8.4 Service of the Actuator HYC4016M Series€¦ · Service and Maintenance / Service of the...

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Master Language is English Hot Runner System Instruction Manual SVC-17-0001_EN-Rev03RESTRICTED: Property of Synventive. - 136 - All rights reserved. Errors and omissions exceptedFor limited third party distribution based on need and intended use. © 2015 Synventive Molding Solutions

Service and Maintenance / Service of the Actuator HYC4016M Series

8.4 Service of the Actuator HYC4016M Series

8.4.1 Technical Data HYC4016M01-F/-R, HYC4016M03-F/-R, HYC4016M05-F/-R

Actuator, bolted to manifold.

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(A) CLOSED(B) OPEN(C) COOLING

Valve pin operationOperation medium hydraulicOperating pressure 40 bar (580 psi)Pressure range 40 - 80 bar (580 - 1160 psi)

for operating pressure > 40 bar (600 psi) please consult Synventive

Flow rate 3 l/min / 40 bar (580 psi)Valve pin response time ~0,5 s / 40 bar (580 psi)Valve pin stroke 16 mmValve pin adjustment ± 1,5 mm

via adjustment threads from outsideClosing force 5027 N / 40 bar (580 psi)Opening force 3365 N / 40 bar (580 psi)Connections M 12 x 1,5 (8-L)CoolingMedium Cooling waterFlow rate 6 l/minPressure max. 8 bar (116 psi)Temperature 30 °C - 60 °C (86 °F - 140 °F)

Temp. difference IN/OUT max. 5 °CConnections M 12 x 1,5 (8-L)

max. 3 actuators in a rowValve pinValve pin diameter Ø 6 mm, Ø 8 mmAttachment Quick coupling, antirotation

NOTICETo ensure long life and continued flawless operation of the actuator, we recommend using a service medium that complies with the requirements of classification 21/18/13 pursuant to ISO 4406.The coolant used should be properly modified, e.g. filtered water with an anti-corrosion and frost-proof agent.

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8.4.2 Exploded View HYC4016M SeriesThis section describes the disassembly and reassembly process to replace seals.In this section the actuator parts are identified with the numbers indicated in the following figure, which shows the components.

NOTICEAlways tighten the screws to the torques specified in the respective table (section 13).

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Actuator parts HYC4016M SeriesNo. Qty. Description Item

(1) 1 Housing Complete HYC4016HC

(1.1) 1 Cylinder housing HYC4016CH01

(1.2) 1 Piston Assembly HYC401PI01

(1.2.1) 1 Piston, bottom HYC4016PB01

(1.2.2) 1 Piston, top HYC4016PT01

(1.3) 1 Piston magnet (Magnets assembled with Loctite 510)

PNC7518MAG02

(1.4) 4 Socket head cap screw DIN7991 (M04X016)

(1.5) 1 Adjustment screw HYC4016AS01

(1.6) 1 Adjustment screw cover HYC4013AC01

(1.7) 1 Position pin HYC4016PP01

(1.8) 1 Socket set screw DIN913-M06X12-45H

(1.9) 2 Socket head cap screw DIN915-M3X5-450HV

(1.10) 2 Socket cap screw DIN912-M5X8-12.9

(1.11) 1 Sealing kit (complete) HYC4016SK01

(1.11.1) 1 Piston seal K30-40-40-32-3.2

(1.11.2) 1 Rod seal Y22331PS074

(1.11.3) 1 Guiding element C1-2038-V3664

(1.11.4) 1 O-ring seal VIOR35X2.2FPM80

(1.11.5) 1 O-ring seal VIOR4X1FPM80

(1.11.6) 1 Guiding element FB2.3-1.5L70.5

(1.12) 1 Brake shoe HYC4016BS01

(2) 1 Heat deflector / Hydraulic CLY

HYC40HD01

(3) 1 Cooling plate (F) full contact surface

HYC4018CP01

(3) 1 Cooling plate (R) reduced contact surface

HYC4018CP02

(4) 1 Mounting plate HYC4013MP02

(5) 4 Socket head cap screw DIN912-M6x85-12.9

(6) 4 Socket head cap screw DIN912-M6X14-12.9

(7) 1 Positionsensor HESASSYXX

(8) 3 Pan Head Machine Screw DIN7985-M3x3

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8.4.3 Tools for Assembling and Disassembling the ActuatorThe following overview contains a list of special tools needed for the assembly and disassembly of the actuator and to replace seals.The assembly and disassembly tools are identified with the numbers indicated in the following figure, which shows the components in this section.

