hot runner system installation guide rev11...this manual is intended for tooling and molding...

S t a b i l i z e y o u r P r o c e s s

H O T R U N N E R T E C H N O L O G Y

Hot Runner SystemInstallation Guide

SVC-17-0001_EN-Rev11 EN 10 / 2019 DTP: KA

ENMaster Language is English Hot Runner System Installation Guide SVC-17-0001_EN-Rev11RESTRICTED: Property of Synventive. - 2 - All rights reserved. Errors and omissions exceptedFor limited third party distribution based on need and intended use. © 2019 Synventive Molding Solutions


Hot Runner System Installation Guide

IntroductionDear 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

Headquarters:

USA – Peabody, MA Synventive Molding Solutions Inc.10 Centennial DrivePeabody, MA 01960Tel.: +1 978 750 8065Fax: +1 978 646 3600Email: [email protected]

Germany – BensheimSynventive Molding Solutions GmbHHeimrodstraße 10P. O. Box 312364625 BensheimTel. :+49 (0)6251 9332-0Fax :+49 (0)6251 9332-90Email: [email protected]

China – SuzhouSynventive Molding Solutions (Suzhou) Co. Ltd.12B Gang Tian Industrial SquareSuzhou Industrial Park, China 215021Tel.: +86 512 6283 8870Fax: +86 512 6283 8890Email: [email protected]

Customer Service:

North America24/7 Technical Support Line1-800-367-5662 – Press 4 from the Main Menu

EuropeTechnical Support+49 6251 93320 (8:00 am - 5:00 pm)For after hours service, please contact your local service representative

Asia24/7 Technical Support+86 512 62838870-866 (8:30 am - 5:00 pm)

+86 13862017765 after hours

Copyright 2019 Synventive Molding Solutions.




Table of Contents1 Safety Instructions .............................................................................................................81.1 CE approved Equipment ............................................................................................................... 81.2 Purpose of use of a Hot Runner System ..................................................................................... 81.2.1 Use compatible with the intended Purpose .....................................................................................................................81.2.2 UseinconflictwiththeintendedPurpose ........................................................................................................................8

1.3 DefinitionofQualifiedPersonswithTechnicalKnowledge ....................................................... 81.4 SafetyInstructionswithintheInstructionManual ...................................................................... 91.5 TheHRSystemInstructionManual/PartoftheSynventiveCustomerDocumentation ........ 91.6 Safety Instructions and Symbols used ...................................................................................... 101.6.1 DangerSymbolsDefinitions ...........................................................................................................................................101.6.2 Mandatory Safety Signs of the Personal Protective Equipment ..................................................................................101.6.3 Symbols of Warnings ......................................................................................................................................................101.6.4 Symbols of Prohibition .................................................................................................................................................... 11

1.7 General Safety Instructions ........................................................................................................ 112 Product Description .........................................................................................................142.1 Nozzle Types................................................................................................................................. 152.1.1 API heating .....................................................................................................................................................................152.1.2 APT heating ....................................................................................................................................................................152.1.3 Sprue Bushing Nozzles...................................................................................................................................................162.1.4 Support Ring Nozzles .....................................................................................................................................................162.1.5 Threaded Nozzles ...........................................................................................................................................................17

2.2 Hot Half ......................................................................................................................................... 183 Preparation for Incorporation .........................................................................................193.1 UnpackingtheHotRunnerSystem ............................................................................................ 203.2 CleaningHotRunnersandCutout ............................................................................................. 223.3 List of necessary Tools ............................................................................................................... 234 InstallationoftheHotRunnerSystem ...........................................................................244.1 General Instructions for Installation .......................................................................................... 244.1.1 Requirements on the Injection Mold ...............................................................................................................................254.1.2 Requirements on Temperature Control ..........................................................................................................................26

4.2 Table - Expansion Gap (Joint Z) ................................................................................................ 27




