Hot runner technology 16e-06 series Installation and user guide

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Nozzle 16E-06 / 22E-06 Series

10.1.4 Nozzle 16E-06 / 22E-06 Series

NOTICE

Always tighten the screws to the torque specified in the respective table in section 13.

Hazard of Pressurized Air

Pressurized air blow can result in hot plastic or foreign bodies entering the

eyes, causing vision damage.

Following work must be carried out by qualied and experienced persons.

Use personal protective equipment: Face protection, hearing protection and

gloves.

For rst aid contact your medical / safety representing.

Heavy Weight Hazard

Transport and lifting equipment should be operated only by trained

personnel.

Operate lifting and transport equipment slowly and carefully to avoid uncontrolled

swinging of the manifold.

Lifting and transport equipment for lifting Hot Runner Systems shall be approved

and properly rated taking into account the weight and size of the manifold.

When unpacking the Hot Runner System, there is a risk of injury due to falling

parts and sharp edges. Maintain a minimum distance of 1 m from the Hot Runner

System.

Use personal protective equipment, such as head gear, safety shoes and work

gloves.

For rst aid contact your medical / safety representing.

Hot Surfaces Hazard

Contact between the skin and hot surfaces could result in burns.

Use personal protective equipment, such as gloves, apron, sleeves and face

protection, to guard against burns.

When servicing or handling the hot runner system outside the manifold plates

or the injection molding machine, care must be taken to heed the hot surface

exposure warnings.

For rst aid contact your medical / safety representing.

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Nozzle 16E-06 / 22E-06 Series

NOTICE

Hazard of Material Damage

Without consulting Synventive it is not permitted to do modications to the

hot runner system e.g. geometrical changes to the nozzle tip, except the part

shape adjustment in the area of material allowance.

10.1.4.1Technical Data - Threaded Nozzle 16E-06 / 22E-06 Series

Threaded Nozzle 16E-06

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Flow bore (J) Ø 16 mm

Nozzle length (L) 90 - 1000 mm

Nozzle cutout (D) Ø 45 mm (L <450mm)

Ø 45 / Ø 52 mm (L

≥450mm)

Thermocouple Type J, Type K

Nozzle tips VSP, VTP, VSW, VTW,

TFP, TTP, TTW

Threaded Nozzle 22E-06

Flow bore (J) Ø 22 mm

Nozzle length (L) 100 - 1000 mm

Nozzle cutout (D) Ø 55 mm (L <450mm)

Ø 55 / Ø 62 mm (L

≥450mm)

Thermocouple Type J, Type K

Nozzle tips VSP, VTP, VSW, VTW,

TFP, TTP, TTW

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Nozzle 16E-06 / 22E-06 Series

10.1.4.2Parts of the Nozzles 16E-06 / 22E-06

In this section the nozzle parts are identied with the numbers indicated in the following gure.

NOTICE

Always tighten the screws to the torque specified in the respective table in section 13.

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Pos. Description

1Nozzle body

2Head ring

3Head heater (optional)

4Retaining ring

5Front heater

6Retaining ring

7Cover tube

8Tip

9Wear insert (optional)

10 Cooling bushing (optional)

11 Pre-centering ring (optional)

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Nozzle 16E-06 / 22E-06 Series

10.1.4.3 Cooling bushing (optional)

Cooling bushing type 16nc-04

Pos. QYT Part No. Description

1 1 16NC-B-03 16E Cooling Bushing

2 1 16NC-DT-01-MOD 16E Distance Tube

3 1 16NC-C-01 16E Cover

4 1 VIOR-47.29X2.62-FPM-80-G Viton O-Ring

5 1 VIOR-53.64X2.62-FPM-80-G Viton O-Ring

6 4 DIN6325-3m6x8 Paralell pin

7 4 DIN912-M5x14-12.9 Hexagon socket cap screw. DIN912-M5x14-12.9

Cooling bushing type 22nc-04

Pos. QYT Part No. Description

1 1 22NC-B-03 22E Cooling Bushing

2 1 22NC-DT-01-MOD 22E Distance Tube

3 1 22NC-C-01 22E Cover

4 1 VIOR-56.82X2.62-FPM-80-G Viton O-Ring

5 1 VIOR-63.17X2.62-FPM-80-G Viton O-Ring

6 4 DIN6325-3m6x8 Paralell pin

7 4 DIN912-M5x14-12.9 Hexagon socket cap screw. DIN912-M5x14-12.9

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Disassembly / Assembly Tools

10.1.5 Disassembly / Assembly Tools

In this section the Stripping and Mounting Tool parts are identied with the numbers indicated in the following gure.

10.1.5.1Nozzle Heater Disassembly Tool AT-FHA-032 for the Heater Type FHA#-032-###-##

The dismantling tool is required to pull the front heater from the nozzle body or the sprue bushing.

The adapter AT-FHA-032-C-05 is only required for the sprue bushing.

