Operating Manual: Hot Runner Technology

Operating manual
Hot runner technology

• System
• Nozzles
Table of contents
© GÜNTHER Heisskanaltechnik GmbH

Sachsenberger Straße 1
D-35066 Frankenberg (Eder)
Telephone: +49 (0) 6451 5008-0

Fax: +49 (0) 6451 5008-94
email: info@guenther-heisskanal.de
Internet: www.guenther-heisskanal.de
17.03.2016 V.2.0
2 www.guenther-heisskanal.de
Table of contents
1 General .................................................................................... 6
1.1 Information on this manual ............................................ 6
1.2 Explanation of symbols .................................................. 7
1.3 Limitation of liability ........................................................ 8
1.4 Warranty conditions ....................................................... 8
1.5 Copyright........................................................................ 9
1.6 Spare parts .................................................................... 9
1.7 Warranty terms .............................................................. 9
1.8 Customer Service .......................................................... 9
2 Safety .................................................................................... 10
2.1 Customer’s responsibility ............................................. 10
2.2 Personnel requirements ............................................... 11
2.2.1 Qualifications ................................................ 11
2.2.2 Unauthorized persons .................................. 12
2.2.3 Training......................................................... 12
2.3 Correct use .................................................................. 13
2.4 Personal protective equipment .................................... 14
2.5 Specific dangers .......................................................... 15
2.6 Safety features ............................................................. 17
2.7 Securing against switching on ..................................... 18
2.8 Conduct in a dangerous situation and in case of
accidents ...................................................................... 19
2.9 Environmental protection ............................................. 19
3 Technical data ...................................................................... 20

3.1 Connection values ....................................................... 20
3.2 Operating conditions .................................................... 21
3.3 Lubricants .................................................................... 21
3.4 Type plate (example) ................................................... 22
4 Structure and function ........................................................ 23

4.1 Overview of hot runner system .................................... 23
4.2 Connections for current and temperature sensor ........ 25
4.2.1 Power receptacle -CMT-/thermoplug -
CMLK- .......................................................... 25
4.2.2 Power receptacle -FKT-/thermoplug -
CMLK- .......................................................... 26
5 Transport, packaging and storage ..................................... 27

5.1 Safety notes for transport ............................................ 27
5.2 Symbols on the packing ............................................... 28
www.guenther-heisskanal.de 3
Table of contents
5.3 Transport inspection.....................................................29

5.4 Transport ......................................................................29
5.5 Packing ........................................................................30
5.6 Storage .........................................................................31
6 Installation and commissioning .........................................32

6.1 Safety ...........................................................................32
6.2 Preparations .................................................................33
6.2.1 Checking prerequisites .................................33
6.2.2 Tools required ...............................................34
6.2.3 Measuring height adjustment .......................35
6.2.4 Heat expansion gap “K” ................................35
6.3 Installation ....................................................................37
6.3.1 “Hot half” assembly .......................................37
6.3.2 Installation of valve gate systems with
lifting plate mechanism .................................42
6.3.3 Installation of valve gate systems with
sliding cam mechanism ................................44
6.3.4 Installation of the needle ...............................46
6.4 Notes on the valve-gate ...............................................47
6.5 Commissioning.............................................................49
6.6 Comments/notes ..........................................................53
6.6.1 Gate ..............................................................53
6.6.2 Gating against an inclined surface ...............54
6.6.3 Gating via an intermediate gate ....................55
6.6.4 Reverse gating on a high-gloss visible
surface ..........................................................55
7 Operation ..............................................................................56
7.1 Safety ...........................................................................56
7.2 Switching on .................................................................56
7.3 Switching off .................................................................57
7.4 Activities in case of a process interruption ...................57
7.5 Colour change ..............................................................58
7.6 Shut-down in events of emergency..............................59
8 Troubleshooting ...................................................................60
8.1 Safety ...........................................................................60
8.2 Troubleshooting chart ..................................................63
8.2.1 Defects ..........................................................63
8.2.2 Valve-gate system ........................................65
8.3 Start-up after eliminating fault ......................................66
9 Maintenance ..........................................................................67
Table of contents
9.1 Safety ........................................................................... 67

9.2 Maintenance schedule ................................................. 69
9.3 Maintenance tasks ....................................................... 70
9.3.1 Clean nozzle ................................................. 70
9.3.2 Measuring nozzle temperature inside the
mould ............................................................ 74
9.3.3 Clean needle ................................................ 74
9.3.4 Cleaning manifold ......................................... 75
9.3.5 Replacing O-ring seal on single needle
valves ........................................................... 79
9.3.6 Re-lubricating sliding cam mechanism ......... 80
9.3.7 Soiling ........................................................... 81
9.4 Tightening torques ....................................................... 82
9.4.1 General tightening torques ........................... 82
9.5 Measures after maintenance ....................................... 84
10 Disassembly ......................................................................... 85
10.1 Safety ........................................................................... 85
10.2 Removal of the needle ................................................. 87
10.3 “Hot half” disassembly ................................................. 89
10.4 Disassembly and disposal ........................................... 90
11 Replacement Part List ......................................................... 92
12 Appendix ............................................................................... 93
12.1 Technical information ................................................... 94
12.2 Height adjustment/dimension check ............................ 95
12.3 Hot runner system checklist ......................................... 96
12.4 Declaration of conformity ............................................. 98
13 Index ...................................................................................... 99
General
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1 General
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1.1 Information on this manual

This manual will make it possible for you to safely and efficiently
use the hot runner system.
The manual is part of the hot runner system and must always be
kept in the immediate vicinity of the unit where it is accessible for
the personnel. The personnel must have read this manual carefully
and understood it prior to starting any work. A basic prerequisite for
safe working is compliance with all safety instructions and
instructions on use stated in this manual.
The local health and safety regulations and general safety
regulations for the area where the hot runner system is used also
apply.
Figures in this manual are for basic understanding and may vary
from the actual design of the hot runner system.
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The enclosed manuals for the installed components apply

alongside this Manual.
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General
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1.2 Explanation of symbols

Warnings Warnings are identified by symbols. These warnings are
introduced by signal words, which express the severity of a danger.
Adhere to these warnings and act cautiously in order to avoid
accidents, personal injuries and damage to property.
DANGER!
… indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.
WARNING!
… indicates a potentially hazardous situation which,
if not avoided, could result in death or serious
injury.
CAUTION!
if not avoided, may result in minor or moderate
injury.
CAUTION!
if not avoided, may result in property damage.
Hints and recommendations NOTE!

… emphasizes useful hints and recommendations
as well as information for efficient and trouble-free
operation.
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Special safety notes The following symbols are used in connection with the safety notes
to highlight particular dangers:
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… highlights hazards caused by electric current.

There is a danger of serious injury or death if the
safety notes are not complied with.
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75473
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General
1.3 Limitation of liability

All information and instructions in this manual have been compiled
taking into account the applicable standards and regulations, the
state-of-the-art and our many years of experience.
GÜNTHER accepts no liability for damage due to:
 Failure to follow the manual
 Incorrect use
 Use of untrained personnel
 Unauthorised modifications
 Technical changes
 Use of unapproved spare parts
The actual items supplied may vary from the explanations and
illustrations given here in case of special versions, if additional
options are ordered, or due to the latest technical changes.
Our verbal and written application advice and that obtained from
trials is provided to the best of our knowledge, however it is for
information only and does not release you from the need to
undertake you own testing on the products supplied by us to
ascertain their suitability for the intended processes and purposes.
The application and usage of the products is outside our control
and is therefore your exclusive responsibility. Should,
nevertheless, the possibility of liability arise, liability for all damage
is limited to the value of the goods supplied by us and used by you.
We of course guarantee the quality of our products as defined in
the our general terms and conditions. You will find these on our
website www.guenther-heisskanal.de under “Downloads”, “TOC”.
The legal provisions applicable at the time of the conclusion of
the contract apply.
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We reserve the right to make technical modifications in order to

improve usability.
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1.4 Warranty conditions

You will find expanded warranty conditions for hot runner systems
and hot valves on the homepage www.guenther-heisskanal.de
under “Download/Catalog”.
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General
1.5 Copyright
This Manual is protected by copyright law and exclusively to be
used for internal purposes.
Passing this Manual on to third parties, duplication of any kind –
even in form of excerpts – as well as the use and/or disclosure of
the contents without the written consent of the manufacturer is not
permitted, except for internal purposes.
Violations oblige to compensation. The right for further claims
remains reserved.
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1.6 Spare parts

WARNING!
Safety risk due to incorrect spare parts!
Incorrect or defective spare parts can impair safety
as well as cause damage, malfunctions or
complete failure.
For this reason:
– Only use genuine spare parts from the
manufacturer.
Spare parts can be found in the main catalogue or on the internet
at www.guenther-heisskanal.de.
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1.7 Warranty terms

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The warranty terms are provided in the manufacturer's terms and

conditions.
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1.8 Customer Service

Our Customer Service is always available for technical information.
Notes on the responsible contact partner are on call by phone, fax,
e-mail or via internet, see address of manufacturer on page 2.
Apart from that, our members of staff are permanently interested in
receiving new information and experience resulting from the use of
our products and which could be of great value for future
improvements.
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Safety
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2 Safety
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This paragraph provides an overview of all important safety

aspects for optimal protection of personnel as well as safe and
trouble-free operation.
Disregarding this Manual and safety regulations specified therein
may result in considerable danger.
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2.1 Customer’s responsibility

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The device is implemented commercially. Thus the owner of the

device is subject to legal industrial safety obligations.
In addition to the safety instructions in this Manual, the safety,
accident prevention guidelines and environmental protection
regulations, applicable at the site of implementation must be
complied with. In particular:
 Owner must inform himself of applicable industrial safety
regulations and determine additional hazards that arise due to
the specific working conditions prevailing at the site where the
device is implemented, in a risk analysis. The risk assessment
must be implemented in the form of work instructions for device
operation.
 Owner must check throughout the entire implementation period
of the device, whether the work instructions that owner has
created satisfy current legislation, and must adapt the
instructions if necessary.
 Owner must clearly regulate and specify the responsibilities for
installation, operation, maintenance, and cleaning.
 Owner must ensure that all employees who deal with the device
have read and understood this Manual.
In addition, owner must train personnel at regular intervals and
inform personnel of the hazards.
 Owner must provide personnel with the required protective
equipment.
In addition, owner is responsible to ensure that the device is
always in a technically perfect condition, and therefore the
following applies:
 Owner must ensure that the maintenance intervals described in
these operating instructions are complied with.
 Owner must have all safety devices inspected regularly for
function and completeness.
Safety
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2.2 Personnel requirements

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2.2.1 Qualifications
WARNING!
Danger of injury if insufficiently qualified!
Improper operation can lead to serious personal
injuries or property damage.
Therefore:
– Have all activities performed only by qualified
personnel.
The following qualifications are specified for different areas of
activity listed in the Manual.
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 An instructed person
has been instructed by the customer in an orientation session
on the assigned tasks and possible dangers in case of improper
behavior.
 Qualified personnel
based on their professional training, know-how and experience
as well as knowledge of the applicable standards and
regulations is able to perform assigned work activities and to
detect and avoid possible dangers on their own.
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 A professional electrician
based on his/her professional training, know-how and
experience as well as knowledge of the applicable standards
and regulations is able to perform work on electrical systems
and to detect and avoid possible dangers on his/her own.
The professional electrician has been trained for the special
location where he/she works and knows the relevant standards
and regulations.
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Only persons who are expected to perform their tasks reliably are
permitted as personnel. Persons whose reaction capability is im-
paired, e.g. through drugs, alcohol or medication are not permitted.
 When selecting the personnel, the stipulations regarding age
and occupation applying at the location must be observed.
Safety
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2.2.2 Unauthorized persons
WARNING!
Danger for unauthorized persons!
Unauthorized persons not meeting the
requirements outlined here are not aware of the
dangers in the work area.
Therefore:
– Keep unauthorized persons away from the work
area.
– If in doubt, address the persons and direct them
to leave the work area.
– Interrupt work activities as long as unauthorized
persons are present in the work area.
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2.2.3 Training
Personnel must be trained by the customer on a regular basis. For
record-keeping purposes, a log of training conducted must be kept.
Date Name Type of training Training Signature

conducted by
Fig. 1
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Safety
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2.3 Correct use

The unit is designed and built exclusively for the correct use
described here.
The hot runner system is used for plasticised plastic melt

 To transport it from the injection unit to the cavity (direct
gating) or the auxiliary gate (indirect gating)
 To ensure it is in the molten state over the entire production
process.
Correct use also includes compliance with all the information in this
manual.
Any use beyond the correct use or any other form of use of the unit
is considered incorrect use and can result in dangerous situations.
WARNING!
Danger due to incorrect use!
Incorrect use of the unit can result in dangerous
situations.
In particular, do not use the unit as follows:
– Outside the original intended application.
– In a potentially explosive atmosphere.
Claims of any nature due to damage as a result of incorrect use
are excluded.
Safety
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2.4 Personal protective equipment

Wearing of personal protective equipment is required when
working to minimize the health hazards.
 Always wear the protective equipment that is necessary for the
respective task when working.
 Follow the instructions on personal protective equipment that
are posted in the work area.
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Wear generally Generally wear for all kind of work:

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Protective clothing
are tight fitting working clothes with low tear resistance, with light
sleeves and without any sticking out parts. These clothes are
mainly a protection against being caught by moving machine parts.
Do not wear rings, chains, necklaces, and other jewellery.
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Safety boots
to protect against heavy parts falling down or slipping on slippery
ground.
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Personal protective equipment When performing special tasks it is necessary to wear personal
for special tasks protective equipment. This personal protective equipment will be
separately specified in the chapters of this Manual. This special
protective equipment is explained below.
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Protective gloves
to protect the hand against friction, graze, punctures or deep cuts
as well as contact with hot surfaces.
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Safety goggles
to protect the eyes against parts flying around or squirts of fluids.
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Light breathing mask

as protection against hazardous dusts.
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Safety
2.5 Specific dangers

The following section lists the residual risks that have been
determined by the risk assessment.
 Heed the safety instructions listed here, and the warnings in
subsequent chapters of this Manual, to reduce health hazards
and to avoid dangerous situations.
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Electric current DANGER!

