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Husky Unify Installation Manual

Manifold system
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Unify Manifold System
Hot Runner Installation Manual
Original Instructions

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Summary of Contents for Husky Unify

  • Page 1 Unify Manifold System Hot Runner Installation Manual Original Instructions...
  • Page 2 This product manual is intended to provide information for safe operation and/or maintenance. Husky reserves the right to make changes to products in an effort to continually improve the product features and/or performance. These changes may result in different and/or additional safety measures that are communicated to customers through bulletins as changes occur.

  • Page 3: General Information

    Upgrades are available that can improve your output, reduce cycle times, and add functionality to your Husky equipment. To see what upgrades are available for your Husky equipment, visit our website at www.husky.co or call your nearest Husky Regional Service and Sales Office.

  • Page 4: Hot Runner Refurbishing

    2.2 — March 2021 Unify Manifold System Hot Runner Refurbishing Husky offers services for repairing, modifying, and retrofitting Husky hot runners. Contact your Husky Regional Service and Sales office for details. Hot Runner Refurbishing...

  • Page 5: Table Of Contents

    1.8.4 Single Probe Thermocouple Removal Tools................... 15 1.8.5 Crimping Tools for Contact Pins (25 or 64 Pin Connectors)...............15 1.8.6 Unify Nozzle Assembly Tool..........................16 1.8.7 Unify Hydraulic Actuator Seal Installation Tools..................16 Chapter 2: Safety Summary..........................17 2.1 Qualified Personnel................................17 2.2 Safety Guidelines................................17 2.3 Safety Hazards..................................
  • Page 6 2.2 — March 2021 Unify Manifold System 2.6.1 Personal Protective Equipment (PPE)......................24 2.6.2 Safety Equipment............................. 25 2.7 Material Safety Data Sheet (MSDS)..........................25 2.8 Materials, Parts and Processing............................ 26 2.9 Safety Latch Bars................................26 2.10 Lift Bars and Swivel Hoist Rings..........................27 Chapter 3: Specifications..........................
  • Page 7 6.10.4.2 Installing Triton Nozzle Heaters on U750-UP Systems............. 93 6.10.5 Removing and Installing HTM Nozzle Heaters for U1000 Systems..........95 6.11 Replacing the Hydraulic or Pneumatic Manifold Hoses ...................95 6.12 Grounding the Unify System............................96 6.13 Testing Heaters................................97 6.14 Removing and Installing the Cavity Plate......................97 6.14.1 Removing the Cavity Plate On a Work Bench..................
  • Page 8 2.2 — March 2021 Unify Manifold System 6.15.1.2 Disassembling the Hot Runner for Fluidized Bed Cleaning.........106 6.15.1.3 Removing the PEEK Bushings....................108 6.16 Removing Insulating Gate Bubbles (If Equipped).................... 108 6.17 Removing and Installing the Sprue Heater (If Equipped)................112 6.17.1 Removing a Sprue Heater with a Built-In Thermocouple............. 112 6.17.2 Removing a Sprue Heater with a Separate Thermocouple............

  • Page 9: Chapter 1 Introduction

    Husky equipment and systems are designed for injection molding applications only, using approved materials and operating within design guidelines. Contact your nearest Husky Regional Service and Sales office if you plan to use a Husky product for anything other than its intended use.

  • Page 10: Documentation

    Keep all manuals in a convenient location for future reference. 1.5.1 Manuals Husky manuals aid in the safe and proper use of Husky products. Where applicable, the manuals provide instructions on installation, operation and maintenance. Personnel should thoroughly review all manuals provided with their Husky equipment prior to performing any tasks.

  • Page 11: Engineering Drawings And Schematics

    1.5.2 Engineering Drawings and Schematics Each Husky hot runner is provided with a set of drawings and schematics specific to the hot runner. These are used for troubleshooting the hot runner and ordering spare parts. NOTE: Each drawing and schematic is specific to the hot runner it is provided with.

  • Page 12: Training

    Manuals and other reference material, which have been prepared by Husky for the operation and maintenance of Husky equipment, do not in any way absolve the employer from fulfilling these obligations and Husky disclaims liability for injury to personnel which is attributable to the employer's failure to do so.
  • Page 13 Use of any other type or grade of resin/filler could affect part quality and/or the performance of the hot runner. Before using a different type or grade of resin/filler, contact Husky. CAUTION! Mechanical hazard – risk of damage to the hot runner. Never operate the hot runner outside of the melt and mold temperatures indicated on the nameplate.

  • Page 14: Special Tools

    Unify Manifold System Special Tools The following sections list various component-specific tools developed by Husky for use during maintenance of hot runner systems. Contact Husky to order special tools applicable to your hot runner system. 1.8.1 Nozzle Tip Sockets and Heater Removal Tools...

  • Page 15: Thermocouple Wire Stripping Tools

    Hot Runner Installation Manual v 2.2 — March 2021 Introduction Size Points Drive Part Number 15 mm 3/8 inch 2449784 15 mm 3/8 inch 3253170 16 mm 3/8 inch 2402461 16 mm 3/8 inch 2816670 17 mm 3/8 inch 2308879 20 mm 1/2 inch 3722920...

