BALA OP EN SYSTEMInstruction ManualV E R . N O . 0 3 0 7 – M N B O E N OGreetingsThank you for using YUDO Hot Runner System.YUDO fabricated Hot Runner System with its best efforts so that customers can use it most easily. However, there are many parts for customers to pay attention because it is a technical product.Please read this manual well and use it.YUDO reserves the right to change the provisions of these descriptions and specifications at any time without notification to customers.Please discuss with YUDO in advance when technical support is needed.Contents1. Basic Structure of YUDO Hot Runner System1) Basic Structure of Nozzle2. Outline of Hot Runner System3. Kinds of Hot Runner System1) Open Gate, Shut Off Gate, Valve Gate4. Meaning of YUDO Open Nozzle Standard1) BALA Open (CC, CA, CE, CF Type) Specification2) BALA Open (TAC, TOE, TLC Type) SpecificationBALA 18 SeriesBALA 25 SeriesBALA 35 SeriesBALA 45 Series3) Shape and symbol of gate4) Nozzle part machining5) Gate part machining6) Machining of Locating Ring Part7) Machining of Lead Wire Slot Part8) MODU Plate Machining (Clamping Plate, Spacer Block, Hold Plate)9) Machining of Connecting System Part5. Check Items of Hot Runner System1) Check of Hot Runner System Part 2) Electric Check of Hot Runner System3) Dimensional Check of Hot Runner System6. Assembly of Hot Runner System (MODU System)7. Operation of Hot Runner System1) Installation 2) Caution before operation3) Maintenance8. Disassembly and Assembly1) Disassembly and assembly when replacing nozzle heater and T/C9. How to Recognize Product Standard and System10. Trouble and CountermeasureA -Not being heatedB -Occurrence of carbonizationC -Resin leakageD -In case that resin leaks on manifold but heater is not disconnected.E -In case that resin leaks on manifold, heater is not disconnected, and coolant leaks todestroy insulation of heater.F -In case that manifold heater is disconnected.1. Basic Structure of YUDO Hot Runner SystemPLAN VIEWSIDE VIEWHot Runner and Mold Parts ListNo No.. Description DescriptionNo No.. Description Description1 Locating Ring19 Socket Head Cap Bolt 2 Socket Head Cap Bolt 20 Lower Insulation Pad 3 Clamping Plate 21 Dowel Pin 4 Spacer Plate 22 Dowel Pad 5 Holding Plate 23 Lock Pin 6 Cavity Plate24 Sheath Heater 7 MODU Assy Bolt(B2) 25 Seal Ring 8 Mold Assy Bolt(B1) 26 Nozzle Body 9 Socket Head Cap Bolt 27 Tube Heater 10 Center Pin Cover 28 Snap Ring 11 Center Pin 29 Nozzle Tip12 Nozzle Locator 30 Nozzle Thermocouple 13 Socket Head Cap Bolt 31 Gate Bush14 Pin Guide Bush Support Pad 32Power +T/C Connector 15 Upper Insulation Pad 16 Upper Insulation Pad 17 Manifold Thermocouple 18Manifold Block1) Basic Structure of NozzleNozzle serves a route to feed the resin injected by injector to cavity, and is a device to maintain resin at constant temperature until it is injected.Nozzle may be used by selecting proper specification according to injection amount, and selecting proper type of nozzle according to shape or characteristics of gate part.Nozzle Parts ListNoNo DescriptionDescription BALA 18BALA 18 25BALA 25 35BALA 35 Q’ty ty RemarkRemark 1Cu Ring Ø 22*2.3t 12Nozzle Ø 38*L Ø 50*L Ø 60*L 13Nozzle T/C TPIC□□ or TPCA□□ 14Nozzle HeaterHT18□□ orHC18□□HT25□□orHC25□□HT35□□ orHC 35 □□15 C Tip Insert TC Ø 10.5*47 Ø 13*55 Ø 17*66 16 C Tip Bush Ø 12.5*34.6 Ø 16*41.5 Ø 22*51.4 17Snap Ring ACRICS000180ACRICS000250ACRICS000350 18CA Gate Bush Ø 25*15 Ø 35*20 Ø 45*25 19CF Gate Bush Ø 28*18 Ø 38*25 Ø 48*30 11010 LCA Gate Bush Ø 12.5*44 Ø 16*51.5 Ø 22*62 11111 LCF Gate Bush Ø 25*26, 31 Ø 35*40, 50 Ø 45*55, 65 11212 CE Gate Bush Ø 25*15 Ø 35*20 Ø 45*25 1CC Type2. Outline of Hot Runner SystemHot runner system is a method devised to produce product continuously without sprue or runner through the heated runner which serves a route of melted resin in order to fill cavity in plastic injection mold