Mold-Masters Dura PLUS User Manual
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Mold-Masters Dura PLUS User Manual

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version 2
Dura+ User Manual
Original Instructions

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Summary of Contents for Mold-Masters Dura PLUS

  • Page 1 User Manual version 2 Dura+ User Manual Original Instructions...

  • Page 3: Table Of Contents

    1.2 Documentation ....................1-1 1.3 Release Details ....................1-1 1.4 Warranty ......................1-1 1.5 Returned Goods Policy ..................1-2 1.6 Movement or Resale of Mold-Masters Products or Systems ......1-2 1.7 Copyright ......................1-2 1.8 Units of Measure and Conversion Factors ............1-3 Section 2 - Global Support ..........2-1 2.1 Corporate Offices....................2-1...
  • Page 4 Section 6 - SeVG Plus Actuator ........6-1 6.1 Introduction ......................6-1 6.2 SeVG Plus Actuator Models ................6-1 6.3 SeVG Plus Actuator in Dura Plus Systems ............6-1 6.4 SeVG Plus Model Options ..................6-2 6.4.1 SE40-20 Actuator - Non Cooled ..............6-2 6.4.2 SE40-20C Actuator - Cooled ..............6-3 6.4.3 SE20-15 Model - Non Cooled ..............6-4...
  • Page 5 11.9 Checking Nozzle Tip Height ................11-11 11.10 Nozzle Thermocouple Removal ..............11-12 11.11 Torque Settings ................... 11-12 11.11.1 Gate Seal Torque Settings ..............11-12 11.11.2 System and Plate Screw Torques ............11-13 © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 6 Section 12 - Troubleshooting ..........1 Section 13 - Glossary of Terms ........13-1 Index ..................I Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 7: Section 1 - Introduction

    Section 1 - Introduction The purpose of this manual is to assist users in the integration, operation and maintenance of a Dura Plus Hot Runner. This manual is designed to cover most system configurations. If you need additional information specific to your system, or information in another language, please contact your representative or a Mold-Masters office.

  • Page 8: Returned Goods Policy

    INTRODUCTION 1.5 Returned Goods Policy Please do not return any parts to Mold-Masters without pre-authorization and a return authorization number supplied by Mold-Masters Limited. Our policy is one of continuous improvement and we reserve the right to alter product specifications at any time without giving notice.

  • Page 9: Units Of Measure And Conversion Factors

    Pound per square inch 0.069 bar Pound per square inch 6.895 kPa Revolutions per minute Second Degree ° Degree Celsius ° ° 0.556 ( F -32) Degree Fahrenheit ° ° C +32 © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 10: Section 2 - Global Support

    +39 049/5019955 South Korea El Marques, Queretaro C.P. 76246 fax: +39 049/5019951 tel: +82-31-431-4756 Mexico italy@moldmasters.com tel: +52 442 713 5661 (sales) korea@moldmasters.com tel: +52 442 713 5664 (service) mexico@moldmasters.com © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 11: International Representatives

    Gaydamatska str., 3, office 116 123308 Moscow 2310 Slovenska Bistrica Kemenskoe City Dnipropetrovsk Russia Slovenija Region 51935, Ukraine tel: +7 (495) 199-14-51 +386 59 969 117 tel: +38 (038) 277-82-82 moldmasters@system.com.ru info@picta.si moldmasters@parkgroup.com.ua Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 12: Section 3 - Safety

    SAFETY Section 3 - Safety Please be aware that the safety information provided by Mold-Masters does not absolve the integrator and employer from understanding and following international and local standards for safety of machinery. It is the responsibility of the end integrator to integrate the final system, provide...