  • Page 16: Unify Nozzle Assembly Tool

    Unify Nozzle Assembly Tool Nozzle Part Number Ultra 750 6685641 Ultra 1000 6611265 1.8.7 Unify Hydraulic Actuator Seal Installation Tools Nozzle Description Part Number Ultra 750 / Ultra 1000 Tool Sub Assembly 6618499 This part is included in the sub assembly...

  • Page 17: Chapter 2 Safety Summary

    Do not operate the mold/hot runner if scheduled preventive maintenance has not been performed • Do not use a magnetic platen without approval from Husky and the magnetic platen supplier/manufacturer • Do not operate a hot runner outside the maximum melt and mold temperatures specified on...

  • Page 18: Mechanical Hazards

    Seized Screws or Plugs If screws or plugs cannot be removed by normal methods using standard tooling and force, there is a high possibility these items have become seized; contact Husky for repair recommendation. WARNING! Mechanical and/or flying debris hazard - Tool breakage: risk projectile debris, serious injury and/or mechanical damage.

  • Page 19: High Pressure Hazards

    Hot Runner Installation Manual v 2.2 — March 2021 Safety Summary Molten Material • Never touch process material purged or otherwise flowing from the nozzle, mold, hot runner or feed throat area. Molten material can appear cool on the surface, but remain very hot on the inside. Wear personal protective equipment when handling purged material.

  • Page 20: Hydraulic System Pressure Hazards

    Hoses must be inspected periodically for signs of sweating and/or blistering. Rubber hoses naturally age with time and require replacement at regular intervals as per the manufacturer's specifications and Husky maintenance requirements. Steel tubes should be tested using dye penetrant.

  • Page 21: Slip, Trip Or Fall Hazards

    Hot Runner Installation Manual v 2.2 — March 2021 Safety Summary 2.3.6 Slip, Trip or Fall Hazards Do not walk, stand, climb or sit on machine surfaces not approved for safe access. Do not step on the tie bar or any surfaces with grease and/or oil. Use a safety approved platform, walkway and step ladders designated to access areas that are not accessible from the floor.
  • Page 22 2.2 — March 2021 Unify Manifold System Safety Symbol Safety Symbol General Description of Symbol (ANSI) (ISO) High Pressure Molten Material This symbol indicates the presence of a high pressure molten material hazard that could cause death or severe burns.

  • Page 23: Lockout And Tagout

    Hot Runner Installation Manual v 2.2 — March 2021 Safety Summary Safety Symbol Safety Symbol General Description of Symbol (ANSI) (ISO) Read Manual Before Operation This symbol indicates that qualified personnel should read and understand all instructions in the equipment manuals before working on the equipment.

  • Page 24: Personal Protective Equipment And Safety Equipment

    2.2 — March 2021 Unify Manifold System Personal Protective Equipment and Safety Equipment Personal injury can be avoided when personnel wear appropriate protective gear and use special safety equipment. The following describes the safety gear and equipment that should be used when working with the machine and any auxiliary equipment.

  • Page 25: Safety Equipment

    Material Safety Data Sheet (MSDS) WARNING! Chemical hazard - Some of the chemicals used with Husky equipment are potentially hazardous and could cause injury and illness. Before storing, handling, or working with any chemical or hazardous material, thoroughly read and understand each applicable Material Safety Data Sheet (MSDS), use recommended personal protective equipment and follow the manufacturer’s instructions.

  • Page 26: Materials, Parts And Processing

    Always refer to the applicable Material Safety Data Sheet before doing the following: • handling a chemical product • disassembling any portion of Husky equipment that may result in exposure to a chemical product Contact the material supplier to obtain a copy of the MSDS sheet. Materials, Parts and Processing To prevent personal injury or damage to the equipment, make sure of the following: •...

  • Page 27: Lift Bars And Swivel Hoist Rings

    Make sure all lifting equipment is rated for the load and in safe operating condition. Follow the recommendations and use care when moving or handling plates or assemblies. For instructions about lifting plates and plate assemblies and using the Husky provided lift bar and swivel hoist rings, refer to Section 4.1.
  • Page 28 2.2 — March 2021 Unify Manifold System...

  • Page 29: Chapter 3 Specifications

    Hot Runner Installation Manual v 2.2 — March 2021 Specifications Chapter 3 Specifications This chapter outlines the necessary temperature, electrical, air and lubricant information needed to operate and maintain the manifold system. Weight The full weight of the manifold system assembly is listed on the assembly drawings. Operating Temperature The hot runner must operate within a specific temperature range to prevent internal resin leakage and damage to internal components as the result of thermal expansion.

  • Page 30: Nozzle Heaters

    2.2 — March 2021 Unify Manifold System DANGER! Electrical hazard – risk of serious injury, fire and/or overload of electrical components. Do not use a controller with an amperage rating less than that required by the heaters. Do not use a controller with a higher amperage rating than the connectors or cables to the hot runner.

