Husky Unify User manual

Unify Manifold System
Hot Runner Installation Manual
Original Instructions

Issue: v 2.2 — March 2021
Document No.: 7593574
This product manual is intended to provide information for safe operation and/or maintenance.
Husky reserves the right to make changes to products in an eort to continually improve the
product features and/or performance. These changes may result in dierent and/or additional
safety measures that are communicated to customers through bulletins as changes occur.
This document contains information which is the exclusive property of Husky Injection Molding
Systems Limited. Except for any rights expressly granted by contract, no further publication or
commercial use may be made of this document, in whole or in part, without the prior written
permission of Husky Injection Molding Systems Limited.
Notwithstanding the foregoing, Husky Injection Molding Systems Limited grants permission to its
customers to reproduce this document for limited internal use only.
Husky®product or service names or logos referenced in these materials are trademarks of Husky
Injection Molding Systems Ltd. and may be used by certain of its aliated companies under
license.
All third-party trademarks are the property of the respective third-party and may be protected by
applicable copyright, trademark or other intellectual property laws and treaties. Each such third-
party expressly reserves all rights into such intellectual property.
©2016 – 2021 Husky Injection Molding Systems Ltd. All rights reserved.
v 2.2 — March 2021 Unify Manifold System
ii

General Information
Telephone Support Numbers
North America Toll free 1-800-465-HUSKY (4875)
Europe EC (most countries) 008000 800 4300
Direct and Non-EC + (352) 52115-4300
Asia Toll Free 800-820-1667
Direct: [phone]
Latin America Brazil [phone]
Mexico [phone] option 5
For on-site service, contact your nearest Husky Regional Service and Sales oce.
For non-emergency questions and issues you may also e-mail Husky at [e-mail].
Husky Regional Service and Sales Oces
For the location closest to you, please visit www.husky.co.
Product Upgrades
Upgrades are available that can improve your output, reduce cycle times, and add functionality to
your Husky equipment.
To see what upgrades are available for your Husky equipment, visit our website at www.husky.co
or call your nearest Husky Regional Service and Sales Oce.
Ordering Spare Parts
All spare parts for Husky equipment can be ordered through your nearest Husky Parts
Distribution Center or online at www.husky.co.
Hot Runner Installation Manual v 2.2 — March 2021
Telephone Support Numbers iii

Hot Runner Refurbishing
Husky oers services for repairing, modifying, and retrotting Husky hot runners. Contact your
Husky Regional Service and Sales oce for details.
v 2.2 — March 2021 Unify Manifold System
iv Hot Runner Refurbishing