4.3 InstallationofHRSystemswithSupportRingNozzles(APT) ................................................. 284.3.1 Support Ring Nozzle Installation ....................................................................................................................................294.3.2 For non pre-wired Systems ............................................................................................................................................334.3.3 For pre-wired Systems ....................................................................................................................................................33

4.4 InstallationofHRSystemswithThreadedNozzles(API)......................................................... 344.4.1 Preparation for System Installation ................................................................................................................................354.4.2 Nozzle Tip Adjustment ....................................................................................................................................................384.4.3 For non pre-wired Systems ............................................................................................................................................424.4.4 For pre-wired Systems ....................................................................................................................................................42

4.5 InstallationofPLUG´NPLAY®HRSystemswithThreadedNozzles ...................................... 434.5.1 Preparation for System Installation ................................................................................................................................444.5.2 System Installation ..........................................................................................................................................................464.5.3 Nozzle Tip Adjustment ....................................................................................................................................................484.5.4 For non pre-wired Systems ............................................................................................................................................524.5.5 For pre-wired Systems ....................................................................................................................................................52

4.6 InstallationofHRSystemswithThreadedNozzles(APT) ....................................................... 534.6.1 Preparation for System Installation ................................................................................................................................544.6.2 Nozzle Tip Adjustment ....................................................................................................................................................584.6.3 For non pre-wired Systems ............................................................................................................................................624.6.4 For pre-wired Systems ....................................................................................................................................................62

5 Start-upoftheHotRunnerSystem ................................................................................635.1 Preparation for Start up ............................................................................................................... 655.2 PowerSupplyConnection .......................................................................................................... 655.2.1 Grounding Check ...........................................................................................................................................................665.2.2 VerificationofHeaterGrounding ....................................................................................................................................665.2.3 InformationonHeaterConnection .................................................................................................................................67

5.3 Hot Runner System Start-up ....................................................................................................... 685.4 ColorChange ............................................................................................................................... 715.4.1 Color Change of direct contact Nozzles (plunged through-Nozzles) ...........................................................................715.4.2 Color change of Nozzles with pre-chamber isolation without removable cavity plate ................................................735.4.3 Color change of Nozzles with pre-chamber isolation and replaceable cavity plate ...................................................73

5.5 HotRunnerSystemSwitch-off ................................................................................................... 755.6 StorageofHotRunnerSystemduringShutdowns .................................................................. 76




6 DefectIdentificationandTroubleshooting ....................................................................776.1 Defects Table ................................................................................................................................ 777 ServiceandMaintenance ................................................................................................817.1 MaintenanceofValveGateSystems .......................................................................................... 817.1.1 Checklist for Valve Gate System Maintenance .............................................................................................................817.1.2 CleaningouttheHotRunnerSystem ............................................................................................................................82

8 Actuators ...........................................................................................................................838.1 HydraulicActuators ..................................................................................................................... 838.1.1 ActuatorHBSeries ..........................................................................................................................................................848.1.2 ActuatorHYC4520M04Series .......................................................................................................................................968.1.3 Actuator QCVG16M04/-MF04/-M06/-M07 .................................................................................................................. 114

8.2 PneumaticActuators ................................................................................................................. 1308.2.1 Actuator PB Series ........................................................................................................................................................1318.2.2 Actuator PNC3008B02 .................................................................................................................................................1428.2.3 Actuator PNC4508B Series ..........................................................................................................................................1598.2.4 Actuator PNC4512B Series ..........................................................................................................................................1748.2.5 Actuator PNC6018B-02 ................................................................................................................................................1898.2.6 Actuator VP4008P Series .............................................................................................................................................2028.2.7 Actuator VP8016P Series .............................................................................................................................................218

9 ValvePins ........................................................................................................................2339.1 ValvePinDismantling ................................................................................................................ 2339.2 PlateActuation ........................................................................................................................... 2369.2.1 Plate Actuation, Actuators above Plate ........................................................................................................................2369.2.2 Plate Actuation, Actuators below Plate.........................................................................................................................254

