EWIKON HPS III Series User manual

HPS III hot runner systems
for side gating
Operating manual
Valid for:
HPS III adapter nozzles
HPS III-MHL100/200 nozzles
HPS III-MHR100/200 nozzles
HPS III-MHR111 nozzles
HPS III-MHR112 nozzles
HPS III-MHR122 nozzles
HPS III-MH1 nozzles
HPS III-T/TE manifolds
Complete hot halves
Version: 2.0

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1. General remarks .......................................................................................................................................................... 7
1.1 Information on this operating manual ............................................................................................................................ 7
1.2 Manufacturer ................................................................................................................................................................. 7
1.3 Formal information on the operating manual ................................................................................................................ 7
1.4 Conventions .................................................................................................................................................................. 8
1.4.1 Instructions and system responses ............................................................................................................................... 8
1.4.2 Enumerations ................................................................................................................................................................ 8
1.4.3 Abbreviations ................................................................................................................................................................ 8
2. Safety instructions ...................................................................................................................................................... 9
2.1 Safety instructions and symbols used ........................................................................................................................... 9
2.1.1 Signalwordsforhazardclassication ......................................................................................................................... 10
2.1.2 Explanation of pictograms ........................................................................................................................................... 10
2.2 Intended use ............................................................................................................................................................... 11
2.3 Improper use ............................................................................................................................................................... 11
2.4 Qualicationofsta󰀨..................................................................................................................................................... 11
2.4.1 Demandsonspecialisedsta󰀨 ..................................................................................................................................... 11
2.5 Personal Protective Equipment (PPE) ........................................................................................................................ 12
2.5.1 Symbols of the personal protective equipment ........................................................................................................... 12
2.6 General hazards and safety measures ....................................................................................................................... 12
2.7 Electrical equipment .................................................................................................................................................... 14
2.8 Spare and wear parts, auxiliary and operating materials ............................................................................................ 14
2.9 Limitation of liability ..................................................................................................................................................... 14
2.10 Warranty terms ............................................................................................................................................................ 15
2.11 Standards and directives ............................................................................................................................................. 15
3. Technical data ........................................................................................................................................................... 16
3.1 Mechanicalspecications ........................................................................................................................................... 16
3.1.1 Main dimensions of the HPS III hot runner system ..................................................................................................... 16
3.1.2 Operating parameters of the HPS III hot runner system ............................................................................................. 16
3.2 Electricalspecications ............................................................................................................................................... 16
3.2.1 Connections/connector pin assignment ...................................................................................................................... 16
3.3 Hydraulic/pneumaticspecications(driveunits) ....................................................................................................... 16
3.4 Operating conditions ................................................................................................................................................... 16
3.4.1 Noise emission ............................................................................................................................................................ 16
3.4.2 Cooling agent .............................................................................................................................................................. 17
3.5 Type plate .................................................................................................................................................................... 17
4. Functional description of the HPS III hot runner system ...................................................................................... 18
5. Installation ................................................................................................................................................................. 20
5.1 Transport ..................................................................................................................................................................... 20
5.1.1 Safety information on transport ................................................................................................................................... 20
5.1.2 Recommended lifting accessories and slings ............................................................................................................. 21
5.1.3 Check the lifting accessories and slings before use ................................................................................................... 21
Content

