked The finished product has large, dull and laminate appearance areas on the surface. Probable Cause: Molding Machine • Back flow valve ring damaged Mold • Hot spots • Material trapped in certain areas Material • Contamination of resin or machine •...
  • Page 123 Troubleshooting ® Parts are Stringing The finished product has thin plastic strings attached to the sprue. Probable Cause: Molding Machine • High back pressure • High nozzle temperature Mold • Incorrect sprue Material • Melt strength inadequate Solution • Reduce back pressure •...
  • Page 124 Troubleshooting ® Parts are Warped The finished product has pressure differences/stress on its surface, causing the part to be disfigured. Probable Cause: Molding Machine • Wrong cooling time • High injection pressure Mold • Gate located in wrong area • Undercuts too big •...
  • Page 125 Troubleshooting ® Parts have Weld Lines The finished product has lines where two flow fronts meet and have not fused, creating the possibility of weak areas and stress fractures. Probable Cause: Molding Machine • Low injection speed • Low injection pressure •...
  • Page 127 Glossary of Terms ® Section 17 - Glossary of Terms Aspect Ratio: Ratio of total flow length to average wall Closed-loop Control: System for monitoring complete, thickness. injection molding- process conditions of temperature, pressure and time, and automatically making any Back Pressure: The pressure applied to the plastic dur- changes required to keep part production within preset ing screw recovery.
  • Page 128 Glossary of Terms ® Hot Runner Mold: A mold in which the runners are Machine Nozzle: The hollow-cored, metal nose screwed insulated from the chilled cavities and are kept hot. Hot into the injection end of a plasticator. The nozzle matches runner molds make parts that have no scrap.
  • Page 129 Glossary of Terms ® Short Shot: Failure to completely fill the part or cavities of the mold. Edges may appear melted. Shot: The complete amount of melt injected during a molding cycle, including that which fills the runner system. Shot Capacity: Generally based on polystyrene, this is the maximum weight of plastic that can be displaced or injected by a single injection stroke.
  • Page 131 Index ® Index Glossary of Terms 17-1 Ground Shorts Test 6-1 Accu-Line System 13-1 Actuators 10-1 Assembly 5-1 Heater Continuity 6-2 Hot Half Assembly 7-1 Hydraulic or Pneumatic System 4-4 Back Up Ring 10-2 Hydraulic / Pneumatic 10-1 Blisters 16-5 Bridged Hydraulic Pneumatic System 4-5 Bridge Manifold Systems, mounting screws 5-11 Bubbles 16-5...
  • Page 132 Index ® Pressure Disk Details 5-13 Thermocouple Installation (Master-Series) 5-4 Start Up & Shut Down 14-7 Thermocouple Removal 5-5 System Start Up & Shut Down 14-7 Thermocouple Wiring Guidelines 6-3 System with cast in heater element 14-2 Three Piece Center Heater Installation 5-17 Melt-Link 15-4 TIT Edge Gated System 12-1 Moisture Related Issues 16-1...
  • Page 134 When this hot runner system has been integrated into the mold, please ensure that this user manual is for- warded to the molder / end user together with the mold. www.moldmasters.com ® Mold-Masters and the Mold-Masters logo are registered trademarks of Mold-Masters (2007) Limited. © 2013...