and by maintaining it as melted state.Advantage and Disadvantage of Hot Runner System◈Advantage1) Because product must be produced using 100% of new resin without any loss at all time,defect or trouble due to foreign material can be prevented.2) Filling up cavity is needed only, because resin is always being melted up to gate, thus thetime of injection, measurement, cooling and frame opening/closing is shortened as well asthe time to take out sprue and runner.3) Improvement of product qualityBecause the injection pressure of injection molder is directly transferred to cavity, theproblem of product shrinkage, weld, and deformation due to internal stress can be solved.4) Increase of mechanical efficiencyEfficiency of molder is enhanced because injection amount, pressure, mold openingdistance may be decreased as much as the amount of sprue and runner.5) Extension of mold lifeThe pressure exerted on the mold is decreased due to decrease of injection pressure and 3-stage mold of large type may be converted into 2-stage mold in case of using hot runnersystem, so that the trouble which can occur in 3-stage mold may be prevented.◈Disadvantage1) Increase of mold cost : Hot runner components and controller are necessary.2) Technical manpower is necessary for maintenance and repair.3) Sufficient review is necessary for mold design depending on shape of resin and productused.3. Kinds of Hot Runner System1) OPEN GATEa. Direct Gate : This is the most basic system where flow route is equipped with heater.(There are BALA series in YUDO.)b. Pin Point Type Gate : Gate mark may be minimized, but a little more pressure is required.Type Basic Shape Product Shape of Gate Part Nozzle Type Direct Gate BALA TOE,TOL SystemPin Point TypeGateBALA CC, CA,CF System2) SHUT – OFF GATEa.Spring Type Valve Gate :This is the most simple valve gate system, but much injectionpressure is required, so that gate mark is unstable.(There are no related products in YUDO)b.Electrical Shut–off Gate :This may be mainly used for small products, but specialtemperature control device is required, and high technology is required for management of function.(LOVO Series Nozzles of YUDO)◈Valve GateHydraulic Valve GateHydraulic Valve GateAdvantage Disadvantagea. High pressure can be obtained by usingrelatively small cylinder.b. The life of “0” ring used is long relatively.a. Hydraulic unit is required.b. Because oil is used, there is much possibility of oilleakage and surrounding is not clean when oiling.c. Operation and management is difficult.d. There are many elements of troubles due tocarbonization of oil.e. Response speed is slow relatively.Pneumatic Valve GatePneumatic Valve GateAdvantage Disadvantagea. Structure is simple.b. Response speed is relatively fast.c. Operation and management are easy.d. Equipment investment cost is relatively small.e. Because air is used, damaging of “0” ringdoes not cause contamination of surrounding.a. Relatively large cylinder is required.b. The life of “0” ring is shorter than hydraulic type.4. Meaning of YUDO Valve Nozzle Standard1) BALA (Open CC, CA, CF Type) SpecificationBIS Series(Single Type) BIM Series(Manifold Type).2) BALA (Open TAC, TOE, TLC Type) SpecificationBIS Series (Single Type) BIM Series(Manifold Type)BIM Series(Manifold Type)a. BALA 18 Series a. BALA 18 Series♦ Nozzle length L: Minimum = 075mm Maximum = 175mm♦ T/C MODEL : TPIC06(J) or TPCA06(K) ♦ L length can be made according to order.b. BALA 25 Series b. BALA 25 Series♦ Nozzle length L: Minimum = 090mm Maximum = 320mm♦ T/C MODEL : TPIC06 or TPCA06♦ L length can be made according to order.BIS Series BIS SeriesNozzle Nozzle Model Model Model L HEATER HEATERMODEL MODELT/C T/CMODEL MODELBIM Series BIM SeriesNozzle Nozzle Model Model Model BIS-18-□□□-075 075 HT180351 TP□□051 BIM-18-□□□-075 BIS-18-□□□-085 085 HT180451 TP□□061 BIM-18-□□□-085 BIS-18-□□□-095 095 