  • Page 31: Power Fluctuation

    Hot Runner Installation Manual v 2.2 — March 2021 Specifications NOTE: To establish proper polarity when connecting thermocouples, follow the electrical schematic. For J-type thermocouples, the white wire is positive (+) and the red wire is negative (-). This wire color coding follows the ANSI J-Type North American Standard.

  • Page 32: Pneumatic Manifold Operating Limits

    2.2 — March 2021 Unify Manifold System The hydraulic fluid maximum operating pressure depends on the size of the Unify System. 3.4.2 Pneumatic Manifold Operating Limits Description Value Maximum operating air pressure 12.5 bar (180 psi) Air must be filtered and conditioned according to Section 3.6...

  • Page 33: Hydraulic Cooling Water Specifications

    Hot Runner Installation Manual v 2.2 — March 2021 Specifications • Typical air pressure required is 5.52 to 8.27 bar (80 to 120 psi) , unless otherwise specified in the mold manufacturer’s documentation. NOTE: For many pneumatic VG applications, air pressure of 7 bar (100 psi) may be sufficient, while some applications may require up to 12.5 bar (180 psi) for optimal and stable performance.

  • Page 34: Recommended Lubricants

    The following are recommended lubricants to be used during the assembly and maintenance of Husky hot runners: NOTE: Husky recommends only the following lubricants and assumes no responsibility for lubricants not specified. It is the customers responsibility when consulting with an alternate supplier to make sure a suitable equivalent is used.

  • Page 35: Rust Inhibitor Specifications

    Hot Runner Installation Manual v 2.2 — March 2021 Specifications Type/ Trade Name Part Quantity Used For Description Number Static application Kem-A-Trix 3936720 113 g (4 oz) Guide pins, alignment Grease Fahrenheit 800 Squeeze Tube dowels, screw heads Bearing Gel and threads, O-ring 3936725 397 g (14 oz)

  • Page 36: Hydraulic And Pneumatic Actuator Component Specifications

    2.2 — March 2021 Unify Manifold System 3.12 Hydraulic and Pneumatic Actuator Component Specifications The following tables contain the component descriptions and quantities for the large and small Hydraulic and Pneumatic actuators. 3.12.1 Large Hydraulic Actuator Components 12 11...

  • Page 37: Small Hydraulic Actuator Components

    Hot Runner Installation Manual v 2.2 — March 2021 Specifications Table 3-1: Large Hydraulic Actuator Components (Continued) Item Component Description Quantity Wear Ring Cylinder Rod Step Seal Scraper Seal O-Ring Cylinder Spring Pin S/A Stop Block SCHS M4 X 10 mm (0.40 in) 3.12.2 Small Hydraulic Actuator Components Figure 3-2: Small Hydraulic Actuator Components...

  • Page 38: Shcs M6 X 90 Mm (3.5 In)

    2.2 — March 2021 Unify Manifold System Table 3-2: Small Hydraulic Actuator Components (Continued) Item Component Description Quantity SHCS M6 x 25 mm (1 in) Cylinder Standard Stroke Short Stroke (APP) Adapter fitting JIC AN4 to NPT for Hydraulic...

  • Page 39: Large And Small Pneumatic Actuator Components

    Hot Runner Installation Manual v 2.2 — March 2021 Specifications 3.12.3 Large and Small Pneumatic Actuator Components Figure 3-3: Large and Small Pneumatic Actuator Components Table 3-3: Large and Small Pneumatic Actuator Components Item Component Description Actuator Size Quantity SHCS M6 x 75 mm (2.95 in) SHCS M6 x 16 mm (0.63 in) Cylinder Cap Small...

  • Page 40: Large And Small Pneumatic Actuator With Thermal Regulator Components

    2.2 — March 2021 Unify Manifold System Table 3-3: Large and Small Pneumatic Actuator Components (Continued) Item Component Description Actuator Size Quantity GLYD Ring O Ring Cylinder Small Large Spring Pin S/A Stop Block Small Large SHCS M4 x 10 mm (0.39 in) 3.12.4...

  • Page 41: Piston Seal

    Hot Runner Installation Manual v 2.2 — March 2021 Specifications Table 3-4: Large and Small Pneumatic Actuator with Thermal Regulator Components (Continued) Item Component Description Actuator Size Quantity Cylinder Cap Small Large Gasket Small Large Adapter fitting JIC AN4 to NPT for Air Piston Seal Small Large...
  • Page 42 2.2 — March 2021 Unify Manifold System...

  • Page 43: Chapter 4 Installation And Removal

    This lifting equipment is designed specifically for the mold/hot runner assembly. When Husky provides special lifting equipment, use only Husky specified and supplied lifting equipment. Use Husky special lifting equipment to lift only the designated mold or hot runner or component.

  • Page 44: Lifting And Handling Using A Single Lifting Point

    Crushing hazard – risk of death or serious injury. Misuse of lifting equipment could lead to equipment failure and cause death or serious injury. Use Husky only specified or supplied lifting equipment for lifting the assembly or the component for which the equipment has been designated by Husky.

