Hot Runner System Instruction Manual - Synventive · C Company P Products A Application T Technology 2015 Rev02 Hot Runner System Instruction Manual SVC-17-0001_EN-Rev03 EN 11 / 2015

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Hot Runner SystemInstruction Manual

SVC-17-0001_EN-Rev03 EN 11 / 2015 KA

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Master Language is English Hot Runner System Instruction Manual SVC-17-0001_EN-Rev03 RESTRICTED: Property of Synventive. - 2 - All rights reserved. Errors and omissions excepted For limited third party distribution based on need and intended use. © 2015 Synventive Molding Solutions

IntroductionDear Customers,Thank you for purchasing a Synventive Hot Runner System. Our objective is to provide you with a product that is a good fit for the application, trouble free in performance, and support it with the best service in the industry. If problems occur during the use of this product please contact us at one of the locations provided.This manual is designed as a reference only document for the proper installation, operation and maintenance of Synventive Hot Runner Systems as well as a guideline for securing occupational health and safety in connection with the use of this system. Synventive does not warrant that the information is complete or accurate for every application. Synventive reserves the right to make changes to this document from time to time as new products are developed and new information identified.This manual contains essential information, to ensure its general applicability to Synventive Hot Runner Systems. The customer is exclusively responsible for the protection of their equipment and personnel. Synventive is not liable for any personal injury or damage caused by improper use, installation or handling of the product. This product should only be installed and used by fully trained and qualified personnel. The customer is required to provide the necessary personal protective equipment, such as protective gloves, hearing protection, protective shields etc. In no case does this document provided by Synventive release the customer from its obligations. This manual is intended for tooling and molding personnel who install and maintain the hot runner system. It should be forwarded with the hot runner system when shipped from the tool maker to the molder or between molding locations.This document is copyright protected and it is intended exclusively for the users of Synventive Hot Runner Systems. It may not be copied and distributed without the written consent of Synventive Molding Solutions.

Yours faithfully,

Synventive Molding Solutions

Headquarters:

USA – Peabody, MA Synventive Molding Solutions Inc.10 Centennial DrivePeabody, MA 01960Tel.: +1 978 750 8065Fax: +1 978 646 3600Email: [email protected]

Germany – BensheimSynventive Molding Solutions GmbHHeimrodstraße 10P. O. Box 312364625 BensheimTel. :+49 (0)6251 9332-0Fax :+49 (0)6251 9332-90Email: [email protected]

China – SuzhouSynventive Molding Solutions (Suzhou) Co. Ltd.12B Gang Tian Industrial SquareSuzhou Industrial Park, China 215021Tel.: +86 512 6283 8870Fax: +86 512 6283 8890Email: [email protected]

Customer Service:

North America24/7 Technical Support Line1-800-367-5662 – Press 4 from the Main Menu

EuropeTechnical Support+49 6251 93320 (8:00 am - 5:00 pm)For after hours service, please contact your local service representative

Asia24/7 Technical Support+86 512 62838870-866 (8:30 am - 5:00 pm)

+86 13862017765 after hours

Copyright 2015 Synventive Molding Solutions.

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Table of Contents1 Safety Instructions ...........................................................................................................141.1 CE approved Equipment ............................................................................................................. 141.2 Purpose of use of a Hot Runner System ................................................................................... 141.2.1 Use compatible with the intended Purpose ...................................................................................................................141.2.2 UseinconflictwiththeintendedPurpose ......................................................................................................................141.3 DefinitionofQualifiedPersonswithTechnicalKnowledge ..................................................... 141.4 SafetyInstructionswithintheInstructionManual .................................................................... 151.5 TheHRSystemInstructionManual/PartoftheSynventiveCustomerDocumentation ...... 151.6 Safety Instructions and Symbols used ...................................................................................... 151.6.1 Symbols of Danger Categorisation ................................................................................................................................161.6.2 Mandatory Safety Signs of the Personal Protective Equipment ..................................................................................161.6.3 Warning Symbols ............................................................................................................................................................161.6.4 Prohibited Symbols .........................................................................................................................................................171.7 General Safety Instructions ........................................................................................................ 172 Product Description .........................................................................................................202.1 Nozzle Types................................................................................................................................. 212.1.1 API heating .....................................................................................................................................................................212.1.2 APT heating ....................................................................................................................................................................212.1.3 Sprue Bushing Nozzles...................................................................................................................................................222.1.4 Support Ring Nozzles .....................................................................................................................................................222.1.5 Threaded Nozzles ...........................................................................................................................................................232.2 Hot Half ......................................................................................................................................... 243 Preparation for Incorporation .........................................................................................253.1 UnpackingtheHotRunnerSystem ............................................................................................ 263.2 CleaningHotRunnersandCut-Out.......................................................................................... 283.3 List of necessary Tools ............................................................................................................... 294 InstallationoftheHotRunnerSystem ...........................................................................304.1 General Instructions for Installation .......................................................................................... 304.1.1 Requirements on the Injection Mold ...............................................................................................................................304.1.2 Requirements on Temperature Control ..........................................................................................................................324.2 Table-ExpansionGap(JointZ) ................................................................................................ 33