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5.1.4 Attachment points ....................................................................................................................................................... 22
5.1.5 Working load limit for lifting accessories and slings .................................................................................................... 22
5.1.6 Removal from transport crate ...................................................................................................................................... 24
5.1.7 Transport and movement during installation ............................................................................................................... 24
5.2 General safety instructions .......................................................................................................................................... 26
5.3 Technical Requirements .............................................................................................................................................. 29
5.3.1 Tools and operating materials ..................................................................................................................................... 29
5.3.2 Standard parts ............................................................................................................................................................. 32
5.4 Checks before installation ........................................................................................................................................... 33
5.4.1 Notes on mould layout ................................................................................................................................................ 33
5.4.2 Standard dimensions of hot runner systems .............................................................................................................. 33
5.4.3 Dimensions to be checked for a hot runner system with HPS III-MHL and HPS III-MHR nozzles .............................. 34
5.5 Installation of HPS III adapter systems ....................................................................................................................... 37
5.5.1 Installation of adapter systems with nozzles for standard and front installation .......................................................... 37
5.6 Installation of HPS III hot runner systems for direct side gating .................................................................................. 43
5.6.1 Installation of systems with HPS III-MHL100/200 or HPS III-MHR100/200 nozzles ................................................... 43
5.6.2 Installation of systems with HPS III-MHR111 nozzles ................................................................................................. 53
5.6.3 Installation of systems with HPS III-MHR112 nozzles ................................................................................................. 59
5.6.4 Installation of systems with HPS III-MHR122 nozzles ................................................................................................ 65
5.6.5 InstallationofsystemswithHPSIII-MH1nozzlesforsidegatingwithopenowchannel .......................................... 71
5.6.6 Installation of a hot half with HPS III-MH nozzles ....................................................................................................... 78
5.7 Electrical connection of hot runner systems ................................................................................................................ 88
5.7.1 Safety instructions ....................................................................................................................................................... 88
5.7.2 General information ................................................................................................................................................... 90
5.7.3 Wiring of 1-drop hot runner systems ........................................................................................................................... 94
5.7.4 Wiring of 2-drop hot runner systems ........................................................................................................................... 95
5.7.5 Wiring of 4-drop hot runner systems (manifold with 2 control zones) ......................................................................... 96
5.7.6 Wiring of 6-drop hot runner systems (manifold with 2 control zones) ......................................................................... 97
5.7.7 Wiring of 8-drop hot runner systems (manifold with 2 control zones) ......................................................................... 98
5.7.8 Wiring of 8-drop hot runner systems (manifold with 4 control zones) ......................................................................... 99
5.8 Checks after installation ............................................................................................................................................ 100
6. Start-up and instructions for operation ................................................................................................................ 101
6.1 Safety instructions ..................................................................................................................................................... 101
6.2 Requirements for operation ....................................................................................................................................... 103
6.3 Start-up and operation of hot runner systems with HPS III-MH nozzles ................................................................... 104
6.3.1 First-timestart-upandllingofahotrunnersystemwithHPSIII-MHnozzleswithheatconductivetips ................. 104
6.3.2 Start-upofalreadylledhotrunnersystemswithHPSIII-MHnozzleswithheatconductivetips............................. 104
6.3.3 First-timestart-upandllingofahotrunnersystemwithHPSIII-MHvalvegatenozzles........................................ 105
6.3.4 Start-upofalreadylledhotrunnersystemswithHPSIII-MHvalvegatenozzles ................................................... 106
6.3.5 Colour and material changes .................................................................................................................................... 106
6.3.6 Shutdown of a system with HPS III-MH nozzles (system / single tip / single cavity) ................................................ 107
Content

5HPS-III-Seitenanspritzung-Heißkanalsystem_Inhalt_BA_V-2-0_EN
6.4 Possible malfunctions ............................................................................................................................................... 108
6.4.1 Troubleshooting ......................................................................................................................................................... 108
7. Maintenance ............................................................................................................................................................ 109
7.1 Safety instructions ..................................................................................................................................................... 109
7.2 Instructions for maintenance ..................................................................................................................................... 109
7.3 Maintenance schedule .............................................................................................................................................. 109
7.4 Deinstallation / installation of tip inserts for HPS III-MH nozzles ............................................................................... 110
7.4.1 Safety instructions ..................................................................................................................................................... 110
7.4.2 Deinstallation / installation of tip inserts for HPS III-MH nozzles ............................................................................... 111
7.4.3 Deinstallation of tip inserts ........................................................................................................................................ 112
7.4.4 Cleaning of tip inserts ................................................................................................................................................ 112
7.4.5 Installation of tip inserts ............................................................................................................................................. 112
7.5 HPS III-MHL100/200 (valve gate) nozzles – exchange of thermocouple .................................................................. 113
7.6 HPS III-MHR100/200 (valve gate) nozzles – exchange of thermocouple ................................................................. 117
7.7 Instructions for service and repair ............................................................................................................................. 122
8. Decommissioning ................................................................................................................................................... 123
8.1 Safety instructions ..................................................................................................................................................... 123
8.2 Instructions for disposal ............................................................................................................................................ 124
9. Tightening torques .................................................................................................................................................. 125
9.1 Tightening torques for socket head screws ............................................................................................................... 125
9.2 Tightening torques for manifold screw connections and retaining screws ................................................................ 127
9.3 Tightening torques for clamping covers of HPS III-MH nozzles ................................................................................ 128
Content

