HB-THERM M8146-EN User manual

Temperatur Control Technology
www.hb-therm.ch
M8146-EN 2019-07 1/16
2019-07
Page
Assembly Instructions
M8146-EN
Spare parts Vario-5 switching and buffer valve
Contents
Precondition...................................................................................2
Procedure .......................................................................................2
Preparation.....................................................................................3
Sleeve and seal (O/ID T27098)......................................................4
Piston with sleeve and seal (O/ID T27099, T28434)....................7
Sealing set (O/ID T27101, T27102)..............................................12
Complete linear stepper motor (O/ID T27595, T28433)............14
Inspection.....................................................................................16
Parts list........................................................................................16

Assembly Instructions M8146-EN
M8146-EN 2019-07 2/16
Precondition
WARNING!
Danger for unauthorized persons!
Conversion work may only be carried out by
specialist staff who have been trained accordingly.
Therefore:
–Keep unauthorized persons away from the work
area.
NOTE!
Knowledge of the Instruction Manual is a
precondition for carrying out conversion work on
the unit.
Procedure
DANGER!
Danger to life caused by electric current!
Touching conductive parts causes a direct danger
to life.
Therefore:
–For all work on the electrical system, for
maintenance, cleaning or repair work,
disconnect from the mains or disconnect all
phases of the external power supply and secure
them against being switched on again. Check
unit is isolated from power supply.
WARNING!
Danger of crushing due to rolling away or
tipping
With an uneven floor or when the castors are not
locked, there is a danger that the unit tips over or
rolls away causing crushing.
Therefore:
–Only install the unit on an even floor.
–Ensure that the castors are locked.

Assembly Instructions M8146-EN
M8146-EN 2019-07 3/16
Preparation
1. Proceed as follows to cool down the system and carry out
mould evacuation:
Select module no. "VCn" with the or key.
Display menu page Functions.
Select the Cooling parameter and activate with the key.
Select the parameter Mould evacuation and press the key.
The activated function is indicated with the symbol.
2. Proceed as follows to mount or disassemble the multiphase
motors:
Display the menu page Service \ Support (Profile support)
Set the parameter Positioning valve heating to „25 %“.
Set the parameter Positioning valve cooling to „25 %“.
Set the parameter Positioning valve buffer to „0 %“.
NOTICE!
The user profile must be set to support in order to
access the parameter (  Operating instructions:
chapter Operation).
3. Switch off all main switches, unplug the mains plug and empty
the switching unit.
4. Removing the covers of the switching unit (Operating
instructions: chapter Maintenance).

Assembly Instructions M8146-EN
M8146-EN 2019-07 4/16
Sleeve and seal (O/ID T27098)
1. Carry out preparation (page 3).
on the multiphase motor, the switching module (M 5,6)
2. Proceed as follows to disassemble the multiphase
motor (M 5,6):
Fig. 1: Remove switching unit buffer (19)
CAUTION!
Risk of burns!
During operation, the multiphase motor (M 5,6)
becomes hot. Danger of burns, if touched.
Therefore:
–Wear thermal gloves when touching or let the
multiphase motor cool down.
In order to remove the switching buffer unit (19), disassemble
2x pipe couplings (label 1) and remove 2x screws (label 2).
Remove the switching buffer unit (19) on the side.
To disassemble the protection cover of the accumulator (16),
remove 2x screws (label 3).
Fig. 2: Remove the multiphase motor
M 5,6
NOTICE!
Observe following when disassembling the
multiphase motor:
- Positioning of the multiphase motors
 Preparation page 3.
- Alignment of the groove of the coupling, to allow the
piston rod to extend  Fig. 5.
Withdraw the cable connector of the multiphase motor (M 5.6).
Loosen the 4 fixing screws (label 4) (approx. 8–10 mm).
Slightly pull out downwards the multiphase motor (M 5,6) and
move out of coupling.
Fig. 3: Replacing the guide bush
3. Proceed as follows in order to replace the guide bush:
Remove the fixing screw (label 5) holding the guide bush at the
bottom of the switching (20) resp. buffer module (21).
Remove the guide bush (label 6).
NOTICE!
Do not remove the mounting rod to assemble the
guide bush.
Assemble the new guide bush. The mounting rod is being
pressed out by the piston.
Remove the mounting rod, it is no longer needed.
Fix the guide bush with the fixing screw.
1
32
4
6
5

