Mold-Masters Master Series User manual

Original Instructions
Hot Runner
User Manual

®
Table of Contents
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
iii
Table of Contents
Section 1 - Introduction ...................................................1-1
Intended Use ....................................................................................................................... 1-1
Operator Training and Safety .............................................................................................. 1-1
Warranty ............................................................................................................................ 1-1
Documentation .................................................................................................................... 1-1
Release Details ................................................................................................................... 1-1
Trademarks and Patents ..................................................................................................... 1-2
Section 2 - Global Support ..............................................2-1
Manufacturing Facilities....................................................................................................... 2-1
Regional Ofces .................................................................................................................. 2-1
International Representatives.............................................................................................. 2-2
Section 3 - Safety..............................................................3-1
Introduction.......................................................................................................................... 3-1
Common Injection Molding Safety Hazards ........................................................................ 3-1
Safety Symbols Typical to Injection Molding Machines....................................................... 3-4
Hot Runner Safety Warnings............................................................................................... 3-5
Section 4 - Preparation ....................................................4-1
Introduction.......................................................................................................................... 4-1
Screw Lengths..................................................................................................................... 4-1
Tools Required..................................................................................................................... 4-1
Unpacking............................................................................................................................ 4-2
Cleaning .............................................................................................................................. 4-2
Establishing Your System Type ........................................................................................... 4-3
System With Cast In Heater Element.................................................................................. 4-3
System With Hydraulic or Pneumatic Units......................................................................... 4-4
System with Bridged Hydraulic Pneumatic System............................................................. 4-5

®Table of Contents
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
iv
Section 5 - Assembly .......................................................5-1
Introduction.......................................................................................................................... 5-1
Gate Seal Finishing ............................................................................................................. 5-3
Hot Valve / Hot Sprue / F Type ............................................................................................ 5-3
Water-cooled Gate Insert Installation (Option) .................................................................... 5-3
Master-Series Thermocouple Installation ............................................................................ 5-4
Master-Series Thermocouple Removal ............................................................................... 5-5
Dura Line Thermocouple Installation................................................................................... 5-5
Nozzle Insertion................................................................................................................... 5-7
Nozzle Wire Layout ............................................................................................................. 5-7
Valve Bushings .................................................................................................................... 5-8
Mounting the Manifold ......................................................................................................... 5-9
Main Manifolds ...................................................................................................................5-11
Pressure Disk Installation ..................................................................................................5-13
EcoDisk Installation ............................................................................................................5-14
Installing Heater Plates.......................................................................................................5-15
Installation of Inlet Components .........................................................................................5-16
Section 6 - Electrical Testing...........................................6-1
Introduction.......................................................................................................................... 6-1
Wiring Check ....................................................................................................................... 6-1
Electrical Safety Testing ...................................................................................................... 6-1
Thermocouple Wiring Guidelines ........................................................................................ 6-3
Functional Test with a Temperature Controller .................................................................... 6-3
Re-testing ............................................................................................................................ 6-3
Section 7 - Hot Half Assembly.........................................7-1
Introduction.......................................................................................................................... 7-1
Assembling the Hot Half...................................................................................................... 7-1
Stack Mold Cavity Plate Installation .................................................................................... 7-2

®
Table of Contents
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
v
Section 8 - System Start Up & Shut Down .....................8-1
Introduction ......................................................................................................................... 8-1
Pre-Start up ......................................................................................................................... 8-1
Shut Down .......................................................................................................................... 8-2
Section 9 - Color Change.................................................9-1
General Tips ........................................................................................................................ 9-1
Procedure A: Simple & Effective.......................................................................................... 9-1
Procedure B: More Comprehensive .................................................................................... 9-2
Section 10 - Hydraulic / Pneumatic
Actuators.........................................................................10-1
Installation and Assembly of the Valve Actuator.................................................................10-1
Valve Pin Lapping Procedure for Tapered Valve Pins ........................................................10-5
Valve Pin Finishing of Head................................................................................................10-5
Valve Pin Assembly ............................................................................................................10-6
Installing the Valve Actuator to the Hydraulic Plate ............................................................10-7
Maintenance Procedure .....................................................................................................10-8
Extraction Tools for Hydraulic Units & Pistons....................................................................10-9
Section 11 - Maintenance Procedures .........................11-1
Introduction.........................................................................................................................11-1
Valve Disk Removal............................................................................................................11-1
Gate Seal Maintenance......................................................................................................11-5
Gate Seal Removal ............................................................................................................11-5
Gate Seal Replacement .....................................................................................................11-6
Sprint Gate Seal Maintenance............................................................................................11-7
Sprint Nozzle Tip Removal .................................................................................................11-7
Cleaning Nozzle Insulator Cap...........................................................................................11-8
Installing Nozzle Insulator Cap...........................................................................................11-8
Valve Actuator Maintenance ...............................................................................................11-8
Sprint Nozzle Tip Installation ..............................................................................................11-8
Latching..............................................................................................................................11-9

