Hot Runner System Instruction Manual Rev1.4 11 / 2011 RK
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 01960 Tel.: +1 800 367 5662 Tel.: +1 978 750 8065 Fax: +1 978 646 3600 Email: info@synventive.com Germany Bensheim Synventive Molding Solutions GmbH Heimrodstraße 10 P. O. Box 3123 64625 Bensheim Tel. :+49 (0)6251 9332-0 Fax :+49 (0)6251 9332-90 Email: infohrde@synventive.com China Suzhou Synventive Molding Solutions (Suzhou) Co. Ltd. 12B Gang Tian Industrial Square Suzhou Industrial Park, China 215021 Tel.: +86 512 6283 8870 Fax: +86 512 6283 8890 Email: infohrcn@synventive.com Copyright 2011 Synventive Molding Solutions. Current version at www.synventive.com - 2-2011 All rights reserved
Table of Contents 1 Safety Instructions...12 1.1 CE approved Equipment... 12 1.2 Purpose of use of a Hot Runner System... 12 1.2.1 Use compatible with the intended Purpose...12 1.2.2 Use in conflict with the intended Purpose...12 1.3 Definition of Qualified Persons with Technical Knowledge... 12 1.4 Safety Instructions within the Instruction Manual... 13 1.5 The HR System Instruction Manual / Part of the Synventive Customer Documentation... 13 1.6 Safety Instructions and Symbols used... 13 1.6.1 Symbols of Danger Categorisation...14 1.6.2 Mandatory Safety Signs of the Personal Protective Equipment...14 1.6.3 Warning Symbols...14 1.6.4 Prohibited Symbols...15 1.7 General Safety Instructions... 15 2 Product Description...18 2.1 Nozzle Types... 19 2.1.1 API heating...19 2.1.2 APT heating...19 2.1.3 Sprue Bushing / Single Nozzle...20 2.1.4 Support Ring / Face fit Nozzles...20 2.1.5 Threaded / Screw fit Nozzles...21 2.2 Hot Half... 22 3 Preparation for Incorporation...23 3.1 Unpacking the Hot Runner System... 24 3.2 Cleaning Hot Runners and Cut - Out... 25 3.3 List of necessary Tools... 27 4 Installation of the Hot Runner System...28 4.1 General Instructions for Installation... 28 4.1.1 Requirements on the Injection Mold...28 4.1.2 Requirements on Temperature Control...30 4.2 Table - Expansion Gap (Joint Z)... 31 Current version at www.synventive.com - 3-2011 All rights reserved
4.3 Installation of HR Systems with Support Ring / Face fit Nozzles (API)... 32 4.3.1 Support Ring / Face fit Nozzle Installation...33 4.3.2 Center Support and Support Pillar Adjustment...34 4.3.3 Mounting of the Positioning Dowel...37 4.3.4 Check of Manifold Top...38 4.3.5 Thrust Pad Adjustment and Expansion Gap (joint Z) Adjustment...40 4.3.6 Final Assembly of the Hot Runner System and the Mold Plate...41 4.3.7 For non pre-wired Systems...42 4.4 Installation of HR systems with Support Ring / Face fit Nozzles (APT)... 43 4.4.1 Support Ring / Face fit Nozzle Installation...44 4.4.2 For non pre-wired Systems...48 4.5 Installation of HR Systems with Threaded / Screw fit Nozzles (API)... 49 4.5.1 Preparation for System Installation...50 4.5.2 Nozzle Tip Adjustment...53 4.5.3 For non pre-wired Systems...58 4.6 Installation of PLUG N PLAY (VB/06E) HR Systems with Threaded / Screw fit Nozzles... 59 4.6.1 Preparation for System Installation...60 4.6.2 System Installation...62 4.6.3 Nozzle Tip Adjustment...65 4.6.4 For non pre-wired Systems...69 4.7 Installation of HR Systems with Threaded / Screw fit Nozzles (APT)... 70 4.7.1 Preparation for System Installation...71 4.7.2 Nozzle Tip Adjustment...75 4.7.3 For non pre-wired Systems...79 5 Start-up of the Hot Runner System...80 5.1 Preparation for Start up... 82 5.2 Power Supply Connection... 82 5.2.1 Grounding Check...83 5.2.2 Verification of Heater Grounding...83 5.2.3 Information on Heater Connection...84 5.3 Hot Runner System Start-up... 85 5.4 Color Change... 88 5.4.1 Color Change of direct contact Nozzles (plunged through-nozzles)...88 Current version at www.synventive.com - 4-2011 All rights reserved