Assembly Instructions M8146-EN
M8146-EN 2019-07 5/16
F
Fig. 4: Mount the multiphase motor M 5,6
4. Proceed as follows to mount the multiphase motor (M 5,6):
NOTICE!
Observe following when mounting the multiphase
motor:
- Loosen the 4 fixing screws enough (approx.
8-10 mm) to enable an easier installation.
- Alignment of the groove of the coupling, to allow
the piston rod to retract (label 7  Fig. 5).
Engage the multiphase motor, turn into final position and fix
with the 4 screws.
Fig. 5: Visual control of the groove
alignment
WARNING!
Improper installation can cause material
damage!
Wrongly mounted multiphase motors can lead to
dysfunction and/or material damage.
Therefore:
–Observe correct mounting, visual control to
check the engagement of the piston rod in the
coupling Fig. 29.
Fig. 6: Assemble the switching unit
buffer (19)
Connect the cable connector of the multiphase motor (M 5.6).
Engage the switching buffer unit (19) on the side.
Mount the switching buffer unit (19) with 2x pipe couplings
(label 8) as well as 2x screws (label 9) on the base plate.
Mount the protection cover of the accumulator with two screws
(label 10).
7
8
109

Assembly Instructions M8146-EN
M8146-EN 2019-07 6/16
on the multiphase motor, the buffer module (M 7)
Fig. 7: Disassemble the multiphase
motor M 7
5. Proceed as follows to disassemble the multiphase
motor (M 7):
Withdraw the cable connector of the multiphase motor (M 7).
Loosen 2x fixing screws (label 1) of the multiphase
motor (M 7).
Turn the multiphase motor (M 7), slightly pull out downwards
and move out of connection.
Fig. 8: Replacing the guide bush
6. Proceed as follows in order to replace the guide bush:
Remove the fixing screw (label 5) holding the guide bush at the
bottom of the switching (20) resp. buffer module (21).
Remove the guide bush (label 6).
NOTICE!
Do not remove the mounting rod to assemble the
guide bush.
Assemble the new guide bush. The mounting rod is being
pressed out by the piston.
Remove the mounting rod, it is no longer needed.
Fix the guide bush with the fixing screw.
7. Proceed as follows to mount the multiphase motor (M 7):
Engage the multiphase motor, turn into final position and fix
with the two screws.
Connect cable plug of the multiphase motor.
8. Carry out inspection (page 16).
1
6
5

Assembly Instructions M8146-EN
M8146-EN 2019-07 7/16
Piston with sleeve and seal
(O/ID T27099, T28434)
1. Carry out preparation (page 3).
For switching module (20)
2. Proceed as follows to disassemble the multiphase
motor (M 5,6):
Fig. 9: Remove switching unit buffer (19)
CAUTION!
Risk of burns!
During operation, the multiphase motor (M 5,6)
becomes hot. Danger of burns, if touched.
Therefore:
–Wear thermal gloves when touching or let the
multiphase motor cool down.
In order to remove the switching buffer unit (19), disassemble
2x pipe couplings (label 1) and remove 2x screws (label 2).
Remove the switching buffer unit (19) on the side.
To disassemble the protection cover of the accumulator (16),
remove 2x screws (label 3).
Fig. 10: Remove the multiphase motor
M 5,6
NOTICE!
Observe following when disassembling the
multiphase motor:
- Positioning of the multiphase motors
 Preparation page 3.
- Alignment of the groove of the coupling, to allow the
piston rod to extend  Fig. 15
Withdraw the cable connector of the multiphase motor (M 5.6).
Loosen the 4 fixing screws (label 4) (approx. 8–10 mm).
Slightly pull out downwards the multiphase motor (M 5,6) and
move out of coupling.
Fig. 11: Remove the cover of the switching
module
3. Proceed as follows to disassemble the cover:
Disassemble the flexible tube of the tool circuit exit (OUT M).
Disassemble the main line temperature sensor (BT 1).
Disassemble 8x screws (label 1) and remove cover.
4. Carefully move out the piston rod upwards.
1
32
4
1
BT 1