Table of Contents
General Information..........................................................................................................................................iii
Telephone Support Numbers..................................................................................................................................................iii
Husky Regional Service and Sales Oces...........................................................................................................................iii
Product Upgrades........................................................................................................................................................................iii
Ordering Spare Parts...................................................................................................................................................................iii
Hot Runner Refurbishing.......................................................................................................................................................... iv
Chapter 1: Introduction..................................................................................................................................... 9
1.1 Purpose of the Equipment................................................................................................................................................9
1.2 Restrictions of Use............................................................................................................................................................... 9
1.3 Unauthorized Modications............................................................................................................................................ 9
1.4 Auxiliary Equipment........................................................................................................................................................... 9
1.5 Documentation..................................................................................................................................................................10
1.5.1 Manuals................................................................................................................................................................ 10
1.5.2 Engineering Drawings and Schematics....................................................................................................11
1.5.3 Safety Alert Conventions............................................................................................................................... 11
1.6 Training................................................................................................................................................................................. 12
1.7 Nameplates..........................................................................................................................................................................12
1.7.1 Hot Runner Nameplate...................................................................................................................................12
1.8 Special Tools........................................................................................................................................................................14
1.8.1 Nozzle Tip Sockets and Heater Removal Tools.......................................................................................14
1.8.2 Standard Nozzle Tip Sockets.........................................................................................................................14
1.8.3 Thermocouple Wire Stripping Tools.......................................................................................................... 15
1.8.4 Single Probe Thermocouple Removal Tools........................................................................................... 15
1.8.5 Crimping Tools for Contact Pins (25 or 64 Pin Connectors)...............................................................15
1.8.6 Unify Nozzle Assembly Tool..........................................................................................................................16
1.8.7 Unify Hydraulic Actuator Seal Installation Tools....................................................................................16
Chapter 2: Safety Summary.............................................................................................................................17
2.1 Qualied Personnel.......................................................................................................................................................... 17
2.2 Safety Guidelines...............................................................................................................................................................17
2.3 Safety Hazards.................................................................................................................................................................... 17
2.3.1 Mechanical Hazards.........................................................................................................................................18
2.3.2 Burn Hazards...................................................................................................................................................... 18
2.3.3 High Pressure Hazards.................................................................................................................................... 19
2.3.3.1 Hydraulic System Pressure Hazards...........................................................................................20
2.3.4 Electrical Hazards..............................................................................................................................................20
2.3.5 Gas, Vapor and Dust Emissions....................................................................................................................20
2.3.6 Slip, Trip or Fall Hazards..................................................................................................................................21
2.3.7 Lifting Hazards...................................................................................................................................................21
2.4 Safety Signs......................................................................................................................................................................... 21
2.5 Lockout and Tagout..........................................................................................................................................................23
2.6 Personal Protective Equipment and Safety Equipment...................................................................................... 24
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2.6.1 Personal Protective Equipment (PPE)........................................................................................................24
2.6.2 Safety Equipment............................................................................................................................................. 25
2.7 Material Safety Data Sheet (MSDS)............................................................................................................................. 25
2.8 Materials, Parts and Processing....................................................................................................................................26
2.9 Safety Latch Bars................................................................................................................................................................26
2.10 Lift Bars and Swivel Hoist Rings................................................................................................................................. 27
Chapter 3: Specications................................................................................................................................. 29
3.1 Weight................................................................................................................................................................................... 29
3.2 Operating Temperature.................................................................................................................................................. 29
3.3 Electrical System Specications................................................................................................................................... 29
3.3.1 Controller Requirements................................................................................................................................29
3.3.2 Nozzle Heaters................................................................................................................................................... 30
3.3.3 Manifold Heaters...............................................................................................................................................30
3.3.3.1 Spare Thermocouple Wires.......................................................................................................... 30
3.3.4 Power Fluctuation............................................................................................................................................ 31
3.4 Operating Specications................................................................................................................................................ 31
3.4.1 Hydraulic Manifold Operating Limits........................................................................................................ 31
3.4.2 Pneumatic Manifold Operating Limits......................................................................................................32
3.5 Hydraulic Fluid Specications.......................................................................................................................................32
3.6 Pneumatic Specications............................................................................................................................................... 32
3.7 Hydraulic Cooling Water Specications.................................................................................................................... 33
3.8 Pneumatic Cooling Water Specications..................................................................................................................33
3.9 Recommended Lubricants.............................................................................................................................................34
3.10 Rust Inhibitor Specications....................................................................................................................................... 35
3.11 Torque Specications.................................................................................................................................................... 35
3.12 Hydraulic and Pneumatic Actuator Component Specications.................................................................... 36
3.12.1 Large Hydraulic Actuator Components................................................................................................. 36
3.12.2 Small Hydraulic Actuator Components..................................................................................................37
3.12.3 Large and Small Pneumatic Actuator Components.......................................................................... 39
3.12.4 Large and Small Pneumatic Actuator with Thermal Regulator Components..........................40
Chapter 4: Installation and Removal.............................................................................................................. 43