  • Page 13: Safety Hazards

    9. Hoses 10. Area inside the guards and outside the mold area Front view with guards removed Front View with Guards Removed Figure 3-1 Injection molding machine hazard areas Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 14 Hazards due to reduction in mechanical strength of the plasticizing and / or injection cylinder due to overheating. Feed Opening Pinching and crushing between injection screw movement and housing. See Figure 3-1 area 6 © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 15 Power Operated Gate Crush or impact hazards caused by the movement of the power operated gates. Vapors and Gases Certain processing conditions and / or resins can cause hazardous fumes or vapors. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 16: Operational Hazards

    • Never perform any work on the mold machine unless the hydraulic pump has been stopped. • Check frequently for possible oil leaks / water leaks. Stop the machine and make repairs. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 17 Failure to support the machine can result in severe injury or death. • Mold cable from the controller to the mold must be removed before servicing the mold. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 18: General Safety Symbols

    Warning – Slip, Trip or Fall Hazard Do not climb on equipment surfaces. Serious slip, trip or fall injuries can result from personnel climbing on equipment surfaces. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 19: Wiring Check

    Switching the machinery into Auto mode without having verified the control interlocks and motion sequence are correct, may cause damage to machinery and / or equipment. Failure to do wiring or connections properly will result in equipment failure. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 20: Lockout Safety

    • Burns from contact with hot parts, materials or equipment such as furnaces • Fires and explosions • Chemical exposures from gases or liquids released from pipelines © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 21: Electrical Lockout

    The last lock to be removed should be that of the person supervising the lockout and this responsibility should not be delegated. © Industrial Accident Prevention Association, 2008. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 22: Energy Forms And Lockout Guidelines

    Shut off, lock (with chains, built- • Storage tanks and vessels in lockout devices, or lockout attachments) and tag valves. • Bleed off excess liquids or gases. • Blank lines as necessary. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 23: Disposal

    3-12 3.6 Disposal WARNING Milacron Mold-Masters declines any responsibility for personal injury or personal damage arising from reuse of the individual components, if these parts are used other than for the original and proper intended purpose. 1. Hot Runner and system components must be disconnected from the power supply fully and properly before disposal, including electricity, hydraulics, pneumatics and cooling.

  • Page 24: Dura Plus Safety Hazards

    • Always cover E-Drive belt area / molding machine drop out area / bench top with a proper protective cover before any bench test or in-mold testing. • Always unplug the controller before performing any maintenance work. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 25 Make sure the lifting eyebolt, lifting chain and crane are rated to adequately support the weight of the plate(s). Failure to do so can cause a serious injury. • All maintenance on Mold-Masters products should be performed by properly trained personnel based on local law or regulation requirements. •...
  • Page 26 • When replacing heater plates or other heated components always replace with Mold-Masters components of the same type and install as originally specified on Mold-Masters General Assembly drawings. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 27: Section 4 - Preparation

    Section 4 - Preparation WARNING Ensure that you have fully read “Section 3 - Safety” before unpacking, cleaning or assembling parts of the Dura Plus Hot Runner system. The following section is a step-by-step guide to prepare your Mold-Masters system for use.

  • Page 28: Screw Lengths

    2. After removing all restraints, attach the crane to the hoist and carefully remove the system from the shipping crate. 3. Check that all mold base dimensions are correct and correspond to Mold- Masters General Assembly drawing. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 29: Cleaning

    2. Clean all surfaces and dowel holes, ensuring that no debris, burrs, shavings, dust, dirt or other foreign material which could interfere with measurements, exists. Ream holes out if necessary. 3. Remove tape from inlet and clean. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 30: Section 5 - Assembly

    Ensure that you have fully read “Section 3 - Safety” before assembling parts of the Dura Plus Hot Runner system. Some Dura Plus systems are designed in modules for easy installation, quick startups and user friendly maintenance. Some systems may be supplied with certain additional components for “Plug &...

  • Page 31: Pre-Assembly Checks Of Gate Seals And Nozzle

    CAUTION Gate seals are torqued at ambient (room) temperature at Mold-Masters. Please torque each seal at processing temperature to the torque value specified to prevent material leakage from the gate seal. 1. Apply die spotting blue compound to the gate seal (and liner, if used) to ensure a proper contact on sealing surface.