5.4.2 Color change of Nozzles with pre-chamber isolation without removeable cavity plate...90 5.4.3 Color change of Nozzles with pre-chamber isolation and replaceable cavity plate...90 5.5 Hot Runner System Switch-off... 92 5.6 Storage of Hot Runner System during Shutdowns... 93 6 Defect Identification and Troubleshooting...94 6.1 Defects Table... 94 7 Service and Maintenance...98 7.1 Maintenance of Valve Gate Systems... 98 7.1.1 Checklist for Valve Gate System Maintenance...98 7.1.2 Cleaning out the Hot Runner System...99 8 Actuators...100 8.1 Service of the Actuator HYC2508M02/M03... 101 8.1.1 Technical Data HYC2508M02/M03...101 8.1.2 Exploded View HYC2508M02/M03...102 8.1.3 Tools for Assembling and Disassembling the Actuator...103 8.1.4 Cut-out information HYC2508M02/M03 without SynCool...104 8.1.5 SynCool 1 - Option...105 8.1.6 SynCool 2 - Option...107 8.1.7 Disassembling the Actuator HYC2508M02/M03...109 8.1.8 Assembling the Actuator HYC2508M02 / M03... 112 8.2 Service of the Actuator HYC4018M03/M04/M05...118 8.2.1 Technical Data HYC4018M03/M04/M05... 118 8.2.2 Exploded View HYC4018M03/M04/M05... 119 8.2.3 Tools for Assembling and Disassembling the Actuator...120 8.2.4 Cut-out Information HYC4018M03/M04/M05 without SynCool...121 8.2.5 SynCool 1 - Option...122 8.2.6 SynCool 2 - Option...124 8.2.7 Disassembling the Actuator HYC4018M03/M04/M05...126 8.2.8 Assembling the Actuator HYC4018M03/M04/M05...130 8.3 Service of the Actuator QCVG16... 135 8.3.1 Technical Data QCVG16...135 8.3.2 Exploded View QCVG16...136 8.3.3 Disassembling the Actuator QCVG16...137 Current version at www.synventive.com - 5-2011 All rights reserved
8.3.4 Assembling the Actuator QCVG16...140 8.4 Service of the Actuator PNC3008B... 146 8.4.1 Technical Data PNC3008B...146 8.4.2 Exploded View PNC3008B...147 8.4.3 Cut-out information PNC3008B...148 8.4.4 Tools for Assembling, Disassembling and Adjusting the Actuator...149 8.4.5 Disassembling Actuator PNC3008B...150 8.4.6 Assembling the Actuator PNC3008B...153 8.5 Service of the Actuator PNC5018M01... 158 8.5.1 Technical Data PNC5018M01...158 8.5.2 Technical Data Micro Switch PS-MS-O-01...159 8.5.3 Position Control Display Module PC-DM-08-01...159 8.5.4 Exploded View PNC5018M01...160 8.5.5 Tools for Assembling and Disassembling the Actuator...161 8.5.6 Cut-out information PNC5018M01...162 8.5.7 Disassembling the Actuator PNC5018M01...163 8.5.8 Assembling the Actuator PNC5018M01...166 8.6 Service of the Actuator PNC6018M01... 172 8.6.1 Technical Data PNC6018M01...172 8.6.2 Technical Data Micro Switch PS-MS-O-01...173 8.6.3 Position Control Display Module PC-DM-08-01...173 8.6.4 Exploded View PNC6018M01...174 8.6.5 Tools for Assembling and Disassembling the Actuator...175 8.6.6 Cut-out information PNC6018M01...176 8.6.7 Disassembling the Actuator PNC6018M01...177 8.6.8 Assembling the Actuator PNC6018M01...181 8.7 Service of the Actuator PNC6018M02... 186 8.7.1 Technical Data PNC6018M02...186 8.7.2 Exploded View PNC6018M02...187 8.7.3 Tools for Assembling and Disassembling the Actuator...188 8.7.4 Cut-out information PNC6018M02...189 8.7.5 Disassembling the Actuator PNC6018M02...190 8.7.6 Assembling the Actuator PNC6018M02...193 8.8 Service of the Actuator PNC7518M03... 198 Current version at www.synventive.com - 6-2011 All rights reserved
