Mold-Masters Hot Runner Equipment Manuals

Manuals and User Guides for Mold-Masters Hot Runner Equipment. We have 3 Mold-Masters Hot Runner Equipment manuals available for free PDF download: User Manual, Troubleshooting Manual

Mold-Masters Hot Runner User Manual (319 pages)

Brand: Mold-Masters | Category: Industrial Equipment | Size: 25.21 MB

Table of Contents
3
Section 1 - Introduction

12
- Intended Use
  12
- Documentation
  12
- Release Details
  12
- Returned Goods Policy
  13
- Movement or Resale of Mold-Masters Products or Systems
  13
- Copyright
  13
- Units of Measure and Conversion Factors
  14
Section 2 - Global Support

15
- Corporate Offices
  15
Section 3 - Safety

17
- Safety Hazards
  18
- Operational Hazards
  21
- General Safety Symbols
  23
- Wiring Check
  24
- Lockout Safety
  25
  - Electrical Lockout
    26
  - Energy Forms and Lockout Guidelines
    27
- Disposal
  28
- Hot Runner Safety Hazards
  29
Section 4 - Preparation

32
- Tools Required
  32
- Screw Lengths
  33
- Unpacking
  34
- Cleaning
  34
- Establish Your System Type
  35
Section 5 - Assembly

40
Section 6 - Electrical Testing

90
Section 7 - Hot Half Assembly

96
- Hot Half Assembly
  96
- Stack Mold Cavity Plate Installation
  98
Section 8 - System Startup and Shutdown

100
- Pre-Startup
  100
- Startup
  101
  - Standard Hot Runner Systems
    101
  - Stack Mold Systems
    102
- Shutdown
  102
  - Standard Hot Runner Systems
    103
  - Stack Mold System
    103
Section 9 - Color Change

104
- General Tips
  104
- Procedure A: Simple and Effective
  104
- Procedure B: more Comprehensive
  105
Section 10 - Hydraulic / Pneumatic Actuators

107
- Valve Actuator Installation and Assembly
  107
- Pre-Installation
  108
- Cylinder Bottom Assembly
  108
- Piston Assembly
  109
  - 5500 Series Only
    109
  - 6X00 Series and 7100 Series
    109
- Cylinder Top Assembly
  110
- Valve Pin Finishing of Tip
  110
  - 5500 Series
    110
  - 6X00 Series
    112
  - 7100 Series
    112
  - 8X00 Series
    114
  - 8600 - AR Series
    115
- Valve Pin Lapping Procedure for Tapered Valve Pins
  116
  - 5500 Series and 6X00 Series
    116
- Valve Pin Finishing of Head
  117
  - 5500 Series
    117
- Valve Pin Assembly
  118
  - 5500 Series
    118
  - 6X00 Series
    118
  - Hydraulic Limit Switch Option (6500 Series and 6600 Series)
    119
  - 7100 Series
    120
- Install the Valve Actuator to the Hydraulic Plate
  121
  - 5500 Series and 6X00 Series
    121
  - Hydraulic Limit Switch Option (6500 Series and 6600 Series)
    123
- Proximity Sensor Installation for Hydraulic Limit Switch Option
  124
  - Cutout Options Based on Stroke
    125
- Test the Proximity Sensor for Hydraulic Limit Switch Option
  126
- Maintenance Procedures for 5500 Series, 6X00 Series and 7100 Series
  126
  - For Oil Systems
    127
  - For Pneumatic Systems
    127
- Extraction Tools for Hydraulic and Pneumatic Actuators
  128
Section 11 - Slimstack Actuator

130
- Introduction
  130
- Slimstack Actuator Assembly
  131
- Assembly Procedure
  132
- Installation
  142
Section 12 - Sevg Plus Actuator

146
- Introduction
  146
- Sevg Plus Actuator Models
  146
- Sevg Plus Actuator in Hot Runner Systems
  146
- Sevg Plus Model Options
  147
  - SE40-20 Actuator - Non Cooled
    147
  - SE40-20C Actuator - Cooled
    148
  - SE20-15 Actuator - Non Cooled
    149
- Sevg Plus in Plate Mounted Systems
  150
- SE40-20 Model
  150
  - SE20-15 Model
    150
- Assembly and Installation
  151
- Disassembly
  156
  - SE40-20 and SE40-20C Models
    156
  - SE20-15 Model
    157
Section 13 - E-Drive

