Montador A

PR-25 Instruction Manual

PR-25Mounting Press

Patents are pending in U.S.A.and other countries.

Minor revisions may not be reflectedin this manual.

©1999 LECO® Corporation

Part Number 200-262

November 1999

1–2 PR-25 Introduction

This page intentionally left blank.

Introduction PR-25 1–3

1 1 Introduction

Illustrations .......................................................................... 1–4

Warranty.............................................................................. 1–5

Warning and Caution Symbols.................................................. 1–7

Interference to Other Devices .................................................. 1–8

Major Equipment and Accessories List ....................................... 1–9

Components and Accessories List ........................................... 1–12

Options .............................................................................. 1–13

Consumables ...................................................................... 1–14

Specifications...................................................................... 1–16

2 Installation

Illustrations .......................................................................... 2–2

Installation ........................................................................... 2–3

Mount Heights....................................................................... 2–7

3 Operation

Illustrations .......................................................................... 3–2

Controls and Indicators........................................................... 3–3

Operation............................................................................. 3–5

Molding Pressures and Times ................................................... 3–8

4 Maintenance

Molding Defects..................................................................... 4–3

Heater Cooler Removal........................................................... 4–5

5 Illustration

6 Index

Introduction


Illustrations

Figure 1–1......... PR-25 Mounting Press—Front View................1–17

Figure 2–1......... PR-25 Mounting Press—Back View ................2–5

Figure 2–2......... Heater Cooler Assembly Alignment ...............2–6

Figure 2–3......... Heater Cooler Assembly at 45o .....................2–6

Figure 2–4......... Heater Cooler Assembly Positioned Correctly ..2–6

Figure 3–1......... Pressure Gauge .........................................3–4

Figure 3–2......... Controls and Indicators...............................3–4

Figure 3–3......... Double Mount Cross-Section ........................3–9

Figure 5–1......... Interior—Left Side View ..............................5–3

Figure 5–2......... Interior—Right Side View ............................5–4

Figure 5–3......... Exploded View—1 ......................................5–5



Figure 5–6......... Heater Cooler Assembly ..............................5–8

Figure 5–7......... Switch Assemblies .....................................5–9

Figure 5–8......... PR-25 Flow Diagram...................................5–10


Warranty

Equipment manufactured by LECO Corporation, St. Joseph,Michigan is warranted free from defect in material andworkmanship for a period of six months from the date ofinstallation. Equipment not manufactured by LECO is covered tothe extent of warranty provided by the original manufacturerand this warranty does not cover any equipment, new or used,purchased from anyone other than LECO Corporation. Allreplacement parts shall be covered under warranty for a periodof thirty days from date of purchase. LECO makes no otherrepresentation or warranty of any other kind, expressedor implied, with respect to the goods sold hereunder,whether as to merchantability, fitness for purpose, orotherwise.

Expendable items such as crucibles, combustion tubes,chemicals, and items of like nature are not covered by thiswarranty.

LECO's sole obligation under this warranty shall be to repair orreplace any part or parts which, to our satisfaction, prove to bedefective upon return prepaid to LECO Corporation, St. Joseph,Michigan. This obligation does not include labor to installreplacement parts, nor does it cover any failure due toaccident, abuse, neglect, or use in disregard of instructionsfurnished by LECO. In no event shall damages for defectivegoods exceed the purchase price of the goods, and LECO shallnot be liable for incidental or consequential damageswhatsoever.

All claims in regard to the parts or equipment must be madewithin ten (10) days after Purchaser learns of the facts uponwhich the claim is based. Authorization must be obtained fromLECO prior to returning any other parts. This warranty is voidedby failure to comply with these notice requirements.


Notice

The warranty on LECO equipment remains valid only whengenuine LECO replacement parts are employed. Since LECO hasno control over the quality or purity of consumable products notmanufactured by LECO, the specifications for accuracy ofresults using LECO instruments are not guaranteed unlessgenuine LECO consumables are employed in conjunction withLECO instruments. If purchaser defaults in making payment forany parts or equipment, this warranty shall be void and shallnot apply to such parts and equipment. No late payment orcure of default in payment shall extend the warranty periodprovided herein.

