Synventive Hb series User manual

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

8.1.1 Actuator HB Series

8.1.1.1Technical Data

Doc006521.png Doc006419.png

Parameters HB2508# HB4016#

Valve Pin Diameter 3 mm, 3.8 mm 5 mm, 6 mm, 8 mm, 12 mm

Nozzle Series 06E, 09E 12E, 16E, 22E

Pin Adjustment +/- 1 mm +/- 1.5 mm

MIn/Max Close Forces 1963/2945N 5027/7540N

Min/Max Open Forces 443/2267N 3506/5259N

Min/Max. Hydraulic Pressure 40/60 bar (600/870 psi) 40/60 bar (600/870 psi)

Valve Pin Stroke 8 mm 16 mm

Hydraulic Connections M10x1.0 M10x1.0

Cooling Temperature 30-60°C 30-60°C

Cooling Connections M10x1.0 M12x1.5

Recommended HB4016 Actuator Pressure

Settings when Hydraulic Manifold Block

is not Supplied on Hot Runner

Diameter

(mm)

Actuator Pressure

PSI Bar

5 300 20

Thermocouple and Position Sensor optional on all models.

Maximum 3 Actuators per cooling zone on all models.

6 450 30

8 & 12 600 40

NOTICE

To ensure long life and continued flawless operation of the actuator, we recommend using a service

medium that complies with the requirements of classification 21/18/13 pursuant to ISO 4406.

The coolant should be properly modified e.g. filtered water with an anti-corrosion and frost proof agent.

After switching off the Hot Runner heater, the cooling for the actuator should remain on for at least

15 minutes, to avoid damage to the Actuator seals and the position sensor.

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

8.1.1.2Overview of the described actuators

This manual describes the assembly process to build the HB Series Actuators. The Actuator parts are

identied with the numbers indicated in the following gure, which shows the components.

NOTICE

Always tighten the screws to the torques specified in the respective table in section 13.

Doc008513.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

Doc008514.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

8.1.1.3HB Series assemblies

The picture shows the HB401606-10 as example.

Doc008515.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

8.1.1.4HB Series seal kits

The picture shows the housing complete from actuator HB401606-10 as example.

Doc008516.png

At service, the parts from the seal set should be replaced.

Seal kit

HB250806-11

HB250806-15

HB250807-11

HB250807-15

HB401606-10

HB401606-15

HB401606-17

HB401607-10

HB401607-15

HB401607-17

Item Description Qty Item Qty Item

1 Seal Kit 1 SKT2508 1 SKT4016

1.1 Piston Seal 1 2G0/25-19-2.9 1 K30-40-40-32-3.2

1.2 Guiding Element 1 15.2X12X1.6/1.6 1 FB2.3-1.5L70.5

1.3 O-Ring Seal 1 VIOR-21.95X1.78-FPM-

75-G

1 VIOR-35X2.28-FPM-80-G

1.4 Rod Seal 1 C1-1028-V3664 1 C1-2038-V3664

1.5 Retaining Ring 1 DIN472-27X1,2 1 DIN472-42X1,75

1.6 Restrictor 1 EIS-TM-04-010 1 EIS-TM-04-010

NOTICE

1) All components must be cleaned (and oil free) prior to beginning assembly process.

2) All Seals and O-rings must be lubricated prior to installation.

3) This procedure is intended for use together with HCO-HB####-##, HB######-## drawings.

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

8.1.1.5HB assembly tools

These tools are needed for assembly and service of the Actuator. The tools are identied with the

numbers indicated in the following gure.

No. Description Figure HB2508 HB4016

T3 Valve pin disassembly tool

Doc001229.tif

ATCYL0805 ATCYL0303

T4 Piston seal installation cone

Doc006650.png

ATCYL0203 ATCYL0304

T5 Piston seal spread tube

Doc006651.png

ATCYL0202 ATCYL0105

T6 Piston seal calibration sleeve

Doc006652.png

ATCYL0204 ATCYL0107

T9 Piston and cap assembly tool

Doc006653.png

ATCYL45 ATCYL27

T10 Dowel insertion tool

Doc006654.png

ATCYL48 ATCYL49

T11 Top CV plug assembly tool

Doc006655.png

Tool not needed ATCYL40

T13 CV Plug Tool

Doc006657.png

EIS-HT-050 EIS-HT-050

T14 Adjustment Tool

Doc006420.png

ATA01 ATA01

T15 Piston Cap Tool

Doc008087.png

AT-PIC25010

AT-PIC2502

AT-PIC4001

AT-PIC4002

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

8.1.1.6Dismounting the Actuators of the HB Series

Danger to Life by Hydraulics

Serious personnel injury or death can result from connecting or

disconnecting hydraulic hoses under pressure.

