Mold-Masters Hot Runner User manual

Hot Runner User Manual
Hot Runner
User Manual
version 31
Original Instrucons

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 ............................................................................................................1-2
1.8 Units of Measure and Conversion Factors .........................................................1-3
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 Safety Hazards ...................................................................................................3-2
3.2 Operational Hazards...........................................................................................3-5
3.3 General Safety Symbols.....................................................................................3-7
3.4 Wiring Check ......................................................................................................3-8
3.5 Lockout Safety....................................................................................................3-9
3.5.1 Electrical Lockout.....................................................................................3-10
3.5.2 Energy Forms and Lockout Guidelines....................................................3-11
3.6 Disposal............................................................................................................3-12
3.7 Hot Runner Safety Hazards..............................................................................3-13
Section 4 - Preparation ....................................................4-1
4.1 Tools Required....................................................................................................4-1
4.2 Screw Lengths....................................................................................................4-2
4.3 Unpacking...........................................................................................................4-3
4.4 Cleaning .............................................................................................................4-3
4.5 Establish Your System Type ...............................................................................4-4
4.5.1 System With Cast-in Heater Element ........................................................4-4
4.5.2 System With Hydraulic or Pneumatic Units ...............................................4-5
4.5.3 System with Bridged Hydraulic Pneumatic System...................................4-6
4.5.4 Centi or Deci System with MasterSHIELD Technology .............................4-7
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Section 5 - Assembly .......................................................5-1
5.1 Cutaway of a Cast-in System .............................................................................5-1
5.2 Cutaway of a Bolt-in System ..............................................................................5-2
5.3 Cutaway of a MasterSHIELD System.................................................................5-3
5.4 Gate Seal Finishing ............................................................................................5-3
5.5 Hot Valve / Hot Sprue / F Type ...........................................................................5-4
5.6 Water-Cooled Gate Insert Installation (Optional)................................................5-5
5.7 Thermocouple Installation ..................................................................................5-6
5.8 Thermocouple Removal For Non-Front Mounted Thermocouples .....................5-8
5.9 Dura Line Thermocouple Installation..................................................................5-9
5.10 Nozzle Insertion..............................................................................................5-12
5.10.1 Nozzle Insertion for Master-Series and Dura Lines...............................5-12
5.10.2 Step Installation .....................................................................................5-13
5.10.3 Nozzle Insertion—ThinPAK Centi and Deci...........................................5-14
5.10.4 Nozzle Insertion—MasterSHIELD Centi, Deci, and Pico.......................5-16
5.10.5 Nozzle Insertion—MasterSHIELD Femto ..............................................5-19
5.11 Nozzle Wire Layout.........................................................................................5-23
5.11.1 Back Mounted Thermocouples ..............................................................5-23
5.11.2 Front Mounted Thermocouples..............................................................5-23
5.12 Emergency Heater Sleeve..............................................................................5-24
5.12.1 Installation of Emergency Heater Sleeve...............................................5-24
5.12.2 Removal of Emergency Heater Sleeve..................................................5-27
5.13 Valve Bushings ...............................................................................................5-28
5.13.1 Types of Valve Bushings........................................................................5-28
5.13.2 Valve Bushing Installation......................................................................5-28
5.14 Mount the Manifold .........................................................................................5-30
5.14.1 Manifold Locator ....................................................................................5-31
5.14.2 Manifold Locating Dowel Pin .................................................................5-32
5.14.3 Manifold and Slot Locator......................................................................5-32
5.15 Manifold Thermocouple Installation................................................................5-33
5.16 Main Manifolds ...............................................................................................5-34
5.16.1 Inlet Seal Installation - Without Step.....................................................5-34
5.16.2 Inlet Seal Installation - With Step...........................................................5-35
5.17 Pressure Disk / Valve Disk Installation ...........................................................5-35
5.17.1 Pressure Disk: Final Grinding Required ................................................5-36
5.17.2 Pressure Disk Installation ......................................................................5-38
5.17.3 Pressure Disk: Final Grinding Not Required..........................................5-38
5.17.4 EcoDisk Installation ...............................................................................5-39
5.17.5 Valve Disk - Final Grinding Required.....................................................5-40
5.18 Support Bushing Installation for Systems with MasterSHIELD ......................5-42
5.19 Valve Disk Installation for Systems with MasterSHIELD ................................5-43
5.20 Heater Plates Installation................................................................................5-44
5.21 Inlet Components Installation .........................................................................5-46
5.21.1 Back Plate Installation ...........................................................................5-46
5.21.2 Center Heater Installation......................................................................5-47
5.21.3 Three Piece Center Heater Installation..................................................5-47
5.21.4 Inlet Extension Installation.....................................................................5-48
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5.21.5 Inlet Extension with Pressure Sleeve ....................................................5-49
