Hot Runner System Instruction Manual
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1 Hot Runner System Instruction Manual Rev / 2011 RK
2 Introduction Dear Customers, Thank you for purchasing a Synventive Hot Runner System. Our objective is to provide you with a product that is a good fit for the application, trouble free in performance, and support it with the best service in the industry. If problems occur during the use of this product please contact us at one of the locations provided. This manual is designed as a reference only document for the proper installation, operation and maintenance of Synventive Hot Runner Systems as well as a guideline for securing occupational health and safety in connection with the use of this system. Synventive does not warrant that the information is complete or accurate for every application. Synventive reserves the right to make changes to this document from time to time as new products are developed and new information identified. This manual contains essential information, to ensure its general applicability to Synventive Hot Runner Systems. The customer is exclusively responsible for the protection of their equipment and personnel. Synventive is not liable for any personal injury or damage caused by improper use, installation or handling of the product. This product should only be installed and used by fully trained and qualified personnel. The customer is required to provide the necessary personal protective equipment, such as protective gloves, hearing protection, protective shields etc. In no case does this document provided by Synventive release the customer from its obligations. This manual is intended for tooling and molding personnel who install and maintain the hot runner system. It should be forwarded with the hot runner system when shipped from the tool maker to the molder or between molding locations. This document is copyright protected and it is intended exclusively for the users of Synventive Hot Runner Systems. It may not be copied and distributed without the written consent of Synventive Molding Solutions. Yours faithfully, Synventive Molding Solutions Sales agencies: USA Peabody, MA Synventive Molding Solutions 10 Centennial Drive Peabody, MA Tel.: Tel.: Fax: info@synventive.com Germany Bensheim Synventive Molding Solutions GmbH Heimrodstraße 10 P. O. Box Bensheim Tel. :+49 (0) Fax :+49 (0) infohrde@synventive.com China Suzhou Synventive Molding Solutions (Suzhou) Co. Ltd. 12B Gang Tian Industrial Square Suzhou Industrial Park, China Tel.: Fax: infohrcn@synventive.com Copyright 2011 Synventive Molding Solutions. Current version at All rights reserved
3 Table of Contents 1 Safety Instructions CE approved Equipment Purpose of use of a Hot Runner System Use compatible with the intended Purpose Use in conflict with the intended Purpose Definition of Qualified Persons with Technical Knowledge Safety Instructions within the Instruction Manual The HR System Instruction Manual / Part of the Synventive Customer Documentation Safety Instructions and Symbols used Symbols of Danger Categorisation Mandatory Safety Signs of the Personal Protective Equipment Warning Symbols Prohibited Symbols General Safety Instructions Product Description Nozzle Types API heating APT heating Sprue Bushing / Single Nozzle Support Ring / Face fit Nozzles Threaded / Screw fit Nozzles Hot Half Preparation for Incorporation Unpacking the Hot Runner System Cleaning Hot Runners and Cut - Out List of necessary Tools Installation of the Hot Runner System General Instructions for Installation Requirements on the Injection Mold Requirements on Temperature Control Table - Expansion Gap (Joint Z) Current version at All rights reserved
4 4.3 Installation of HR Systems with Support Ring / Face fit Nozzles (API) Support Ring / Face fit Nozzle Installation Center Support and Support Pillar Adjustment Mounting of the Positioning Dowel Check of Manifold Top Thrust Pad Adjustment and Expansion Gap (joint Z) Adjustment Final Assembly of the Hot Runner System and the Mold Plate For non pre-wired Systems Installation of HR systems with Support Ring / Face fit Nozzles (APT) Support Ring / Face fit Nozzle Installation For non pre-wired Systems Installation of HR Systems with Threaded / Screw fit Nozzles (API) Preparation for System Installation Nozzle Tip Adjustment For non pre-wired Systems Installation of PLUG N PLAY (VB/06E) HR Systems with Threaded / Screw fit Nozzles Preparation for System Installation System Installation Nozzle Tip Adjustment For non pre-wired Systems Installation of HR Systems with Threaded / Screw fit Nozzles (APT) Preparation for System Installation Nozzle Tip Adjustment For non pre-wired Systems Start-up of the Hot Runner System Preparation for Start up Power Supply Connection Grounding Check Verification of Heater Grounding Information on Heater Connection Hot Runner System Start-up Color Change Color Change of direct contact Nozzles (plunged through-nozzles)...88 Current version at All rights reserved