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4.3 InstallationofHRSystemswithSupportRingNozzles(APT) ................................................. 344.3.1 Support Ring Nozzle Installation ....................................................................................................................................354.3.2 For non pre-wired Systems ............................................................................................................................................394.4 InstallationofHRSystemswithThreadedNozzles(API)......................................................... 404.4.1 Preparation for System Installation ................................................................................................................................414.4.2 Nozzle Tip Adjustment ....................................................................................................................................................444.4.3 For non pre-wired Systems ............................................................................................................................................494.5 InstallationofPLUG´NPLAY®HRSystemswithThreadedNozzles ...................................... 504.5.1 Preparation for System Installation ................................................................................................................................514.5.2 System Installation ..........................................................................................................................................................534.5.3 Nozzle Tip Adjustment ....................................................................................................................................................564.5.4 For non pre-wired Systems ............................................................................................................................................604.6 InstallationofHRSystemswithThreadedNozzles(APT) ....................................................... 614.6.1 Preparation for System Installation ................................................................................................................................624.6.2 Nozzle Tip Adjustment ....................................................................................................................................................664.6.3 For non pre-wired Systems ............................................................................................................................................70

5 Start-upoftheHotRunnerSystem ................................................................................715.1 Preparation for Start up ............................................................................................................... 735.2 PowerSupplyConnection .......................................................................................................... 735.2.1 Grounding Check ...........................................................................................................................................................745.2.2 VerificationofHeaterGrounding ....................................................................................................................................745.2.3 InformationonHeaterConnection .................................................................................................................................755.3 HotRunnerSystemStart-up ....................................................................................................... 765.4 ColorChange ............................................................................................................................... 795.4.1 Color Change of direct contact Nozzles (plunged through-Nozzles) ...........................................................................795.4.2 Color change of Nozzles with pre-chamber isolation without removable cavity plate ................................................815.4.3 Color change of Nozzles with pre-chamber isolation and replaceable cavity plate ...................................................815.5 HotRunnerSystemSwitch-off ................................................................................................... 835.6 StorageofHotRunnerSystemduringShutdowns .................................................................. 846 DefectIdentificationandTroubleshooting ....................................................................856.1 Defects Table ................................................................................................................................ 85

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7 ServiceandMaintenance ................................................................................................897.1 MaintenanceofValveGateSystems .......................................................................................... 897.1.1 Checklist for Valve Gate System Maintenance .............................................................................................................897.1.2 CleaningouttheHotRunnerSystem ............................................................................................................................90

