Page 1 HPS III valve gate Valid for: hot runner systems HPS III-S nozzles HPS III-T/TE manifolds Operating manual Single drive units Synchronous plate drives Complete hot halves Version: 2.0...
Page 3: Table Of Contents
Content General remarks ................................7 Information on this operating manual ..........................7 Manufacturer ................................. 7 Formal information on the operating manual ........................ 7 Conventions .................................. 8 1.4.1 Instructions and system responses ..........................8 1.4.2 Enumerations ................................8 1.4.3 Abbreviations ................................8 Safety instructions ..............................
Page 4 Content 5.1.4 Attachment points ............................... 22 5.1.5 Working load limit for lifting accessories and slings ....................22 5.1.6 Removal from transport crate ............................24 5.1.7 Transport and movement during installation ....................... 24 General safety instructions ............................26 Technical Requirements .............................. 29 5.3.1 Tools and operating materials .............................
Page 5 Content 5.6.6 Wiring of 6-drop hot runner systems (manifold with 2 control zones) ................. 95 5.6.7 Wiring of 8-drop hot runner systems (manifold with 2 control zones) ................. 96 5.6.8 Wiring of 8-drop hot runner systems (manifold with 4 control zones) ................. 97 Checks after installation ..............................
Page 6 Content Instructions for disposal ............................135 Tightening torques ..............................136 Tightening torques for socket head screws ....................... 136 Tightening torques for manifold screw connections and retaining screws ..............138 Tightening torques for tip inserts ..........................139 9.4 Tightening torques for screws to fix the valve pin in the valve pin retainer ............... 140 Tightening torques for drive units ..........................
Page 7: General Remarks
1.3 Formal information on the operating manual Person in charge of documentation: Henning Becker Item number: not specified Version: Printing date: 21/04/2020 Language: German (original operating manual) © Copyright, 2020 All rights reserved. Full or partial reproduction subject to prior written approval by EWIKON Heißkanalsysteme GmbH HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN...
Page 8: Conventions
General remarks 1.4 Conventions 1.4.1 Instructions and system responses Operating steps that have to be carried out by the operator are displayed as a numbered list. The sequence of the steps has to be adhered to. Example: 1. Operating step 1 2.
Page 9: Safety Instructions
Safety instructions 2. Safety instructions The HPS III hot runner system conforms to the machinery directive 2006/42/EG and has been designed, manufactured and checked for safety according to the applicable safety rules and legislation and the state of the art. The HPS III hot runner system is delivered in perfect working order.
Page 10: Signal Words For Hazard Classification
Safety instructions 2.1.1 Signal words for hazard classification HAZARD! 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, will result in death or serious injury. CAUTION! indicates a potentially hazardous situation which, if not avoided, will result in minor injury or material damage.
Page 11: Intended Use
Any different and unintended use is excluded and may result in personal injuries and material damage. Warranty expires in this case. EWIKON hot runner systems and single nozzles are only to be used for injection moulding applications, assembled in an enclosed injection mould. They are used to process thermoplastic resins according to their individual processing requirements and to pass them gently from the injection unit to the cavity by optimum temperature distribution and flow paths.
Page 12: Personal Protective Equipment (Ppe)
Safety instructions 2.5 Personal Protective Equipment (PPE) Wear the necessary protective equipment when working on or near the machine. Special information on the personal protective equipment in the work area has to be observed. 2.5.1 Symbols of the personal protective equipment Always wear the following when carrying out any work: Protective clothes: To protect your body wear tight-fitting clothes with low resistance to tearing, without protruding parts and with long sleeves and long trousers.
Page 13 Safety instructions Risk of burns • Hot surfaces Many components of the hot runner systems get very hot and may cause severe skin burns when being touched. • Hot material (plastic melt) Never touch material leaking from the nozzle/the mould/the hot runner or the material inlet. Even material that seems to be cooled down already may still be hot inside the core and cause burns.
Page 14: Electrical Equipment
The use of non-OEM spare and wear parts as well as auxiliary material may pose risks. Only use original parts or parts approved by EWIKON Heißkanalsysteme GmbH. Only use auxiliary and operating materials which are suitable for their intended use (compare chapter „5.3 Technical Requirements“).
Page 15: Warranty Terms
2.10 Warranty terms For warranty conditions of cold and hot runner systems and components please refer to the terms and conditions of EWIKON. 2.11 Standards and directives EWIKON hot runner systems conform to the following European directives: • Machinery Directive 2006/42/EC •...
Page 16: Technical Data
Technical data 3. Technical data 3.1 Mechanical specifications 3.1.1 Main dimensions of the HPS III hot runner system Description Quantity/size (approx.) Unit Dimensions See catalogue / PO-related documents mm Weight See catalogue / PO-related documents kg Chart 2: Main dimensions of the HPS III hot runner system 3.1.2 Operating parameters of the HPS III hot runner system Description Quantity/size (approx.)
Page 17: Cooling Agent
Technical data 3.4.2 Cooling agent The use of unsuitable cooling agents may result in deposits and corrosion in the component to be cooled. This will negatively affect the functionality of the hot runner system. Components of the hot runner system may be damaged by a reduced coo- ling performance in the worst case. Cooling agents (water) have to satisfy the following minimum requirements: •...
Page 18: Functional Description Of The Hps Iii Hot Runner System
Functional description of the HPS III hot runner system 4. Functional description of the HPS III hot runner system The schematic diagrams of the components of a HPS III hot runner system and the installation space shown in this docu- ment should not be regarded as the only valid general layout but only present one of many possible assembly configura- tions.
Page 19 Functional description of the HPS III hot runner system Start of cycle Valve gate nozzle(s) open(s)* Valve gate nozzle(s) close(s)* Picture 3: Injection moulding cycle * for valve gate systems ** recommended for open systems A hot runner system is used to distribute plastic melt between the injection moulding unit of an injection moulding machine and the cavities of an injection mould (compare picture 2).