AT-FHA-032

Pos. Qty. Part No. Description

T4.1 1AT-FHA-032-C-01 Disassembly Tool Socket

T4.2 1AT-FHA-032-C-02 Disassembly Tool Sleeve

T4.3 1AT-FHA-032-C-05 Disassembly Tool IB24 Adapter

Nut

T4.4 1GN817-4-4-CK Indexing plunger; Pin Bore=4;

l1=4

T4.5 2DIN913-M6x12-45H Flat Point Socket Set Screw 45H

Alloy Steel

T4.6 1ISO4017-

M12X100-12.9

Full Thread Hexagon Screw

ISO4017

10.1.5.2Nozzle Heater Disassembly Tool AT-FHA-041 for the Heater Type FHA#-041-###-##

The dismantling tool is required to pull the front heater from the nozzle body.

AT-FHA-041

Pos. Qty. Part No. Description

T4.1 1AT-FHA-041-C-01 Disassembly Tool Socket

T4.2 1AT-FHA-041-C-02 Disassembly Tool Sleeve

T4.3 - - -

T4.4 1GN817-4-4-CK Indexing plunger; Pin Bore=4;

l1=4

T4.5 2DIN913-M6x12-45H Flat Point Socket Set Screw 45H

Alloy Steel

T4.6 1ISO4017-

M12X100-12.9

Full Thread Hexagon Screw

ISO4017

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Disassembly / Assembly Tools

10.1.5.3Spreader Tool Head Heater Type HHA#-0##-###-##

With this tool the head heaters can be spread apart to make it easier to pull them off the nozzle body.

AT-HHA-00

No. Qty. Part No. Description

T5.1 1AT-HHA-C-0-01 Head Heater Spreader

T5.2 1DIN316-A2-M4x16 Metric DIN 316 Wing

Screws M4x16

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Disassembly / Assembly Tools

lNozzle Tip Assembly Tools

Tip Assembly Tool for 16E-06 Nozzle Tips

TTW, TTP, TFP

Tip Assembly Tool for 22E-06 Nozzle Tips

TTW, TTP, TFP

(T2) AT-16-040102 (T1) AT-16-040101 (T2) AT-22-040102 (T1) AT-22-040101

Also used for the assembly of seal caps. Also used for the assembly of seal caps.

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Color Coding of Thermocouples

10.2 MS-Heating Element

There are two types of Molding Solution heaters.

Front Heaters FHA#-0##-###-## and Head Heaters HHA#-0##-###-##.

The thermocouple is pressed in rmly and cannot be replaced.

All heaters are available either with a thermocouple type J (#HAJ-0##-###-##) or a thermocouple type K (#HAK-0##-###-##).

10.2.1 Color Coding of Thermocouples

NOTICE

Take notice of the production and color identification of thermocouple cables.

Synventive uses J and K type thermocouples. Their color coding is given in the following table.

Table 1: International color coding for temperature sensors

Type International standard IEC 584-3

Black + Black

- White

Green + Green

- White

Coating Litz wire “+”

Litz wire “-”

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Color Coding of Thermocouples

10.2.1.1Disassembly the Nozzle 16E-06 / 22E-06 Series

Disassembling the Nozzle Heaters

1) Remove the retaining ring (6) from the nozzle tip (8).

2) Remove the pre-centering ring (11).

NOTICE

The pre-centering ring (11) is only provided on explicit

customer request.

3) Turn the hexagon head screw (T4.6) of the disassembly tool

completely backwards.

4) Pull the button from indexing plungers (T4.4) and x the position by

turning the button (T4.4) by 90°.

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Color Coding of Thermocouples

5) Guide the socket (T4.1) of the disassembly tool over the nozzle

insert (8).

NOTICE

The socket (T4.1) is seated onto the nozzle tip (8) and

slides back into the sleeve (T4.2).

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Color Coding of Thermocouples

6) Loosen the indexing plungers (T4.4), by turning the button 90°.

7) Position the disassembly tool until the indexing plungers (T4.4)

snaps into the hole of the cover tube (7) and the front heater (5).

8) Turn the hexagon head screw (T4.6) clockwise.

NOTICE

By turning the hexagon head screw (T4.6) the front

heater (5) together with the cover tube (7) is pulled off the

nozzle body (1).

9) Turn down the hexagon head screw (T4.6) completely.

10) Remove the front heater (5).

11) Remove the Cover Tube (7).

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Color Coding of Thermocouples

12) Remove the retaining ring (4).

13) Spread the head heater (3) with the spreading tool (T5).

14) Remove the head heater (3).

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Disassembling the Nozzle Tip and Nozzle Body

10.2.2 Disassembling the Nozzle Tip and Nozzle Body

Hazard of Pressurized Air

Pressurized air blow can result in hot plastic or foreign bodies entering the

eyes, causing vision damage.

Following work must be carried out by qualied and experienced persons.

Use personal protective equipment: Face protection, hearing protection and

gloves.

For rst contact your medical / safety representing.

Hot Surfaces Hazard

Contact between the skin and hot surfaces could result in burns.

Use personal protective equipment, such as work gloves, apron, sleeves and face

protection, to guard against burns.