8 Actuators ...........................................................................................................................918.1 ServiceoftheActuatorHYC2508MSeries ................................................................................ 928.1.1 TechnicalDataHYC2508M02-F,HYC2508M02-R,HYC2508M03-F,HYC2508M03-R ...........................................928.1.2 ExplodedViewHYC2508MSeries ................................................................................................................................938.1.3 Tools for Assembling and Disassembling the Actuator .................................................................................................948.1.4 Enhancements,OptionsandAccessories .....................................................................................................................958.1.5 DisassemblingtheActuatorHYC2508MSeries ............................................................................................................998.1.6 AssemblingtheActuatorsHYC2508MSeries .............................................................................................................1028.2 ServiceoftheActuatorHYC4018MSeries .............................................................................. 1078.2.1 TechnicalDataHYC4018M03-F/-R,HYC4018M04-F/-R,HYC4018M05-F/-R ........................................................1078.2.2 ExplodedViewHYC4018MSeries ..............................................................................................................................1088.2.3 Tools for Assembling and Disassembling the Actuator ...............................................................................................1098.2.4 Enhancements,OptionsandAccessories ................................................................................................................... 1108.2.5 DisassemblingtheActuatorHYC4018MSeries .......................................................................................................... 1138.2.6 AssemblingtheActuatorHYC4018MSeries ............................................................................................................... 1178.3 ServiceoftheActuatorHYC4520M04Series .......................................................................... 1218.3.1 TechnicalDataHYC4520M04-F,HYC4520M04-R .....................................................................................................1218.3.2 ExplodedViewHYC4520M04Series ..........................................................................................................................1228.3.3 Tools for Assembling and Disassembling the Actuator ...............................................................................................1238.3.4 Enhancements,OptionsandAccessories ...................................................................................................................1248.3.5 DisassemblingtheActuatorHYC4520M04Series ....................................................................................................1258.3.6 Disassembling the Adjustment Screw Assembly and Piston .....................................................................................1278.3.7 AssemblingtheActuatorHYC4520M04Series ..........................................................................................................1308.4 ServiceoftheActuatorHYC4016MSeries .............................................................................. 1368.4.1 TechnicalDataHYC4016M01-F/-R,HYC4016M03-F/-R,HYC4016M05-F/-R ........................................................1368.4.2 ExplodedViewHYC4016MSeries ..............................................................................................................................1378.4.3 Tools for Assembling and Disassembling the Actuator ...............................................................................................1388.4.4 Enhancements,OptionsandAccessories ...................................................................................................................1398.4.5 DisassemblingtheActuatorHYC4016MSeries ..........................................................................................................1408.4.6 AssemblingtheActuatorHYC4016MSeries ...............................................................................................................144

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8.4.7 InstallingtheActuatorHYC4016MSeriesontheHotRunner ....................................................................................1498.5 ServiceoftheActuatorPNC4508M02Series .......................................................................... 1508.5.1 TechnicalDataPNC4508M02-F,PNC4508M02-R .....................................................................................................1508.5.2 Exploded View PNC4508M02 Series ..........................................................................................................................1518.5.3 Tools for Assembling and Disassembling the Actuator ...............................................................................................1528.5.4 Enhancements,OptionsandAccessories ...................................................................................................................1538.5.5 Disassembling the Actuator PNC4508M02 Series .....................................................................................................1548.5.6 Assembling the Actuator PNC4508M02 Series ..........................................................................................................1578.6 ServiceoftheActuatorPNC7518M03Series .......................................................................... 1638.6.1 TechnicalDataPNC7518M03-F,PNC7518M03-R .....................................................................................................1638.6.2 Exploded View PNC7518M03 Series ..........................................................................................................................1648.6.3 Enhancements,OptionsandAccessories ...................................................................................................................1658.6.4 Tools for Assembling and Disassembling the Actuator ...............................................................................................1668.6.5 Disassembling the Actuator PNC7518M03 Series .....................................................................................................1678.6.6 Assembling the Actuator PNC7518M03 Series ..........................................................................................................1708.7 ServiceoftheActuatorPNC7518M04Series .......................................................................... 1748.7.1 TechnicalDataPNC7518M04-F,PNC7518M04-R .....................................................................................................1748.7.2 Exploded View PNC7518M04 Series ..........................................................................................................................1758.7.3 Tools for Assembling and Disassembling the Actuator ...............................................................................................1768.7.4 Enhancements,OptionsandAccessories ...................................................................................................................1778.7.5 Disassembling the Actuator PNC7518M04 Series .....................................................................................................1788.7.6 Assembling the Actuator PNC7518M04 Series ..........................................................................................................1828.8 ServiceoftheActuatorPNC5018M01Series .......................................................................... 1888.8.1 TechnicalDataPNC5018M01-F,PNC5018M01-R .....................................................................................................1888.8.2 Exploded View PNC5018M01 Series ..........................................................................................................................1898.8.3 Tools for Assembling and Disassembling the Actuator ...............................................................................................1908.8.4 Enhancements,OptionsandAccessories ...................................................................................................................1918.8.5 Disassembling the Actuator PNC5018M01 Series .....................................................................................................1938.8.6 Assembling the Actuator PNC5018M01 Series ..........................................................................................................1968.9 ServiceoftheActuatorPNC6018M01Series .......................................................................... 2028.9.1 TechnicalDataPNC6018M01-F,PNC6018M01-R .....................................................................................................2028.9.2 Exploded View PNC6018M01 Series ..........................................................................................................................2038.9.3 Tools for Assembling and Disassembling the Actuator ...............................................................................................2048.9.4 Enhancements,OptionsandAccessories ...................................................................................................................205