Section 6 - Electrical Testing...........................................6-1
6.1 Safety .................................................................................................................6-1
6.2 Electrical Wiring Check.......................................................................................6-2
6.3 Electrical Safety Testing .....................................................................................6-2
6.3.1 Verify Equipment to its Technical Documentation......................................6-2
6.3.2 Insulation Resistance Test ........................................................................6-2
6.3.3 Verication of Conditions for Protection by Automatic Disconnection of Supply
6-3
6.3.4 Verication of Continuity of Protective Bonding Circuit..............................6-3
6.3.5 Verication of Fault Loop Impedance ........................................................6-3
6.3.6 Thermocouple Continuity Test ...................................................................6-4
6.3.7 Pinch Point Test.........................................................................................6-4
6.3.8 Heating Element Check.............................................................................6-4
6.3.9 Ungrounded Thermocouple Continuity Test ..............................................6-5
6.4 Thermocouple Wiring Guidelines .......................................................................6-5
6.5 Functional Test with a Temperature Controller ...................................................6-5
6.6 Re-testing ...........................................................................................................6-5
Section 7 - Hot Half Assembly.........................................7-1
7.1 Hot Half Assembly ..............................................................................................7-1
7.2 Stack Mold Cavity Plate Installation ...................................................................7-3
Section 8 - System Startup and Shutdown ....................8-1
8.1 Pre-Startup .........................................................................................................8-1
8.2 Startup ................................................................................................................8-2
8.2.1 Standard Hot Runner Systems..................................................................8-2
8.2.2 Stack Mold Systems ..................................................................................8-3
8.3 Shutdown............................................................................................................8-3
8.3.1 Standard Hot Runner Systems..................................................................8-4
8.3.2 Stack Mold System....................................................................................8-4
Section 9 - Color Change.................................................9-1
9.1 General Tips .......................................................................................................9-1
9.2 Procedure A: Simple and E󰀨ective .....................................................................9-1
9.3 Procedure B: More Comprehensive ...................................................................9-2
Section 10 - Hydraulic / Pneumatic Actuators ............ 10-1
10.1 Valve Actuator Installation and Assembly .......................................................10-1
10.2 Pre-Installation................................................................................................10-2
10.3 Cylinder Bottom Assembly..............................................................................10-2
10.4 Piston Assembly .............................................................................................10-3
10.4.1 5500 Series Only ...................................................................................10-3
10.4.2 6X00 Series and 7100 Series................................................................10-3
10.5 Cylinder Top Assembly ...................................................................................10-4
10.6 Valve Pin Finishing of Tip ...............................................................................10-4
10.6.1 5500 Series............................................................................................10-4
10.6.2 6X00 Series ...........................................................................................10-6
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10.6.3 7100 Series............................................................................................10-6
10.6.4 8X00 Series ...........................................................................................10-8
10.6.5 8600 - AR Series....................................................................................10-9
10.7 Valve Pin Lapping Procedure for Tapered Valve Pins ..................................10-10
10.7.1 5500 Series and 6X00 Series..............................................................10-10
10.8 Valve Pin Finishing of Head.......................................................................... 10-11
10.8.1 5500 Series..........................................................................................10-11
10.9 Valve Pin Assembly ......................................................................................10-12
10.9.1 5500 Series..........................................................................................10-12
10.9.2 6X00 Series .........................................................................................10-12
10.9.3 Hydraulic Limit Switch Option (6500 Series and 6600 Series) ............10-13
10.9.4 7100 Series..........................................................................................10-14
10.10 Install the Valve Actuator to the Hydraulic Plate .........................................10-15
10.10.1 5500 Series and 6X00 Series............................................................10-15
10.10.2 Hydraulic Limit Switch Option (6500 Series and 6600 Series) ..........10-17
10.11 Proximity Sensor Installation for Hydraulic Limit Switch Option .................10-18
10.11.1 Cutout Options Based on Stroke .......................................................10-19
10.12 Test the Proximity Sensor for Hydraulic Limit Switch Option......................10-20
10.13 Maintenance Procedures for 5500 Series, 6X00 Series and 7100 Series .10-20
10.13.1 For Oil Systems: ................................................................................10-21
10.13.2 For Pneumatic Systems:....................................................................10-21
10.14 Extraction Tools for Hydraulic and Pneumatic Actuators ............................10-22
Section 11 - Slimstack Actuator ....................................11-1
11.1 Introduction .....................................................................................................11-1
11.2 Slimstack Actuator Assembly.......................................................................... 11-2
11.3 Assembly Procedure....................................................................................... 11-3
11.4 Installation..................................................................................................... 11-13
Section 12 - SeVG Plus Actuator ................................. 12-1
12.1 Introduction.....................................................................................................12-1
12.2 SeVG Plus Actuator Models ...........................................................................12-1