Danger to life caused by electric current!
Touching conductive parts causes a direct danger
to life. Damage to insulations or individual
components can cause danger to life.
Therefore:
– In the event of damage to insulation switch off
the power supply immediately and have the
defective parts repaired.
– Work on the electric system must be carried out
only by skilled electricians.
– De-energize the machine for all work on the
electrical system.
– Before maintenance, cleaning or repair work,
switch off the power supply and secure it
against being switched on again.
– Do not bridge fuses or make them ineffective.
When changing fuses make sure you use the
correct amperage.
– Keep moisture away from conductive parts. This
can cause short circuit.
Safety
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Hydraulics WARNING!
Danger to life caused by hydraulic energies!
Hydraulic energies can cause severe or even fatal
injuries.
Hydraulically driven parts may unexpectedly start
to move.
In case of damage to individual components
hydraulic fluid may escape under high pressure.
Therefore:
– Have work on the hydraulic system only carried
out by trained expert personnel.
– Before starting work on the hydraulic system
shut down the system and relieve the pressure.
Completely relieve pressure accumulators.
– Do not change pressures to values higher than
the specified maximum values.
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Hot operating materials WARNING!

Danger of burning by hot operating materials!
Operating materials may become very hot during
operation and cause burns when contacted.
Therefore:
– Before handling operating materials check their
temperature. Allow to cool down, if necessary.
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Sharp corners and pointed edges CAUTION!

Danger of injuring on corners and edges!
Sharp corners and pointed edges can cause graze
and cuts in the skin.
Therefore:
– Take care when working near sharp corners
and pointed edges.
– Wear protective gloves, if in doubt.
Safety
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Hot surfaces CAUTION!

Danger of burning on hot surfaces!
Contact with hot components can cause severe
burns.
Therefore:
– Always wear protective clothes and protective
gloves when working on hot components.
– Before starting work make sure that all
components have cooled down to ambient
temperature.
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2.6 Safety features

WARNING!
Mortal danger due to non-functional safety
features!
Safety is only ensured if the safety features are
intact.
For this reason:
– Prior to starting work, check whether the safety
features are functional and correctly installed.
– Never disable safety features.
– Ensure safety features such as emergency stop
buttons, pull cords, etc. are always accessible.
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Integration in an emergency The unit is designed for use within a system. It does not have its
shutdown concept necessary own control unit or an autonomous emergency shutdown function.
Before operating the unit, install emergency shutdown systems for
the unit and integrate in the safety chain of the system control unit.
Connect the emergency shutdown systems so that situations that

could endanger human life or property are prevented upon
interruption of the power supply or activation of the power supply
after an interruption.
The emergency shutdown functions must be accessible at all
times.
Safety
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2.7 Securing against switching on

DANGER!
Danger to life caused by uncontrolled
reconnection of electrical power supply!
There is a risk of the electric power supply being
switched on again when working in a danger zone.
This creates danger to the life of persons in the
danger zone.
Therefore:
– Follow the instructions for securing the
equipment against switching on in the sections
of these operating instructions.
– To secure against switching on again follow the
sequence described below.
Switch secured with padlock Securing against switching on:

on: …….. at …… o’clock 1. Switch off the electric power supply.
DO NOT SWITCH ON 2. If possible secure the switch with a padlock and attach a
The padlock must be removed only clearly visible warning label to the switch, as shown in Fig. 2.
by: ………………… 3. Have the key stored with the staff member nominated on the
after it has been ensured that no label.
persons are inside the danger zone.
Fig. 2
Switched off 4. If a switch cannot be secured with a padlock, stand up a sign

on: …….. at …… o’clock as shown in Fig. 3.
DO NOT SWITCH ON 5. After all work has been completed, make sure that there are
The equipment may be switched on no persons in the danger zone.
only by: ………………… 6. Make sure that all protective device are correctly in place and
fully functional.
after it has been ensured that no
persons are inside the danger zone. 7. Remove the sign only if this has been confirmed.
Fig. 3
Pos : 2.48 /KN 2006-SM /Sic her hei t/010 1.1 Ver halten i m Gefahrenfall und bei Unfällen @ 8\mod_1143382088320_2.doc @ 81517
Safety
2.8 Conduct in a dangerous situation and in case of accidents

Preventive action  Always be prepared for accidents or fire!
 Keep first aid equipment (first aid kit, covers, etc.) and fire
extinguisher close at hand.
 Instruct your personnel about accident reporting, first aid and
rescuing facilities.
 Keep escape routes and access ways clear for rescue vehicles.
In case of emergencies  Operate the emergency stop immediately.

 Initiate first aid measures.
 Rescue persons from the danger zone.
 Inform responsible persons at the place of action.
 Call for rescue service.
 Keep access ways clear for rescue vehicles.
Pos : 2.50 /KN 2006-SM /Sic her hei t/011 U mweltsc hutz/011 U mwelts chutz Titel und Einführung @ 9\mod_1143987199086_2.doc @ 84177
2.9 Environmental protection

CAUTION!
Environmental hazard caused by incorrect
handling!
Incorrect handling of environmentally hazardous
substances, especially incorrect waste disposal,
can cause considerable damage to the
environment.
Therefore:
– Always comply with the following information.
– If environmentally hazardous substances are
accidentally released into the environment, you
must immediately apply appropriate
countermeasures. If in doubt, consult the
responsible municipal authority to inform about
the damage.
The following environmentally hazardous substances are used:
Pos : 2.51 /KN 2006-SM /Sic her hei t/011 U mweltsc hutz/Sc hmierstoffe @ 9\mod_1143987769095_2.doc @ 84198
Lubricants Lubricants like greases and oils contain toxic substances. These
must not be released into the environment. They must be disposed
of by a special waste disposal company.
Pos : 2.52 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Sic her heit/Verar beitungsmaterial @ 56\mod_1199958715116_2.doc @ 893984
Material processed Pay attention to the safety data sheet from the manufacturer of the
material.
Technical data
Pos : 3.2 /KN2006- SM/T echnisc he D aten/001 1 Tec hnisc he Daten_Ti tel @ 8\mod_1143124628960_2.doc @ 80563
3 Technical data
Pos : 3.3 /KN2006- SM/T echnisc he D aten/002 1.1 Ansc hlus s werte_Titel @ 9\mod_1143988625840_2.doc @ 84226
3.1 Connection values

Pos : 3.4 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Technisc he Daten/002 1.1.0 Anschl uss werte @ 56\mod_1199959012234_2.doc @ 893995
Electrical Parameter Value Unit
Voltage 230 V~
System* Parameter Value Unit
Max. permissible operating 2,000 bar

pressure in the hot runner system
Max. ambient temperature 450 °C
* If special nozzles or other components with a pressure limit (less

than 2,000 bar) are fitted to systems or individual tools, this
situation is documented in the height adjustment and on the type
plate.
Hydraulic Parameter Value Unit
Single needle valve 40 bar
Lifting plate mechanism 40-60 bar
Sliding cam mechanism 40-60 bar
Pneumatic** Parameter Value Unit
Single needle valve 8-10 bar
Lifting plate mechanism 8-10 bar
Sliding cam mechanism 8-10 bar
** For specific countries a pressure of 6 bar may also be adequate.

If higher pressures are required, a pressure booster is required. In
this case, contact customer service (see page 2).
NOTE!
Pay attention to the balancing of the oil feed and oil
outlet ducts as well as of the air feed and air outlet
ducts.
Technical data
Thermocouple Parameter
FeCuNi in line with DIN IEC 584, DIN 43714

Pos : 3.6 /KN2006- SM/T echnisc he D aten/003 1.1 Betriebs beding ung en_Titel @ 9\mod_1143989042992_2.doc @ 84240
3.2 Operating conditions

Pos : 3.7 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Technisc he Daten/003 1.1.0 Betriebsbedingungen @ 56 \mod_1199959077079_2.doc @ 894015
Environment Parameter Value Unit
Industrial indoor environment
Duration Parameter Value Unit
Continuous operation
Pos : 3.9 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Technisc he Daten/1.1 Schmi erstoffe @ 89\mod_1227700944373_2.doc @ 1367144
3.3 Lubricants
Application area Lubricants Manufacturer
Single needle valve Turmogrease Lubricant

-ENV- N2-STR Consult
(surface over which the
O-rings slide)
Sliding cam mechanism Barrierta L55/2 Klüber

-ANES- High-temperature Lubrication
(sliding surface) long-life grease
Technical data
Pos : 3.11 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/T ec hnis che D aten/008 1.1 T ypensc hild_Titel @ 98\mod_1247637044085_2.doc @ 1477023
3.4 Type plate (example)

Pos : 3.12 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/T ec hnis che D aten/008 1.1.0 T ypensc hild @ 56\mod_1199959473721_2.doc @ 894055
The type plate contains the following information:

 Manufacturer
Anschlusselemente/ Connecting Elements/
Buse de raccordement
 Connection elements
Verteiler/ Manifold/
Distributeur  Manifold
Düsentyp/ Nozzle Type/  Nozzle type
Réf. Buse
 Order number
85
95
Auftrags-Nr./Order Number/
Commande N°  Delivery date
Lieferdatum/Delivery Date/
Livraison
 Manufacturer's address
35066 Frankenberg
Tel. +49 (0) 6451/ 5008-0
info@guenther-heisskanal.de Other type plates:
Made in Germany
 Nozzle
 Hot half, layout
Ø3,2
 2 components
58
68
Fig. 4: Type plate (example)

Pos : 3.14 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/T ec hnis che D aten/Weitere tec hnisc he D aten... @ 58\mod_1201780241343_2.doc @ 1021266
Further technical data are available in the catalogue and on the

internet at www.guenther-heisskanal.de.
Structure and function
Pos : 4.2 /KN2006- SM/Aufbau und F unktion/001 1 Aufbau und F unkti on_Titel @ 8\mod_1143713625726_2.doc @ 83163
4 Structure and function

Pos : 4.3 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Aufbau und Funkti on/002 1.1 Ü bersic ht Heiß kanals ystem @ 56\mod_1200402368555_2.doc @ 898388
4.1 Overview of hot runner system
Fig. 5: Hot runner system
1 Holes on the clamping plate 15 Cylindrical pin to prevent twisting

2 Connection elements 16 Valve needle
3 Locating ring 17 Hot runner nozzle
4 Sealing assembly 18 Temperature control
(only for nozzles with needle valve) 19 Support piece
5 Needle actuation 20 Manifold
6 Pressure pad 21 Assembly depth in the cavity plate
7 Heat expansion gap K 22 Height of the nozzle head
8 Clamping plate/lifting plate 23 Installation height of the hot runner
9 Air circulation above and below depending on 24 Manifold height
the position of the mould 25 Height of the pressure pad + heat expansion
10 Frame plate gap K
11 High temperature insulating plate 26 Close-to-manifold screw connection
12 Cable channel 27 Position/screw connection dependent on the
13 Supporting plate nozzle type and run of the manifold heater
14 Cavity plate
28 Surface mounted thermocouple
Pos : 4.5 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Aufbau und Funkti on/Kurz bes chr eibung @ 56\mod_1199964922509_2.doc @ 894162
The hot runner system is used to move the plasticised melt from
the injection unit to the cavity (direct gating) or the auxiliary gate
(indirect gating) and to ensure it is in the molten state over the
entire production process.
Pos : 4.7 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Aufbau und Funkti on/005 1.1 Ans chl üss e D üse @ 56\mod_1199964991893_2.doc @ 894194
4.2 Connections for current and temperature sensor

4.2.1 Power receptacle -CMT-/thermoplug -CMLK-
 Nozzle type:
 8-10SET/DET
 5-12NEST
 4-10SHT/DHT/NHT
 4-16SLT/DLT
 4-12NLT
 8-12SMT/DMT/NMT
 Connection nozzle type (only for power receptacle CMT):
 AKD
 ASD
Fig. 6: Connections power receptacle -CMT-/thermoplug -CMLK-
1 Power receptacle -CMT- 5 Positive -red-

2 Ground wire -PE- 6 Negative -blue-
3 Neutral wire -N- 7 Screen yellow/green
4 Phase wire -L- 8 Thermoplug -CMLK-
4.2.2 Power receptacle -FKT-/thermoplug -CMLK-

 Nozzle type:
 4-6STT/DTT/NTT
Fig. 7: Connections power receptacle -FKT-/thermoplug -CMLK-
1 Power receptacle -FKT- 5 Positive -red-

2 Ground wire -PE- 6 Negative -blue-
3 Neutral wire -N- 7 Screen yellow/green
4 Phase wire -L-
8 Thermoplug -CMLK-
Transport, packaging and storage
Pos: 5.2 /KN2006-SM/Transport, Verpackung und Lagerung/001 1 Transport, Verpackung und Lagerung_Titel @ 9\mod_1144048567385_2.doc @ 84504
5 Transport, packaging and storage
Pos : 5.3 /KN2006- SM/Trans por t, Ver pac kung und Lag erung/002 1.1 Sic herheits hinweis e für den Tr ans port_Titel @ 9\mod_1144048644190_2.doc @ 84511
5.1 Safety notes for transport

Pos : 5.4 /KN2006- SM/Trans por t, Ver pac kung und Lag erung/002 1.1.0 Vorsic ht Tr ansportsc häden bei unsac hgemäß em Trans por t_Vorsic ht!Sac hsc haden @ 12 \mod_1144051344560_2.doc @ 84539
Improper transport CAUTION!

