SINGLE VALVE III Instruction Manual YUDO SINGLE VALVE NOZZLE SERIES III V E R. N O. 0 2 0 9 M N S V E N O
Greetings Thank you for using YUDO Single Valve III System. YUDO fabricated Single Valve III System with its best efforts so that customers can use it most easily. However, there are many parts for customers to pay attention because it is a technical product. Please read this manual well and use it. YUDO reserves the right to change the provisions of these descriptions and specifications at any time without notification tocustomers. Please discuss with YUDO in advance when technical support is needed.
Contents. Structure of Single Valve III and Parts List ) Section View(SAS Type) 2) Section View (SLS Type) 3) Parts List 2. Features of Single Valve III ) Advantages and Operating Principles. 2) Operation 3. Application Design of Single Valve III ) General Arrangement Detail 2) Dimensions - Electrical Socket and Solenoid Valve 3) Schematic Layout Nozzle Machining Detail Nozzle Location Ring Options 4) Gate Machining Detail (VV, LVF Type) 4. Installation - Machanical ) Items to be checked prior to assembling to the mould 2) Assembling to the mould 3) Items to be checked after mould is assembled 5. Operation ) Installation 2) Precautions prior to start-up operation. 6. Maintenance ) Mould Storage 2) Disassembly and Assembly Instructions 3) Replacing the Nozzle Heater and Thermocouple 4) Replacing the Body Heater and thermocouple 7. Trouble Shooting Guide ) How to Disassemble & Assemble the Single Valve Nozzle. )-. How to replace Nozzle Heater or Nozzle Thermocouple )-2. How to replace Body Heater or Thermocouple 2) Troubleshooting - Electrical 2
. Construction of Single Valve III, Parts List ) Section View(SAS Type) ( Design Changes Incorporated Without Prior Notice ) Figure 3
2) SECTION View(Single Valve III Long Type) Locating Ring Extention Body Thermocouple -L Can be adjusted by request - Up to 300mm length : Heater and T/C - Over 300mm length : 2 Heater and 2 T/c Extention Body Extention Body Heater Top Cover Figure 2 4
3) Parts List ITEM DESCRIPTION SAS 22 Series SAS 32 Series SAS 42 Series Q' TY REMARK Top Cover Ø90*24 Ø05*24 Ø20*24 2 Body Heater HT3202 HT4202 HT5202 3 Body Ø42*56.5 Ø52*58.5 Ø62*60.5 4 Wear Ring B=2.4, T=.55 HOUSING 5 Viton Ring ARP 228 ARP 23 ARP 235 HOUSING 6 Piston Ø74.2*54 Ø84.2*56 Ø94.4*56 7 Runner Ring Ø8*2.3 Ø0*2.3 Ø3*2.3 2ea in case of two holes 8 Glyd Ring GS55044-0750-230 GS55044-0850-335 GS55044-0950-338 PISTON 9 Viton Ring ARP 23 ARP 235 ARP 238 PISTON 0 Viton Ring ARP 227 ARP 230 ARP 233 PISTON Viton Ring ARP 48 ARP 52 ARP 53 BOTTOM 2 Wear Ring B=2.4 T=.55 PISTON 3 Bottom Ø90*3 Ø05*34 Ø20*34 4 Lock Pin Ø6*5 2 5 Nozzle Heater Refer to table # 6 Nozzle Refer to table # 7 Valve Pin Refer to table # 8 Snap Ring S22 S32 S42 9 Locate Ring Ø50*42 Ø50*42 Ø65*42 Option Parts 20 Body T/C TP-IC-066 IC or CA 2 Bolt M4*8 M5*8 M6*8 4 22 Bolt M4*25 M6*25 M8*25 4 23 Housing Ø90*54 Ø05*56 Ø20*56 24 Bolt M4*2 M5*2 M6*2 4 25 Wire Lock 8.6*0*3T 26 Bolt FLAT HEAD CAP M4*5 27 Nozzle T/C Refer to table # 5
4) Single Valve III Model 6
<Table # > Nozzle Model L Heater T/C Valve Pin Q,ty REMARK SAS22 9 9 HT220443 TP 086 Ø4*86.48 SAS22 30 30 HT220553 TP 096 Ø4*97.45 SAS22 43 43 HT220683 TP 06 Ø4*2.45 SAS22 50 50 HT220753 TP 6 Ø4*9.40 SAS22 67 67 HT220923 TP 26 Ø4*36.35 SAS22 80 80 HT22053 TP 36 Ø4*49.32 SAS32 5 5 HT320653 TPV 6 Ø6*6.4 SAS32 62 SAS32 75 SAS32 82 SAS32 99 SAS32 22 SAS32 232 SAS32 252 SAS32 272 SAS32 292 62 75 82 99 22 232 252 272 292 HT320753 HT320893 HT320953 HT3233 HT32253 HT32453 HT32653 HT32853 HT322053 TP 26 TP 36 TP 46 TP 56 TP 66 TP 86 TP 206 TP 226 TP 246 Ø6*27.38 Ø6*40.34 Ø6*47.33 Ø6*64.28 Ø6*77.25 Ø6*97.9 Ø6*27.4 Ø6*237.09 Ø6*257.04. Nozzle protrusion based on V V Type length Indicated size + A = Total nozzle length 2. Valve Pin length depending on nozzle length. 3. Thermocouple type depending on nozzle SAS42 60 60 HT420683 TP 06 Ø0*22.39 length SAS42 70 70 HT420783 TP 6 Ø0*32.36 SAS42 85 85 HT420943 TP 36 Ø0*47.32 SAS42 209 209 HT4283 TP 56 Ø0*7.26 SAS42 220 220 HT42283 TP 66 Ø0*82.23 SAS42 233 233 HT42423 TP 86 Ø0*95.2 SAS42 250 250 HT42583 TP 96 Ø0*22.5 SAS42 270 270 HT42783 TP 26 Ø0*232. SAS42 290 290 HT42983 TP 236 Ø0*252.05 SAS42 30 30 HT42283 TP 256 Ø0*27.99 7