8.8.1 Technical Data PNC7518M03...198 8.8.2 Exploded View PNC7518M03...199 8.8.3 Tools for Assembling and Disassembling the Actuator...200 8.8.4 Cut-out Information PNC7518M03...201 8.8.5 Disassembling the Actuator PNC7518M03...202 8.8.6 Assembling the Actuator PNC7518M03...205 8.9 Service of the Actuator PNC7518M04... 210 8.9.1 Technical Data PNC7518M04...210 8.9.2 Exploded View PNC7518M04... 211 8.9.3 Tools for Assembling and Disassembling the Actuator...212 8.9.4 Cut-out Information PNC7518M04...213 8.9.5 Disassembling the Actuator PNC7518M04...214 8.9.6 Assembling the Actuator PNC7518M04...218 8.10 Service of the Actuator PNC4508M02... 225 8.10.1 Technical Data PNC4508M02...225 8.10.2 Exploded View PNC4508M02...226 8.10.3 Tools for Assembling and Disassembling the Actuator...227 8.10.4 Cut-out PNC4508M02...228 8.10.5 Disassembling the Actuator PNC4508M02...229 8.10.6 Assembling the Actuator PNC4508M02...232 8.11 Service of the Actuator VP4008P Series... 237 8.11.1 Technical Data VP4008P Series...237 8.11.2 Explosion view of the VP4008P Series...238 8.11.3 Cut-out Information VP4008P Series...239 8.11.4 Basic Dimensions in Mold...240 8.11.5 First mounting of Actuator VP4008P...242 8.11.6 Dismounting the Actuator VP4008P...243 8.12 Service of the Actuator VP8016P Series... 245 8.12.1 Technical Data VP8016P Series...245 8.12.2 Explosion view of the VP8016P Series...246 8.12.3 Cut-out Information VP8016P Series...247 8.12.4 Basic Dimensions in Mold...248 8.12.5 First mounting of Actuator VP8016P...250 8.12.6 Dismounting the Actuator VP8016P...251 Current version at www.synventive.com - 7-2011 All rights reserved
8.13 Service of the Actuator PNC4508B... 253 8.13.1 Technical Data PNC4508B...253 8.13.2 Exploded View PNC4508B...254 8.13.3 Cut-out information PNC4508B...255 8.13.4 Tools for Assembling, Disassembling and Adjusting the Actuator...256 8.13.5 Disassembling Actuator PNC4508B...257 8.13.6 Assembling the Actuator PNC4508B...259 8.14 Service of the Actuator PNC6018B... 264 8.14.1 Technical Data PNC6018B...264 8.14.2 Exploded View PNC6018B...265 8.14.3 Cut-out information PNC6018B...266 8.14.4 Tools for Assembling, Disassembling and Adjusting the Actuator...267 8.14.5 Disassembling Actuator PNC6018B...268 8.14.6 Assembling the Actuator PNC6018B...270 8.15 Service of the Actuator HYC4520M04... 274 8.15.1 Technical Data HYC4520M04...274 8.15.2 Exploded View HYC4520M04...275 8.15.3 Tools for Assembling and Disassembling the Actuator...276 8.15.4 Cut-out information HYC4520M04...277 8.15.5 Disassembling the Actuator HYC4520M04...278 8.15.6 Disassembling the Adjustment Screw Assembly and Piston...280 8.15.7 Assembling the Actuator HYC4520M04...283 8.16 Service of the Actuator ELA5708P... 290 8.16.1 Technical Data ELA5708P...290 8.16.2 ELA5708P Components...291 8.16.3 Cut-out Information ELA5708P...292 8.16.4 Dismounting the Actuator ELA5708P...293 8.16.5 Mounting the Actuator ELA5708P...294 8.17 Service of the Actuator ELA8708P... 296 8.17.1 Technical Data ELA8708P...296 8.17.2 ELA8708P Components...297 8.17.3 Cut-out Information ELA8708P...298 8.17.4 Dismounting the Actuator ELA8708P...299 8.17.5 Mounting the Actuator ELA8708P...300 Current version at www.synventive.com - 8-2011 All rights reserved
9 Valve Pins...302 9.1 Valve Pin Dismantling... 302 9.2 Valve Pin Height Adjustment HYC2508 / HYC4018 Series... 305 9.2.1 Height Adjustment of Cylindrical shut-off Valve Pin...306 9.2.2 Height Adjustment of Conical shut-off Valve Pin...307 9.3 Valve Pin Height Adjustment QCVG Actuator... 308 9.3.1 Height Adjustment of shut-off Valve Gate Pins with QCVG Actuator...309 9.4 Valve Pin Height Adjustment PNC3008B... 313 9.4.1 Valve Pin Adjustment Tool kit...313 9.4.2 Adjustment at mounted Hot Runner System...314 9.5 Valve Pin Height Adjustment PNC5018M / PNC6018M Series... 317 9.5.1 Height Adjustment of Cylindrical shut-off Valve Pin...318 9.5.2 Height Adjustment of Conical shut-off Valve Pin...319 9.6 Valve Pin Height Adjustment PNC7518 Series... 320 9.6.1 Height Adjustment of Cylindrical shut-off Valve Pin...321 9.6.2 Height Adjustment of Conical shut-off Valve Pin...322 9.7 Valve Pin Height Adjustment PNC4508M Series... 323 9.7.1 Height Adjustment of Cylindrical shut-off Valve Pin...324 9.7.2 Height Adjustment of Conical shut-off Valve Pin...325 9.8 Valve Pin Height Adjustment VP4008P Series... 