  • Page 45: Picking Up Plates Using A Single Lifting Point

    Hot Runner Installation Manual v 2.2 — March 2021 Installation and Removal Lower the plate slowly onto the edge of the secured wood block. Continue to slowly lower the plate until it tips over towards the work surface. Lay the plate down on the work surface. 4.1.1.2 Picking Up Plates Using a Single Lifting Point When lifting a plate that has been laid down using a single lifting point, the lifting device may go...

  • Page 46: Lifting And Handling Using Multiple Lifting Points

    2.2 — March 2021 Unify Manifold System WARNING! Impact hazard – risk of serious injury. The plate could swing in a pendulum motion just as the plate is lifted off of the wood block. Lift slowly to reduce the pendulum motion. Stand clear of the possible swing area to prevent injury.

  • Page 47: Lifting Using A Lift Bar

    NOTE: The maximum weight the bar can lift is stamped on the Husky lift bar. If using a lift bar that is not provided by Husky, make sure the lift bar is suitably rated for the weight of the mold/hot runner assembly.

  • Page 48: Lifting Using Swivel Hoist Rings

    • The work piece surface must be flat, providing complete contact for the hoist ring bushing. Metric and Imperial swivel hoist rings are available through your nearest Husky Parts Distribution Center. Swivel hoist rings purchased from other suppliers must meet or exceed the following specifications.

  • Page 49: Installing And Removing The Manifold Assembly

    Minimum rated capacity at any pull angle (between 0° horizontal pull and 90° vertical pull) Installing and Removing the Manifold Assembly Use the following procedures to install and remove the Unify manifold assembly to the mold. 4.2.1 Installing the Manifold into the Plates To install the Unify manifold into the plates, do the following: Install the assembly guide rods into the tapped holes in the manifold plate pocket.
  • Page 50 2.2 — March 2021 Unify Manifold System Disconnect the overhead lifting device and remove the hoist rings from the manifold. Install the screws that secure the manifold to the plate. Each drop has four screws surrounding it. IMPORTANT! Torque the screws that secure the manifold to the plate as specified in the assembly drawings. Do not over-torque the screws.
  • Page 51 Installation and Removal Figure 4-5: Torque Cross-Pattern 1. Manifold 2. Torque Sequence Number 3. Drop Screw If desired, add hold down screws (M6 or ¼ - 20) to each mounting tab on the unify frame and torque to the specified values. IMPORTANT! For cross Manifold design, make sure that the alignment pull dowels that keep the cross and main manifolds aligned during assembly, shipping, and installation are removed.

  • Page 52: Removing The Manifold Assembly From The Mold

    Figure 4-6: Unify Frame with Mounting Tabs 1. Mounting Tabs 2. Unify Frame 4.2.2 Removing the Manifold assembly from the Mold To remove the Unify manifold assembly from the mold, do the following: Lock out and tag the machine. Refer to Section 2.5 for more information.
  • Page 53 Hot Runner Installation Manual v 2.2 — March 2021 Installation and Removal WARNING! Crushing hazard – risk of death or serious injury. Inadequate lifting equipment can fail and could cause death or serious injury. Make sure all lifting equipment is rated for the load and in safe operating condition.
  • Page 54 2.2 — March 2021 Unify Manifold System...

  • Page 55: Chapter 5 Startup And Operation

    NOTE: If the hot runner is installed in a Husky machine, refer to the startup instructions in the machine manufacturer’s documentation. To startup the hot runner for operation, perform the following procedures in order:...

  • Page 56: Heating Up The Hot Runner, Mold And Machine

    2.2 — March 2021 Unify Manifold System CAUTION! Mechanical hazard – risk of damage to the hot runner. In the event of water leaking into the hot runner, the nozzle heaters could fail. Make sure all water is removed before starting up the hot runner.

  • Page 57: Precharging The Hot Runner

    Hot Runner Installation Manual v 2.2 — March 2021 Startup and Operation If equipped, turn on the controller. CAUTION! Mechanical hazard – risk of damage to the hot runner. Never operate the hot runner outside of the melt and mold temperatures indicated on the nameplate. Internal resin leakage or component damage could occur.

  • Page 58: Producing Test Parts

    2.2 — March 2021 Unify Manifold System Clean the machine nozzle, stationary platen and purge guard of any resin deposits. Refer to the machine manufacturer’s documentation for more information. Make sure the machine nozzle is firmly seated against the sprue bushing.
  • Page 59 Hot Runner Installation Manual v 2.2 — March 2021 Startup and Operation Check that all parts have been properly molded. Manually control the ejector functions to eject the parts. If all cavities are producing parts, reset the injection pressure to the recommended value. 10.
  • Page 60 2.2 — March 2021 Unify Manifold System...

  • Page 61: Chapter 6 Maintenance

    WARNING! Chemical hazard - Some of the chemicals used when servicing or maintaining Husky equipment are potentially hazardous and could cause injury and illness. Before storing, handling, or working with any chemical or hazardous material, thoroughly read and understand each applicable Material Safety Data Sheet (MSDS), use recommended personal protective equipment and follow the manufacturer’s instructions.