158
- Typical E-Drive System
  158
  - E-Drive Components
    160
  - E-Drive Safety
    161
- Assembly
  162
- Assembly Detail
  163
  - Hot Runner Assembly
    163
  - Interface Plate Assembly
    163
  - Synchro-Plate Assembly
    164
  - Ball-Screw Preparation
    165
  - Ball-Screw Lubrication
    165
  - Ball-Screw Assembly
    166
  - Ball-Screw Maintenance
    167
  - Top Plate Assembly
    167
  - Attach the Synchro-Plate to Top Plate Assembly
    167
  - Tension Belt Assembly
    167
  - Inspect Parallelism of the Synchro-Plate
    169
  - Assemble the Insulation Plate and Locating Ring
    169
  - Perform E-Drive Controller Checks
    170
  - Install the Hot Half into the Mold
    170
- First Time Installation or Replacement of the Belt
  170
- Check for Misalignment
  172
Section 14 - Mag-Pin Option

173
- Mag-Pin Assembly (3D View)
  174
- Mag-Pin Safety
  174
- Mag-Pin Operation
  175
- Handling Magnets
  177
- Assembly Summary
  178
- Assembly Details
  178
- Mag-Pin Extraction
  184
Section 15 - Maintenance

188
- Valve Disk Removal
  188
  - Extraction of 1-Piece Valve Disk
    189
  - Extraction of 2-Piece Valve Disk
    191
- Valve Disk Extraction Tool Overview
  193
- Terminal End Removal and Installation
  195
  - Terminal End Removal
    195
  - Terminal Installation
    195
  - Terminal Assembly
    196
- Heater Plate Power Lead Removal
  198
  - Installation
    199
- Gate Seal Maintenance
  199
  - Multi-Cavity Systems
    199
  - Gate Seal Removal
    200
  - Gate Seal Replacement
    201
- Sprint Gate Seal Maintenance
  203
  - Sprint Nozzle Tip Removal
    203
  - Sprint Nozzle Tip Installation
    204
- Clean Nozzle Insulator Cap
  205
- Installing Nozzle Insulator Cap
  205
- Valve Actuator Maintenance
  206
- Check Nozzle Tip Height
  206
- Latches
  207
- Latch the Cavity Plate to the Core Half (Cold Half)
  207
- Latch the Cavity Plate to the Manifold Plate (Hot Half)
  209
- Torque Settings
  211
Section 16 - TIT Edge Gated System

214
- TIT Edge Gated System
  214
- TIT Edge Gate Seals
  215
  - Remove the Gate Seal
    215
Section 17 - Accu-Line

216
- Accu-Line™ with Valve Bushing
  216
  - Accu-Line™ with Valve Bushing
    217
  - Pre-Assembly
    217
- Accu-Line™ with Valve Bushing - Assembly
  217
- Accu-Line™ with Valve Insert
  
  224
  - Pre-Assembly of Accu-Line™ with Valve Insert
    225
- Assembly of Accu-Line™ with Valve Insert
  
  226
Section 18 - Melt-Disk System

237
- Reverse Melt-Link Identification
  237
- System with Cast-In Heater Element
  238
- Melt-Disk Preparation / Cleaning
  239
- Nozzle Thermocouple Assembly
  241
- Melt-Disk Thermocouple Assembly
  241
- Optional Quick Disconnect Terminal Ends
  243
  - Crimp the Quick Disconnects
    244
  - Assemble the System with Quick Disconnects
    244
- Assembly of Melt Disk to the Nozzle
  245
  - Reverse Two-Piece Melt-Link
    245
  - One-Piece Melt-Link
    246
- Melt-Disk System Startup
  247
  - Startup - Melt Link
    247
  - Startup - Reverse Melt Link ONLY
    248
- Melt-Disk System Shutdown
  249
  - Shutdown - Melt Link
    249
  - Shutdown - Reverse Melt Link ONLY
    250
- Disassembly for Maintenance
  250
  - For Melt Link
    250
  - For Reverse Melt Link
    250
- Melt-Disk Reassembly after Maintenance
  251
Section 19 - Melt-CUBE Systems