®Table of Contents
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
vi
Checking Nozzle Tip Height ...............................................................................................11-9
Latching the Cavity Plate to the Manifold Plate (Hot Half)................................................ 11-11
Torque Settings................................................................................................................. 11-12
Section 12 - TIT Edge Gated System ............................12-1
Introduction.........................................................................................................................12-1
TIT Edge Gated System.....................................................................................................12-1
TIT Edge Gate Seals..........................................................................................................12-1
Section 13 - Accu-Line System .....................................13-1
Accu-Line Body Assembly..................................................................................................13-1
Pre-Assembly .....................................................................................................................13-2
Accu-Line Assembly Procedure..........................................................................................13-2
Section 14 - Melt-Disk System.......................................14-1
Introduction.........................................................................................................................14-1
Safety .................................................................................................................................14-1
System with cast in heater element....................................................................................14-2
Melt-Disk Preparation / Cleaning........................................................................................14-3
Nozzle Thermocouple Assembly ........................................................................................14-4
Melt-Disk Thermocouple Assembly ....................................................................................14-4
Assembly of Melt Disk to the Nozzle .................................................................................14-6
Melt-Disk System Start Up & Shut Down ...........................................................................14-7
Disassembly for Maintenance ............................................................................................14-7
Melt-Disk Reassembly after Maintenance..........................................................................14-7
Section 15 - Melt-Cube System .....................................15-1
Introduction.........................................................................................................................15-1
Safety .................................................................................................................................15-1
Melt-Cube Components......................................................................................................15-2
Example Melt-Cube System ..............................................................................................15-3
Assemble Melt-Cube into Cavity Block...............................................................................15-6
Startup and Shutdown .......................................................................................................15-9
Maintenance - Replacing a Tip...........................................................................................15-9

®
Table of Contents
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
vii
Section 16 - Troubleshooting .......................................16-1
Introduction.........................................................................................................................16-1
Moisture Related Issues.....................................................................................................16-1
Pre-Molding Precautions ....................................................................................................16-2
Establishing Root Cause ....................................................................................................16-2
Fault Identication ..............................................................................................................16-2
Defect Types, Causes and Remedies Index ......................................................................16-3
Parts have Dark Specks.....................................................................................................16-4
Parts have Blisters and/or Bubbles ....................................................................................16-5
Parts have Flow Marks.......................................................................................................16-6
Parts have Burn Marks.......................................................................................................16-7
Parts are Delaminating.......................................................................................................16-8
Parts have Dimensional Irregularities.................................................................................16-9
Parts are Discolored.........................................................................................................16-10
Parts Contain Flash.......................................................................................................... 16-11
Parts Surface has Jetting .................................................................................................16-12
Parts Surface is Rough.....................................................................................................16-14
Parts are Sticking to Cavity ..............................................................................................16-15
Parts are Sticking to Core.................................................................................................16-16
Parts are Short .................................................................................................................16-17
Parts have Sinks or Voids.................................................................................................16-18
Parts are Streaked............................................................................................................16-20
Parts are Stringing............................................................................................................16-21
Parts are Warped .............................................................................................................16-22
Parts have Weld Lines......................................................................................................16-23
Section 17 - Glossary of Terms .....................................17-1
Index .................................................................................18-i

®
Introduction
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
1-1
Section 1 - Introduction
We would like to take this opportunity to thank you for purchasing a Mold-Masters hot runner.
The purpose of this manual is to assist users in the integration, operation and maintenance of Mold-Masters sys-
tems. 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 ofce.
Intended Use
Mold-Masters Hot Runners and Systems have been built to process thermoplastic material at the required tempera-
ture for injection molding and must not be used for any other purpose.
Operator Training and Safety
Before unpacking, moving, integrating or using the equipment, please read the manual, especially Section 3 - Safe-
ty, for important information. Please also 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 also the obligation of the employer to properly train and instruct
its personnel in the safe operation of equipment, including maintenance and the use of all the safety devices. In
addition, the employer must provide its personnel with all necessary protective clothing, including such items as a
face shield and heat resistant gloves.
Warranty
Your original system documentation contains warranty details. If for any reason, parts must be returned to
Mold-Masters, it is essential to obtain prior pre-authorization and a return authorization number.
Documentation
The documentation package provided with your hot runner / system will include any or all of the following:
• EC declaration of conformity
• The Bill of Materials (BOM). Together with the general assembly drawing, the Bill of Materials should be
referenced when ordering spare parts.
• General assembly (GA) drawing used to integrate your hot runner system into the mold.
• Hot half drawing used to integrate hot half to cavity plate.
NOTE
This manual should also be used in conjunction with other relevant manuals, e.g. Mold Machine
Manual and Controller Manual.
When ordering this manual, please reference the document number below.
Release Details
Document # Release Date Version
HRUM-EN-XX-V18 May 2014 18