Page 20: Installation
Installation 5. Installation The following information is intended to help you install the HPS III hot runner system. In addtion, the assembly staff has to have the know-how required to install an HPS III hot runner system. The described installation processes are examples for standard nozzles and standard systems. Special systems may require different procedures! Please observe the instructions in the order specific documents. 5.1 Transport This chapter describes how to transport a hot runner system without damaging it and how to ensure occupational safety for the staff.
Page 21: Recommended Lifting Accessories And Slings
• • Spacer bolt for attachment swivel (allowed for L2X systems only, can only be purchased from EWIKON). The spacer bolts must not be used for other transport processes! See PPicture 6. They should only be used when attach- ment swivels can not be used for lack of space.
Page 22: Attachment Points
Before transport the working load limit for the used lifting accessories and slings must be checked in the following order: 1. How heavy is the load? • The weight of single components, systems or hot halves is indicated on the EWIKON note of delivery (net weight, without packaging). If this information is not available anymore the weight can be estimated. However, there should be a sufficient margin up •...
Page 23 Installation 3. Is one single attachment point sufficient to lift the load vertically stretched or is more than one attachment point necessary to lift the load? Only for the transport of hot halves, nozzle sides or individual mould plates usually one single attachment point is suffici- • ent (see Picture 13) as the gravity centre usually coincides with the attachment point! In this case the lifting capacity is 100 %.
Page 24: Removal From Transport Crate
Depending on the manufacturer and design of the attachment swivel the maximum possible load capacity must no longer be utilized. If the attachment swivels recommended by EWIKON are used for such installation work (see chapter „5.1.2 Recommended lifting accessories and slings“), the maximum load capacity of an attachment swivel should always be reduced by at least the half.
Page 25 Installation Putting hot runner assemblies (hot halves, mould plates, manifolds or L2X systems) from lying (horizontal) into upright (vertical) position. 1. The hot runner assembly must be placed on an even, 100% load capacity non-slip surface. 2. Screw in attachment swivels and affix them to a crane. 3. Put a wooden lath on the working surface and secure against slipping.
Page 26: General Safety Instructions
Installation NOTE! Pay attention to system characteristics The work steps described just show how to move the system most commonly. Depending on the system layout further measures which have to be determined individually may be necessary to move and assemble hot runner assemblies in a safe way.
Page 27 Dimensional check (for details please also see chapter „5.4 Checks before installation“) Check of the given installation dimensions, fit sizes, form and location tolerances of the mould plates surround- ing the hot runner system (for information please see the current catalogues in the download section on www. ewikon.com). The following dimensions have to be checked in particular: • Mould plate dimensions.
Page 28 Installation Protect the cable ends When wiring the system make sure that the thermo and power lines do not protrude from the outer edges of the mould and are protected against damage. The distances between hot runner and cables inside the mould have to be dimensioned in such a way that there is no damage to the components caused by excessive heat.
Page 29: Technical Requirements
Installation 5.3 Technical Requirements Specific connections and hoses are used for supply lines (hydraulic, cooling water). 5.3.1 Tools and operating materials Tool Version EWIKON item no. Abrasive paper / Exchange of nozzle heater Various non-woven web Allen key For hexagon socket head cap screw Depending on system and components. according to DIN EN ISO 4062 For wrench sizes see chapter „9.
Page 30 Installation Tool Version EWIKON item no. Cleaning of flow channels Maintenance mouthpiece ask EWIKON Mandrel Installation of cable marker Metal cable tie Fixation of cables of L2X systems 19667 Multimeter Measuring of resistance Outside micrometre Control of check dimensions Oxy-acetylene burner Deinstallation of a screw bush...
Page 31 Installation Tool Version EWIKON item no. For specifications see manufacturer Webbing slings and round Lifting and moving of hot halves, slings systems (L2X) and plate assemblies Wire brush, soft Cleaning of e.g sealing surfaces Preferably brass wire, do not use brass- coated wire or steel wire...
Page 32: Standard Parts
Only standard parts which are approved for operation in EWIKON hot runner systems must be used. The following standard parts with the associated standards are approved for EWIKON hot runner systems. Particularly for screws the associated strength classes (see chapter 5.5 Assembly of the system / the components) and tightening torques (compare chapter „9.
Page 33: Checks Before Installation
Check of gate diameter NOTE! See the EWIKON HPS III catalogue, chapter 5 "General assembly notes" , for a detailled description of general assembly notes and mould layout. The current version of the catalogue can be found on www.ewikon.com in the download section.
Page 34: Dimensions To Be Checked For A Hps Iii Hot Runner System With Hps Iii-S Nozzles For Standard Installation And Front Installation
Installation 5.4.3 Dimensions to be checked for a HPS III hot runner system with HPS III-S nozzles for standard installation and front installation z349-01 Picture 22: Example: Dimensions to be checked for a HPS III hot runner system with HPS III-S nozzles for standard installation and front installa- tion HPS-III-Heißkanalsystem_Vorspann-Prüfmaße-System_BA_V-2-0_EN...
Page 35 (The screw connection for the manifold is only as shown in the drawing (recommended by required when nozzles for standard installation are EWIKON) or grinding of the top pressure pads used. When nozzles for front installation are on the manifold.
Page 36: Installation Of Hps Iii Valve Gate Hot Runner Systems
Installation of HPS III valve gate hot runner systems 5.5 Installation of HPS III valve gate hot runner systems 5.5.1 Installation of valve gate systems with individual drive units and synchronous plate systems for HPS III-S nozzles for standard and front installation z381-01 Picture 23: General layout of a valve gate system with with individual drive units and synchronous plate systems for HPS III-S nozzles for standard and front installation...
Page 37 Pos. 54 Intermediate plate Use approved standard parts only Pos. 56 Contour plate Only standard parts which are approved for use in EWIKON hot runner systems must be used. See chapter „5.3 Technical Requi- rements“. Screw connection for manifold The screw connection for the manifold (pos.