Assembly Instructions M8146-EN
M8146-EN 2019-07 8/16
Fig. 12: Replacing the guide bush
5. Proceed as follows in order to replace the guide bush:
Remove the fixing screw (label 5) holding the guide bush at the
bottom of the switching (20) resp. buffer module (21).
Remove the guide bush (label 6).
NOTICE!
Do not remove the mounting rod to assemble the
guide bush.
Assemble the new guide bush. The mounting rod is being
pressed out by the piston.
Remove the mounting rod, it is no longer needed.
Fix the guide bush with the fixing screw.
6. Carefully assemble the piston rod
Fig. 13: Mount the cover of the switching
module
7. Proceed as follows to mount the cover of the switching
module (20):
WARNING!
Damages if leaking!
The re-use of used seals can cause leaking.
Therefore:
–seals are to be compulsory replaced after each
disassembly of the cover.
WARNING!
Damages if leaking!
Leaking if torque is wrong.
Therefore:
–Tighten cover of the switching module with
37 Nm.
Remove the old seals, clean the sealing surface and place the
new seals (label 1).
Attach the cover and tighten the 8 screws with a torque of
37 Nm.
Mount main line of the temperature sensor (BT 1) at the cover.
Connect the flexible tube of the tool circuit exit (OUT M).
F
8. Proceed as follows to mount the multiphase motor (M 5,6):
NOTICE!
Observe following when mounting the multiphase
motor:
- Loosen the 4 fixing screws enough (approx.
8-10 mm) to enable an easier installation.
- Alignment of the groove of the coupling, to allow
the piston rod to retract (label 7  Fig. 15)
Engage the multiphase motor, turn into final position and fix
with the 4 screws.
6
5
1

Assembly Instructions M8146-EN
M8146-EN 2019-07 9/16
Fig. 14: Mount the multiphase motor M 5,6
Fig. 15: Visual control of the groove
alignment
WARNING!
Improper installation can cause material
damage!
Wrongly mounted multiphase motors can lead to
dysfunction and/or material damage.
Therefore:
–Observe correct mounting, visual control to
check the engagement of the piston rod in the
coupling Fig. 15
Fig. 16: Assemble the switching unit
buffer (19)
Connect the cable connector of the multiphase motor (M 5.6).
Engage the switching buffer unit (19) on the side.
Mount the switching buffer unit (19) with 2x pipe couplings
(label 8) as well as 2x screws (label 9) on the base plate.
Mount the protection cover of the accumulator with two screws
(label 10).
7
8
109

Assembly Instructions M8146-EN
M8146-EN 2019-07 10/16
For buffer module (21)
Fig. 17: Disassemble the multiphase
motor M 7
9. Proceed as follows to disassemble the multiphase
motor (M 7):
Withdraw the cable connector of the multiphase motor (M 7).
Loosen 2x fixing screws (label 1) of the multiphase
motor (M 7).
Turn the multiphase motor (M 7), slightly pull out downwards
and move out of connection.
Fig. 18: Remove the cover of the buffer
module
10.Proceed as follows to disassemble the cover:
Disassemble flexible tube of the buffer entry (c).
Disassemble the temperature sensor of the buffer (BT 3).
Disassemble the 1 screw on the rear panel of the unit.
Disassemble 4x screws (label 2) and remove cover.
11.Carefully move out the piston rod upwards.
Fig. 19: Replacing the guide bush
12.Proceed as follows in order to replace the guide bush:
Remove the fixing screw (label 5) holding the guide bush at the
bottom of the switching (20) resp. buffer module (21).
Remove the guide bush (label 6).
NOTICE!
Do not remove the mounting rod to assemble the
guide bush.
Assemble the new guide bush. The mounting rod is being
pressed out by the piston.
Remove the mounting rod, it is no longer needed.
Fix the guide bush with the fixing screw.
13.Carefully assemble the piston rod
1
2
BT 3
c
6
5

Assembly Instructions M8146-EN
M8146-EN 2019-07 11/16
Fig. 20: Mount the cover of the buffer
module
14.Proceed as follows to mount the cover of the buffer
module (21):
WARNING!
Damages if leaking!
The re-use of used seals can cause leaking.
Therefore:
–seals are to be compulsory replaced after each
disassembly of the cover.
WARNING!
Damages if leaking!
Leaking if torque is wrong.
Therefore:
–Tighten cover of the buffer module with 10 Nm.
Remove the old seal, clean the sealing surface and place the
new seal (label 3).
Fit the cover and tighten with the 4 screws.
Mount the 1 screw on the rear panel of the unit.
Mount the temperature sensor of the buffer (BT 3) at the cover.
Connect the flexible tube of the buffer exit (c).
15.Proceed as follows to mount the multiphase motor (M 7):
Engage the multiphase motor, turn into final position and fix
with the two screws.
Connect cable plug of the multiphase motor.
16.Carry out inspection (page 16).
3
c

