Mold-Masters Fusion Series User manual

version 14
User Manual
Original Instrucons

Table of Contents
Section 1 - Introduction ...................................................1-1
1.1 Intended Use ......................................................................................................1-1
1.2 Documentation ...................................................................................................1-1
1.3 Release Details ..................................................................................................1-1
1.4 Warranty .............................................................................................................1-2
1.5 Returned Goods Policy.......................................................................................1-2
1.6 Movement or Resale of Mold-Masters Products or Systems .............................1-2
1.7 Copyright ............................................................................................................1-3
1.8 Units of Measure and Conversion Factors .........................................................1-3
1.9 Trademarks and Patents ....................................................................................1-4
Section 2 - Global Support ..............................................2-1
2.1 Corporate O󰀩ces................................................................................................2-1
2.2 International Representatives.............................................................................2-2
Section 3 - Safety..............................................................3-1
3.1 Operator Training and Safety .............................................................................3-1
3.2 Safety Hazards ...................................................................................................3-2
3.3 Operational Hazards...........................................................................................3-5
3.4 General Safety Symbols.....................................................................................3-7
3.5 Wiring Check ......................................................................................................3-8
3.6 Lockout Safety....................................................................................................3-9
3.6.1 Electrical Lockout.....................................................................................3-10
3.6.2 Energy Forms and Lockout Guidelines....................................................3-11
3.7 Disposal............................................................................................................3-12
3.8 FUSION SERIES®G2 Safety Hazards.............................................................3-13
Section 4 - Preparation ....................................................4-1
4.1 Tools Required....................................................................................................4-1
4.2 Screw Lengths....................................................................................................4-1
4.3 Unpacking...........................................................................................................4-2
4.4 Cleaning .............................................................................................................4-2
4.5 Hydraulic Cylinder Assembly ..............................................................................4-3
4.6 Pneumatic Cylinder Assembly ............................................................................4-9
4.7 Waterless Hydraulic Actuator Assembly ...........................................................4-14
4.7.1 Assemble the Piston Assembly of the Waterless Hydraulic Actuator.......4-15
4.7.2 Assemble the Cylinder Body Assembly of the Waterless Hydraulic Actuator .
4-17
4.7.3 Assemble the Cylinder Assembly of the Waterless Hydraulic Actuator ...4-19
4.7.4 Assemble the Anti-Rotation Waterless Hydraulic Actuator ......................4-20
4.8 Waterless Pneumatic Actuator Assembly .........................................................4-21
4.9 Piston Assembly for Waterless Pneumatic Actuator.........................................4-22
4.10 Adjust Valve Pin Length for Waterless Actuator (Optional).............................4-23
4.11 Cylinder Body Assembly for Waterless Pneumatic Actuator...........................4-24
4.12 Cylinder Assembly for Waterless Pneumatic Actuator....................................4-28
4.13 Cylinder Assembly for Waterless Pneumatic Actuator - Anti-Rotation Version4-30
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FSG2 User Manual