4.1 Lifting and Handling........................................................................................................................................................ 43
4.1.1 Lifting and Handling Using a Single Lifting Point.................................................................................44
4.1.1.1 Laying Down Plates Using a Single Lifting Point..................................................................44
4.1.1.2 Picking Up Plates Using a Single Lifting Point.......................................................................45
4.1.2 Lifting and Handling Using Multiple Lifting Points..............................................................................46
4.1.3 Lifting Using a Lift Bar..................................................................................................................................... 47
4.1.4 Lifting Using Swivel Hoist Rings..................................................................................................................48
4.2 Installing and Removing the Manifold Assembly..................................................................................................49
4.2.1 Installing the Manifold into the Plates......................................................................................................49
4.2.2 Removing the Manifold assembly from the Mold................................................................................ 52
Chapter 5: Startup and Operation.................................................................................................................. 55
5.1 Preparing the Hot Runner.............................................................................................................................................. 55
5.2 Heating Up the Hot Runner, Mold and Machine....................................................................................................56
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5.3 Precharging the Hot Runner..........................................................................................................................................57
5.4 Producing Test Parts.........................................................................................................................................................58
Chapter 6: Maintenance...................................................................................................................................61
6.1 Scheduled and Non-Scheduled Maintenance........................................................................................................61
6.1.1 Preventive Maintenance.................................................................................................................................62
6.1.2 Service Procedures...........................................................................................................................................62
6.2 Removing and Installing Nozzle Stacks.....................................................................................................................63
6.2.1 Removing the Nozzle Stack...........................................................................................................................63
6.2.2 Installing the Nozzle Stack.............................................................................................................................63
6.3 Changing the Resin Color...............................................................................................................................................66
6.4 Extending Nozzle and Sprue Heater Wire Leads....................................................................................................67
6.5 Removing and Installing the Hydraulic Actuator ................................................................................................. 69
6.5.1 Removing the Hydraulic Actuator from the Manifold.........................................................................69
6.5.2 Installing the Hydraulic Actuator on the Manifold...............................................................................70
6.6 Removing and Installing the Pneumatic Actuator ...............................................................................................72
6.6.1 Removing the Pneumatic Actuator from the Manifold...................................................................... 72
6.6.2 Installing the Pneumatic Actuator to the Manifold..............................................................................73
6.7 Adjusting the Valve Stem Preload for Hydraulic Actuators................................................................................74
6.8 Replacing the Hydraulic and Pneumatic Seals....................................................................................................... 78
6.9 Removing and Installing Valve Stems........................................................................................................................78
6.9.1 Removing a Valve Stem..................................................................................................................................78
6.9.2 Installing a Valve Stem....................................................................................................................................79
6.10 Removing and Installing Nozzle Heaters............................................................................................................... 79
6.10.1 Removing and Installing Ultra Nozzle Heaters (UNH) on U750 Systems................................... 80
6.10.1.1 Removing Ultra Nozzle Heaters (UNH) on U750 Systems...............................................80
6.10.1.2 Installing Ultra Nozzle Heaters (UNH) on U750 Systems.................................................80
6.10.2 Removing and Installing Ultra Nozzle Heaters (UNH) With Ring Thermocouples..................83
6.10.2.1 Removing Ultra Nozzle Heaters (UNH) With Ring Thermocouples............................. 83
6.10.2.2 Installing Ultra Nozzle Heaters (UNH) With Ring Thermocouples............................... 84
6.10.3 Removing and Installing Bi-Metal Heaters on U750 and U1000 Systems................................. 89
6.10.3.1 Removing Bi-Metal Nozzle Heaters on U750 and U1000 Systems...............................89
6.10.3.2 Installing Bi-Metal Nozzle Heaters on U750 and U1000 Systems.................................89
6.10.4 Removing and Installing Triton Heaters on U750-UP Systems......................................................92
6.10.4.1 Removing Triton Nozzle Heaters on U750-UP Systems...................................................92
6.10.4.2 Installing Triton Nozzle Heaters on U750-UP Systems.....................................................93
6.10.5 Removing and Installing HTM Nozzle Heaters for U1000 Systems.............................................. 95
6.11 Replacing the Hydraulic or Pneumatic Manifold Hoses ...................................................................................95
6.12 Grounding the Unify System...................................................................................................................................... 96
6.13 Testing Heaters................................................................................................................................................................ 97
6.14 Removing and Installing the Cavity Plate.............................................................................................................. 97
6.14.1 Removing the Cavity Plate On a Work Bench...................................................................................... 98
6.14.2 Installing the Cavity Plate On a Work Bench........................................................................................ 99
6.14.3 Removing the Cavity Plate In the Machine........................................................................................ 101
6.14.4 Installing the Cavity Plate In the Machine.......................................................................................... 103
6.15 Inspecting and Cleaning Manifolds.......................................................................................................................104
6.15.1 Cleaning Using a Fluidized Bed Process.............................................................................................. 105
6.15.1.1 Assistance...................................................................................................................................... 106
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6.15.1.2 Disassembling the Hot Runner for Fluidized Bed Cleaning.........................................106
6.15.1.3 Removing the PEEK Bushings.................................................................................................108
6.16 Removing Insulating Gate Bubbles (If Equipped)............................................................................................ 108
6.17 Removing and Installing the Sprue Heater (If Equipped)..............................................................................112
6.17.1 Removing a Sprue Heater with a Built-In Thermocouple............................................................. 112
6.17.2 Removing a Sprue Heater with a Separate Thermocouple.......................................................... 112
6.17.3 Installing a Sprue Heater with a Built-In Thermocouple................................................................113
6.17.4 Installing a Sprue Heater with a Separate Thermocouple............................................................ 114
6.18 Removing and Installing the Sprue Bushing......................................................................................................115
6.18.1 Removing the Sprue Bushing..................................................................................................................116
6.18.2 Installing the Sprue Bushing....................................................................................................................116
6.19 Removing and Installing Nozzle Tip Insulators (If Equipped).......................................................................118
6.19.1 Removing the Nozzle Tip Insulators..................................................................................................... 118
6.19.2 Installing Nozzle Tip Insulators............................................................................................................... 119
Chapter 7: Storage and Shipping..................................................................................................................121
7.1 Corrosion Protection......................................................................................................................................................121
7.2 Short Term Storage........................................................................................................................................................ 121
7.2.1 Storing in the Machine.................................................................................................................................122
7.2.2 Storing Outside the Machine.....................................................................................................................122
7.3 Long Term Storage......................................................................................................................................................... 123
7.4 Shipping the Hot Runner............................................................................................................................................. 123
v 2.2 — March 2021 Unify Manifold System
viii