  • Page 62: Preventive Maintenance

    Removing and Installing value stems Section 6.9 Removing and Installing nozzle heaters Section 6.10 Replacing the hydraulic or pneumatic manifold hoses Section 6.11 Grounding the unify system Section 6.12 Removing and Installing the cavity plate Section 6.14 Inspecting and cleaning manifolds Section 6.15 Removing insulating gate bubbles (if equipped) Section 6.16...

  • Page 63: Removing And Installing Nozzle Stacks

    6.2.1 Removing the Nozzle Stack To remove the nozzle stack from a Unify manifold system, do the following: Remove the Unify from the machine and position it so the nozzle stacks can be accessed. Refer to Section 4.2.2.
  • Page 64 2.2 — March 2021 Unify Manifold System Install the anti-rotation tab, spring and locator on the housing. Figure 6-2: Anti-Rotation Tab, Spring and Locator on Nozzle Housing 1. Anti-Rotation Tab 2. Spring 3. Locator 4. Nozzle Heater 5. Nozzle Housing 6. Retainer 7. Nozzle Install the nozzle tip and nozzle heater and thermocouple on the housing.
  • Page 65 Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Install the nozzle assembly tool over the housing assembly until the dowels of the tool engage with receiving holes in the manifold. With the assembly tool in place, install the stepped washers and stepped washer fasteners. Apply the fastener preload according to the assembly drawing.

  • Page 66: Changing The Resin Color

    2.2 — March 2021 Unify Manifold System 12. Measure the nozzle tip height from the manifold (Dimension T) to verify it matches the assembly drawing. Refer to Figure 6-4. Figure 6-4: Measure Preloaded Retainer Height and Nozzle Tip Height from Manifold 1.

  • Page 67: Extending Nozzle And Sprue Heater Wire Leads

    Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Lock out and tag the machine and controller (if equipped). For machine lockout and tag procedures refer to the machine documentation. Remove all traces of the original resin from the material feed equipment. Depending on application restrictions, add one of the following to the material feed equipment to reduce the cleaning time required: •...
  • Page 68 2.2 — March 2021 Unify Manifold System IMPORTANT! This procedure is only for nozzle and sprue heater leads when standard lead lengths are not long enough. This procedure is not to be used for extending thermocouple wire leads. Splicing thermocouple wires will cause false and/or erratic temperature readings.

  • Page 69: Removing And Installing The Hydraulic Actuator

    Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Figure 6-7: Completed Wire Lead Extension Removing and Installing the Hydraulic Actuator This section describes how to remove and install the hydraulic actuator. 6.5.1 Removing the Hydraulic Actuator from the Manifold To remove the hydraulic actuator from the manifold, do the following: WARNING! Skin puncture hazard –...

  • Page 70: Installing The Hydraulic Actuator On The Manifold

    2.2 — March 2021 Unify Manifold System Figure 6-8: Removing and Installing an Actuator 1. Screw 2. Actuator 3. Spring Pin 4. Valve Stem 5. Shim 6. Bushing Cap Loosen the screws on outer perimeter of actuator. Remove the shim and label the shim with the drop location.
  • Page 71 Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Figure 6-9: Removing and Installing a Shim 1. Valve Stem 2. Shim Labeled with Drop Location 3. Bushing Cap Lower the hydraulic actuator vertically onto the drop location. The actuator is labeled by drop location (Refer to Section 6.5.1).

  • Page 72: Removing And Installing The Pneumatic Actuator

    2.2 — March 2021 Unify Manifold System Tighten the screws installed in step 4. Refer to the assembly drawings for torque specifications. Push the spring pin to engage it with the valve stem. Connect the hydraulic and water hoses to the actuator.

  • Page 73: Installing The Pneumatic Actuator To The Manifold

    Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Remove the screws on the outer perimeter of the actuator. Remove the actuator vertically from the manifold. Label the actuator with the drop location. 6.6.2 Installing the Pneumatic Actuator to the Manifold To install the pneumatic actuator to the manifold, do the following: Make sure that the piston in the actuator is in the closed position.

  • Page 74: Adjusting The Valve Stem Preload For Hydraulic Actuators

    Husky delivers the stem preload as identified on the assembly drawing. For VG style nozzle tips, where tapered stems shut-off on a gate or cavity insert, Husky delivers the stem preload as identified on the assembly drawing. This assumes that the gate insert L dimension is within specification.
  • Page 75 Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Figure 6-14: Measuring the Stem Seat Depth 1. Hydraulic Actuator 2. Dimension V Measure and record the height of the stem from the bushing cap (Dimension W) as shown in Figure 6-15.
  • Page 76 2.2 — March 2021 Unify Manifold System Figure 6-15: Measuring the Stem Height 1. Dimension W 2. Valve Stem 3. Bushing Cap The shim thickness is engraved on the shim. Refer to Figure 6-15. Record this value. If the shim thickness has been modified, measure and record the new shim thickness.
  • Page 77 Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Figure 6-16: Measuring the Shim Height 1. Shim Height 2. Valve Stem 3. Bushing Cap Adjusting the Valve Stem Preload for Hydraulic Actuators...