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NOTICEThese tools are not included with the Hot Runner System and must be ordered from Synventive separately.

Assembly and Disassembly Tools - ATCYL03No. Description Item

(T1) Adjustment tool cpl. ATCYL0301

(T2) Fitting nut cpl. ATCYL0302

(T3) Valve pin disassembly tool ATCYL0303

(T4) Installation cone ATCYL0304

(T5) Spread tube ATCYL0105

(T6) Calibration sleeve ATCYL0107

(T9) Assembly tool cpl. ATCYL0407

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8.4.4 Enhancements, Options and AccessoriesCooling Full for Valve Pin

Guide

Cooling Reduced for Valve Pin

Guide

SynCool® 1 Positionsensor

HYC4016M01-F ● − ● ●HYC4016M01-R − ● ● ●HYC4016M03-F ● − ● ●HYC4016M03-R − ● ● ●HYC4016M05-F ● − ● ●HYC4016M05-R − ● ● ●

● Standard○ Optional− not possible

8.4.4.1 Cooling Plate with Contact Surface to the Valve Pin GuideHYC4016M01-F /M03-F / M05-F with cooling plate HYC4018CP01 for full contact surface to the valve pin guide.HYC4016M01-R /M03-R / M05-R with cooling plate HYC4018CP02 for reduced contact surface to the valve pin guide.

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8.4.4.2 SynCool® 1The cooling plate between the actuator and the manifold to facilitate cooling of the valve pin guide and the actuator to thermally separate it from the hot manifold surface.The SynCool® 1 technology provides in addition an indirect cooling which allows the operator on certain applications at <280 °C operating & <80 °C mold temperature, to switch off the complete system including the mold and actuator cooling without the risk of decomposing the hydraulic oil.

Component SynCool® 1

No. Qty. Description Item01 1 Heat deflector HYC40HD01

NOTICEHeat deflector must has contact with the mold.

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8.4.5 Disassembling the Actuator HYC4016M Series

Hydraulic

Danger to Life by HydraulicSerious personal injury or death can result from connecting or disconnecting hydraulic hoses under pressure.Hydraulic works must be carried out by qualified persons.The hoses in the Hot Runner System and in the injection mold are under high pressure and high temperatures.Before disconnecting or connecting any hydraulic hoses:

The injection machine / hydraulic pump must be shut down The electrical disconnect properly locked out Pressure from the hoses must be removed

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1) Close the valve pin gate, so that the piston (1.2) is in bottom position.2) Remove the hydraulic hoses from the actuator connection ports.3) Remove the 4 socket head cap screws (5).

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4) Slide the cylinder in the direction of hydraulic connections or to the oposite side.

NOTICEThis will disengage the actuator from the valve pin.The movement does not depend on the direction of connections for coolant distribution (b).

NOTICEOn the actuator top is a sign ‘Pin Release’This refers to the disengage direction of the actuator from the valve pin. Doc003130.png

5) Remove the actuator housing (1.1) from the heat deflector (2).

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8.4.5.1 Dismounting the Positionsensor

1) Unscrew the 3 pan head machine screws (8).

NOTICEDo not touch the printed circuit board, instead handle the steel enclosure.

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8.4.5.2 Disassembling the Adjustment Screw Assembly

1) Loosen the socket set screw (1.8).2) Remove the brake shoe (1.12)3) Using the disassembly tool T9 to unscrew the adjustment screw

assembly (1.5) (1.6) out of the actuator housing (1.1).

NOTICEThe socked head cap screws (1.10) can be left in the adjustment screw (1.5).

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4) Screw the fitting nut (T2.1) (T2.2) into the actuator housing (1.1).

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5) Install a valve pin (VP) so it engages into the slots of the piston (1.2).6) Pull the piston (1.2) with the valve pin (VP) while turning the fitting nut

(T2.1) (T2.2) until the piston (1.2) is released.7) Dismount the piston seal (1.11.1) elements

● O-ring (1.11.1) (a) ● Sealing element (1.11.1) (b)

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8) Unscrew the 2 hexagon socket set screws (1.9).9) Dismount the adjustment screw cover (1.6) from the adjustment screw

(1.5).10) Dismount seals:

(1.11.6) Rod seal(1.11.2) Rod seal(1.11.3) Guiding element(1.11.4) O-ring seal

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8.4.6 Assembling the Actuator HYC4016M Series

8.4.6.1 Installing the Piston SealTo mount the piston seal (1.11.1) on the piston (1.2), proceed as follows:

1) Fit the mounting cone (T4) on the piston (1.2).

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NOTICEAfter disassembly of the sealing elements, the original seals should be replaced.

