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EWIKON L2X Operating Manual

Drop-in hot runner system
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L2X Drop-in systems
L2X Drop-in valve gate systems
Version: 2.0
L2X Drop-in hot runner system
Operating manual

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Summary of Contents for EWIKON L2X

  • Page 1 L2X Drop-in hot runner system Valid for: L2X Drop-in systems Operating manual L2X Drop-in valve gate systems Version: 2.0...

  • Page 3: Table Of Contents

    Functional description of the HPS III hot runner system ..................18 Installation ................................. 20 Transport ..................................20 5.1.1 Safety information on transport ........................... 20 5.1.2 Recommended lifting accessories and slings ......................21 5.1.3 Check the lifting accessories and slings before use ....................21 HPS-III-L2X-Heißkanalsystem_Inhalt_BA_V-2-0_EN...
  • Page 4 5.4.1 Notes on mould layout ..............................33 5.4.2 Standard dimensions of hot runner systems ......................33 5.4.3 Dimensions to be checked for a L2X Drop-in hot runner system ................34 Installation of L2X Drop-in hot runner systems ......................37 Electrical connection of hot runner systems ........................ 41 5.6.1 Safety instructions ...............................
  • Page 5 7.4.8 Deinstallation of two-piece nozzle tips ........................69 7.4.9 Installation of two-piece nozzle tips ..........................70 L2X (valve gate) nozzles – exchange of thermocouple ....................71 Deinstallation / exchange of valve pins ........................74 7.6.1 Drive units with pistons - deinstallation und exchange of valve pins ................74 7.6.2 Electric drive unit –...
  • Page 6 HPS-III-L2X-Heißkanalsystem_Inhalt_BA_V-2-0_EN...

  • 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

    ]. Possibly protruding areas (nozzles, wiring box) do not have to be taken into consideration. The volume of a manifold (without nozzles) or an L2X system (nozzles have already been screwed to the manifold) can be approached using the largest external dimensions of the manifold (L = largest linear expansion, B = largest width expansion, H = thickness of manifold).
  • Page 23 • At least 2 attachment points are necessary to lift manifolds or L2X systems as otherwise it will not be possible to lift the load in a directed way. This is often absolutely necessary when carrying out installation work. When 2 attachment points are used to lift loads the following situations have to be distinguished: The load is distributed between two evenly stressed but sloping legs (see Picture 14).

  • Page 24: Removal From Transport Crate

    Chart 8: Assessment of stress of slings (source: BGI 556, for detailed information see above) 5.1.6 Removal from transport crate How to remove a hot half, an L2X system or a manifold from a transport crate or a pallet (see Picture 14, Picture 15 and Picture 16).
  • 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

    • Particularly for L2X drop-in systems many system versions are possible. When any transport or assembly work is carried out it has to be ensured that protruding components (e.g. nozzles, heater outlets or wiring) as well as components with reduced stability (e.g.
  • Page 27 Pay attention to temperatures during installation The HPS III hot runner system has to be installed when it is cold (room temperature) (exception: L2X systems). Excessive temperatures during installation may result in damage to the melt sealing area and thus leakage during operation.
  • 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

    19103/19104 Chain slings Lifting and moving of hot halves, According to DIN EN 1677 (with metal tag) systems (L2X) and plate assemblies (metal tag according to DIN 685) Clamping device Maintenance of HPS III-MHR nozzles Cordless screwdriver Exchange of valve pin seal of valve gate...
  • Page 30 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 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 Operating material...

  • 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 L2X Drop-In Hot Runner System

    Installation 5.4.3 Dimensions to be checked for a L2X Drop-in hot runner system z349-04 Picture 22: Example: Dimensions to be checked for a L2X Drop-in hot runner system HPS-III-Heißkanalsystem_Vorspann-Prüfmaße-L2X_BA_V-2-0_EN...
  • Page 35 Installation Example: Dimensions to be checked for a L2X Drop-in hot runner system Installation space (for EWIKON parts) Pos. 1 Locating ring Manifold height Pos. 2 Sprue bush Manifold height Pos. 3 Manifold + top pressure pad Pos. 4 Top pressure pad Manifold height Pos.
  • Page 36 HPS-III-L2X-Heißkanalsystem_Montage_BA_V-2-0_EN...

  • Page 37: Installation Of L2X Drop-In Hot Runner Systems

    Pos. 53 Nozzle retainer frame 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“. Electrical connector box...
  • Page 38 Installation of L2X Drop-in hot runner systems Introduction The installation steps described in the following generally apply for L2X Drop-in hot runner systems for open gating as well as for valve gate systems. Any differences are explicitly mentioned in the describing text. Preliminary measures Dimensions to be checked: Dimension H3 + ∆S between the upper surface of the nozzle retainer frame plate (pos.
  • Page 39 Installation of L2X Drop-in hot runner systems Installation WARNING! Suspended load Death and severe crushing of body or extremities. • Keep clear of and do not pass under suspended loads. • Keep clear of suspended loads while they are being transported.
  • Page 40 (pos. 1.2) and the surface of the nozzle retainer frame plate (pos. 53) and compare it to the value given in the drawing provided by EWIKON. 3. Install the clamping plate (pos. 51) and the insulating plate (pos. 50).