  • Page 78: Replacing The Hydraulic And Pneumatic Seals

    • Husky can refurbish the actuator. • Husky can replace the seals or a seal kit that includes new seals can be ordered from Husky. NOTE: It is recommended that Husky performs the actuator seal replacement. Instructions on disassembling the actuator and installing the new seals are included in the seal kit.

  • Page 79: Installing A Valve Stem

    Clean the manifold bushing cap to provide a clean surface. Use the Unify Stem Removal tool (HPN 6700292) to slide the stem adapter over the valve stem head. Make sure that the removal tool assembly is sitting squarely on the manifold bushing cap.

  • Page 80: Removing And Installing Ultra Nozzle Heaters (Unh) On U750 Systems

    2.2 — March 2021 Unify Manifold System • Bi-metal heaters for U750 and U1000 systems • Triton heaters for U750-UP systems • HTM heaters for U1000 systems 6.10.1 Removing and Installing Ultra Nozzle Heaters (UNH) on U750 Systems The following procedures describe how to remove and install Ultra Nozzle Heaters (UNH) nozzle on U750 systems.
  • Page 81 Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Figure 6-18: Ultra Nozzle Heater (UNH) Assembly 1. Retaining Clip 2. Thermocouple Ring 3. Ultra Nozzle Heater (UNH) 4. Wave Spring 5. Nozzle tip Slide the nozzle heater over the nozzle housing far enough to show the retaining clip groove on the nozzle tip.
  • Page 82 2.2 — March 2021 Unify Manifold System Install the nozzle retainer but do not tighten it. Route the nozzle heater and thermocouple wires through the wire passages on the nozzle retainer. Refer to Figure 6-20. Figure 6-20: Routing the wires 1.

  • Page 83: Removing And Installing Ultra Nozzle Heaters (Unh) With Ring Thermocouples

    Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Figure 6-21: Staggering the Knuckles in the Wire Grooves NOTE: All wire, including heater or thermocouple wire, that could contact a heated component such as a nozzle housing or manifold must be mineral insulated high temperature wire (hard lead). If the mineral insulated lead is not long enough to allow this, additional steps must be taken, such as using high temperature sleeving, to prevent the knuckles and PTFE or Kapton insulated wire (soft lead) from overheating.

  • Page 84: Installing Ultra Nozzle Heaters (Unh) With Ring Thermocouples

    2.2 — March 2021 Unify Manifold System Figure 6-22: Ultra Nozzle Heater (UNH) Assembly With a Ring Thermocouple 1. Retaining Clip 2. Ring Thermocouple 3. Ultra Nozzle Heater (UNH) 4. Nozzle Tip 5. Wave Spring Remove the nozzle heater.
  • Page 85 Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Figure 6-23: Ultra Nozzle Heater (UNH) Assembly With a Ring Thermocouple 1. Retaining Clip 2. Ring Thermocouple 3. Ultra Nozzle Heater (UNH) 4. Nozzle Tip 5. Wave Spring Slide the nozzle heater over the nozzle housing far enough to show the retaining clip groove on the nozzle tip.
  • Page 86 2.2 — March 2021 Unify Manifold System CAUTION! Mechanical hazard – risk of damage to the hot runner. Do not bend the nozzle heater wires at a 90° angle. Do not bend the nozzle heater wires directly at the lead exit of the heater body.
  • Page 87 Hot Runner Installation Manual v 2.2 — March 2021 Maintenance The heater and thermocouple spring back to the retaining ring and maintain contact with each other after being pushed down (0.5 to 2mm) on the housing. See the following figure. Figure 6-27: Heater/ Thermocouple Spring Back to Retaining Ring Removing and Installing Nozzle Heaters...
  • Page 88 2.2 — March 2021 Unify Manifold System NOTE: If the heater and thermocouple do not spring back to the snap ring or maintain contact with each other, the bends in the wiring may be at fault. • Wire routing must not over constrain heater positioning on nozzle.

  • Page 89: Removing And Installing Bi-Metal Heaters On U750 And U1000 Systems

    Hot Runner Installation Manual v 2.2 — March 2021 Maintenance 10. Crimp the wire ends and connect the wires to the appropriate multi-pin connectors. Refer to the electrical schematic for more information. 11. Test each nozzle heater. Refer to Section 6.13 for more information.
  • Page 90 2.2 — March 2021 Unify Manifold System Figure 6-31: Bi-Metal Nozzle Heater Assembly 1. Front Ring 2. Retaining Clip 3. Bi-Metal Nozzle Heater 4. Thermocouple 5. Nozzle Tip Install the retaining clip around the nozzle tip. Connect the thermocouple to the nozzle heater.
  • Page 91 Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Figure 6-32: Routing the wires 1. Nozzle Retainer 2. Nozzle Retainer Wire Passage 3. Wire Channel Install the nozzle retainer but do not tighten it. Route the wires into the wire channel on the manifold frame. Make sure all wiring is properly retained in the wire channel using wire clips.

  • Page 92: Removing And Installing Triton Heaters On U750-Up Systems

    2.2 — March 2021 Unify Manifold System Figure 6-33: Staggering the Knuckles in the Wire Grooves NOTE: All wire, including heater or thermocouple wire, that could contact a heated component such as a nozzle housing or manifold must be mineral insulated high temperature wire (hard lead). If the...