Page 38: Installation Of A Hps Iii-S Valve Gate Nozzle
Installation of HPS III valve gate hot runner systems 5.5.2 Installation of a HPS III-S valve gate nozzle Installation of a HPS III-S valve gate nozzle for standard installation HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents.
Page 39 Installation of HPS III valve gate hot runner systems Installation of a HPS III-S valve gate nozzle for front installation HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
Page 40: Manifold Installation
(pos. 53) and the contact surface for the centre support of the manifold and compare it to the value given in the drawing provided by EWIKON. z342-04 Picture 26: Check of reference dimensions before installation of...
Page 41 Installation of HPS III valve gate hot runner systems Manifold installation - installation procedure z345-14 Picture 29: Screw connection for manifold with socket head screws (only for standard installation!) z342-05 Picture 28: Installation of manifold (left: standard installation, right: front installation) 1.
Page 42: Installation Of Valve Gate Systems With Individual Drive Units For Hps Iii-S Nozzles For Standard And Front Installation
Installation of HPS III valve gate hot runner systems 5.5.4 Installation of valve gate systems with individual drive units for HPS III-S nozzles for standard and front installation z342-25 Picture 30: General layout of a valve gate system with individual drive units for HPS III-S nozzles for standard and front installation HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 43 Use approved standard parts only Pos. 53 Nozzle retainer frame plate Only standard parts which are approved for use in EWIKON hot Pos. 56 Contour plate runner systems must be used. See chapter „5.3 Technical Requi- rements“.
Page 44 Installation of HPS III valve gate hot runner systems HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 45: Drive Unit Integrated In Clamping Plate (Version 1)
7. Connect the supply lines for compressed air / hydraulic fluid to the corresponding connections in the clamping plate. 8. Pressurise the supply bore (F: Forward) (hydraulic pressure max. 50 bar - EWIKON recommendation 30 bar; pneumatic pressure max. 10 bar - EWIKON recommendation 6 bar) so that the piston is fully pushed into the "valve pin closed" position. Thereby the housing bottom (pos.
Page 46 Installation of HPS III valve gate hot runner systems Drive unit integrated in clamping plate (version 1) - check of clearance ∆S, installation of clamping plate and locating ring z342-08 Picture 33: Check of clearance ∆S and subsequent installation steps HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 47 (pos. 53) and compare it to Connected power supply during installation the value given in the drawing provided by EWIKON. 2. Install the clamping plate (pos. 51) and the insulating Risk of deadly electric shock or severe injuries due to live compo- nents.
Page 48 Installation of HPS III valve gate hot runner systems HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 49: Drive Unit Integrated In Clamping Plate (Version 2)
Installation of HPS III valve gate hot runner systems 5.5.6 Drive unit integrated in clamping plate (version 2) - Installation in the clamping plate WARNING! Sharp edges and heavy components • Cut injuries to body and extremities, mainly to the hands. Crushing of fingers or hand.
Page 50 Installation of HPS III valve gate hot runner systems Drive unit integrated in clamping plate (version 2) - check of clearance ∆S, installation of clamping plate and locating ring z342-10 Picture 35: Check of clearance ∆S and subsequent installation steps HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 51 (pos. 53) and compare it to Connected power supply during installation the value given in the drawing provided by EWIKON. 2. Install the clamping plate (pos. 51) and the insulating Risk of deadly electric shock or severe injuries due to live compo- nents.
Page 52 Installation of HPS III valve gate hot runner systems HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 53: Drive Unit Placed On Manifold (Coupled)
Installation of HPS III valve gate hot runner systems 5.5.7 Drive unit placed on manifold (coupled) Installation on the manifold z342-11 Picture 36: Drive unit placed on manifold (coupled) - installation 1. Slide the drive unit (pos. 9) carefully and without tilting over the centring device (pos.
Page 54 Installation of HPS III valve gate hot runner systems Drive unit placed on manifold (coupled) - check of clearance ∆S, installation of clamping plate and locating ring z342-12 Picture 37: Check of clearance ∆S and subsequent installation steps HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 55 The hot runner system and the mould have to be disconnected clamping plate. For more information regarding connec- from the voltage source during installation. tions and accessories see the EWIKON valve gate main catalogue. WARNING! 4. Install the insulating plate (pos. 50).
Page 56: Drive Unit Placed On Manifold (Screwed-On) (Version 1)
Installation of HPS III valve gate hot runner systems 5.5.8 Drive unit placed on manifold (screwed-on) (version 1) Check of clearance ∆S, installation on the manifold z342-13 Picture 38: Drive unit placed on manifold (coupled) - check of clearance ∆S and installation on the manifold HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 57 (pos. 53) and compare it to Connected power supply during installation the value given in the drawing provided by EWIKON. 2. Slide the drive unit (pos. 10) carefully and without tilting Risk of deadly electric shock or severe injuries due to live compo- nents.
Page 58 Installation of HPS III valve gate hot runner systems Drive unit placed on manifold (screwed-on) (version 1) installation of clamping plate and locating ring z342-14 Picture 39: Installation of clamping plate and locating ring HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 59 HAZARD! in the clamping plate. For more information regarding Connected power supply during installation connections and accessories see the EWIKON valve gate main catalogue. Risk of deadly electric shock or severe injuries due to live compo- nents.
Page 60: Drive Unit Placed On Manifold (Screwed-On) (Version 2)
Installation of HPS III valve gate hot runner systems 5.5.9 Drive unit placed on manifold (screwed-on) (version 2) Check of clearance ∆S, installation on the manifold z342-23 Picture 40: Drive unit placed on manifold (coupled) - check of clearance ∆S and installation on the manifold HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 61 (pos. 53) and compare it to Connected power supply during installation the value given in the drawing provided by EWIKON. 2. Place cooling ring (pos. 14.1) flush with socket head Risk of deadly electric shock or severe injuries due to live compo- nents.