  • Page 32: Assembly Of Gate Seals To Nozzle

    3. Install gate seal and liner. 4. Torque to specified values. Refer to the General Assembly drawing for torque values. 5. Heat nozzle to processing temperature and re-torque seal. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 33: Thermocouple Installation For 01 Nozzle

    4. Press thermocouple carefully alongside nozzle body and install retaining clip(s). Check parts list for recommended number of clips for the nozzle type. Check that the thermocouple fits into the recess of the clip. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 34 6. Use heat resistant tape to secure the nozzle wires and thermocouple wires just above or below the insulator pod. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 35: Nozzle Flange Assembly

    Make sure the ball plunger top surface is lower than the flange top surface by at least 0.08 mm (0.003 in.). 0.08 mm 3. Apply die spotting blue compound to the thread to ensure a proper contact with the flange. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 36 Remember to re-torque at process temperature when system assembly is complete. 5. Insert five spring clips (SPRG15) into the M6 shoulder bolt (SHSSM6X25), and apply anti-seize compound to the thread. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 37 Make sure the balls sit completely inside the dimple. 7. Torque the two M5 shoulder bolts to 9.5 Nm (84 lbf.in.). Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 38: Sub-Manifold Assembly For Drop-In System

    Apply die spotting blue compound here 2. Line up the valve disk stem into the manifold hole. 3. Install the valve disk flange on top of the valve disk stem. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 39 7. Apply anti-seize compound to screws, reinstall the valve disk stem and valve disk flange and torque in a crossing pattern. Refer to the General Assembly drawing for torque values. 8. Install the valve pin to verify fit. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 40 Install Valve Disk (Valve Disk Design) - continued 9. Install screws in a crossing pattern to nozzle through the manifold. NOTE Ensure nozzle terminal end is in the direction noted on the General Assembly drawing. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 41: Pneumatic System Installation

    3. Apply anti-seize compound to screws. Optional: Install anti-rotation collar to the bottom of cooling plate. Ensure proper alignment after reassembly. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 42 Refer to the General Assembly drawing for torque values. 5. Place the cylinder housing onto the cylinder cooling plate. 6. Insert the valve pin into the piston. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 43 8. Install the piston top into the piston. NOTE Use soft vise jaws with cutout for piston body to prevent damage to the part. 9. Install the piston into the cylinder housing. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 44: Hydraulic System Installation

    Refer to the General Assembly drawing for torque values. 5.5.3 Hydraulic System Installation 1. Install the spacers on top of the manifold or valve disk flange. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 45 3. Apply anti-seize compound to the screws. 4. Torque screws in a crossing pattern, gradually increasing torque to the specified value. Refer to the General Assembly drawing for torque values. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 46 Heater plates are not shown in pictures below for clarity. 2. Install dowel pin. 3. Apply die spotting blue compound valve disk stem. Apply die spotting blue compound here © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 47 5. Install valve disk flange on top of valve disk stem. 6. Install the screws and torque to the specific value. Refer to the General Assembly drawing for torque values. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 48 9. Apply anti-seize compound to the screws and reinstall the valve disk stem and valve disk flange, torquing in a crossing pattern to the specified value. Refer to the General Assembly drawing for torque values. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 49: Actuator Assembly

    12. Valve pin Pneumatic cylinder section view Figure 5-2 Pneumatic cylinder components NOTE Pneumatic actuators with spring packages are available for certain sizes. See General Assembly drawing for details. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 50 1. Install the rod seal (2 pieces). 2. Use the piston to push the seal into position. 3. Install the rod wiper seal (2 pieces). 4. Use the piston to push the seal into position. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 51 7. Tighten the piston top. NOTE Use soft vise jaws with cutout for piston body to prevent damage to the part. 8. Assemble the piston into the cylinder body. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 52 10. Assemble the cylinder top to the cylinder body. 11. Apply anti-seize compound to the screws. 12. Install the cylinder top screws. 13. Install the piston collar to the cylinder body. Piston collar © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 53: Install Hydraulic Actuator Assembly

    8. Piston seals 9. Retaining ring 10. Rod seal 11. Cooling channel 12. Support spacer 13. Valve pin anti-rotation collar Hydraulic cylinder section view Figure 5-3 Hydraulic cylinder assembly components Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 54 1. Place the two pieces that make the rod seal into the pocket of the cylinder body. 2. Press the seals into the housing. 3. Install the rod seal retainer clip. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 55 4. Place pipe sealant on threads of the water circuit pipe plug. Install the water circuit pipe plug. 5. Install the piston seals (3 pieces). Split retainer ring Piston seal O-ring 6. Install the O-ring. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 56 ASSEMBLY 5-27 Install Hydraulic Actuator Assembly - continued 7. Install the piston seal. 8. Install the split retainer ring. 9. Install the valve pin. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 57 11. Install the piston top. 12. Tighten the piston top. NOTE Use soft vise jaws with cutout for piston body to prevent damage to the part. 13. Install the cylinder top seal. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 58 14. Assemble the piston into the cylinder body. 15. Assemble the cylinder top to the cylinder body. 16. Apply anti-seize compound to the screws. Install the cylinder top screws. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 59: Install Sub-Manifold Heater Plates (Option)