  • Page 93: Installing Triton Nozzle Heaters On U750-Up Systems

    Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Figure 6-34: Triton Heater Assembly 1. Retaining Clip 2. Thermocouple and Retaining Ring 3. Triton Nozzle Heater 4. Nozzle Tip 5. Wave Spring Remove the necessary wire clips to expose the nozzle heater and thermocouple wires. Disconnect the thermocouple and retaining ring from the nozzle heater.
  • Page 94 2.2 — March 2021 Unify Manifold System Slide the nozzle heater over the nozzle housing far enough to show the retaining clip groove on the nozzle tip. Slide the thermocouple and retaining ring over the nozzle tip, onto the nozzle heater, far enough to show the retaining clip groove on the nozzle tip.

  • Page 95: Removing And Installing Htm Nozzle Heaters For U1000 Systems

    Husky recommends that hydraulic or pneumatic manifold hoses be replaced after three years of operation. Contact Husky for more information about the options below. • To replace the hoses, return the Unify system to Husky. Husky will assemble, correctly route and test the new hoses. •...

  • Page 96: Grounding The Unify System

    6.12 Grounding the Unify System When the Unify system is installed in the mold plates, a path to ground exists through the manifold assembly and into the mold plates. However, when the system is removed from the mold plates for bench testing, a separate ground wire must be installed and connected to ground.

  • Page 97: Testing Heaters

    A common problem with heaters is moisture absorption due to the hygroscopic nature of the insulation. A heater with a low case to center conductor insulation reading (<10K Ω) should be baked out and retested to determine if moisture was the cause. Contact Husky for more information.

  • Page 98: Removing The Cavity Plate On A Work Bench

    2.2 — March 2021 Unify Manifold System CAUTION! Risk of damage to the sealing surfaces. Hot runner nozzles must be at room temperature (<25 °C or <77 °F) before removing or installing the cavity plate to avoid damage to the sealing surfaces.

  • Page 99: Installing The Cavity Plate On A Work Bench

    Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Attach an overhead lifting device to the hoist rings and lift the cavity plate. Use the pry slots between the plate and hot runner to help separate the cavity plate. WARNING! Crushing hazard –...
  • Page 100 2.2 — March 2021 Unify Manifold System Figure 6-39: Cavity and Nozzle Sealing Diameters 1. Nozzle and Cavity Plate Sealing Diameters 2. Gate Bubble 3. Cavity Plate 4. Nozzle Housing 5. Manifold Plate Apply a static application grease to the hot runner alignment dowels. Refer to Section 3.9...

  • Page 101: Removing The Cavity Plate In The Machine

    Hot Runner Installation Manual v 2.2 — March 2021 Maintenance CAUTION! Mechanical hazard – risk of damage to the mold and hot runner. The nozzles and manifold must be at room temperature (< 25 °C or < 77 °F) before the cavity plate is connected to the hot runner.
  • Page 102 2.2 — March 2021 Unify Manifold System Install safety latch bars between the cavity plate and hot runner on both sides of the assembly. A minimum of two safety latch bars are required. Figure 6-40: Latching the Cavity Plate to the Hot Runner (Overhead View) 1.

  • Page 103: Installing The Cavity Plate In The Machine

    Hot Runner Installation Manual v 2.2 — March 2021 Maintenance CAUTION! Mechanical hazard – risk of damage to the mold and hot runner. The nozzles and manifold must be at room temperature (< 25 °C or < 77 °F) before the cavity plate is separated from the hot runner.

  • Page 104: Inspecting And Cleaning Manifolds

    2.2 — March 2021 Unify Manifold System CAUTION! Mechanical hazard – risk of damage to the mold and hot runner. The nozzles and manifold must be at room temperature (< 25 °C or < 77 °F) before the cavity plate is connected to the hot runner.

  • Page 105: Cleaning Using A Fluidized Bed Process

    If the sealing surfaces are damaged in any way, replace the nozzle housings. Make sure the manifolds are clean and flat. NOTE: Use only Husky recommended high temperature power and thermocouple wire. NOTE: Refer to the electrical schematic when replacing wiring. Check all manifold, heater and thermocouple wiring. Replace as necessary.

  • Page 106: Assistance

    Husky does not recommend using a fluidized bed to clean mold plates and components. 6.15.1.1 Assistance Husky provides a full system repair and cleaning service, in addition to helping customers find a local fluidized bed cleaning process. Contact your nearest Husky Regional Service and Sales office for more information.
  • Page 107 Beryllium Copper (BeCu) components, such as manifold bushings, manifold inserts, some nozzle tips and tip retainers, etc. NOTE: Contact Husky for verification of the component’s material before cleaning it with a fluidized bed process. Make sure all electrical wiring and thermocouples are removed.