5 5.4.2 Color change of Nozzles with pre-chamber isolation without removeable cavity plate Color change of Nozzles with pre-chamber isolation and replaceable cavity plate Hot Runner System Switch-off Storage of Hot Runner System during Shutdowns Defect Identification and Troubleshooting Defects Table Service and Maintenance Maintenance of Valve Gate Systems Checklist for Valve Gate System Maintenance Cleaning out the Hot Runner System Actuators Service of the Actuator HYC2508M02/M Technical Data HYC2508M02/M Exploded View HYC2508M02/M Tools for Assembling and Disassembling the Actuator Cut-out information HYC2508M02/M03 without SynCool SynCool 1 - Option SynCool 2 - Option Disassembling the Actuator HYC2508M02/M Assembling the Actuator HYC2508M02 / M Service of the Actuator HYC4018M03/M04/M Technical Data HYC4018M03/M04/M Exploded View HYC4018M03/M04/M Tools for Assembling and Disassembling the Actuator Cut-out Information HYC4018M03/M04/M05 without SynCool SynCool 1 - Option SynCool 2 - Option Disassembling the Actuator HYC4018M03/M04/M Assembling the Actuator HYC4018M03/M04/M Service of the Actuator QCVG Technical Data QCVG Exploded View QCVG Disassembling the Actuator QCVG Current version at All rights reserved
6 8.3.4 Assembling the Actuator QCVG Service of the Actuator PNC3008B Technical Data PNC3008B Exploded View PNC3008B Cut-out information PNC3008B Tools for Assembling, Disassembling and Adjusting the Actuator Disassembling Actuator PNC3008B Assembling the Actuator PNC3008B Service of the Actuator PNC5018M Technical Data PNC5018M Technical Data Micro Switch PS-MS-O Position Control Display Module PC-DM Exploded View PNC5018M Tools for Assembling and Disassembling the Actuator Cut-out information PNC5018M Disassembling the Actuator PNC5018M Assembling the Actuator PNC5018M Service of the Actuator PNC6018M Technical Data PNC6018M Technical Data Micro Switch PS-MS-O Position Control Display Module PC-DM Exploded View PNC6018M Tools for Assembling and Disassembling the Actuator Cut-out information PNC6018M Disassembling the Actuator PNC6018M Assembling the Actuator PNC6018M Service of the Actuator PNC6018M Technical Data PNC6018M Exploded View PNC6018M Tools for Assembling and Disassembling the Actuator Cut-out information PNC6018M Disassembling the Actuator PNC6018M Assembling the Actuator PNC6018M Service of the Actuator PNC7518M Current version at All rights reserved
7 8.8.1 Technical Data PNC7518M Exploded View PNC7518M Tools for Assembling and Disassembling the Actuator Cut-out Information PNC7518M Disassembling the Actuator PNC7518M Assembling the Actuator PNC7518M Service of the Actuator PNC7518M Technical Data PNC7518M Exploded View PNC7518M Tools for Assembling and Disassembling the Actuator Cut-out Information PNC7518M Disassembling the Actuator PNC7518M Assembling the Actuator PNC7518M Service of the Actuator PNC4508M Technical Data PNC4508M Exploded View PNC4508M Tools for Assembling and Disassembling the Actuator Cut-out PNC4508M Disassembling the Actuator PNC4508M Assembling the Actuator PNC4508M Service of the Actuator VP4008P Series Technical Data VP4008P Series Explosion view of the VP4008P Series Cut-out Information VP4008P Series Basic Dimensions in Mold First mounting of Actuator VP4008P Dismounting the Actuator VP4008P Service of the Actuator VP8016P Series Technical Data VP8016P Series Explosion view of the VP8016P Series Cut-out Information VP8016P Series Basic Dimensions in Mold First mounting of Actuator VP8016P Dismounting the Actuator VP8016P Current version at All rights reserved