®Introduction
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
1-2
Trademarks and Patents
ACCU-VALVE, DURA, E-MULTI, FLEX-DURA FLEX-SERIES, FUSION-SERIES, HOT EDGE, MASTERPROBE,
MASTER-SHOT, MOLD-MASTERS, MELT-DISK, MOLD-MASTERS ACADEMY, MASTER-SERIES, MASTER-
SOLUTION, MASTERSPEED, MERLIN, MOLD-MASTERS SYSTEM, MPET, STACK-LINK, are the registered
trademarks of MOLD-MASTERS (2007) LIMITED.
Information contained herein is, to our best knowledge, true and accurate, but all recommendations or sugges-
tions are made without guarantee. Since the conditions of use are beyond our control, Mold-Masters disclaims
any liability incurred in connection with the use of our products and information contained herein. No person is
authorized to make any statement or recommendation not contained herein, and any such statement or recom-
mendation so made shall not bind Mold-Masters. Furthermore, nothing contained herein shall be construed as
a recommendation to use any product in conict with existing patents covering any products or its use, and no
license implied or in fact granted herein under the claims of any patents.
No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechani-
cal, including photocopy, recording, or any information storage and retrieval system without permission in writing
from the publisher. All details, standards and specications may be altered in accordance with technical develop-
ment without prior notication.
May be manufactured under one or more of the following U.S. Patents:
5284436, 5299928, 5312242, 5326251, 5334008, 5334010, 5346388, 5366369, 5366370, 5387099, 5405258,
5421716, 5427519, 5429491, 5437093, 5441197, 5443381, 5460510, 5474440, 5494433, 5496168, 5507635,
5507636, 5536165, 5591465, 5599567, 5614233, 5641526, 5644835, 5652003, 5658604, 5695793, 5700499,
5704113, 5705202, 5707664, 5720995, 5792493, 5795599, 5820899, 5843361, 5849343, 5853777, 5935615,
5935616, 5935621, 5942257, 5952016, 5980236, 6009616, 6017209, 6030198, 6030202, 6062841, 6074191,
6077067, 6079972, 6095790, 6099780, 6113381, 6135751, 6162043, 6162044, 6176700, 6196826, 6203310,
6230384, 6270711, 6274075, 6286751, 6302680, 6318990, 6323465, 6348171, 6350401, 6394784, 6398537,
6405785, 6440350, 6454558, 6447283, 6488881, 6561789, 6575731, 6625873, 6638053, 6648622, 6655945,
6675055, 6688875, 6701997, 6739863, 6752618, 6755641, 6761557, 6769901, 6776600, 6780003, 6789745,
6830447, 6835060, 6840758, 6852265, 6860732, 6869276, 6884061, 6887418, 6890473, 6893249, 6921257,
6921259, 6936199, 6945767, 6945768, 6955534, 6962492, 6971869, 6988883, 6992269, 7014455, 7018197,
7022278, 7025585, 7025586, 7029269, 7040378, 7044191, 7044728, 7048532, 7086852, 7105123, 7108502,
7108503, 7115226, 7118703, 7118704, 7122145, 7125242, 7125243, 7128566, 7131832, 7131833, 7131834,
7134868, 7137806, 7137807, 7143496, 7156648, 7160100, 7160101, 7165965, 7168941, 7168943, 7172409,
7172411, 7175419, 7175420, 7179081, 7182591, 7182893, 7189071, 7192268, 7192270, 7198740, 7201335,
7210917, 7223092, 7238019, 7244118, 7252498, 7255555, 7258536, 7270538, 7303720, 7306454, 7306455,
7314367, 7320588, 7320589, 7320590, 7326049, 7344372, 7347684, 7364425, 7364426, 7370417, 7377768,
7381050, 7396226, 7407379, 7407380, 7410353, 7410354, 7413432, 7416402, 7438551, 7462030, 7462031,
7462314, 7465165, 7470122, 7507081, 7510392, 7513771, 7513772, 7517214, 7524183, 7527490, 7544056,
7547208, 7553150, 7559760, 7559762, 7565221, 7581944, 7611349, 7614869, 7614872, 7618253, 7658605,
7658606, 7671304, 7678320, 7686603, 7703188, 7713046, 7722351, 7731489, 7753676, 7766646, 7766647,
7775788, 7780433, 7780434, 7794228, 7802983, 7803306, 7806681, 7824163, 7845936, 7850442, 7874833,
7877163, 7891969, 7918660, 7918663, 7931455, 7963762, 7988445, 7998390, 8062025, 8066506, 8113812,
8142182, 8152513, 8167608, 8202082, 8206145, 8210842, 8241032, 8280544, 8282386, 8308475, 8308476,
8328546, D525592, RE38265, RE38396, RE38920, RE39935, RE40478, RE40952, RE41536E, RE41648E+
Pending.
© 2014 MOLD-MASTERS (2007) LIMITED, ALL RIGHTS RESERVED

