8.2 Service of the Actuator HYC4018M Series and Maintenance / Service of the Actuator HYC4018M...

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Master Language is English Hot Runner System Instruction Manual SVC-17-0001_EN-Rev03RESTRICTED: Property of Synventive. - 107 - All rights reserved. Errors and omissions exceptedFor limited third party distribution based on need and intended use. © 2015 Synventive Molding Solutions

Service and Maintenance / Service of the Actuator HYC4018M Series

8.2 Service of the Actuator HYC4018M Series

8.2.1 Technical Data HYC4018M03-F/-R, HYC4018M04-F/-R, HYC4018M05-F/-R

Actuator, bolted to manifold.

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

Valve pin operationOperation medium hydraulicOperating pressure 40 bar (580 psi)Pressure range 40 - 60 bar (580 - 870 psi)

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

Flow rate 3 l/min / 40 bar (580 psi)Valve pin response time ~0,5 s / 40 bar (580 psi)Valve pin stroke 18 mmValve pin adjustment ± 1,5 mm

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

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

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

NOTICETo ensure long life and continued flawless operation of the actuator, we recommend using a service medium that complies with the requirements of classification 21/18/13 pursuant to ISO 4406.The coolant used should be properly modified, e.g. filtered water with an anti-corrosion and frost-proof agent.After switch off the hot runner heater, the cooling for the actuator have to be turned on for at least 15 minutes, to avoid damages of the actuator sealing.

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8.2.2 Exploded View HYC4018M SeriesHYC4018M03 Series - This actuator is especially for the option SynCool® 1 or 2 and/or the option with Thermocouple.HYC4018M04 Series - This actuator is the usual actuator.HYC4018M05 Series - This actuator is for position monitoring with flow sensor ITEM RVM/U-4/1S.This section describes the disassembly and reassembly process to replace seals.In this section the actuator parts are identified with the numbers indicated in the following figure, which shows the components.

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

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Actuator parts HYC4018M SeriesNo. Qty. Description Item

(1) 1 Housing Complete Type 03 (HYC4018M03)Type 04 (HYC4018M04)Type 05 (HYC4018M05)

HYC4018HC03HYC4018HC04HYC4018HC05

(1.1) 1 Cylinder housing(HYC4018M03 Series)

HYC4018CH02

(1.1) 1 Cylinder housing(HYC4018M04 Series)(HYC4018M05 Series)

HYC4018CH03

(1.2) 1 Piston D40(HYC4018M03 Series)(HYC4018M04 Series)

HYC4018PI01

(1.2) 1 Piston D40(HYC4018M05 Series)

HYC4018PI02

(1.3) 1 Adjustment screw HYC4013AS02

(1.4) 1 Adjustment screw cover HYC4013AC01

(1.5) 1 Positioning pin HYC4018PP01

(1.6) 1 Socket set screw DIN913-M8X12-45H

(1.7) 2 Socket head cap screw DIN915-M3X5-450HV

(1.8) 2 Socket head cap screw DIN912-M5X8-12.9

(1.9) 1 Sealing kit (complete) HYC4013SK01

(1.9.1) 1 Piston seal K30-40-40-32-3.2

(1.9.2) 1 Rod seal C1-2038-V3664

(1.9.3) 1 Guiding element FB2.3-1.5L70.5

(1.9.4) 1 O-ring seal VIOR35X2.2FPM80

(1.9.5) 1 O-ring seal VIOR4X1FPM80

(2) 1 Cooling plate (F) full contact surface

HYC4018CP01

(2) 1 Cooling plate (R) reduced contact surface

HYC4018CP02

(3) 1 Mounting plate HYC4013MP02

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

(5) 4 Socket head cap screw DIN912-M6X14-12.9

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

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

Assembly and Disassembly Tools - ATCYL03No. Description Item

(T1) Adjustment tool cpl. ATCYL0301

(T2) Fitting nut cpl. ATCYL0302

(T3) Valve pin disassembly tool ATCYL0303

(T4 Installation cone ATCYL0304

(T5) Spread tube ATCYL0105

(T6) Calibration sleeve ATCYL0107

(T9) Assembly tool cpl. ATCYL0407

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8.2.4 Enhancements, Options and AccessoriesCooling Full for Valve Pin

Guide

Cooling Reduced for Valve Pin

Guide

SynCool® 1 SynCool® 2 Thermocouple Flowsensor

HYC4018M03-F ● − ○ ○ ○ −HYC4018M03-R − ● ○ ○ ○ −HYC4018M04-F ● − − − − −HYC4018M04-R − ● − − − −HYC4018M05-F ● − − − − ○HYC4018M05-R − ● − − − ○

● Standard○ Optional− not possible

8.2.4.1 Cooling Plate with Contact Surface to the Valve Pin GuideHYC4018M03-F / M04-F / M05-F with cooling plate HYC4018CP01 for full contact surface to the valve pin guide.HYC4018M03-R / M04-R / M05-R with cooling plate HYC4018CP02 for reduced contact surface to the valve pin guide.

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8.2.4.2 SynCool® 1 - OptionSynCool® 1 technology is applicable for the HYC4018M03 series actuator.The cooling plate between the actuator and the manifold to facilitate cooling of the valve pin guide and the actuator to thermally separate it from the hot manifold surface.The SynCool® 1 technology provides in addition an indirect cooling which allows the operator on certain applications at <280 °C operating & <80 °C mold temperature, to switch off the complete system including the mold and actuator cooling without the risk of decomposing the hydraulic oil.