8 8.13 Service of the Actuator PNC4508B Technical Data PNC4508B Exploded View PNC4508B Cut-out information PNC4508B Tools for Assembling, Disassembling and Adjusting the Actuator Disassembling Actuator PNC4508B Assembling the Actuator PNC4508B Service of the Actuator PNC6018B Technical Data PNC6018B Exploded View PNC6018B Cut-out information PNC6018B Tools for Assembling, Disassembling and Adjusting the Actuator Disassembling Actuator PNC6018B Assembling the Actuator PNC6018B Service of the Actuator HYC4520M Technical Data HYC4520M Exploded View HYC4520M Tools for Assembling and Disassembling the Actuator Cut-out information HYC4520M Disassembling the Actuator HYC4520M Disassembling the Adjustment Screw Assembly and Piston Assembling the Actuator HYC4520M Service of the Actuator ELA5708P Technical Data ELA5708P ELA5708P Components Cut-out Information ELA5708P Dismounting the Actuator ELA5708P Mounting the Actuator ELA5708P Service of the Actuator ELA8708P Technical Data ELA8708P ELA8708P Components Cut-out Information ELA8708P Dismounting the Actuator ELA8708P Mounting the Actuator ELA8708P Current version at All rights reserved
9 9 Valve Pins Valve Pin Dismantling Valve Pin Height Adjustment HYC2508 / HYC4018 Series Height Adjustment of Cylindrical shut-off Valve Pin Height Adjustment of Conical shut-off Valve Pin Valve Pin Height Adjustment QCVG Actuator Height Adjustment of shut-off Valve Gate Pins with QCVG Actuator Valve Pin Height Adjustment PNC3008B Valve Pin Adjustment Tool kit Adjustment at mounted Hot Runner System Valve Pin Height Adjustment PNC5018M / PNC6018M Series Height Adjustment of Cylindrical shut-off Valve Pin Height Adjustment of Conical shut-off Valve Pin Valve Pin Height Adjustment PNC7518 Series Height Adjustment of Cylindrical shut-off Valve Pin Height Adjustment of Conical shut-off Valve Pin Valve Pin Height Adjustment PNC4508M Series Height Adjustment of Cylindrical shut-off Valve Pin Height Adjustment of Conical shut-off Valve Pin Valve Pin Height Adjustment VP4008P Series Thermal Expansion Calculation Height Adjustment of Cylindrical shut-off Valve pin Height Adjustment of Conical shut-off Valve pin Valve Pin Height Adjustment VP8016P Series Thermal Expansion Calculation Height Adjustment of Cylindrical shut-off Valve pin Height Adjustment of Conical shut-off Valve pin Valve Pin Height Adjustment PNC4508B / PNC6018B Valve Pin Adjustment Tool Kit Adjustment at mounted Hot Runner System Valve Pin Height Adjustment HYC4520M Height Adjustment of Cylindrical shut-off Valve Pin Current version at All rights reserved
10 Height Adjustment of Conical shut-off Valve Pin Nozzles Nozzles (API) Nozzle under the manifold and Accessories for single Nozzles, example of CBFT nozzle Dismantling a single Nozzle and Nozzles under the manifold from injection mold Dismantling single Nozzles from Injection Mold Assembling the single Nozzle Nozzles 06E Series (API) Disassembly Nozzle 06E Assembling Nozzle 06 E Nozzles (APT) Replacing Nozzle Tips, Inserts and Nozzle Tip Seals (APT) Installing Nozzle Tips, Inserts and Nozzle Tip Seals (APT) Sprue Bushing / Single Nozzle 16S01_V Technical Data - Sprue Bushing / Single Nozzle 16S01_V Technical Data - Cooling Unit CU16SVH Mold Cut-out Single Nozzle 16S01_V / Actuator HYC2314S01 Parts List Dismounting the Cylinder Housing HYC2314S01 and the Seal Kit Assembly of the Cylinder Housing HYC2314S01 on the Nozzle Dismounting and Mounting of the Thermocouple Valve Pin Height Adjustment Disassembling the Sprue Bushing / Single Nozzle out of the Mold Sprue Bushing / Single Nozzle GBN...S Technical Data - Sprue Bushing / Single Nozzle GBN...S Technical Data - Cooling Unit CU16SVP Mold Cut-out Single Nozzle GBN... S01 Parts List Dismounting the Pneumatic Cylinder Housing and Sealing Assembly of the Pneumatic Cylinder Housing on the Nozzle Dismounting and Mounting of the Thermocouple Valve Pin Height Adjustment Disassembling the Sprue Bushing / Single Nozzle out of the Mold Current version at All rights reserved
11 10.6 Nozzles 09E Series (API) Disassembly Nozzle 09E Assembling Nozzle 09 E Nozzle Cooling with Cooling Insert / Bushing General Product Description - Cooling Insert / Bushing Outgate Cooling Distance Tube Assembly View 16E Cooling Bushing Assembly View 16E Cooling Insert Dismounting and Mounting Manifold Plugs Dismounting Manifold Plugs (APT) Cleaning the Flow Bores Mounting Manifold Plugs (APT) Shutdown Returning the Hot Runner System Disposal Annex Units used Torques Additional rules for using Screws pursuant to DIN 912 / ISO 4762 Screws Tool Specifications Instructions on Torques for Synventive parts under SPI Glossary and List of Abbreviations EC Declaration of Conformity Patents Global Offices Current version at All rights reserved
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