Mold-Masters Fusion G2 Manuals

Manuals and User Guides for Mold-Masters Fusion G2. We have 1 Mold-Masters Fusion G2 manual available for free PDF download: User Manual

Mold-Masters Fusion G2 User Manual (192 pages)

Brand: Mold-Masters | Category: Industrial Equipment | Size: 10 MB

Table of Contents
3
Section 1 - Introduction
11
Intended Use
11
Documentation
11
Release Details
11
Table 1-1 Release Details
11
Warranty
12
Returned Goods Policy
12
Movement or Resale of Mold-Masters Products or Systems
12
Copyright
13
Units of Measure and Conversion Factors
13
Table 1-2 Units of Measure and Conversion Factors
13
Trademarks and Patents
14
Section 2 - Global Support
15
Corporate Offices
15
International Representatives
16
Section 3 - Safety
17
Operator Training and Safety
17
Safety Hazards
18
Table 3-1 Safety Hazards
20
Operational Hazards
21
General Safety Symbols
23
Table 3-2 Typical Safety Symbols
23
Wiring Check
24
Lockout Safety
25
Electrical Lockout
26
Energy Forms and Lockout Guidelines
27
Table 3-3 Energy Forms, Energy Sources and General
27
Disposal
28
FUSION SERIES ® G2 Safety Hazards
29
Section 4 - Preparation
32
Tools Required
32
Screw Lengths
32
Unpacking
33
Cleaning
33
Hydraulic Cylinder Assembly
34
Pneumatic Cylinder Assembly
40
Waterless Hydraulic Actuator Assembly
45
Assemble the Piston Assembly of the Waterless Hydraulic Actuator
46
Assemble the Cylinder Body Assembly of the Waterless Hydraulic Actuator
48
Assemble the Cylinder Assembly of the Waterless Hydraulic Actuator
50
Assemble the Anti-Rotation Waterless Hydraulic Actuator
51
Waterless Pneumatic Actuator Assembly
52
Piston Assembly for Waterless Pneumatic Actuator
53
Adjust Valve Pin Length for Waterless Actuator (Optional)
54
Table 4-1 Valve Pin and Spacer Combinations
54
Cylinder Body Assembly for Waterless Pneumatic Actuator
55
Install the Rod Seal (2 Pieces)
56
Use the Piston to Push the Seal into Position
57
Install the Wiper Seal (2 Pieces)
57
Use the Piston to Push the Seal into Position
58
Cylinder Assembly for Waterless Pneumatic Actuator
59
Cylinder Assembly for Waterless Pneumatic Actuator - Anti-Rotation Version
61
Section 5 - Assembly
65
Typical FUSION SERIES ® G2 Systems
66
FUSION SERIES ® G2 Drop-In System
67
FUSION SERIES ® G2 Lite System
67
Gate Seal Finishing
68
Hot Valve / Hot Sprue / F Type
68
Table 5-1 Typical Contact Length
68
Re-Torque at Process Temperature
69
Check Nozzle Core to Manifold Fit
69
Assemble Nozzle to Manifold
71
Nozzle Assembly for Systems with Protective Sleeves
72
Heater Retaining Clip Installation
75
Nozzle Assembly for Systems Without Protective Sleeves
77
Install Nozzle Heaters and Sleeves
77
Install Thermocouple
77
Install Thermocouple Onto Nozzle Body (Optional)
78
Install the Thermocouple Onto the Nozzle Body (F3000/4000 Nozzles)
79
Heater Retaining Clip Installation
80
Flange Nozzle Assembly
81
Gate Seal and Nozzle Assembly
83
Check Gate Seal to Nozzle Fit
83
Assemble Gate Seals to Nozzle
84
Install Manifold Locator
85
Install Support Bushings
85
Install Manifold Thermocouple
87
Install Inlet
88
Install Inlet Thermocouple
90
Install Inlet Extension Tip
90
Install Valve Insert or Valve Disk
92
Install Valve Insert (Valve Insert Design)
92
Install Valve Disk (Valve Disk Design)
95
Install Cylinder on Manifold
97
Pneumatic System
97
Hydraulic System
102
Waterless Hydraulic and Pneumatic Actuator Systems
104
Install Wiring
109
Install Wire Armor to Manifold
109
Install Wiring
110
Electrical Routing into Electrical Box
110
Solenoid Valve Wiring
111
Connect Solenoid Valve Bank
114
Hydraulic Valvebank Connection
114
Pneumatic Valve Bank Connection
115
Install Hydraulic Flow Control Valve
116
Install Actuator Position Sensor
