10.12 Sprue Bushing 12S Series

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Following work must be carried out by qualified and experienced persons. Use personal protective equipment: Face protection, hearing protection and gloves.

1 10.12 Sprue Bushing 12S Series lways tighten the screws to the torque specified in the respective table in section 13. Hazard of ressurized ir ressurized air blow can result in hot plastic or foreign bodies entering the eyes, causing vision damage. Following work must be carried out by qualified and experienced persons. Use personal protective equipment: Face protection, hearing protection and gloves. Hazard of Material Damage Without consulting Synventive it is not permitted to do modifications to the hot runner system e.g. geometrical changes to the nozzle tip, except the part shape adjustment in the area of material allowance echnical Data - Sprue Bushing 12S Sprue Bushing 12S Flow Bore (J) Nozzle Length (L) Nozzle ut-out (D) hermocouple Nozzle ips Ø 12 mm mm Ø 35 mm ype J, ype K F,, W Doc tif Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

2 Locations of the Sprue Bushing 12S arts In this section the nozzle parts are identified with the numbers indicated in the following figure. lways tighten the screws to the torque specified in the respective table in section 13. os. art No. Description E###-NB-04- MOD Nozzle body HJ-024-###-01 Nozzle heater N-R-01 Nozzle component ring version=1 (Heater locating ring) N-R-02 Nozzle component ring version=2 (Heater locating ring) 1.5 DIN471-22X1.2 DIN DIN914-M3X3-45H Socket set screw DIN914-M3x3-45-H N_#### Nozzle tip (Example W) N_##-03 ip nut Full flow insert orpedo SHB ### Nozzle Head 3 H Nozzle Head Heating 4.1 X hermocouple ype J 4.1 X hermocouple ype K 5 DIN6325-3M6X8 arallel in DIN m6x08 Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

numbers indicated in the following figure. 3.1 Nozzle ip ssembly ool os. art No.

2 Heater Disassembly ool ompl. 12E-0101 os. art No. Description 1.

2 12E-010102 Heater Disassembly ool 12E ype 02 1.

3 ssembly ools In this section the Stripping and Mounting ool parts are identified with the numbers indicated in the following figure Nozzle ip ssembly ool os. art No. Description 1 12S-01 Nut 2 06S-02 Holder Doc png Doc png Heater Disassembly ool ompl. 12E-0101 os. art No. Description E Heater Disassembly ool 12E ype E Heater Disassembly ool 12E ype E Heater Disassembly ool 12E ype 03 Doc png Nozzle Disassembly ool os. art No. Description 3 12S-01 Nut 4 06S-02 Holder Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

10.12.4 Nozzle hermocouple 10.12.4.1 Dismounting Nozzle hermocouple For dismounting of the thermocouple the nozzle heater must be dismantled from the nozzle.

4 Nozzle hermocouple Dismounting Nozzle hermocouple For dismounting of the thermocouple the nozzle heater must be dismantled from the nozzle. 1) Lever the clamp of the nozzle heater with a screwdriver and pull the thermocouple (x) from its seat. 2) ull the top of the thermocouple (x) from the bracket of the nozzle heater (1.2.1). he thermocouple is pressed in. Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

10.12.4.2 Mounting Nozzle hermocouple OIE For assembly of the thermocouple the nozzle heater must be dismantled from the nozzle.

5 Mounting Nozzle hermocouple OIE For assembly of the thermocouple the nozzle heater must be dismantled from the nozzle. olor oding of hermocouples ake notice of the production and color identification of thermocouple cables. Synventive uses J and K type thermocouples. heir color coding is given in the following table. able 1: International color coding for temperature sensors ype International standard IE Black J Green K + Black - White + Green - White oating Litz wire + Litz wire - Doc png 2) Lever the clamp of the nozzle heater with a screwdriver and fix the thermocouple (x) below the clamp at the nozzle heater. 1) ush the thermocouple (x) under the bracket of the nozzle heater (1.2.1). he fixing is needed to secure the position. thermocouple (well-fixed in the holder) causes correct measured values. Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

in a vice via using the tool holder (4). It is not allowed to clamp the nozzle in a vice directly. 5.

png 2) ull the nozzle head heater (3) from the nozzle head (2.1) Doc005476.png 3) ull the thermocouple (4.