LECO Corporation is not responsible for damage to anyassociated instruments, equipment, or apparatus nor will LECObe held liable for loss of profit or other special damagesresulting from abuse, neglect, or use in disregard ofinstructions. The Buyer, their employees, agents, andsuccessors in interest assume all risks and liabilities for theoperation, use, and/or misuse of the product(s) describedherein and agree to indemnify, hold harmless, and defend theseller from any and all claims and actions arising from anycause whatsoever, including seller's negligence for personalinjury incurred in connection with the use of said product(s)and any and all damages proximately resulting therefrom.

CautionThe instrument should be operated only by technically qualifiedindividuals who have fully read and understand theseinstructions. The instrument should be operated only inaccordance with these instructions.

The operator should follow all of the warnings and cautions setforth in the manual and the operator should follow and employall applicable standard laboratory safety procedures.

LECO is a registered trademark of LECO Corporation.Windows is a registered trademark of Microsoft Corporation.Excel is a registered trademark of Microsoft Corporation.Windows 95 is a trademark of Microsoft Corporation.Windows 3.1 is a trademark of Microsoft Corporation.


Warning and Caution Symbols

The following symbols may be found on LECO equipment ortheir components. These symbols indicate the use of specificsafety guidelines. Important safety information is highlighted inthis manual by one of the following symbols as well asWARNING and CAUTION statements. Operator and servicepersonnel must follow these instructions for personal safety andto prevent damage to the equipment.

This symbol indicates a risk of electrical shock.Refer to the manual for specific instructions.

This symbol indicates a high temperaturesurface. Refer to the manual for specificinstructions.

This symbol indicates a caution. Refer to themanual for specific instructions.

LECO equipment should be operated only by technicallyqualified individuals who have fully read and understand theinstructions detailed in this manual. The equipment should beoperated only in accordance with these instructions.

The operator should follow all of the warnings and cautions setforth in this manual and the operator should follow and employall applicable standard laboratory safety procedures.

CAUTION

!

WARNING

WARNING


Interference to Other Devices

This equipment has been tested and found to comply with thelimits for a Class A digital device, pursuant to Part 15 of theFCC Rules and Regulations. These limits are designed toprovide reasonable protection against harmful interferencewhen this equipment is operated in a commercial environment.This equipment generates, uses and can radiate radiofrequency energy and, if not installed and used in accordancewith the instructions, may cause interference to radiocommunications. Operation of this equipment in a residentialarea is likely to cause harmful interference in which case theuser will be required to correct the interference at his ownexpense.


Major Equipment and Accessories List

Items listed below and repeated throughout this manual are subject to revision.Please consult the packing slip received with the instrument.

814-200-100 PR-25 115V with 1.00 inch Heater Cooler Package

1 814-200 PR-25 115V Mounting Press including:

1 200-262 Instruction Manual

1 814-200-050 Component Pack (for complete listing, seeComponents and Accessories List, page 1–12)

1 807-543 Power Cord

1 807-927-100 Heater Cooler Assembly

1 811-308 Bakelite Black Preform (1.00 inch)

1 807-922* Hazard Materials Pack (for complete listing, seeComponents and Accessories List, page 1–12)









* Packed and shipped separately in the U.S.A. Not included with international shipments dueto shipping restrictions. These items are essential for operation. Contact your local LECOdistributor for quotation and delivery.



1 814-300 PR-25 Mounting Press including:








Components and Accessories List

814-200-050 Component Pack

4 163-021 Insert

1 537-103 Tubing (15 Ft)

1 774-672 Plastic Tubing (6 Ft)

1 805-757 Fitting

1 805-758 Fitting

1 807-615 Fitting

1 811-110 Powder Bakelite (1/Lb)

807-922* Hazardous Material Pack

1 811-271 Silicon Aerosol Release Agent



Options

800-635 Cotton Gloves (pair)

804-099 Replacement Engraver Tip (Carbide)

804-120 Electric Engraver

811-271 Silicon Release Agent, Aerosol (6 oz)

811-272 Wax Release Agent, Powder (2 oz)

811-273 Wax Release Agent, Aerosol (16 oz)


Consumables

• For a complete list of all LECO metallographic consumable,request catalog number 203-826.