HT180551 TP□□071 BIM-18-□□□-095 BIS-18-□□□-105 105 HT180651 TP□□081 BIM-18-□□□-105 BIS-18-□□□-115 115 HT180751 TP□□091 BIM-18-□□□-115 BIS-18-□□□-125 110 HT180851 TP□□101 BIM-18-□□□-125 BIS-18-□□□-135 135 HT180951 TP□□111 BIM-18-□□□-135 BIS-18-□□□-145145HT181051 TP□□121BIM-18-□□□-145BIS Series BIS Series Nozzle Model Nozzle Model L HEATER HEATERMODEL MODEL T/C T/CMODEL MODEL BIM Series BIM SeriesNozzle Model Nozzle Model BIS-25-□□□-090 090 HT250433 TP□□06 BIM-25-□□□-090 BIS-25-□□□-100 100 HT250533 TP□□07 BIM-25-□□□-100 BIS-25-□□□-110 110 HT250633 TP□□08 BIM-25-□□□-110 BIS-25-□□□-120 120 HT250733 TP□□09 BIM-25-□□□-120 BIS-25-□□□-130 130 HT250833 TP□□10 BIM-25-□□□-130 BIS-25-□□□-140 140 HT250933 TP□□11 BIM-25-□□□-140 BIS-25-□□□-150 150 HT251033 TP□□12 BIM-25-□□□-150 BIS-25-□□□-160 160 HT251133 TP□□13 BIM-25-□□□-160 BIS-25-□□□-170 170 HT251233 TP□□14 BIM-25-□□□-170 BIS-25-□□□-180180HT251333TP□□15BIM-25-□□□-180c. BALA 35 Series c. BALA 35 Series♦ N ozzle length L: Minimum = 90mm Maximum = 370mm♦ Two heaters and T/C are used, if nozzle length L is 330mm or more. ♦ T/C MODEL : TPIC06 or TPCA06♦ L length can be made according to order.d. BALA 45 Series d. BALA 45 Series♦ N ozzle length L: Minimum = 110mm Maximum = 320mm♦ Two heaters and T/C are used, if nozzle length L is 310mm or more. ♦ T/C MODEL : TPIC06 or TPCA06 ♦ L length can be made according to order.BIS Series BIS SeriesNozzle Model Nozzle Model L HEATER HEATERMODEL MODELT/C T/CMODEL MODELBAM Series BAM SeriesNozzle Model Nozzle Model BIS-35-□□□-090 090 HT350483 TP□□046 BIM-35-□□□-090 BIS-35-□□□-100 100 HT350583 TP□□056 BIM-35-□□□-100 BIS-35-□□□-110 110 HT350683 TP□□066 BIM-35-□□□-110 BIS-35-□□□-120 120 HT350783 TP□□076 BIM-35-□□□-120 BIS-35-□□□-130 130 HT350883 TP□□086 BIM-35-□□□-130 BIS-35-□□□-140 140 HT350983 TP□□096 BIM-35-□□□-140 BIS-35-□□□-150 150 HT351083 TP□□106 BIM-35-□□□-150 BIS-35-□□□-160 160 HT351183 TP□□116 BIM-35-□□□-160 BIS-35-□□□-170 170 HT351283 TP□□126 BIM-35-□□□-170 BIS-35-□□□-180180HT351383 TP□□136BIM-35-□□□-180BAS Series BAS SeriesNozzle Model Nozzle Model L HEATER HEATERMODEL MODEL T/C T/CMODEL MODEL BAM Series BAM SeriesNozzle Model Nozzle Model BIS-45-□□□-110 110 HT3504 TP□□04 BIM-45-□□□-110 BIS-45-□□□-120 120 HT3505 TP□□05 BIM-45-□□□-120 BIS-45-□□□-130 130 HT3506 TP□□06 BIM-45-□□□-130 BIS-45-□□□-140 140 HT3507 TP□□07 BIM-45-□□□-140 BIS-45-□□□-150 150 HT3508 TP□□08 BIM-45-□□□-150 BIS-45-□□□-160 160 HT3509 TP□□09 BIM-45-□□□-160 BIS-45-□□□-170 170 HT3510 TP□□10 BIM-45-□□□-170 BIS-45-□□□-180 180 HT3511 TP□□11 BIM-45-□□□-180 BIS-45-□□□-190 190 HT3512 TP□□12 BIM-45-□□□-190 BIS-45-□□□-200200HT3513TP□□13BIM-45-□□□-2003) Shape and symbol of gateModel and SymbolModel and Symbol Gate Shape Gate Shape ApplicationApplication BIM □□□ CC BIS □□□ CC- To obtain pin-point gate using open nozzle system.- Gate area to be machined by customer.BIM □□□ CA BIS □□□ CABIM □□□ CE BIS □□□ CE- Precisely machined Gate Bush will be applied. - Lengh of LCA is the height of cavity plate.- In addition to the gate mark, the gate bush mark will be added to the part. - Easy replaceable Gate bush.BIM □□□ CF BIS □□□ CF- Gate bush designed to enable hot or cold fluid to flow directly around the gate. - Fast cycle molding applications.- Molding condition improved in engineering - Easy replaceable Gate BushBIM □□□ LCA BIS □□□ LCA- Precisely machined Gate Bush will be applied - Length of LCA is the height of cavity plate- In addition to the gate mark, the gate bush mark will be added to the part- Easy replaceable Gate BushBIM □□□ LCF BIS □□□ LCF- Gate bush designed to enable hot or cold fluid to flow directly around the gate. - Fast cycle molding applications.