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email: info@guenther-heisskanal.de
Internet: www.guenther-heisskanal.de
17.03.2016 V.2.0
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Hot runner technology
Table of contents
1 General .................................................................................... 6
1.1 Information on this manual ............................................ 6
1.2 Explanation of symbols .................................................. 7
1.3 Limitation of liability ........................................................ 8
1.4 Warranty conditions ....................................................... 8
1.5 Copyright........................................................................ 9
1.6 Spare parts .................................................................... 9
1.7 Warranty terms .............................................................. 9
1.8 Customer Service .......................................................... 9
2 Safety .................................................................................... 10
2.1 Customer’s responsibility ............................................. 10
2.2 Personnel requirements ............................................... 11
2.2.1 Qualifications ................................................ 11
2.2.2 Unauthorized persons .................................. 12
2.2.3 Training......................................................... 12
2.3 Correct use .................................................................. 13
2.4 Personal protective equipment .................................... 14
2.5 Specific dangers .......................................................... 15
2.6 Safety features ............................................................. 17
2.7 Securing against switching on ..................................... 18
2.8 Conduct in a dangerous situation and in case of
accidents ...................................................................... 19
2.9 Environmental protection ............................................. 19
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Hot runner technology
Table of contents
7 Operation ..............................................................................56
7.1 Safety ...........................................................................56
7.2 Switching on .................................................................56
7.3 Switching off .................................................................57
7.4 Activities in case of a process interruption ...................57
7.5 Colour change ..............................................................58
7.6 Shut-down in events of emergency..............................59
8 Troubleshooting ...................................................................60
8.1 Safety ...........................................................................60
8.2 Troubleshooting chart ..................................................63
8.2.1 Defects ..........................................................63
8.2.2 Valve-gate system ........................................65
8.3 Start-up after eliminating fault ......................................66
9 Maintenance ..........................................................................67
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Hot runner technology
Table of contents
10 Disassembly ......................................................................... 85
10.1 Safety ........................................................................... 85
10.2 Removal of the needle ................................................. 87
10.3 “Hot half” disassembly ................................................. 89
10.4 Disassembly and disposal ........................................... 90
12 Appendix ............................................................................... 93
12.1 Technical information ................................................... 94
12.2 Height adjustment/dimension check ............................ 95
12.3 Hot runner system checklist ......................................... 96
12.4 Declaration of conformity ............................................. 98
13 Index ...................................................................................... 99
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Hot runner technology
General
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1 General
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Hot runner technology
General
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DANGER!
… indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.
WARNING!
… indicates a potentially hazardous situation which,
if not avoided, could result in death or serious
injury.
CAUTION!
… indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate
injury.
CAUTION!
… indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
Special safety notes The following symbols are used in connection with the safety notes
to highlight particular dangers:
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Hot runner technology
General
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Hot runner technology
General
1.5 Copyright
This Manual is protected by copyright law and exclusively to be
used for internal purposes.
Passing this Manual on to third parties, duplication of any kind –
even in form of excerpts – as well as the use and/or disclosure of
the contents without the written consent of the manufacturer is not
permitted, except for internal purposes.
Violations oblige to compensation. The right for further claims
remains reserved.
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Hot runner technology
Safety
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2 Safety
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Hot runner technology
Safety
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2.2.1 Qualifications
WARNING!
Danger of injury if insufficiently qualified!
Improper operation can lead to serious personal
injuries or property damage.
Therefore:
– Have all activities performed only by qualified
personnel.
The following qualifications are specified for different areas of
activity listed in the Manual.
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An instructed person
has been instructed by the customer in an orientation session
on the assigned tasks and possible dangers in case of improper
behavior.
Qualified personnel
based on their professional training, know-how and experience
as well as knowledge of the applicable standards and
regulations is able to perform assigned work activities and to
detect and avoid possible dangers on their own.
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A professional electrician
based on his/her professional training, know-how and
experience as well as knowledge of the applicable standards
and regulations is able to perform work on electrical systems
and to detect and avoid possible dangers on his/her own.
The professional electrician has been trained for the special
location where he/she works and knows the relevant standards
and regulations.
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Only persons who are expected to perform their tasks reliably are
permitted as personnel. Persons whose reaction capability is im-
paired, e.g. through drugs, alcohol or medication are not permitted.
When selecting the personnel, the stipulations regarding age
and occupation applying at the location must be observed.
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Hot runner technology
Safety
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WARNING!
Danger for unauthorized persons!
Unauthorized persons not meeting the
requirements outlined here are not aware of the
dangers in the work area.
Therefore:
– Keep unauthorized persons away from the work
area.
– If in doubt, address the persons and direct them
to leave the work area.
– Interrupt work activities as long as unauthorized
persons are present in the work area.
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2.2.3 Training
Personnel must be trained by the customer on a regular basis. For
record-keeping purposes, a log of training conducted must be kept.
Fig. 1
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Safety
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Correct use also includes compliance with all the information in this
manual.
Any use beyond the correct use or any other form of use of the unit
is considered incorrect use and can result in dangerous situations.
WARNING!
Danger due to incorrect use!
Incorrect use of the unit can result in dangerous
situations.
In particular, do not use the unit as follows:
– Outside the original intended application.
– In a potentially explosive atmosphere.
Claims of any nature due to damage as a result of incorrect use
are excluded.
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Hot runner technology
Safety
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Protective clothing
are tight fitting working clothes with low tear resistance, with light
sleeves and without any sticking out parts. These clothes are
mainly a protection against being caught by moving machine parts.
Do not wear rings, chains, necklaces, and other jewellery.
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Safety boots
to protect against heavy parts falling down or slipping on slippery
ground.
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Personal protective equipment When performing special tasks it is necessary to wear personal
for special tasks protective equipment. This personal protective equipment will be
separately specified in the chapters of this Manual. This special
protective equipment is explained below.
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Protective gloves
to protect the hand against friction, graze, punctures or deep cuts
as well as contact with hot surfaces.
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Safety goggles
to protect the eyes against parts flying around or squirts of fluids.
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Hot runner technology
Safety
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Hot runner technology
Safety
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Hydraulics WARNING!
Danger to life caused by hydraulic energies!
Hydraulic energies can cause severe or even fatal
injuries.
Hydraulically driven parts may unexpectedly start
to move.
In case of damage to individual components
hydraulic fluid may escape under high pressure.
Therefore:
– Have work on the hydraulic system only carried
out by trained expert personnel.
– Before starting work on the hydraulic system
shut down the system and relieve the pressure.
Completely relieve pressure accumulators.
– Do not change pressures to values higher than
the specified maximum values.
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Hot runner technology
Safety
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Pos : 2.44 /KN 2006-SM /Sic her hei t/008 Sicherheits einric htungen/Kein eigener Not-Aus ( Ger ät) @ 12\mod_1143556430564_2.doc @ 82730
Integration in an emergency The unit is designed for use within a system. It does not have its
shutdown concept necessary own control unit or an autonomous emergency shutdown function.
Before operating the unit, install emergency shutdown systems for
the unit and integrate in the safety chain of the system control unit.