12.3 SeVG Plus Actuator in Hot Runner Systems..................................................12-1
12.4 SeVG Plus Model Options..............................................................................12-2
12.4.1 SE40-20 Actuator - Non Cooled ............................................................12-2
12.4.2 SE40-20C Actuator - Cooled .................................................................12-3
12.4.3 SE20-15 Actuator - Non Cooled ............................................................12-4
12.5 SeVG Plus in Plate Mounted Systems ...........................................................12-5
12.6 SE40-20 Model...............................................................................................12-5
12.6.1 SE20-15 Model......................................................................................12-5
12.7 Assembly and Installation ...............................................................................12-6
12.7.1 Attach the Water Lines (Cooled Models Only).......................................12-7
12.7.2 Assemble and Install the Valve Pin Holder ............................................12-8
12.7.3 Install the Motor and Valve Pin Assembly..............................................12-8
12.8 Disassembly .................................................................................................12-11
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12.8.1 SE40-20 and SE40-20C Models:.........................................................12-11
12.8.2 SE20-15 Model....................................................................................12-12
Section 13 - E-Drive....................................................... 13-1
13.1 Typical E-Drive System...................................................................................13-1
13.1.1 E-Drive Components .............................................................................13-3
13.1.2 E-Drive Safety........................................................................................13-4
13.2 Assembly ........................................................................................................13-5
13.3 Assembly Detail ..............................................................................................13-6
13.3.1 Hot Runner Assembly............................................................................13-6
13.3.2 Interface Plate Assembly .......................................................................13-6
13.3.3 Synchro-Plate Assembly........................................................................13-7
13.3.4 Ball-Screw Preparation..........................................................................13-8
13.3.5 Ball-Screw Lubrication...........................................................................13-8
13.3.6 Ball-Screw Assembly .............................................................................13-9
13.3.7 Ball-Screw Maintenance......................................................................13-10
13.3.8 Top Plate Assembly .............................................................................13-10
13.3.9 Attach the Synchro-Plate to Top Plate Assembly.................................13-10
13.3.10 Tension Belt Assembly.......................................................................13-10
13.3.11 Inspect Parallelism of the Synchro-Plate ...........................................13-12
13.3.12 Assemble the Insulation Plate and Locating Ring..............................13-12
13.3.13 Perform E-Drive Controller Checks ...................................................13-13
13.3.14 Install the Hot Half into the Mold........................................................13-13
13.4 First Time Installation or Replacement of the Belt ........................................13-13
13.5 Check for Misalignment ................................................................................13-15
Section 14 - Mag-Pin Option......................................... 14-1
14.1 Mag-Pin Assembly (3D View) .........................................................................14-2
14.2 Mag-Pin Safety ...............................................................................................14-2
14.3 Mag-Pin Operation .........................................................................................14-3
14.4 Handling Magnets...........................................................................................14-5
14.5 Assembly Summary........................................................................................14-6
14.6 Assembly Details ............................................................................................14-6
14.6.1 Place the Magnet on Top of Magnet Retainer .......................................14-7
14.6.2 Polarity Check........................................................................................14-7
14.6.3 Clean the Magnet Holder.......................................................................14-7
14.6.4 Assemble the Magnetic Retainer to Magnet Holder ..............................14-8
14.6.5 Place the Magnet Holder and Magnet into the Housing ........................14-8
14.6.6 Assemble the Nut and Lock Magnet Holder ..........................................14-9
14.6.7 Assemble the Valve Pin into the Valve Pin Holder.................................14-9
14.6.8 O-Ring Installation into Valve Pin Holder.............................................14-10
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14.6.9 Assemble Valve Pin into Housing Assembly........................................14-10
14.6.10 Install Mag-Pin Assembly into the Synchro-Plate ..............................14-11
14.7 Mag-Pin Extraction .......................................................................................14-12
Section 15 - Maintenance.............................................. 15-1
15.1 Valve Disk Removal........................................................................................15-1
15.1.1 Extraction of 1-piece Valve Disk ............................................................15-2
15.1.2 Extraction of 2-piece Valve Disk ............................................................15-4
15.2 Valve Disk Extraction Tool Overview ..............................................................15-6
15.3 Terminal End Removal and Installation ..........................................................15-8
15.3.1 Terminal End Removal...........................................................................15-8
15.3.2 Terminal Installation ...............................................................................15-8
15.3.3 Terminal Assembly.................................................................................15-9
15.4 Heater Plate Power Lead Removal ..............................................................15-11
15.4.1 Installation............................................................................................15-12
15.5 Gate Seal Maintenance ................................................................................15-12
15.5.1 Multi-Cavity Systems ...........................................................................15-12
15.5.2 Gate Seal Removal..............................................................................15-13
15.5.3 Gate Seal Replacement.......................................................................15-14
15.6 Sprint Gate Seal Maintenance......................................................................15-16
15.6.1 Sprint Nozzle Tip Removal ..................................................................15-16
