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DME Mold Master EcoOne Series User Manual

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User Manual
version 1
UM-EO-ENG-01
Original Instructions

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Summary of Contents for DME Mold Master EcoOne Series

  • Page 1 User Manual version 1 UM-EO-ENG-01 Original Instructions...

  • Page 3: Table Of Contents

    SmartONE Contents Introduction ........................5 Intended Use ........................5 Documentation........................5 Release Details .......................5 Warranty .........................5 Returned Goods Policy ....................6 Movement or Resale of Mold-Masters Products or Systems ..........6 Copyright ........................6 Global Support ........................7 Corporate Offices ......................7 International Representatives ..................8 Safety ..........................9 Overview ........................10 Operational Hazards .....................13 Wiring Check ........................15 Lockout Safety ......................16...
  • Page 4 Manifold and Component Wiring Guidelines ..............32 Ground Connection .....................32 Power and Thermocouple Connector Placement ............32 Confirm Zone Numbering With Respect To Cavity Numbers ........32 Wire Channels ......................32 Recheck Resistances of Heaters and Thermocouples ..........32 Adding Additional Wire to Nozzle Heater Leads ............32 Adding Additional Wire to Thermocouple Leads ............32 System Start-up Guidelines ...................33 Instructions Prior to Installation of the Hot Runner System ..........33...

  • Page 5: Introduction

    EcoONE Introduction The purpose of this manual is to assist users in the integration, operation and maintenance of a 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 6: Returned Goods Policy

    EcoONE Returned Goods Policy Please do not return any parts to Mold-Masters without pre-authorization and a return authorization number supplied by Mold-Masters. Our policy is one of continuous improvement and we reserve the right to alter product specifications at any time without giving notice. Movement or Resale of Mold-Masters Products or Systems This documentation is intended for use in the country of destination for which the product or system was purchased.

  • Page 7: Global Support

    EcoONE Global Support Corporate Offices GLOBAL HEADQUARTERS ASIAN HEADQUARTERS EUROPEAN CANADA CHINA/HONG KONG/TAIWAN HEADQUARTERS Mold-Masters (2007) Limited GERMANY / Mold-Masters (KunShan) Co, Ltd 233 Armstrong Avenue Zhao Tian Rd SWITZERLAND Georgetown, Ontario Lu Jia Town, KunShan City Mold-Masters Europa GmbH Canada L7G 4X5 Jiang Su Province Neumattring 1...

  • Page 8: International Representatives

    EcoONE Corporate Offices - continued Mold-Masters Regional Offices (cont.) SPAIN SINGAPORE* TURKEY Mold-Masters Singapore PTE. Ltd. Mold-Masters Europa GmbH Mold-Masters Europa GmbH No 48 Toh Guan Road East C/ Tecnología, 17 Merkezi Almanya Türkiye #06-140 Enterprise Hub Edificio Canadá PL. 0 Office A2 İstanbul Şubesi 08840 –...

  • Page 9: Safety

    EcoONE 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 necessary e-stop connections, safety interlocks and guarding, to select the appropriate electrical cable for the region of use and to ensure compliance with all relevant standards.

  • Page 10: Overview

    EcoONE Overview WARNING Refer to all machine manuals and local regulations and codes for safety information. The following safety hazards are most commonly associated with plastic injection molding equipment (see European Standard EN201 or American Standard ANSI/SPI B151.1). Refer to the following illustration of hazard areas when reading the “Table 2 Safety Hazards”.
  • Page 11 EcoONE Table 2 Safety Hazards Hazard Area Potential Hazards Mold Area Mechanical Hazards Area between the Crushing and / or shearing and / or impact hazards caused by: platens. • Movement of the platen. See Figure 1 area 1 • Movements of the injection barrel(s) into the mold area.
  • Page 12 EcoONE Table 2 Safety Hazards Hazard Area Potential Hazards Feed Opening Pinching and crushing between injection screw movement and housing. See Figure 1 area 6 Area of the Heater Burns and / or scalds due to operating temperature of: Bands of the Plasticiz- •...