- Molding condition improved in engineering - Easy replaceable Gate BushBIM □□□ TAC BIS □□□ TAC- Simple construction for Direct Injection- In addition to the gate mark, the gate bush mark will be added to the part- Easy replaceable Gate BushBIM □□□ TLC BIS □□□ TLC- Simple application- Wide application, poor gate vestige and post molding op eration required- Restricted application to heat -sensitive material- Simple construction for Direct Injection with minimum sprue.BIM □□□ TOE BIS □□□ TOE- In addition to the gate mark, the gate bush mark will be added to the part- Easy replaceable Gate Bush- Simple construction for Direct Injection4) Nozzle part machining1) The part with * mark should be precisely machined.2) YUDO requires holding plate by all means in using hot runner. Of course, there is noproblem in using YUDO system by directly attaching nozzle to cavity plate. However, when hot runner is disassembling and assembling is repeated on the way of test injection andcorrection of mold, this may cause of resin leakage, heater wire breakage, etc.but also Such increase of manhour causes more cost than addition of holding plate in terms of total cost in the end, and causes drop in reliability of mold.Structure of general hot runner Structure with holding plate required by YUDOStructure with holding plate required by YUDO3) Machine the space where nozzle flange partwill be inserted in holding plate.4) Machine lead wire slot.Machine heater so that lead wire may come outof the lower surface of holding plate. Onlysuch arrangement makes it possible to changeheater directly on injection machine withoutdisambling and assembling of hot runner incase of wire disconnection.5) Use M8-P1.25 tap for manifold clamping bolt.Bolt position is 68mm in manifold widthdirection and 60mm in length direction asshown in the drawing below.MODELMODEL LØDØD ØD1ØD1 ØD2ØD2 BIM 18 □□ □□□ □□□ 32 38 40 BIM 25 □□ □□□ □□□ 40 50 55 BIM 35 □□ □□□ □□□ 50 60 655) Gate part machininga. CC a. CC Type Gate Type Gate Type GateMODEL MODELØD ØDØD1ØD1 ØD2ØD2 ØGATE ØGATE L L1L1L2L2 R BIM 18 CC □□□ 32 18 14 0.6~1.6 9 12 14.5 7 BIM 25 CC □□□ 40 25 20 1.0~2.0 12.32 15 18 10 BIM 35 CC □□□5035 28 2.0~4.0 16.5202314b. CA Type Gate b. CA Type GateMODEL MODELØH ØHØD ØD ØD1ØD1 L1L1 L2L2 BIM 18 CA □□□ 32 8 20 2 10 BIM 25 CA □□□ 40 12 28 2.5 12 BIM 35 CA □□□ 50 14 38 3 17 BIM 45 CA □□□6020483.520C. C. CF Type Gate CF Type Gate CF Type GateMODEL MODELØDH ØDH ØD1ØD1 ØD2ØD2ØD ØD ØD3ØD3 L1L1 L2L2 L3L3L4L4BIM 18 CF □□□ 32 20 28 8 3 2 10 18 11.5 BIM 25 CF □□□ 40 28 38 12 6 2.5 12 25 15.5 BIM 35 CF □□□ 50 38 48 14 6 3 17 30 20~1 BIM 35 CF □□□6048582063.5203524.5The most important dimension is ØD1. It is designed sothat inflow of resin into heater part may be prevented by side contact of ØD1 and nozzle end part.L1 dimension is important, but there is thermal expansion, so that L1 section is not major point of resin leakage.There should be coolant hole within a maximum of 30mm from gate center.There should be coolant hole within a maximum of 30mm from Gate center.There should be coolant hole within a maximum of 35mm from gate center.e. LCA Type Gate d. CE Type Gate e. LCA Type GateCE CE MODEL MODELE ØD ØD ØD1ØD1 L1L1 L2L2 LCA LCA MODEL MODELH ØD ØD ØD1ØD1 L1L1 L2L2 BIM 18 328 20 2 10 BIM 18 408 20 2 10 BIM 25 40 12 28 2.5 12 BIM 25 50 12 28 2.5 12 BIM 35 50 14 38 3 17 BIM 35 60 14 38 3 14 BIM 45 60 20483.520BIM 457020483.520g. TOE, TOL Type Gatef. LCF Type Gateg. TOE, TOL Type GateM ODEL ODEL L5L5 L6L6 L7L7 L8L8 L9L9 ØH ØH ØH1ØH1 P F R N E BIM 18 2 10 18 11.5 6 32 40 21.5 38 7 2.5 15 BIM 25 2.5 12 25 15.5 6 40 50 26.5 50 10 3 30 BIM 35 3 17 30 20 8 50 60 31.5 60 14 3 40 BIM 45 3.5203524.58 60 70 36.5 70 19 3 45e. CC Type Gate Machining Me e. CC Type Gate Machining Method thod thod① Cut and rough the part while nozzle will be assembled on cavity plate with machining center.ⓐ part should be cut as circular machining at first so that reference may be caught during discharging machining of gate part.ⓑ part should be machined with drill or end mill as roughing concept.