15.6.2 Sprint Nozzle Tip Installation ...............................................................15-17
15.7 Clean Nozzle Insulator Cap..........................................................................15-18
15.8 Installing Nozzle Insulator Cap .....................................................................15-18
15.9 Valve Actuator Maintenance .........................................................................15-19
15.10 Check Nozzle Tip Height ............................................................................15-19
15.11 Latches .......................................................................................................15-20
15.12 Latch the Cavity Plate to the Core Half (Cold Half) ....................................15-20
15.13 Latch the Cavity Plate to the Manifold Plate (Hot Half) ..............................15-22
15.14 Torque Settings...........................................................................................15-24
15.14.1 Torque Settings of Dura-Plus Gate Seals..........................................15-24
15.14.2 Torque Settings of Master-Series Gate Seals....................................15-24
15.14.3 Torque Settings of Summit-Series Gate Seals ..................................15-24
15.14.4 Torque Settings of Dura Gate Seals ..................................................15-25
15.14.5 Torque Settings of ThinPAK Gate Seals ............................................15-25
15.14.6 System and Plate Screw Torques......................................................15-26
Section 16 - TIT Edge Gated System ........................... 16-1
16.1 TIT Edge Gated System .................................................................................16-1
16.2 TIT Edge Gate Seals ......................................................................................16-2
16.2.1 Remove the Gate Seal ..........................................................................16-2
Section 17 - Accu-Line™ .............................................. 17-1
17.1 Accu-Line™ with Valve Bushing .....................................................................17-1
17.1.1 Accu-Line™ with Valve Bushing -
Pre-Assembly .............................................................................................17-2
17.2 Accu-Line™ with Valve Bushing - Assembly ..................................................17-2
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Hot Runner User Manual

17.3 Accu-Line™with Valve Insert .........................................................................17-9
17.4 Pre-Assembly of Accu-Line™with Valve Insert............................................17-10
17.5 Assembly of Accu-Line™with Valve Insert................................................... 17-11
Section 18 - Melt-Disk System...................................... 18-1
18.1 Reverse Melt-Link Identication .....................................................................18-1
18.2 System with Cast-in Heater Element..............................................................18-2
18.3 Melt-Disk Preparation / Cleaning....................................................................18-3
18.4 Nozzle Thermocouple Assembly ....................................................................18-5
18.5 Melt-Disk Thermocouple Assembly ................................................................18-5
18.6 Optional Quick Disconnect Terminal Ends .....................................................18-7
18.6.1 Crimp the Quick Disconnects ................................................................18-8
18.6.2 Assemble the System with Quick Disconnects......................................18-8
18.7 Assembly of Melt Disk to the Nozzle ..............................................................18-9
18.7.1 Reverse Two-Piece Melt-Link ................................................................18-9
18.7.2 One-piece Melt-Link.............................................................................18-10
18.8 Melt-Disk System Startup .............................................................................18-11
18.8.1 Startup - Melt Link................................................................................18-11
18.8.2 Startup - Reverse Melt Link ONLY.......................................................18-12
18.9 Melt-Disk System Shutdown.........................................................................18-13
18.9.1 Shutdown - Melt Link ...........................................................................18-13
18.9.2 Shutdown - Reverse Melt Link ONLY ..................................................18-14
18.10 Disassembly for Maintenance ....................................................................18-14
18.10.1 For Melt Link......................................................................................18-14
18.10.2 For Reverse Melt Link........................................................................18-14
18.11 Melt-Disk Reassembly after Maintenance ..................................................18-15
Section 19 - Melt-CUBE Systems................................. 19-1
19.1 Identify Your Melt-CUBE Design.....................................................................19-2
19.1.1 The Melt-CUBE Design A ......................................................................19-2
19.1.2 The Melt-CUBE Design B......................................................................19-2
19.2 Example of a Melt-CUBE System...................................................................19-3
19.3 Melt-CUBE Design A ......................................................................................19-4
19.3.1 Melt-CUBE Design A: Gate Seal Assembly...........................................19-5
19.3.2 Melt-CUBE Design A: Maintenance Toolkit............................................19-5
19.3.3 Melt-CUBE Design A: Dual Nozzle Assembly........................................19-6
19.3.4 Melt-CUBE Design A: Inspection...........................................................19-6
19.3.5 Melt-CUBE Design A: Cleaning .............................................................19-6
19.3.6 Melt-CUBE Design A: Assemble Melt-CUBE Thermocouple.................19-7
19.3.7 Melt-CUBE Design A: Assemble Ground Wire ......................................19-7
19.3.8 Melt-CUBE Design A: Assemble Melt Transfer Link to Melt-CUBE .......19-8
19.3.9 Melt-CUBE Design A: Assemble into Cavity Block ................................19-9
19.3.10 Melt-CUBE Design A: Assembly (Cold Condition)...............................19-9
19.3.11 Melt-CUBE Design A: Retighten Wedge Screws (Hot Condition)......19-14
19.3.12 Melt-CUBE Design A: Replace a Transfer Seal / Torpedo.................19-16
19.4 Melt-CUBE Design B ....................................................................................19-19
19.4.1 Melt-CUBE Design B: Components.....................................................19-19
19.4.3 Melt-CUBE Design B: Inspection.........................................................19-20
19.4.2 Melt-CUBE Design B: Maintenance Toolkit .........................................19-20
19.4.4 Melt-CUBE Design B: Cleaning...........................................................19-21
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19.4.5 Melt-CUBE Design B: Install the Thermocouple..................................19-22
19.4.6 Melt-CUBE Design B: Attach the Ground Wire....................................19-23
19.4.7 Melt-CUBE Design B: Install the Melt Transfer Link ............................19-23
19.4.8 Melt-CUBE Design B: Assemble the Melt-CUBE.................................19-25
19.4.9 Melt-CUBE Design B: Install Gate Seals and Cavity Inserts ...............19-28