6 Disassembly Nozzle 12S For work on the nozzle (with assembled nozzle head), the nozzle must be clamped in a vice via using the tool holder (4). It is not allowed to clamp the nozzle in a vice directly Disassembling Nozzle Head Heater 1) Loosen the screws Head heater (3) clamp band. Doc png 2) ull the nozzle head heater (3) from the nozzle head (2.1) Doc png 3) ull the thermocouple (4.1) out of the nozzle head (2.1) Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

10.12.5.2 Disassembling the Nozzle Heater 1) Dismount the head heater (3) from the nozzle head (2.1),as described in the above section 10.12.6.1. 2) Remove the retaining ring (1.

png 4) Unscrew and remove the socket set screw (1.6) from the nozzle heater locating ring (1.4). Doc005479.

It is not allowed to clamp the nozzle in a vice directly. 5) lace the nozzle with the head (2.1) in the holder (4).

7 Disassembling the Nozzle Heater 1) Dismount the head heater (3) from the nozzle head (2.1),as described in the above section ) Remove the retaining ring (1.5) from the nozzle tip (1.7.1). 3) Remove the nozzle component ring version (1.3) - Heater locating ring. Doc png 4) Unscrew and remove the socket set screw (1.6) from the nozzle heater locating ring (1.4). Doc png For work on the nozzle (with assembled nozzle head), the nozzle must be clamped in a vice via using the tool holder (4). It is not allowed to clamp the nozzle in a vice directly. 5) lace the nozzle with the head (2.1) in the holder (4). 6) Mount a retaining ring DIN471 with the part number M1800H35 (x) below the holder (4) in the gap of the nozzle head. Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

For work on the nozzle (with assembled nozzle head), the nozzle must be clamped in a vice via using the tool holder (4).

8) Mount the heater disassembly tool ype 01 (1.1). he lower edge of the heater removal tool type 01 (1.

2) along the disassembly tool ype 03 (1.3). Doc005482.png 10) Screw disassembly tool ype 03 (1.

8 For work on the nozzle (with assembled nozzle head), the nozzle must be clamped in a vice via using the tool holder (4). It is not allowed to clamp the nozzle in a vice directly. 7) Fix the holder (4) in a vice. 8) Mount the heater disassembly tool ype 01 (1.1). he lower edge of the heater removal tool type 01 (1.1) must be set below the nozzle heater (1.2.1). Doc png 9) Slide disassembly tool ype 02 (1.2) along the disassembly tool ype 03 (1.3). Doc png 10) Screw disassembly tool ype 03 (1.3) onto disassembly tool ype 01 (1.1). Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

11) o remove the nozzle heater (1.2.1), slide the disassembly tool ype 02 (1.2) against the disassembly tool ype 03 (1.3) repeatedly until the nozzle heater (1.2.1) is released.

vision damage. Following work must be carried out by qualified and experienced persons.

9 11) o remove the nozzle heater (1.2.1), slide the disassembly tool ype 02 (1.2) against the disassembly tool ype 03 (1.3) repeatedly until the nozzle heater (1.2.1) is released. Doc png Disassembling the Nozzle and the Nozzle ip Hazard of ressurized ir ressurized air blow can result in hot plastic or foreign bodies entering the eyes, causing vision damage. Following work must be carried out by qualified and experienced persons. Use personal protective equipment: Face protection, hearing protection and gloves. 1) Dismount the nozzle head heater (3) from the nozzle head (2.1), as described in the above section ) Dismount the nozzle heater (1.2.1) from the nozzle (1.1), as described in the above section ) Fix the holder (4) in a vice. Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

For work on the nozzle (with assembled nozzle head), the nozzle must be clamped in a vice via using the tool holder (4). It is not allowed to clamp the nozzle in a vice directly.