®
Global Support
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
2-1
Section 2 - Global Support
Manufacturing Facilities
Regional Ofces
Version: April 25, 2014 – Page 1 of 2
Updates are available from http://www.moldmasters.com/index.php?s=support&o=downloads
Global Melt Delivery and
Control Systems Technology
Manufacturing Facilities / Produktionsstandorte
GLOBAL HEADQUARTERS
CANADA
Mold-Masters (2007) Limited
233 Armstrong Avenue
Georgetown, Ontario
Canada L7G 4X5
tel: [phone]
fax: [phone]
[e-mail]
EUROPEAN HEADQUARTERS
GERMANY / SWITZERLAND
Mold-Masters Europa GmbH
Postfach/P.O. Box 19 01 45
76503 Baden-Baden, Germany
Neumattring 1
76532 Baden-Baden, Germany
tel: [phone]
fax: [phone]
[e-mail]
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]
[e-mail]
SOUTH AMERICAN
HEADQUARTERS
BRAZIL
Mold-Masters do Brasil Ltda.
Estrada Municipal Mineko Ito, nº4305
Loteamento Industrial Veccon Zeta
Sumaré/ SP
Brazil
tel: [phone]
fax: [phone]
[e-mail]
INDIA
Mold-Masters Technologies
Private Limited
# 247, Alagesan Road,
Shiv Building, Saibaba Colony.
Coimbatore T. N.
India 641 011
tel: [phone]
fax: [phone]
[e-mail]
JAPAN
Mold-Masters K.K.
1-4-17 Kurikidai, Asaoku
Kawasaki, Kanagawa
Japan, 215-0032
tel: [phone]
fax: [phone]
[e-mail]
UNITED KINGDOM
Mold-Masters (UK) Ltd
Netherwood Road
Rotherwas Ind. Est.
Hereford, HR2 6JU
United Kingdom
tel: [phone]
fax: [phone]
[e-mail]
U.S.A.
Mold-Masters Injectioneering LLC
103 Peyerk Court
Romeo, MI 48065, USA
tel: [phone] (USA only)
tel: [phone]
fax: [phone]
[e-mail]
Regional Offices / Regionale Büros
AUSTRIA / East and South
East Europe
Mold-Masters Handelsges.m.b.H.
Pyhrnstrasse 16
A-4553 Schlierbach
Austria
tel: [phone]
fax: [phone]
[e-mail]
CZECH REPUBLIC
Mold-Masters Europa GmbH
Hlavni 823
75654 Zubri
Czech Republic
tel: [phone]
fax: [phone]
[e-mail]
FRANCE
Mold-Masters France
ZI la Marinière,
2 Rue Bernard Palissy
91070 Bondoufle
tel: [phone]
fax: [phone]
[e-mail]
KOREA
Mold-Masters Korea Ltd
708 Byucksan Digital Valley 5 Cha,
60-73 Gasan-dong, Geumcheon-gu,
Seoul,153-788,South Korea
tel: [phone]
fax: [phone]
[e-mail]
MEXICO
MM Hot Runner Injection México,
S.A. de C.V.
Av. San Carlos No. 4 – Nave 2
Parque Industrial Lerma
Lerma, Estado de México
52000, México
tel: [phone]
fax: [phone]
[e-mail]
POLAND
Mold-Masters Europa GmbH
Skr. Pocztowa 59
00-908 Warszawa
Poland
tel: [phone]
fax: [phone]
[e-mail]
Version: April 25, 2014 – Page 1 of 2
Updates are available from http://www.moldmasters.com/index.php?s=support&o=downloads
Global Melt Delivery and
Control Systems Technology
Manufacturing Facilities / Produktionsstandorte
GLOBAL HEADQUARTERS
CANADA
Mold-Masters (2007) Limited
233 Armstrong Avenue
Georgetown, Ontario
Canada L7G 4X5
tel: [phone]
fax: [phone]
[e-mail]
EUROPEAN HEADQUARTERS
GERMANY / SWITZERLAND
Mold-Masters Europa GmbH
Postfach/P.O. Box 19 01 45
76503 Baden-Baden, Germany
Neumattring 1
76532 Baden-Baden, Germany
tel: [phone]
fax: [phone]
[e-mail]
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]
[e-mail]
SOUTH AMERICAN
HEADQUARTERS
BRAZIL
Mold-Masters do Brasil Ltda.
Estrada Municipal Mineko Ito, nº4305
Loteamento Industrial Veccon Zeta
Sumaré/ SP
Brazil
tel: [phone]
fax: [phone]
[e-mail]
INDIA
Mold-Masters Technologies
Private Limited
# 247, Alagesan Road,
Shiv Building, Saibaba Colony.
Coimbatore T. N.
India 641 011
tel: [phone]
fax: [phone]
[e-mail]
JAPAN
Mold-Masters K.K.
1-4-17 Kurikidai, Asaoku
Kawasaki, Kanagawa
Japan, 215-0032
tel: [phone]
fax: [phone]
[e-mail]
UNITED KINGDOM
Mold-Masters (UK) Ltd
Netherwood Road
Rotherwas Ind. Est.
Hereford, HR2 6JU
United Kingdom
tel: [phone]
fax: [phone]
[e-mail]
U.S.A.
Mold-Masters Injectioneering LLC
103 Peyerk Court
Romeo, MI 48065, USA
tel: [phone] (USA only)
tel: [phone]
fax: [phone]
[e-mail]
Regional Offices / Regionale Büros
AUSTRIA / East and South
East Europe
Mold-Masters Handelsges.m.b.H.
Pyhrnstrasse 16
A-4553 Schlierbach
Austria
tel: [phone]
fax: [phone]
[e-mail]
CZECH REPUBLIC
Mold-Masters Europa GmbH
Hlavni 823
75654 Zubri
Czech Republic
tel: [phone]
fax: [phone]
[e-mail]
FRANCE
Mold-Masters France
ZI la Marinière,
2 Rue Bernard Palissy
91070 Bondoufle
tel: [phone]
fax: [phone]
[e-mail]
KOREA
Mold-Masters Korea Ltd
708 Byucksan Digital Valley 5 Cha,
60-73 Gasan-dong, Geumcheon-gu,
Seoul,153-788,South Korea
tel: [phone]
fax: [phone]
[e-mail]
MEXICO
MM Hot Runner Injection México,
S.A. de C.V.
Av. San Carlos No. 4 – Nave 2
Parque Industrial Lerma
Lerma, Estado de México
52000, México
tel: [phone]
fax: [phone]
[e-mail]
POLAND
Mold-Masters Europa GmbH
Skr. Pocztowa 59
00-908 Warszawa
Poland
tel: [phone]
fax: [phone]
[e-mail]