19.4.10 Melt-CUBE Design B: Install Melt Block ............................................19-29
19.4.11 Melt-CUBE Design B: Disassembly of Transfer Seal / Torpedo and Melt
Block .........................................................................................................19-30
19.5 Optional Quick Disconnect Terminal Ends ...................................................19-32
19.5.1 Crimp the Quick Disconnects ..............................................................19-33
19.5.2 Assemble the System with Quick Disconnects....................................19-33
19.5.3 Assemble Melt-CUBE into Cavity Block...............................................19-33
19.6 Startup and Shutdown ..................................................................................19-34
19.6.1 Startup .................................................................................................19-34
19.6.2 Shutdown.............................................................................................19-34
Section 20 - Troubleshooting ....................................... 20-1
20.1 Moisture Related Issues .................................................................................20-1
20.1.1 Resin Moisture Contamination...............................................................20-1
20.1.2 Resin Drying Issues...............................................................................20-2
20.1.3 Importance of Pre-Drying Resin ............................................................20-2
20.2 Pre-Molding Precautions ................................................................................20-2
20.2.1 History....................................................................................................20-2
20.2.2 Material..................................................................................................20-2
20.2.3 Hardware ...............................................................................................20-3
20.2.4 Settings..................................................................................................20-3
20.3 Establishing Root Cause ................................................................................20-3
20.4 Fault Identication ..........................................................................................20-3
20.5 Defect Types, Causes and Remedies Index ..................................................20-4
20.6 Troubleshooting Typical Problems..................................................................20-5
20.6.1 Dark Specks ..........................................................................................20-5
20.6.2 Blisters or Bubbles.................................................................................20-6
20.6.3 Flow Marks ............................................................................................20-7
20.6.4 Burn Marks ............................................................................................20-8
20.6.5 Delaminating Parts ................................................................................20-9
20.6.6 Dimensional Irregularities ....................................................................20-10
20.6.7 Discolored Parts ..................................................................................20-11
20.6.8 Flash....................................................................................................20-12
20.6.9 Jetting ..................................................................................................20-13
20.6.10 Pitted Parts ........................................................................................20-14
20.6.11 Rough Surface ...................................................................................20-15
20.6.12 Parts Sticking to Cavity......................................................................20-16
20.6.13 Parts Sticking to Core........................................................................20-17
20.6.14 Short Parts.........................................................................................20-18
20.6.15 Sinks or Voids ....................................................................................20-19
20.6.16 Splay..................................................................................................20-20
20.6.17 Streaks...............................................................................................20-21
20.6.18 Stringing.............................................................................................20-22
20.6.19 Warped Parts.....................................................................................20-23
20.6.20 Weld Lines.........................................................................................20-24
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Hot Runner User Manual

Section 21 - Glossary of Terms ........................................
21-1
Index ...................................................................................
I
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Hot Runner User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

Section 1 - Introduction
The purpose of this manual is to assist users in the integration, operation and
maintenance of a Hot Runner. This manual is designed to cover most system
congurations. If you need additional information specic to your system,
or information in another language, please contact your representative or a
Mold-Masters o󰀩ce.
1.1 Intended Use
Mold-Masters Hot Runner systems have been built to process thermoplastic
material at the required temperature for injection molding and must not be
used for any other purpose.
This manual is written for use by skilled persons who are familiar with
injection molding machinery and their terminology. Operators should be
familiar with plastic injection molding machines and the controls of such
equipment. Maintenance persons should have su󰀩cient understanding of
electrical safety to appreciate the dangers of 3-phase supplies. They should
know how to take appropriate measures to avoid any danger from electrical
supplies.
1.2 Documentation
This manual is part of the documentation package for your order and should
be referenced along with the following documents included in the package:
• The Bill of Materials (BOM). Together with the General Assembly drawing,
the Bill of Materials should be referenced when ordering spare parts.
• General Assembly drawing used to integrate your Hot Runner system into
the mold.
• Hot Half drawing used to integrate Hot Half into cavity plate.
• CE declaration of conformity and declaration of incorporation (EU only)
NOTE
This manual should also be used in conjunction with other relevant
manuals, e.g. Mold Machine Manual and Controller Manual.
1.3 Release Details
When ordering this manual, please reference the document number below.
Table 1-1 Release Details
Document Number Release Date Version
HR-UM-EN-00-30-1 July 2019 30-1
HR-UM-EN-00-30-2 January 2020 30-2
HR-UM-EN-00-30-3 March 2020 30-3
HR-UM-EN-00-30-4 June 2020 30-4
HR-UM-EN-00-30-5 July 2020 30-5
HR-UM-EN-00-30-6 September 2020 30-6
HR--UM--EN--00--31 January 2021 31
1-1INTRODUCTION
Hot Runner User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

Table 1-1 Release Details
Document Number Release Date Version
HR--UM--EN--00--31-1 April 2021 31-1
HR--UM--EN--00--31-2 May 2021 31-2
HR--UM--EN--00--31-3 June 2021 31-3
1.4 Warranty
For current warranty information please refer to the documents available from
our website: www.moldmasters.com/support/warranty or contact your Mold-
Masters representative.