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Hot runner technology
Safety
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Fig. 2
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Hot runner technology
Safety
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Lubricants Lubricants like greases and oils contain toxic substances. These
must not be released into the environment. They must be disposed
of by a special waste disposal company.
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Material processed Pay attention to the safety data sheet from the manufacturer of the
material.
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Hot runner technology
Technical data
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3 Technical data
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Voltage 230 V~
NOTE!
Pay attention to the balancing of the oil feed and oil
outlet ducts as well as of the air feed and air outlet
ducts.
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Hot runner technology
Technical data
Thermocouple Parameter
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Continuous operation
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3.3 Lubricants
Application area Lubricants Manufacturer
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Hot runner technology
Technical data
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Auftrags-Nr./Order Number/
Commande N° Delivery date
Lieferdatum/Delivery Date/
Livraison
Manufacturer's address
35066 Frankenberg
Tel. +49 (0) 6451/ 5008-0
info@guenther-heisskanal.de Other type plates:
Made in Germany
Nozzle
Hot half, layout
Ø3,2
2 components
58
68
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Hot runner technology
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Hot runner technology
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The hot runner system is used to move the plasticised melt from
the injection unit to the cavity (direct gating) or the auxiliary gate
(indirect gating) and to ensure it is in the molten state over the
entire production process.
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Hot runner technology
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5 Transport, packaging and storage
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Hot runner technology
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Top
The arrows in this sign symbolize the top side of the package.
They must always point up, as otherwise the content may get
damaged.
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Fragile
Identifies packages with fragile or sensitive content.
Handle package with care, do not drop and do not subject to shock
loads.
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NOTE!
Claim any damage as soon as it is detected.
Compensation claims can only be submitted within
the applicable complaints periods.
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5.4 Transport
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Attachment points
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Transport of packages by crane Packages with lifting eyes can be transported by crane under the
following conditions:
Crane and lifting tackle must be sufficiently dimensioned for the
weight of the package.
The operator must have authorization for operating the crane.
Hooking up:
1. Fasten ropes, belts or multi-point tackle as shown in Fig. 9.
2. Make sure that the package is hanging straight, if necessary
observe an eccentric centre of gravity.
Fig. 9
3. Start transport.
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Hot runner technology
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Transport of pallets by crane Packages on pallets can be transported by crane under the
following conditions:
Crane and lifting tackle must be sufficiently dimensioned for the
weight of the package.
The operator must have authorization for operating the crane.
Fastening lifting tackle:
1. Fasten ropes, belts or multi-point tackle on the pallet as
shown in Fig. 10.
2. Make sure that the package will not be damaged by the lifting
tackle. If necessary use other lifting tackle.
3. Start transport.
Fig. 10
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Transport of pallets by forklift truck Packages on pallets can be transported by forklift truck under the
following conditions:
The forklift truck must match the weight of the transport units.
The operator must have authorization for operating the forklift
truck.
Picking up:
1. Insert the forks of the forklift truck between or under the pallet
beams.
2. Insert the forks until they appear on the opposite side.
3. Make sure that pallets with eccentric centre of gravity will not
tip over.
Fig. 11
4. Lift the package and start transport.
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5.5 Packing
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Concerning packing The individual packages have been packed to match the transport
conditions that can be expected. Only environmentally friendly
materials were used for packing.
The packing has the function of protecting the individual
components against damage, corrosion, etc., until they are finally
assembled. The packing material must therefore not be damaged
and should only be removed just before assembly takes place.
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Handling packing materials If there is no returns agreement for the packing, separate materials
according to type and size and direct to further use or recycling.
CAUTION!
Environmental damage caused by incorrect
waste disposal!
Packing materials are valuable raw materials and
can continue to be used in many cases or sensibly
reconditioned and recycled.
Therefore:
– Dispose of packing materials environmentally.
– Follow the locally valid waste disposal
regulations. If necessary employ a special
waste disposal company to dispose of packing
material.
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5.6 Storage
Pos : 5.35 /KN 2006-SM /Transport, Verpac kung und Lager ung/007 1.1.0 Lagerung der Pac kstüc ke @ 9\mod_1144055767050_2.doc @ 84833
NOTE!
Packages may be marked with notes for storage,
which may exceed the requirements mentioned
here. These must be adhered to.
Pos : 6.1 /KN2006- SM/nL.... ...... Seitenumbr uc h .......... @ 8\mod_1141998334703_0.doc @ 75491
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Hot runner technology
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6.1 Safety
Pos: 6.4 /KN2006-Projekte/Günther Heißkanaltechnik/Installation & Inbetriebnahme/003 1.1.0 Personal @ 101\mod_1274421400668_2.doc @ 1575092
Personnel Installation and initial commissioning are only allowed to
be undertaken by specially trained skilled personnel.
Work on the electrical system is only allowed to be
undertaken by electricians.
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Personal protective equipment The following protective equipment is to be worn during all
installation and initial commissioning work:
Protective clothing
Safety shoes
NOTE!
Specific reference is made in the warnings in this
section to additional protective equipment that is
necessary for specific tasks.
Pos : 6.7 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 6.8 /KN2006- SM/Installation & Inbetri ebnahme/003 1.1.0 Elektrische Anlage_Gefahr! @ 23\mod_1144397463440_2.doc @ 86397
Pos : 6.10 /KN 2006-SM /Installati on & Inbetriebnahme/003 1.1.0 Sic hern g egen Wiedereinschalten_Gefahr! @ 9\mod_1144397709746_2.doc @ 86414
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Hot runner technology
Pos : 6.12 /KN 2006-SM /Installati on & Inbetriebnahme/003 1.1.0 Gr undl egendes _Warnung! @ 12\mod_1144396463455_2.doc @ 86390
WARNING!
Danger of injury due to improper installation
and commissioning!
Improper installation and commissioning can result
in severe personal injury or material damage.
Therefore:
– Prior to beginning installation, ensure that there
is sufficient space to work.
– Handle open sharp-edged components with
care.
– Make sure that the assembly location is clean
and well organized. Components that are
loosely stacked or lying around can cause
accidents.
– Assemble components properly. Comply with
specified screw tightening torques.
– Secure components so that they cannot fall or
tip over.
Pos : 6.13 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
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6.2 Preparations
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External housing installed on the mould with adequately long spacer sleeves
due to convection of heat?
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Hot runner technology
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Tools
Hex wrenches
Torque wrench
Cross-bladed/flat-bladed screwdriver
Wire strippers
Crimping tool
Side cutters
Depth gauge
Micrometer
Hydraulic/pneumatic connection
Pos : 6.19 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 H öhenaufbau messen @ 83\mod_1221124801860_2.doc @ 1315216
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Hot runner technology
Dimensions Measurement
[mm]
Dimension “L”
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The dimension “K” necessary for the heat expansion (see sheet
“Height adjustment/dimension check” in the appendix) must be
provided by grinding the pressure pads (12 mm).