  • Page 13: Operational Hazards

    EcoONE Operational Hazards WARNING • Refer to all machine manuals and local regulations and codes for safety information. • The equipment supplied is subjected to high injection pressures and high temperatures. Ensure that extreme caution is observed in the operation and maintenance of the injection molding machines.
  • Page 14 EcoONE WARNING • A crushing hazard exists between the nozzle and mold melt inlet during carriage forward motion. • A possible shearing hazard exists between the edge of the injection guard and the injection housing during injection. • The open feed port could present a hazard to a finger or a hand inserted during operation of the machine.

  • Page 15: Wiring Check

    EcoONE Wiring Check CAUTION System Mains Supply Wiring: • Before connecting the system to a power supply, it is important to check that the wiring between the system and the power supply has been done correctly. • Particular attention must be given to the current rating of the power supply. For example, if a controller is rated at 63A, then the power supply must also be rated at 63A.

  • Page 16: Lockout Safety

    EcoONE Lockout Safety WARNING DO NOT enter the cabinet without first isolating the supplies. High voltage and amperage cables are connected to the controller and the mold. Electrical power must be shut off and lockout / tagout procedures followed prior to installing or removing any cables. Use lockout / tagout to prevent operation during maintenance.

  • Page 17: Electrical Lockout

    EcoONE Electrical Lockout WARNING - READ MANUAL Refer to all machine manuals and local regulations and codes. NOTE In some instances, there may be more than one power source feeding equipment and steps must be taken to ensure that all sources are effectively locked out. Employers must provide an effective lockout/tagout program.

  • Page 18: Energy Forms And Lockout Guidelines

    EcoONE Energy Forms and Lockout Guidelines Table 3 Energy Forms, Energy Sources and General Lockout Guidelines Energy Form Energy Source Lockout Guidelines Electrical Energy • Power transmission lines • Turn off power at machine first (i.e., at point • Machine power cords of operation switch), and then at the main •...

  • Page 19: Disposal

    EcoONE Disposal WARNING 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 (electricity, hydraulics, pneumatics and cooling).

  • Page 20: Hot Runner Safety Hazards

    EcoONE Hot Runner Safety Hazards WARNING • The equipment supplied is subjected to high injection pressures and high temperatures. • Ensure that extreme caution is observed in the operation and maintenance of the Hot Runner system and the injection molding machines. •...
  • Page 21 EcoONE WARNING • Water and / or hydraulics on the mold may be in close proximity to electrical connections and equipment. Water leakage may cause an electrical short circuit. Hydraulic fluid leakage may cause a fire hazard. Always keep water and / or hydraulic hoses and fittings in good condition to avoid leaks.
  • Page 22 EcoONE CAUTION All Mold-Masters heated components are manufactured to standards that ensure safe and reliable operation provided that the following precautions are met: • To maximize heater element and component life, the temperature must be controlled and maintained within safe operating limits. Mold-Masters strongly recommends individual control of each heated component, including heater plates, with a reliable temperature controller that includes soft-start protection.

  • Page 23: Guidelines

    EcoONE Guidelines To ensure success of each hot runner application, it is important that mold designers take the following factors into consideration: Selection of proper steel for the nozzle gate area. Proper machining of gate detail to supplied print. Proper cooling of the gate area to ensure proper gate vestige and to minimize drool or stringing of the material.

  • Page 24: System Assembly Guidelines

    EcoONE Confirm the manifold plate thickness is as specified on the supplied drawings. This dimension is important because a change in plate thickness will affect the total stack up of the system and alter the machining dimensions of the nozzle counterbore (C-bore). Provide a wire channel to protect and properly route wiring to the terminal box.