Section 5 - Assembly .......................................................5-1
5.1 Typical FUSION SERIES®G2 Systems..............................................................5-1
5.1.1 FUSION SERIES®G2 Drop-in System......................................................5-3
5.1.2 FUSION SERIES®G2 Lite System............................................................5-3
5.2 Gate Seal Finishing ............................................................................................5-4
5.2.1 Hot Valve / Hot Sprue / F Type ..................................................................5-4
5.3 Re-torque at Process Temperature ....................................................................5-5
5.4 Check Nozzle Core to Manifold Fit .....................................................................5-5
5.5 Assemble Nozzle to Manifold .............................................................................5-7
5.6 Nozzle Assembly for Systems with Protective Sleeves ......................................5-8
5.6.1 Heater Retaining Clip Installation ............................................................5-11
5.7 Nozzle Assembly for Systems without Protective Sleeves ...............................5-13
5.7.1 Install Nozzle Heaters and Sleeves.........................................................5-13
5.7.2 Install Thermocouple ...............................................................................5-13
5.7.3 Install Thermocouple onto Nozzle Body (Optional) .................................5-14
5.7.4 Install the Thermocouple onto the Nozzle Body (F3000/4000 nozzles) ..5-15
5.7.5 Heater Retaining Clip Installation ............................................................5-16
5.7.6 Flange Nozzle Assembly .........................................................................5-17
5.8 Gate Seal and Nozzle Assembly ......................................................................5-19
5.8.1 Check Gate Seal to Nozzle Fit.................................................................5-19
5.8.2 Assemble Gate Seals to Nozzle ..............................................................5-20
5.9 Install Manifold Locator.....................................................................................5-21
5.10 Install Support Bushings.................................................................................5-21
5.11 Install Manifold Thermocouple........................................................................5-23
5.12 Install Inlet ......................................................................................................5-24
5.12.1 Install Inlet Thermocouple......................................................................5-26
5.12.2 Install Inlet Extension Tip .......................................................................5-26
5.13 Install Valve Insert or Valve Disk.....................................................................5-28
5.13.1 Install Valve Insert (Valve Insert Design) ...............................................5-28
5.13.2 Install Valve Disk (Valve Disk Design) ...................................................5-31
5.14 Install Cylinder on Manifold ............................................................................5-33
5.14.1 Pneumatic System.................................................................................5-33
5.14.2 Hydraulic System...................................................................................5-38
5.15 Waterless Hydraulic and Pneumatic Actuator Systems..................................5-40
5.16 Install Wiring ...................................................................................................5-45
5.16.1 Install Wire Armor to Manifold................................................................5-45
5.16.2 Install Wiring ..........................................................................................5-46
5.16.3 Electrical Routing into Electrical Box .....................................................5-46
5.16.4 Solenoid Valve Wiring............................................................................5-47
5.17 Connect Solenoid Valve Bank ........................................................................5-50
5.17.1 Hydraulic Valvebank Connection ...........................................................5-50
5.17.2 Pneumatic Valve Bank Connection........................................................5-51
5.18 Install Hydraulic Flow Control Valve ...............................................................5-52
5.19 Install Actuator Position Sensor......................................................................5-54
5.20 Water Cooled Gate Insert Installation.............................................................5-59
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FSG2 User Manual

Section 6 - SeVG Plus Actuator ......................................6-1
6.1 Introduction.........................................................................................................6-1
6.2 SeVG Plus Actuator Models ...............................................................................6-1
6.3 SeVG Plus Actuator in FUSION SERIES® Systems .........................................6-1
6.4 SeVG Plus Models .............................................................................................6-2
6.4.1 SE40-20 Actuator - Non Cooled ................................................................6-2
6.4.2 SE40-20C Actuator - Cooled .....................................................................6-3
6.5 Manifold Mounted Systems ................................................................................6-4
6.5.1 SE40-20 Model..........................................................................................6-4
6.5.2 SE40-20C Model .......................................................................................6-5
6.6 SeVG Plus in Manifold Mounted Systems..........................................................6-6
6.7 Assembly and Installation ...................................................................................6-7
6.8 Disassembly .....................................................................................................6-12
Section 7 - Electrical Testing...........................................7-1
7.1 Safety .................................................................................................................7-1
7.2 Electrical Wiring Check.......................................................................................7-1
7.3 Electrical Safety Testing .....................................................................................7-2
7.3.1 Verify Equipment to its Technical Documentation......................................7-2
7.3.2 Insulation Resistance Test.........................................................................7-2
7.3.3 Verication of Conditions for Protection by Automatic Disconnection of Supply
7-2
7.3.4 Verication of Continuity of Protective Bonding Circuit..............................7-2
7.3.5 Verication of Fault Loop Impedance ........................................................7-3
7.4 Thermocouple Continuity Test ............................................................................7-3
7.5 Pinch Point Test..................................................................................................7-3
7.6 Heating Element Check......................................................................................7-4
7.7 Thermocouple Wiring Guidelines .......................................................................7-4
7.8 Functional Test with a Temperature Controller ...................................................7-4
7.9 Retesting ............................................................................................................7-4
Section 8 - System Installation........................................8-1
8.1 Unpacking...........................................................................................................8-1
8.2 Pre-Installation....................................................................................................8-2
8.3 Install Manifold Locator Dowel............................................................................8-2
8.4 System Installation .............................................................................................8-3
8.4.1 Installation of a System with Flanged Nozzles ..........................................8-4
8.5 System Test ........................................................................................................8-5
Section 9 - System Startup and Shutdown ....................9-1
9.1 Pre-Startup .........................................................................................................9-1
9.2 Startup ................................................................................................................9-2
9.2.1 Shutdown...................................................................................................9-3
Section 10 - Color Change............................................ 10-1
10.1 Introduction.....................................................................................................10-1
10.2 Color Change for a Hot Tip / Sprue System ...................................................10-1
10.3 Color Change for a Valve Gate System..........................................................10-2
10.4 Locating a Source of Contamination ..............................................................10-2
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FSG2 User Manual