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Hot runner technology
Pos : 6.23 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & In betriebnahme/Tabelle Wärmedehnspalt “K” @ 56\mod_1200391190741_2.doc @ 898221
Pos : 6.25 /KN 2006-SM /Installati on & Inbetriebnahme/005 1.1 Installation_Titel @ 9\mod_1144401700720_2.doc @ 86428
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Hot runner technology
6.3 Installation
Pos : 6.26 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/005 1.1.1 Montage der Heiß en Seite @ 56\mod_1199966467489_2.doc @ 894333
NOTE!
The system is sealed, if the height is adjusted
correctly, by the pretension between material tube
(nozzle) and the surface of the manifold.
Steps 1 to 16 are the same as the actions for assembling valve
gate systems with a lifting plate or sliding cam mechanism.
NOTE!
Using a permanent marker (e.g. Edding felt tip pen)
the layer of ink is thinner than, e.g., engineering
blue and therefore the imprint is clearer.
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Hot runner technology
4. Fit clamping plate (1) to the frame plate (3). If necessary, fit
struts and check the exact height.
5. Using a torque wrench (2), tighten the screws to the stipulated
tightening torque (for tightening torque see section “Tightening
torques”).
CAUTION!
Damage due to incorrect wiring!
If the wires are laid incorrectly, they may be
damaged, e.g., by heat.
Fig. 16: Fitting nozzles For this reason:
– Ensure the wires do not touch the manifold.
DANGER!
Mortal danger due to electrical power!
There is immediate mortal danger on physical
contact with live parts.
For this reason:
– Only have work on the electrical system
undertaken by electricians.
NOTE!
Depending on the cavity plate, screws longer than
the guide pillars may need to be screwed into the
frame plate for support. As an alternative, the
mould can also be supported with strips.
8. Place the assembled clamping and frame plate including the
nozzle on the struts in the horizontal direction.
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Hot runner technology
CAUTION!
Risk of burns due to hot surfaces!
Contact with hot components can cause burns.
For this reason:
– During all work near hot components, always
wear protective clothing and gloves.
– Prior to all work, ensure all components have
cooled to ambient temperature.
12. Check imprints between nozzles (2) and manifold (1) and
clamping plate and pressure pads.
CAUTION!
Damage due to leaks!
Improper or incorrect height adjustment can result
in leaks.
For this reason:
– If the imprints are inadequate, check height
adjustment again.
Fig. 17: Check nozzle for leaks
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Hot runner technology
14. Fit nozzles (1) to the frame plate (2) and tighten using a
torque wrench taking into account the stipulated tightening
torque (for tightening torques see section “Tightening
torques”).
15. Lay wire 3 in the cable channel (for wiring diagram see
appendix).
NOTE!
Depending on the cavity plate, screws longer than
the guide pillars may need to be screwed into the
Fig. 19: Fitting nozzles frame plate for support. As an alternative, the
mould can also be supported with strips.
For further assembly steps on valve gate systems with lifting
plate mechanism, see section “Assembly of valve gate systems
with lifting plate mechanism”
For further assembly steps on valve gate systems with sliding
cam mechanism, see section “Assembly of valve gate systems
with sliding cam mechanism”
16. Fit clamping plate (1) to the frame plate (3). If necessary, fit
struts and check the exact height.
17. Using a torque wrench (2), tighten the screws to the stipulated
tightening torque (for tightening torque see section “Tightening
torques”).
18. Wire the mould are per the schedule and circuit diagram (see
appendix).
DANGER!
Mortal danger due to electrical power!
There is immediate mortal danger on physical
contact with live parts.
For this reason:
– Only have work on the electrical system
undertaken by electricians.
Fig. 21: Wiring mould
40 www.guenther-heisskanal.de
Hot runner technology
19. Check wiring and record resistance values in the table below.
Heaters: Resistance
and insulation
resistance (max.
1,000 V)
Temperature sensor
resistance
The “hot half” has been completed and checked for correct
function.
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Hot runner technology
1. Fit guide sleeves (3) and needle receptacle (2) to the lifting
plate mechanism.
2. Using a torque wrench, tighten the screws (1) to the stipulated
tightening torque (for tightening torques see section
“Tightening torques”).
3. Fit lifting plate (1) to the manifold frame plate and using a
torque wrench, tighten the screws to the stipulated tightening
torque (for tightening torques see section “Tightening
torques”).
4. Fit guide pins (2) and ball guide.
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Hot runner technology
DANGER!
Mortal danger due to electrical power!
There is immediate mortal danger on physical
contact with live parts.
For this reason:
– Only have work on the electrical system
undertaken by electricians.
9. Check wiring and record resistance values in the table below.
Thermocouple resistance
Pos : 6.30 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/005 1.1.1 Montage von N adel verschl usss ystemen mit Sc hi ebemechanis mus @ 83\mod_1221200777747_2.doc @ 1316109
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Hot runner technology
1. Fit clamping plate (1) to the manifold frame plate and using a
torque wrench, tighten the screws to the stipulated tightening
torque (for tightening torques see section “Tightening
torques”).
NOTE!
Due to the high temperature long-life grease, the
sliding cam mechanism will function correctly over
a long period even with high temperatures in the
area of the frame plate and clamping plate (up to
100 °C). Pay attention to the data sheets from the
Fig. 28: Control rails manufacturer of the high temperature long-life
grease.
4. Assemble components.
5. Undertake function test in the clamping plate.
NOTE!
If necessary, the control rails must be reworked by
grinding.
6. Lubricate lubrication ducts at the grease nipples.
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Hot runner technology
WARNING!
Risk of injury due to moving components!
Moving components can cause serious injuries.
For this reason:
– Do not reaching into moving parts.
8. Check the function of the sliding cam mechanism in
conjunction with the drive medium.
Fig. 29: Fitting drive cylinder
9. Wire the mould are per the schedule and circuit diagram (see
appendix).
DANGER!
Mortal danger due to electrical power!
There is immediate mortal danger on physical
contact with live parts.
For this reason:
– Only have work on the electrical system
undertaken by electricians.
10. Check wiring and record resistance values in the table below.
Thermocouple resistance
Pos : 6.32 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/005 1.1.1 Ei nbau der N adel @ 83\mod_1221198529182_2.doc @ 1316063
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Hot runner technology
CAUTION!
Risk of burns due to hot surfaces!
Contact with hot components can cause burns.
For this reason:
– During all work near hot components, always
wear protective clothing and gloves.
1. Warm up hot runner system to processing temperature (see
manual for the machine's control system).
2. Screw needle (1) into the needle receptacle (2) and fit in the
lifting plate mechanism (3).
3. Fit cover (1) to the lifting plate mechanism (3) and using a
torque wrench, tighten the screws (2) to the stipulated
tightening torque (for tightening torques see section
“Tightening torques”).
46 www.guenther-heisskanal.de
Hot runner technology
Pos : 6.34 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1 Hi nweise zum Nadel versc hluss @ 83\mod_1221457411820_2.doc @ 1317653
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Hot runner technology
Prerequisites CAUTION!
Damage due to improper preparation!
If attention is not paid to the following information,
the needle guide or the needle may be damaged.
For this reason:
– It is imperative the following information is
followed.
The hot runner system and the mould are completely installed
and wired.
The needle drive is in the “Needle closed” position.