② Cut the part where nozzle end part will be assembled.(ⓒ part in the drawing).Adjust depth while machining circle at machining center because this part has precise tolerance. Circle machining method is shown in the drawing.③ Machine ⓓ part by machining shape with end mill.④ Machine the gate in rough state using end millwith 0.5mm side allowance.⑤ Machine the gate part with electric discharge. Discharge electricity with sufficient time in order to make it smooth as far as possiblebecause gate part is a flow route of resin. Machine gate part with electric discharge by all means.The reason isthat precise machining is necessary to avoid gate deformation to product surface direction due to machining force in case that cavity is weak, but also when tool swings the concentricity between ⓒpart and gate will not coincide with each other, in case that machining is performed with end mill or drill. Shape of jig for electric discharge is shown in the drawing.It is possible to maintain surface hardness of gate and to lengthenthe life of gate through heat-treatment of gate surface by electric discharge machining.6) Machining of Locating Ring PartUse of MNL 23, 33Use of MNL 23, 33① Locating ring fixes mold and nozzle locator and functions as a guide with respect to center of injector holding plate. Locating ring seat should be fixed so as not to be moved by machining hole on clamping plate by all means. And, some part(a part) of locating ring should be designed so as to be pressed by injector fixing plate. Fixing of locating ring with only locating ring fixing bolt may be a cause of resin leakage by injection back pressure. Moving of locating ring maybe a cause of resin leakage between nozzle locator and manifold. ② Machine the locating ring seat on clamping plate.③ Machine the seat on clamping plate in order to assemble nozzle locator. ④ Locating ring should be machined by contractor in accordance with specification of injector.⑤ Refer to the drawing in the right side for machining method.7) Machining of Lead Wire Slot Part① Machine the lead wire slot by selecting a hole of proper size according to wire quantity. ② Wire surface should be prevented from being damaged drawing wiring by machining the slot in proper round(minimum R10) at the part where wire slot is bent.③ Lead wire slot should be machined differently according to quantity of wire. ④ Wire slot machining size pursuant to the quantity of wire is as follows.Nozzle Lead WireNozzle Lead Wire Slot Machining Detail Slot Machining Detail Slot Machining DetailW = 26 W=46DP Zone DP Zone 10 1~2 10 1~4 15 3~4 15 5~8 20 5~6 20 9~12 25 7~8 25 13~15 309~103016~188) MODU Plate Machining(Clamping Plate, Spacer Block, Hold Plate)① Machine the guide pin hole for fixing MODU plate position. It is more advantageous to machine those 3 MODU plates and cavity platesimultaneously when machining guide pin hole. Simultaneous machining can reduce error due to machining during MODU plate assembly.② Machine the dimension by referring to the drawing.③ Machine the bolt hole for fixing MODU plate. Machine the hole in clamping plate and spacer block, and machine the tap in hold plate.④ Bolt(B2) standard differs according to mold base standard. If the size of mold base is 600mm or less, install 4 or more M16 units of bolts ; and if the size of mold base is 600mm or more, installmore than 6 units of M16 bolts or 4 units of M20 bolts.⑤ Machine the bolt hole for fixing MODU plate and cavity plate. Machine the hole on MODUplate and machine the tap on cavity plate. Follow the dimension for machining position and bolt specification, and the enterprise should provide exact location and specification when ordering MODU.