®Global Support
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
2-2
International Representatives
Regional Ofces - Con’t.
Version: April 25, 2014 –Page 2of 2
Updates are available from http://www.moldmasters.com/index.php?s=support&o=downloads
Regional Offices (cont.) / Regionale Büros (Forts.)
SINGAPORE / MALAYSIA
INDONESIA / THAILAND
Mold-Masters Singapore PTE. Ltd.
No 48 Toh Guan Road East
#06-140 Enterprise Hub
Singapore 608586
Republic of Singapore
tel: [phone]
fax: [phone]
[e-mail]
SPAIN
Mold-Masters España
Serennia Business Center
Buenos Aires 37-29
08902 Hospitalet de Llobregat
Barcelona, Spain
tel: [phone]
fax: [phone]
[e-mail]
Turkey
Mold-Masters Europa GmbH
Merkezi Almanya Türkiye İstanbul Şubesi
Alanaldı Caddesi Bahçelerarası
Sokak No:31 D:1
İçerenköy-Ataşehir/İSTANBUL
Te l : [phone]
Fax: [phone]
[e-mail]
International Representatives /Internationale Vertretungen
Argentina
Sollwert S.R.L.
La Pampa 2849 2∫ B
C1428EAY Buenos Aires
Argentinia
tel: [phone]
fax: [phone] Ext. 35
[e-mail]
Australia
Comtec I P E
1084 South Road,
Edwardstown, South Australia 5039
PO Box 338, Magill,
South Australia 5072
tel: [phone]
fax: [phone]
[e-mail]
[e-mail]
Bulgaria
Mold-Trade OOD
62, Aleksandrovska St.
Ruse City
Bulgaria
tel: [phone]
fax: [phone]
[e-mail]
Denmark, Norway, Sweden
Englmayer A/S
Skenkelsoevej 9, Postbox 35
DK -3650 Oelstykke, Denmark
tel: [phone]
fax: [phone]
[e-mail]
Finland
Oy Scalar Ltd.
Viertolantie 12
11120 Riihimaki, Finland
tel: [phone]
fax: [phone]
[e-mail]
Greece
Ionian Chemicals S.A.
21 Pentelis Ave.
15235 Vrilissia
Athens
Greece
tel: [phone]
fax: [phone]
[e-mail]
Ireland
Bray Engineering Services
Mr. Liam Shortt
Unit F3
Network Enterprise Business Park
Kilcoole, Co. Wicklow, Ireland
tel: [phone]
fax: [phone]
[e-mail]
Israel
ASAF INDUSTRIES Ltd.
29 Habanai Street
PO Box 5598 Holon 58154
Israel
tel: [phone]
fax: [phone]
[e-mail]
Italy
Commerciale Isola SPA
Via G.B. Tiepolo 3
35010 Cadoneghe, (Padova)
Italy
tel: [phone]
fax: [phone]
[e-mail]
Portugal
Gecim LDA
Rua Fonte Dos Ingleses, No 2
Engenho
2430-130 Marinha Grande, Portugal
tel: [phone]
fax: [phone]
[e-mail]
Romania
Tehnic Mold Trade SRL
Str. W. A Mozart nr. 17
Sect. 2
020251 Bucharesti
Romania
tel: [phone]
fax : [phone]
[e-mail]
Russia
PORTMOLD Company LC
Gefsimanskie prudy 4,
141307 Sergiev Posad
Russia
tel: [phone]
fax: [phone]
[e-mail]
Vietnam
Mold-Masters
Singapore PTE. Ltd.
No 48 Toh Guan Road East
#06-140 Enterprise Hub
Singapore 608586
Republic of Singapore