Section 11 - Maintenance...............................................11-1
11.1 Recommended Torque Settings......................................................................11-1
11.2 Tubular Heater Installation and Replacement.................................................11-3
11.2.1 Storage ..................................................................................................11-3
11.2.2 Removing a Heater Element..................................................................11-3
11.2.3 Installing a New Heater Element............................................................ 11-3
11.2.4 New Heater Startup ............................................................................... 11-6
11.3 Solenoid Valve Bank.......................................................................................11-6
11.3.1 Hydraulic Solenoid Valve Bank ..............................................................11-6
11.3.2 Components of a Hydraulic Solenoid Valve Bank.................................. 11-7
11.3.3 Pneumatic Solenoid Valve Bank ............................................................11-9
11.3.4 Components of a Hydraulic Solenoid Valve Bank.................................. 11-9
11.4 Recommended Spare Parts .........................................................................11-13
Section 12 - Troubleshooting ....................................... 12-1
12.1 Introduction.....................................................................................................12-1
12.2 Moisture Related Issues .................................................................................12-2
12.2.1 Resin Moisture Contamination...............................................................12-2
12.2.2 Resin Drying Issues...............................................................................12-2
12.2.3 Importance of Pre-Drying Resin ............................................................12-2
12.3 Pre-Molding Precautions ................................................................................12-3
12.4 Establishing Root Cause ................................................................................12-4
12.4.1 Fault Identication..................................................................................12-4
12.5 Troubleshooting Typical Problems..................................................................12-5
12.5.1 Dark Specks ..........................................................................................12-5
12.5.2 Blisters or Bubbles.................................................................................12-6
12.5.3 Flow Marks ............................................................................................12-7
12.5.4 Burn Marks ............................................................................................12-8
12.5.5 Delaminating Parts ................................................................................12-9
12.5.6 Dimensional Irregularities ....................................................................12-10
12.5.7 Discolored Parts ..................................................................................12-11
12.5.8 Flash....................................................................................................12-12
12.5.9 Jetting ..................................................................................................12-13
12.5.10 Pitted Parts ........................................................................................12-14
12.5.11 Rough Surface ...................................................................................12-15
12.5.12 Parts Sticking to Cavity......................................................................12-16
12.5.13 Parts Sticking to Core........................................................................12-17
12.5.14 Short Parts.........................................................................................12-18
12.5.15 Sinks or Voids ....................................................................................12-19
12.5.16 Splay..................................................................................................12-20
12.5.17 Streaks...............................................................................................12-21
12.5.18 Stringing.............................................................................................12-22
12.5.19 Warped Parts.....................................................................................12-23
12.5.20 Weld Lines.........................................................................................12-24
Index ......................................................................................I
Section 13 - Index.................................................................I
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FSG2 User Manual

List of Tables
Table 1-1 Release Details.........................................................................................1-1
Table 1-2 Units of Measure and Conversion Factors ...............................................1-3
Table 3-1 Safety Hazards .........................................................................................3-3
Table 3-2 Typical Safety Symbols.............................................................................3-7
Table 3-3 Energy Forms, Energy Sources and General
Lockout Guidelines ...........................................................................................3-11
Table 4-1 Valve Pin and Spacer Combinations ......................................................4-16
Table 5-1 Typical Contact Length .............................................................................5-4
Table 6-1 SEVG Plus Actuator Models .....................................................................6-1
Table 6-2 FUSION SERIES® Systems: SeVG Plus Actuator
Selection.............................................................................................................6-1
Table 11-1 Recommended Torque Settings............................................................ 11-2
Table 11-2 Actuator Spare Seal Kits .....................................................................11-13
Table 11-3 Nozzle Spring Clip ..............................................................................11-13
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FSG2 User Manual