Hydraulic works must be carried out by qualied persons.

Use personal protective equipment, such as face protection, headgear, anti oil

gloves.

The hoses in Hot Runner Systems and the injection mold are under high

pressure and high temperatures.

Before disconnecting or connecting any Hydraulic hoses:

●The injection machine / hydraulic pump must be shut down.

●The electrical disconnect properly locked out.

●Pressure from the hoses must be removed.

For rst aid contact your medical / safety representing

Dismounting Procedure

1) Locate and remove the four screws (F) on

top of the actuator housing (A).

2) Push the whole actuator housing (A) in

the direction specied on the pin release

indicator label (I).

This will disengage the actuator from the

valve pin.

Doc006358.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

3) Lift the entire actuator housing (A) out of the

assembly. Removal of the cooling plate (B)

is not required when removing the actuator

housing assembly.

Doc006356.png

4) Unscrew and remove the M6 socket head

cap screws (R).

5) Lift out the mounting plate (S).

Doc006357.png

8.1.1.7Seal Replacement

Disassembly

1) Remove Snap Ring (A).

LETTER PART

1.1 Piston Seal

1.2 Guiding Element

1.3 O-Ring Seal

1.4 Rod Seal

1.5 Retaining Ring

1.6 Restrictor

Doc008517.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

2) Remove piston (E) and cap (F) with a valve

pin.

Doc008518.png

3) Separate piston (E) from cap (F).

Doc008505.png

4) Use tools T15.1 and T15.2 to disassemble the

piston cap PC02 from PC01.

5) Remove Rod Seal 1.4.

Doc008506.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

6) Dismount seals:

●Piston Seal (1.1)

●Guiding Element (1.2)

●O-Ring Seal (1.3)

●Rod Seal (1.4)

7) After disassembly of the sealing elements,

the original seals must be replaced. See the

following sections for additional details.

Doc008507.png

8.1.1.8Cooling Plate Maintenance

Cooling Plate Removal

1) With the actuator dismounted, lift up the cooling

plate (2).

Doc006359.png

Cleaning the Cooling Plate

Removing the cooling plate plug

(VSTI10X10RVITCF) facilitates the cleaning of the

cooling plate.

1) Remove the cooling plate plug (3 ) with a HEX5

wrench.

2) Clean the cooling plate (2).

3) Replace plug by torqueing to 6 Nm.

Doc006360.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

Replace of the Restrictor

The seal kit is also supplied with a replacement Restrictor (1.6). Replace the Restrictor

(1.6) at the same intervals as when replacing the actuator seals.

1) Unscrew and remove the Plug (A).

2) Unscrew and remove the Restrictor (1.6).

Doc008508.png

3) Insert the Restrictor (1.6) into the housing

and torque.

NOTICE

Use a torque wrench for a torque of

2 Nm (1.63 ft-lbs).

4) Insert Plug (A) and torque.

NOTICE

Use a torque wrench for a torque of

12 Nm (8.9 ft-lbs).

Doc008509.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

8.1.1.9Assembling the Actuator HB Series

Installing the Piston Seal

1) Liberally lubricate Piston Seals 1.1 with

hydraulic oil:

NOTICE

The piston seal kit consists of a piston

seal ring and an O-ring. They are

combined as one unit.

Doc008528.png

2) Insert O-ring into piston seal groove.

Doc008529.png

3) Insert Sealing Element (1.1b) into piston

seal groove (over the O-ring 1.1a) using the

mounting cone (T4) and spreader sleeve (T5).

Doc006695.png

4) Precisely align the piston seal (1.1) with the

calibration sleeve (T3).

Doc006692.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

5) Screw in the restrictor (1.6) into housing and

torque to specication on drawing (2 Nm).

Doc008523.png

6) Insert threaded plug (PP) and torque to

specication on drawing (12 Nm Min).

Doc006674.png

7) Liberally lubricate Rod Seal (1.4) with Krytox

GPL205 and insert Rod Seal (1.4) into Piston

Cap (PC01) in orientation shown.

Doc008088.png and Doc008527.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

8) Use tools T15 Mount piston cap (pc01 and

pc02).

15Nm for HB2508

45Nm for HB4016

Doc008089.png

9) Liberally lubricate Guiding Element (1.2)

and O-Ring Seal (1.3) with Krytox GPL205

and insert them into Piston Cap.

Doc008090.png

NOTICE

To avoid damage to the seals, the T9 assembly

tool should be used.

10) Guide the piston cap onto the assembly tool

(T9).

Doc008525.png

11)Set the piston on the assembly tool (T9)

and slide the piston cap onto the piston.