tel: [phone]
fax: [phone]
[e-mail]
www.moldmasters.com
Version: April 25, 2014 –Page 2of 2
Updates are available from http://www.moldmasters.com/index.php?s=support&o=downloads
Regional Offices (cont.) / Regionale Büros (Forts.)
SINGAPORE / MALAYSIA
INDONESIA / THAILAND
Mold-Masters Singapore PTE. Ltd.
No 48 Toh Guan Road East
#06-140 Enterprise Hub
Singapore 608586
Republic of Singapore
tel: [phone]
fax: [phone]
[e-mail]
SPAIN
Mold-Masters España
Serennia Business Center
Buenos Aires 37-29
08902 Hospitalet de Llobregat
Barcelona, Spain
tel: [phone]
fax: [phone]
[e-mail]
Turkey
Mold-Masters Europa GmbH
Merkezi Almanya Türkiye İstanbul Şubesi
Alanaldı Caddesi Bahçelerarası
Sokak No:31 D:1
İçerenköy-Ataşehir/İSTANBUL
Te l : [phone]
Fax: [phone]
[e-mail]
International Representatives /Internationale Vertretungen
Argentina
Sollwert S.R.L.
La Pampa 2849 2∫ B
C1428EAY Buenos Aires
Argentinia
tel: [phone]
fax: [phone] Ext. 35
[e-mail]
Australia
Comtec I P E
1084 South Road,
Edwardstown, South Australia 5039
PO Box 338, Magill,
South Australia 5072
tel: [phone]
fax: [phone]
[e-mail]
[e-mail]
Bulgaria
Mold-Trade OOD
62, Aleksandrovska St.
Ruse City
Bulgaria
tel: [phone]
fax: [phone]
[e-mail]
Denmark, Norway, Sweden
Englmayer A/S
Skenkelsoevej 9, Postbox 35
DK -3650 Oelstykke, Denmark
tel: [phone]
fax: [phone]
[e-mail]
Finland
Oy Scalar Ltd.
Viertolantie 12
11120 Riihimaki, Finland
tel: [phone]
fax: [phone]
[e-mail]
Greece
Ionian Chemicals S.A.
21 Pentelis Ave.
15235 Vrilissia
Athens
Greece
tel: [phone]
fax: [phone]
[e-mail]
Ireland
Bray Engineering Services
Mr. Liam Shortt
Unit F3
Network Enterprise Business Park
Kilcoole, Co. Wicklow, Ireland
tel: [phone]
fax: [phone]
[e-mail]
Israel
ASAF INDUSTRIES Ltd.
29 Habanai Street
PO Box 5598 Holon 58154
Israel
tel: [phone]
fax: [phone]
[email protected]
Italy
Commerciale Isola SPA
Via G.B. Tiepolo 3
35010 Cadoneghe, (Padova)
Italy
tel: [phone]
fax: [phone]
[e-mail]
Portugal
Gecim LDA
Rua Fonte Dos Ingleses, No 2
Engenho
2430-130 Marinha Grande, Portugal
tel: [phone]
fax: [phone]
[e-mail]
Romania
Tehnic Mold Trade SRL
Str. W. A Mozart nr. 17
Sect. 2
020251 Bucharesti
Romania
tel: [phone]
fax : [phone]
[e-mail]
Russia
PORTMOLD Company LC
Gefsimanskie prudy 4,
141307 Sergiev Posad
Russia
tel: [phone]
fax: [phone]
[e-mail]
Vietnam
Mold-Masters
Singapore PTE. Ltd.
No 48 Toh Guan Road East
#06-140 Enterprise Hub
Singapore 608586
Republic of Singapore
tel: [phone]
fax: [phone]
[e-mail]
www.moldmasters.com