6) Use a wrench to loosen the nozzle (1.1) from the nozzle head (2.1) via the tool nut (3) by rotation (counter clockwise). Doc005487.

10 For work on the nozzle (with assembled nozzle head), the nozzle must be clamped in a vice via using the tool holder (4). It is not allowed to clamp the nozzle in a vice directly. 4) lace the nozzle (1.1) with the head side in the holder (4) to fix the nozzle against rotation. Doc png 5) lace the tool nut (3) over the nozzle body (1.1) at the hexagonal shape. 6) Use a wrench to loosen the nozzle (1.1) from the nozzle head (2.1) via the tool nut (3) by rotation (counter clockwise). Doc png Hot Surfaces Hazard and Hot Surfaces Following work must be carried out by qualified and experienced persons. Use personal protective equipment: Face protection, hearing protection and gloves. 7) Fix the dismounted nozzle body (1.1) on the hexagonal shape in a vise. Hot Surfaces Hazard ontact between the skin and the hot nozzle could result in burns. Never use an acetylene or welding torch, as severe nozzle damage can occur from over-heating. 8) o remove cold plastic in melt consistence, heat the nozzle tip (1.7.1) by using a heat gun, to the maximum temperature of 200 (392 F). Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

9) Unscrew the nozzle tip (1.7.1) from the nozzle body (1.1) using a ring wrench. Doc004723-5489.

11 9) Unscrew the nozzle tip (1.7.1) from the nozzle body (1.1) using a ring wrench. Doc png Hazard of ressurized ir ressurized air blow can result in hot plastic parts or foreign bodies entering the eyes, causing vision damage. 10) lean the nozzle (through nozzle head) using pressurized air to remove as much residual plastic as possible. Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

10.12.6 ssembling Nozzle 12S For work on the nozzle (with assembled nozzle head), the nozzle must be clamped in a vice via using the tool holder (2).

12 ssembling Nozzle 12S For work on the nozzle (with assembled nozzle head), the nozzle must be clamped in a vice via using the tool holder (2). It is not allowed to clamp the nozzle in a vice directly. os. art No. Description E###-NB-04- MOD Nozzle Body HJ-024-###-01 Nozzle heater N-R-01 Nozzle component ring version=1 (Heater locating ring) N-R-02 Nozzle component ring version=2 (Heater locating ring) 1.5 DIN471-22X1.2 DIN DIN914-M3X3-45H Socket Set Screw DIN914-M3x3-45-H N_#### Nozzle ip (Example W) N_##-03 ip nut Full flow insert orpedo SHB ### Nozzle Head 1 3 H Nozzle Head Heating 4.1 X hermocouple ype J 4.1 X hermocouple ype K 5 DIN6325-3M6X8 arallel in DIN m6x08 Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

10.12.6.1 ssembling the Nozzle ip 1) 2) 3) 4) W Nozzle ip ssembly 1) lace the tip nut (a) into the tool (2). 2) Using the tool (1) to push the tip insert (b) into the tip nut (a).

png 1) 2) 3) 4) Nozzle ip ssembly 1) lace the tip nut (a) on the tool (2). 2) Using the tool (1) to push the tip insert (b) into the tip nut (a). 3) lace the torpedo (c) on the tip insert (b).

13 ssembling the Nozzle ip 1) 2) 3) 4) W Nozzle ip ssembly 1) lace the tip nut (a) into the tool (2). 2) Using the tool (1) to push the tip insert (b) into the tip nut (a). 3) lace the torpedo (c) on the tip insert (b). 4) Using the tool (1) to push the torpedo (c) and the tip insert (b) into the tip nut (a). Doc png 1) 2) 3) 4) Nozzle ip ssembly 1) lace the tip nut (a) on the tool (2). 2) Using the tool (1) to push the tip insert (b) into the tip nut (a). 3) lace the torpedo (c) on the tip insert (b). 4) Using the tool (1) to push the torpedo (c) and the tip insert (b) into the tip nut (a). Doc png 1) 2) F Nozzle ip ssembly Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

png good good good incorrect Doc004688.png See examples of good and incorrect insert installations.