    Current bronze heater plates are directly interchangeable with previous copper based plates that may exist on your Mold-Masters system. However, when multiple heater plates are controlled by one thermocouple, these heater plates must be made of the same material, must be of equal voltage and must be located in similar thermal environments.

  • Page 60: Install Heater Plates

    Refer to the General Assembly drawing for torque values. 2. The heater plates are supplied with the power wires connected. Place a zone number on each wire and thermocouple. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 61: Tubular Heater Installation And Replacement For Bridge

    60204-1 or NFPA79. CAUTION CAUTION Mold-Masters only recommends field replacement of flexible heater elements only. We do not recommend field replacement of heater elements that are brazed or pasted into the manifold. For these types of heater elements, please contact your service representative.

  • Page 62: Remove A Heater Element

    Always start the heater element installation from the middle point of the path. We recommend installing the heater element gradually from both sides in parallel. This will help to get an equal exit length. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 63 8. Do not bend the unbendable zones of the heater element. This is the last 35 mm (1.4 in) area on each end. See below: 35 mm (1.4 in) Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 64 9. Crimp the wire with the proper size crimper pin. Connect it to the heater threaded pin with the ceramic terminal connector. 10. After all connections are finished, test the electrical connections to proper electrical standards. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 65: Bridge Assembly

    5. Rotate the center heater to align with the tapped holes in the manifold and align terminals with cutout. 6. Install mounting screws through the center heater into the tapped holes of the manifold. Use anti-seize compound on the screws. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 66: Inlet Extension With Heater Sleeves

    1. Center heater 2. Screw 3. Thermocouple Figure 5-4 Back plate (heated) 5.10.3 Inlet Extension with Heater Sleeves 1. Apply die spotting blue compound to bottom of inlet. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 67 5. Clean the die spotting blue compound from the inlet and manifold. 6. Reinstall inlet. Torque screws in a crossing pattern, gradually increasing torque to specified value. Refer to the General Assembly drawing for torque values. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 68 8. Clean die spotting blue compound from inlet seal and inlet. 9. Install inlet heaters and sleeves as per specified drawing. 10. Apply anti-seize compound to threads and install inlet seal to inlet. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 69 11. Torque to specified value. Refer to the General Assembly drawing for torque values. 12. Install thermocouple into slot until it bottoms out. 13. Bend 180 degrees. 14. Install thermocouple clip. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 70: Wiring Channel

    8. U-shaped bracket 4. Side cover 9. Insulator 5. Wire channel body Figure 5-5 Wiring channel 10. Bolt 4 11. Retainer flange 12. Quick disconnect Figure 5-6 Wiring channel quick connect © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 71 12. Quick disconnect: consists of a straight plug and a fixed socket. The straight plug is attached to the fixed socket, which allows for quicker installation and removal of prewired sub assemblies Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 72: Sub-Manifold Wiring

    9. Repeat above for each zone. Name connector number according to drop number. Be sure to locate the connectors inside the wire armor. See “5.10.4 Wiring Channel” on page 5-41 for further details. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 73: Thermocouple Wiring

    2. Label all heater and thermocouple zones. 3. Use heat resistant tape to group thermocouple heater zones together and to avoid losing labels. 4. Repeat for all zones. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 74: Wiring Channel Installation

    2. Mount the wiring channel to the manifold from the side. The slot holes of U-shaped bracket must align with the manifold mounting holes. 3. Mount any other accessories or adapter plates to the wiring channel. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 75 5. Organize all sorted power, thermocouple and other control wires to the wiring channel then install side covers. 6. Run all hoses above the wiring channel. Fasten to the U-shaped bracket, if needed. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 76: Electrical Box

    1. Install plugs into electrical box. 5.11.6 Solenoid Valve Wiring 1. Install solenoid coil wires into electrical plugs as per wiring schematic in General Assembly drawings. 2. Install plugs into electrical box. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 77: Section 6 - Sevg Plus Actuator

    SeVG Plus actuator in your system. 6.3 SeVG Plus Actuator in Dura Plus Systems The Dura Plus system has the flexibility to use all three models of SeVG Plus actuator, depending on the type of system. See Table 6-2.