®
Safety
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
3-1
Section 3 - Safety
Introduction
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 such items as a face shield and heat
resistant gloves.
• Ensure the original and continuing competence of personnel caring for, setting up, inspecting and maintain-
ing injection molding equipment.
• Establish and follow a program of periodic and regular inspections of injection molding equipment to ensure
they are 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.
Common Injection Molding Safety Hazards
The following safety hazards are most commonly associated with plastic injection molding equipment in general
(see European Standard EN201 or American Standard ANSI/SPI B151.1).
WARNING
Also refer to all machine manuals and local regulations and codes for safety information.
(1) Mold area
(2) Clamping mechanism area
(3) Area of movement of core and ejector drive
mechanisms outside areas 1& 2
(4) Nozzle area
(5) Plasticizing 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
210 5
3
Top View with Guards Removed
Top View with Guards Removed
2
5
9
1
4
769
8
Front View with Guards Removed
Figure 3-1: Injection molding machine (HIMM) with horizontal
clamping unit and horizontal injection unit, shown without guards for
illustration clarity.

®Safety
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
3-2
Hazard Area Potential Hazards
Mold Area
Area between the plat-
ens.
See Figure 3-1 item 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 of the molds.
• 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 outside
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 shutoff 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 adaptor/
barrelhead/end cap
to the extruder 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 plasticiz-
ing 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 discharg-
ing 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.

®
Safety
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
3-3
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 plasticiz-
ing 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 discharg-
ing 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.

®Safety
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
3-4
Safety Symbols Typical to Injection Molding Machines
GENERAL DESCRIPTION OF SYMBOL
General – Warning
Indicates an immediate or potentially hazardous situation, which if not avoid-
ed, could result in a serious injury or death.
Warning – Barrel cover grounding strap
Lockout/Tagout procedures must be followed before removing the barrel
cover. Barrel cover can become energized upon removal of grounding straps
and contact can result in death or serious injury. Grounding straps must be
reconnected before reconnecting power to machine.
Warning – Crushing and/or impact points
Contact with moving parts can cause serious crushing injury. Always keep
guards in place.
Warning – Crush hazard closing mold
Warning – Hazardous voltage
Contact with hazardous voltages will cause death or serious injury. Turn off
power and review electrical schematics before servicing equipment. May con-
tain more than one live circuit. Test all circuits before handling to make sure
circuits have been de-energized.
Warning – High pressure
Overheated uids may cause severe burns. Discharge pressure before dis-
connecting water lines.
Warning – High pressure accumulator
Sudden release of high pressure gas or oil can cause death or serious injury.
Discharge all gas and hydraulic pressure before disconnecting or disassem-
bling accumulator.
Warning – Hot surfaces
Contact with exposed hot surfaces will cause serious burn injury. Wear pro-
tective gloves when working near these areas.
Mandatory – Lockout/Tagout
Ensure that all energies are properly locked out, and remain locked out until
the service work is completed. Servicing equipment without disabling all inter-
nal and external power sources can cause death or serious injury. De-ener-
gize all internal and external power sources (electrical, hydraulic, pneumatic,
kinetic, potential, and thermal).
Warning – Molten material Splashing Hazard
Molten material or high pressure gas can cause death or severe burns. Wear
personal protective equipment while servicing the feed throat, nozzle, mold
areas, and when purging the injection unit.
Warning – Read manual before operation
Personnel should read and understand all instructions in the manuals before
working on equipment. Only properly trained personnel should operate the
equipment.
Warning – Slip, Trip, or Fall Hazard
Do not climb on equipment surfaces. Serious slip, trip, or fall injuries can
result from personnel climbing on equipment surfaces.
Caution - Failure to follow instructions may damage equipment
CAUTION

®
Safety
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
3-5
Hot Runner Safety Warnings
The equipment supplied is subjected to high injection pressures and high temperatures.
Ensure that extreme caution is observed in the operation and maintenance of the hot runner system and the
injection molding machines.
• Do not operate the equipment with unconned long hair, loose clothing or jewelry, including name badges,
neckties, etc. These may get caught by the moving belt mechanism and can cause death or serious injury.
• Never disable or bypass a safety device.
• It is highly recommended that all operators wear face shields and use heat resistant gloves when working
around the feed throat, purging the machine or cleaning the gates of the mold.
• Check frequently for possible oil or water leaks. Stop the machine and make repairs.
• Remove purgings from the machine immediately.
• Never touch or inspect the timing belt when power is on and motor and controller are connected. Unplug the
controller before any maintenance.
• Always cover belt area with proper protecting sheet before any bench test or in-mold testing.
• High voltage and amperage cables are connected to the controller (220VAC). There is also a high voltage
cable connection between the servo motor and controller.
• Unplug the controller before performing any maintenance work.
• Hoses tted to the mold will contain high or low temperature uids or air under high pressure. The operator
must shut down and lockout these systems as well as relieving any pressure before performing any work with
these hoses.
• Never perform any work on the mold unless the hydraulic pump has been stopped.
• High voltage and amperage cables are connected to the mold. Electric power must be shut off prior to install-
ing or removing any cables.
• Water and or hydraulics on the mold may be in close proximity to electrical connections and equipment.
Water leakage may cause an electrical short circuit. Hydraulic uid leakage may cause a re hazard. Always
keep water and/or hydraulic hoses and ttings in good condition to avoid leaks.
• All maintenance on Mold-Masters products should be performed by properly trained personnel based on local
law or regulation requirements. Electrical products may not be grounded when removed from the assembled
or normal operating condition.
• Ensure proper grounding of all electrical products before performing any maintenance to avoid potential risk
of electrical shock.
• Check that all coolant, hydraulic and air lines as well as electrical cables will not interfere with the moving
parts of the mold, machine or robot. The lines must be of sufcient length so that they will not strain or pinch
when the mold halves separate.
• For water-cooled gate inserts, coolant must be maintained with the proper mixture to prevent corrosion and
circuit blockage.
• Care must be taken to ensure the nozzle terminal ends do not come in contact with the hydraulic uid. The
nozzles may short out or become damaged.
• Do not mix electrical power cables with thermocouple extension cables. They are not designed to carry the
power load or list accurate temperature readings in each other’s application.