1.5 Returned Goods Policy
Please do not return any parts to Mold-Masters without pre-authorization and
a return authorization number supplied by Mold-Masters.
Our policy is one of continuous improvement and we reserve the right to alter
product specications at any time without giving notice.
1.6 Movement or Resale of Mold-Masters
Products or Systems
This documentation is intended for use in the country of destination for which
the product or system was purchased.
Mold-Masters takes no responsibility for documentation of products or
systems if they are relocated or resold outside the intended country of
destination, as stated on the accompanying invoice and/or waybill.
1.7 Copyright
© 2021 Mold-Masters (2007) Limited. All Rights Reserved. Mold-Masters®
and the Mold-Masters logo are trademarks of Mold-Masters.
1-2
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
Hot Runner User Manual

1.8 Units of Measure and Conversion Factors
NOTE
The dimensions given in this manual are from original manufacturing
drawings.
All values in this manual are in S.I. units or subdivisions of these units.
Imperial units are given in parenthesis immediately after the S.I. units.
Table 1-2 Units of Measure and Conversion Factors
Unit Abbreviation Conversion value
bar Bar 14.5 psi
in. Inch 25.4 mm
kg Kilogram 2.205 lb
kPa Kilopascal 0.145 psi
lb Pound 0.4536 kg
lbf Pound force 4.448 N
lbf.in. Pound force inch 0.113 Nm
min Minute
mm Millimeter 0.03937 in.
mΩ Milliohm
N Newton 0.2248 lbf
Nm Newton meter 8.851 lbf.in.
psi Pound per square inch 0.069 bar
psi Pound per square inch 6.895 kPa
rpm Revolutions per minute
s Second
°Degree
°CDegree Celsius 0.556 (°F -32)
°FDegree Fahrenheit 1.8 °C +32
1-3INTRODUCTION
Hot Runner User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

Section 2 - Global Support
2.1 Corporate Ofces
ASIAN HEADQUARTERS
CHINA/HONG KONG/TAIWAN
Mold-Masters (KunShan) Co, Ltd
Zhao Tian Rd
Lu Jia Town, KunShan City
Jiang Su Province
People’s Republic of China
tel: [phone]
fax: [phone]
[email protected]
JAPAN
Mold-Masters K.K.
1-4-17 Kurikidai, Asaoku Kawasaki,
Kanagawa
Japan, 215-0032
tel: [phone]
fax: [phone]
[email protected]
GLOBAL HEADQUARTERS
CANADA
Mold-Masters (2007) Limited
233 Armstrong Avenue
Georgetown, Ontario
Canada L7G 4X5
tel: [phone]
fax: [phone]
[email protected]
SOUTH AMERICAN
HEADQUARTERS
BRAZIL
Mold-Masters do Brasil Ltda.
R. James Clerk Maxwel,
280 – Techno Park, Campinas
São Paulo, Brazil, 13069-380
tel: [phone]
[email protected]
UNITED KINGDOM & IRELAND
Mold-Masters (UK) Ltd Netherwood
Road
Rotherwas Ind. Est.
Hereford, HR2 6JU
United Kingdom
tel: [phone]
fax: [phone]
[email protected]
EUROPEAN
HEADQUARTERS
GERMANY /
SWITZERLAND
Mold-Masters Europa GmbH
Neumattring 1
76532 Baden-Baden, Germany
tel: [phone]
fax: [phone]
[email protected]
INDIAN HEADQUARTERS
INDIA
Milacron India PVT Ltd. (Mold-
Masters Div.)
3B,Gandhiji Salai,
Nallampalayam, Rathinapuri
Post, Coimbatore T.N. 641027
tel: [phone]
fax: [phone]
[email protected]
USA
Mold-Masters Injectioneering
LLC, 29111 Stephenson
Highway, Madison Heights, MI
48071, USA
tel: [phone] (USA
only) tel: [phone]
fax: [phone]
[email protected]
Mold-Masters Regional Offices
AUSTRIA / EAST &
SOUTHEAST EUROPE
Mold-Masters Handelsges.m.b.H.
Pyhrnstrasse 16
A-4553 Schlierbach
Austria
tel: [phone]
fax: [phone]
[email protected]
ITALY
Mold-Masters Italia
Via Germania, 23
35010 Vigonza (PD)
Italy
tel: [phone]
fax: [phone]
[email protected]
CZECH REPUBLIC
Mold-Masters Europa GmbH
Hlavni 823
75654 Zubri
Czech Republic
tel: [phone]
fax: [phone]
[email protected]
KOREA
Mold-Masters Korea Ltd. E
dong, 2nd floor, 2625-6,
Jeongwang-dong, Siheung
City, Gyeonggi-do, 15117,
South Korea
tel: [phone]
[e-mail]
FRANCE
Mold-Masters France
ZI la Marinière,
2 Rue Bernard Palissy
91070 Bondoufle, France
tel: [phone]
fax: [phone]
[email protected]
MEXICO
Milacron Mexico Plastics Services
S.A. de C.V.