Compression Mounting Supplies

Description Qty Color LECOPart Number

Black 811-111Red 811-118

Green 811-1235 lb

(2.27 kg)Green/Brown

811-128

Black 811-111-250

BakeliteThermosetting

Powder andPellets Powder

250 lb Drum(113 kg) Green 811-154-110

Filler Qty Color LECOPart Number

1 lb(.454 kg)

811-144Mineral

5 lb(2.27 kg)

811-145

Mineral(-20 Mesh)

5 lb(2.27 kg)

Black

811-145-120

1 lb(.454 kg)

811-140

EpoxyThermosetting

Powder

Glass5 lb

(2.27 kg)

Green811-141

Filler Qty ColorLECO

Part Number1 lb

(.454 kg)811-134

5 lb(2.27 kg)

811-135Mineral

50 lb(22.5 kg)

811-633

1 lb(.454 kg)

811-136

5 lb(2.27 kg)

811-137Glass Fiber

50 lb(22.5 kg)

Blue

811-277

1 lb(.454 kg)

811-138*

Diallyl PhthalateThermosetting

Powder

Copper5 lb

(2.27 kg)

Copper811-139*

Note


Mold Size Qty Color LECOPart Number

Black 811-301

Red 811-3131.00 inch 100

Green 811-325

Black 811-305

Red 811-3171.25 inch 100

Green 811-32

Black 811-309

Red 811-321

PreformsThermosetting

1.50 inch 100

Green 811-333

Qty Color LECOPart Number

1 lb(.454 kg)

811-132

5 lb(2.27 kg)

811-133

Lucite ®

ThermoplasticPowder

Lucite is aregistered

trademark ofDUPONT

50 lb(22.5 kg)

Clear(For

TransparentMounts)

811-625


Specifications

The PR-25 is an automatic mounting press that incorporates aunique, pneumatic-hydraulic system. The PR-25 incorporatesan integral, 1200-watt heater cooler and a larger mold heightto allow safe, rapid, and reliable production of mounts.

Dimensions

Height ............................................27.00 inches (686 mm)

Width.............................................14.50 inches (368 mm)

Depth ............................................15.50 inches (394 mm)

Electrical Power Requirements

814-200 .........................................115 VAC, ±10%, 50/60 Hz, 11 Amps

814-300 .........................................230 VAC, ±10%, 50/60 Hz, 6 Amps

Gases Required ..................................Compressed Air, 85 psi (5.86 bars),source must be water and oil free

Other Utilities Required ......................Continuously flowing water supply andnon-restricting gravitational drain.


Figure 1–1PR-25 Mounting Press—Front View

Installation PR-25 2–1

2 Illustrations .......................................................................... 2–2

Installation ........................................................................... 2–3

Mount Heights....................................................................... 2–7

Installation

2–2 PR-25 Installation

Illustrations

Figure 2–1......... PR-25 Mounting Press—Back View ................2–5

Figure 2–2......... Heater Cooler Assembly Alignment ...............2–6

Figure 2–3......... Heater Cooler Assembly at 45o .....................2–6

Figure 2–4......... Heater Cooler Assembly Positioned Correctly ..2–6


Installation

ELECTRICAL SHOCK HAZARDThis equipment uses 115 or 230 VAC powersupplies. Contact with these voltages can belethal. Do not apply power until instructed todo so.

1. Place the instrument on a work surface that has aconvenient air supply, water supply, electrical powersupply, and gravitational drain. Refer to the Specificationssection, page 1–16, for more information.

2. Connect the air supply to the air inlet on the back of thePR-25 (figure 2-1, page 2–5).

3. Turn the regulator control knob, located on the front panelof the PR-25, all the way to the left (counterclockwise).

4. Turn the ram down knob clockwise to the full closeposition.

POSSIBLE JACK DAMAGEDo not over turn the knob. Turning the knob toofar could result in damage to the jack.

5. Turn the air supply on and set it for 85 psi.

6. Turn the ram height selector switch to the up position.

7. Adjust the regulator control knob for the mold size to beused. Tube push rod should be 1 to 2 inches above theunit.

8. Thread the bottom ram onto the screw that attaches theram to the push rod.

• Make sure that the bottom ram, heater cooler assembly,and mold assembly are clean to assure proper fit and easeof assembly.

WARNING

CAUTION

!

Note


9. Hold the heater cooler assembly in position over thebottom ram (figure 2-2, page 2–6, and rotate the heatercool assembly 45-degrees to the left (figure 2-3,page 2–6).

• This rotation matches the collar with the bottom moldassembly configuration.

