Yudo HOT RUNNER Instruction Manual

HOT RUNNER
USER’S HANDBOOK

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THANK YOU FOR CHOOSING A YUDO SYSTEM.
This system is manufactured using the most modern engineering technologies and manufacturing processes,
but it is absolutely necessary the compliance with the best practices for operation and maintenance, in order
to offer the maximum performance and reliability.
YUDO GLOBAL

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TABLE OF CONTENTS
1. Safety ............................................................................................................................................................................................... 4
1.1. Safety Procedures ............................................................................................................................................................ 4
2. System Reception ..................................................................................................................................................................... 5
3. System Installation and Disassembly .............................................................................................................................. 6
3.1. Preparation ........................................................................................................................................................................... 6
3.2. System Handling for Installation ................................................................................................................................ 6
3.3. Assembly and Disassembly Instructions ............................................................................................................... 9
Module A - Single Nozzle Type ........................................................................................................................................... 9
Module B - Basic HR System Type ................................................................................................................................ 11
Module C1 - Pre Wired (PW) Eco Modu System – Sliding Nozzles Type .................................................. 13
Module C2 - Pre Wired (PW) Eco Modu System – Threaded Nozzles Type............................................ 15
Module D - Hot Half Modu System Type ..................................................................................................................... 17
4. System Startup and Shutdown ........................................................................................................................................ 18
4.1. Startup ................................................................................................................................................................................. 18
4.2. Shutdown ........................................................................................................................................................................... 18
5. Process Adviser ....................................................................................................................................................................... 19
5.1. Color Change ................................................................................................................................................................... 19
5.2. Glass Fiber ........................................................................................................................................................................ 19
5.3. Material Degradation .................................................................................................................................................... 19
6. Preventive Maintenance ...................................................................................................................................................... 20

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1. S AFETY
Injection systems are equipped with heating elements - electrical resistances - that function with electric
current.
The use of electricity requires several care. Negligence to use proper safety procedures
against electrical risks can cause fatal or irrecoverable damage.
YUDO is not responsible for damages caused by negligence or failure to comply with appropriate safety
procedures.
If you have questions about any security procedure in systems installation and handling, please contact
YUDO.
1.1. S AFETY P ROCEDURES
During handling and Hot Runner System operation, high temperature and high pressure injection are used.
In order to protect the operator in the workplace, it is important to ensure that all safety devices are installed in
equipment as follows:
- Warning Labels placed in the mold and machine;
- Reference to the machine user manual for safety procedures and checks when they are not internally
defined.
- Adequate individual protection equipment must be used to protect individual against high temperature
surfaces, gases or liquids expelling, falls and cuts.
- To avoid serious burns wear protective clothing heat resistant, heat resistant gloves and face protection,
including safety goggles. Use adequate ventilation for fumes.
- Contact with hot nozzle can cause severe burns. Use signs in a visible place stating "DANGER"
- Before performing any electrical work, check the Hot Runner System is properly connected to the earth.
Failure to do so can result in a serious injury or death.
- All electrical power and thermocouple cables must be secured to prevent damage during assembly.
The power and Thermo collective sockets should not have direct contact with the mold.
It must be ensured an adequate connection of the Hot Runner System to earth.
- The operator shall ensure that, before system startup, it must be earthed or protected by equivalent security
measures. In case of mains connection in different systems, or system components of normal operation
specified, must be ensured proper grounding or other security measures equivalent to each component.
ATTENTION : Normally, the system is designed for a 2000 bar injection pressure

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2. S YSTEM R ECEPTION
Recommendations
Make sure that the box is received in good condition.
Open box carefully, regard to its position so that parts do not fall with its opening.
Make sure the box content corresponds to the document accompanying the load (packing list).
Visually inspect the system and its components. Check if it is damaged or defective, visually detectable.
If you detect any anomaly relating to previous sections, report immediately to YUDO

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3. S YSTEM I NSTALLATION AND D ISASSEMBLY
Preliminary considerations
The procedures described below are essential for proper operation and use of the system.
All assembly and disassembly processes that are not detailed described, should be performed with
appropriate tool and with enough and proper strength.
In case of any doubt contact YUDO.
YUDO does not assume responsibility for problems that may occur due to non-observance of these
standards.
3.1. P REPARATION
Previously to system installation in the mold is required that the mold housing for the system is prepared. It is
particularly important:
3.1.1. Housings dimensions are in the correct measures, within the tolerances and finishing established by the
project;
3.1.2. It is clean, chipless and without moisture, oils or other;
3.1.3. That all edges are disguised with rays or chamfers. Sharp edges are a real danger to the system,
3.1.4. The area of the front seal should be ground to fit (not be eroded);
3.1.5. If the material of the clamping plate has a strength of < 1000N/mm2, the contact points on which the
pressure pads of the manifold and the nozzle heads rest, have to be reinforced with sufficient strength;
3.1.6. The radius of the sprue bush (RA) has to be adapted to the radius of the machine nozzle (RM). (RA >
RM + 1);
3.1.7. After measuring the heights of all Hot Runner components, calculate the height of the frame plate
according to the determined air-gap measure.
3.1.8. If sealing rings between nozzles and manifold are used they must be exchanged every time after having
dismantled the Hot Runner system.
3.2. S YSTEM H ANDLING FOR I NSTALLATION
Injection systems have different handling ways depending on the type of construction.
YUDO offers 4 types of system construction:
A - Single Nozzle
Single Nozzle Open
Single Nozzle Valve SAS
Single Nozzle Valve TSV