List of Figures
Figure 3-1 Injection molding machine hazard areas.................................................3-2
Figure 4-1 Screw length ...........................................................................................4-1
Figure 4-2 Hydraulic cylinder components ...............................................................4-3
Figure 4-3 Pneumatic cylinder components .............................................................4-9
Figure 4-4 Waterless pneumatic components ........................................................4-14
Figure 4-5 Install piston seals and guide ring .........................................................4-15
Figure 4-6 Install valve pin and spacers .................................................................4-15
Figure 4-7 Install O-ring for rod seal.......................................................................4-18
Figure 4-8 Install rod seal .......................................................................................4-18
Figure 4-9 Rod seal assembly................................................................................4-19
Figure 4-10 Install O-ring for wiper seal .................................................................4-19
Figure 4-11 Install wiper seal..................................................................................4-19
Figure 4-12 Rod seal and wiper seal assemblies...................................................4-20
Figure 4-13 Install the piston ..................................................................................4-21
Figure 4-14 Install the top seal ...............................................................................4-21
Figure 4-15 Assembled cylinder - note ports ..........................................................4-22
Figure 4-16 Install piston seals and guide ring .......................................................4-23
Figure 4-17 Anti rotation dowel...............................................................................4-23
Figure 4-18 Install valve pin and spacers ...............................................................4-24
Figure 4-19 Anti rotation version: install the piston.................................................4-24
Figure 4-20 Anti rotation version: install the top seal..............................................4-25
Figure 4-21 Anti rotation version: assembled cylinder............................................4-25
Figure 5-1 FUSION SERIES®G2 system with thread nozzle...................................5-1
Figure 5-2
FUSION SERIES® G2 ange nozzle...................................................................5-1
Figure 5-3 FUSION SERIES®G2 hydraulic system .................................................5-2
Figure 5-4 FUSION SERIES®drop-in system ..........................................................5-3
Figure 5-5 FUSION SERIES®lite system.................................................................5-3
Figure 5-6 Example contact length “H”.....................................................................5-4
Figure 5-7 Completed protective sleeve assembly.................................................5-12
Figure 5-8 Nozzle center guiding ring.....................................................................5-15
Figure 5-9 Pneumatic actuator mounted on top of valve disk ange......................5-35
Figure 5-10 Hydraulic actuator mounted on top of valve disk ange......................5-36
Figure 5-11 Waterless actuator models: valve disk and
valve insert........................................................................................................5-38
Figure 5-12 Install valve insert or valve disk...........................................................5-38
Figure 5-13 Valve insert design: install support pillars ...........................................5-38
Figure 5-14 Valve disk design: install support pillars..............................................5-39
Figure 5-15 Screw shoulder bolts into support pillar ..............................................5-40
Figure 5-16 Torque shoulder bolts..........................................................................5-40
Figure 5-17 Check tooling pocket...........................................................................5-41
Figure 5-18 Bolt clamp plate...................................................................................5-42
Figure 5-19 Hydraulic ow control valve - connections ..........................................5-50
Figure 5-21 Actuator with position sensor ..............................................................5-51
Figure 5-20 Top sensor mounting assembly installation.........................................5-54
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FSG2 User Manual

Figure 6-1 SE40-20 actuator ....................................................................................6-2
Figure 6-2 SE40-20C actuator..................................................................................6-3
Figure 6-3 SE40-20 actuator ....................................................................................6-4
Figure 6-4 SE40-20C actuator..................................................................................6-5
Figure 6-5 SE40-20 actuator in a manifold mounted system ...................................6-6
Figure 6-6 Bulkhead connectors and template.........................................................6-7
Figure 6-7 Motor rod ats .........................................................................................6-8
Figure 6-8 Valve pin holder components ..................................................................6-9
Figure 6-9 Motor locating spigot ...............................................................................6-9
Figure 6-10 Insert the screws to fasten the assembly ............................................6-10
Figure 6-11 Place cables into insulated sheath ......................................................6-10
Figure 6-12 Attach cables to wiring channel...........................................................6-11
Figure 6-13 Remove B screws ...............................................................................6-13
Figure 11-1 Pressure reducing and relieving valve ................................................11-7
Figure 11-2 Manometer mounting port ................................................................... 11-8
Figure 11-3 Solenoid connector.............................................................................. 11-9
Figure 11-4 Manual override switch...................................................................... 11-12
List of Figures
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FSG2 User Manual