®Safety
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
3-6
CAUTIONS
All Mold-Masters heated components are manufactured to standards that ensure safe and reliable operation
provided that the following precautions are met:
• To maximize heater element and component life, the temperature must be controlled and maintained
within safe operating limits. Mold-Masters strongly recommends individual control of each heated compo-
nent, including heater plates, with a reliable temperature controller that includes soft-start protection.
• Always operate the system using correctly installed “J” type thermocouples connected to a reliable tem-
perature controller with “soft-start” protection.
• Avoid running the system for long periods on “manual” control.
• Use caution when applying power in “manual” mode. Use minimum heat required for the process to avoid
overheating and possible damage to components.
• Always replace pinched or damaged thermocouples.
• When “grouping” heated components together and controlling more than one load from a single thermo-
couple, make sure that the components are of similar material, wattage, size and are exposed to the same
thermal conditions.
• When replacing heater plates or other heated components always replace with Mold-Masters components
of the same type and install as originally specied on Mold-Masters general assembly drawings.
CAUTION

®
Preparation
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
4-1
Screw Lengths
The use of an incorrect size, length and grade screw
could cause the screw to shear, fatigue or stretch
beyond its yield point, resulting in expensive downtime
of the hot runner.
WARNING
Be aware of warnings placed on the assem-
bly drawings. When the manifold is heated
the metal expands stretching the mounting
screws, if screw lengths are shortened there
is a possibility of shearing.
The expansion factor is calculated into the
length of each screw size.
Section 4 - Preparation
Introduction
The following section is a step-by-step guide to preparing your Mold-Masters system for use.
WARNING
DO NOT SHORTEN SCREW
S.H.C.S. M12 X 130
(ISO-GRADE 12.90
OR ½ - 13 X 4.75
(ASTM A574)
NOT SUPPLIED BY
Mold-Masters
EXAMPLE
Tools Required
Depending on the size and complexity of your hot
runner system, you will require most of the tools
and materials listed below.
• Allen keys - Depending on system, set of met-
ric or imperial size keys for use on cap screws
(4, 5, 6, 8 and 10 mm or imperial equivalent)
• Nickel based anti-seize compound - to prevent
oxidation of screw threads that could cause
screws to seize with high temperatures
• Solvents (denatured alcohol) - for removal of
rust inhibitors
• Calibrated torque wrench - for consistent
screw pressure throughout the system
• Pliers - for general assembly work
• Circlip pliers - to remove and install Circlip in
valve systems
• Micrometer - (sizes 0-6” and 0-150 mm) to
check system part and plate thickness
• Depth micrometer - to check bore depths
• Slot head screw driver - used in installing ther-
mocouples and ground wires
• Slot head screw driver (small) - used in fasten-
ing electrical wires to connectors
• Crimping tool - for fastening connector pins
when necessary
• Wire strippers - for preparing wires
• Utility knife - for cutting tape, wires etc.
• Glass tape - used for grouping wires into
zones
• Bluing Compound - for checking face contact
• Sockets
• Lapping compound for valve gate systems
• Plastic face hammer
• Proper actuator installation / extraction tools
Figure 4-2
Figure 4-1

®Preparation
Not under documentation control if printed. May be revised without notice. ©05-2014
Electronic version is available at www.moldmasters.com
Hot Runner User Manual Revision 18
4-2
Unpacking
1. Carefully remove all components from the ship-
ping box and check that all components listed on
the packing slip were supplied.
2. Check that all mold base dimensions are correct
and correspond to Mold-Masters general assem-
bly drawings.
Cleaning
All nozzles, manifolds and hot runner components
must be free of the rust inhibitor applied at the factory.
1. Disassemble the system.
2. Wipe down the nozzle body.
3. Remove the part and wipe clean.
4. If necessary, use a cotton swab to clean nar-
row interior surfaces or screw threads. For large
surfaces such as mold plates, use thinner in spray
form to clean channels and recesses.
Figure 4-3 Figure 4-4