Incorrect items should not be further processed. 10.12.6.

14 1) lace the tip nut on the tool (2). 2) Using the tool (1) to push the tip insert (b) into the tip nut (a). Doc png good good good incorrect Doc png See examples of good and incorrect insert installations. Make sure the insert must not exceeds the height of the nozzle tip head. Incorrect items should not be further processed ssembling the Nozzle ip on the Nozzle 1) Fix the nozzle body on the hexagonal shape in a vice. Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

2) pply spotting ink on the nozzle tip (1.7.1) bottom surface (SF1). 3) Screw in the nozzle tip (1.7.1) hand-tight into the nozzle body (1.1) until seated. 4) Unscrew the nozzle tip (1.7.1) from the nozzle body (1.

he nozzle must bear uniformly on the outer surfaces uniformly and flatly, in particular on the nozzle body contact face. In case of any uncertainty, clean the surfaces with a cleaning cloth.

Doc005522.png 7) Lubricate the thread (not the face) of the nozzle tip body with hightemperature assembly paste (antiseize compound).

15 2) pply spotting ink on the nozzle tip (1.7.1) bottom surface (SF1). 3) Screw in the nozzle tip (1.7.1) hand-tight into the nozzle body (1.1) until seated. 4) Unscrew the nozzle tip (1.7.1) from the nozzle body (1.1). Doc png 5) heck the matching between the nozzle body (1.1) surface (SF2) and the nozzle tip (1.7.1) surface (SF1). he nozzle must bear uniformly on the outer surfaces uniformly and flatly, in particular on the nozzle body contact face. In case of any uncertainty, clean the surfaces with a cleaning cloth. If the next ink test is still unsatisfactory - please contact Synventive ustomer Service or echnical Support. 6) With a positive ink test clean the surfaces and proceed to the next step. Doc png 7) Lubricate the thread (not the face) of the nozzle tip body with hightemperature assembly paste (antiseize compound). his is an important measure to prevent thread corrosion due to aggressive gases, which could be released during plastics processing. Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

8) ighten the nozzle tip (1.7.1) at the nozzle by room temperature. Use torque wrench with wrench insert (HEX21) and a torque of 100 Nm. Doc005489.png 10.12.6.

It is not allowed to clamp the nozzle in a vice directly. 1) Fix the holder (4) in a vice. Doc005485.tif 2) lace the nozzle head (2.1) in the holder (4).

16 8) ighten the nozzle tip (1.7.1) at the nozzle by room temperature. Use torque wrench with wrench insert (HEX21) and a torque of 100 Nm. Doc png ssembling the Nozzle Body For work on the nozzle (with assembled nozzle head), the nozzle must be clamped in a vice via using the tool holder (4). It is not allowed to clamp the nozzle in a vice directly. 1) Fix the holder (4) in a vice. Doc tif 2) lace the nozzle head (2.1) in the holder (4). Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

3) pply spotting ink on the nozzle body (1.1) bottom surface (SF1) Doc005524.png 4) Screw in the nozzle body (1.

png 6) heck the matching between the nozzle head (2.1) bottom surfaces (SF2) and the nozzle body (1.1) surface (SF1).

In case of any uncertainty, clean the surfaces with a cleaning cloth.