2. Features of Single Valve III ) Advantages ) In-Line Valve Pin and Cylinder Assembly Design provides a Fast, Smooth and Stabilised Operation of the Valve Pin movement. (Patent) 2) The In-Line design concept ensures Wear on the Contact Surfaces is minimised. 3) Elimination of Cams and Levers ensures that the Single Valve Nozzle can be Installed in a Small Space. 4) The Single Valve Nozzle - Series III is suitable for processing a wide range of General Purpose and Engineering Thermoplastics. Model SAS 22 SAS 32 SAS 42 Injection Quantity Up to 00 grm Up to 500 grm Up to 500 grm 2) Operation ) The Gate is Opened and Closed by applying air pressure to the Valve Piston (6) using a solenoid valve which is controlled by signals from the injection moulding machine. 2) Gate Open - before the Start of the injection process the Valve Piston (6) is operated to the open position, and is held open until the injection process has been completed. 3) Gate Close - after the completion of the injection process the Valve Piston (6) position is reversed to Close the Gate, by applying air pressure to the close side of the piston 4) The Air Pressure must be maintained in this reversed direction on the Valve Piston (6) to ensure that the gate is properly Closed, and held in this position until the next gate open signal is given by the injection moulding machine. 5) Air Pressure required to operate the Single Valve Nozzle must be a minimum of 6.0 bar. 6) Should the Air Pressure to operate the Single Valve Nozzle - Series III be below 6.0 bar an Air Booster is recommended to be used - refer to page 7 for details. 7) Additional lubrication is required for the Single Valve Nozzle - Series III if the Air Supply is generated 'Oil Free'. 8
3. Application design of Single Valve III ) LIST OF DRAWINGS. The drawings provided by YUDO illustrate the design features and specify the mould and installation requirements to ensure that the system is correctly installed into a mould. Therefore, it is essential that the mould is manufactured to the sizes specified and installed as illustrated by the drawings provided in this instruction manual. 9
)-. Application Design ELECTRICAL CONNECTOR AND SOLENOID VALVE DIMENSIONS 0
)-2. Application Design 2
- V (Standard type) F, F : Gate bush type - L2 indicates the size of the top plate for use with standard items. * Use the size of 'T' as reference when making Locate Ring. (See Paragraph 4--7) - V (Standard type) S, F S: Side touch Colour Change type F : Gate bush type - L2 indicates the size of the top plate for use with standard items. * Use the size of 'T' as reference when making Locate Ring. (See Paragraph 4--7) 2
- When the top plate is larger than the nozzle Adjust the thickness of the Locating Ring T and align with the top plate; or the top of the Locating Ring must be higher than the top surface of the mold top plate. The most important matter to prevent resin leakage is to ensure the section of the Locating Ring and the face of the nozzle are assembled in such a way that they make perfect contact with each other. The thickness of the Locating Ring T can be 8mm to 23mm as a maximum. To make products with greater thickness, use a nozzle larger by one step.. - When the top plate is smaller than the nozzle (L > L2) The minimum size of the Locating Ring should be same as that shown in Figures, and a hole must be drilled on the Locating Ring to connect the heater wire and the air line with pipe, as shown in <Fig. 2>. T 8mm MODEL Minimum Locating Ring Size SAS 22 Ø 50 SAS 32 Ø 60 SAS 42 Ø 80 Figure 2. 3
2) Single Valve III LAY-OUT 2 Zones Controller MODEL : VABT0 Air Booster If Air pressure is less than 6.0kg.f/cm 2