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8.9.5 Disassembling the Actuator PNC6018M01 Series .....................................................................................................2078.9.6 Assembling the Actuator PNC6018M01 Series ..........................................................................................................2108.10 ServiceoftheActuatorPNC6018M02Series .......................................................................... 2158.10.1TechnicalDataPNC6018M02-F,PNC6018M02-R .....................................................................................................2158.10.2 Exploded View PNC6018M02 Series ..........................................................................................................................2168.10.3 Tools for Assembling and Disassembling the Actuator ...............................................................................................2178.10.4Enhancements,OptionsandAccessories ...................................................................................................................2188.10.5 Disassembling the Actuator PNC6018M02 Series .....................................................................................................2198.10.6 Assembling the Actuator PNC6018M02 Series ..........................................................................................................2228.11 ServiceoftheActuatorPNC3008B02 ....................................................................................... 2268.11.1 Technical Data PNC3008B02 .......................................................................................................................................2268.11.2 Exploded View PNC3008B02 ......................................................................................................................................2278.11.3ToolsforAssembling,DisassemblingandAdjustingtheActuator ..............................................................................2288.11.4 Disassembling Actuator PNC3008B02 ........................................................................................................................2298.11.5 Assembling the Actuator PNC3008B02 .......................................................................................................................2328.12 ServiceoftheActuatorPNC4508BSeries ............................................................................... 2388.12.1TechnicalDataPNC4508B-01,PNC4508B-02 ...........................................................................................................2388.12.2 Exploded View PNC4508B Series ...............................................................................................................................2398.12.3ToolsforAssembling,DisassemblingandAdjustingtheActuator ..............................................................................2408.12.4 Disassembling Actuator PNC4508B Series ................................................................................................................2418.12.5 Assembling the Actuator PNC4508B Series ...............................................................................................................2448.13 ServiceoftheActuatorPNC6018BSeries ............................................................................... 2508.13.1TechnicalDataPNC6018B-01,PNC6018B-02 ...........................................................................................................2508.13.2 Exploded View PNC6018B Series ...............................................................................................................................2518.13.3ToolsforAssembling,DisassemblingandAdjustingtheActuator ..............................................................................2528.13.4 Disassembling Actuator PNC6018B Series ................................................................................................................2538.13.5 Assembling the Actuator PNC6018B Series ...............................................................................................................2568.14 ServiceoftheActuatorQCVG16M01,QCVG16M02 ................................................................ 2618.14.1 Technical Data QCVG16 Series ...................................................................................................................................2618.14.2 Exploded View QCVG16 Series ..................................................................................................................................2628.14.3 Disassembling the Actuator QCVG16 Series ..............................................................................................................2638.14.4 Assembling the Actuator QCVG16 Series ...................................................................................................................2668.14.5 Actuator Bleeding QCVG16 .........................................................................................................................................271

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8.15 ServiceoftheActuatorVP4008PSeries .................................................................................. 2728.15.1TechnicalDataVP4008P01,VP4008P0301 ...............................................................................................................2728.15.2 Explosion view of the VP4008P Series ........................................................................................................................2738.15.3 Basic Dimensions in Mold .............................................................................................................................................2748.15.4 First mounting of Actuator VP4008P ............................................................................................................................2768.15.5 Dismounting the Actuator VP4008P .............................................................................................................................2788.16 ServiceoftheActuatorVP8016PSeries .................................................................................. 2808.16.1TechnicalDataVP8016P0501,VP8016P0601,VP8016P0801 ................................................................................2808.16.2 Explosion view of the VP8016P Series ........................................................................................................................2818.16.3 Basic Dimensions in Mold .............................................................................................................................................2828.16.4 First mounting of Actuator VP8016P ............................................................................................................................2848.16.5 Dismounting the Actuator VP8016P .............................................................................................................................285