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B - Basic HR System
The system is provided with the major components, manifold, nozzles, cylinders, etc., separately.
The specific composition of each system is in accordance with the project drawing approved by the client.
C - Pre Wired (PW) Eco Modu System
The system comes pre-assembled (prewired), with rails, plugs, connections and raccords.
The specific composition of each system is in accordance with the project drawing approved by the client.
D - Hot Half Modu System
This integrated system is provided in the dimensions of the mold plates. In these cases the injection
system is provided already assembled inside the plates which form the mold structure in the same fixed
part. It does not include cavity plates or any other mold structure.

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In any case the system has sensitive components which require extra care:
- Electrical components - resistances, thermocouples, electrical coils
- Tips and torpedoes with high thermal conductivity, but low mechanical strength.
- Seals and gaskets susceptible to blows, cuts, or crushing.
Identify the type of construction applicable to your system. For each type of construction there are specific
instructions,
Module A - Single Nozzle Type
Module B – Basic HR System Type
Module C1 – Pre Wired (PW) Eco Modu – Sliding Nozzles Type
Module C2 – Pre Wired (PW) Eco Modu – Threaded Nozzles Type
Module D – Hot Half Modu System Type

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3.3. I NSTALLATION AND D ISASSEMBLY I NSTRUCTIONS
M ODULE A - S INGLE N OZZLE T YPE
GPS Open Nozzle
SAS Valve Nozzle
TSV Valve Nozzle
Installation
1. Make the dimensional housing verification with special care for the tight tolerance fitting zones and system
seating dimensions according to the CAD file information. In case of doubt or unclear information contact
YUDO.
2. Make sure the housing is in proper condition to receive the hot runner and correct position to proceed with
assembling without risks for people and equipment.
3. Place the nozzle into its housing. If there are sliding bushes they must be placed in its position in the mold
before the nozzle. Attention to the position pegs, when applicable.
4. Move aside of dangerous areas all electrical cables to avoid crushing them.
5. After positioning the electrical cables check if they are all in good condition.
6. Identify properly and clearly all the wires for proper identification at any time.
7. Follow the system electrical areas numbering according to the design, also visible on the ID Card.
8. Assemble the centering ring. Tighten in a balanced way. The centering ring has to adjust the system as
shown in the draft of the injection system. Be careful not to pinch the wires.
9. Connect the wires taking into account:
- Wires should have only sufficient and required length that allows easy opening of the electrical box cover
and checking connections.
- Wires should consider connecting terminals appropriate to your connection plug. The non-use or partial use
of terminals can lead to system malfunction.
- Wires cannot be added without YUDO technical opinion.
- Plugs and their electrical box must be placed in order to be protected from stroke or other accidents that may
damage the set.
- The plugs must always be placed in appropriate boxes. The use of inappropriate boxes are the cause of
many failures and system malfunctions and its injection.
10. After finishing the assembly, check if there is no undue electrical current passage and if continuity is doing
in the right poles.
11. Normally thermocouples give electrical current passage to the mold, but not resistances.
12. Check the heating system: Heat the system at 150 ° C, stabilize the temperature of all electrical heating
zones and keep heating for 10 minutes.
- Always use soft start (slow heating) up to the temperature of 100 ° C.
13. Check the correct Valve Pins movement by activating the respective cylinders (Only for valve gate
systems).For air or oil supply for piston operation, heat resistant pipes shall be mounted, resisting up to
180ºC. Consider piping specifications according to maximum operating pressure either pneumatic or
hydraulic. Consider safety factor to avoid rupture problems.
14. Let the system cool down.
15. Keep the system in a place free of moisture, metal chips or under possible physical shocks. Other care
considered suitable will be important to keep the system in good working order.
If any system anomaly is detected, it should be reported to YUDO.

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Disassembly
1. Ensure that the system is at a temperature below 50 ° C.
2. Remove the clamping plate of the mold (plate 1), and the insulation plate when applicable.
3. Find the eyebolts placement points in the manifold (points of eyebolts that offer more resistance). Put in two
of these points which are spaced apart (when applicable).
4. Lift the system until it back off 50 mm.
5. If the system is balanced continue until it is completely out of the mold.
6. If the system is unbalanced, change the position of eyebolts to balance. After the system has already back
off of the housing 50 mm, already can use points of eyebolts off the manifold.
7. Place the system slowly on suitable surface. Take into account that the system has many hot spots that can
be easily damaged. It is recommended that this is placed upon easels seating only the manifold.
Any anomaly detected in the system must be reported to YUDO.