Assembly Instructions M8146-EN
M8146-EN 2019-07 12/16
Sealing set (O/ID T27101, T27102)
1. Carry out preparation (page 3).
For switching module (20)
Fig. 21: Remove the cover of the switching
module
2. Proceed as follows to disassemble the cover:
Disassemble the flexible tube of the tool circuit exit (OUT M).
Disassemble the main line temperature sensor (BT 1).
Disassemble 8x screws (label 1) and remove cover.
Fig. 22: Mount the cover of the switching
module
3. Proceed as follows to mount the cover of the switching
module (20):
WARNING!
Damages if leaking!
The re-use of used seals can cause leaking.
Therefore:
–seals are to be compulsory replaced after each
disassembly of the cover.
WARNING!
Damages if leaking!
Leaking if torque is wrong.
Therefore:
–Tighten cover of the switching module with
37 Nm.
Remove the old seals, clean the sealing surface and place the
new seals (label 1).
Attach the cover and tighten the 8 screws with a torque of
37 Nm.
Mount main line of the temperature sensor (BT 1) at the cover.
Connect the flexible tube of the tool circuit exit (OUT M).
For buffer module (21)
Fig. 23: Remove the cover of the buffer
4. Proceed as follows to disassemble the cover:
Disassemble flexible tube of the buffer entry (c).
Disassemble the temperature sensor of the buffer (BT 3).
Disassemble the 1 screw on the rear panel of the unit.
Disassemble 4x screws (label 2) and remove cover.
1
BT 1
1
2
BT 3
c

Assembly Instructions M8146-EN
M8146-EN 2019-07 13/16
module
Fig. 24: Seal between switching and buffer
module
5. Proceed as follows to replace the seal of the switching (20)
and buffer module (21):
Disassemble flexible tube of the buffer entry (b).
Disassemble the return line of the temperature sensor (BT 2).
Disassemble 1 screw on the rear panel of the unit and the
4 screws (label 2).
Remove the old seal, clean the sealing surface and place the
new seal (label 3).
WARNING!
Damages if leaking!
Leaking if torque is wrong.
Therefore:
–Tighten buffer module (21) with 10 Nm.
Attach buffer module and tighten the 4 screws (label 2) with a
torque of 10 Nm.
Mount the 1 screw on the rear panel of the unit.
Mount the return line temperature sensor (BT 2) at the buffer
module.
Connect flexible tube of the buffer entry (b).
Fig. 25: Mount the cover of the buffer
module
6. Proceed as follows to mount the cover of the buffer
module (21):
WARNING!
Damages if leaking!
The re-use of used seals can cause leaking.
Therefore:
–seals are to be compulsory replaced after each
disassembly of the cover.
WARNING!
Damages if leaking!
Leaking if torque is wrong.
Therefore:
–Tighten cover of the buffer module with 10 Nm.
Remove the old seal, clean the sealing surface and place the
new seal (label 3).
Fit the cover and tighten with the 4 screws.
Mount the 1 screw on the rear panel of the unit.
Mount the temperature sensor of the buffer (BT 3) at the cover.
Connect the flexible tube of the buffer exit (c).
7. Carry out inspection (page 16).
b
BT 2
3
2
3
c

Assembly Instructions M8146-EN
M8146-EN 2019-07 14/16
Complete linear stepper motor
(O/ID T27595, T28433)
1. Carry out preparation (page 3).
on the multiphase motor, the switching module (M 5,6)
2. Proceed as follows to disassemble the multiphase
motor (M 5,6):
Fig. 26: Remove switching unit buffer (19)
CAUTION!
Risk of burns!
During operation, the multiphase motor (M 5,6)
becomes hot. Danger of burns, if touched.
Therefore:
–Wear thermal gloves when touching or let the
multiphase motor cool down.
In order to remove the switching buffer unit (19), disassemble
2x pipe couplings (label 1) and remove 2x screws (label 2).
Remove the switching buffer unit (19) on the side.
To disassemble the protection cover of the accumulator (16),
remove 2x screws (label 3).
Fig. 27: Remove the multiphase motor
M 5,6
NOTICE!
Observe following when disassembling the
multiphase motor:
- Positioning of the multiphase motors
 Preparation page 3.
- Alignment of the groove of the coupling, to allow the
piston rod to extend  Fig. 29.
Withdraw the cable connector of the multiphase motor (M 5.6).
Loosen the 4 fixing screws (label 4) (approx. 8-10 mm).
Slightly pull out downwards the multiphase motor (M 5,6) and
move out of coupling.
F
Fig. 28: Mount the multiphase motor M 5,6
3. Proceed as follows to mount the multiphase motor (M 5,6):
NOTICE!
Observe following when mounting the multiphase
motor:
- Loosen the 4 fixing screws enough (approx.
8-10 mm) to enable an easier installation.
- Alignment of the groove of the coupling, to allow
the piston rod to retract (label 7  Fig. 29.).
Engage the multiphase motor, turn into final position and fix
with the 4 screws.
1
32
4