9 ValvePins ........................................................................................................................2879.1 ValvePinDismantling ................................................................................................................ 2879.2 ValvePinHeightAdjustmentHYC2508MSeries ..................................................................... 2909.2.1 HeightAdjustmentofCylindricalshut-offValvePin .....................................................................................................2919.2.2 HeightAdjustmentofConicalshut-offValvePin .........................................................................................................2929.3 ValvePinHeightAdjustmentHYC4018M,HYC4016MSeries ................................................ 2939.3.1 HeightAdjustmentofCylindricalshut-offValvePin .....................................................................................................2949.3.2 HeightAdjustmentofConicalshut-offValvePin .........................................................................................................2959.4 ValvePinHeightAdjustmentHYC4520MSeries ..................................................................... 2969.4.1 HeightAdjustmentofCylindricalshut-offValvePin .....................................................................................................2979.4.2 HeightAdjustmentofConicalshut-offValvePin .........................................................................................................2989.5 ValvePinHeightAdjustmentPNC4508MSeries ..................................................................... 2999.5.1 HeightAdjustmentofCylindricalshut-offValvePin .....................................................................................................3009.5.2 HeightAdjustmentofConicalshut-offValvePin .........................................................................................................3019.6 ValvePinHeightAdjustmentPNC7518MSeries ..................................................................... 3029.6.1 HeightAdjustmentofCylindricalshut-offValvePin .....................................................................................................3039.6.2 HeightAdjustmentofConicalshut-offValvePin .........................................................................................................3049.7 ValvePinHeightAdjustmentPNC5018M/PNC6018MSeries ............................................... 3059.7.1 HeightAdjustmentofCylindricalshut-offValvePin .....................................................................................................3069.7.2 HeightAdjustmentofConicalshut-offValvePin .........................................................................................................307

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9.8 ValvePinHeightAdjustmentPNC3008B02 ............................................................................. 3089.8.1 Valve Pin Adjustment Tool Kit .......................................................................................................................................3089.8.2 AdjustmentatmountedHotRunnerSystem ...............................................................................................................3099.9 ValvePinHeightAdjustmentPNC4508B/PNC6018BSeries ................................................ 3139.9.1 Valve Pin Adjustment Tool Kit .......................................................................................................................................3139.9.2 AdjustmentatmountedHotRunnerSystem ...............................................................................................................3149.10 ValvePinHeightAdjustmentQCVGActuator ......................................................................... 3179.10.1HeightAdjustmentofshut-offValveGatePinswithQCVGActuator .........................................................................3189.11 ValvePinHeightAdjustmentVP4008PSeries ........................................................................ 3229.11.1 Thermal Expansion Calculation ....................................................................................................................................3239.11.2HeightAdjustmentofCylindricalshut-offValvepin .....................................................................................................3249.11.3HeightAdjustmentofConicalshut-offValvepin ..........................................................................................................3279.12 ValvePinHeightAdjustmentVP8016PSeries ........................................................................ 3309.12.1 Thermal Expansion Calculation ....................................................................................................................................3319.12.2HeightAdjustmentofCylindricalshut-offValvepin .....................................................................................................3329.12.3HeightAdjustmentofConicalshut-offValvepin ..........................................................................................................335

10 Nozzles ............................................................................................................................33810.1 Nozzles06ESeries(API) ........................................................................................................... 34010.1.1 Dismounting Thermocouple..........................................................................................................................................34210.1.2 Mounting Thermocouple ...............................................................................................................................................34310.1.3 Disassembly Nozzle 06E ..............................................................................................................................................34410.1.4 Assembling Nozzle 06E ................................................................................................................................................34610.2 Nozzles09ESeries(API) ........................................................................................................... 35110.2.1 Dismounting Thermocouple..........................................................................................................................................35210.2.2 Mounting Thermocouple ...............................................................................................................................................35310.2.3 Disassembly Nozzle 09E ..............................................................................................................................................35410.2.4 Assembling Nozzle 09E ................................................................................................................................................35610.3 Nozzles12ESeries(API) ........................................................................................................... 36110.3.1 Dismounting Thermocouple..........................................................................................................................................36310.3.2 Mounting Thermocouple ...............................................................................................................................................36410.3.3 Disassembly Nozzle 12E ..............................................................................................................................................36510.3.4 Assembling Nozzle 12E ................................................................................................................................................367