Circuito El Marques norte #55
Parque Industrial El Marques
El Marques, Queretaro C.P. 76246
Mexico
tel: [phone] (sales)
tel: [phone] (service)
[email protected]
2-1GLOBAL SUPPORT
Hot Runner User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

2.2 International Representatives
Corporate Ofces - continued
Mold-Masters Regional Offices (cont.)
SPAIN
Mold-Masters Europa GmbH
C/ Tecnología, 17
Edificio Canadá PL. 0 Office A2
08840 – Viladecans
Barcelona
tel: [phone]
e: [email protected]
TURKEY
Mold-Masters Europa GmbH
Merkezi Almanya Türkiye
İstanbul Şubesi
Alanaldı Caddesi Bahçelerarası
Sokak No: 31/1
34736 İçerenköy-Ataşehir
Istanbul, Turkey
tel: [phone]
fax: [phone]
[email protected]
SINGAPORE*
Mold-Masters Singapore PTE. Ltd.
No 48 Toh Guan Road East
#06-140 Enterprise Hub
Singapore 608586
Republic of Singapore
tel: [phone]
fax: [phone]
[email protected]
*Coverage includes Southeast
Asia, Australia, and New Zealand
Mold-Masters International Representatives
Argentina
Sollwert S.R.L.
La Pampa 2849 2∫ B
C1428EAY Buenos Aires
Argentina
tel: [phone]
fax: [phone] Ext.
35 [email protected]
Denmark*
Englmayer A/S
Dam Holme 14-16
DK – 3660 Stenloese
Denmark tel: [phone]
fax: [phone]
[email protected]
*Coverage includes Norway
and Sweden
Israel
ASAF Industries Ltd. 29 Habanai
Street
PO Box 5598 Holon 58154 Israel
tel: [phone]
fax: [phone]
s[email protected]
Russia
System LLC
Prkt Marshala Zhukova 4
123308 Moscow
Russia
tel: [phone]
[email protected]
Belarus
HP Promcomplect
Sharangovicha 13
220018 Minsk
tel: [phone]
fax: [phone]
e:[email protected]
Finland**
Oy Scalar Ltd.
Tehtaankatu
10 11120 Riihimaki
Finland
tel: [phone]
fax: [phone]
[email protected]
**Coverage includes Estonia
Portugal
Gecim LDA
Rua Fonte Dos Ingleses, No 2
Engenho
2430-130 Marinha Grande
Portugal
tel: [phone]
fax: [phone]
[email protected]
Slovenia
RD PICTA tehnologije d.o.o.
Žolgarjeva ulica 2
2310 Slovenska Bistrica
Slovenija
[phone]
[email protected]
Bulgaria
Mold-Trade OOD
62, Aleksandrovska
St. Ruse City
Bulgaria
tel: [phone]
fax: [phone]
[email protected]
Greece
Ionian Chemicals S.A.
21 Pentelis Ave.
15235 Vrilissia, Athens
Greece
tel: [phone]
fax: [phone]
[email protected]
Romania
Tehnic Mold Trade SRL
Str. W. A Mozart nr. 17 Sect. 2
020251 Bucharesti
Romania
tel: [phone]
fax : [phone]
[email protected]
Ukraine
Company Park LLC
Gaydamatska str., 3, office 116
Kemenskoe City Dnipropetrovsk
Region 51935, Ukraine
tel: [phone]
[email protected]
2-2
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
GLOBAL SUPPORT
Hot Runner User Manual

Section 3 - Safety
Please be aware that the safety information provided by Mold-Masters
does not absolve the integrator and employer from understanding and
following international and local standards for safety of machinery. It is the
responsibility of the end integrator to integrate the nal system, provide
necessary e-stop connections, safety interlocks and guarding, to select the
appropriate electrical cable for the region of use and to ensure compliance
with all relevant standards.
It is the responsibility of the employer to:
• Properly train and instruct its personnel in the safe operation of
equipment, including the use of all the safety devices.
• Provide its personnel with all necessary protective clothing, including a
face shield and heat resistant gloves.
• Ensure the original and continuing competence of personnel caring for,
setting up, inspecting and maintaining injection molding equipment.
• Establish and follow a program of periodic and regular inspections of
injection molding equipment to ensure it is in safe operating condition and
proper adjustment.
• Ensure that no modications, repairs, or rebuild of portions are made
to the equipment that reduces the level of safety existing at time of
manufacture or remanufacture.
3-1SAFETY
Hot Runner User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

3.1 Safety Hazards
WARNING
Refer to all machine manuals and local regulations and codes for safety
information.
The following safety hazards are most commonly associated with plastic
injection molding equipment (see European Standard EN201 or American
Standard ANSI/SPI B151.1).
Refer to the illustration of hazard areas below when reading the “Table 3-1
Safety Hazards” on page 3-3.
Figure 3-1 Injection molding machine hazard areas.