Doc008524.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

12) Use the assembly tool (T9) to guide the

piston into the housing. With the assembly

tool, the piston can be rotated so that the hole

in the piston is aligned with the anti-rotation

pin.

Doc008526.png

13) Install retaining ring (1.5).

Doc008530.png

Mounting the Actuator on a Manifold

1) Position the mounting plate on the manifold.

2) Lubricate the thread of the hexagon socket

head cap screws (5) with high temperature

assembly paste (anti-seize compound).

NOTICE

Anti-seize compound is an important

measure to prevent thread corrosion

due to aggressive gasses which could

be released during plastic processing.

3) Screw the mounting plate (3) onto the manifold

with the socket head cap screws (5) M6x14.

4) Place the cooling plate (2) on the mounting

plate (3). Doc006359.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

5) Insert valve pin (6) into bushing (7).

6) Slide the actuator so it engages the pin head

slots of the piston.

7) Lubricate the thread of the socket head cap

screws (F) with high temperature assembly

paste (anti-seize compound).

NOTICE

Anti-seize compound is an important

measure to prevent thread corrosion

due to aggressive gasses which could

be released during plastic processing.

8) Secure the actuator with socket head cap

screws (F).

9) Tighten the socket head cap screws (F) in

an “X” pattern (a, d, c, and b). Use a torque

wrench to torque to specications listed in the

table in section 13.

NOTICE

Do not use cylinder housing as

support to get the system into the

mold, (no hammering e.g.)

Doc006243.png

Doc006358.png

8.1.1.10 Position Sensor

The Position Sensor (J) provides the user

with additional information such as if the pins

are in the fully open, fully closed or in an

intermediate position.

NOTICE

The position sensor (J) has a

maximum temperature rating of

150 degrees C and a maximum

cable (K) rating of 200 degrees C.

Doc006386.png.

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

Removal

NOTICE

Before removal and installation

check that the cable (K) is not

pinched and is free of tension.

1) Locate and remove the three M3 screws

(L) on the side of the actuator housing (A).

2) Gently remove the position sensor (J) and

cable (K) making sure not to touch the

printed circuit board underneath.

Doc006385.png.

Installation

NOTICE

When reinstalling make sure the

mating surface is clean of oil and

debris.

1) Place sensor in the correct location and

install the three M3 screws (L).

2) Torque M3 screws to 1.5 Nm.

Doc006421.png

Master Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev13

H O T R U N N E R T E C H N O L O G Y

Hot Runner System Installation Guide

Service and Maintenance / Actuator HB Series

8.1.1.11 Valve Pin Adjustment

Hot Surfaces Hazard

Contact between the skin and hot surfaces could result in

burns.

Use personal protective equipment, such as gloves, apron,

sleeves and face protection, to guard against burns. When

servicing or handling the hot runner system outside the manifold

plates or the injection molding machine, care must be taken to

heed the hot surface exposure warnings.

1) Bring the manifold and mold to the operating temperatures for the

material to be molded.

2) Insert the adjustment tool (T14), Synventive part number ATA01,

on the top of the actuator.

3) Loosen the locking screw (M6).

4) Close the valve gate by applying pneumatic pressure on the

closed port.

5) Rotate the adjusting screw (AJS) in a clockwise (forward)

direction to pre-set the valve pin position.

●Conical Gate: Turn the adjusting screw (AJS) clockwise

until the valve pin seats rmly in the gate.

When valve pin position is achieved, then turn adjusting

screw clockwise (forward) an additional 1/10th of a turn

in order to achieve proper valve pin position during

operation. 1/10th increments are provided adjacent to

the screw for reference.

●Cylindrical Gate: Turn the adjusting screw (AJS)

clockwise until the valve pin protrudes beyond the gate

according to dimension specied on general assembly

drawing.

NOTICE

One full (360 degree) rotation equals one millimeter of

adjustment. Stop if heavy resistance is felt.

Do not overtighten as damage to components may

occur. Remove pneumatic pressure and loosen the

adjusting screw (AJS).

6) Remove adjustment tool (T14) and tighten locking screw (M6) to

the specication on the locking screw.

NOTICE

It is necessary to always adjust the pin position by

rotating the adjusting screw (AJS) in a clockwise

(forward) direction in order to achieve proper pin position

during operation. In the event that the actuator was

“over adjusted” or needs re-adjustment, first remove

pressure from the “close” port, fully loosen the adjusting

screw (AJS) then return to step 4.

Doc006420.png

Doc006387.jpg

Doc006354.png

Doc006355.png

Torque Value locking screw (M6)

HB2508 - 14 Nm / HB4016 - 18 Nm

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