252
Section 20 - Troubleshooting

287
- Moisture Related Issues
  287
  - Resin Moisture Contamination
    287
  - Resin Drying Issues
    288
  - Importance of Pre-Drying Resin
    288
- Pre-Molding Precautions
  288
  - History
    288
  - Material
    288
  - Hardware
    289
  - Settings
    289
- Establishing Root Cause
  289
- Fault Identification
  289
- Defect Types, Causes and Remedies Index
  290
- Troubleshooting Typical Problems
  291
  - Dark Specks
    291
  - Blisters or Bubbles
    292
  - Flow Marks
    293
  - Burn Marks
    294
  - Delaminating Parts
    295
  - Dimensional Irregularities
    296
  - Discolored Parts
    297
  - Flash
    298
  - Jetting
    299
  - Pitted Parts
    300
  - Rough Surface
    301
  - Parts Sticking to Cavity
    302
  - Parts Sticking to Core
    303
  - Short Parts
    304
  - Sinks or Voids
    305
  - Splay
    306
  - Streaks
    307
  - Stringing
    308
  - Warped Parts
    309
  - Weld Lines
    310

Mold-Masters Hot Runner User Manual (256 pages)

Brand: Mold-Masters | Category: Industrial Equipment | Size: 20.48 MB

Table of Contents
3
Section 1 - Introduction
10
Intended Use
10
Documentation
10
Release Details
10
Warranty
11
Returned Goods Policy
11
Movement or Resale of Mold-Masters Products or Systems
11
Copyright
11
Units of Measure and Conversion Factors
12
Section 2 - Global Support
13
Corporate Offices
13
International Representatives
14
Section 3 - Safety
15
Overview
16
Operational Hazards
19
General Safety Symbols
21
Wiring Check
22
Lockout Safety
23
Electrical Lockout
24
Energy Forms and Lockout Guidelines
25
Disposal
26
Hot Runner Safety Hazards
27
Section 4 - Preparation
30
Tools Required
30
Screws
31
Length
31
Grade
31
Torque Settings
32
Master-Series Gate Seals
32
Summit-Series Gate Seals
32
Dura Gate Seals
32
Others
33
Unpacking
34
Cleaning
34
Overview of System Types
35
Non-Valved System
35
Valve Gate System
36
Valve Gate System with Bridge
37
Non-Valved System with Mastershield Technology
38
Valved System with Mastershield Technology
39
System Cutaways
40
Brazed-In/Paste-In System
40
Bolt-In System
41
Mastershield System
42
Section 5 - Assembly
43
Finishing a Gate Seal
43
Installing a Water-Cooled Gate Insert
43
Thermocouples
44
Installing a Master Series-Style Thermocouple
44
Installing a Dura Line Thermocouple
47
Removing a Non-Front Mounted Thermocouple
49
Installing a Nozzle
50
Master-Series and Dura Lines
50
Mastershield Centi, Deci, and Pico
51
Mastershield Femto
54
Installing a Nozzle Step
58
Nozzle Wire Layout
59
Back Mounted Thermocouples
59
Front Mounted Thermocouples
59
Installing a Valve Bushing
60
Types
60
Installing
60
Mounting a Manifold
62
Manifold Locator
63
Manifold Locating Dowel Pin
64
Installing a Manifold Thermocouple
65
Mounting a Main Manifold
66
Installing an Inlet Seal
66
Installing a Manifold Step
67
Installing a Pressure Disk or a Valve Disk in a Master-Series System
67
Pressure Disk: Final Grinding Required
68
Installing a Pressure Disk
70
Pressure Disk: Final Grinding Not Required
70
Installing a Valve Disk
71
Installing a Support Bushing or a Valve Disk in a Mastershield System
72
Installing a Support Bushing
72
Installing a Valve Disk
73
Installing a Heater Plate
75
Installing Inlet Components
77
Unheated Back Plate
77
Heated Back Plate
78
Center Heater (Direct Mount)
79
Center Heater (Indirect Mount)
80
Inlet Extension
81
Inlet Extension with Pressure Sleeves
82
Slimstack Actuator
83
Hydraulic and Pneumatic Actuators
84
Valve Actuator Assembly
84
Pre-Installation
85
Assembling a Cylinder Bottom
85
Piston Assembly
86
5500 Series
86
6X00 and 7100 Series
86
Assembling a Cylinder Top
87
Finishing the Tip of a Valve Pin
87
5500 Series
87
6X00 Series
89
7100 Series
89
8X00 Series
91
8600-AR Series
92
Lapping a Tapered Valve Pin-5500 and 6X00 Series
93
Finishing the Head of a Valve Pin-5500 Series
94
Valve Pin Assembly
95
5500 Series
95
6X00 Series
95
7100 Series
96
Installing a Valve Actuator in a Hydraulic Plate
97
5500 Series
97
6X00 Series
98
Installing a Hydraulic Limit-Switch Option-6500 and 6600 Series
99
Installing a Proximity Sensor
100
Cutout Options Based on Stroke
101
Testing the Proximity Sensor of a Hydraulic Limit-Switch Option
102
Sevg Plus Actuator
103
E-Drive
104
Typical System
104
Components
106
Safety
107
Assembly
108
Attaching a Hot Runner Assembly
109
Attaching a Plate Assembly
109
Assembling a Synchro-Plate
110
Preparing a Ball Screw
111
Lubricating a Ball Screw
111
Assembling a Ball Screw
112
Maintaining a Ball-Screw
113
Assembling a Top Plate
113
Attaching a Synchro-Plate to a Top Plate Assembly