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7HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
General remarks
1. General remarks
1.1 Information on this operating manual
This operating manual has been created in accordance with the directive 2006/42/EC toenablethesafeande󰀩cient
operation of HPS III hot runner systems (hereinafter called hot runner system).
1.2 Manufacturer
EWIKON Heißkanalsysteme GmbH
Siegener Straße 35
35066 Frankenberg
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.ewikon.com
1.3 Formal information on the operating manual
Person in charge of documentation: Henning Becker
Itemnumber:   notspecied
Version: 2.0
Printing date: 21/04/2020
Language: German (original operating manual)
© Copyright, 2020
All rights reserved. Full or partial reproduction subject to prior written
approval by EWIKON Heißkanalsysteme GmbH
NOTE!
Improper operation of the device may result in severe personal injury and considerable material damage!
You must carefully read this operating manual and familiarise yourself with the safety installations before
installing,commissioningormaintainingthedevice.Donotoperatethedevicewithouthavingreceivedappropriate
training.

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General remarks
1.4 Conventions
1.4.1 Instructions and system responses
Operating steps that have to be carried out by the operator are displayed as a numbered list. The sequence of the steps has
to be adhered to.
Example:
1. Operating step 1
2. Operating step 2
1.4.2 Enumerations
Enumerations without mandatory sequence are displayed as a list with bullet points.
Example:
• Point 1
• Point 2
1.4.3 Abbreviations
The following terms and abbreviations are used in the operating manual:
Abbreviation Meaning
PPE Personal Protective Equipment
HPS High Performance Systems
EU European Union
BR Installation space
H1 Manifold height
H2 Manifold height + top pressure pad
H3 Manifold height + pressure pad with
centering + top pressure pad
H4 Manifold height + top pressure pad +
bottom pressure pad
P Height of nozzle retainer frame plate
B Height of top pressure pad
KH Nozzle body height
X Nozzle length (lower edge of nozzle
body to article surface)
∆S Gap dimension Delta S
RASprue bush radius
RMMachine nozzle radius
N Height of hold-down device
HR Retainer ring height
G Height from centre axis of tip to end of
nozzle
X X dimension of nozzle
TK1 / TK2 / TK3 Standard dimensions to determine
gap dimension
G Thread
P Fit
SW Widthacrossats
T Blueing area
Abbreviation Meaning
m Mass
ρDensity
V Volume
L x B x H Length x width x height (e.g. mould
plate, hot half)
F Force
M Bending moment
THK Hot runner temperature
(processing temperature)
TWZ Mould temperature
∆T Di󰀨erenceTHK -TWZ
Chart 1: Terms and abbreviations

9HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Safety instructions
2. Safety instructions
The HPS III hot runner system conforms to the machinery directive 2006/42/EG and has been designed, manufactured and
checked for safety according to the applicable safety rules and legislation and the state of the art.
The HPS III hot runner system is delivered in perfect working order.
The HPS III hot runner system may pose risks, if it is:
• notoperatedbyprofessionallytrainedsta󰀨.
• used improperly or not used as intended.
• not in perfect order regarding safety.
2.1 Safety instructions and symbols used
Signal words introduce the safety instructions and are marked by symbols. They draw the user's attention to possible
hazardous situations that may occur during installation, operation and maintenance. Safety instructions must be followed
to prevent accidents, personal injury or material damage.
Warnings
• Protect against possible personal injury and material damage when followed
• Classify the extent of hazard by the signal word
• Indicate the risk of personal injury by hazard signs
• Indicate the type and source of hazard
• Indicate the risk and possible consequences
• Show measures to prevent hazards and prohibit certain behaviours
WARNING! = signal word
Source of hazard
Possible consequences, if ignored.
• Measures/prohibitions.
The hazard sign marks warnings which warn against personal injuries.
Source of hazard
The source of hazard indicates the cause of hazard.
Possible consequences, if ignored
If the warnings are ignored, possible consequences are e. g. crushing, burnings or other severe injuries.
Measures/Prohibitions
"Measures/Prohibitions" lists actions that are to be carried out to prevent a hazard (e. g. stop a drive unit) or that are
prohibited to prevent a hazard.

10 HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Safety instructions
2.1.1 Signal words for hazard classication
HAZARD!
indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING!
indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury.
CAUTION!
indicates a potentially hazardous situation which, if not avoided, will result in minor injury or material damage.
NOTE!
indicates useful additional information and tips to promote trouble-free operation and to prevent material
damage
2.1.2 Explanation of pictograms
Read
operating manual Caution! Risk of electrocution
Caution!
Hot surface Caution! Oxidising agents
Caution!
Suspended loads Caution! Risk of crushing
Caution!
Explosive atmosphere Caution! Hand injuries or cuts
Caution!
Pressurised systems Caution! Forklift trucks operating

11HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Safety instructions
2.2 Intended use
EWIKON hot runner systems are exclusively designed for the intended use described in this manual.
Anydi󰀨erentandunintendeduseisexcludedandmayresultinpersonalinjuriesandmaterialdamage.
Warranty expires in this case.
EWIKON hot runner systems and single nozzles are only to be used for injection moulding applications, assembled in an
enclosed injection mould.
They are used to process thermoplastic resins according to their individual processing requirements and to pass them gently
fromtheinjectionunittothecavitybyoptimumtemperaturedistributionandowpaths.
In order to use the hot runner system as intended it is essential that all tips and information given in this operating manual
are read, understood and followed.
To ensure safe operation of the hot runner system, the given maintenance & inspection schedule has to be adhered to.
The system is designed for an injection pressure of 2000 bar.
The resin used has to be processed according to the guidelines of the material manufacturer.
Use of the HPS III hot runner system
Use the HPS III exclusively for its intended use and in perfect condition as regards safety! This is the only way
to guarantee a reliable operation of the HPS III hot runner system.
2.3 Improper use
Anyusedeviatingfromtheusedenedunder"Intendeduse"orthatgoesbeyondthatuseisconsideredimproperuse.
2.4 Qualication of sta󰀨
Thesta󰀨hastoprovethatitisqualiedtoperformassembly,maintenanceandrepair.Anylackofknowledgehastobe
eliminatedbytrainingandbriengthesta󰀨.
2.4.1 Demands on specialised sta󰀨
ImproperuseofEWIKONhotrunnersystemsmayresultinpersonalinjuriesormaterialdamage.Onlyspecialisedsta󰀨is
allowed to carry out any work.
Onlyspecialisedsta󰀨isallowedtoinstallandoperateEWIKONhotrunnersystems.Specialisedsta󰀨istrained,hasproven
knowledge and experience in operating e. g. injection moulding units or electrical machines and devices as well as knowl-
edge of the relevant regulations and is able to indepently identify possible hazards and prevent them by taking protective
measures.