Page 62 Installation of HPS III valve gate hot runner systems Drive unit placed on manifold (screwed-on) (version 2) installation of clamping plate and locating ring z342-24 Picture 41: Installation of clamping plate and locating ring HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 63 HAZARD! in the clamping plate. For more information regarding Connected power supply during installation connections and accessories see the EWIKON valve gate main catalogue. Risk of deadly electric shock or severe injuries due to live compo- nents.
Page 64: Installation Of Valve Pin
Installation of HPS III valve gate hot runner systems 5.5.10 Installation of valve pin The installation process described below is valid for the following drive unit versions: • Drive unit integrated in clamping plate (version 1) • Drive unit integrated in clamping plate (version 2) •...
Page 65 Installation of HPS III valve gate hot runner systems HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 66: Electric Drive Unit
Installation of HPS III valve gate hot runner systems 5.5.11 Electric drive unit Check of clearance ∆S, installation of clamping plate and locating ring z342-17 Picture 44: Check of clearance ∆S and subsequent installation steps HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 67 (pos. 53) and compare it to Connected power supply during installation the value given in the drawing provided by EWIKON. 2. Install the intermediate plate (pos. 54), the insulating Risk of deadly electric shock or severe injuries due to live compo- nents.
Page 68 Installation of HPS III valve gate hot runner systems Electric drive unit - installation in the clamping plate z342-19 Picture 46: Installation of an electric drive unit HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 69 Cut injuries to body and extremities, mainly to the hands. Crushing of fingers or hand. • me provided by EWIKON. 4. Wire the nozzles and the manifold according to the Control of live components before installation wiring scheme. Please pay attention to the notes in The electrical equipment of the hot runner system should be chapter „5.6 Electrical connection of hot runner sys-...
Page 70: Installation Of Synchronous Plate Valve Gate Systems For Hps Iii-S Nozzles For Standard And Front Installation
Installation of HPS III valve gate hot runner systems 5.5.12 Installation of synchronous plate valve gate systems for HPS III-S nozzles for standard and front installation z381-02 Picture 47: General layout of a synchronous plate valve gate system for HPS III-S nozzles for standard and front installation HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 71 Pos. 25 Guiding system (version 2) Use approved standard parts only (for restriceted installation space) Only standard parts which are approved for use in EWIKON hot Pos. 50 Insulating plate runner systems must be used. See chapter „5.3 Technical Requi- rements“.
Page 72: Drive Unit Integrated In Clamping Plate (Version 2) For Synchronous Plate Systems
Installation of HPS III valve gate hot runner systems 5.5.13 Drive unit integrated in clamping plate (version 2) for synchronous plate systems - Installation in the clamping plate WARNING! Sharp edges and heavy components • Cut injuries to body and extremities, mainly to the hands. Crushing of fingers or hand.
Page 73: Installation Of The Synchronous Plate Version 1
Installation of HPS III valve gate hot runner systems 5.5.14 Installation of the synchronous plate version 1 z381-05 Picture 49: Installation of the synchronous plate version 1 1. Bolt the intermediate plate (pos. 54) to the nozzle retai- ner frame plate (pos. 53). WARNING! 2.
Page 74: Installation Of The Guiding System Version 1 For Synchronous Plate Systems
Installation of HPS III valve gate hot runner systems 5.5.15 Installation of the guiding system version 1 for synchronous plate systems z381-06 Picture 50: Installation of the guiding system version 1 1. Screw the shoulder screw (pos. 23) into the intermediate plate (pos.
Page 75 Installation of HPS III valve gate hot runner systems Installation of the guiding system (version 1) for synchronous plate systems 1. Screw the guide bushing with flange (pos. 24.3) with socket head screws (pos. 24.4) into the clamping plate (pos. 51) and tighten with matching torque. See chapter „9.
Page 76: Installation Of The Synchronous Plate And Guiding System Version 2
Installation of HPS III valve gate hot runner systems 5.5.16 Installation of the synchronous plate and guiding system version 2 z381-09 Picture 52: Installation of the synchronous plate and guiding system version 2 HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 77 Installation of HPS III valve gate hot runner systems Installation of the synchronous plate and guiding system version 2 1. Drive the guide pillar (pos. 25.1) into the intermediate plate (pos. 54) as far as it will go. WARNING! 2. Apply a thin coat of high performance grease (see chap- Suspended load ter „5.3.1 Tools and operating materials“) to the ball cage (pos.
Page 78: Installation Of The Valve Pin (For Version 1 And 2)
Installation of HPS III valve gate hot runner systems 5.5.17 Installation of the valve pin (for version 1 and 2) z381-10 Picture 53: Installation of the valve pin 1. Insert the valve pin (pos. 17) carefully into the valve pin retainer (pos.
Page 79: Adjusting The Valve Pin Length By Adapting The Spacer Bushings (For Version 1 And 2)
Installation of HPS III valve gate hot runner systems 5.5.18 Adjusting the valve pin length by adapting the spacer bushings (for version 1 and 2) z381-07 Picture 54: Adapting the spacer bushing 1. Grind both end faces of the spacer bushings (pos. 8.3) neatly (max.
Page 80: Dimensional Check For Adjusting The Valve Pin Length (For Version 1 And 2)
Installation of HPS III valve gate hot runner systems 5.5.19 Dimensional check for adjusting the valve pin length (for version 1 and 2) z381-08 Picture 55: Specifications for spacer bushing and valve pin length HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 81 Dim. A: Protrusion of the valve pin in cold condition. This dimension position (valve pin closed). Hold the supply pressure. is contained in the drawing provided by EWIKON. 3. Use gauge blocks (accuracy class 1) to built the protru- Gauge blocks: Gauge blocks are blocks which are manufactured sion of the valve pin A (see Note) + min.
Page 82: Installation Of A Hot Half With Hps Iii Valve Gate Nozzles
„5.4 Checks before installation“ must be checked and compared with the values provided with the installation drawing. Use approved standard parts only Only standard parts which are approved for use in EWIKON hot runner systems must be used. See chapter „5.3 Technical Requi- rements“.