Improper transport can result in damage!
Improper transport can cause extensive material
damage.
Therefore:
– When unloading the transport units upon
delivery and during in-house transport, exercise
caution and observe the symbols on the
package.
– Use only the provided attachment points.
– Do not remove packaging material until units
are ready for assembly.
Pos : 5.6 /KN2006- SM/Trans por t, Ver pac kung und Lag erung/002 1.1.0 War nung! Lebensgefahr durch sc hwebende Las ten @ 12 \mod_1144048709603_2.doc @ 84518
Suspended loads WARNING!

Life-threatening hazard due to suspended
loads!
When lifting loads a life-threatening hazard is
posed by falling loads or swinging parts.
Therefore:
– Never position yourself under a suspended
load!
– Heed the instructions concerning the intended
lifting points.
– Do not attach to projecting machine
components or to the eyes of attached
components; ensure that the sling gear is
securely seated.
– Only use approved lifting gear and slings with
sufficient bearing capacity.
– Do not use frayed or scored rope or belts.
– Do not lay ropes and belts on sharp edges and
corners, do not knot or twist ropes and belts.
Pos : 5.8 /KN2006- SM/Trans por t, Ver pac kung und Lag erung/002 1.1.0 Auß ermi ttiger Sc hwer punkt_War nung! @ 12 \mod_1144502588366_2.doc @ 87475
Eccentric center of gravity WARNING!

Danger of falling due to eccentric center of
gravity!
Packing crates can have an eccentric center of
gravity. The wrong kind sling gear attachment can
tilt the packing crate and cause life-threatening
injuries.
Therefore:
– Comply with the instructions marked on packing
crates.
– Attach the crane hook in such a manner that it
is over the center of gravity.
– Lift carefully and observe if the load tips. If
required change the position of the sling gear.
Pos : 5.10 /KN 2006-SM /Transport, Verpac kung und Lager ung/003 Symbole auf der Verpac kung/003 1.1 Symbol e auf der Verpac kung _Titel @ 9\mod_1144051573255_2.doc @ 84546
5.2 Symbols on the packing

Pos : 5.11 /KN 2006-SM /Transport, Verpac kung und Lager ung/003 Symbole auf der Verpac kung/Oben @ 9\mod_1144051638161_2.doc @ 84553
Top
The arrows in this sign symbolize the top side of the package.
They must always point up, as otherwise the content may get
damaged.
Pos : 5.13 /KN 2006-SM /Transport, Verpac kung und Lager ung/003 Symbole auf der Verpac kung/Vor Nässe sc hützen @ 9\mod_1144053598688_2.doc @ 84673
Protect against wetness

Protect packages against wetness and keep dry.
Pos : 5.15 /KN 2006-SM /Transport, Verpac kung und Lager ung/003 Symbole auf der Verpac kung/Zer brec hlich @ 9\mod_1144053717149_2.doc @ 84680
Fragile
Identifies packages with fragile or sensitive content.
Handle package with care, do not drop and do not subject to shock
loads.
Pos : 5.17 /KN 2006-SM /Transport, Verpac kung und Lager ung/004 1.1 Transporti nspektion_Ti tel @ 9\mod_1144054094956_2.doc @ 84694
5.3 Transport inspection

Pos : 5.18 /KN 2006-SM /Transport, Verpac kung und Lager ung/004 1.1.0 Transporti nspektion - Inhalt, Kurz for m @ 9\mod_1144054141858_2.doc @ 84751
Check the delivery immediately on receipt for completeness and

transport damage.
If externally detectable transport damage is found, proceed as
follows:
 Do not accept the delivery, or only with reservation.
 Record the extent of transport damage in the transport
documents or on the delivery note of the forwarding agent.
 Start complaints procedure.
NOTE!
Claim any damage as soon as it is detected.
Compensation claims can only be submitted within
the applicable complaints periods.
Pos : 5.20 /KN 2006-SM /Transport, Verpac kung und Lager ung/006 1.1 Transport_Titel @ 12\mod_1145448098995_2.doc @ 90990
5.4 Transport
Pos : 5.21 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Tr ansport/005 1.1.0 Ansc hlagpunkte @ 56\mod_1199966211792_2.doc @ 894293
Attachment points
The various components have threaded holes for fastening ring

screws (1) as attachment points.
Use suitable ring screws in accordance with DIN EN 580.
Fig. 8: Example ring screws as attachment

points
Pos : 5.23 /KN 2006-SM /Transport, Verpac kung und Lager ung/006 1.1.0 Transport von Pac kstüc ken mit dem Kr an @ 9\mod_1144393009755_2.doc @ 86327
Transport of packages by crane Packages with lifting eyes can be transported by crane under the
following conditions:
 Crane and lifting tackle must be sufficiently dimensioned for the
weight of the package.
 The operator must have authorization for operating the crane.
Hooking up:
1. Fasten ropes, belts or multi-point tackle as shown in Fig. 9.
2. Make sure that the package is hanging straight, if necessary
observe an eccentric centre of gravity.
Fig. 9
3. Start transport.
Pos : 5.25 /KN 2006-SM /Transport, Verpac kung und Lager ung/006 1.1.0 Transport von Pal etten mit dem Kran @ 9 \mod_1144391982978_2.doc @ 86313
Transport of pallets by crane Packages on pallets can be transported by crane under the
 Crane and lifting tackle must be sufficiently dimensioned for the
weight of the package.
 The operator must have authorization for operating the crane.
Fastening lifting tackle:
1. Fasten ropes, belts or multi-point tackle on the pallet as
shown in Fig. 10.
2. Make sure that the package will not be damaged by the lifting
tackle. If necessary use other lifting tackle.
3. Start transport.
Fig. 10
Pos : 5.27 /KN 2006-SM /Transport, Verpac kung und Lager ung/006 1.1.0 Transport von Pal etten mit dem Gabels tapl er @ 9\mod_1144392667613_2.doc @ 86320
Transport of pallets by forklift truck Packages on pallets can be transported by forklift truck under the
 The forklift truck must match the weight of the transport units.
 The operator must have authorization for operating the forklift
truck.
Picking up:
1. Insert the forks of the forklift truck between or under the pallet
beams.
2. Insert the forks until they appear on the opposite side.
3. Make sure that pallets with eccentric centre of gravity will not
tip over.
Fig. 11
4. Lift the package and start transport.
Pos : 5.29 /KN 2006-SM /Transport, Verpac kung und Lager ung/005 1.1 Verpac kung _Titel @ 9\mod_1144054971395_2.doc @ 84772
5.5 Packing
Pos : 5.30 /KN 2006-SM /Transport, Verpac kung und Lager ung/005 1.1.0 Zur Ver pac kung @ 9\mod_1144055345537_2.doc @ 84786
Concerning packing The individual packages have been packed to match the transport
conditions that can be expected. Only environmentally friendly
materials were used for packing.
The packing has the function of protecting the individual
components against damage, corrosion, etc., until they are finally
assembled. The packing material must therefore not be damaged
and should only be removed just before assembly takes place.
Pos : 5.32 /KN 2006-SM /Transport, Verpac kung und Lager ung/005 1.1.0 U mg ang mit Verpac kungsmaterialien_Vorsic ht @ 9\mod_1144055030585_2.doc @ 84779
Handling packing materials If there is no returns agreement for the packing, separate materials
according to type and size and direct to further use or recycling.
CAUTION!
Environmental damage caused by incorrect
waste disposal!
Packing materials are valuable raw materials and
can continue to be used in many cases or sensibly
reconditioned and recycled.
Therefore:
– Dispose of packing materials environmentally.
– Follow the locally valid waste disposal
regulations. If necessary employ a special
waste disposal company to dispose of packing
material.
Pos : 5.34 /KN 2006-SM /Transport, Verpac kung und Lager ung/007 1.1 Lagerung_Ti tel @ 38\mod_1179315679426_2.doc @ 471243
5.6 Storage
Pos : 5.35 /KN 2006-SM /Transport, Verpac kung und Lager ung/007 1.1.0 Lagerung der Pac kstüc ke @ 9\mod_1144055767050_2.doc @ 84833
Storage of packages Store packages under the following conditions:

 Do not store outdoors.
 Store in a dry and dust-free environment.
 Do not subject to aggressive media.
 Protect against direct sunlight.
 Avoid mechanical vibrations.
 Storage temperature: 59 to 95 °F.
 Relative air humidity: max. 60 %.
 For storage periods longer than 3 months check the general
condition of all parts and packaging regularly. If necessary
refresh or renew the conservation.
NOTE!
Packages may be marked with notes for storage,
which may exceed the requirements mentioned
here. These must be adhered to.
Pos : 6.1 /KN2006- SM/nL.... ...... Seitenumbr uc h .......... @ 8\mod_1141998334703_0.doc @ 75491
Installation and commissioning
Pos : 6.2 /KN2006- SM/Installation & Inbetri ebnahme/001 1 Ins tall ati on und Ers tinbetriebnahme_Titel @ 9\mod_1144393592402_2.doc @ 86334
6 Installation and commissioning

Pos : 6.3 /KN2006- SM/Installation & Inbetri ebnahme/002 1.1 Sic her heit_Titel @ 9 \mod_1144395122392_2.doc @ 86369
6.1 Safety
Pos: 6.4 /KN2006-Projekte/Günther Heißkanaltechnik/Installation & Inbetriebnahme/003 1.1.0 Personal @ 101\mod_1274421400668_2.doc @ 1575092
Personnel  Installation and initial commissioning are only allowed to
be undertaken by specially trained skilled personnel.
 Work on the electrical system is only allowed to be
undertaken by electricians.
Pos : 6.6 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Installati on & Inbetriebnahme/003 1.1.0 Pers önlic he Schutz ausrüs tung @ 56\mod_1199966348077_2.doc @ 894313
Personal protective equipment The following protective equipment is to be worn during all
installation and initial commissioning work:
 Protective clothing
 Safety shoes
NOTE!
Specific reference is made in the warnings in this
section to additional protective equipment that is
necessary for specific tasks.
Pos : 6.8 /KN2006- SM/Installation & Inbetri ebnahme/003 1.1.0 Elektrische Anlage_Gefahr! @ 23\mod_1144397463440_2.doc @ 86397
Electrical system DANGER!

Danger to life due to electric current!
A life-threatening hazard exists if there is contact
with live components. Switched on electrical
components can execute uncontrolled movements
and cause the most serious injuries.
Therefore:
– Prior to starting work switch off the power
supply and safeguard it from being switched on
again.
Pos : 6.10 /KN 2006-SM /Installati on & Inbetriebnahme/003 1.1.0 Sic hern g egen Wiedereinschalten_Gefahr! @ 9\mod_1144397709746_2.doc @ 86414
Securing against switching on DANGER!

Danger to life caused by uncontrolled switching
on again!
switched on again when installing the device. This
imposes danger to the life of persons in the danger
zone.
Therefore:
– Before starting work, switch off all power
supplies and secure against switching on again.
Pos : 6.12 /KN 2006-SM /Installati on & Inbetriebnahme/003 1.1.0 Gr undl egendes _Warnung! @ 12\mod_1144396463455_2.doc @ 86390
WARNING!
Danger of injury due to improper installation
and commissioning!
Improper installation and commissioning can result
in severe personal injury or material damage.
Therefore:
– Prior to beginning installation, ensure that there
is sufficient space to work.
– Handle open sharp-edged components with
care.
– Make sure that the assembly location is clean
and well organized. Components that are
loosely stacked or lying around can cause
accidents.
– Assemble components properly. Comply with
specified screw tightening torques.
– Secure components so that they cannot fall or
tip over.
Pos : 6.14 /KN 2006-SM /Installati on & Inbetriebnahme/004 1.1 Vor ber eitungen_Titel @ 9\mod_1144401857223_2.doc @ 86442
6.2 Preparations
Pos : 6.15 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 Vorauss etz ung en pr üfen @ 83\mod_1221123891147_2.doc @ 1315194
6.2.1 Checking prerequisites

The prerequisites for installation must be checked based on the
following checklist. Only continue with installation once all points
have been met.
Prerequisite Met Not met
Adequate screw fastening available?