17 3) pply spotting ink on the nozzle body (1.1) bottom surface (SF1) Doc png 4) Screw in the nozzle body (1.1) hand-tight into the nozzle head thread until seated. 5) Unscrew the nozzle body (1.1) from the nozzle head (2.1). Doc png 6) heck the matching between the nozzle head (2.1) bottom surfaces (SF2) and the nozzle body (1.1) surface (SF1). he nozzle head must bear on all surfaces uniformly and flatly, in particular on the nozzle head contact face. In case of any uncertainty, clean the surfaces with a cleaning cloth. If the next ink test is still unsatisfactory, please - contact Synventive ustomer Service or echnical Support. 7) With a positive ink test, clean the surfaces and proceed to the next step. Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

8) Lubricate the thread (not the face) of the nozzle body with hightemperature assembly paste (antiseize compound).

png 9) ighten the nozzle body (1.1) to the nozzle head. Use torque wrench with wrench insert and the torque specified in the torque table in section 13. Doc005487.png 10.12.6.

2) lace the nozzle head heater (3) on the nozzle head (2.1). he nozzle head heater secures the thermocouple by covering it in the vertical groove.

18 8) Lubricate the thread (not the face) of the nozzle body with hightemperature assembly paste (antiseize compound). his is an important measure to prevent thread corrosion due to aggressive gases, which could be released during plastics processing. Doc png 9) ighten the nozzle body (1.1) to the nozzle head. Use torque wrench with wrench insert and the torque specified in the torque table in section 13. Doc png Mounting the Nozzle Head Heater 1) Install the thermocouple, ensuring it is seated correctly in the internal heater groove and nozzle head groove. 2) lace the nozzle head heater (3) on the nozzle head (2.1). he nozzle head heater secures the thermocouple by covering it in the vertical groove. he heating wire must exit through the central recess of the nozzle head. 3) ttach the head heater (4.1) with the socket set screw (x) Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

It is not allowed to clamp the nozzle in a vice directly. 1) Slide heater locating, ring (1.4), onto the nozzle body (1.

Doc005529.png 2) Bend the leads of the nozzle heater about 90 degrees. Use round-nosed pliers only. Doc005540.png 3) ush the nozzle heater (1.2.1) onto the nozzle (1.

19 Mounting the Nozzle Heater For work on the nozzle (with assembled nozzle head), the nozzle must be clamped in a vice via using the tool holder (2). It is not allowed to clamp the nozzle in a vice directly. 1) Slide heater locating, ring (1.4), onto the nozzle body (1.1) up to the surface of the hexagon. he opening of the heater locating ring (1.4), must be line up with the cable connections (see customer drawing). Doc png 2) Bend the leads of the nozzle heater about 90 degrees. Use round-nosed pliers only. Doc png 3) ush the nozzle heater (1.2.1) onto the nozzle (1.1). Ensure the orientation of the wire leads (y) matches opening in component ring (1.4) and nozzle head (2.1). Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

4) lace the pre centering ring version=1 (1.3) on the nozzle heater (1.2.1). he component ring (1.

1). Doc005531.png 6) Move the nozzle component ring (1.4) and nozzle heater (1.2.

6) by a ½ up to ¾ turn. Doc005533.png 8) Unit the heater and thermocouple (ex) leads. Doc005539.

20 4) lace the pre centering ring version=1 (1.3) on the nozzle heater (1.2.1). he component ring (1.3) is for pre centering of the nozzle in the cut-out. 5) Mount the retaining ring (1.5) at the nozzle tip (1.7.1). Doc png 6) Move the nozzle component ring (1.4) and nozzle heater (1.2.1) tight to the nozzle component ring (1.3). 7) Fix the nozzle component ring (1.4) with the socket set screw (1.6) by a ½ up to ¾ turn. Doc png 8) Unit the heater and thermocouple (ex) leads. Doc png Master Language is English Hot Runner System Instruction Manual SV _-Rev03 RESRIED: roperty of Synventive ll rights reserved. Errors and omissions excepted

10.6 Single Valve Gate Nozzle 16S01_V

Single Valve Gate Nozzle 16S01_V 10.6 Single Valve Gate Nozzle 16S01_V 10.6.1 echnical Data - Single Valve Gate Nozzle 16S01_V Doc003304.png Single Valve Gate Nozzle including ctuator HY2314S01 Valve pin