4. INSTALLATION-MACHANICAL Correct assembly of the SVIII to the mould directly affects the satisfactory operation of the system. Check and verify that the SVIII and the mould have been manufactured according to the sizes shown on the working drawing provided by YUDO. Should the SVIII be trialed with an incorrect assembly the system might be damaged. Pay particular attention on the sizes marked with asterisk (*) as they are important. Unless the indicated size tolerances are adhered to, serious problems may occur with respect to system operation. YUDO will not be held liable for incorrect installation or use of the equipment. ) Items to be checked prior to assembling to the mould ) Check that the sizes of the mould are as the drawing issued by Yudo. 2) Adhere to the accurate sizes indicated on the Yudo drawing, the fit of the Location Ring 3) to the Nozzle Body is important for providing the correct seal of the nozzle assembly. (See Paragraph 3)-) 3) Clean and prepare the location areas for accepting the SVIII nozzle prior to commencing. assembly. 4) Ensure that the securing bolts fit correctly in the hole locations. 5) Check the SVIII nozzle assembly and mould for any damage prior to assembling. 6) Exercise care not to damage the Heater or T/C wire when assembling the SVIII nozzle. 2) Assembling to the mould ) Install location pins. (Failure to install the location pins will cause the nozzle to turn and might cause damage to the Heater and Thermocouple. 2) Position the Valve Pin in the Open position using an air supply nozzle. (Always ensure when Installing or removing the SVIII from the mould, that the valve pin is in the open position to prevent damage to the valve pin or gate area). 3) Before assembling the nozzle to the mould, identify and mark the Nozzle Heater and T/C wires, and the Body Heater and T/C wires. (Once the Locate Ring is assembled, it is difficult to distinguish the nozzle wires and the body wires.) 4) Install the solenoid valve to the top clamping plate. (For installation details and position, refer to section 3.. and section 3..2 in the Application Design information.) 5) Use Ø0 mm steel pipe or Cu tube between the nozzle and the solenoid valve, and bend to fit the air line machined channel in the top clamping plate. (While Cu pipe is easily assembled, it is easily bent during the process of assembling or disassembling after a number of times, and sometimes the nuts may become loose causing air leakage. Check carefully when assembling or disassembling, and replace, if necessary.) 6) Assemble the nozzle to the mould. 7) Verify that the nozzle top cover face is higher than the mould top section by.+ tolerance indicated in the diagram opposite. This tolerance is extremely important, and unless it is adhered to, material leakage will result. 5
INSTALLATION (Continued). 8) Verify that the nozzle Locate Ring is firmly clamped in position and in contact with the nozzle face. The face (a) and the face (b) must be in contact with each other as the dimensions specified. The face(c) and the fact (d) must match with each other, or the face (c) must be.+ tolerance as specified compared with the face (d). If the tolerance is minus (-) material leakage might occur. Clamp M2*2 bolts carefully and evenly when assembling the Locate Ring. Ensure that the securing bolts are tightened in sequence. 9) Connect air lines to the respective connections on the SVIII nozzle. 0) Connect the Heater and T/C cables ensuring that Heater and T/C are formed into a single set. Check and verify that the + and? leads are correctly connected to the specific zone prior to operation. Connect wires in the correct order of sequence. nozzle heater power and T/C cables correctly paired, with the T/C (+) and (-) also in the correct sequence. The T/C polarity is distinguished as indicated in the table below. CA (K) IC (J) Item.+.- Covering color Striped red Striped blue Material quality Chromel Alumel Magnetism Non-magnetic Magnetic Covering color Striped red Striped yellow Material quality Iron Constantan Magnetism Magnetic Non-magnetic ) Always use connectors when wiring. YUDO s standard connectors use the HAN 6E specifications provided by Harting Co. 2) Installing air nipples Install PT /4 air nipples to the solenoid valve. 3) Items to be checked after mould is assembled. ) Verify if the Locate Ring surface is protruding higher than the clamping plate surface of the mould.(see No. 8 Assembling sequence) 2) Check and confirm the operating status of the valve pin prior to final mould assembly. 3) Poor operation of the valve after assembling indicates a problem in the alignment of the Nozzle assembly. 6