Chapter 1 Introduction
This chapter describes the manifold system, training opportunities, and the available equipment
manuals.
1.1 Purpose of the Equipment
Husky equipment and systems are designed for injection molding applications only, using
approved materials and operating within design guidelines.
Contact your nearest Husky Regional Service and Sales oce if you plan to use a Husky product
for anything other than its intended use.
1.2 Restrictions of Use
Husky injection molding equipment must never be:
• operated by more than one person
• used for any purpose other than that described in Section 1.1, unless otherwise approved by
Husky
• used to extrude any materials not outlined in the scope of the harmonized EN201 or ANSI
B151.1 standard
• operated or serviced by personnel unfamiliar with the inherent risks and necessary
precautions related to injection molding equipment
• operated at temperatures higher than the maximum permissible temperature for the resin
1.3 Unauthorized Modications
Unauthorized modications or reconstruction of any Husky injection molding system is strictly
prohibited. Modications can be unsafe and/or void warranty.
Contact your nearest Husky Regional Service and Sales oce to discuss modications or
requirements for Husky systems.
1.4 Auxiliary Equipment
Husky is only responsible for the interaction of Husky equipment and systems with auxiliary
equipment when Husky is the system integrator. If auxiliary equipment is removed, the user must
install proper safeguards to prevent access to the hazards.
Hot Runner Installation Manual v 2.2 — March 2021 Introduction
Purpose of the Equipment 9

For information about integrating non-Husky auxiliary equipment, contact your nearest Husky
Regional Service and Sales oce.
1.5 Documentation
A full set of manuals, drawings, schematics, certicates and other documentation are available for
every Husky hot runner.
The following describes the documentation provided with each system, along with common
conventions all readers should be familiar with.
IMPORTANT!
Keep all manuals in a convenient location for future reference.
1.5.1 Manuals
Husky manuals aid in the safe and proper use of Husky products. Where applicable, the manuals
provide instructions on installation, operation and maintenance.
Personnel should thoroughly review all manuals provided with their Husky equipment prior to
performing any tasks. Proceed with tasks only if all instructions are understood and always follow
applicable workplace safety requirements.
IMPORTANT!
Images in the manuals are for reference only and may not represent specic equipment details.
Refer to engineering drawings and schematics and the HMI for specic details.
The following manuals are provided with each Husky machine upon delivery:
Installation
Manual
Describes the basic installation of the manifold system.
Service Manual Describes the installation, startup, operation, shut down and maintenance of the
hot runner system.
NOTE:
Refer to the hot runner Service Manual for specic removal and maintenance
instructions.
These manuals are available online through www.husky.co.
v 2.2 — March 2021 Unify Manifold System
10 Documentation