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10.4 Nozzles(APT) ............................................................................................................................. 37310.4.1ReplacingNozzleTips,InsertsandNozzleTipSeals(APT) ......................................................................................37410.4.2InstallingNozzleTips,InsertsandNozzleTipSeals(APT) ........................................................................................37710.5 SingleValveGateNozzle12S01_V ........................................................................................... 38210.5.1 Technical Data - Single Valve Gate Nozzle 12S01_V .................................................................................................38210.5.2TechnicalData-CoolingUnitCU12SVH01 ................................................................................................................38310.5.3 Mold Cut-out ..................................................................................................................................................................38410.5.4SingleAxisValveGate12S01_V/ActuatorHYC2013S01PartsList .......................................................................38610.5.5DismountingtheCylinderHousingHYC2013S01andtheSealKit ...........................................................................39010.5.6AssemblyoftheCylinderHousingHYC2013S01ontheNozzle ...............................................................................39210.5.7 Dismounting and Mounting of the Thermocouple .......................................................................................................39910.5.8ValvePinHeightAdjustment .........................................................................................................................................40110.5.9 Disassembling the Single Valve Gate Nozzle out of the Mold ....................................................................................40210.6 SingleValveGateNozzle16S01_V ........................................................................................... 40310.6.1 Technical Data - Single Valve Gate Nozzle 16S01_V .................................................................................................40310.6.2TechnicalData-CoolingUnitCU16SVH01 ................................................................................................................40410.6.3 Mold Cut-out ..................................................................................................................................................................40510.6.4SingleValveGateNozzle16S01_V/ActuatorHYC2314S01PartsList ...................................................................40710.6.5DismountingtheCylinderHousingHYC2314S01andtheSealKit ........................................................................... 41110.6.6AssemblyoftheCylinderHousingHYC2314S01ontheNozzle ...............................................................................41310.6.7 Dismounting and Mounting of the Thermocouple .......................................................................................................42010.6.8ValvePinHeightAdjustment .........................................................................................................................................42210.6.9 Disassembling the Single Valve Gate Nozzle out of the Mold ....................................................................................42310.7 SingleValveGateNozzleGAN...S01 ........................................................................................ 42410.7.1 Technical Data - Single Valve Gate Nozzle GAN...S01 ..............................................................................................42410.7.2 Technical Data - Cooling Unit CU12SVP01 .................................................................................................................42510.7.3 Mold Cut-out ..................................................................................................................................................................42610.7.4SingleValveGateNozzleGAN...S01PartsList ......................................................................................................42810.7.5DismountingthePneumaticCylinderHousingandSealing .......................................................................................43010.7.6AssemblyofthePneumaticCylinderHousingontheNozzle ....................................................................................43210.7.7 Dismounting and Mounting of the Thermocouple .......................................................................................................43510.7.8ValvePinHeightAdjustment .........................................................................................................................................43710.7.9 Disassembling the Single Valve Gate Nozzle out of the Mold ....................................................................................438

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10.8 SingleValveGateNozzleGBN...S01 ........................................................................................ 439

10.8.1 Technical Data - Single Valve Gate Nozzle GBN...S01 ..............................................................43910.8.2 Technical Data - Cooling Unit CU16SVP01 .................................................................................................................44010.8.3 Mold Cut-out ..................................................................................................................................................................44110.8.4SingleValveGateNozzleGBN...S01PartsList ......................................................................................................44410.8.5DismountingthePneumaticCylinderHousingandSealing .......................................................................................44610.8.6AssemblyofthePneumaticCylinderHousingontheNozzle ....................................................................................44810.8.7 Dismounting and Mounting of the Thermocouple .......................................................................................................45110.8.8ValvePinHeightAdjustment .........................................................................................................................................45310.8.9 Disassembling the Single Valve Gate Nozzle out of the Mold ....................................................................................45410.9 SingleValveGateNozzleCBNS ............................................................................................... 45510.9.1 Technical Data - Cooling Unit CU07SVP01 .................................................................................................................45610.9.2 Mold Cutout ...................................................................................................................................................................45710.9.3SingleValveGateNozzleCBNSPartsList .................................................................................................................45910.9.4DismountingthePneumaticCylinderHousingandSealing .......................................................................................46110.9.5 Assembly of the Pneumatic Actuator on the Nozzle ...................................................................................................46310.9.6 Dismounting and Mounting of the Thermocouple .......................................................................................................46610.9.7ValvePinHeightAdjustment .........................................................................................................................................46810.9.8 Disassembling the Single Valve Gate Nozzle out of the Mold ....................................................................................46910.10SprueBushing06SSeries ........................................................................................................ 47010.10.1 Technical Data - Sprue Bushing 06S .........................................................................................................................47010.10.2 Mold Cutout .................................................................................................................................................................47110.10.3LocationsoftheSprueBushing06SParts................................................................................................................47210.10.4Disassembly/AssemblyTools ...................................................................................................................................47310.10.5 Dismounting Nozzle Thermocouple ...........................................................................................................................47410.10.6 Mounting Nozzle Thermocouple ................................................................................................................................47410.10.7 Disassembly Nozzle 06S ............................................................................................................................................47610.10.8 Assembling Nozzle 06S..............................................................................................................................................48110.11SprueBushing09SSeries ........................................................................................................ 48810.11.1 Technical Data - Sprue Bushing 09S .........................................................................................................................48810.11.2LocationsoftheSprueBushing09SParts................................................................................................................48910.11.3 Assembly Tools ...........................................................................................................................................................49010.11.4 Nozzle Thermocouple .................................................................................................................................................491