The needles are pre-adjusted so that they do not collide with
the needle guide during “needle closing”.
The needles are around 1 mm behind the edge of the item.
Adjusting needle 1. Connect the mould to the control system (see manual for the
control system) and to the temperature control.
CAUTION!
Risk of burns due to hot surfaces!
Contact with hot components can cause burns.
For this reason:
– During all work near hot components, always
wear protective clothing and gloves.
2. Bring mould to operating temperature.
3. Warm up hot runner system to processing temperature (see
manual for the control system).
4. Fix the needle drive in the “needle closed” position (e.g. using
compressed air on the “Close needle” connection”).
48 www.guenther-heisskanal.de
Hot runner technology
3 mm M8 x 0.50 15 Nm
5 mm M10 x 0.75 30 Nm
Pos : 6.36 /KN 2006-SM /Installati on & Inbetriebnahme/007 1.1 Ers tinbetriebnahme_Titel @ 9 \mod_1144401802375_2.doc @ 86435
6.5 Commissioning
Pos : 6.37 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/Ersti nbetri ebnahme @ 83\mod_1221459809859_2.doc @ 1317700
WARNING!
Mortal danger due to hydraulic energy!
Hydraulic energy can cause serious or mortal
injuries.
Hydraulically driven parts can move unexpectedly.
If individual parts are damaged, hydraulic fluid may
escape under high pressure.
For this reason:
– Only have work undertaken on the hydraulics by
trained skilled personnel.
– Prior to starting work on the hydraulic system,
first shut it down and de-pressurise it. Fully de-
pressurise accumulator.
Check that it is de-pressurised.
– Do not change pressure settings beyond the
maximum values.
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Hot runner technology
WARNING!
Risk of injury due to pneumatic energy!
Pneumatic energy can cause very serious injuries.
Pneumatically driven parts can move unexpectedly.
In case of damage to individual components, air
may escape under high pressure and, e.g. injury
your eyes.
For this reason:
– Only have work undertaken on the pneumatics
by trained skilled personnel.
– Prior to starting work on the pneumatic system,
first de-pressurise it. Pay attention to the
accumulator. Also fully de-pressurise it.
– Do not change pressure settings beyond the
maximum values.
CAUTION!
Damage due to placing in operation the
hydraulic or pneumatic system prematurely!
The system is only sealed at operating
temperature.
For this reason:
– Only place in operation hydraulic or pneumatic
system once the system has been heated up to
operating temperature.
NOTE!
During initial commissioning, a little smoke may
be produced due to the evaporating corrosion
inhibitor.
50 www.guenther-heisskanal.de
Hot runner technology
Standard Prerequisites:
The mould is connected to the cooling circuits and the related
system via a hose connection as per the temperature control
diagram and the temperature stipulated is set.
The hot runner system is connected to the control system (see
manual for the control system).
NOTE!
The maximum permissible operating pressure in
the hot runner system is 2,000 bar.
1. Bring mould to stipulated temperature.
2. Warm up hot runner system to processing temperature using
the soft-start function in the control system (see manual for
the control system).
3. Starting up: Fill system with low pressure. During this process
observe injection speed and mould characteristics.
Valve-gate NOTE!
To achieve appropriate needle speeds (needle
closing time 20–40 ms / 7–10 mm travel), the
operating valve (hydraulic/pneumatic) must be
designed to a corresponding size. Dimension the
connection hoses to suit the flow rate. Keep the
distance between pressure generation and load
(mould) low.
NOTE!
Pay attention to the balancing of the oil feed and oil
outlet ducts as well as of the air feed and air outlet
ducts.
1. Switch on mould temperature control.
NOTE!
Using the soft-start function the manifold is warmed
up to approx. 100 °C and kept at this temperature
for approx. 10 minutes.
2. Warm up manifold to processing temperature using the soft-
start function in the controller (see manual for the controller).
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Hot runner technology
NOTE!
To prevent cold material residue in the nozzles, the
nozzle temperature on warming up/starting the hot
runner system must be set approx. 20K higher,
taking into account the material data from the
manufacturer of the plastic. After reaching the
required temperature the hot runner must be heated
through for 10 minutes. Only then is it allowed to
actuate the needles and start with the injection.
In addition, the hot runner should always be shut
down with the needles closed so the needles do
not have to expel cold material from the PM pieces
the first time they are closed.
3. Ensure prior to actuating the drive that the specified
processing temperature for the plastic has been reached.
NOTE!
During initial commissioning, several injection
operations may be necessary to completely fill the hot
runner with plastic. Until complete part filling is
achieved, the cavities must be checked for remaining
incompletely filled parts at the end of every cycle.
For the final check, use the “Hot runner system
checklist” (see section “Appendix”).
Recommendation for process The holding pressure and the holding pressure time should be
parameters on the valve-gate set as low as possible.
The nozzle and mould temperature should be in the upper third
of the temperature range specified by the material
manufacturer. This setting should ensure that the needle can
close without problems and no damage to the components can
be produced by already solidified plastic in the injection gate.
The settings can be optimised starting from this point.
If the needle no longer closes completely, the upper limit for the
holding pressure time has been reached. The holding pressure
time should then be reduced again by approx. 5-10%.
52 www.guenther-heisskanal.de
Hot runner technology
Pos : 6.38 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 6.39 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1 Anmer kung en/Hinweise @ 93\mod_1235546918087_2.doc @ 1402404
6.6 Comments/notes
Pos : 6.40 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 Anguss punkt @ 93\mod_1235547164608_2.doc @ 1402425
6.6.1 Gate
The function of the hot runner nozzle is significantly affected by
the diameter øD ( Fig. 35) of the gate.
NOTE!
98% of all faults on commissioning a mould are
due to the incorrect design of the gate geometry.
Gate geometry
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Hot runner technology
NOTE!
You can download the “Delta-Tool” program for
determining ΔL on our website www.guenther-
heisskanal.de.
Pos : 6.42 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 Anspritzen auf einer sc hrägen Fläc he @ 93\mod_1235547310023_2.doc @ 1402448
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Hot runner technology
Pos : 6.43 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 6.44 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 Anspritzen über einen Z wisc henang uss @ 93 \mod_1235547377034_2.doc @ 1402471
Pos : 6.46 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 R üc kwärtiges Ans pritzen auf einer H oc hglanz-Sic htfl äche @ 93\mod_1235547680312_2.doc @ 1402494
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Hot runner technology
Operation
7 Operation
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7.1 Safety
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Personal protective equipment Wear the following protective equipment during all work related to
operation:
Protective clothing
Safety shoes
Safety glasses
Pos : 7.5 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75473
7.2 Switching on
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See manual for the injection moulding machine and notes in the
section “Installation and initial commissioning”.
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Hot runner technology
Operation
See manual for the injection moulding machine and notes in the
section “Installation and initial commissioning”.
Pos : 7.13 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
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On shutting down the hot runner system, all control circuits can be
switched off at the same time.
CAUTION!
Damage due to improper shut down!
A build up of heat after shutting down can cause
damage to the hot runner system.
For this reason:
– Place needles in the “closed” position.