Top view with guards removed
Front view with guards removed
210 5
3
Top View with Guards Removed
2
5
9
1
4
769
8
Front View with Guards Removed
1. Mold area
2. Clamping mechanism area
3. Area of movement of
core and ejector drive
mechanisms outside areas
1 and 2
4. Machine nozzle area
5. Plasticating and / or
injection unit area
6. Feed opening area
7. Area of the heater bands
of the plasticizing and / or
injection cylinders
8. Parts discharge area
9. Hoses
10. Area inside the guards and
outside the mold area
3-2
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
Hot Runner User Manual

Table 3-1 Safety Hazards
Hazard Area Potential Hazards
Mold Area
Area between the
platens.
See Figure 3-1 area 1
Mechanical Hazards
Crushing and / or shearing and / or impact hazards caused by:
• Movement of the platen.
• Movements of the injection barrel(s) into the mold area.
• Movements of cores and ejectors and their drive mechanisms.
• Tie bar motion.
Thermal Hazards
Burns and / or scalds due to operating temperature of:
• The mold heating elements.
• Plasticized material released from / through the mold.
Clamping
Mechanism Area
See Figure 3-1 area 2
Mechanical Hazards
Crushing and / or shearing and/or impact hazards caused by:
• Movement of the platen.
• Movement of the drive mechanism of the platen.
• Movement of the core and ejector drive mechanism.
Movement of Drive
Mechanisms Out-
side the Mold Area
and Outside the
Clamping
Mechanism Area
See Figure 3-1 area 3
Mechanical Hazards
Mechanical hazards of crushing, shearing and / or impact caused by the
movements of:
• Core and ejector drive mechanisms.
Nozzle Area
The nozzle area is
the area between the
barrel and the sprue
bushing.
See Figure 3-1 area 4
Mechanical Hazards
Crushing, shearing hazards, and / or impact hazards caused by:
• Forward movement of the plasticizing and / or injection unit including
nozzle.
• Movements of parts of the power operated nozzle shuto󰀨 and their
drives.
• Over pressurization in the nozzle.
Thermal Hazards
Burns and or scalds due to operating temperature of:
• The nozzle.
• Plasticized material discharging from the nozzle.
Plasticizing and / or
Injection Unit Area
Area from the
adapter / barrel head /
end cap to the ex-
truder motor above
the sled including the
carriage cylinders.
See Figure 3-1 area 5
Mechanical Hazards
Crushing, shearing and / or drawn-into hazards caused by:
• Unintentional gravity movements e.g. for machines with plasticizing
and / or injection unit positioned above the mold area.
• The movements of the screw and / or the injection plunger in the
cylinder accessible through the feed opening.
• Movement of the carriage unit.
Thermal Hazards
Burns and or scalds due to operating temperature of:
• The plasticizing and / or injection unit.
• The heating elements e.g. heater bands.
• The plasticized material and / or vapors discharging from the vent
opening, feed throat or hopper.
Mechanical and / or Thermal Hazard
Hazards due to reduction in mechanical strength of the plasticizing and /
or injection cylinder due to overheating.
3-3SAFETY
Hot Runner User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

Table 3-1 Safety Hazards
Hazard Area Potential Hazards
Feed Opening
See Figure 3-1 area 6
Pinching and crushing between injection screw movement and housing.
Area of the Heater
Bands of the
Plasticizing and / or
Injection Cylinders
See Figure 3-1 area 7
Burns and / or scalds due to operating temperature of:
• The plasticizing and / or injection unit.
• The heating elements e.g. heater bands.
• The plasticized material and / or vapors discharging from the vent
opening, feed throat or hopper.
Parts Discharge
Area
See Figure 3-1 area 8
Mechanical Hazards
Accessible Through the Discharge Area
Crushing, shearing and / or impact hazards caused by:
• Closing movement of the platen.
• Movements of cores and ejectors and their drive mechanisms.
Thermal Hazards
Accessible Through the Discharge Area
Burns and or scalds due to operating temperature of:
• The mold.
• Heating elements of the mold.
• Plasticized material released from/through the mold.
Hoses
See Figure 3-1 area 9
• Whipping action caused by hose assembly failure
• Possible release of uid under pressure that can cause injury.
• Thermal hazards associated with hot uid.
Area Inside the
Guards and Outside
the Mold Area
See Figure 3-1 area
10
Crushing and / or shearing and/or impact hazards caused by:
• Movement of the platen.
• Movement of the drive mechanism of the platen.
• Movement of the core and ejector drive mechanism.
• Clamp opening movement.
Electrical Hazards • Electric shock or burns due to contact with live conductive parts.
• Electrical or electromagnetic disturbance generated by the motor
control unit.
• Electrical or electromagnetic disturbance that can cause failures in
the machine control systems and adjacent machine controls.
• Electrical or electromagnetic disturbance generated by the motor
control unit.
Hydraulic
Accumulators
High pressure discharge.
Power Operated
Gate
Crush or impact hazards caused by the movement of the power operated
gates.
Vapors and Gases Certain processing conditions and / or resins can cause hazardous
fumes or vapors.
3-4
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
Hot Runner User Manual