Assembly Instructions M8146-EN
M8146-EN 2019-07 15/16
Fig. 29: Visual control of the groove
alignment
WARNING!
Improper installation can cause material
damage!
Wrongly mounted multiphase motors can lead to
dysfunction and/or material damage.
Therefore:
–Observe correct mounting, visual control to
check the engagement of the piston rod in the
coupling Fig. 29.
Fig. 30: Assemble the switching unit
buffer (19)
Connect the cable connector of the multiphase motor (M 5.6).
Engage the switching buffer unit (19) on the side.
Mount the switching buffer unit (19) with 2x pipe couplings
(label 8) as well as 2x screws (label 9) on the base plate.
Mount the protection cover of the accumulator with two screws
(label 10).
on the multiphase motor, the buffer module (M 7)
Fig. 31: Disassemble the multiphase
motor M 7
4. Proceed as follows to disassemble the multiphase
motor (M 7):
Withdraw the cable connector of the multiphase motor (M 7).
Loosen 2x fixing screws (label 1) of the multiphase
motor (M 7).
Turn the multiphase motor (M 7), slightly pull out downwards
and move out of connection.
5. Proceed as follows to mount the multiphase motor (M 7):
Engage the multiphase motor, turn into final position and fix
with the two screws.
Connect cable plug of the multiphase motor.
6. Carry out inspection (page 16).
7
8
109
1

Assembly Instructions M8146-EN
M8146-EN 2019-07 16/16
Inspection
1. Proceed as follows for inspection:
2. Plug all main plugs and switch on the main switch.
3. Switch the system on with the key and check tightness
and functioning.
4. Switch the system off with the key.
5. Switch off all main switches.
6. Fit the covers correctly on the switching unit.
Parts list
Pos
Description
O/ID
O/ID
T27098
T27099
T28434
T27101
T27102
T27595
T28433
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
01
Bush 18x4x33 (mounted)
T25912
1
1
1
-
-
-
-
02
Ring 11x4x2,4 (mounted)
T27139
1
1
1
-
-
-
-
03
Scraper ARLON (mounted)
T27138
1
1
1
-
-
-
-
04
Circlip DIN 427 (mounted)
N10411
1
1
1
-
-
-
-
05
Grease Barrierta L55/2 (mounted)
H1056
1
1
1
-
-
-
-
06
Cylinder pin DIN 6325-4h6x30 (mounted)
B1306553
1
1
1
-
-
-
-
07
O-Ring 10x2-FFKM75 (mounted)
T25432
1
1
1
-
-
-
-
08
Seal 4x10x4-FFKM (mounted)
T25590
1
1
1
-
-
-
-
09
Screw M4x6-TORX (mounted)
B3061615
1
1
1
-
-
-
-
10
Piston complete 25
T26658
-
1
-
-
-
-
-
11
Piston complete 22
T28042
-
-
1
-
-
-
-
12
Seal Sigraflex 39x47x1
T25808
-
2
-
2
-
-
-
13
Seal Sigraflex 29x37x1
T26758
-
-
1
-
1
-
-
14
Seal Sigraflex 24x32x1
T25838
-
-
-
-
1
-
-
15
Linear step motor type 57 with bracket
T27430
-
-
-
-
-
1
-
16
Linear step motor with bracket
T28036
-
-
-
-
-
-
1
17
Hexagon screw M4x8-A2
B3061322
-
-
-
-
-
-
2
18
Hexagon screw M4x12-A2
B1237837
-
-
-
-
-
4
-
19
Assembly instructions German
M8146-DE
1
1
1
1
1
1
1
20
Assembly instructions English
M8146-EN
1
1
1
1
1
1
1
21
Assembly instructions French
M8146-FR
1
1
1
1
1
1
1