– Leave the mould cooling to run at around 30 °C
for around 30 minutes.
Pos : 7.15 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
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NOTE!
The specific processing temperature for the plastic
must be reached prior to actuating the drive.
If the melt is purged through the open mould/the hot runner,
open the needles during injecting-through and close during the
dosing phase.
Pos : 7.17 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
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Hot runner technology
Operation
NOTE!
The specific processing temperature for the plastic
must be reached prior to actuating the drive.
Increase hot runner temperature by approx. 20 °C
(maximum upper processing temperature).
Continue processing with new colour.
If necessary, continue processing with higher injection pressure
and/or higher injection speed.
For very small shot weights, it is recommended to first inject
through the open mould – however only with back pressure or
with low injection pressure.
NOTES!
Evaluate design of the mould.
Ensure the inserts/mould plates are adequately
bolted in place.
_TT nozzle must remain fitted in the cavity plate to
avoid damage to the system.
NOTE!
For a quicker colour change, it is recommended to
use cleaning granulate. Various trials have shown
that by using cleaning granulate, a colour change
can also be performed with good results even with
TPE. During this process the different temperature
ranges of the cleaning granulate must be taken into
account.
Pos : 7.19 /KN 2006-SM /nL.......... Sei tenumbr uch .......... @ 8\mod_1141998334703_0.doc @ 75491
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Hot runner technology
Operation
Pos : 7.20 /KN 2006-SM /Bedi enung/007 1.1 Stillsetzen i m N otfall _Titel @ 9\mod_1144405047456_2.doc @ 86622
After rescue measures 7. Inform the responsible authorities, if required by the severity of
the incident.
8. Deploy expert personnel to rectify the fault.
WARNING!
Danger to life caused by too early switching on
again!
Danger to life for all persons in the danger zone
when switching the machine back on.
Therefore:
– Before switching on again make sure that no
persons are inside the danger zone.
9. Check the machine and ensure that all safety features have
been installed and are fully functional before restarting the
machine.
Pos : 8.1 /F I/.......... Seitenumbr uch .......... @ 0\mod272_2.doc @ 1523
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Hot runner technology
Troubleshooting
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8 Troubleshooting
The following chapter describes possible causes of faults and the
steps required to eliminate them.
In the event of frequent faults, reduce the maintenance intervals to
correspond to the actual working load.
In the event of faults that cannot be eliminated through the
following instructions, please contact the manufacturer (service
address on page 2).
Pos : 8.3 /KN2006- SM/Stör ung en/002 1.1 Sic herheit_Titel @ 9\mod_1144439648502_2.doc @ 86965
8.1 Safety
Pos : 8.4 /KN2006- SM/Stör ung en/003 1.1.0 Pers onal --> Standar d --> ggf. anpas sen @ 12\mod_1144439649253_2.doc @ 86972
Pos : 8.6 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Stör ungen/003 1.1.0 Persönliche Sc hutzausr üstung --> Kopier vorlag e @ 83\mod_1221476507902_2.doc @ 1318393
Personal protective equipment Wear the following protective equipment during all troubleshooting
work:
Protective clothing
Safety shoes
Safety glasses
NOTE!
Specific reference is made in the warnings in this
section to additional protective equipment that is to
be worn for specific tasks.
Pos : 8.7 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 8.8 /KN2006- SM/Stör ung en/003 1.1.0 El ektrisc he Anl age_Gefahr! @ 12\mod_1144439649994_2.doc @ 86979
60 www.guenther-heisskanal.de
Hot runner technology
Troubleshooting
Pos : 8.10 /KN 2006-SM /Störungen/003 1.1.0 Sic her n geg en Wi ederei nsc halten_Gefahr! @ 9\mod_1144439652427_2.doc @ 87000
Pos : 8.12 /KN 2006-SM /Störungen/003 1.1.0 Grundlegendes _Warnung! @ 12\mod_1144439650705_2.doc @ 86986
Pos : 8.14 /KN 2006-SM /Sic her hei t/007 Besondere Gefahr en/Heiß e Oberfl äc hen_Vorsicht! @ 8\mod_1143375956657_2.doc @ 81349
www.guenther-heisskanal.de 61
Hot runner technology
Troubleshooting
Pos : 8.16 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Störungen/HIN WEIS! Kalibrier ung der Regelg eräte @ 83\mod_1222245026000_2.doc @ 1322567
NOTE!
In case of controllers, depending on the frequency
of use and the ambient conditions, calibration in
accordance with BGV A3 must be performed at
least once a year (see manual for controllers).
Pos : 8.17 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 8.18 /KN 2006-SM /Störungen/003 1.1.0 Verhalten bei Stör ung en (Ger ät) @ 12 \mod_1144441786782_2.doc @ 87241
NOTE!
The chapter “Troubleshooting” below provides
information on who is authorised to eliminate the
fault.
Pos : 8.19 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
62 www.guenther-heisskanal.de
Hot runner technology
Troubleshooting
8.2.1 Defects
Defect Problem Rectification Rectification by
Foreign body in the Higher nozzle temperature Clean nozzles (see Specialist
injection gate than usual section “Cleaning personnel
Injection gate quality poorer nozzles”)
Foreign body in the Black and fan-shaped burns Remove foreign body Specialist
nozzle/material tube spread over the entire item from the hot runner personnel
Temperature actual value at nozzle, remove material
the nozzle fluctuates during tube/nozzle tip
injection by ± 20 K
Nozzle in contact in the Insulation gap inadequate Adapt for fore chamber Specialist
fore chamber area Higher temperatures geometry to the personnel
necessary GÜNTHER specifications
www.guenther-heisskanal.de 63
Hot runner technology
Troubleshooting
Dimension “L” in the The tip is too far back at the Change the installation Specialist
mould too large injection gate and is not dimension “L” to suit the personnel
adequately supplied with heat specification of 200.00
Example: The dimension “L” has mm
been manufactured too large by
the toolmaker:
Required: 200.00 mm;
Actual: 202.7 mm
64 www.guenther-heisskanal.de
Hot runner technology
Troubleshooting
The pressure to close the The needle closing force is Increase pressure depending on Specialist
needle is too low too low type of drive (pneumatic max. personnel
10 bar, hydraulic max. 60 bar)
Incorrect control signal The “Close needle” Check control signal, change Specialist
command arrives too late program if necessary personnel
or too early
Diameter of the pipework The hose diameter is too Adapt diameter; use hoses as Specialist
(pneumatic/ small for the required short as possible personnel
hydraulic hoses) is too amount of oil/air
small
The mechanism is jammed Broken metal parts, chips Check mechanism and clean or Specialist
by soiling or damage or similar are jamming the repair personnel
mechanism
Holding pressure time too The material in the Reduce holding pressure time Specialist
long injection gate area has and increase temperature in the personnel
already solidified gating area
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Hot runner technology
Troubleshooting
Pos : 8.23 /KN 2006-SM /Störungen/007 1.1 Inbetriebnahme nac h behobener Störung_Titel @ 12\mod_1144442691882_2.doc @ 87276
66 www.guenther-heisskanal.de
Hot runner technology
Maintenance
9 Maintenance
Pos : 9.3 /KN2006- SM/War tung/002 1.1 Sic herheit_Titel @ 9\mod_1144434831619_2.doc @ 86811
9.1 Safety
Pos : 9.4 /KN2006- SM/War tung/003 1.1.0 Pers onal --> Standar d --> ggf. anpassen @ 13\mod_1144434832402_2.doc @ 86818
Pos : 9.6 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Wartung/003 1.1.0 Persönliche Sc hutz ausr üstung -->Kopier vorlage @ 56\mod_1200041876826_2.doc @ 894743
Personal protective equipment Wear the following protective equipment during all maintenance
work:
Protective clothing
Safety shoes
Safety glasses
NOTE!