Page 83 Introduction and preliminary measures z351-03 Picture 56: Preliminary measures 1. Lift the hot half carefully out of the transport crate. Due to the better force application point EWIKON re- WARNING! commends to use attachment swivels only (pos. a, see Suspended load chapter „5.1 Transport“...
Page 84 Installation of HPS III valve gate hot runner systems Installation z351-09 Picture 57: Installation HPS-III-Nadelverschluss-Heißkanalsystem_Montage_BA_V-2-0_EN...
Page 85 Connected power supply during installation installation drawing provided by EWIKON. For required reference dimensions also see chapter Risk of deadly electric shock or severe injuries due to live compo- nents.
Page 86: Electrical Connection Of Hot Runner Systems
Electrical connection of hot runner systems 5.6 Electrical connection of hot runner systems 5.6.1 Safety instructions HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live components. • The HPS III hot runner system, the single tip, the hot half and the mould have to be disconnected from the voltage source during installation.
Page 87 Electrical connection of hot runner systems NOTE! Mechanical stress of cable ends The cable ends must not be subject to tensile stress. Protect the cable ends When wiring the system make sure that the thermo and power lines do not protrude from the outer edges of the mould and are protected against damage.
Page 88: General Information
Electrical connection of hot runner systems 5.6.2 General information Wiring of the hot runner components must be performed by qualified staff according to DIN EN 60204-1 and the generally recognized codes of practice. Heaters designed for a rated voltage of 230V AC are used. Please make sure that the voltage applied corresponds to this specification. The heaters are connected to the plug according to the arrangement given in the wiring diagram of the respec- tive hot runner system. The following pictures give an overview of the cable assignment of HPS III nozzles and manifolds. 230V L (orange) N (grey)
Page 89 Electrical connection of hot runner systems Thermo + (black) Side view of manifold - (white) L (brown) 230V N (blue) 230V Thermo Top view of manifold Top view of manifold z343-03 Picture 59: Cable assignment of HPS III manifolds (shown: one control zone) L (black) 230V N (blue)
Page 90 The power and thermo collective plugs are numbered consecutively: (230 V: X-1.1, X-2.1, X-3.1... / Thermo: X-1.2, X-2.2, X-3.2..). EWIKON recommends to apply this numbering scheme also when purchasing components instead of hot halves. A - A view on tips X-2.1...
Page 91 Electrical connection of hot runner systems Wiring order (Example: 6-drop system): The control zones are numbered consecutively, beginning at the position of the first nozzle (top left). Each control zone has a heater and a thermocouple assigned. First all nozzles (H-01 - H-06) should be wired, then all manifold heaters (M-01 - M-02) and at last the heater of the connecting nozzle (CN-01). The contact allocation follows DIN 16765, part A. Detailed wiring instructions for standard system configurations are shown on the following pages.
Page 92: Wiring Of 1-Drop Hot Runner Systems
Electrical connection of hot runner systems 5.6.3 Wiring of 1-drop hot runner systems Picture 63: Wiring of standard-1-drop hot runner systems X-1.1 X-1.2 Key to the symbols Control zone Heater nozzle Heater manifold 230 V Thermo Control Plug 230 V / 10-pin Contact Plug thermo / 10-pin Contact...
Page 93: Wiring Of 2-Drop Hot Runner Systems
Electrical connection of hot runner systems 5.6.4 Wiring of 2-drop hot runner systems Picture 64: Wiring of standard-2-drop hot runner systems X-1.1 X-1.2 Key to the symbols Control zone Heater nozzle Heater manifold 230 V Thermo Control Plug 230 V / 10-pin Contact Plug thermo / 10-pin Contact...
Page 94: Wiring Of 4-Drop Hot Runner Systems (Manifold With 2 Control Zones)
Electrical connection of hot runner systems 5.6.5 Wiring of 4-drop hot runner systems (manifold with 2 control zones) Picture 65: Wiring of standard-4-drop hot runner systems (manifold with two control zones) X-1.1 X-1.2 Key to the symbols Control zone Heater nozzle Heater manifold 230 V Thermo...
Page 95: Wiring Of 6-Drop Hot Runner Systems (Manifold With 2 Control Zones)
Electrical connection of hot runner systems 5.6.6 Wiring of 6-drop hot runner systems (manifold with 2 control zones) Picture 66: Wiring of standard-6-drop hot runner systems (manifold with two control zones) X-1.2 Key to the symbols X-1.1 Control zone Heater nozzle Heater manifold Heater band sprue bush...
Page 96: Wiring Of 8-Drop Hot Runner Systems (Manifold With 2 Control Zones)
Electrical connection of hot runner systems 5.6.7 Wiring of 8-drop hot runner systems (manifold with 2 control zones) Picture 67: Wiring of standard-8-drop hot runner systems (manifold with two control zones) X-1.2 Key to the symbols X-1.1 Control zone Heater nozzle Heater manifold Heater band sprue bush...
Page 97: Wiring Of 8-Drop Hot Runner Systems (Manifold With 4 Control Zones)
Electrical connection of hot runner systems 5.6.8 Wiring of 8-drop hot runner systems (manifold with 4 control zones) Picture 68: Wiring of standard-8-drop hot runner systems (manifold with four control zones) X-2.1 X-2.2 X-1.1 X-1.2 230 V Thermo Key to the symbols Control Plug 230 V / 24-pin Contact...
Page 98: Checks After Installation
(for a short time) • Check response of the respective thermocouple • When using a EWIKON controller this procedure can be automatically carried out by using the diagnosis function. To be checked in heated condition (operating temperature) Leak tightness and function of drive units (hydraulic fluid, pressurised air) by repeatedly moving the valve pin to the end • positions in manual mode while the mould is opened.