Screw property class 12.9
10 mm air to manifold available?
Receptacle for dowel pins available?
Receptacle for support piece available?
Adequate cooling available in the gate area?
Separate cooling circuits available?
Adequately large cable channels available?
External housing installed on the mould with adequately long spacer sleeves
due to convection of heat?
Pos : 6.17 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 Benötigtes Wer kzeug @ 83\mod_1222248788043_2.doc @ 1322612
6.2.2 Tools required

For speedy installation, it is sensible to have all the necessary tools
available prior to starting work.
Tools
Hex wrenches
Socket wrench with sockets
Torque wrench
Cross-bladed/flat-bladed screwdriver
Wire strippers
Crimping tool
Side cutters
Depth gauge
Micrometer
Electronic test instrument for checking insulation and ground wire

resistance
Socket set for needle adjustment
Power and thermocouple cables
Hydraulic/pneumatic connection
Controller for mould temperature control

Pos : 6.19 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 H öhenaufbau messen @ 83\mod_1221124801860_2.doc @ 1315216
6.2.3 Measuring height adjustment

 Only to be undertaken by a skilled person
 Additional protective equipment required:
 Protective gloves
With aid of the sheet in the appendix “Height adjustment/dimension

check”, measure the height adjustment.
Then document the dimensions in the table below.
Dimensions Measurement
[mm]
Distance: Nozzle and pressure pad contact
Check contact face on the support piece
Tolerance on the nozzle contact faces

0.03 mm
Dimension “L”
Calculate dimension “K” using table
Dimension of the titanium pressure pieces
Finish titanium pressure pads:

Check fore chamber geometry
Injection gate diameters all the same?
Pos : 6.21 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 Wär medehns palt “K” @ 58\mod_1201851398714_2.doc @ 1022044
6.2.4 Heat expansion gap “K”

The height difference between manifold and frame plate must be
determined on the individual parts.
The dimension “K” necessary for the heat expansion (see sheet
“Height adjustment/dimension check” in the appendix) must be
provided by grinding the pressure pads (12 mm).
The table below gives ΔT the temperature difference between the

processing temperature and the mould temperature.
The “Delta-Tool” program (Fig. 12) for calculating the heat

expansion gap “K” is available as a free download on the internet
from www.guenther-heisskanal.de.
Fig. 12: “Delta-Tool” program

Pos : 6.23 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & In betriebnahme/Tabelle Wärmedehnspalt “K” @ 56\mod_1200391190741_2.doc @ 898221
Table heat expansion gap “K”
Manifold ΔT [°C] 100 150 200 250 300 350

height
36 mm K (mm) 0.021 0.059 0.098 0.137 0.177 0.217
46 mm K (mm) 0.033 0.078 0.124 0.170 0.218 0.264
56 mm K (mm) 0.046 0.097 0.150 0.203 0.258 0.311

Pos : 6.25 /KN 2006-SM /Installati on & Inbetriebnahme/005 1.1 Installation_Titel @ 9\mod_1144401700720_2.doc @ 86428
6.3 Installation
Pos : 6.26 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/005 1.1.1 Montage der Heiß en Seite @ 56\mod_1199966467489_2.doc @ 894333
6.3.1 “Hot half” assembly

 Only to be undertaken by appropriately qualified personnel.
 Work on the electrical system is only allowed to be undertaken
by an electrician.
NOTE!
The system is sealed, if the height is adjusted
correctly, by the pretension between material tube
(nozzle) and the surface of the manifold.
Steps 1 to 16 are the same as the actions for assembling valve
gate systems with a lifting plate or sliding cam mechanism.
1. Fit manifold (1) to the frame plate (3).

2. Fit pressure pads (2) to the manifold (1).
Fig. 13: Fitting manifold and pressure

pads
3. Mark pressure pads and sealing faces (2) on the nozzles

using a permanent marker (1) (e.g. Edding felt-tip pen).
NOTE!
Using a permanent marker (e.g. Edding felt tip pen)
the layer of ink is thinner than, e.g., engineering
blue and therefore the imprint is clearer.
Fig. 14: Marking sealing face on the

nozzles
4. Fit clamping plate (1) to the frame plate (3). If necessary, fit
struts and check the exact height.
5. Using a torque wrench (2), tighten the screws to the stipulated
tightening torque (for tightening torque see section “Tightening
torques”).
Fig. 15: Fitting clamping plate
6. Fit nozzles (1) to the supporting plate/frame plate (2) and

tighten taking into account the stipulated tightening torque (for
tightening torques see section “Tightening torques”).
7. Label wires as per the wiring diagram and lay in the cable
channel (for wiring diagram see appendix).
CAUTION!
Damage due to incorrect wiring!
If the wires are laid incorrectly, they may be
damaged, e.g., by heat.
Fig. 16: Fitting nozzles For this reason:
– Ensure the wires do not touch the manifold.
DANGER!
Mortal danger due to electrical power!
There is immediate mortal danger on physical
contact with live parts.
For this reason:
– Only have work on the electrical system
NOTE!
Depending on the cavity plate, screws longer than
the guide pillars may need to be screwed into the
frame plate for support. As an alternative, the
mould can also be supported with strips.
8. Place the assembled clamping and frame plate including the
nozzle on the struts in the horizontal direction.
CAUTION!
Risk of burns due to hot surfaces!
Contact with hot components can cause burns.
For this reason:
– During all work near hot components, always
wear protective clothing and gloves.
– Prior to all work, ensure all components have
cooled to ambient temperature.
9. Warm up manifold to processing temperature (see manual for

the control system).
10. Switch off control system (see manual for the control system)
and leave the hot runner system to cool down to room
temperature.
11. Remove clamping plate and nozzles.
12. Check imprints between nozzles (2) and manifold (1) and
clamping plate and pressure pads.
CAUTION!
Damage due to leaks!
Improper or incorrect height adjustment can result
in leaks.
For this reason:
– If the imprints are inadequate, check height
adjustment again.
Fig. 17: Check nozzle for leaks
13. Fit revised pressure pads (2) to the manifold (1).
Fig. 18: Fitting manifold and pressure

pads
14. Fit nozzles (1) to the frame plate (2) and tighten using a
torque wrench taking into account the stipulated tightening
torque (for tightening torques see section “Tightening
torques”).
15. Lay wire 3 in the cable channel (for wiring diagram see
appendix).
NOTE!
Depending on the cavity plate, screws longer than
the guide pillars may need to be screwed into the
Fig. 19: Fitting nozzles frame plate for support. As an alternative, the
mould can also be supported with strips.
 For further assembly steps on valve gate systems with lifting
plate mechanism, see section “Assembly of valve gate systems
with lifting plate mechanism”
 For further assembly steps on valve gate systems with sliding
cam mechanism, see section “Assembly of valve gate systems
with sliding cam mechanism”
16. Fit clamping plate (1) to the frame plate (3). If necessary, fit
struts and check the exact height.
17. Using a torque wrench (2), tighten the screws to the stipulated
tightening torque (for tightening torque see section “Tightening
torques”).
18. Wire the mould are per the schedule and circuit diagram (see
appendix).
DANGER!
For this reason:
Fig. 21: Wiring mould
19. Check wiring and record resistance values in the table below.
Check wiring Resistance Insulation Ground

resistance wire
resistance
Heaters: Resistance
and insulation
resistance (max.
1,000 V)
Temperature sensor
resistance
20. Check arrangement of the heater in relation to the

temperature sensor using a controller (see manual for the
controller).
21. Connect ground wire to the earth terminal.
 The “hot half” has been completed and checked for correct
function.
Fig. 22: “Hot half” completed

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6.3.2 Installation of valve gate systems with lifting plate mechanism

 Prerequisite: Height adjustment completed taking into account

the heat expansion gap “K”.
Fig. 23: Height adjustment completed
1. Fit guide sleeves (3) and needle receptacle (2) to the lifting
plate mechanism.
2. Using a torque wrench, tighten the screws (1) to the stipulated
tightening torque (for tightening torques see section
“Tightening torques”).
Fig. 24: Lifting plate mechanism
3. Fit lifting plate (1) to the manifold frame plate and using a
torque wrench, tighten the screws to the stipulated tightening
torques”).
4. Fit guide pins (2) and ball guide.
Fig. 25: Lifting plate
5. Fit lifting plate mechanism (1) to lifting plate (2).

6. Fit support (3) between lifting plate and clamping plate.
7. Fit clamping plate and using a torque wrench, tighten the
screws to the stipulated tightening torque (for tightening
torques see section “Tightening torques”).
8. Wire the mould as per the schedule and circuit diagram (see
appendix).
Fig. 26: Fitting lifting plate mechanism
DANGER!
For this reason:
Check wiring Resistance Insulation

resistance
Heaters: Resistance and insulation

resistance (max. 500 V)
Thermocouple resistance

thermocouple using a controller (see manual for the
controller).
12. Fit needle (see section “Installation of the needle”).

Pos : 6.30 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/005 1.1.1 Montage von N adel verschl usss ystemen mit Sc hi ebemechanis mus @ 83\mod_1221200777747_2.doc @ 1316109
6.3.3 Installation of valve gate systems with sliding cam mechanism

 Prerequisite: Height adjustment completed taking into account

the heat expansion gap “K”.
1. Fit clamping plate (1) to the manifold frame plate and using a
torque wrench, tighten the screws to the stipulated tightening
torques”).
2. Check control rails (1) and keys for correct function.

3. Lubricate control rails and keys using a high temperature
long-life grease.
NOTE!
Due to the high temperature long-life grease, the
sliding cam mechanism will function correctly over
a long period even with high temperatures in the
area of the frame plate and clamping plate (up to
100 °C). Pay attention to the data sheets from the
Fig. 28: Control rails manufacturer of the high temperature long-life
grease.
4. Assemble components.
5. Undertake function test in the clamping plate.
NOTE!
If necessary, the control rails must be reworked by
grinding.
6. Lubricate lubrication ducts at the grease nipples.
7. Fit drive cylinder (1).
WARNING!
Risk of injury due to moving components!
Moving components can cause serious injuries.
For this reason:
– Do not reaching into moving parts.
8. Check the function of the sliding cam mechanism in
conjunction with the drive medium.
Fig. 29: Fitting drive cylinder
9. Wire the mould are per the schedule and circuit diagram (see
appendix).
DANGER!
For this reason:
Check wiring Resistance Insulation

resistance
Heaters: Resistance and insulation

resistance (max. 500 V)
Thermocouple resistance

thermocouple using a controller (see manual for the
controller).

Pos : 6.32 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/005 1.1.1 Ei nbau der N adel @ 83\mod_1221198529182_2.doc @ 1316063
6.3.4 Installation of the needle

CAUTION!
For this reason:
1. Warm up hot runner system to processing temperature (see
manual for the machine's control system).
2. Screw needle (1) into the needle receptacle (2) and fit in the
lifting plate mechanism (3).
Fig. 30: Fitting needle
3. Fit cover (1) to the lifting plate mechanism (3) and using a
torque wrench, tighten the screws (2) to the stipulated
tightening torque (for tightening torques see section
“Tightening torques”).
Fig. 31: Fitting cover
4. Screw adjusting nut (1) onto the needle (2).

5. Adjust needle (see section “Adjustment of the needle”).
Fig. 32: Screwing on adjusting nut

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6.4 Notes on the valve-gate

Pay attention to the following information on the adjustment of the

needles:
 The needles are only pre-adjusted on the delivery of the “hot
valves”. They must be re-adjusted after the installation of the
cavity plate once the operating temperature has been reached.
 The needles have a basic hardness of 64HRC (HSS steel). On
valve gate system without LA needle guide made of PM steel,
pay attention to the selection of the material for the inserts. If
Fig. 33: Valve needles with adjusting
necessary, consult GÜNTHER (for contact address see
thread
page 2).
 After shutting down the hot runner, the mould cooling must
continue to run for approx. 30 minutes to prevent damage to the
hot runner,
e.g. to the sealing rings due to the build up of heat.
Prerequisites CAUTION!
Damage due to improper preparation!
If attention is not paid to the following information,
the needle guide or the needle may be damaged.
For this reason:
– It is imperative the following information is
followed.
 The hot runner system and the mould are completely installed
and wired.
 The needle drive is in the “Needle closed” position.
 The needles are pre-adjusted so that they do not collide with
the needle guide during “needle closing”.
 The needles are around 1 mm behind the edge of the item.
Adjusting needle 1. Connect the mould to the control system (see manual for the
control system) and to the temperature control.
CAUTION!
For this reason:
2. Bring mould to operating temperature.
manual for the control system).
4. Fix the needle drive in the “needle closed” position (e.g. using
compressed air on the “Close needle” connection”).
5. Using the set of wrenches supplied (1), place the needle in

the front position (at the cavity) by turning to the right. By
turning to the left, the needle is placed in the rear position (out
of the cavity).
6. Measure needle position using a depth gauge or a dial gauge
and re-adjust if necessary.
7. Tighten the lock nut, operate the needle drive 2 to 3 times,
then check the needle position again.
Needle diameter Thread Tightening torque

Fig. 34: Adjusting needle 2 mm M6 x 0.50 9 Nm
3 mm M8 x 0.50 15 Nm
5 mm M10 x 0.75 30 Nm
8. Place needle in the “closed” position.