  • Page 78: Sevg Plus Model Options

    5. Motor locating spigot 2. Valve pin holder (bottom) 6. Motor mount flange 3. Valve pin holder (top) 7. SHCSM6X25 4. Motor rod 8. Motor Figure 6-1 SE40-20 actuator Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 79: Se40-20C Actuator - Cooled

    IMPORTANT Mold-Masters assumes no responsibility for connection, monitoring and / or maintenance of any cooling system associated with an SeVG Plus system. 6. Motor mount flange 1.

  • Page 80: Se20-15 Model - Non Cooled

    5. Motor locating flange 1. Valve pin 6. Motor 2. Valve pin holder (bottom) 7. SHCSM5X155 3. Valve pin holder (top) 4. Motor locating spigot Figure 6-3 SE20-15 actuator Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 81: Plate Mounted Systems

    2. Frame plate 3. Actuator plate 4. Manifold plate Note: non cooled model shown Figure 6-4 SE40-20 actuator in a Dura Plus system 6.6.1 SE20-15 Model 1. SeVG Plus actuator 2. Frame plate 3. Actuator plate 4. Manifold plate Figure 6-5 SE20-15 actuator in a Dura Plus system ©...

  • Page 82: Assembly And Installation

    A template for the appropriate hole pattern is provided in Figure 6-6. Front view Rear view Bulkhead connectors Hole pattern template Figure 6-6 Bulkhead connectors and template Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 83: Attach The Water Lines (Cooled Models Only)

    Figure 6-7 Motor rod flats IMPORTANT If the Dura Plus system contains plastic, heat the system to processing temperature before the assembly is placed and see the hot surfaces warning above. Make sure that the cooling system is also connected.

  • Page 84: Assemble And Install The Valve Pin Holder

    [6 to 7 ft-lbs]. See Figure 6-9. 1. Motor rod 2. Valve pin holder (top) 3. Valve pin holder (bottom) 4. Valve pin Figure 6-9 Valve pin holder components Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 85 Attach to the actuator plate with four SHCSM6X25 screws. Torque to 18 Nm [13 ft-lbs].See Figure 6-10 and Figure 6-11. Figure 6-10 Install the SE40-20 Figure 6-11 Install the 40-20C actuator © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 86 See Figure 6-13. Figure 6-12 Install the SE20-15 actuator × Figure 6-13 Use the correct screws Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 87: Disassembly

    3. Remove the four SHCSM6X25 mounting screws. See Figure 6-14. Figure 6-14 Remove the four mounting screws 4. Pull motor up until the valve pin is free to disengage. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 88: Se20-15 Model

    3. Remove the two SHCSM5X155 mounting screws. See Figure 6-15. Figure 6-15 Remove the two mounting screws 4. Pull motor up until the valve pin is free to disengage. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 89: Manifold Mounted Systems

    7. Valve pin holder (bottom) 8. Valve disk stem 9. Valve pin 10. Valve disk flange 11. Spacer 12. Water fitting 13. Cooling plate 14. Assembly screw Figure 6-16 SE40-20 actuator © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 90: Se40-20C Model

    13. Cooling plate 14. Assembly screw 15. Motor cooling connections ** JIC 37” flared fitting end (9/16/-18 thread for 3/8 inch outer diameter tube ends) Figure 6-17 SE40-20C actuator Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 91: Sevg Plus In Manifold Mounted Systems

    SEVG PLUS ACTUATOR 6-15 6.10 SeVG Plus in Manifold Mounted Systems Figure 6-18 SE40-20 actuator in a manifold mounted system © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 92: Assembly And Installation

    A template for the appropriate hole pattern is provided in Figure 6-19. Front view Rear view Bulkhead connectors Hole pattern template Figure 6-19 Bulkhead connectors and template Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 93: Assemble And Install The Valve Pin Holder