2) Mount the O-ring (1.11.1) (a) into the seal groove of the piston (1.2).3) Lubricate the Sealing element (1.11.1) (b) of the piston seal (1.2) with

hydraulic oil or white grease.4) Using the spreader sleeve (T5) and the mounting cone (T4), push the

sealing element (1.11.1) (b) into the seal groove of the piston (1.2).

NOTICEThe sealing element (1.11.1)(b) is placed in the seal grove of the piston (1.2) above the O-ring (1.11.1) (a).

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5) Insert the piston (1.2) uniformly in the calibration sleeve (T6).

NOTICEThis will precisely align the piston seal (1.11.1) with the piston (1.2).

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8.4.6.2 Installing the Adjustment Screw Assembly into the Actuator Housing

1) Position the fitting nut (T2.1) (T2.2) over the piston (1.2).

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NOTICEDuring mounting of the piston (1.2), it is important the piston is not jammed in the actuator housing (1.1).

2) Install the piston (1.2) while turning clockwise the fitting nut (T2.1) (T2.2) into the actuator housing (1.1) up to the stop.

3) Use the adjustment tool (T1) to ensure the position pin (1.7) align into the piston.

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NOTICEAfter disassembly of the sealing elements, the original seals should be replaced.

4) Lubricate the following seals with hydraulic oil or white grease:(1.11.6) Rod seal(1.11.2) Rod seal(1.11.3) Guiding element(1.11.4) O-ring seal

5) Install the seals on the adjustment screw cover (1.6) and adjustment screw (1.5).

6) Attach the adjustment screw cover (1.6) with 2 hexagon socket set screws (1.9) at the adjustment screw (1.5).

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7) Screw the two socked head cap screws (1.10) into the adjustment screw assembly (1.5) (1.6).

NOTICEUse a torque wrench for a torque of 5 Nm (3.7 ft-lbs).

8) Screw in the prepared adjustment screw assembly (1.5) (1.6) into the actuator housing (1.1) by using the disassembly tool (T9). Doc005878.png

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9) Turn the adjustment screw (1.5) by using a PIN (ø5) into the desired position.

NOTICE6,5 mm between bottom actuator housing (1.1) and adjustment screw (1.5) bottom.

10) Lock the adjustment screw (1.5) with the socket set screw (1.8) via the brake shoe (1.12) in the actuator housing (1.1).

NOTICEUse a torque wrench for a torque of 10 Nm (7.5 ft-lbs).

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8.4.6.3 Installing the Positionsensor

1) Check the operation of the sensor

NOTICEUse the sensor input/output module with a voltmeter.The output should be within the range of 0.0v to 5.0v.The voltage should be high when the valve gate is in the closed position and low when the valve gate is open.

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2) Wipe down surface where Positionsensor is to be attached.

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3) Attach positionsensor (7) with 3 pan head machine screws (8) to the actuator housing (1.1).

NOTICEUse a torque wrench for a torque of 1.5 Nm (1.1 ft-lbs) minimum.

NOTICEDo not touch the printed circuit board, instead handle the steel enclosure.

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8.4.6.4 Mounting the Actuator on the Manifold

1) Make sure that the SynCool heat deflector (2) is positioned on the cooling plate (3).

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Insertion of valve pin head into piston cut-out.

NOTICEDo not use the cylinder housing as support to get the system into the mold (no hammering e.g.).

This sign refers to the direction of valve pin release.

2) Slide the actuator so it engages the pin head slots of the piston(1.2).3) Place the actuator on the heat deflector (2).4) Move the actuator so that the valve pin (VP) head slides in the final

position inside the piston (1.2) cut-out.

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5) Lubricate the thread of the socket head cap screws (5) with high-temperature assembly paste (anti-seize compound).

NOTICEThis is an important measure to prevent thread corrosion due to aggressive gases, which could be released during plastics processing.

6) Screw the Actuator with socket head cap screws (5).

NOTICETighten the socket head cap screws (5) in an X pattern (a, d, c, b).Use torque wrench with wrench insert and the torque specified in the respective table in section 13.

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For valve pin height adjustment see section “9.3 Valve Pin Height Adjustment HYC4018M Series”

8.4.7 Installing the Actuator HYC4016M Series on the Hot Runner

1) The sensor cable must be routed to the wire-guard.

NOTICEAn awareness of the cut-out in the top clamp plate is necessary to avoid the cable being damaged during assembly. Wire ties or fiberglass tape can be used to secure the cable to a safe path.

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8.4 Service of the Actuator HYC4016M Series€¦ · Service and Maintenance / Service of the...

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