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6.5 Commissioning
Pos : 6.37 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/Ersti nbetri ebnahme @ 83\mod_1221459809859_2.doc @ 1317700
WARNING!
Mortal danger due to hydraulic energy!
Hydraulic energy can cause serious or mortal
injuries.
Hydraulically driven parts can move unexpectedly.
If individual parts are damaged, hydraulic fluid may
escape under high pressure.
For this reason:
– Only have work undertaken on the hydraulics by
trained skilled personnel.
– Prior to starting work on the hydraulic system,
first shut it down and de-pressurise it. Fully de-
pressurise accumulator.
Check that it is de-pressurised.
– Do not change pressure settings beyond the
maximum values.
WARNING!
Risk of injury due to pneumatic energy!
Pneumatic energy can cause very serious injuries.
Pneumatically driven parts can move unexpectedly.
In case of damage to individual components, air
may escape under high pressure and, e.g. injury
your eyes.
For this reason:
– Only have work undertaken on the pneumatics
by trained skilled personnel.
– Prior to starting work on the pneumatic system,
first de-pressurise it. Pay attention to the
accumulator. Also fully de-pressurise it.
– Do not change pressure settings beyond the
maximum values.
CAUTION!
Damage due to placing in operation the
hydraulic or pneumatic system prematurely!
The system is only sealed at operating
temperature.
For this reason:
– Only place in operation hydraulic or pneumatic
system once the system has been heated up to
operating temperature.
NOTE!
During initial commissioning, a little smoke may
be produced due to the evaporating corrosion
inhibitor.
If the hot runner system is cold, there is no positive sealing

between nozzles and manifold. Sealing is only achieved by the
pretension on reaching the operating temperature.
Prior to initially commissioning the hot runner system, check using

the “Hot runner system checklist” (see appendix).
Standard Prerequisites:
 The mould is connected to the cooling circuits and the related
system via a hose connection as per the temperature control
diagram and the temperature stipulated is set.
 The hot runner system is connected to the control system (see
manual for the control system).
NOTE!
The maximum permissible operating pressure in
the hot runner system is 2,000 bar.
1. Bring mould to stipulated temperature.
2. Warm up hot runner system to processing temperature using
the soft-start function in the control system (see manual for
the control system).
3. Starting up: Fill system with low pressure. During this process
observe injection speed and mould characteristics.
Valve-gate NOTE!
To achieve appropriate needle speeds (needle
closing time 20–40 ms / 7–10 mm travel), the
operating valve (hydraulic/pneumatic) must be
designed to a corresponding size. Dimension the
connection hoses to suit the flow rate. Keep the
distance between pressure generation and load
(mould) low.
NOTE!
Pay attention to the balancing of the oil feed and oil
outlet ducts as well as of the air feed and air outlet
ducts.
1. Switch on mould temperature control.
NOTE!
Using the soft-start function the manifold is warmed
up to approx. 100 °C and kept at this temperature
for approx. 10 minutes.
2. Warm up manifold to processing temperature using the soft-
start function in the controller (see manual for the controller).
NOTE!
To prevent cold material residue in the nozzles, the
nozzle temperature on warming up/starting the hot
runner system must be set approx. 20K higher,
taking into account the material data from the
manufacturer of the plastic. After reaching the
required temperature the hot runner must be heated
through for 10 minutes. Only then is it allowed to
actuate the needles and start with the injection.
In addition, the hot runner should always be shut
down with the needles closed so the needles do
not have to expel cold material from the PM pieces
the first time they are closed.
3. Ensure prior to actuating the drive that the specified
processing temperature for the plastic has been reached.
Sequence of an injection cycle: 1. Cycle start

2. Open needle
3. Injection start
4. Holding pressure
5. Close needle
6. Cooling time
7. Eject
8. Cycle end
NOTE!
During initial commissioning, several injection
operations may be necessary to completely fill the hot
runner with plastic. Until complete part filling is
achieved, the cavities must be checked for remaining
incompletely filled parts at the end of every cycle.
For the final check, use the “Hot runner system
checklist” (see section “Appendix”).
Recommendation for process  The holding pressure and the holding pressure time should be
parameters on the valve-gate set as low as possible.
 The nozzle and mould temperature should be in the upper third
of the temperature range specified by the material
manufacturer. This setting should ensure that the needle can
close without problems and no damage to the components can
be produced by already solidified plastic in the injection gate.
The settings can be optimised starting from this point.
 If the needle no longer closes completely, the upper limit for the
holding pressure time has been reached. The holding pressure
time should then be reduced again by approx. 5-10%.
Pos : 6.39 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1 Anmer kung en/Hinweise @ 93\mod_1235546918087_2.doc @ 1402404
6.6 Comments/notes
Pos : 6.40 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 Anguss punkt @ 93\mod_1235547164608_2.doc @ 1402425
6.6.1 Gate
 The function of the hot runner nozzle is significantly affected by
the diameter øD ( Fig. 35) of the gate.
NOTE!
98% of all faults on commissioning a mould are
due to the incorrect design of the gate geometry.
Gate geometry
 The correct position of the 80° chamfer is checked using a

measuring ball.
 The gate must increase in size with the 80° chamfer. The edge
(1) must be sharp for clean separation.
Fig. 35: Gate geometry
 Sheet for determining the gate
Fig. 36: Checking the gate
Gate diameter < 1.2 mm
 For a gate diameter smaller than øD = 1.2 mm the nozzle must

be fitted in a recessed position. You can take the values for ΔL
from the “Delta-Tool” tables in the appendix.
NOTE!
You can download the “Delta-Tool” program for
determining ΔL on our website www.guenther-
heisskanal.de.
Fig. 37: Installing the nozzle in recessed

position
 Re-working the gate by drilling out is incorrect. The gate must

be eroded to the required diameter at 80°, as a cylindrical
portion (1) will result in a higher separation residue and the flow
gap around the tip will remain almost unchanged.
Fig. 38: Re-working the gate point

Pos : 6.42 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 Anspritzen auf einer sc hrägen Fläc he @ 93\mod_1235547310023_2.doc @ 1402448
6.6.2 Gating against an inclined surface

 To achieve even and defined separation at the injection gate, if
possible gating should always be against a flat surface as far as
possible.
Varying separation can result in fluctuations in the production
process.
1 advantageous
2 advantageous
3 disadvantageous
Fig. 39: Gating against an inclined surface
Pos : 6.44 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 Anspritzen über einen Z wisc henang uss @ 93 \mod_1235547377034_2.doc @ 1402471
6.6.3 Gating via an intermediate gate

 To obtain defined, even separation, the diameter ød must be
0.5 mm larger all round than the diameter øD. The injection
gate has the same diameter as the intermediate gate. If
possible, employ a catch pit in the intermediate gate.
Fig. 40: Gating via an intermediate gate

Pos : 6.46 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/1.1.1 R üc kwärtiges Ans pritzen auf einer H oc hglanz-Sic htfl äche @ 93\mod_1235547680312_2.doc @ 1402494
6.6.4 Reverse gating on a high-gloss visible surface

 For the gate area beside the nozzle and on the ejector side,
adequate cooling is recommended to be able to dissipate the
additional heat caused by shearing.
It is imperative the cooling circuits (1) are operated separately
from the other temperature control circuits (2).
Fig. 41: Reverse gating

Operation
Pos : 7.2 /KN2006- SM/Bedienung/001 1 Bedi enung _Titel @ 9 \mod_1144402040153_2.doc @ 86491
7 Operation
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7.1 Safety
Pos : 7.4 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Bedi enung/003 1.1.0 Pers önlic he Sc hutz ausrüs tung @ 83\mod_1221466797453_2.doc @ 1317785
Personal protective equipment Wear the following protective equipment during all work related to
operation:
 Safety shoes
 Safety glasses
Pos : 7.6 /KN2006- SM/Bedienung/003 1.1.0 Grundl egendes @ 12\mod_1144402038705_2.doc @ 86477
Improper operation WARNING!

Risk of injury due to improper operation!
Improper operation can result in severe personal
injuries or material damage.
Therefore:
– Perform all the operating steps in accordance
with the information in this operator's manual.
– Ensure that all covers and safety devices are
installed and in proper working condition before
starting work.
– Never deactivate safety equipment during
operation.
– Ensure tidiness and cleanliness in the working
area. Loose components and tools lying around
or on top of each other are sources of
accidents.
Pos : 7.8 /KN2006- SM/Bedienung/005 1.1 Eins chalten_Titel @ 9 \mod_1144404971995_2.doc @ 86598
7.2 Switching on
Pos : 7.9 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Bedi enung/Si ehe BA der Spritzguss masc hine @ 59 \mod_1202372568778_2.doc @ 1026438
See manual for the injection moulding machine and notes in the
section “Installation and initial commissioning”.
Pos : 7.11 /KN 2006-SM /Bedi enung/006 1.1 Auss chalten_Titel @ 9 \mod_1144405011820_2.doc @ 86605
Operation
7.3 Switching off

Pos : 7.12 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Bedi enung/Si ehe BA der Spritzguss maschi ne @ 59\mod_1202372568778_2.doc @ 1026438
See manual for the injection moulding machine and notes in the
section “Installation and initial commissioning”.
Pos : 7.14 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Bedi enung/Beim Absc halten... @ 83\mod_1221467795625_2.doc @ 1317951
On shutting down the hot runner system, all control circuits can be
switched off at the same time.
CAUTION!
Damage due to improper shut down!
A build up of heat after shutting down can cause
damage to the hot runner system.
For this reason:
– Place needles in the “closed” position.
– Leave the mould cooling to run at around 30 °C
for around 30 minutes.
Pos : 7.16 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Bedi enung/1.1 T ätig keiten bei Pr oz ess unter brec hung @ 83\mod_1221466942567_2.doc @ 1317909
7.4 Activities in case of a process interruption

Pay attention to the following points in the case of a process
interruption:
 Place needles in the “closed” position.
 Lower the hot runner temperature by 50 °C to 100 °C
depending on the material and time at standstill.
 To prevent damage to the gate bores and needles due to cold
material, do not actuate the needles when the injection
moulding machine is in the set-up mode or on purging the unit.
NOTE!
The specific processing temperature for the plastic
must be reached prior to actuating the drive.
 If the melt is purged through the open mould/the hot runner,
open the needles during injecting-through and close during the
dosing phase.
Pos : 7.18 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Bedi enung/1.1 F arbwec hs el/Systems pül ung @ 59 \mod_1202371886798_2.doc @ 1026417
Operation
7.5 Colour change

See manual from the manufacturer of the injection moulding
machine.
Also pay attention to the following points:
NOTE!
The specific processing temperature for the plastic
must be reached prior to actuating the drive.
 Increase hot runner temperature by approx. 20 °C
(maximum upper processing temperature).
 Continue processing with new colour.
 If necessary, continue processing with higher injection pressure
and/or higher injection speed.
 For very small shot weights, it is recommended to first inject
through the open mould – however only with back pressure or
with low injection pressure.
NOTES!
 Evaluate design of the mould.
 Ensure the inserts/mould plates are adequately
bolted in place.
 _TT nozzle must remain fitted in the cavity plate to
avoid damage to the system.
 If fitted: Clean mould at a 2nd parting line (for colour change,

maintenance or repair work on the hot runner nozzles) and hot
runner nozzles (in particular the gate area).
 Lower hot runner temperature again and optimise.
NOTE!
For a quicker colour change, it is recommended to
use cleaning granulate. Various trials have shown
that by using cleaning granulate, a colour change
can also be performed with good results even with
TPE. During this process the different temperature
ranges of the cleaning granulate must be taken into
account.
Pos : 7.19 /KN 2006-SM /nL.......... Sei tenumbr uch .......... @ 8\mod_1141998334703_0.doc @ 75491
Operation
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7.6 Shut-down in events of emergency

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In dangerous situations machine movements must be stopped and

the power supply switched off as quickly as possible.
Shut-down in events In dangerous situations proceed as follows:

of emergency 1. Use the nearest emergency stop switch to trigger an
emergency stop.
2. Inform responsible persons at the place of action.
3. Call for medical help and fire brigade.
4. Rescue persons from the danger zone, apply First Aid
measures.
5. Switch off the main switch and secure against switching on
again.
6. Keep access ways clear for rescue vehicles.
After rescue measures 7. Inform the responsible authorities, if required by the severity of
the incident.
8. Deploy expert personnel to rectify the fault.
WARNING!
Danger to life caused by too early switching on
again!
Danger to life for all persons in the danger zone
when switching the machine back on.
Therefore:
– Before switching on again make sure that no
persons are inside the danger zone.
9. Check the machine and ensure that all safety features have
been installed and are fully functional before restarting the
machine.
Pos : 8.1 /F I/.......... Seitenumbr uch .......... @ 0\mod272_2.doc @ 1523
Troubleshooting
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8 Troubleshooting
The following chapter describes possible causes of faults and the
steps required to eliminate them.
In the event of frequent faults, reduce the maintenance intervals to
correspond to the actual working load.
In the event of faults that cannot be eliminated through the
following instructions, please contact the manufacturer (service
address on page 2).
Pos : 8.3 /KN2006- SM/Stör ung en/002 1.1 Sic herheit_Titel @ 9\mod_1144439648502_2.doc @ 86965
8.1 Safety
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Personnel  The troubleshooting procedures described here can be

performed by the operator unless otherwise marked.
 Some work may be performed only by specially trained
personnel or only by the manufacturer, in which case special
notice is given in the description of the individual faults.
 All work on the electrical system must be performed by a
professional electrician.
Pos : 8.6 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Stör ungen/003 1.1.0 Persönliche Sc hutzausr üstung --> Kopier vorlag e @ 83\mod_1221476507902_2.doc @ 1318393
Personal protective equipment Wear the following protective equipment during all troubleshooting
work:
 Safety shoes
 Safety glasses
NOTE!
section to additional protective equipment that is to
be worn for specific tasks.
Pos : 8.8 /KN2006- SM/Stör ung en/003 1.1.0 El ektrisc he Anl age_Gefahr! @ 12\mod_1144439649994_2.doc @ 86979
Electrical System DANGER!