⑥ The length of ØD H7g6 part of guide pin should be H+5mm or more longer from the holdplate face(cavity plate position must be fixed in advance of fixing the end part of nozzle when assembling MODU), and the length of ØD-3 part should be fabricated 10~15mm longer than the longest nozzle(cavity plate position is guided first,rather than nozzle tip end part when assembling mold). Otherwise, the end part of nozzle tip contacts with mold and is damaged when assembling MODU plate on mold.⑦ Guide pin specification is as followsStandard used Standard usedDD1D1D2D2D3D3HH1H1Mb MbCPN30L 30 35.5 46 60 10 8 M6 CPN40L 40 45.5 67 90 20 10 M12 CPN254L 25.4 30.5 46 60 10 8 M6 CPN3175L31.7535.546601010M6⑧ Guide pin is 10~15mm longer than nozzle to be assembled to cavity plate first, so thatnozzle is guided by cavity plate.⑨ Because precise fitting is made when assembling ⓐpart of nozzle, guide pin must beassembled to cavity plate first to play a role of guide.9) Machining of Connecting System PartConnector is a component used to make electric connection smooth with the mold, and is essentially used in the mold equipped with hot runner system.24P connector is used as standard connector in YUDO.It is generally more convenient to install connector at the upper surface of mold or on the opposite surface of worker.The drawing below shows an example of machining, and the machining size differs according to quantity of connector.In processing of maching of mold, the datum base plane will be the base plane of the hold plate5. Check Items of Hot Runner System1) Check of Hot Runner System PartCheck if the quantity of component is accurate by checking part list of the system. In theevent that the quantity of component is not accurate in system assembly, the assemblyschedule may be delayed due to lack of component.Especially, check if the quantity of “0” ring, pin and bolt coincide with the necessaryquantities.In case of MODU type, check if the component to be assembled on MODU plate whichshould be attached.(Connecting Box, Solenoid Valve, Wiring Name Plate)1) Check if heater and T/C are properly assembled to the nozzle. Give number to heater andT/C and bind lead wire together, so as to prevent from wrong wiring,between heater andT/C wire.2) Check if the component are attached exactly on manifold.(Upper, Lower Riser Pad, Nozzle Locator, Thermocouple, etc.)Give number to heater and T/C and bind lead wire together, so as to prevent from confused wiring.3) Please Check whether MODU system has assembled correctly.Check if the heater and the snap ring were assembled correctly and the nozzle tip is fostened properly.4) Check connecting box.Check if there is connector and solenoid valve and if the quantity is proper.Check if silencer and one touch nipple are attached to solenoid valve.2) Electric Check of Hot Runner SystemBecause hot runner is equipped with electric components differently from other moldcomponents, thorough check is necessary. Especially, the insulation state and divisionbetween heater wire and T/C wire are very important in heater part. It should be checked by all means.(1) Check of Nozzle Heater and T/C(1) Check of Nozzle Heater and T/C① Check insulation state by between the powerline of nozzle heater and body of nozzle by useof tester. At this time, resistance should beselected by turning selection switch of tester.② Check resistance of heater or existence of open wire between two power lines by use of tester. The checked resistance value may be basis of determining capacity of heater and capacity of controller. At this time, select resistance by turning knob switch of tester.Calculation method is as follows.(Diagram of Ω law)If the measured resistance value and the voltage are known, it may be calculated with E 2/R. Ex) If R=60Ω E=220 VW=E 2/R 2202/60=806.66 W③ Check if there is any open wire between two linesof thermocouple(T/C) by use of tester. There are ground and non-ground type in T/C. Generally, ground type is used. However, non-ground type T/C should be used in case of ultra-preciseinjection. T/C is grounded to nozzle-body in case of ground type, and it is insulated in case of non-ground type.