Specific reference is made in the warnings in this
section to additional protective equipment that is to
be worn for specific tasks.
Pos : 9.7 /KN2006- SM/nL---------- Abschnittsende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 9.8 /KN2006- SM/War tung/003 1.1.0 El ektrisc he Anl age_Gefahr @ 21\mod_1144434833265_2.doc @ 86825
Pos : 9.10 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Störungen/HIN WEIS! Kalibrier ung der Regelg eräte @ 83\mod_1222245026000_2.doc @ 1322567
NOTE!
In case of controllers, depending on the frequency
of use and the ambient conditions, calibration in
accordance with BGV A3 must be performed at
least once a year (see manual for controllers).
Pos : 9.11 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
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Hot runner technology
Maintenance
Pos : 9.12 /KN 2006-SM /Wartung/003 1.1.0 Sic her n geg en Wi eder einsc halten_Gefahr @ 9\mod_1144434835685_2.doc @ 86846
Pos : 9.14 /KN 2006-SM /Wartung/003 1.1.0 Grundlegendes _Warnung @ 13 \mod_1144434834059_2.doc @ 86832
Pos : 9.16 /KN 2006-SM /Sic her hei t/007 Besondere Gefahr en/Heiß e Oberfl äc hen_Vorsich t! @ 8\mod_1143375956657_2.doc @ 81349
Pos : 9.18 /KN 2006-SM /Wartung/004 1.1.0 U mwelts chutz _Titel @ 9 \mod_1144436206520_2.doc @ 86867
68 www.guenther-heisskanal.de
Hot runner technology
Maintenance
Pos : 9.22 /KN 2006-SM /Wartung/006 1.1 Wartungs plan_Titel (Anleitung) @ 13\mod_1144437014193_2.doc @ 86888
Pos : 9.24 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/006 1.1.0 Wartungspl an @ 56\mod_1200041918869_2.doc @ 894763
Every 200,000 shots (on Clean needle drive mechanism Specialist personnel
usage of thermoplastic
elastomer (TPE) or
polymers for which the
viscosity is heavily reduced
by shearing)
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Hot runner technology
Maintenance
Pos : 9.26 /KN 2006-SM /Wartung/007 1.1 Wartungs arbeiten_Titel @ 13\mod_1144437737575_2.doc @ 86902
CAUTION!
Damage due to incorrect clamping of the
nozzle!
If the nozzle is clamped incorrectly, the material
tube may rotate as well on drilling out the plastic.
This situation could cause damage to the heater
and/or thermocouple connections.
Fig. 42: Clamping nozzle For this reason:
– Always clamp the nozzle at the nozzle housing.
2. Clamp nozzle at the nozzle housing (2) in a vice fitted with
aluminium jaws (1 and 3).
CAUTION!
Damage due to inserting the drill too far!
On drilling out the plastic, ensure you do not drill
too far into the material tube, as the cross-section
of the bore reduces at point (1). The drilling depth
is dependent on the nozzle type and the nozzle
length.
70 www.guenther-heisskanal.de
Hot runner technology
Maintenance
NOTE!
The diameter of the drill must be 0.2 mm to 0.5 mm
smaller than the diameter of the material tube. The
material tube diameter is dependent on the nozzle
type.
CAUTION!
Risk of injury due to hot surfaces!
You may suffer burns on touching the nozzle.
For this reason:
– After warming up the nozzle, only pick it up
using the connections (1).
CAUTION!
Damage due to improper removal of the
insulating cap!
On pulling off the insulating cap, the nozzle tip may
come undone if the cap is rotated to the left. If it is
rotated to the right, the nozzle tip may be
damaged.
For this reason:
– Only pull off insulating cap when warmed up.
Fig. 46: Removing insulating cap
– Always pull off insulating cap straight to the
front.
5. Pull off insulating cap (1) straight to the front.
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Hot runner technology
Maintenance
CAUTION!
Risk of injury due to hot plastic!
You may suffer burns on contact with the plastic
expelled.
For this reason:
– During all work near hot components, always
wear protective clothing and gloves.
– Ensure nobody can be hit by the plastic
expelled.
7. Apply several compressed air pulses to the material tube.
NOTE!
The diameter of the wire brush should be same as
the diameter of the material tube.
10. Repeat steps 7 to 9 until no more plastic is expelled at the
nozzle or the material tube.
Fig. 48: Wire brush
72 www.guenther-heisskanal.de
Hot runner technology
Maintenance
12. Insert an external thermometer (3) from the rear into the
material tube and push into the nozzle to the nozzle tip stop
(1).
13. Compare temperature with the required temperature set.
NOTE!
The temperature measured at the nozzle tip is
around 50 °C below the required temperature set
on the controller.
Fig. 49: Measuring positions for external
temperature measurement
NOTE!
The temperature measured is around 80 to 90 °C
below the required temperature set on the
controller. When installed, this temperature
difference is compensated in conjunction with a hot
manifold.
NOTE!
If the temperature measurement is made with a flat
temperature sensor applied directly to the nozzle
tip, the result measured will be incorrect. The
temperature measured on the nozzle tip is
significantly below the temperature that is actually
present in the nozzle.
NOTE!
Have damaged or worn nozzle tips changed
by GÜNTHER (for contact data see page 2).
In general it is possible to replace nozzle tips
within a day.
Pos : 9.28 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
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Hot runner technology
Maintenance
Pos : 9.29 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/1.1.1 D üsentemper atur inner hal b des Werkzeuges mes sen @ 90 \mod_1229086610466_2.doc @ 1373331
NOTE!
Have damaged or worn nozzle tips changed by
Fig. 50: Measuring position for external GÜNTHER (for contact data see page 2). In general
temperature measurement it is possible to replace nozzle tips within a day.
Pos : 9.30 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 9.31 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/007 1.1.1 N adel r einigen @ 83 \mod_1222236126821_2.doc @ 1322466
CAUTION!
Damage due to improper cleaning!
Improper cleaning can cause damage to the needle.
For this reason:
– Do not clean needle by sand blasting.
– Do not use abrasive techniques for cleaning.
NOTE!
Useful aids for releasing the plastic:
Cleaning spray manufactured by Klüber Chemie
(Lusin Clean L 21)
Solvent, e.g. acetone
Cloth manufactured by Kingspor (Micro Fine Grey,
article number 264053)
What to do if the plastic cannot be 3. Heat needle to maximum 752 °F using a gas flame.
removed using solvents 4. Remove plastic residue using a brass brush.