Page 99: Start-Up And Instructions For Operation
Injection moulding processes must only be carried out with maximum pressures of 2000 bar. If the process requires higher pressures a written permission of EWIKON Heißkanalsysteme GmbH is needed.
Page 100 Start-up and instructions for operation CAUTION! A HPS III hot runner system must only be started up when used as intended within an injection mould. Respect operating temperatures For all further checks the HPS III hot runner system must be heated to operating tem- perature in order to avoid damage to hot runner components.
Page 101: Requirements For Operation
Start-up and instructions for operation 6.2 Requirements for operation • The radius of the sprue bush (R) or the radius of the contact surface of a single tip respectively has to be adapted to the radius of the machine nozzle (R M ) (recommendation: R > R M + 1). •...
Page 102: Start-Up Of A Hps Iii Hot Runner System
Start-up of a HPS III hot runner system 6.3 Start-up of a HPS III hot runner system NOTE! In general the start-up of a hot runner system with HPS III single tips, a L2X system as well as a valve gate system is carried out analougosly to the start-up of a system with HPS III-S nozzles. Possible differences are specified in the text. Please pay special attention to the instructions for operating a valve gate sytem in chapter „6.4 Instructions for the operation of valve gate systems“.
Page 103 Start-up of a HPS III hot runner system NOTE! If despite of intensive purging old material still remains visible in the moulded part (visible flow marks on the surface or inside transparent parts) the so called „cap“ the area of frozen plastic between nozzle tip and gate must be removed. Recommended tools for the following installation steps The use of non-approved assembly tools may result in damage to the HPS III nozzles. •...
Page 104: Instructions For The Operation Of Valve Gate Systems
This causes damage in the gating geometry. When valve pins are operated in an unfilled system a clamping device must be provided in order to prevent the gate exchange inserts from being pulled out. Suitable solutions are the use of flat headed cylinder screws, clamping sleeves or retaining rings. Depending on the available installation space EWIKON can recommend a suitable clamping version. In general the start-up of valve gate systems is carried out analogous to other externally heated systems. (see chapter „6.3.1 First-time start-up and filling of a HPS III hot runner system“ and „6.3.2 Start-up of an already filled HPS III hot runner system“.
Page 105: Machine Downtimes > 5 Minutes Of Systems With Hps Iii-S Nozzles (System / Single Tip / Single Cavity)
Instructions for the operation of valve gate systems 6.4.1 Machine downtimes > 5 minutes of systems with HPS III-S nozzles (system / single tip / single cavity) • For machine downtimes of more than 5 minutes the temperature of the hot runner system should be decreased (50°C - 60°C below processing temperature) in order to avoid thermal degradation of the material in the system.
Page 106: Possible Malfunctions
Possible malfunctions 6.5 Possible malfunctions 6.5.1 Troubleshooting Error Possible cause / measure Temperature of control zone exceeds Check if the thermocouple and power connections are allocated correctly set temperature (heat up each zone separately). Controller indicates broken thermocoup- Check thermocouple at the nozzle and/or thermocouple cable and controller le.
Page 107: Maintenance
Maintenance 7. Maintenance 7.1 Safety instructions WARNING! Hot surfaces / hot material (plastic melt) Body burns by hot surfaces. • Let the HPS III hot runner system and all components cool down completely to ambient temperature before starting maintenance work / disassembling. Never touch material leaking from the nozzle/the mould/the hot runner or the material inlet.
Page 108: Installation / Deinstallation Of Nozzle Tips
If a nozzle tip can not be screwed out use the controller to raise the nozzle temperature in steps. • If the nozzle tip is still not screwable please contact the EWIKON customer service. See chapter „7.7 Inst- ructions for service and repair“.
Page 109: General Information
Two-piece nozzle tips always have a separate item number for each of their components. Tipp: In case that a cleaning of the flow channel of the nozzle is required EWIKON offers a maintenance mouthpiece with drill guide. See chapter „5.3.1 Tools and operating materials“. The maintenance mouthpiece is installed after the tip insert has been removed (replaces the tip insert). It allows the precise insertion of a drill bit to remove most of the frozen plastic in the flow channel. The diameter of the drill bit should be 1/10 mm...
Page 110: Versions Of Nozzle Tips, Nosepieces And Screw-On Gate Bushes
Maintenance 7.4.3 Versions of nozzle tips, nosepieces and screw-on gate bushes z352-01 Picture 70: Overview of the different versions of nozzle tips, mouth pieces and screw-on gate bushes Pos. 1 Example: HPS III-S nozzle for standard installation Pos. 1.7 Nozzle tip with sealing ring (one-piece) HPS III-S nozzle for front installation Pos. 1.8 Nozzle tip with nosepiece (one-piece) HPS III-SXE single tip Pos.
Page 111: Exchange Of Nozzle Tips With Nozzle Installed In The Mould
Maintenance 7.4.4 Exchange of nozzle tips with nozzle installed in the mould Standard installation An exchange of nozzle tips must only be carried out when the nozzle is locked against rotation by a dowel pin in the mould. Otherwise the heater or the thermocouple may be teared off. Attention: When HPS III-S nozzles with flow channel Ø...
Page 112: Deinstallation Of One-Piece Nozzle Tips
Maintenance 7.4.6 Deinstallation of one-piece nozzle tips WARNING! Sharp edges and heavy components • Cut injuries to body and extremities, mainly to the hands. Crushing of fingers or hand. • Hot surfaces Burns to the body caused by hot surfaces. NOTE! When nozzle tips of HPS III nozzles or HPS III-SXE single tips are z352-07 exchanged while the nozzle is installed in the mould a lock against rotation (dowel pin, pos 1.10) must be installed.
Page 113: Installation Of One-Piece Nozzle Tips
Maintenance 7.4.7 Installation of one-piece nozzle tips WARNING! Sharp edges and heavy components • Cut injuries to body and extremities, mainly to the hands. Crushing of fingers or hand. • Hot surfaces Burns to the body caused by hot surfaces. NOTE! When nozzle tips of HPS III nozzles or HPS III-SXE single tips are z352-14 exchanged while the nozzle is installed in the mould a lock against rotation (dowel pin, pos 1.10) must be installed.