    2. Install this assembly onto the top piece of the valve pin holder. Torque to 8 to 10 Nm [6 to 7 ft-lbs]. See “Figure 6-21 Valve pin holder components” on page 6-18. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 94: Install The Motor And Valve Pin Assembly

    9. Place the motor locating spigot and valve pin assembly onto the cooling plate. NOTE Ensure that the motor shaft is aligned with the cooling plate bore. Motor locating spigot Figure 6-22 Motor locating spigot Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 95: Attach The Water Lines (Cooled Models Only)

    Use Flats From Wrench Resistance Method • do not exceed 2 flats for tube connections to the fitting • do not exceed 1.5 flats for swivel nut / hose connections © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 96: Install Cables

    Figure 6-25 Attach cables to wiring channel IMPORTANT The cables must not be allowed to touch the manifold or other heated components. 13. Continue assembly with the clamp plate. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 97: Disassembly

    Damaged cables can cause a permanent failure of the motor. 1. Cool the system to room temperature, between 10°C and 40°C (50°F and 104°F). 2. Disconnect the water hoses from the actuator and / or clamp plate. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 98 Heat the system to allow any plastic to become soft. • Remove the four SHCSM6X90 mounting screws from the motor flange, which is attached to the cooling plate. 7. Remove the motor / valve pin assembly. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 99: Section 7 - Accu-Line

    29. Dowel pin 30. Cooling plug 31. Jiffy plug 32. Dowel pin 33. Cylinder top 34. Socket head cap screw 35. Support sleeve 36. Insulation plate Figure 6-27 Accu-Line™ body assembly © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 100: Accu-Line™ With Valve Insert - Assembly

    Valve pin Figure 7-1 Components for Accu-Line™ non front mounted model Outer cylinder - front mounted Heated adapter Straight hose Clip Figure 7-2 Additional components for Accu-Line™ front mounted model Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 101 Non Front Mounted Model: Front Mounted Model: 4. Insert the jiffy plugs for cooling connection into the supply ports of the cylinder. Non Front Mounted Model: Front Mounted Model: © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 102 6. Apply grease to the O-ring assembly grooves in the outer surface of the piston. 7. Use your fingers and gently push the O-ring into the groove in the piston. Make sure that the O-ring seats firmly in the groove. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 103 NOTE Ensure that the top surface of the piston and cylinder are level with one another. Non Front Mounted Models: Level Front Mounted Models: Level © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 104 ACCU-LINE™ Accu-Line™ with Valve Insert Assembly - continued 9. Insert the dowel pin into the outer cylinder assembly. Non Front Mounted Models: Front Mounted Models: Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 105 Ensure that the O-ring seats firmly in the groove. Non Front Mounted Models: Front Mounted Models: 11. Apply grease to the O-ring assembly grooves in the inner and outer surface of the cylinder top. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 106 14. Install the cylinder top into the outer cylinder. Align the cylinder top with the anti rotation dowel. NOTE Ensure that the O-rings are not disturbed from their positions. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 107 15. Insert the screws and torque to 7 Nm (5 lbf-ft). Non Front Mounted Models: Front Mounted Models: 16. Place the insulation plate on the cylinder body and install the support sleeves. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 108 Non Front Mounted Models: 1. Insulation plate 2. Sleeve 3. Cover plate 4. Socket head cap screw Front Mounted Models: Insulation plate 2. Sleeve 3. Cover 4. Socket head cap screws Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 109 IMPORTANT Steps 19 and 20 are optional for systems that contain actuation connections within the plates. 19. Install the actuation connections into the bottom supply ports of the cylinder. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 110 2. Ground wire assembly 3. Thermocouple assembly 23. Use a box spanner and assemble the valve insert into the heated body with a torque of 54 Nm (40 lbf-ft). Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 111 NOTE Hecto nozzles do not need the screws to be installed in this procedure. Two screws will be installed with the heated body. DECI nozzles only MEGA nozzles only © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 112 32. Insert the valve pin head into the keyhole slot in the valve pin holder and slide the holder so that the pin head is located in the narrow portion of the slot. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 113 IMPORTANT Ensure that these two measurements are equal. NOTE Air gap will be determined by the flange depth in the mold plate. Non Front Mounted Models: Front Mounted Models: © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 114 Accu-Line™ with Valve Insert Assembly - continued 34. Carefully place the nozzle assembly into the hydraulic unit. NOTE Ensure that the nozzle terminal end is correctly oriented. Non Front Mounted Models: Front Mounted Models: Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 115 Accu-Line™ with Valve Insert Assembly - continued 35. Secure the valve pin holder to the piston with a shoulder head screw. Torque to 3 Nm (2.2 lbf-ft). Non Front Mounted Models: Front Mounted Models: © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 116 Front Mounted Models: Front mounted Accu-Line™ models have built in wire channel cutouts for easy connection to the electrical box. See Figure 7-3. Cutout Figure 7-3 Cutout on front mounted models Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 117: Section 8 - Electrical Testing

