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