12 HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Safety instructions
2.5 Personal Protective Equipment (PPE)
Wear the necessary protective equipment when working on or near the machine. Special information on the personal
protective equipment in the work area has to be observed.
2.5.1 Symbols of the personal protective equipment
Always wear the following when carrying out any work:
Protective clothes:Toprotectyourbodyweartight-ttingclotheswithlowresistancetotearing,without
protruding parts and with long sleeves and long trousers. Do not wear rings, chains or any other jewelry.
Safety shoes: To protect yourself against electric shocks, melt splashes, heavy, falling objects and slips
and falls on slippery surfaces.
Always wear the following when carrying out special work:
Safety glasses: To protect your eyes
against scattering debris, heat and melt
splashes.
Ear protection: To protect your ears
against loud ambient noise.
Face mask: To protect your face against
scattering debris, heat and melt splashes. Protective helmet: To protect your head against falling objects and sharp edges.
Protective gloves (heat resistant):
To protect your hands against extreme
heat, abrasions, punctures and more
severe injuries.
Heat resistant apron: To protect your
body against extreme heat.
2.6 General hazards and safety measures
The company operating the system must comply with the statutory obligations on occupational safety. In addition to the
safety instructions of this manual the safety, accident prevention and environment protection provisions applicable for the
system'srangeofusemustbeadheredto.Theoperatingcompanymustclearlydeneresponsibilitesandmakesurethatall
sta󰀨operatingthesystemhasreadandunderstoodthismanual.Thecompanyalsohastoinformabouthazardsatregular
intervals.Personalprotectiveequipmenthastobemadeavailabletothesta󰀨.Maintenanceintervalshavetoberespected.
Risk of physical injuries by high pressure or unexpected material leakage
• Unexpected material leakage may result in burns. There is a risk of serious injuries or death and/or
damage to the hot runner.
• There is also a risk of burns, if water gets onto or into the hot runner. If the water reaches dangerous-
ly high temperatures, the metal housing may burst and cause serious injuries due to emerging water
vapour or melting resins.
Safety measures
• Make sure the hot runner system heats up evenly. Particularly for large manifolds it may be necessa-
ry to switch on nozzle and sprue bush heaters simultaneously, but later than the manifold heaters.
• Makesurethenozzletipsand/orthegatesarenotblockedbysolidiedresinthathasahighermel-
ting pont and that there is no humidity on the hot runner system, e.g. caused by a leaky temperature
control circuit (please see chapter „6.3 Start-up of a HPS III hot runner system“).

13HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Safety instructions
Risk of burns
• Hot surfaces
Many components of the hot runner systems get very hot and may cause severe skin burns when
being touched.
• Hot material (plastic melt)
Never touch material leaking from the nozzle/the mould/the hot runner or the material inlet. Even
material that seems to be cooled down already may still be hot inside the core and cause burns.
Safety measures
• Please make sure you wear your personal protective equipment (PPE) when working near or on a
hot runner system. Pay special attention to warnings indicating hot surfaces. All components have
to be cooled down to ambient temperature before you start working. Exceptions to these rules are
explicitly mentioned.
Risk of electric shocks
• Danger to life by electric shock.
Touching live surfaces may result in severe or even lethal injuries.
• Always keep water away from live components and the hot runner. There is a risk of short circuits!
Safety measures
• Electrical systems have to be disconnected from the mains and secured against being switched on
again before any work is carried out. Only authorised electricians are allowed to carry out any work
on electrical systems.
• All components have to be connected to a suitable power source according to the wiring diagrams
and under consideration of the applicable local regulations. Injection moulding machine and hot run-
ner systems have to be grounded.
Risk of physical injuries by suspended/heavy loads
• Onlytrainedsta󰀨isauthorisedtooperateliftingdevicesandforklifttrucks.Proceedslowlyandwith
care. Prevent the uncontrolled swinging of the loads (e. g. the manifold).
Safety measures
• Lifting devices and forklift trucks have to be designed to bear the weight and the size of the hot run-
ner system/manifold. Make sure to use the marked lifting points.
Risk of physical injuries by pressurised connecting lines
(e.g. air, hydraulics, water)
• All supply lines for the medium supply of the hot runner and/or the hot runner system or the hot half
havetobelongenoughtopreventanystresswhenthemouldhalvespart.Theymustnotbea󰀨ected
by moving parts of the mould or of the machine. Prevent the hoses from rubbing over the edges of
the mould as they may be damaged because this might cause a spontaneous leakage of pressurised
process media (pressurised air, hydraulic oil, water).
Safety measures
• Make sure you have depressurised all supply lines before carrying out any work.
Only skilled personnel is allowed to carry out work on the supply lines. Please wear your personal
protective equipment (PPE).
Risk of physical injuries by sharp edges and corners
• Sharp edges and corners pose a risk of injury, possibly resulting in skin abrasions and cut injuries.
Safety measures
• Make sure you wear protective gloves when working near sharp edges and corners.
Proceed with care.
• Make sure the system is clean and free of burrs.