5. Operation ) Installation ) Mount the mould onto the machine, and connect accessories. (cooling lines, core cylinders, and others) 2) Connect the air line to the solenoid valve. (YUDO solenoid system is attached to the electrical connecting box.) 3) Connect the signal wire from the injection machine to the solenoid valve. (See 3-2 Layout drawing) 4) Connect the Controller s cable to the connecting box. (Ensure that the connection box is securely fastened to the mould). 5) A 2-zone Controller (or 3-zone, in the case of long nozzle) must be used. 6) Connect the Power Supply to the controller and turn on the main switch. Turn on the soft start switch of each unit one by one in sequence, and check temperature variation. 2) Precautions prior to start-up operation. ) Prior to and after mounting the mould to the machine, always check the heater and T/C for the correct connection, and any air leaks. 2) Manually operate the injection signal, and check the operating condition of the valve pin. 3) If no problems are discovered in all functions, start operating according to the following procedure. 4) Open the cooling lines to the mould, and check all functions of the mould and injection machine. In case the check takes a long period of time, change the controller temperature to the Preheat function. If the material used is heat sensitive, take extra precautions as the material may become carbonized. 5) If there is no problem in the operation of the mould and machine, set the nozzle temperature approximately 0 Deg C higher than the material processing temperature. Open the mould and inject or 2 shots. Checking the amount of material injected, and the operation of the pin. 6) Close the mould, and inject approximately 0 short-shots, to check the flow balance of the material.. 7) Commence the injection cycle after setting the temperature of the Single Valve Nozzle to the same temperature as recommended for the material being processed, 8) If it takes a long period of time to check the product, always lower the controller temperature to approximately 70% of the operating temperature to prevent carbonization of the material. 9) Start normal injection work. 0) If mass production is temporarily suspended, lower the nozzle temperature to a level which is approximately 70% below the operating temperature. ) In case carbonization occurs, stop the operation of the mould immediately, and purge the Single Valve Nozzle 3-4 times to remove the carbonized material. 7
6. Maintenance Maintenance is extremely important exercise with any piece of equipment. A regular maintenance programme will increase the operating life of the Single Valve Nozzle -. Series III, and also the life and performance of the mould. ) Upon completion of mass production, remove any materials or other foreign matter from the mould and the Single Valve Nozzle assembly. 2) Remove all water and oil, and spray anti-corrosive agent to prevent rust. 3) Store the mould in a well-ventilated place free of humidity. 4) If the mould is to be stored for a long period of time, take appropriate measures to prevent water from getting into the heater. Remove humidity from the system. 5) When production is started again, increase the Single Valve Nozzle temperature 0 C above the material processing or melting temperature, and check the operation of the valve pin manually. Operate machine in the same sequence as specified in Paragraph 5--6. 8