    Ensure that you have fully read “Section 3 - Safety” before beginning electrical testing. This section contains guidelines for electrical testing of your Mold-Masters Dura Plus Hot Runner system. The testing is based on the following European and North American standards: •...

  • Page 118: Ground Shorts Test

    1. Mold power connector 2. Thermocouple connector Figure 8-1 Mold plug Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 119: Pinch Point Test

    • If there are not enough control zones, heat sources that have the same wattage and affect the same environment may be grouped together. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 120: Heating Test With A Temperature Controller

    Stay with the system and monitor the initial heating to minimize risk. 8.9 Retesting Where a portion of the electrical equipment is changed or modified, that portion must be reverified and retested, as appropriate. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 121: Section 9 - System Installation

    Ensure that you have fully read “Section 3 - Safety” before installing the Dura Plus Hot Runner system. The following section is a step-by-step guide to install the Mold-Masters Dura Plus Hot Runner into the existing manifold plate system or spacer block system. 9.1 Prior to Assembly...

  • Page 122: Install Sub-Manifold Assembly

    2. Using a depth micrometer, verify the dimensions of the manifold pocket to those specified on the print. 3. Apply die spotting blue the manifold locator into the bore to ensure proper seating. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 123: Install Manifold Locator And Anti-Rotation Dowel

    6. Torque bridge screws in a crossing pattern gradually increasing torque to specified value. Refer to the General Assembly drawing for torque values. 7. Measure and confirm drop height as specified on General Assembly drawing. 8. Repeat for each drop. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 124: Final Installation Steps

    2. Connect all the plumbing (air and water hoses) to the sub-manifold unit. 3. Install screws to secure electrical and solenoid interface to exterior of mold base. 4. Install clamp plate. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 125: Section 10 - System Startup And Shutdown

    When running thermally sensitive materials, use a thermally stable material as recommended by the material supplier for the initial startup. After the Dura Plus system is installed in the molding machine, make sure to bleed all the air out of the hydraulic lines, if applicable. Failure to do so could result in high gate vestige.

  • Page 126: Startup

    Hot Runner interface. 5. Set injection time and pressure according to part size, gate size and material. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 127: Stack Mold Systems

    1. Turn off all heat to the system. 2. Leave the mold cooling system ON, including valve actuator water, until the Hot Runner system temperature is within 100°F (37.7°C) of the mold temperature. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 128: Stack Mold System

    1. Shutdown spacers, sub-bridges and bridges. 2. Reduce nozzle temperatures to 230°F (110°C). 3. Wait 20 minutes. 4. Shutdown manifolds, submanifolds, inlets and nozzles. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 129: Section 11 - Maintenance Procedures

    WARNING Ensure that you have fully read “Section 3 - Safety” before doing maintenance procedures on the Dura Plus Hot Runner system. This chapter is a guide to maintaining selective components. Repairs that should be performed by Mold-Masters personnel are not included.

  • Page 130: Terminal End Removal

    2. Grip the element sleeve at the threaded area and turn counter clockwise. If the wires rotate with the sleeve, damage may result. 3. Remove the seal. 4. Remove the set screw from the ceramic sleeve. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 131: Terminal Assembly

    2. Ensure the terminal end is clean. 3. Slide the element sleeve, silicon seal and ceramic insulator onto the wires. 4. Slide crimps onto leads. Stranded wire should extend beyond the crimp. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 132 6. Grasp the crimp with the crimping tool, slide the crimp into position over the terminal post and crimp the connection. 7. Slide the ceramic insulators and silicon seal into place. 8. Complete the repair by screwing the element sleeves into position. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 133 Terminal Assembly - continued 9. Slide the second ceramic insulator and silicone seal into place. 11. Complete the assembly by screwing the element sleeve into position. Figure 11-2 Nozzle terminal assembly © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 134: Heater Plate Power Lead Replacement