  • Page 108: Removing The Peek Bushings

    2.2 — March 2021 Unify Manifold System 6.15.1.3 Removing the PEEK Bushings Due to the extreme temperatures in a fluidized bed (454 °C or 850 °F), Polyetheretherketone (PEEK) bushings must be removed from the manifold heater ends. The PEEK bushings will melt if subjected to the cleaning process.
  • Page 109 Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Figure 6-44: Gate Bubbles 1. Gate Bubbles To remove the insulating gate bubbles, do the following: Remove the cavity plate. Refer to Section 6.14 for more information. Connect the hot runner to a controller. Turn on the controller.
  • Page 110 2.2 — March 2021 Unify Manifold System NOTE: The Vicat Softening Temperature for the resin type is recommended. Refer to the resin supplier’s documentation for more information. Once the nozzle tips have reached their setpoint approximately 120 °C (248 °F), wait until the gate bubble on the first nozzle tip is soft enough to remove and then turn off all the nozzle tip heaters.
  • Page 111 Hot Runner Installation Manual v 2.2 — March 2021 Maintenance 10. Remove any insulating gate bubbles in the cavity plate. If required, carefully heat the gate bubbles with a propane torch and then wipe the deposits away with a clean, soft cloth or soft wire brush.

  • Page 112: Removing And Installing The Sprue Heater (If Equipped)

    2.2 — March 2021 Unify Manifold System NOTE: If the hot runner is still in the machine the cooling water can be turned on to cool the hot runner down. 13. Install the cavity plate. Refer to Section 6.14 for more information.

  • Page 113: Installing A Sprue Heater With A Built-In Thermocouple

    Remove the front ring, retaining clip and thermocouple. Using a heater removal tool, remove the sprue heater from the sprue bushing. Refer to Section 1.8 for a list of special Husky tools and order numbers. 6.17.3 Installing a Sprue Heater with a Built-In Thermocouple...

  • Page 114: Installing A Sprue Heater With A Separate Thermocouple

    2.2 — March 2021 Unify Manifold System Figure 6-48: Installing the Sprue Heater 1. Retaining Clip 2. Lead Exit 3. Sprue Heater and Thermocouple 4. Sprue Bushing Align the thermocouple wires with the wire channels in the backing plate.

  • Page 115: Removing And Installing The Sprue Bushing

    Using a heater removal tool, pull the sprue heater up until it makes contact with the retaining clip. Refer to Section 1.8 for a list of special Husky tools and order numbers. NOTE: All wiring near the sprue heater must be either a high temperature braid or sleeved using a high temperature sleeving.

  • Page 116: Removing The Sprue Bushing

    2.2 — March 2021 Unify Manifold System 6.18.1 Removing the Sprue Bushing To remove the sprue bushing, do the following: Remove the hot runner from the machine. Refer to Section 4.2.2 for more information. Remove the sprue heater. Refer to Section 6.17...
  • Page 117 Hot Runner Installation Manual v 2.2 — March 2021 Maintenance Figure 6-51: Sprue Bushing and Manifold Sealing Faces 1. Manifold 2. Spigot Pocket Face 3. Spigot Face 4. Locating Diameters CAUTION! Crushing hazard – risk of damage to equipment. Screws used to install the sprue bushing must meet specific requirements.

  • Page 118: Removing And Installing Nozzle Tip Insulators (If Equipped)

    If reuse is absolutely necessary (i.e. unscheduled maintenance with no spares on hand), order new nozzle tip insulators and replace as soon as possible. Contact your nearest Husky Regional Service and Sales Office or www.husky.co.

  • Page 119: Installing Nozzle Tip Insulators

    If reuse is absolutely necessary (For example, unscheduled maintenance with no spares on hand), order new nozzle tip insulators and replace as soon as possible. Contact your nearest Husky Regional Service and Sales Office or www.husky.co.
  • Page 120 Mechanical hazard – risk of damage to the hot runner. Due to geometric variations between the gate details and the witness marks left in nozzle tip insulators by the nozzle tips, Husky does not recommend reusing nozzle tip insulators. Previously used nozzle tip insulators should always be replaced with new nozzle tip insulators whenever possible.

  • Page 121: Chapter 7 Storage And Shipping

    Hot Runner Installation Manual v 2.2 — March 2021 Storage and Shipping Chapter 7 Storage and Shipping Hot runner surfaces are sensitive to many environmental conditions and require special methods for storage and shipping to avoid damage. NOTE: The storage instructions in Section 7.2 are recommended when shipping the hot runner by air.

  • Page 122: Storing In The Machine

    2.2 — March 2021 Unify Manifold System 7.2.1 Storing in the Machine Open the clamp to full shutheight. Lock out and tag the machine and controller (if equipped). Refer to Section 2.5 for more information. Clean the mold, hot runner and molding surfaces of dirt, debris and condensation.

  • Page 123: Long Term Storage

    Hot Runner Installation Manual v 2.2 — March 2021 Storage and Shipping Spray all accessible faces and molding surfaces with LPS 2 protective spray. Allow surfaces to dry for approximately two hours. Refer to Section 3.10 for specifications on protective spray. If additional coats are required, make sure the hot runner has thoroughly dried before the next application.
  • Page 124 When returning a mold and/or hot runner to Husky for refurbishing, include the following items for testing purposes: •...

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