7. Trouble Shooting ) How to Disassemble & Assemble the Single Valve Nozzle. () Unfasten Bolts from Bottom 4-M6*2 Bolts (2) Unfasten Bolts from Top Cover 4-M6*8 Bolts (3) Remove Top Cover from Housing (4) Remove Heater from Body (5) Remove T/C from Body (6) Remove Housing from Piston Push down Body to seperate (7) Unfasten Bolts from Body SAS 22 SAS 32 SAS 42 4-M4*25 Bolts 4-M6*25 Bolts 4-M8*25 Bolts (8) Remove Body from Piston (9) Remove Piston and Valve Pin from Nozzle. (0) Remove Valve Pin from Piston () Runner Ring can be used only one time It should be replaced every time * Assembly is in reverse order 9
)- How to replace Body Heater or Thermocouple () Unfasten Bolt from Bottom -M4*5 Flat Headed Bolt (2) Remove Wire Lock from Bottom (3) Remove Snap Ring from Nozzle (4) Remove Nozzle Heater from Nozzle (5) Remove Thermocople from Nozzle Heater * Assembly is in reverse order 20
)-2 How to replace Body Heater or Thermocouple () Unfasten Bolts from Top Cover 4-M6*8 Bolts (2) Remove Top Cover from Housing (3) Remove Heater from Body [Make T/C Straight] (4) Remove T/C from Body Heater * Assembly is in reverse order 2
2) Troubleshooting - Electrical Symptom Causes Corrective action and check points. Heater disconnected.. Use a test meter to check the heater and T/C. A. Temperature not rising 2. Improper contact between. Use a test meter to check all cable connections 2. Verify that the connecting pins are secure. 3. Controller malfunctioning.. Check the sensor type IC(J) or CA(K). 4. T/C polarity reversed.. Check the controller, and check each function. 2. Reverse the T/C leads and re-connect.. Check the Heater(s) and T/C(s). 2. Check all pin and cable connections. Figure 3. Verify that the connecting pins are secure. 22
Symptom Causes Correction Action and Check Points B. Valve pin no operating or not operating smoothly Figure. Defective signal connection.. Check the signal connection (DC24V,AC0,220V) 2. Use a test meter to verify that the signal is present at the connection plug.. Disassemble the cylinder for inspection (See Fig. 7-, 7--, and 7--2) 2. Piston O-rings damaged or worn 3. Inadequate air supply.. Check air supply and check all joints. 4. Internal damage of Solenoid valve.. Loosen slightly the solenoid joints and 5. Poor Air Supply.. Check the connections to the main compressor and peripheral equipment. 2. Install an air booster if the air pressure is 6.0 bar or less. (Model:VABT0) 6. Valve pin and nozzle tolerance not appropriate. 7.Pin faces (slide way) damaged.. Remove material from inside the system.. If the material is an engineering plastic, or mixed with glass fiber, disassemble and check 8. Ingress of foreign matter.. In most cases, foreign matter is collected in the gate area. Disassemble, and visually check 9. Material leakage within piston.. Check signal connection (DC24V,AC0,220V).Disassemble and check the assembly. (See Fig. 7-, 7--, and 7--2) 2. Check the nozzle and pin clearance 2. Check injection signal at connecting plug.. 3. Air piping defect check points 23
Sympto Causes Correction Action and Check Points C. Carboniz ation occurred. Overheat 2. Carbonization caused by the material remaining inside the machine cylinder. 3 Carbonization occurring within the retention zone inside the nozzle assembly.. Check the carbonized part of the product. 2. Check centered around the gate. 3. Check the T/C clamped state. Check the time of changing the material inside the injection machine cylinder. 2. Check the body and nozzle retention part.. Check the carbonized part of the product centered around the product gate. -. If carbonization occurs at a point near the gate, as shown in the Figure, it indicates carbonization is caused by the material which has accumulated around the tip -. If carbonization occurs at a point away from the gate, as shown in the Figure, it indicates carbonization is caused by the material accumulating inside the injection machine cylinder or the Single Valve Nozzle Body. Figure -. If carbonization occurs in the form of a line, as shown in the Figure, it indicates that carbonization is caused by the material which has accumulated inside the Single Valve Nozzle -Series III - Body or Nozzle Tip area. 2. Check the T/C clamped status, as shown in the Figure. Check the T/C clamped status of the nozzle body heater. -Verify if the nozzle and the body T/C are not changed with each other. 24