  • Page 41: 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 42 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 43: 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 44 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 30: Cable assignment of HPS III manifolds (shown: one control zone) L (black) 230V N (blue)
  • Page 45 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 46 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 47: Wiring Of 1-Drop Hot Runner Systems

    Electrical connection of hot runner systems 5.6.3 Wiring of 1-drop hot runner systems Picture 34: 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 48: Wiring Of 2-Drop Hot Runner Systems

    Electrical connection of hot runner systems 5.6.4 Wiring of 2-drop hot runner systems Picture 35: 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 49: 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 36: 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 50: 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 37: 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 51: 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 38: 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 52: 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 39: 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 53: 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 54: 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 55 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 56: 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 57: 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 58 (soft wire, see chapter „5.3.1 Tools and operating materials“). 7. Switch off the hot runner. Let the mould cooling stay switched on. 8. Install the contour plate in cold condition. 9. Switch on the hot runner. 10. After processing temperature is reached start moulding. HPS-III-Heißkanalsystem_Inbetriebnahme-System-Einzeldüsen-L2X-NV_BA_V-2-0_EN...

  • Page 59: 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 60: Machine Downtimes > 5 Minutes Of Systems With Hps Iii-S Nozzles (System / Single Tip / Single Cavity)

    • The injection moulding machine should feature a signal input and output to read and send error messages from and to the hot runner controller. • Modern hot runner controllers feature an automatic decreasing function. HPS-III-Heißkanalsystem_Inbetriebnahme-System-Einzeldüsen-L2X-NV_BA_V-2-0_EN...

  • Page 61: 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 62: 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 63: 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 64: General Information

    The installation / deinstallation procedure for nozzle tips described in the following is valid for HPS III-S nozzles for front and standard installation as well as for HPS III-SXE single tips. The nozzle tip exchange for L2X Drop-in hot runner systems is carried out analogous to a HPS III system. If the nozzle tip is installed/deinstalled while the L2X system is not installed in a mould it has to be fixed by using clamps or screw clamps.

  • Page 65: 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 41: 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 66: 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 67: 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 68: 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 69: 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 48: 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 70: 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 71: L2X (Valve Gate) Nozzles - Exchange Of Thermocouple

    Maintenance 7.5 L2X (valve gate) nozzles – exchange of thermocouple Picture 56: L2X Düse, 6mm 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 72 Maintenance L2X (valve gate) nozzles – exchange of thermocouple 1. Clamp the nozzle in the vice at the connecting nut. Picture 58: Clamp the nozzle 2. Disassemble the protective tube. It may be necessary to use two screwdrivers as levers to untighten the protec- tive tube.
  • Page 73 6. Check functioning of the new thermocouple by heating up the nozzle with a controller. 7. For notes for installation of the nozzle please refer to chapter „5.5 Installation of L2X Drop-in hot runner sys- tems“. Picture 61: Installation of the new thermocouple...

  • Page 74: 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 75 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 76: 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 77: 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 78: 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 79: 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 80: 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 81 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 82: 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 83: Tightening Torques For Tip Inserts

    NV95158... NV95218... NV95258-V01... NV95308-V01... NV95408-V01... NV95538... NV95159... NV95219... NV95259-V01... NV95309-V01... NV95309-V01... HPSIII-NVI EN306...L EN309...L EN312...L EN218...L EN312...H EN218...H HPSIII-L2X 95063..95093..95123..95182..HPSIII-L2X-NV NV95063... NV95093... NV95123... NV95182.. HPSIII-MV 95...-3 / 95...-4 93...-3 Tightening torque [Nm] Tightening 22.1 36.9 73.8 torque [ft·lb]...

  • Page 84: Tightening Torques For Hps Iii-L2X Nozzles

    147.51 (Part No. 95123) 18 mm M42x1,5 339.28 (Part No. 95183) Chart 16: Tightening torques for HPS III-L2X nozzles (Part connecting nut / Nozzle) NOTE! The tightening torques given above are valid for an installation temperature of 200 °C. HPS-III-Heißkanalsystem_Anziehdrehmomente-L2X-Duesen_BA_V-2-0_EN...

  • Page 85: Tightening Torques For Screws To Fix The Valve Pin In The Valve Pin Retainer

    Jamming of the valve pin must be avoided! 9.6 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 86: Tightening Torques For Valve Pin Retainer For Electric Drive Units

    9.8 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. 9.8.1 Tightening torques for one-piece valve pin seals Valve pin Ø [mm]...

  • Page 87: Tightening Torques For Two-Piece Valve Pin Seals

    9.8.2 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 88 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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