  • Page 25: Assembly Guidelines

    EcoONE Assembly Guidelines Step 1 Nozzle Measurements Check the “A” dimension of the nozzle assemblies to ensure this dimension is within specification and to establish a base for all other dimensions. Record the value on the Master Inspection Sheet. Gate seal torques: Torque - Open Gate Torque - Valve Gate Nozzle Series...
  • Page 26 EcoONE Step 2 C-Bore Depth Measurement Inspect the manifold plate that will house the nozzle bodies for flatness. Ensure the wire channels are free of any burrs and that all directional changes incorporate generous radii. All nozzle head counterbore depths (Figure 2) are to be +0.025 to – 0.00 mm from the design dimension. Measure the counterbore in three locations to ensure flatness.
  • Page 27 EcoONE Step 3 Head Height Install the nozzles into their respective counterbores. Check the height from the top of the nozzle head to the top of the manifold plate. Record these dimensions as “C” on the Master Inspection Sheet (Figure 3). Manifold Plate Nozzle Plate Figure 4 Head Height...
  • Page 28 EcoONE new diagram be made. A copy of the revised wiring diagram should be forwarded to the Applications Engineering Department to keep the system file current. This will facilitate troubleshooting any problems that might arise at a later time. Step 5 Properly Position the Manifold using Two Dowel Pins The first dowel will be located at the center of the manifold.
  • Page 29 EcoONE Step 8 Check “E” Dimension Check and record the dimension “E” from the bottom of the clamp plate manifold cutout surface to the center manifold surface. Record this dimension as “E” on the Master Inspection Sheet. Step 9 Size and Install Upper Support Pads Size and install the upper support pads into the underside of the clamp plate.
  • Page 30 EcoONE Step 11 Install Nozzle Heater Sleeves Flip over the hot half assembly to let nozzles tips face up. Install the nozzle heater sleeve (Figure 6): • Place a zone number on each wire and thermocouple • Try to organize and tape wires by zone and plug •...

  • Page 31: Final Assembly

    EcoONE Step 13 Prepare to Install Seal Rings Next remove the manifold, taking care to protect wiring, and prepare to install seal rings into the head of the nozzles. Check to see that all nozzles and their locations are properly marked. Mark all nozzles, manifold power, and thermocouple leads to ensure proper connection into the system terminal box.

  • Page 32: Manifold And Component Wiring Guidelines

    EcoONE Manifold and Component Wiring Guidelines Ground Connection A ground connection must exist between the hot runner system (mold base) and the temperature control system. This is accomplished via the mold power cable, which contains a ground wire (green) provided on the connector.

  • Page 33: System Start-Up Guidelines

    EcoONE System Start-up Guidelines Instructions Prior to Installation of the Hot Runner System Perform the following checks before installing the hot runner system into the press. With the system properly grounded, execute an electrical check of each control zone for both power and thermocouple connections.

  • Page 34: Manifold Filling Procedures

    EcoONE Manifold Filling Procedures WARNING Never inject plastic through the hot runner system with the mold open. CAUTION Make sure you wear proper safety equipment such as gloves and face shield at all times. Never use a torch to open frozen-off gates. This may damage tips, gate detail, or the mold itself. If you insert anything into the gate or tip to clear it, you must first back the machine nozzle away from the tool.
  • Page 35 EcoONE NOTE If the system will not start up, throttle down or shut off water to the “A” plate. Water to the manifold plate should remain on. If the machine will not extrude with the tool open, close the tool, jog the screw forward, open the tool, close the tool, and jog the screw forward again.

  • Page 36: Master Inspection Sheet

    EcoONE Master Inspection Sheet Heater & Thermocouple (T/C) Drops Nozzle Dimensions Ohm Measurement: Heater Nozzle Nozzle Nozzle Nozzle Nozzle Nozzle Nozzle Nozzle Nozzle Nozzle Nozzle Nozzle Nozzle Nozzle Nozzle Nozzle *Head ** Average "C" plus “H–1”dimension Height Assembly Date Quote No. Assembled By Manifold “H-1”...
  • Page 37 NORTH AMERICA CANADA (Global HQ) U.S.A. tel: +1 905 877 0185 tel: +1 248 544 5710 e: canada@moldmasters.com e: usa@moldmasters.com SOUTH AMERICA BRAZIL (Regional HQ) MEXICO tel: +55 19 3518 4040 tel: +52 442 713 5661 (sales) e: brazil@moldmasters.com e: mexico@moldmasters.com EUROPE AUSTRIA GERMANY (Regional HQ)

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