Sympto Causes Correction Action and Check Points D. Gate mark defective. Pin operation defective 2. Shortage of air pressure 3. Unsatisfactory injection control 4. Defective signal ) Operating condition of the mould. (alignment of the nozzle assembly and gate) 2) Check the cooling line system inside the mould. ) Refer to item 5 of Paragraph B ) Dwelling time unnecessarily too long. ) Verify that the signals to the solenoid valve are correctly installed and / or Figure connection selected.. Check the mould working condition, as shown in the Figure. -. mould and nozzle alignment. -. Gate machining options. ) Taper Type 2) Straight Type 3) Gate marks resulting from defective gate conditions. 25
Symptom Causes Correction Action and Check Points Gate mark pattern. Valve pin manufactured in taper type when the gate is straight type. 2. Valve pin is closed when the gate is completely hardened.. Make valve pin and the gate in the same type. 2. Reduce the dwelling time during injection. Gate mark pattern 3. When air pressure is insufficient 3. Use an air booster if air pressure is 6.0kgf/cm2 or less. (MODEL : VABT0) 4. Temperature around the Gate 4. Increase the nozzle temperature, or adjust the mold cooling conditions. 5. Foreign matter infiltrated into 5. Check and remove. Gate made larger than the valve pin. Rectify by installing a gat bush. (See working drawing 3-3-4 VA Type Gate). Valve pin temperature too high.. Add cooling line around the gate to improve cooling conditions. Gate mark pattern Gate mark pattern. The gate diameter is larger than the pin diameter. 2. Lower the nozzle temperature.. Change pin or reduce the gate diameter.. Pin too short.. Check the pin length Gate mark pattern 2. Air pressure low. 2. Use an air booster if air pressure is 6.0 bar or less. (MODEL : VABT0) 26
Symptom Causes Correction Action and Check Points Material leakage. mould inadequately assembled.. Check the sizes of the mould 2. System not assembled correctly and check the nozzle operation. 3. The machine nozzle and the SV III radius 'R' do not match.. Re-assemble in the correct sequence.. Potential material leakage points of Single Valve nozzle - Series III. Adjust the the radius R of suit SV III 2. Causes of material leakage and corrective action by each point Point A : Clearance exists between the valve pin and the nozzle causing material leakage. Point B :Problem occurs because the Radius does not match correctly at the contact point between the injection machine and Single Valve nozzle - Series III. The nozzle radius the injection machine nozzle must be less than the nozzle radius of the Single Valve Nozzle - Series III by mm minimum The machine nozzle bore must be smaller than the size of the SVIII inlet bore. Point C: This is the sealing ring used to prevent material leakage from body and nozzle. Once the nozzle is disassembled, the original sealing ring must not be re-used. A new sealing ring must be fitted before the nozzle is re-assembled. The main cause of the material leakage in this area is caused by the nozzle Locating Ring not clamping the Single Valve Nozzle - Series III correctly. Refer to section 4. Installation - Mechanical and verify the dimensions are correct. The main cause of material leakage in this area is that the sizes are incorrect. Point D: This problem occurs because the mould and the nozzle diameters are not correct. Damage tothe sealing diameter will also result in material leakage in this area. Therefore, it is essential to check the dimensions and condition of these areas thoroughly prior to assembling the Single Valve Nozzle - Series III in the mould. 27