    2. Crimp the leads to the terminal ends. 3. Slide ceramic sleeve over the terminal end. 4. Tighten the set screws on the ceramic sleeve to secure the terminal assembly. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 135: Gate Seal Maintenance

    NOTE Use the socket supplied in the Mold-Masters tool kit to loosen the gate seal. It is recommended to use a temperature controller for this procedure. If a temperature controller is not available, contact your nearest Mold-Masters Service Department.

  • Page 136: Gate Seal Removal

    It is recommended the nozzle be removed from the system before removing the gate seal. Use the socket supplied in the Mold-Masters tool kit to loosen the gate seal. The following procedure applies to all gate seals, including carbide, with threads larger than an M6.

  • Page 137: Gate Seal Replacement

    CAUTION Gate seals are torqued at ambient (room) temperature at Mold-Masters. Please torque each seal at processing temperature to the torque value specified to prevent material leakage from the gate seal. 1. Clean the nozzle, especially the thread and runner.
  • Page 138 7. Torque the gate seal to the appropriate value. Refer to “Gate Seal Torque Settings” on page 11-12. 8. Check that the seal has bottomed out, heat nozzle to process temperature and re-torque seal. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.

  • Page 139: Checking Nozzle Tip Height

    4. Move vernier to correct reference point on nozzle tip as indicated by the General Assembly drawing. 5. Check that nozzle height is within drawing specification. 6. Repeat for each nozzle. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

  • Page 140: Nozzle Thermocouple Removal

    11.11.1 Gate Seal Torque Settings CAUTION CAUTION Gate seals are torqued at ambient (room) temperature at Mold-Masters. Please torque each seal at processing temperature to the torque value specified to prevent material leakage from the gate seal. Table 11-2 Gate Seal Torque Settings Nozzle...

  • Page 141: System And Plate Screw Torques

    CAUTION CAUTION Bridge manifold mounting screws should be torqued 1/3 higher than specified on General Assembly drawings. Quality and length of screws must be as specified on Mold-Masters General Assembly drawings. Table 11-3 Torque Chart for System Assembly Screws Metric...
  • Page 142 One of the best resources may be your resin supplier. To help in this process, we welcome you to reference Mold-Masters Troubleshooting Guide which offers general information related to common issues. This document can be found at https://www.moldmasters.
  • Page 143 Clamping Plate: A plate fitted to a mold and used to fasten the mold to a platen. Clamping Pressure: The pressure applied to the mold to keep it closed during a cycle, usually expressed in tons. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 144 Hot Runner Mold: A mold in which the runners are insulated from the chilled cavities and are kept hot. Hot Runner molds make parts that have no scrap. Injection: The process of forcing melted resin into a mold. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 145 (Machine) Nozzle: The hollow-cored, metal nose screwed into the injection end of a plasticator. The nozzle matches the depression in the mold. This nozzle allows transfer of the melt from the plasticator to the runner system and cavities. © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 146 The resulting friction causes some heating of the resin. Short Shot: Failure to completely fill the part or cavities of the mold. Edges may appear melted. Dura+ User Manual © 2020 Mold-Masters (2007) Limited. All Rights Reserved.
  • Page 147 Vent: A shallow channel or opening cut in the cavity to allow air or gases to escape as the melt fills the cavity. Some glossary content © DRM Associates 2008 / © Protomold 1999-2009 © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 148 Hazard areas 3-2 Warped Parts 12-23 Heater Continuity 8-3 Warranty 1-1 Hot Tip Gate: 13-2 Water Cooled Gate Insert Installation 9-1 Weld Lines 12-24 Wiring Check 8-1 Intended Use 1-1 © 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...
  • Page 149 +65 6261 7793 tel: +82 31 431 4756 tel: +86 512 86162882 e: singapore@moldmasters.com e: korea@moldmasters.com e: china@moldmasters.com   JAPAN tel: +81 44 986 2101 e: japan@moldmasters.com www.moldmasters.com © 2021 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual...

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