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10.11.5 Disassembly Nozzle 09S ............................................................................................................................................49310.11.6 Assembling Nozzle 09S..............................................................................................................................................49910.12SprueBushing12SSeries ........................................................................................................ 50610.12.1 Technical Data - Sprue Bushing 12S .........................................................................................................................50610.12.2LocationsoftheSprueBushing12SParts................................................................................................................50710.12.3 Assembly Tools ...........................................................................................................................................................50810.12.4 Nozzle Thermocouple .................................................................................................................................................50910.12.5 Disassembly Nozzle 12S ............................................................................................................................................ 51110.12.6 Assembling Nozzle 12S..............................................................................................................................................51710.13InletBushingIB-24/IB-32 ......................................................................................................... 52610.13.1 Technical Data IB-24 ...................................................................................................................................................52710.13.2 Technical Data IB-32 ...................................................................................................................................................52710.13.3 Dismounting and Mounting of the Inlet Bushing on the Manifold .............................................................................52810.14InletBushingIB-50 .................................................................................................................... 53310.14.1 Technical Data IB-50 ...................................................................................................................................................53410.14.2 Dismounting and Mounting of the Inlet Bushing on the Manifold .............................................................................53510.15NozzleCoolingwithCoolingInsert/Bushing......................................................................... 53810.15.1GeneralProductDescription-CoolingInsert/Bushing ...........................................................................................53810.15.2OutgateCooling ..........................................................................................................................................................53910.15.3 Distance Tube .............................................................................................................................................................53910.15.4 Assembly View 16E Cooling Bushing .......................................................................................................................54010.15.5 Assembly View 16E Cooling Insert ............................................................................................................................541

11 DismountingandMountingManifoldPlugs ................................................................54211.1 DismountingManifoldPlugs(APT) .......................................................................................... 54211.1.1 Cleaning the Flow Bores ...............................................................................................................................................54311.2 MountingManifoldPlugs(APT) ................................................................................................ 54312 Accessories ....................................................................................................................54412.1 ServiceforthePositionSensor ................................................................................................ 54512.1.1 Tools for the Position Sensor Service ..........................................................................................................................54512.2 BasicPositionSensorInformation .......................................................................................... 54612.2.1 Installing the Position Sensor........................................................................................................................................54612.2.2InstallingoftheActuatorwithPositionSensorontheHotRunner .............................................................................54812.2.3 Position Sensor Troubleshooting Guide ......................................................................................................................549

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13 Torques............................................................................................................................55113.1 RelevantPartsattachedwithScrewspursuanttoISO4762(DIN912) ................................. 55113.2 ToolSpecifications .................................................................................................................... 55113.3 Instructions on Torques for Synventive parts ......................................................................... 55214 Shutdown ........................................................................................................................55514.1 ReturningtheHotRunnerSystem ........................................................................................... 55514.2 Disposal ...................................................................................................................................... 55615 Annex ..............................................................................................................................55715.1 Units used ................................................................................................................................... 55715.2 GlossaryandListofAbbreviations .......................................................................................... 55815.3 Patents ........................................................................................................................................ 56015.4 GlobalOffices/SalesAgencies ............................................................................................... 561

Hot Runner System Instruction Manual - Synventive · C Company P Products A Application T Technology 2015 Rev02 Hot Runner System Instruction Manual SVC-17-0001_EN-Rev03 EN 11 / 2015

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