5. Leave needle to cool to ambient temperature.
6. Fit needle (see section “Installation of the needle”).
Pos : 9.32 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
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Hot runner technology
Maintenance
Pos : 9.33 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/007 1.1.1 Verteiler Rei nigen @ 83\mod_1222236034875_2.doc @ 1322443
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Hot runner technology
Maintenance
NOTE!
On manifolds with shrunk deflection plugs, only
these techniques are suitable or possible.
Mechanical
NOTE!
The drill diameter must be 0.2 mm to 0.5 mm
smaller than the diameter of the material duct to
prevent damage to the surface of the ducts.
4. Using a round wire brush clamped in the battery-operated
drill, brush out the material ducts.
5. Sand-blast manifold.
NOTE!
On manifolds (2) for valve gate systems, the fits (3)
in the assembly seals (1) must be protected
against the blasting medium.
76 www.guenther-heisskanal.de
Hot runner technology
Maintenance
Fit manifold
1 Cross bore
2 Nozzle outlet bore
3 Sealing surface
4 Sealing plug
5 Threaded plug
6 Sealing surface
7 Connection element
M10 x 1 30 Nm
M12 x 1 75 Nm
M14 x 1 80 Nm
M24 x 2 200 Nm
www.guenther-heisskanal.de 77
Hot runner technology
Maintenance
NOTE!
In valve gate systems, the tightening torque is
20 Nm lower in the area of fit H5 – sealing
element.
In area Ø 8 mm: M12 x 1; 35 to 40 Nm.
6. Check imprint. Ensure the imprint and the sealing surface are
correct.
10. Mark or paint sealing surface (6) on the connection flange (7)
with engineer's blue.
11. Screw in connection flange (7) and tighten with tightening
torque of 200 Nm.
13. Check imprint. Ensure the imprint and the sealing surface (6)
are correct.
14. Fit connection element (7) and tighten with tightening torque
of 200 Nm.
3. Screw in socket.
78 www.guenther-heisskanal.de
Hot runner technology
Maintenance
Fitting assembly seals for valve 1. Check the fit and the sealing surface for damage or soiling. If
gate systems necessary, clean using fine emery paper or round wire brush
(not using the drill).
2. Fit the new assembly seal and check for correct seating
(measure).
3. Screw in the thread for the union nut and tighten to a torque of
30 Nm.
Pos : 9.34 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 9.35 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/1.1.1 O-Ri ng Dichtungen bei Ei nzel nadel ventil en taus chen @ 83\mod_1221470372362_2.doc @ 1318245
CAUTION!
Risk of burns due to hot surfaces!
Contact with hot components can cause burns.
For this reason:
– During all work near hot components, always
wear protective clothing and gloves.
1. Warm up hot runner system to processing temperature (see
manual for the machine's control system).
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Hot runner technology
Maintenance
7. Align the O-rings (2) using the floss (1). For this purpose fit the
floss as shown and move around the
O-ring in circles several times.
NOTE!
This step is necessary, as twisting that occurs on
fitting the O-rings would significantly reduce the
service life.
8. Wait around 30 minutes until the elongation of the O-rings has
disappeared.
9. Smear cylinder surface with O-ring grease (see section
Fig. 58: Aligning O-rings
“Lubricants”).
10. Fit piston into cylinder.
Pos : 9.37 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/1.1.1 Schi ebemechanis mus nac hsc hmier en @ 58\mod_1201786694703_2.doc @ 1021417
NOTE!
Do not use different greases.
Recommended grease manufactured by Klüber
Lubrication: Barrierta L55/2 high temperature long-
Fig. 59: Re-lubricating sliding cam
life bearing grease (for safety data sheet, see
mechanism www.klueber.de).
The grease can be procured via GÜNTHER (for
address see page 2) or via the manufacturer.
80 www.guenther-heisskanal.de
Hot runner technology
Maintenance
NOTE!
On older hot runner systems, the lubrication of the
sliding cam mechanism is undertaken via the
existing ball-valve impact holes (1) in accordance
with DIN 3410 form F.
Pos : 9.39 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/Hi nweis Korrosi ons schutzmi ttel @ 56\mod_1200395196048_2.doc @ 898377
NOTE!
To prevent corrosion on hot runner moulds, these
are often sprayed with LUSIN PROTECT G11 and
O45 corrosion inhibitor manufactured by Klüber.
Both inhibitors form an electrically insulating layer
if heated (like paint).
The corrosion inhibitors have the property of
penetrating into the finest hairline cracks and
corners. For this reason, it may occur that the
contacts on the thermoplug for hot runner nozzles
become insulated and as a result problems occur.
On spraying the hot runner parts, ensure the plugs
for the thermocouple and power connections are
covered or masked prior to spraying so that they
are not sprayed as well.
Pos : 9.40 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 9.41 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/1.1.1 Ver unr einigungen @ 90\mod_1229078400819_2.doc @ 1373286
9.3.7 Soiling
Remove melt that escapes from the seal on the manifold due to the
lifting movement of the needle using a pry bar.
Pos : 9.42 /KN 2006-SM /nL.......... Sei tenumbr uch .......... @ 8\mod_1141998334703_0.doc @ 75491
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Hot runner technology
Maintenance
Pos : 9.43 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/1.1 Anz ugsdr ehmomente_Titel @ 56\mod_1200392789903_2.doc @ 898319
12.9 12.9
M4 6,900 4.8
M5 11,300 9.5
M6 16,000 16
M8 29,300 40
M10 46,600 79
M10 x 1 30 Nm
M12 x 1 75 Nm
M14 x 1 80 Nm
M24 x 2 200 Nm
NOTE!
In valve gate systems, the tightening torque is
20 Nm lower in the area of fit H5 – sealing
element.
In area Ø 8 mm: M12 x 1; 35 to 40 Nm.
82 www.guenther-heisskanal.de
Hot runner technology
Maintenance
Pos : 9.45 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 9.46 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/Tabelle Anzugs drehmomente des Gewindes z ur Nadeljus tage @ 56\mod_1200393170997_2.doc @ 898358
Ø 2 mm M6 x 0.50 9
Ø 3 mm M8 x 0.50 15
Ø 5 mm M10 x 0.75 30
Pos : 9.47 /KN 2006-SM /nL.......... Sei tenumbr uch .......... @ 8\mod_1141998334703_0.doc @ 75491
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Hot runner technology
Maintenance
Pos : 9.48 /KN 2006-SM /Wartung/009 1.1 M aß nahmen nac h erfolgter Wartung_Titel @ 9 \mod_1144438930025_2.doc @ 86930
84 www.guenther-heisskanal.de
Hot runner technology
Disassembly
10 Disassembly
Pos : 10.3 /KN 2006-SM /Demontag e/002 1 Sicherheit_Titel @ 9\mod_1144870285363_2.doc @ 89613
10.1 Safety
Pos: 10.4 /KN2006-Projekte/Günther Heißkanaltechnik/Demontage/003 1.1.0 Personal Demontage @ 101\mod_1274427633185_2.doc @ 1575117
Personnel Disassembly is only allowed to be undertaken by specially
trained skilled personnel.