113
Assembling a Tension Belt
113
Assembling an Insulation Plate and a Locating Ring
116
Doing E-Drive Controller Checks
117
Installing a Hot Half in a Mold
117
Installing or Replacing a Belt
117
Doing a Check for Misalignment
119
Mag-Pin Option
120
Assembly
121
Safety
121
Operation
122
Handling Magnets
124
Summary of the Assembly Procedure
125
Assembling
125
Placing a Magnet on Top of the Magnet Retainer
125
Checking the Polarity of a Magnet
126
Cleaning a Magnet Holder
126
Installing a Magnetic Retainer in a Magnet Holder
127
Placing a Magnet Holder and Magnet into a Housing
127
Assembling a Nut and a Lock Magnet Holder
128
Installing a Valve Pin in a Valve Pin Holder
128
Installing an O-Ring in a Valve Pin Holder
129
Installing a Valve Pin in a Housing Assembly
129
Installing a Mag-Pin Assembly in a Synchro-Plate
130
Single Nozzle Valve System (Accu-Line)
131
Centi Accu-Line with Valve Bushing
131
Pre-Assembly
132
Assembling an Accu-Line System
132
Deci and Hecto Accu-Line with Valve Insert
139
Pre-Assembly
140
Assembling an Accu-Line System
141
TIT Edge-Gated System
152
Removing TIT Edge Gate Seals
152
Melt-Disk System
153
Identifying a Reverse Melt-Link
153
Example
154
Preparing and Cleaning
155
Assembling a Melt-Disk Thermocouple
157
Installing a Melt Disk in a Nozzle
159
Reverse Two-Piece Melt-Link
159
One-Piece Melt-Link
160
Optional Quick Disconnect Terminal Ends
161
Crimping the Quick Disconnects
162
Melt-Cube Systems
163
Identifying Your Melt-Cube Design
163
Melt-Cube Design a (Angled Version)
163
Melt-Cube Design B (Horizontal Version)
164
Example
165
Melt-Cube Design a
166
Gate Seal Assembly
167
Maintenance Toolkit
167
Dual Nozzle Assembly
168
Inspecting
168
Cleaning
168
Assembling a Melt-Cube Thermocouple
169
Assembling a Ground Wire
169
Installing a Melt Transfer Link
170
Installing in a Cavity Block
171
Assembling (Cold Condition)
171
Retightening Wedge Screws (Hot Condition)
176
Replacing a Transfer-Seal/Torpedo
178
Melt-Cube Design B
181
Components
181
Maintenance Toolkit
182
Inspecting
182
Cleaning
183
Installing a Thermocouple
184
Attaching a Ground Wire
185
Installing a Melt Transfer Link
185
Assembling
187
Installing Gate Seals and Cavity Inserts
190
Installing a Melt Block
191
Disassembling a Transfer-Seal/Torpedo and a Melt Block
192
Installing a Melt-Cube in a Cavity Block
194
Section 6 - Hot Half Assembly
195
Assembling a Hot Half
195
Installing a Stack Mold Cavity Plate
197
Section 7 - Electrical Testing
199
Safety
199
Doing a Check of the Electrical Wiring
200
Electrical Safety Testing
200
Doing a Check of Equipment
200
Doing a Test of the Insulation Resistance
200
Doing a Test of the Conditions for Protection by Automatic Disconnection of the Power Supply
201
Doing a Test of the Continuity of the Protective Bonding Circuit
201
Doing a Test of the Impedance of the Fault Loop
201
Doing a Test of the Continuity of a Thermocouple
202
Doing a Pinch Point Test
202
Doing a Check of the Heating Element
202
Doing a Test of the Continuity of the Ungrounded Thermocouple
203
Thermocouple Wiring Guidelines
203
Doing a Functional Test with a Temperature Controller
203
Re-Testing
203
Section 8 - System Startup and Shutdown
205
Pre-Startup
205
Startup
206
Standard Hot Runner Systems
206
Stack Mold Systems
207
Melt-Disk
207
Melt-Link
207
Reverse Melt-Link
208
Melt Cube
209
Shutdown
210
Standard Hot Runner Systems
210
Stack Mold Systems
210
Shutdown Manifolds, Submanifolds, Inlets and Nozzles
210
Melt-Disk
210
Melt Link
211
Reverse Melt Link
211
Melt-Cube
211
Section 9 - Color Change
213
General Tips
213
Procedure A: Simple and Effective
213
Procedure B: Comprehensive
214
Section 10 - Maintenance
216
Valve Disks
216
Removing a 1-Piece Valve Disk
217
Removing a 2-Piece Valve Disk
219
Overview of Valve Disk Extraction Tools
221
Terminal Ends
223
Removing
223
Installing
223
Assembling
224
Heater Plates
226
Removing Power Leads
226
Installing Power Leads
227
Gate Seals
227
Heating the System
227
Removing
228
Replacing
229
Nozzle Tips
231
Checking the Height of a Nozzle Tip
231
Melt-Disk/Melt-Cube
232
Disassembling the Melt Link
232
Disassembling the Reverse Melt Link
232
Reassembling the Melt-Disk/Melt-Cube
232
Actuators
233
Extraction Tools for Hydraulic and Pneumatic Actuators
233
5500 Series, 6X00 Series, and 7100 Series
236
Hydraulic Systems
236
Pneumatic Systems
236
Extracting a Mag-Pin
238
Latches
242
Latching a Cavity Plate to a Core Half (Cold Half)
242
Latching a Cavity Plate to a Manifold Plate (Hot Half)
244
Section 11 - Troubleshooting
246
Section 12 - Glossary of Terms
247
Index
253