Page 114: Deinstallation Of Two-Piece Nozzle Tips
Maintenance 7.4.8 Deinstallation of two-piece nozzle tips WARNING! Sharp edges and heavy components • Cut injuries to body and extremities, mainly to the hands. Crushing of fingers or hand. • Hot surfaces Burns to the body caused by hot surfaces. NOTE! z352-07 Picture 77: Disassembly of contour plate (HPS III-S nozzle) When nozzle tips of HPS III nozzles or HPS III-SXE single tips are exchanged while the nozzle is installed in the mould a lock against rotation (dowel pin, pos 1.10) must be installed.
Page 115: Installation Of Two-Piece Nozzle Tips
Maintenance 7.4.9 Installation of two-piece nozzle tips WARNING! Sharp edges and heavy components • Cut injuries to body and extremities, mainly to the hands. Crushing of fingers or hand. • Hot surfaces Burns to the body caused by hot surfaces. NOTE! When nozzle tips of HPS III nozzles or HPS III-SXE single tips are z352-11 exchanged while the nozzle is installed in the mould a lock against rotation (dowel pin, pos 1.10) must be installed.
Page 116 HPS-III-Heißkanalsystem_Instandhaltung-Fühlerwechsel-S-SXE_BA_V-2-0_EN...
Page 117: Hps Iii-S Nozzles - Exchange Of Thermocouple
Maintenance 7.5 HPS III-S nozzles – exchange of thermocouple 7.5.1 Safety instructions WARNING! Hot surfaces Body burns by hot surfaces. Sharp edges and tips Cut injuries to body and extremities, mainly to the hands CAUTION! Cleaning of nozzles, threads and sealing surfaces Damage to sealing surfaces during installation.
Page 118: Clamping Of Nozzle In A Vice
Maintenance 7.5.2 Clamping of nozzle in a vice z352-03 Picture 85: Clamping of a deinstalled HPS III nozzle in a vice For exchanging the thermocouple at HPS III-S nozzles a vice is required. Protective jaws (pos. 70, preferrably made CAUTION! from aluminium), must be used to avoid damage to the Clamping of nozzle in a vice nozzle.
Page 119: Hps Iii-S3 (Valve Gate) Nozzles - Exchange Of Thermocouple
Maintenance 7.5.3 HPS III-S3 (valve gate) nozzles – exchange of thermocouple Picture 86: HPS III-S3 nozzle for standard installation Pos. 1 Tip insert HAZARD! Pos. 2 Protective tube Pos. 3 Thermocouple Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- Pos.
Page 120 Maintenance HPS III-S3 (valve gate) nozzles – exchange of thermocouple 1. Disassemble tip insert if necessary. Pay attention to the notes in chapter „7.4 Installation / deinstallation of nozzle tips“. 2. Clamp the nozzle in the vice at the pressure tube (see „Picture 85: Clamping of a deinstalled HPS III nozzle in a vice“).
Page 121 Maintenance HPS III-S3 (valve gate) nozzles – exchange of thermocouple 7. Disassemble the broken thermocouple from the cutout and pull it out of the bore in the nozzle. Picture 91: Disassemble the broken thermocouple 8. Coat the tip of the new thermocouple with heat trans- ferring paste (see chapter „5.3.1 Tools and operating materials“) and insert it into the bore in the nozzle as far as it will go.
Page 122 Maintenance HPS-III-Heißkanalsystem_Instandhaltung-Fühlerwechsel-S-SXE_BA_V-2-0_EN...
Page 123: Hps Iii-S4.5 (Valve Gate) Nozzles - Exchange Of Thermocouple
Maintenance 7.5.4 HPS III-S4.5 (valve gate) nozzles – exchange of thermocouple Picture 95: HPS III-S4.5 nozzle for standard installation Pos. 1 Tip insert HAZARD! Pos. 2 Protective tube Pos. 3 Thermocouple Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- Pos.
Page 124 Maintenance HPS III-S4.5 (valve gate) nozzles – exchange of thermocouple 1. Clamp the nozzle in the vice at the pressure tube (see „Picture 85: Clamping of a deinstalled HPS III nozzle in a vice“). Picture 96: Clamp the nozzle 2. Pull off the clamping sleeves carefully. Attention! Nozzles for front installation have a clamping sleeve positioned under the nozzle body.
Page 125 Maintenance HPS III-S4.5 (valve gate) nozzles – exchange of thermocouple 4. Pull broken thermocouple out of the bore in the nozzle and disassemble it. 5. Insert the new thermocouple by feeding it under the nozzle body until it reaches the front of the nozzle. (only required for nozzles for standard installation) Picture 99: Disassemble the broken thermocouple 6.
Page 126 Maintenance HPS-III-Heißkanalsystem_Instandhaltung-Fühlerwechsel-S-SXE_BA_V-2-0_EN...
Page 127: Hps Iii-S6/9/12/18 (Valve Gate) Nozzles - Exchange Of Thermocouple
Maintenance 7.5.5 HPS III-S6/9/12/18 (valve gate) nozzles – exchange of thermocouple Picture 102: HPS III-S6 nozzle for standard installation Pos. 1 Tip insert HAZARD! Pos. 2 Protective tube Pos. 3 Thermocouple Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- Pos.
Page 128 Maintenance HPS III-S6/9/12/18 (valve gate) nozzles – exchange of thermocouple NOTE! The thermocouple exchange for HPS III-SXE nozzles (6 / 9 / 12 mm) is carried out analogous to the thermocouple exchange for HPS III-S nozzles (6 / 9 / 12 / 18 mm) as described here. 1.
Page 129 Maintenance HPS III-S6/9/12/18 (valve gate) nozzles – exchange of thermocouple 5. The nozzle heater and the thermocouple are connected by a protective hose and cable ties. Disconnect the ther- mocouple, disassemble the broken thermocouple from the cutout starting at the base of the pressure tube and pull it out of the bore in the nozzle.