Work on the electrical system is only allowed to be
undertaken by electricians.
Pos : 10.5 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 10.6 /KN 2006-SM /Demontag e/003 1.1.0 Elektrische Anl age_Gefahr @ 13\mod_1144870286332_2.doc @ 89620
Pos : 10.8 /KN 2006-SM /Sic her hei t/007 Besondere Gefahr en/H ydrauli k_Warnung! @ 8\mod_1143376338046_2.doc @ 81358
Hydraulics WARNING!
Danger to life caused by hydraulic energies!
Hydraulic energies can cause severe or even fatal
injuries.
Hydraulically driven parts may unexpectedly start
to move.
In case of damage to individual components
hydraulic fluid may escape under high pressure.
Therefore:
– Have work on the hydraulic system only carried
out by trained expert personnel.
– Before starting work on the hydraulic system
shut down the system and relieve the pressure.
Completely relieve pressure accumulators.
– Do not change pressures to values higher than
the specified maximum values.
Pos : 10.9 /KN 2006-SM /nL---------- Abschnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
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Disassembly
Pos : 10.10 /KN 2006-SM/Sicherheit/007 Bes ondere Gefahr en/Pneumati k_Warnung! @ 8\mod_1143377778556_2.doc @ 81395
Pneumatics WARNING!
Danger of injury caused by pneumatic
energies!
Pneumatic energies can cause severe injuries.
Pneumatically driven parts may start to move
unexpectedly.
In the event of damage to individual components,
air can escape under high pressure and e.g.
damage the eyes.
Therefore:
– Have work on the pneumatic system carried out
only by trained expert personnel.
– Before starting work on the pneumatic system,
shut down the system and relieve the pressure.
Be careful of pressure accumulators. Relieve
also the pressure in accumulators.
– Do not change pressures to values higher than
the specified maximum values.
Pos : 10.11 /KN 2006-SM/nL---------- Absc hnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 10.12 /KN 2006-SM/D emontage/003 1.1.0 Gr undleg endes_Warnung @ 13 \mod_1144870287285_2.doc @ 89627
86 www.guenther-heisskanal.de
Hot runner technology
Disassembly
Pos : 10.14 /KN 2006-Proj ekte/Günther Heiß kanal tec hni k/D emontage/VOR SICHT! U nsachg emäß e D emontage @ 90\mod_1229077021065_2.doc @ 1373264
CAUTION!
Damage due to improper dismantling!
Improper dismantling can result in damage to the
hot runner.
For this reason:
– During the disassembly of form inserts in
conjunction with the needle guide type VA, the
needle must be in the “open” position.
– Ensure the hot runner system is switched off.
Pos : 10.15 /KN 2006-SM/nL---------- Absc hnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 10.16 /KN 2006-Proj ekte/Günther Heiß kanal tec hni k/D emontage/1.1 Ausbau der N adel @ 83\mod_1221465964230_2.doc @ 1317774
CAUTION!
Risk of burns due to hot surfaces!
Contact with hot components can cause burns.
For this reason:
– During all work near hot components, always
wear protective clothing and gloves.
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Hot runner technology
Disassembly
3. Unscrew the needle (2) from the needle receptacle (1) and
pull out using hammer-action puller.
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Disassembly
Pos : 10.18 /KN 2006-Proj ekte/Günther Heiß kanal tec hni k/D emontage/1.1 D emontage Heiß e Sei te @ 83\mod_1221468415169_2.doc @ 1318003
DANGER!
Mortal danger due to electrical power!
There is immediate mortal danger on physical
contact with live parts.
For this reason:
– Only have work on the electrical system
undertaken by electricians.
1. Disconnect wiring.
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Hot runner technology
Disassembly
Pos : 10.20 /KN 2006-Proj ekte/Günther Heiß kanal tec hni k/D emontage/008 1.1 D emontag e und Entsorgung @ 98\mod_1247642320494_2.doc @ 1477046
Scrap metals.
Send plastic elements for recycling.
90 www.guenther-heisskanal.de
Hot runner technology
Disassembly
CAUTION!
Pollution due to incorrect disposal!
Incorrect disposal of materials used will cause
pollution.
For this reason:
– Correctly dispose of electrical scrap, electronic
scrap, lubricants and other oils and greases, if
necessary task a specialist organisation with
disposal.
Pos : 11.1 /KN 2006-SM /nL.......... Sei tenumbr uch .......... @ 8\mod_1141998334703_0.doc @ 75491
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Appendix
12 Appendix
Pos : 12.3 /KN 2006-SM /nL.......... Sei tenumbr uch .......... @ 8\mod_1141998334703_0.doc @ 75491
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Appendix
Pos : 12.4 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Anhang/1.1 T ec hnis che Infor mationen @ 98\mod_1247643068111_2.doc @ 1477100
Pos : 12.5 /KN 2006-SM /nL.......... Sei tenumbr uch .......... @ 8\mod_1141998334703_0.doc @ 75491
GÜNTHER system designer CADHOC V2
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Hot runner technology
Appendix
Pos : 12.6 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Anhang/1.1 H öhenaufbau/Maß kontroll e @ 83\mod_1221477148605_2.doc @ 1318517
Pos : 12.7 /KN 2006-SM /nL.......... Sei tenumbr uch .......... @ 8\mod_1141998334703_0.doc @ 75491
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Hot runner technology
Appendix
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General points
Tip length ∆ t °C mm
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Appendix
Valve gate
Barrierta L55/2
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Hot runner technology
Appendix
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We herewith declare that the unit identified below complies with the provisions of the EC directives noted
below. If it is incorporated in another machine, putting into service is prohibited until it has been determined
that the machine into which the unit identified below is incorporated is compliant with the provision of the
EC Machinery directive 2006/42/EC, Annex VII part B with the applicable Appendix.
Identifier:
Ident number:
_________________________ _________________________
Place and data Quality Manager
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Hot runner technology
Index
13 Index
A M
light.................................................................. 14 O
Copyright .............................................................. 9 P
E disassembly ....................................................85
F maintenance ....................................................67
I installation .......................................................32
Liability .................................................................. 8 Q
Lubricants ........................................................... 19 R
Replacement part list ..........................................92
Replacement parts ..............................................92
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Hot runner technology
Index
S T
Safety Technical data .................................................... 20
general ........................................................... 10 Transport ...................................................... 27, 29
Safety boots ....................................................... 14 Crane ........................................................ 29, 30
Safety features ................................................... 17 Forklift truck .................................................... 30
Safety goggles ................................................... 14 Inspection ....................................................... 29
Spare parts ...........................................................9 Troubleshooting ................................................. 60
Storage ........................................................ 27, 31 Chart ............................................................... 63
Surfaces Type plate .......................................................... 22
hot ...................................................... 17, 62, 68 U
Switching off....................................................... 57 Usage ................................................................. 13
Switching on....................................................... 56 W
Securing against ............................................ 18 Warranty............................................................... 9
Symbols Warranty conditions ............................................. 8
in this manual ....................................................7
Packing........................................................... 28
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