14 HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Safety instructions
Risk of physical injuries by crushing of extremities
• There is a risk of injury when lifting heavy loads during assembly operations, possibly resulting in
crushing of hand or other parts of the body.
Safety measures
• Wear protective gloves to prevent injuries while working around heavy loads.
• Make sure all body parts are kept away from the hazardous area while setting down heavy loads.
2.7 Electrical equipment
HAZARD!
Residual voltage after activation
Risk of death by electric shock and severe injuries caused by live components.
• Check for zero potential before performing any work!
Anyworkonelectricalequipmentmustbecarriedoutbyqualiedelectricians.Alwaysapplythe5safetyruleswhenworking
with electrical components:
• Disconnect from the mains
• Secure against reconnection (by activating the repair switch and installing a safety lock at the same time, if necessary)
• Verify that the installation is dead
• Carry out grounding and short circuiting
• Provide protection against adjacent live parts
Maintenanceworkmustbecarriedoutbyqualiedandtrainedsta󰀨ormaintenancesta󰀨.NeverusetheHPSIIIhotrunner
systemwithfaultyorinoperableelectricalconnections.Incaseofenergysupplydisruptionsimmediatelyswitcho󰀨the
HPS III hot runner system. The maintenance & inspection schedules regarding electrical components given by the manufac-
turers have to be adhered to. Check for damaged insulation at regular intervals.
2.8 Spare and wear parts, auxiliary and operating materials
The use of non-OEM spare and wear parts as well as auxiliary material may pose risks. Only use original parts or parts
approved by EWIKON Heißkanalsysteme GmbH. Only use auxiliary and operating materials which are suitable for their
intended use (compare chapter „5.3 Technical Requirements“).
2.9 Limitation of liability
All information and instructions given in this manual have been compiled in consideration of the applicable standards and
regulations, state of the art as well as our know-how and experience.
EWIKON does not assume liability for any damage caused by:
• Non-observance of this manual
• Improper use
• Useofunskilledsta󰀨
• Unauthorisedretrottingortechnicalmodications
• Use of non-approved spare parts as well as inappropriate auxiliary and operating materials

15HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Safety instructions
The technical service provided verbally, in writing or on the basis of tests represents our best knowledge but is not binding
and does not release you from carrying out additional tests on the products supplied by us regarding their suitability for the
intended use.
The use of the products is beyond our control. Therefore, it is your own responsibility to ensure that the products meet your
specicrequirements.Nevertheless,shouldanissueofliabilityarise,alldamageshallbelimitedtothevalueoftheproducts
supplied by EWIKON and used by you.
We guarantee the perfect quality of our products in accordance with our general terms and conditions of sale and payment
as well as the extended warranty conditions.
These are available on our homepage www.ewikon.com.
The statutory provisions prevailing at the time of conclusion of the contract shall apply.
We reserve the right of technical alterations to develop our products and enhance their performance properties.
2.10 Warranty terms
For warranty conditions of cold and hot runner systems and components please refer to the terms and conditions of
EWIKON.
2.11 Standards and directives
EWIKON hot runner systems conform to the following European directives:
• Machinery Directive 2006/42/EC
• Low Voltage Directive 2014/35/EU
• EN ISO 12100:2010 Safety of machinery -
General principles for design - Risk assessment and risk reduction
• EN 60204-1:2007-06 Safety of machinery -
Electrical equipment of machines - Part 1: General requirements