Electrocution hazard!
An electrocution hazard is posed by contact with
live components. Switched on electrical
and cause serious injuries.
Consequently:
– Prior to starting work, switch off the supply of
electricity and ensure that it cannot be switched
on again.
Troubleshooting
Pos : 8.10 /KN 2006-SM /Störungen/003 1.1.0 Sic her n geg en Wi ederei nsc halten_Gefahr! @ 9\mod_1144439652427_2.doc @ 87000

on again!
switched on again when performing trouble
shooting and repair work. This imposes danger to
the life of persons in the danger zone.
Therefore:
Pos : 8.12 /KN 2006-SM /Störungen/003 1.1.0 Grundlegendes _Warnung! @ 12\mod_1144439650705_2.doc @ 86986
Improper troubleshooting WARNING!

Unauthorized troubleshooting procedures can
result in injury!
Improper troubleshooting procedures can result in
severe personal injury or material damage.
Therefore:
– Prior to beginning installation, ensure that there
is sufficient space to work.
– Make sure that the assembly location is clean
and well organized. Components that are
loosely stacked or lying around can cause
accidents.
– If components have been removed, ensure
proper assembly, install all mounting elements
and comply with screw tightening torques.
Pos : 8.14 /KN 2006-SM /Sic her hei t/007 Besondere Gefahr en/Heiß e Oberfl äc hen_Vorsicht! @ 8\mod_1143375956657_2.doc @ 81349
Troubleshooting

burns.
Therefore:
temperature.
Pos : 8.16 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Störungen/HIN WEIS! Kalibrier ung der Regelg eräte @ 83\mod_1222245026000_2.doc @ 1322567
NOTE!
In case of controllers, depending on the frequency
of use and the ambient conditions, calibration in
accordance with BGV A3 must be performed at
least once a year (see manual for controllers).
Pos : 8.18 /KN 2006-SM /Störungen/003 1.1.0 Verhalten bei Stör ung en (Ger ät) @ 12 \mod_1144441786782_2.doc @ 87241
In case of faults: The following general rules apply:

1. In the event of faults that pose immediate danger to man or
machine, activate the emergency shutoff function immediately.
2. Determine cause of fault.
3. If elimination of the fault requires working in the danger zone,
switch off unit and secure against being switched on again.
4. Immediately inform the person in charge at the equipment
location of the fault.
5. Depending on the type of fault, eliminate the fault or have it
eliminated by an authorized specialist.
NOTE!
The chapter “Troubleshooting” below provides
information on who is authorised to eliminate the
fault.
Troubleshooting
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8.2 Troubleshooting chart

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8.2.1 Defects
Defect Problem Rectification Rectification by
Foreign body in the  Higher nozzle temperature  Clean nozzles (see Specialist
injection gate than usual section “Cleaning personnel
 Injection gate quality poorer nozzles”)
 Smearing on the item  Use a melt filter

(pay attention to
 Item is sometimes complete, pressure losses)
sometimes not
Foreign body in the  Black and fan-shaped burns Remove foreign body Specialist
nozzle/material tube spread over the entire item from the hot runner personnel
 Temperature actual value at nozzle, remove material
the nozzle fluctuates during tube/nozzle tip
injection by ± 20 K
Nozzle in contact in the  Insulation gap inadequate Adapt for fore chamber Specialist
fore chamber area  Higher temperatures geometry to the personnel
necessary GÜNTHER specifications
 High temperature fluctuations

 Stringing
Troubleshooting
Dimension “L” in the The tip is too far back at the Change the installation Specialist
mould too large injection gate and is not dimension “L” to suit the personnel
adequately supplied with heat specification of 200.00
Example: The dimension “L” has mm
been manufactured too large by
the toolmaker:
Required: 200.00 mm;
Actual: 202.7 mm
Leaking system Metal O-ring After thorough testing

and analysing,
GÜNTHER Hot-Runner
Engineering has decided
not to fit any metal O
rings into nozzles,
connecting pieces,
connecting nozzles and
hot-runner systems.
Deep scratches on the sealing Rework the surface of the Specialist

surface manifold personnel
 No pretension on the  Check K dimension Specialist

manifold (see “Height personnel
 K dimension too large adjustment/dimension
check” in the appendix
 Screws stretched or “Delta-Tool”
program)
 Check number of
screws and
grade (specification
12.9)
Troubleshooting
Excessively high  Cylindrical portion at the  Adapt injection gate Specialist

separation at the injection gate geometry (reduce personnel
injection gate  Foreign body in the injection cylindrical portion)
gate  Clean nozzle (see
 Injection gate is damaged or section “Cleaning
broken off nozzle”)
 Re-work injection gate
8.2.2 Valve-gate system

Needle does not close correctly
Cause of fault Explanation Rectification Rectification

by
The pressure to close the The needle closing force is Increase pressure depending on Specialist
needle is too low too low type of drive (pneumatic max. personnel
10 bar, hydraulic max. 60 bar)
The needles are Re-adjust needle and fix Specialist

incorrectly adjusted or the adjusting nut (see section “Notes personnel
lock nut on the adjusting on the valve gate”)
screw has come loose
Incorrect control signal The “Close needle” Check control signal, change Specialist
command arrives too late program if necessary personnel
or too early
Diameter of the pipework The hose diameter is too Adapt diameter; use hoses as Specialist
(pneumatic/ small for the required short as possible personnel
hydraulic hoses) is too amount of oil/air
small
The mechanism is jammed Broken metal parts, chips Check mechanism and clean or Specialist
by soiling or damage or similar are jamming the repair personnel
mechanism
Holding pressure time too The material in the Reduce holding pressure time Specialist
long injection gate area has and increase temperature in the personnel
already solidified gating area
The pneumatic and Change lines Specialist

hydraulic lines are personnel
reversed (opening –
closing)
Troubleshooting
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8.3 Start-up after eliminating fault

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After the rectification of the malfunction, perform the following

steps to place back in operation:
1. Reset emergency stop devices.
2. Clear malfunction on the controller.
3. Ensure there is nobody in the hazard area.
4. Start as per the instructions in the section “Initial
commissioning”.
Maintenance
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9 Maintenance
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9.1 Safety
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Personnel  The maintenance work described here cannot be executed by

the operator unless otherwise indicated.
 Some maintenance tasks can only be executed by trained
qualified personnel, or only by the manufacturer. In these cases
this is separately indicated in the description of the specific
maintenance tasks.
 All work on the electrical equipment should only be executed by
a professional electrician.
Pos : 9.6 /KN2006- Proj ekte/Günther H eiß kanaltec hni k/Wartung/003 1.1.0 Persönliche Sc hutz ausr üstung -->Kopier vorlage @ 56\mod_1200041876826_2.doc @ 894743
Personal protective equipment Wear the following protective equipment during all maintenance
work:
 Safety shoes
 Safety glasses
NOTE!
section to additional protective equipment that is to
be worn for specific tasks.
Pos : 9.8 /KN2006- SM/War tung/003 1.1.0 El ektrisc he Anl age_Gefahr @ 21\mod_1144434833265_2.doc @ 86825
Electrical system DANGER!

Electric power poses a fatal risk!
Contact with live parts may prove fatal. When
switched on, electric components may be subject
to uncontrolled movements and may cause very
serious injury.
Therefore:
– Switch off the power supply before starting
maintenance work, and make sure that it cannot
be switched on accidentally.
Pos : 9.10 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Störungen/HIN WEIS! Kalibrier ung der Regelg eräte @ 83\mod_1222245026000_2.doc @ 1322567
NOTE!
In case of controllers, depending on the frequency
of use and the ambient conditions, calibration in
accordance with BGV A3 must be performed at
least once a year (see manual for controllers).
Maintenance
Pos : 9.12 /KN 2006-SM /Wartung/003 1.1.0 Sic her n geg en Wi eder einsc halten_Gefahr @ 9\mod_1144434835685_2.doc @ 86846

on again!
switched on again when performing maintenance
work. This imposes danger to the life of persons in
the danger zone.
Therefore:
Pos : 9.14 /KN 2006-SM /Wartung/003 1.1.0 Grundlegendes _Warnung @ 13 \mod_1144434834059_2.doc @ 86832
Improperly executed maintenance WARNING!

work Injury hazard posed by improperly executed
maintenance work!
Improper maintenance can cause severe injury or
property damage.
Therefore:
– Prior to starting work ensure that there is
sufficient assembly space.
– Ensure order and cleanliness at the assembly
site! Loose parts and tools, parts and tools
placed on top of each other are hazard sources.
– If components have been removed, ensure that
they are properly mounted; re-install all
mounting elements and comply with all screw
tightening torque specifications.
Pos : 9.16 /KN 2006-SM /Sic her hei t/007 Besondere Gefahr en/Heiß e Oberfl äc hen_Vorsich t! @ 8\mod_1143375956657_2.doc @ 81349

burns.
Therefore:
temperature.
Pos : 9.18 /KN 2006-SM /Wartung/004 1.1.0 U mwelts chutz _Titel @ 9 \mod_1144436206520_2.doc @ 86867
Environmental Protection Comply with the following environmental protection instructions

Pos : 9.19 /KN 2006-SM /Wartung/004 1.1.0.0 Ents orgung F ett @ 9 \mod_1144436328140_2.doc @ 86874
when performing maintenance work:
 Wipe any emerging, used or excessive grease off all lubrication
points that need to be manually supplied with lubricant, and
dispose of in compliance with local regulations.
Pos : 9.20 /KN 2006-SM /Wartung/004 1.1.0.0 Ents orgung Öl @ 9 \mod_1144439240623_2.doc @ 86944
 Catch exchanged oil in suitable containers and dispose of in

compliance with locally valid regulations.
Maintenance
Pos : 9.22 /KN 2006-SM /Wartung/006 1.1 Wartungs plan_Titel (Anleitung) @ 13\mod_1144437014193_2.doc @ 86888
9.2 Maintenance schedule

Maintenance tasks that are required for optimum and trouble-free
operation are described in the sections below.
If increased wear is detected at regular inspections then the
required maintenance intervals must be shortened by the customer
to correspond with the actual signs of wear.
Contact the manufacturer for questions on maintenance work, see
the service address on page 2.
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Interval Maintenance work To be undertaken by
As required Clean nozzle Specialist personnel
Clean needle Specialist personnel
Clean manifold Specialist personnel
Check sliding cam mechanism for wear Specialist personnel
Every 150,000 shots or Lubricate sliding cam mechanism Specialist personnel

weekly
Every 200,000 shots (on Clean needle drive mechanism Specialist personnel
usage of thermoplastic
elastomer (TPE) or
polymers for which the
viscosity is heavily reduced
by shearing)
Approx. every 400,000 Clean needle drive mechanism Specialist personnel

shots
(Dependent on the material
to be processed and the
application)
Maintenance
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9.3 Maintenance tasks

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9.3.1 Clean nozzle

 Only to be undertaken by a skilled person.
 Light face mask
 Facial protection
1. Remove nozzle (see section ““Hot half” disassembly”).
CAUTION!
Damage due to incorrect clamping of the
nozzle!
If the nozzle is clamped incorrectly, the material
tube may rotate as well on drilling out the plastic.
This situation could cause damage to the heater
and/or thermocouple connections.
Fig. 42: Clamping nozzle For this reason:
– Always clamp the nozzle at the nozzle housing.
2. Clamp nozzle at the nozzle housing (2) in a vice fitted with
aluminium jaws (1 and 3).
CAUTION!
Damage due to inserting the drill too far!
On drilling out the plastic, ensure you do not drill
too far into the material tube, as the cross-section
of the bore reduces at point (1). The drilling depth
is dependent on the nozzle type and the nozzle
length.
Fig. 43: Cross-section reduction
Maintenance
3. Using a battery-powered screwdriver/drill, remove the plastic

from the material tube (1).
NOTE!
The diameter of the drill must be 0.2 mm to 0.5 mm
smaller than the diameter of the material tube. The
material tube diameter is dependent on the nozzle
type.
Fig. 44: Material tube
CAUTION!
Risk of injury due to hot surfaces!
You may suffer burns on touching the nozzle.
For this reason:
– After warming up the nozzle, only pick it up
using the connections (1).
4. Connect nozzle to a controller and warm up to the processing

Fig. 45: Connections temperature for the plastic.
CAUTION!
Damage due to improper removal of the
insulating cap!
On pulling off the insulating cap, the nozzle tip may
come undone if the cap is rotated to the left. If it is
rotated to the right, the nozzle tip may be
damaged.
For this reason:
– Only pull off insulating cap when warmed up.
Fig. 46: Removing insulating cap
– Always pull off insulating cap straight to the
front.
5. Pull off insulating cap (1) straight to the front.
Maintenance
6. Set nozzle to 68 to 86 °F above the processing temperature

for the plastic.
CAUTION!
Risk of injury due to hot plastic!
You may suffer burns on contact with the plastic
expelled.
For this reason:
– Ensure nobody can be hit by the plastic
expelled.
7. Apply several compressed air pulses to the material tube.
8. Remove plastic expelled at the nozzle tip (1) using a brass

brush (2).
Fig. 47: Removing plastic
9. Using a round wire brush clamped in the battery-operated

drill, brush out the material tube.
NOTE!
The diameter of the wire brush should be same as
the diameter of the material tube.
10. Repeat steps 7 to 9 until no more plastic is expelled at the
nozzle or the material tube.
Fig. 48: Wire brush
11. Warm up the nozzle to a specific temperature.
Maintenance
Check the nozzle temperature at the nozzle tip:
12. Insert an external thermometer (3) from the rear into the
material tube and push into the nozzle to the nozzle tip stop
(1).
13. Compare temperature with the required temperature set.
NOTE!
The temperature measured at the nozzle tip is
around 50 °C below the required temperature set
on the controller.
Fig. 49: Measuring positions for external
temperature measurement
Check the nozzle temperature on the nozzle head:

14. Insert an external thermometer (3) into position (2) (around 10
mm from the nozzle/manifold contact face) into the material
tube from the rear.
NOTE!
The temperature measured is around 80 to 90 °C
below the required temperature set on the
controller. When installed, this temperature
difference is compensated in conjunction with a hot
manifold.
NOTE!
If the temperature measurement is made with a flat
temperature sensor applied directly to the nozzle
tip, the result measured will be incorrect. The
temperature measured on the nozzle tip is
significantly below the temperature that is actually
present in the nozzle.
NOTE!
Have damaged or worn nozzle tips changed
by GÜNTHER (for contact data see page 2).
In general it is possible to replace nozzle tips
within a day.
Maintenance
Pos : 9.29 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/1.1.1 D üsentemper atur inner hal b des Werkzeuges mes sen @ 90 \mod_1229086610466_2.doc @ 1373331
9.3.2 Measuring nozzle temperature inside the mould

1. Insert an external thermometer (3) from the rear into the
material tube to the nozzle tip stop.
2. Withdraw thermometer around 10 to 15 mm.
NOTE!
Have damaged or worn nozzle tips changed by
Fig. 50: Measuring position for external GÜNTHER (for contact data see page 2). In general
temperature measurement it is possible to replace nozzle tips within a day.
Pos : 9.31 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/007 1.1.1 N adel r einigen @ 83 \mod_1222236126821_2.doc @ 1322466
9.3.3 Clean needle

 Light face mask
 Facial protection
CAUTION!
Damage due to improper cleaning!
Improper cleaning can cause damage to the needle.
For this reason:
– Do not clean needle by sand blasting.
– Do not use abrasive techniques for cleaning.
1. Remove needle (see section “Removal of the needle”).
2. Clean needle using a brass brush or a very fine cloth.
NOTE!
Useful aids for releasing the plastic:
 Cleaning spray manufactured by Klüber Chemie
(Lusin Clean L 21)
 Solvent, e.g. acetone
 Cloth manufactured by Kingspor (Micro Fine Grey,
article number 264053)
What to do if the plastic cannot be 3. Heat needle to maximum 752 °F using a gas flame.
removed using solvents 4. Remove plastic residue using a brass brush.
5. Leave needle to cool to ambient temperature.
Maintenance
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9.3.4 Cleaning manifold

 Light face mask
 Safety glasses
Prerequisites  Nozzles and needles are removed.
 Remove manifold. For this purpose:

1. Unscrew sockets for the power cable.
2. Remove ceramic sleeves (if necessary, break).
3. Undo setscrews (if necessary, drill out).
 Unscrew threaded plug. For this purpose:

1. Hit the threaded plug hard using a drift.
2. Unscrew threaded plug.
 If it is not possible to unscrew the threaded plug:

1. Heat manifold or use penetrating spray (e.g. “Multigliss”).
2. If the hex breaks off, mill out threaded plug.
3. Align thread bore using locating device.
4. Mill out core to the sealing plug.
5. Re-cut thread.
 Remove assembly seals for valve gate systems. For this

purpose:
1. Remove the plastic from the riser bore in the manifold using a
drill. During this process do not damage the surface.
2. Unscrew the union nut (1).

3. Hammer out the assembly seal 3 (2) to the rear using a
suitable drift (diameter < 5 mm (4 mm for assembly seal 2)
made of brass or copper). If necessary, slightly heat the area
around the assembly seal using a gas burner.
Also pay attention to the following information:
 On new components there is an M5 auxiliary thread for removal
using a hammer-action puller.
 Do not heat the manifold too much so that the plastic is not
damaged or runs into the fit.
 Do not damage the fit (3) or the sealing surface (4).
 “Assembly seal 3” stands for needle diameter 3 mm.
Fig. 51:
Maintenance
Thermal Cleaning is undertaken using a pyrolysis technique or fluidised bed

cleaning.
NOTE!
On manifolds with shrunk deflection plugs, only
these techniques are suitable or possible.
Mechanical
1. Remove threaded plug (1) and sealing plug (2).

2. On manifolds for valve gate systems, remove the assembly
seals for the needles (see “Prerequisites”).
Fig. 52: Removing plug
3. Using a battery-powered screwdriver/drill, remove the plastic

from the material ducts.
NOTE!
The drill diameter must be 0.2 mm to 0.5 mm
smaller than the diameter of the material duct to
prevent damage to the surface of the ducts.
4. Using a round wire brush clamped in the battery-operated
drill, brush out the material ducts.
Fig. 53: Removing plastic
5. Sand-blast manifold.
NOTE!
On manifolds (2) for valve gate systems, the fits (3)
in the assembly seals (1) must be protected
against the blasting medium.
Fig. 54: Protecting seal
Maintenance
Fit manifold
1 Cross bore
2 Nozzle outlet bore
3 Sealing surface
4 Sealing plug
5 Threaded plug
Fig. 55: Manifold
6 Sealing surface
7 Connection element
Fig. 56: Connection element
1. Clean sealing surface (6) (abrasive pin).
2. Mark or paint sealing plug (4) with engineer's blue.
3. Fit sealing plug (4).
4. Screw in threaded plug (5) and tighten with a torque wrench

as per the following table.
Threaded plug Value Unit
M10 x 1 30 Nm
M12 x 1 75 Nm
M14 x 1 80 Nm
M16 x 1.5 100 Nm
M18 x 1.5 120 Nm
M20 x 1.5 180 Nm
M24 x 2 200 Nm
Maintenance
NOTE!
 In valve gate systems, the tightening torque is
20 Nm lower in the area of fit H5 – sealing
element.
 In area Ø 8 mm: M12 x 1; 35 to 40 Nm.
5. Unscrew threaded plug (5) and remove sealing plug (4).
6. Check imprint. Ensure the imprint and the sealing surface are
correct.
7. Fit sealing plug (4).
8. Screw in threaded plug (5) and tighten with a torque wrench

as per the table in step 4.
9. Work surface of manifold using an orbital sander (fine grade

emery paper. Ensure all sealing surface are in good condition.
10. Mark or paint sealing surface (6) on the connection flange (7)
with engineer's blue.
11. Screw in connection flange (7) and tighten with tightening
torque of 200 Nm.
12. Unscrew connection element (7).
13. Check imprint. Ensure the imprint and the sealing surface (6)
are correct.
14. Fit connection element (7) and tighten with tightening torque
of 200 Nm.
Fitting power cables 1. Tighten setscrews.
2. Fit ceramic sleeve.
3. Screw in socket.
4. Fit earth cable.
5. Fit temperature sensor.
6. Check power cable for continuity/connection to ground

(meter).
7. Warm-up manifold and check required/actual temperature.
Maintenance
Fitting assembly seals for valve 1. Check the fit and the sealing surface for damage or soiling. If
gate systems necessary, clean using fine emery paper or round wire brush
(not using the drill).
2. Fit the new assembly seal and check for correct seating
(measure).
3. Screw in the thread for the union nut and tighten to a torque of
30 Nm.
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9.3.5 Replacing O-ring seal on single needle valves

 Material: Floss
CAUTION!
For this reason:
manual for the machine's control system).
2. Undo cover and remove using auxiliary thread.
3. Remove needle together with piston using auxiliary thread

and hammer-action puller (see section “Removal of the
needle”).
4. Remove O-rings on the piston.

5. Clean piston and cylinder. The grooves in the single needle
valve must be clean and free of grease.
6. Fit new O-rings (1) to the piston (2).
Fig. 57: Fitting O-rings
Maintenance
7. Align the O-rings (2) using the floss (1). For this purpose fit the
floss as shown and move around the
O-ring in circles several times.
NOTE!
This step is necessary, as twisting that occurs on
fitting the O-rings would significantly reduce the
service life.
8. Wait around 30 minutes until the elongation of the O-rings has
disappeared.
9. Smear cylinder surface with O-ring grease (see section
Fig. 58: Aligning O-rings
“Lubricants”).
10. Fit piston into cylinder.
12. Bolt in place cover.
13. Tighten adjusting nut.
14. Adjust needle (see section “Adjustment of the needle”).

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9.3.6 Re-lubricating sliding cam mechanism

 Special tool required:

 Grease gun
The sliding cam mechanism can be re-lubricated without

disassembly. The grease is pressed in with the aid of a grease gun
via the grease nipple (1) that is accessible from the exterior (see
manual for the grease gun).
NOTE!
Do not use different greases.
Recommended grease manufactured by Klüber
Lubrication: Barrierta L55/2 high temperature long-
Fig. 59: Re-lubricating sliding cam
life bearing grease (for safety data sheet, see
mechanism www.klueber.de).
The grease can be procured via GÜNTHER (for
address see page 2) or via the manufacturer.
Maintenance
NOTE!
On older hot runner systems, the lubrication of the
sliding cam mechanism is undertaken via the
existing ball-valve impact holes (1) in accordance
with DIN 3410 form F.
Fig. 60: Ball-valve impact hole

Pos : 9.39 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/Hi nweis Korrosi ons schutzmi ttel @ 56\mod_1200395196048_2.doc @ 898377
NOTE!
To prevent corrosion on hot runner moulds, these
are often sprayed with LUSIN PROTECT G11 and
O45 corrosion inhibitor manufactured by Klüber.
Both inhibitors form an electrically insulating layer
if heated (like paint).
The corrosion inhibitors have the property of
penetrating into the finest hairline cracks and
corners. For this reason, it may occur that the
contacts on the thermoplug for hot runner nozzles
become insulated and as a result problems occur.
On spraying the hot runner parts, ensure the plugs
for the thermocouple and power connections are
covered or masked prior to spraying so that they
are not sprayed as well.
Pos : 9.41 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Wartung/1.1.1 Ver unr einigungen @ 90\mod_1229078400819_2.doc @ 1373286
9.3.7 Soiling
Remove melt that escapes from the seal on the manifold due to the
lifting movement of the needle using a pry bar.
Maintenance
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9.4 Tightening torques

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9.4.1 General tightening torques

Pretension FV and tightening torque MA, for screws with head
bearing surface in accordance with DIN EN ISO 4014
Shaft screws (µ total = 0.125)
Screw size Pretension Tightening torque

FV [N] MA [Nm]
12.9 12.9
M4 6,900 4.8
M5 11,300 9.5
M6 16,000 16
M8 29,300 40
M10 46,600 79
M12 68,000 135
M16 128,000 340
Threaded plug Value Unit
M10 x 1 30 Nm
M12 x 1 75 Nm
M14 x 1 80 Nm
M16 x 1.5 100 Nm
M18 x 1.5 120 Nm
M20 x 1.5 180 Nm
M24 x 2 200 Nm
NOTE!
 In valve gate systems, the tightening torque is
20 Nm lower in the area of fit H5 – sealing
element.
 In area Ø 8 mm: M12 x 1; 35 to 40 Nm.
Maintenance
Pos : 9.46 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Ins tall ati on & Inbetriebnahme/Tabelle Anzugs drehmomente des Gewindes z ur Nadeljus tage @ 56\mod_1200393170997_2.doc @ 898358
Table of tightening torques for the thread for needle adjustment
Needle Ø Thread Tightening torque

MA [Nm]
Ø 2 mm M6 x 0.50 9
Ø 3 mm M8 x 0.50 15
Ø 5 mm M10 x 0.75 30
Maintenance
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9.5 Measures after maintenance

Pos : 9.49 /KN 2006-SM /Wartung/009 1.1.0 M aß nahmen nac h erfolgter Wartung --> Standard @ 9\mod_1144438981309_2.doc @ 86937
Perform the following steps after completing maintenance and

before switching on the machine:
1. Check all previously loosened screw connections for a tight fit.
2. Check whether all previously removed protective devices and
covers are properly installed again.
3. Make sure that all tools, materials and other equipment used
were removed again from the work area.
4. Clean up work area and remove any substances left over,
such as fluids, processing material or the like.
5. Make sure that all safety features on the machine are fully
functional.
Disassembly
Pos : 10.2 /KN 2006-SM /Demontag e/001 1 D emontage_Titel @ 12\mod_1144501489239_2.doc @ 87447
10 Disassembly
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10.1 Safety
Pos: 10.4 /KN2006-Projekte/Günther Heißkanaltechnik/Demontage/003 1.1.0 Personal Demontage @ 101\mod_1274427633185_2.doc @ 1575117
Personnel  Disassembly is only allowed to be undertaken by specially
trained skilled personnel.
 Work on the electrical system is only allowed to be
Pos : 10.6 /KN 2006-SM /Demontag e/003 1.1.0 Elektrische Anl age_Gefahr @ 13\mod_1144870286332_2.doc @ 89620
Electrical System DANGER!