10 Nozzles ............................................................................................................................26910.1 ThreadedNozzles ...................................................................................................................... 27110.1.1 Nozzle 06E Series .........................................................................................................................................................27110.1.2 Nozzle 09E-02 Series ...................................................................................................................................................28210.1.3 Nozzle 12E Series .........................................................................................................................................................29210.1.4 Nozzle 16E-04 / 22E-04 Series ....................................................................................................................................30410.1.5 Nozzle 12EX16 / 16EX22 Series .................................................................................................................................323

10.2 Nozzles(APT) ............................................................................................................................. 34510.2.1 Replacing Nozzle Tips, Inserts and Nozzle Tip Seals (APT) ......................................................................................346




10.3 SingleAxisValveGateNozzles ................................................................................................ 35410.3.1SingleAxisValveGateNozzle12SVH ........................................................................................................................35410.3.2SingleAxisValveGateNozzle16SVH ........................................................................................................................37910.3.3 Single Axis Valve Gate Nozzle 09SVP .........................................................................................................................40310.3.4 Single Axis Valve Gate Nozzle 12SVP .........................................................................................................................42110.3.5 Single Axis Valve Gate Nozzle 16SVP .........................................................................................................................440

10.4 SprueBushings ......................................................................................................................... 45910.4.1 Sprue Bushing 06S Series ...........................................................................................................................................45910.4.2 Sprue Bushing 09S-02 Series ......................................................................................................................................47610.4.3 Sprue Bushing 12S Series ...........................................................................................................................................49210.4.4 Sprue Bushing 16S-04 / 22S-04 Series .......................................................................................................................510

10.5 InletBushings ............................................................................................................................ 53510.5.1 Inlet Bushing IB-24 / IB-32 Series ................................................................................................................................53510.5.2 Inlet Bushing IB-50 Series ............................................................................................................................................540

11 DismountingandMountingManifoldPlugs ................................................................54511.1 DismountingManifoldPlugs(APT) .......................................................................................... 54511.1.1 Cleaning the Flow Bores ...............................................................................................................................................546

11.2 MountingManifoldPlugs(APT) ................................................................................................ 54612 AccessoriesandTools...................................................................................................54712.1 ServiceforthePositionSensor ................................................................................................ 54812.1.1 Tools for the Position Sensor Service ..........................................................................................................................54812.1.2 Basic Position Sensor Information ...............................................................................................................................54912.1.3 Installing the Position Sensor........................................................................................................................................54912.1.4InstallingoftheActuatorwithPositionSensorontheHotRunner .............................................................................55112.1.5 Position Sensor Troubleshooting Guide ......................................................................................................................552

12.2 W Gate Detail Inspection Procedure & Tools .......................................................................... 53512.2.1 Inspection Tool Introduction ..........................................................................................................................................53512.2.2 Extension Bar ................................................................................................................................................................53512.2.3 Fix Disk...........................................................................................................................................................................53612.2.4 Inspection Tools for Gate Checking..............................................................................................................................53712.2.5 Inspection Procedure ....................................................................................................................................................53812.2.6ValvePinVerification .....................................................................................................................................................544




13 Torques............................................................................................................................54513.1 RelevantPartsattachedwithScrewspursuanttoISO4762(DIN912) ................................. 54513.2 ToolSpecifications .................................................................................................................... 54513.3 Instructions on Torques for Synventive parts ......................................................................... 54614 Shutdown ........................................................................................................................54914.1 ReturningtheHotRunnerSystem ........................................................................................... 54914.2 Disposal ...................................................................................................................................... 55015 Annex ..............................................................................................................................55115.1 Units used ................................................................................................................................... 55115.2 Patents ........................................................................................................................................ 55415.3 GlobalOffices/SalesAgencies ............................................................................................... 555

hot runner system installation guide rev11...this manual is intended for tooling and molding...

Documents