The HYC4018M03 series actuator with SynCool® 1 technology are bolted to the manifold. When applying the option SynCool® 1 following standard specifications are changed:

● The construction height of the Actuator heightened by 2.5 mm ● The used valve pin has to be 2.5 mm longer than the valve pin without

the option SynCool® 1

Component SynCool® 1

No. Qty. Description Item01 1 Heat deflector HYC40HD01

NOTICEHeat deflector must has contact with the mold.

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8.2.4.3 SynCool® 2 - Option

SynCool® 2 technology is applicable for the HYC4018M03 series actuators only.The SynCool® 2 technology provides in addition an indirect cooling which allows the operator on certain applications at <280°C operating & <80°C mold temperature, to switch off the complete system including the mold and actuator cooling without the risk of decomposing the hydraulic oil.

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Component SynCool® 2HYC4018-SC-02No. Qty. Description Item

01 1 HYC4018 Component spring HYC4018C-S-01

02 2 HYC4018 Heat deflector Version = 02 HYC4018-HD-02

03 4 HYC4018 Component bush Version = 01 HYC4018C-B-01

04 4 Hexagon socket cap screw DIN912-M4X12-12.9

05 4 Washer DIN125 Form A ø6,4 DIN125-A6,4-ST

06 4 VITON O-ring seal 5.00x2.0 FPM80 Green VIOR-5x2-FPM80

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NOTICEHeat deflectors must have contact with the mold.

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8.2.5 Disassembling the Actuator HYC4018M Series

Hydraulic

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

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

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

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4) Slide the cylinder in the direction of hydraulic connections (a).

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

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

5) Remove the actuator housing (1) from the cooling plate (2).

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8.2.5.1 Disassembling the Adjustment Screw Assembly

1) Loosen the socket set screw (1.6).2) Using the disassembly tool T9 to unscrew the adjustment screw

assembly (1.3) (1.4) out of the actuator housing (1.1).

NOTICEThe socked head cap screws (1.8) can be left in the adjustment screw (1.3).

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

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

(T2.1) (T2.2) until the piston (1.2) is released.6) Dismount the piston seal (1.9.1) elements

● O-ring (1.9.1) (a) ● Sealing element (1.9.1) (b)

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7) Unscrew the 2 hexagon socket set screws (1.7).8) Dismount the adjustment screw cover (1.4) from the adjustment screw

(1.3).9) Dismount seals:

(1.9.2) Rod seal(1.9.3) Guiding element(1.9.4) O-ring seal

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8.2.6 Assembling the Actuator HYC4018M Series

8.2.6.1 Installing the Piston SealTo mount the piston seal (1.9.1) on the piston (1.2), proceed as follows:

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

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

2) Mount the O-ring (1.9.1) (a) into the seal groove of the piston (1.2).3) Lubricate the Sealing element (1.9.1) (b) of the piston (1.2) with hydraulic

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

sealing element (1.9.1) (b) into the seal groove of the piston (1.2).

NOTICEThe sealing element (1.9.1)(b) is placed in the seal grove of the piston (1.2) above the O-ring (1.9.1) (a)

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

NOTICEThis will precisely align the piston seal (1.9.1) with the piston (1.2).

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8.2.6.2 Installing the Adjustment Screw Assembly into the Actuator housing

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

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

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

3) Use the adjustment tool (T1) to ensure the position pin (1.5) align into the piston.

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

4) Lubricate the following seals with hydraulic oil or white grease:(1.9.2) Rod seal(1.9.3) Guiding element(1.9.4) O-ring seal

5) Install the seals on the adjustment screw cover (1.4) and adjustment screw (1.3).

6) Attach the adjustment screw cover (1.4) with 2 hexagon socket set screws (1.7) at the adjustment screw (1.3). Doc003540.png

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7) Screw the two socked head cap screws (1.8) into the adjustment screw (1.3).

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

8) Screw the prepared adjustment screw (1.3) (1.4) into the actuator housing (1.1) by using the Dis-Assembly tool T9.

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9) Turn the adjustment screw (1.3) by using a PIN (ø5) into the desired position.

NOTICEThe basic position is 6.5 mm between bottom actuator housing (1.1) and adjustment screw (1.5) bottom.

10) Lock the adjustment screw (1.3) with the socket set screw (1.6) in the actuator housing (1.1).

NOTICEUse a torque wrench for a torque of 15 Nm (11 ft-lbs).

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8.2.6.3 Mounting the Actuator on the Manifold

Insertion of valve pin head into piston cut-out.

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

direction of valve pin release.

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

position inside the piston (1.2) cut-out.

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4) Lubricate the thread of the socket head cap screws (4) with high-temperature assembly paste (anti-seize compound).

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

5) Screw the Actuator with socket head cap screws (4).

NOTICETighten the socket head cap screws (4) in an X pattern (a, d, c, b).Use torque wrench with wrench insert and the torque specified in the respective table in section 13.

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For valve pin height adjustment of the actuators HYC4018M Series see section 9.3

8.2 Service of the Actuator HYC4018M Series and Maintenance / Service of the Actuator HYC4018M...

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