Specifications

D-M-E Runnerless Molding Systems
63
The Hot-One System
Guidelines for the use of a manifold block
3. Bench test the unit with the temperature controller set at
150 °C. Ensure all heaters come up to the desired set
point. If desired set point is not reached, trouble shoot
the system.
4. When the mold is installed in the press and all water
connections are made, plug the power and thermocouple
cables into the mold terminal box.
Note:
Confirm the mainframe is off before making connections
to the mold.
5. Set the temperature controller to the correct processing
temperature for the material being molded.
Note:
Allow all heaters to go through a moisture dryout
process.
6. Bring the system up to the correct processing temperatu-
re. Turn on mold water (cooling) and close the mold.
Extremely cold water is not necessary. Water temperatu-
re of 40 °C should keep the “A” side of the mold from ex-
panding at a different rate than the “B” side of the mold.
7. When the runnerless molding system has reached set
point and is normalized, the temperature controllers will
show a green light in the center of the deviation light
display.
8. Make sure that the machine nozzle orifice is as large as,
but not larger than, the nozzle seat orifice on the mani-
fold.
This will allow maximum throughput to the runnerless
molding system and the mold cavities.
9. Be certain that the nozzle radius on the machine barrel
matches the nozzle seat radius on the manifold to
prevent drooling. This should ensure a leak-proof seal.
10. Purge the barrel to ensure stable material enters the ma-
nifold.
11. Move the machine nozzle into position against the mani-
fold nozzle seat.
Manifold Filling Procedures :
1. Ensure that the machine’s nozzle tip is properly seated
on the manifold nozzle seat.
2. Set machine back pressure to 20 to 35 bars.
3. Run the extruder until material flows through all nozzle
orifices (gates). Run for an additional 5-15 sec. Then
clear gates and all mold surfaces of material. If the
machine nozzle will not stay against tool, see
Notes
following these instructions.
4. Move the sled back and decrease back pressure to
normal setting.
5. Set decompression/suck back at a minimum of 12 mm to
control drool.
6. Set molding parameters.
7. Move sled forward.
8. Start the molding process.
9. Check the system for leaks.
Wiring Guidelines
1. Ground connection :
A ground connection must exist between the runnerless
molding system (mold base) and the temperature control
system. This is accomplished via the mold power cable,
which contains a ground wire (green or green/yellow)
provided on the connector.
To prevent electrical shock and ensure personal safety,
the grounding wire should be connected to the mold
base or the terminal box itself.
2.
Power and thermocouple connector placement :
Do not place the mold’s power or thermocouple plugs in
any area where they will be exposed to extreme tempe-
rature or humidity.
3. Confirm zone numbering with respect to cavity numbers.
4. Wire channels :
Use wire channels to ensure that wiring for nozzle and
manifold (including thermocouples) is routed away from
the manifold. Use retainer clips to hold the wiring in the
channels to prevent wires from being cut or pinched du-
ring final assembly.
5. Recheck resistances of heaters and T/Cs. Compare to
previous results. If values are different, trouble-shoot the
system. Compare these values to those provided on
your design.
6. Adding additional wire to nozzle heater lead:
If additional lead length is required, use the same type of
wire and use crimp contacts.
7. Adding additional wire to thermocouple leads:
If additional lead length is required, use only type “J”
thermocouple wire (positive (+) white, negative (-) red).
Note:
In the event that multiple zones are ganged together to
minimize the required number of control zones, it will be
necessary to use one pair of thermocouple wires per
ganged set of nozzles. Run other thermocouple leads
into the therminal box, insulating and identifying each for
use as spares if required at a later date.
Perform the following checks before instal-
ling the runnerless molding system into the
press :
1. With the system properly grounded, execute an electrical
check of each control zone for both power and thermo-
couple connections. Check the heater leads for continui-
ty. The resistance checked to ground of all heater leads
must be greater than 200.000 Ω (200 K Ω).
2. Check each thermocouple circuit for continuity. It is also
important to check for continuity between thermocouples
and heater elements. There should be no circuit be-
tween the heater element and the thermocouple.