118
Water Cooled Gate Insert Installation
123
Section 6 - Sevg Plus Actuator
125
Introduction
125
Sevg Plus Actuator Models
125
Sevg Plus Actuator in FUSION SERIES ® Systems
125
Table 6-1 SEVG Plus Actuator Models
125
Table 6-2 FUSION SERIES ® Systems: Sevg Plus Actuator
125
Sevg Plus Models
126
SE40-20 Actuator - Non Cooled
126
Figure 6-1 SE40-20 Actuator
126
SE40-20C Actuator - Cooled
127
Figure 6-2 SE40-20C Actuator
127
Manifold Mounted Systems
128
SE40-20 Model
128
Figure 6-3 SE40-20 Actuator
128
SE40-20C Model
129
Figure 6-4 SE40-20C Actuator
129
Sevg Plus in Manifold Mounted Systems
130
Figure 6-5 SE40-20 Actuator in a Manifold Mounted System
130
Assembly and Installation
131
Figure 6-6 Bulkhead Connectors and Template
131
Figure 6-7 Motor Rod Flats
132
Figure 6-8 Valve Pin Holder Components
133
Figure 6-9 Motor Locating Spigot
134
Figure 6-10 Insert the Screws to Fasten the Assembly
134
Figure 6-11 Place Cables into Insulated Sheath
135
Figure 6-12 Attach Cables to Wiring Channel
135
Disassembly
136
Figure 6-13 Remove B Screws
137
Section 7 - Electrical Testing
138
Safety
138
Electrical Wiring Check
138
Electrical Safety Testing
139
Verify Equipment to Its Technical Documentation
139
Insulation Resistance Test
139
Verification of Conditions for Protection by Automatic Disconnection of Supply
139
Verification of Continuity of Protective Bonding Circuit
139
Verification of Fault Loop Impedance
140
Thermocouple Continuity Test
140
Pinch Point Test
140
Heating Element Check
141
Thermocouple Wiring Guidelines
141
Functional Test with a Temperature Controller
141
Retesting
141
Section 8 - System Installation
142
Unpacking
142
Pre-Installation
143
Install Manifold Locator Dowel
143
System Installation
144
Installation of a System with Flanged Nozzles
145
System Test
146
Section 9 - System Startup and Shutdown
148
Pre-Startup
148
Startup
149
Shutdown
150
Section 10 - Color Change
152
Introduction
152
Color Change for a Hot Tip / Sprue System
152
Color Change for a Valve Gate System
153
Locating a Source of Contamination
153
Section 11 - Maintenance
154
Recommended Torque Settings
154
Table 11-1 Recommended Torque Settings
155
Tubular Heater Installation and Replacement
156
Storage
156
Removing a Heater Element
156
Installing a New Heater Element
156
New Heater Startup
159
Solenoid Valve Bank
159
Hydraulic Solenoid Valve Bank
159
Figure 11-1 Pressure Reducing and Relieving Valve
160
Components of a Hydraulic Solenoid Valve Bank
161
Figure 11-2 Manometer Mounting Port
161
Pneumatic Solenoid Valve Bank
162
Components of a Hydraulic Solenoid Valve Bank
162
Figure 11-3 Solenoid Connector
162
Figure 11-4 Manual Override Switch
165
Recommended Spare Parts
166
Table 11-2 Actuator Spare Seal Kits
166
Table 11-3 Nozzle Spring Clip
166
Section 12 - Troubleshooting
167
Introduction
167
Moisture Related Issues
168
Resin Moisture Contamination
168
Resin Drying Issues
168
Importance of Pre-Drying Resin
168
Pre-Molding Precautions
169
Establishing Root Cause
170
Fault Identification
170
Troubleshooting Typical Problems
171
Dark Specks
171
Blisters or Bubbles
172
Flow Marks
173
Burn Marks
174
Delaminating Parts
175
Dimensional Irregularities
176
Discolored Parts
177
Flash
178
Jetting
179
Pitted Parts
180
Rough Surface
181
Parts Sticking to Cavity
182
Parts Sticking to Core
183
Short Parts
184
Sinks or Voids
185
Splay
186
Streaks
187
Stringing
188
Warped Parts
189
Weld Lines
190
Index
191

Mold-Masters Categories

Controller Industrial Equipment Laboratory Equipment Temperature Controller

More Mold-Masters Manuals

Mold-Masters Fusion G2 Manuals

Mold-Masters Fusion G2 User Manual (192 pages)

Table of Contents

Related Products

Mold-Masters Categories