Page 130: Deinstallation / Exchange Of Valve Pins
Maintenance 7.6 Deinstallation / exchange of valve pins 7.6.1 Drive units with pistons - deinstallation und exchange of valve pins The procedure for deinstallation of the valve pin as described in the following is valid for the following drive unit versions: •...
Page 131 Maintenance Drive units with pistons - deinstallation und exchange of valve pins 4. After unscrewing the screw the valve pin retainer (pos. 7.7) becomes visible. Screw a threaded rod (pos. c) into the valve pin retainer and connect it with a striking weight (pos.
Page 132: Electric Drive Unit - Deinstallation And Exchange Of Valve Pins
Maintenance 7.6.2 Electric drive unit – deinstallation and exchange of valve pins HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The cold runner system and the mould have to be disconnected from the voltage source during installation.
Page 133: Instructions For Service And Repair
In case of service requests please always have the serial number, order number and type of the used hot runner system ready. • Service www.ewikon.com in the "Contact" menue, submenue "Sales network", "Your contact at EWIKON", "Service department" E-Mail: service@ewikon.com HPS-III-Heißkanalsystem_Servicehinweise_Außerbetriebnahme_BA_V-2-0_EN...
Page 134: Decommissioning
Decommissioning 8. Decommissioning 8.1 Safety instructions HAZARD! Connected power supply during deinstallation Risk of deadly electric shock or severe injuries due to live components. • The hot runner components and the mould have to be disconnected from the voltage source during deins- tallation.
Page 135: Instructions For Disposal
Once disposed components must not be used again. EWIKON disclaims any responsibility for personal injuries and material demage resulting from re-use. In case that no special arrangements regarding return or disposal were agreed with EWIKON the disassembled components have to be recycled after deinstallation: •...
Page 136: Tightening Torques
Only calibrated tightening tools must be used. (When the tightening method/ the tightening tool shows a greater variation (approx. > ±5%) the required tightening torque M A must be appropriately reduced to avoid overstressing (control test required). It must be considered that different tigh- tening methods can show a different variation.) • EWIKON generally recommends to use screws with property class 12.9 only. HPS-III-Heißkanalsystem_Anziehdrehmomente-Zylinderschrauben-Verteilerverschraubung-Halteschrauben_BA_V-2-0_EN...
Page 137 Tightening torques Tightening torques for socket head screws Maximum permissible tightening torque M A at room temperature Lubricated (High temperature Screws in as-delivered condition installation paste, see chapter (slightly oiled) µ G =0.14 „5.3.1 Tools and operating mate- rials“) µ G =0.10 M A [Nm] M A [ft·lb] M A [Nm]...
Page 138: Tightening Torques For Manifold Screw Connections And Retaining Screws
Tightening torques 9.2 Tightening torques for manifold screw connections and retaining screws Thread Tightening torque Lubricated (high temperature installation paste, see chapter „5.3.1 Tools and operating materials“) M A [Nm] M A [ft·lb] Chart 14: Tightening torques for manifold screw connections (for standard installation of nozzles) and retaining screws HPS-III-Heißkanalsystem_Anziehdrehmomente-Zylinderschrauben-Verteilerverschraubung-Halteschrauben_BA_V-2-0_EN...
Page 139: Tightening Torques For Tip Inserts
(see chapter „5.3.1 Tools and operating ma- Width across flats terials“. Installation temperature 220°C. Non-standard tip inserts may require tightening torques which dif- fer from the values given here. In case of doubt always contact EWIKON. Flow channel Ø 3 mm 4.5 mm 6 mm 9 mm...
Page 140: Tightening Torques For Screws To Fix The Valve Pin In The Valve Pin Retainer
Jamming of the valve pin must be avoided! 9.5 Tightening torques for drive units For drive unit For item number Thread Tightening torque (Item number see drawing provided by EWIKON) (screw-in housing Lubricated (high temperature cover) installation paste, see chapter „5.3.1 Tools and operating materials“) M A [Nm] M A [ft·lb]...
Page 141: Tightening Torques For Valve Pin Retainer For Electric Drive Units
9.7 Tightening torques for valve pin seals CAUTION! Replacement of valve pin seals The replacement of valve pin seals may only be carried out from EWIKON trained and specialised staff! Otherwise it may come to leakage during operation and significant material damage. 9.7.1 Tightening torques for one-piece valve pin seals Valve pin Ø [mm]...
Page 142: Tightening Torques For Two-Piece Valve Pin Seals
9.7.2 Tightening torques for two-piece valve pin seals Valve pin Ø [mm] Sealing element Pressure screw Tightening torque item number Thread lubricated (high temperature installation paste, see chapter „5.3.1 Tools and operating materials“) Item number Thread M A [Nm] M A [ft·lb] 22550-SV01 22570 M9x0,75...
Page 143: Tightening Torques For Hps Iii-Nvi Single Valve Gate Nozzles
Tightening torques 9.8 Tightening torques for HPS III-NVI single valve gate nozzles NOTE! Pay attention to preload! The nozzle must be installed with a preload. The preload value de- pends on the nozzle type and is generated by the locating ring. Nozzle type Preload Tightening torque...
Page 144 EWIKON Heißkanalsysteme GmbH Siegener Straße 35 35066 Frankenberg Tel: +49 6451 / 501-0 Fax: +49 6451 / 501-202 E-Mail: info@ewikon.com www.ewikon.com...

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Hps iii-s Hps iii-t Hps iii-te Hps iii

EWIKON HPS III Series Operating Manual

1 General Remarks

2 Safety Instructions

3 Technical Data

4 Functional Description of the HPS III Hot Runner System

5 Installation

6 Start-Up and Instructions for Operation

7 Maintenance

8 Decommissioning

9 Tightening Torques

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