When servicing or handling the hot runner system outside the manifold plates or the

injection molding machine, care must be taken to heed the hot surface exposure

warnings.

For rst contact your medical / safety representing.

Hot Surfaces Hazard

The nozzle is still hot.

NOTICE

To dismount the nozzle tip from the nozzle, if there is plastic

material in the nozzle, the tip must be heated-up.

Never use an acetylene or welding torch, as severe nozzle

damage can occur from over-heating.

NOTICE

When unscrewing the nozzle tip, the nozzle can rotate with the

nozzle tip, this can lead to leakage at the base of the nozzle.

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Disassembling the Nozzle Tip and Nozzle Body

1) Heat the nozzle tip (8) using a heat gun to the maximum temperature of

200 °C (392 °F).

2) Hold the nozzle body (1) rmly using an engineer’s wrench at the

hexagonal shape.

3) Unscrew the nozzle tip (8) from the nozzle body (1) using a ring wrench.

4) Clean the nozzle tip using pressurized air to remove as much residual

plastic as possible.

5) Unscrew nozzle body (1) from the manifold.

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Disassembling the Nozzle Tip and Nozzle Body

10.3 Assembly the Nozzles 16E-06 / 22E-06 Series

In this section the nozzle parts are identied with the numbers indicated in the following gure.

NOTICE

Always tighten the screws to the torque specified in the respective table in section 13.

Doc008837_RIS.png

Pos. Description

1Nozzle body

2Head ring

3Head heater (optional)

4Retaining ring

5Front heater

6Retaining ring

7Cover tube

8Tip

9Wear insert (optional)

10 Cooling bushing (optional)

11 Pre-centering ring (optional)

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Assembling the Nozzle Body and nozzle heaters

10.3.1 Assembling the Nozzle Body and nozzle heaters

1) Apply spotting ink on the nozzle body (1) bottom surface (SF1).

2) Screw in the nozzle body (1) hand-tight into the manifold thread until

seated.

3) Unscrew the nozzle body (1) from the manifold.

4) Check the matching between the manifold bottom surfaces (SF2) and

the nozzle body (1) surface (SF1).

NOTICE

The manifold must bear on all surfaces uniformly and flatly, in

particular on the nozzle head contact face.

In case of any uncertainty, clean the surfaces with a cleaning

cloth. If the next ink test is still unsatisfactory, contact

Synventive Customer Service or Technical Support.

5) With a positive ink test clean the surfaces and proceed to the next step.

6) Lubricate the thread (not the face) of the nozzle body with high-

temperature assembly paste (antiseize compound).

NOTICE

This is an important measure to prevent thread corrosion due

to aggressive gases, which could be released during plastics

processing.

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Assembling the Nozzle Body and nozzle heaters

7) Tighten nozzle body (1) to the manifold.

NOTICE

Use torque wrench with wrench insert and the torque

specified in the torque table in section 13.

8) Slide head ring (2), onto the nozzle body (1) up to the surface of the

hexagon.

NOTICE

The opening of the head ring (2), must be line up with the

cable connections (see customer drawing).

9) Bend the cable at the head heater corresponding to the opening at the

head ring (2).

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Assembling the Nozzle Body and nozzle heaters

10) Slide head heater (3), onto the nozzle body (1) up to the surface of the

head ring (2).

NOTICE

The head heater is only required for longer nozzles.

11) Fix the retaining rings (4) in the slots of the nozzle body (1).

NOTICE

The opening of the retaining rings (4), must be line up with the

cable connections (see customer drawing).

12) Bend the heater and thermocouple leads from the front heater.

NOTICE

Use round-nosed pliers only.

13) Mount the front nozzle heater (5) together with the cover tube (7) onto

the nozzle body (1).

NOTICE

The heating leads of the front heater (5) have to be led into

the openings of the retaining rings (4), the head heater (3)

and the head ring (2).

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Assembling the Nozzle Body and nozzle heaters

14) Use a soft faced hammer to drive the front heater (5) into the right

position.

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Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Nozzle Tip Assembling

10.3.2 Nozzle Tip Assembling

Assembling the Nozzle Tips TTW, TTP, TFP

1) 2) 3) 4) TTW Nozzle Tip Assembly

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1) Place the tip nut (a) into the tool (T2).

2) Using the tool (T1) to push the tip

insert (b) into the tip nut (a).

3) Place the torpedo (c) on the tip insert

(b).

4) Using the tool (T1) to push the

torpedo (c) and the tip insert (b) into

the tip nut (a).

1) 2) 3) 4) TTP Nozzle Tip Assembly

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1) Place the tip nut (a) on the tool (T2).

2) Using the tool (T1) to push the tip

insert (b) into the tip nut (a).

3) Place the torpedo (c) on the tip insert

(b).

4) Using the tool (T1) to push the

torpedo (c) and the tip insert (b) into

the tip nut (a).

1) 2) TFP Nozzle Tip Assembly

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1) Place the tip nut on the tool (T2).

2) Using the tool (T1) to push the tip

insert (b) into the tip nut (a).

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