326 9.8.1 Thermal Expansion Calculation...327 9.8.2 Height Adjustment of Cylindrical shut-off Valve pin...328 9.8.3 Height Adjustment of Conical shut-off Valve pin...331 9.9 Valve Pin Height Adjustment VP8016P Series... 334 9.9.1 Thermal Expansion Calculation...335 9.9.2 Height Adjustment of Cylindrical shut-off Valve pin...336 9.9.3 Height Adjustment of Conical shut-off Valve pin...339 9.10 Valve Pin Height Adjustment PNC4508B / PNC6018B... 342 9.10.1 Valve Pin Adjustment Tool Kit...342 9.10.2 Adjustment at mounted Hot Runner System...343 9.11 Valve Pin Height Adjustment HYC4520M04... 346 9.11.1 Height Adjustment of Cylindrical shut-off Valve Pin...347 Current version at www.synventive.com - 9-2011 All rights reserved
9.11.2 Height Adjustment of Conical shut-off Valve Pin...348 10 Nozzles...349 10.1 Nozzles (API)... 350 10.1.1 Nozzle under the manifold and Accessories for single Nozzles, example of CBFT nozzle...351 10.1.2 Dismantling a single Nozzle and Nozzles under the manifold from injection mold...352 10.1.3 Dismantling single Nozzles from Injection Mold...356 10.1.4 Assembling the single Nozzle...358 10.2 Nozzles 06E Series (API)... 364 10.2.1 Disassembly Nozzle 06E...365 10.2.2 Assembling Nozzle 06 E...368 10.3 Nozzles (APT)... 373 10.3.1 Replacing Nozzle Tips, Inserts and Nozzle Tip Seals (APT)...374 10.3.2 Installing Nozzle Tips, Inserts and Nozzle Tip Seals (APT)...377 10.4 Sprue Bushing / Single Nozzle 16S01_V... 382 10.4.1 Technical Data - Sprue Bushing / Single Nozzle 16S01_V...382 10.4.2 Technical Data - Cooling Unit CU16SVH01...382 10.4.3 Mold Cut-out...383 10.4.4 Single Nozzle 16S01_V / Actuator HYC2314S01 Parts List...385 10.4.5 Dismounting the Cylinder Housing HYC2314S01 and the Seal Kit...389 10.4.6 Assembly of the Cylinder Housing HYC2314S01 on the Nozzle...391 10.4.7 Dismounting and Mounting of the Thermocouple...398 10.4.8 Valve Pin Height Adjustment...400 10.4.9 Disassembling the Sprue Bushing / Single Nozzle out of the Mold...401 10.5 Sprue Bushing / Single Nozzle GBN...S01... 402 10.5.1 Technical Data - Sprue Bushing / Single Nozzle GBN...S01...402 10.5.2 Technical Data - Cooling Unit CU16SVP01...403 10.5.3 Mold Cut-out...404 10.5.4 Single Nozzle GBN... S01 Parts List...406 10.5.5 Dismounting the Pneumatic Cylinder Housing and Sealing...408 10.5.6 Assembly of the Pneumatic Cylinder Housing on the Nozzle...410 10.5.7 Dismounting and Mounting of the Thermocouple...413 10.5.8 Valve Pin Height Adjustment...415 10.5.9 Disassembling the Sprue Bushing / Single Nozzle out of the Mold...416 Current version at www.synventive.com - 10-2011 All rights reserved
10.6 Nozzles 09E Series (API)... 417 10.6.1 Disassembly Nozzle 09E...418 10.6.2 Assembling Nozzle 09 E...421 10.7 Nozzle Cooling with Cooling Insert / Bushing... 425 10.7.1 General Product Description - Cooling Insert / Bushing...425 10.7.2 Outgate Cooling...426 10.7.3 Distance Tube...426 10.7.4 Assembly View 16E Cooling Bushing...427 10.7.5 Assembly View 16E Cooling Insert...428 11 Dismounting and Mounting Manifold Plugs...429 11.1 Dismounting Manifold Plugs (APT)... 429 11.1.1 Cleaning the Flow Bores...430 11.2 Mounting Manifold Plugs (APT)... 430 12 Shutdown...431 12.1 Returning the Hot Runner System... 431 12.2 Disposal... 432 13 Annex...433 13.1 Units used... 433 13.2 Torques... 434 13.2.1 Additional rules for using Screws pursuant to DIN 912 / ISO 4762 Screws...434 13.2.2 Tool Specifications...434 13.2.3 Instructions on Torques for Synventive parts under SPI 02.01...434 13.3 Glossary and List of Abbreviations... 436 13.4 EC Declaration of Conformity... 439 13.5 Patents... 440 13.6 Global Offices... 441 Current version at www.synventive.com - 11-2011 All rights reserved