Mold-Masters Hot Runner Troubleshooting Manual (28 pages)

Brand: Mold-Masters | Category: Industrial Equipment | Size: 0.92 MB

Table of Contents
3
Section 1 - Troubleshooting
5
Moisture Related Issues
5
Pre-Molding Precautions
6
- History
  6
- Material
  6
- Hardware
  6
- Settings
  7
Establishing Root Cause
7
Fault Identification
7
Defect Types, Causes and Remedies Index
8
Troubleshooting Typical Problems
9
- Dark Specks
  9
- Blisters or Bubbles
  10
- Flow Marks
  11
- Burn Marks
  12
- Delaminating Parts
  13
- Dimensional Irregularities
  14
- Discolored Parts
  15
- Flash
  16
- Jetting
  17
- Pitted Parts
  18
- Rough Surface
  19
- Parts Sticking to Cavity
  20
- Parts Sticking to Core
  21
- Short Parts
  22
- Sinks or Voids
  23
- Splay
  24
- Streaks
  25
- Stringing
  26
- Warped Parts
  27

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Mold-Masters Hot Runner Equipment Manuals

Mold-Masters Hot Runner User Manual (319 pages)

Table of Contents

Section 1 - Introduction

Section 2 - Global Support

Section 3 - Safety

Section 4 - Preparation

Section 5 - Assembly

Section 6 - Electrical Testing

Section 7 - Hot Half Assembly

Section 8 - System Startup and Shutdown

Section 9 - Color Change

Section 10 - Hydraulic / Pneumatic Actuators

Section 11 - Slimstack Actuator

Section 12 - Sevg Plus Actuator

Section 13 - E-Drive

Section 14 - Mag-Pin Option

Section 15 - Maintenance

Section 16 - TIT Edge Gated System

Section 17 - Accu-Line

Accu-Line™ with Valve Insert

Assembly of Accu-Line™ with Valve Insert

Section 18 - Melt-Disk System

Section 19 - Melt-CUBE Systems

Section 20 - Troubleshooting

Mold-Masters Hot Runner User Manual (256 pages)

Table of Contents

Mold-Masters Hot Runner Troubleshooting Manual (28 pages)

Table of Contents

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