④ Check if T/C type is IC or CA by checking coating color of T/C.The points how to identify the polarity of T/C is as follows.Division Wire(+) Wire(-)YUDO Sleeve ColorCoating color Red stripe Yellow stripe Material Iron Constantan IC (J)Magnetism Magnetic Non-magnetic YellowCoating colorRed stripe Blue stripe Material Chromel Alumel CA (K)MagnetismNon-magneticMagneticBlueI = current (A) E = voltage (V) R = resistance (Ω) W= power consumption (W)(2) Check of manifold Heater and T/C① Check insulation state between the power lines of manifold heater and manifold block. (Same as how to test insulation of nozzle) ② Check resistance of heater or existence of disconnection between two power lines of nozzle heater. (Same as how to test disconnection of nozzle)③ Check existence of disconnection between two lines of thermocouple(T/C) by use of tester. (Same as how to tester disconnection of nozzle)④ Check whether T/C type is IC or CA by checking coating color of T/C.⑤ Check resistance value between power lines of manifold heater by use of tester. The checked resistance value becomes a basis to determine heater capacity and controller capacity. (Same as how to check resistance value of nozzle) The maximum capacity of YUDO controller is 15A each , and feasible range in proper usage is up to 10~12A.3) Dimensional Check of Hot Runner SystemDimension inspection of hot runner system has close relationship with mold, and dimension measurement is used as important data when assembling mold, so that it should be exactly measured.(1)(1) Dimension check of manifold Dimension check of manifold① Check manifold thickness and riser pad thickness.Manifold thickness is usually 45T(tolerance: +0.05~0), and may be 50T(tolerance: +0.05~0) in some cases. Riser pad thickness is usually 10T(tolerance: 0~-0.02) in upper side ofmanifold and 15T(tolerance: +0.05~0) in lower side. Tolerance scope of measured dimension including riser pad is 70T or 75T(tolerance: -0.04~+0.05).② Check the distance between dowel pin center and gate center for gate position.Manifold gate distance is a dimension to consider thermal expansion quantity, so that it differ from gate distance on mold drawing. Thermal expansion quantity is calculated by using the following formula.◈ FormulaΔL = (1.23*10-5)*L*ΔT ΔT = (To-Tm) ΔL = Thermal expansion quantity 1.23*10-5 = Thermal expansion coefficientTo = Manifold temperature Tm = Mold temperature L = Distance between manifold Center and gateEx) L = 127mm To = 280℃Tm = 60℃ΔT = (280-60) = 220℃ΔL = (1.23*10-5)*127*220 = 0.34366mmThe distance between manifold center and gate is 126.65mm. ③ Thermal expansion quantitypursuant to the length is same as the diagram.(2)(2) Check of nozzle dimension Check of nozzle dimension① Check if the same thermal expansion coefficientof manifold is applied for BALA nozzle. ② Check dimension of nozzle ØD and ØD1 part and 30mm part.③ Check dimension of nozzle L1. The dimension of L1 shall be machined short considering thermal expansion quantity. Because the normal dimension on the drawing is a dimension after thermalexpansion,so the product will be as short as thermal expansion quantity.◈Formula FormulaΔL = (1.08*10-5)*L*ΔT ΔT = (Tn-Tm) ΔL = Thermal expansion quantity(1.08*10-5)=Thermal expansion coefficientT n = Nozzle temperature Tm = Mold temperature, L = Mold size of nozzle touch part④ Nozzle length of the various YUDO models, reflecting thethermal expansion, is as same to the follewingtable.(Generally nozzle length is machined as short as the expected thermal expansion quantity at the nozzle temperature of 2208C ). In case of using special resin, nozzle length should be adjusted by specified injection temperature and mold temperature.⑤ The Tip of CC type is protruded by 0.1mm from gate surfacewhen it is fully assembled.。