Electrocution hazard!
An electrocution hazard is posed by contact with
live components. Switched on electrical
and cause serious injuries.
Consequently:
– Prior to starting the dismantling work switch off
the electrical supply completely and finally.
Pos : 10.8 /KN 2006-SM /Sic her hei t/007 Besondere Gefahr en/H ydrauli k_Warnung! @ 8\mod_1143376338046_2.doc @ 81358
Hydraulics WARNING!
Danger to life caused by hydraulic energies!
Hydraulic energies can cause severe or even fatal
injuries.
Hydraulically driven parts may unexpectedly start
to move.
In case of damage to individual components
hydraulic fluid may escape under high pressure.
Therefore:
– Have work on the hydraulic system only carried
out by trained expert personnel.
– Before starting work on the hydraulic system
Completely relieve pressure accumulators.
Disassembly
Pos : 10.10 /KN 2006-SM/Sicherheit/007 Bes ondere Gefahr en/Pneumati k_Warnung! @ 8\mod_1143377778556_2.doc @ 81395
Pneumatics WARNING!
Danger of injury caused by pneumatic
energies!
Pneumatic energies can cause severe injuries.
Pneumatically driven parts may start to move
unexpectedly.
In the event of damage to individual components,
air can escape under high pressure and e.g.
damage the eyes.
Therefore:
– Have work on the pneumatic system carried out
only by trained expert personnel.
– Before starting work on the pneumatic system,
Be careful of pressure accumulators. Relieve
also the pressure in accumulators.
Pos : 10.11 /KN 2006-SM/nL---------- Absc hnitts ende ---------- @ 8\mod_1141997892953_0.doc @ 75473
Pos : 10.12 /KN 2006-SM/D emontage/003 1.1.0 Gr undleg endes_Warnung @ 13 \mod_1144870287285_2.doc @ 89627
Improper dismantling WARNING!

Injury hazard due to improper dismantling!
Stored residual energy, sharp-edged components,
points and corners on and in the device, or on the
necessary tools can cause serious injuries.
Consequently:
– Prior to starting work ensure that you have
adequate space.
– Deal carefully with sharp-edged components.
– Ensure order and cleanliness at the work area.
Loose parts and tools, parts and tools placed on
top of each other are hazard sources.
– Properly dismantle components. Be aware that
some components have a high dead weight. If
necessary use lifting devices.
– Secure components so that they do not fall
down or fall over.
– Contact the manufacturer if there are any
questions.
Disassembly
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CAUTION!
Damage due to improper dismantling!
Improper dismantling can result in damage to the
hot runner.
For this reason:
– During the disassembly of form inserts in
conjunction with the needle guide type VA, the
needle must be in the “open” position.
– Ensure the hot runner system is switched off.
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10.2 Removal of the needle

NOTE!
The following steps apply to single needle valves,
lifting plate and sliding cam mechanism.

 Additional protective equipment:
 Special tool required:
 Hammer-action puller
 Pliers
CAUTION!
For this reason:
1st variant NOTE!

On the 1st variant, the needle must be re-adjusted
on installation.
settings).
Disassembly
2. Undo adjusting nut (1) from the needle (2).
Fig. 61: Undoing adjusting nut
3. Unscrew the needle (2) from the needle receptacle (1) and
pull out using hammer-action puller.
Fig. 62: Unscrewing needle
2nd variant NOTE!

On the 2nd variant, the needle does not need to be
re-adjusted on installation.
settings).
2. Unscrew the screws (1) and (2).

3. Remove cover (3) using auxiliary thread.
Fig. 63: Removing cover
Disassembly
For single needle valves the following applies:

4. Remove adjusting nut (1), needle (2) and piston (3) together
using auxiliary thread and hammer-action puller.
For lifting plate and sliding cam mechanism:
5. Remove adjusting nut (1), needle (2) and needle receptacle
(3) together using pliers.
6. Mark needle as per the position in the system.
Fig. 64: Removing needle

Pos : 10.18 /KN 2006-Proj ekte/Günther Heiß kanal tec hni k/D emontage/1.1 D emontage Heiß e Sei te @ 83\mod_1221468415169_2.doc @ 1318003
10.3 “Hot half” disassembly

 Only to be undertaken by a skilled person
DANGER!
For this reason:
1. Disconnect wiring.
2. Remove clamping plate (1) from the frame plate (2).
Fig. 65: Removing clamping plate
Disassembly
3. Remove nozzles (1) from the frame plate (2).
Fig. 66: Removing nozzles
4. Remove pressure pads (2) from the manifold (1).

5. Remove manifold (1) from the frame plate (3).
Fig. 67: Removing pressure pads and

manifold
Pos : 10.20 /KN 2006-Proj ekte/Günther Heiß kanal tec hni k/D emontage/008 1.1 D emontag e und Entsorgung @ 98\mod_1247642320494_2.doc @ 1477046
10.4 Disassembly and disposal

Disassembly Prior to disassembly:
 Switch off unit and secure against restarting.

 Physically disconnect all supplies of energy from the unit,
discharge residual energy stored.
 Remove oils and greases as well as the remains of any
materials processed and dispose of with due care for the
environment.
Then clean assemblies and components correctly and dismantle

while observing the applicable local health and safety regulations
and regulations on the protection of the environment.
Disposal Provided an agreement has not been reached on return or

disposal, send dismantled components for recycling:
 Scrap metals.
 Send plastic elements for recycling.
Disassembly
 Dispose of remaining components based on material

characteristics.
CAUTION!
Pollution due to incorrect disposal!
Incorrect disposal of materials used will cause
pollution.
For this reason:
– Correctly dispose of electrical scrap, electronic
scrap, lubricants and other oils and greases, if
necessary task a specialist organisation with
disposal.
The local authorities or specialist disposal organisations will

provide information on correct disposal with due care for the
environment.
Replacement Part List
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11 Replacement Part List

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Spare parts can be found in the main catalogue or on the internet

at www.guenther-heisskanal.de.
Appendix
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12 Appendix
Appendix
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12.1 Technical information

You will find further technical data in the main catalogue in the
related sections, for example
 “Yellow pages”
 “Material-dependent nozzle-selection” page
 Page for the related nozzle/manifold type
You will find additional service information on our website,

www.guenther-heisskanal.de:
 In the “Services” menu
 Delta-Tool calculation program
 Application database
 Seminars
 In the “Download” menu

 Main catalog
 Manual
 In the “About CADHOC” menu
 GÜNTHER system designer CADHOC V2
Appendix
Pos : 12.6 /KN 2006-Pr ojekte/Günther H eiß kanaltechni k/Anhang/1.1 H öhenaufbau/Maß kontroll e @ 83\mod_1221477148605_2.doc @ 1318517
12.2 Height adjustment/dimension check
Appendix
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12.3 Hot runner system checklist

Order confirmation Customer:
no. :
Hot valve fitted by:
Hot valve checked by:
General points
Check cooling bores separately OK
Check cooling bores in the assembly OK

Run/leaks
Arrangement cavity number / nozzle number OK

see further on, wiring diagram
Insulation resistance >1M Ω OK
Ground wire resistance < 0.3 Ω OK
Warming up the hot valve to processing temperature, OK

max 1h
Height adjustment / pretension / K dimension ∆ t °C OK
Tip length ∆ t °C mm
Check guide pin length OK
Vertical pillars (angled) OK
Type plate fitted OK
Transport hooks accessible OK
Visual impression of the mould OK
Wiring diagram to the customer OK
Corrosion inhibitor applied OK
Appendix
Valve gate
Barrierta L55/2
Needle guide play correct? OK
Access to needle adjustment correct? OK
Needle stroke as per drawing in mm mm
Needle open/closed position as per drawing OK
Marking on cylinder (open/closed) OK
Mechanical function test OK
Cylinder and supply line free of leaks OK
1st lubrication through stipulated lubrication ducts performed OK
Appendix
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12.4 Declaration of conformity
Manufacturer's declaration / declaration of incorporation

In the context of the Machinery directive 2006/42/EC, Annex VII part B for partly completed machinery.
We herewith declare that the unit identified below complies with the provisions of the EC directives noted
below. If it is incorporated in another machine, putting into service is prohibited until it has been determined
that the machine into which the unit identified below is incorporated is compliant with the provision of the
EC Machinery directive 2006/42/EC, Annex VII part B with the applicable Appendix.
Identifier:
Ident number:
Directives taken into account: Low voltage directive 2006/ 95/ EC
Frankenberg, __________ i.A
_________________________ _________________________
Place and data Quality Manager
===== Ende der Stüc kliste =====
Index
13 Index
A M
Accident .............................................................. 19 Maintenance .......................................................67
Appendix ............................................................. 93 Maintenance schedule ........................................69
B Maintenance tasks ..............................................70
Breathing mask Material processed .............................................19
light.................................................................. 14 O
C Operating conditions ...........................................21
Commissioning ................................................... 49 Operating materials ............................................16
Connection values .............................................. 20 Operation ............................................................56
Contact ................................................................. 9 Owner .................................................................10
Copyright .............................................................. 9 P
Correct use ......................................................... 13 Packaging ...........................................................27
Customer Service ................................................. 9 Packing ...............................................................30
D Personal protective equipment ...........................14
Danger zones ..................................................... 19 maintenance ....................................................67
Disassembly ................................................. 85, 90 Personnel ............................................................11
Disposal .............................................................. 90 commissioning ................................................60
E disassembly ....................................................85
Electric Current ................................................... 15 initial commissioning .......................................32
Emergency Stop ................................................. 59 installation .......................................................32
Environmental protection .................................... 19 installation .......................................................60
F maintenance ....................................................67
Fire...................................................................... 19 Pneumatics .........................................................86
First Aid............................................................... 19 Professional electrician .......................................11
H Protective clothing ..............................................14
Hydraulics ..................................................... 16, 85 Protective equipment
I installation .......................................................32
Incorrect use ....................................................... 13 malfunctions ....................................................60
Installation........................................................... 37 operation .........................................................56
L Protective gloves ................................................14
Liability .................................................................. 8 Q
Lifting eyes ......................................................... 29 Qualified personnel .............................................11
Lubricants ........................................................... 19 R
Replacement part list ..........................................92
Replacement parts ..............................................92
Index
S T
Safety Technical data .................................................... 20
general ........................................................... 10 Transport ...................................................... 27, 29
Safety boots ....................................................... 14 Crane ........................................................ 29, 30
Safety features ................................................... 17 Forklift truck .................................................... 30
Safety goggles ................................................... 14 Inspection ....................................................... 29
Spare parts ...........................................................9 Troubleshooting ................................................. 60
Storage ........................................................ 27, 31 Chart ............................................................... 63
Surfaces Type plate .......................................................... 22
hot ...................................................... 17, 62, 68 U
Switching off....................................................... 57 Usage ................................................................. 13
Switching on....................................................... 56 W
Securing against ............................................ 18 Warranty............................................................... 9
Symbols Warranty conditions ............................................. 8
in this manual ....................................................7
Packing........................................................... 28

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Operating manual

Hot runner technology

© GÜNTHER Heisskanaltechnik GmbH

Telephone: +49 (0) 6451 5008-0

3 Technical data ...................................................................... 20

4 Structure and function ........................................................ 23

5 Transport, packaging and storage ..................................... 27

5.3 Transport inspection.....................................................29

6 Installation and commissioning .........................................32

9.1 Safety ........................................................................... 67

11 Replacement Part List ......................................................... 92

1.1 Information on this manual

The enclosed manuals for the installed components apply

1.2 Explanation of symbols

Hints and recommendations NOTE!

… highlights hazards caused by electric current.

1.3 Limitation of liability

We reserve the right to make technical modifications in order to

1.4 Warranty conditions

1.6 Spare parts

1.7 Warranty terms

The warranty terms are provided in the manufacturer's terms and

Pos : 1.19 /KN 2006-SM /Allgemeines/170 1.1 Kundendienst_Titel+Text @ 8\mod_1142095433275_2.doc @ 75902

1.8 Customer Service

Pos : 2.1 /F I/.......... Seitenumbr uch .......... @ 0\mod272_2.doc @ 1523

This paragraph provides an overview of all important safety

2.1 Customer’s responsibility

The device is implemented commercially. Thus the owner of the

2.2 Personnel requirements

2.2.2 Unauthorized persons

Date Name Type of training Training Signature

2.3 Correct use

The hot runner system is used for plasticised plastic melt

2.4 Personal protective equipment

Wear generally Generally wear for all kind of work:

Light breathing mask

2.5 Specific dangers

Electric current DANGER!

Hot operating materials WARNING!

Sharp corners and pointed edges CAUTION!

Hot surfaces CAUTION!

2.6 Safety features

Connect the emergency shutdown systems so that situations that

2.7 Securing against switching on

Switch secured with padlock Securing against switching on:

Switched off 4. If a switch cannot be secured with a padlock, stand up a sign

2.8 Conduct in a dangerous situation and in case of accidents

In case of emergencies  Operate the emergency stop immediately.

2.9 Environmental protection

The following environmentally hazardous substances are used:

3.1 Connection values

Electrical Parameter Value Unit

System* Parameter Value Unit

Max. permissible operating 2,000 bar

Max. ambient temperature 450 °C

* If special nozzles or other components with a pressure limit (less

Hydraulic Parameter Value Unit

Single needle valve 40 bar

Lifting plate mechanism 40-60 bar

Sliding cam mechanism 40-60 bar

Max. ambient temperature 100 °C

Pneumatic** Parameter Value Unit

Single needle valve 8-10 bar