16 HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Technical data
3. Technical data
3.1 Mechanical specications
3.1.1 Main dimensions of the HPS III hot runner system
Description Quantity/size (approx.) Unit
Dimensions See catalogue / PO-related documents mm
Weight See catalogue / PO-related documents kg
Chart 2: Main dimensions of the HPS III hot runner system
3.1.2 Operating parameters of the HPS III hot runner system
Description Quantity/size (approx.) Unit
Maximum injection pressure 2000 bar
Maximum operating temperature Depending on order °C
Chart 3: Operating parameters of the HPS III hot runner system
3.2 Electrical specications
3.2.1 Connections/connector pin assignment
Description Quantity/size (approx.) Unit
Voltage 230 V
Frequency 50 Hz
Chart 4: Electrical data (only valid within the EU)
3.3 Hydraulic / pneumatic specications (drive units)
Description Quantity/size (approx.) Unit
Maximum hydraulic pressure (normal operation: 30 bar) 50 bar
Maximum pneumatic pressure (normal operation: 8 bar) 10 bar
Chart 5: Hydraulic / pneumatic data
3.4 Operating conditions
Operating conditions Size (approx.) Unit
Ambient temperature (maximum value) 40 °C
Ambient temperature (minimum value) 10 °C
Relative humidity during operation (no condensation!) 20 to 80 %
Chart 6: Operating conditions
3.4.1 Noise emission
Determining the sound power level of noise sources based on noise pressure measurements acc. to DIN EN ISO 3741
Operating conditions Size (approx.) Unit
Distance to device * mm
Noise pressure level (operation) * dB (A)
Chart 7: Noise emission
* Values can be determined only after the entire system has been started up.

17HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Technical data
3.4.2 Cooling agent
The use of unsuitable cooling agents may result in deposits and corrosion in the component to be cooled. This will negatively
a󰀨ectthefunctionalityofthehotrunnersystem.Componentsofthehotrunnersystemmaybedamagedbyareducedcoo-
ling performance in the worst case. Cooling agents (water) have to satisfy the following minimum requirements:
• Cooling by tap water is not recommended since hard water can cause deposits and corrosion.
• The water has to be clear, colourless and odourless.
• Ithastobefreefromanyoatingorsuspendedmatters.
• A warranty on the resistance of components to be cooled against corrosion attacks cannot be given.
However, the use of suitable cooling agents can considerably enhance this resistance.
3.5 Type plate
Picture 1: Type plate
The system type plate is to be displayed prominently on the
operator side of the mould. Hot halves are delivered with the
type plate already mounted.
The type plate indicates project number, order number, type
of hot runner system, overall performance, drive unit type,
nozzlesusedand,ifnecessary,otherimportantspecica-
tions.
For the exact allocation of heater zones and contact pins
in the plugs please refer to the wiring scheme in the order
specicdocuments.
Respect operating temperatures
Each hot runner system is individually designed for the material to be
processed.Therefore,thespeciedoperatingtemperaturesmustbe
observed.Thetemperaturedi󰀨erence∆Tbetweenhotrunnertempe-
rature THK (processing temperature) and mould temperature TWZ,
must be strictly adhered to.
• Non-observance may cause an escape of melt inside the mould
(∆Ttoolow)ordamagetocomponents(∆Ttoolarge).
CAUTION!

18 HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Functional description of the HPS III hot runner system
4. Functional description of the HPS III hot runner system
The schematic diagrams of the components of a HPS III hot runner system and the installation space shown in this docu-
mentshouldnotberegardedastheonlyvalidgenerallayoutbutonlypresentoneofmanypossibleassemblycongura-
tions.
Pos. 1 Injection mould with hot runner system
Pos. 1.1 Moving mould half (ejector side)
Pos. 1.2 Fixed mould half (nozzle side)
Pos. 1.3 Hot half (nozzle side without contour plate)
Pos. 2 Locating ring
Pos. 3 Sprue bush
Pos. 4 Hot runner manifold
Pos. 5 Hot runner nozzles
Pos. 50 Insulating plate (optional)
Pos. 51 Clamping plate
Pos. 51.1 Clamping plate
with drive unit for valve gate nozzles
z349-03
Picture 2: Layout of an injection mould with HPS III hot runner system for the processing of thermoplastic resins
Pos. 52 Nozzle retainer frame plate
Pos. 53 Contour plate
Pos. 54 Guide bolts
Pos. 55 Moulded part
Pos. 56 Cavity
Pos. 57 Contour plate
Pos. 58 Riser
Pos. 59 Ejector plates
Pos. 60 Ejector pins
Pos. 61 Clamping plate
Pos. 62 Ejector bolts

19HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Functional description of the HPS III hot runner system
Picture 3: Injection moulding cycle * for valve gate systems
** recommended for open systems
A hot runner system is used to distribute plastic melt between the injection moulding unit of an injection moulding machine
and the cavities of an injection mould (compare picture 2). The plastic material remains permanently molten until it enters the
cavities.
The plastic melt made available by the injection moulding unit is guided through the sprue bush to the manifold during the
injection moulding cycle. In the manifold the melt stream for the individual cavities is split and fed to the hot runner nozzles.
The hot runner nozzles guide the melt stream to the cooled cavities (compare picture 3).
If a valve gate system is used, the valve pins are opened when injection starts. While the moulded parts continue to cool
down a holding pressure phase to compensate shrinkage follows after the injection phase with a continued, usually pressu-
re-regulatedmelttransportintothecavity(comparepicture3).Afterthemouldedparthassolidiedtosuchanextentthatno
newmaterialcanenterthecavity,theholdingpressurephasehasnishedandthemouldedpartscooldownuntiltheyreach
a safe demoulding temperature.
If a valve gate system is used the opening towards the cavity (gate) will be closed again by a movement of the valve pins
aftertheholdingpressurephasehasbeennished(comparepicture3).Ifopensystemsareused,adecompressionphase
will follow to prevent plastic melt from leaking from the gate area. While the moulded parts continue to cool down in the
cavity the injection moulding machine can prepare the melt for the next cycle. After the demoulding temperature has been
reached,theinjectionmouldopensandthesolidiedpartsareejected.
Cooling
Start of cycle
Valve gate nozzle(s)
open(s)*
Valve gate nozzle(s) close(s)*
Mould closing
Buildup of barrel
pressure
Injecting
Holding pressure
Reduction of barrel
pressure
Dosing
Mould opening,
ejecting Decompression**

20 HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN
Installation
5. Installation
ThefollowinginformationisintendedtohelpyouinstalltheHPSIIIhotrunnersystem.Inaddtion,theassemblysta󰀨hasto
have the know-how required to install an HPS III hot runner system.
The described installation processes are examples for standard nozzles and standard systems.
Special systems may require di󰀨erent procedures! Please observe the instructions in the order specic documents.
5.1 Transport
This chapter describes how to transport a hot runner system without damaging it and how to ensure occupational safety for
thesta󰀨.
5.1.1 Safety information on transport
NOTE!
Inappropriate transport
Damage to the HPS III hot runner system.
• Onlyspeciallytrainedsta󰀨isauthorisedtotransporttheHPSIIIhotrunnersystem.
• Only use designated attachment points to attach lifting devices.
• Exercise greatest caution when transporting the HPS III hot runner system. Handle with care.
Pendular motion while lifting the hot runner systems with a lifting device (e.g. overhead crane)
Damage to the HPS III hot runner system and/or injection mould.
• Avoid pendular motions! Move HPS III hot runner system slowly and with care.
• When using the lifting device to connect heavy components avoid tilting while lifting and lowering.
WARNING! PPE
Suspended loads
Death and severe crushing of body or extremities.
• Keep clear of and do not pass under suspended loads.
• Keep clear of suspended loads while they are being transported.
• Do not touch lifting devices and lifting accessories while lifting the load.
• Only lift, transport and set down loads, if you have received appropriate training.
• Only use suitable and undamaged lifting devices and lifting accessories which
are checked regularly.
• Do not exceed the maximum load limit of lifting accessories.
Sharp edges and heavy components
• Cut injuries to body and extremities, mainly to the hands.
• Crushingofngersorhand.