10. Once the heater cooler assembly and the collar are alignedproperly, push the heater cooler assembly down into thecollar (figure 2-4, page 2–6).

11. When the heater cooler assembly is down into the collarcorrectly, turn the heater cooler assemblycounterclockwise until it locks in position. The heatercooler assembly is now captive and cannot rotate.

• The indicator lights should be facing the front of the unit.

12. Connect the electrical outlet connector (already connectedto the PR-25) to the electrical inlet on the back of theheater cooler assembly.

POSSIBLE MACHINE DAMAGETo prevent overheating, make sure thisconnector is on all the way and the locking ring isengaged.

13. Connect the water tubing that is already connected to therear of the PR-25 to the back of the heater coolerassembly (figure 2-1, page 2–5).

14. Connect the water supply tubing between the water supplyinlet on the rear of the PR-25 and the facility water supply.

15. Connect the drain tubing to the water drain outlet on therear of the heater cooler and slop the tubing downward tothe laboratory drain.

CAUTION

!

Note

Note


Figure 2–1PR-25 Mounting Press—Back View

ELECTRICAL CONNECTOR

807-538HANDLE HOLDER

807-543 115V807-551 230V

POWER CORD

807-927-100 (115V, 1.00-INCH)807-927-125 (115V, 1.25-INCH)807-927-150 (115V, 1.50-INCH)807-928-100 (230V, 1.00-INCH)807-928-125 (230V, 1.25-INCH)807-928-150 (230V, 1.50-INCH)HEATER COOLER ASSEMBLY

HEATER COOLERWATER INLET

DRAIN OUTLET

772-614WATER OUTLET

ELBOW

AIR INLET

537-103WATER SUPPLY

TUBING(TO FACILITY

WATER SUPPLY)

774-672DRAIN TUBING

(TO FACILITY DRAIN)

WATER INLET


Figure 2–2Heater Cooler Assembly Alignment

Figure 2–3Heater Cooler Assembly at 45o

Figure 2–4Heater Cooler Assembly Positioned Correctly

BOTTOM RAM(SELECT PROPER

RAM FOR HEATER / COOLER1.25”, 1.50”, OR 2.00”)

807-539MOLD COLLAR

LOCKING PIN HOLELOCATION ON MOLD

ASSEMBLY

ALIGNMENT COUPLING

LOCKING PIN CONSISTING OF:807-541 BODY

803-456 SPRING807-540 COLLAR

807-542 KNOB

HYDRAULICCYLINDER ROD


Mount Heights

For relatively consistent mount heights, the graph below listssuggested parameters. This graph represents cured mountheights for mounting media only. The volume of the sample hasnot yet been considered. To compensate for sample volume,the following table is given as an example.

Mold DiameterPowder orPremoldWeight

SampleDimensions

Mold Height

1.00 inch(2.54 cm)

8 grams 1/2 d x 3/8 t 5/8 inch

1.25 inch(3.18 cm)

13.5 grams 5/8 d x 3/8 t 5/8 inch

1.50 inch(3.82 cm)

18.6 grams 15/16 d x 3/8 t 5/8 inch

0 5 10 15 20 250

0.5

1.0

1.5

MOUNTINGHEIGHT

(INCHES)

WEIGHT (GRAMS)POWDER OR PREFORMS

Operation PR-25 3–1

3 Illustrations .......................................................................... 3–2

Controls and Indicators........................................................... 3–3

Operation............................................................................. 3–5

Molding Pressures and Times ................................................... 3–8

Operation

3–2 PR-25 Operation

Illustrations

Figure 3–1......... Pressure Gauge .........................................3–4

Figure 3–2......... Controls and Indicators...............................3–4

Figure 3–3......... Double Mount Cross-Section ........................3–9


Controls and Indicators

• Refer to figure 3-2, page 3–4, for control and indicatorlocations.

Ram Down Knob—Turning the knob clockwise closed thehydraulic cylinder. Turning the knob counterclockwise releasesthe applied pressure.

Ram Control Knob—This knob is used to raise and lower theram piston.

Pressure Regulator Control Knob—Used for adjusting moldpressure. Rotate clockwise to increase pressure,counterclockwise to decrease pressure. Use the outside lockring to lock unit at desired pressure.

Pressure Gauge—Indicates the proper pressure setting for eachavailable mold size (figure 3-1, page 3–4). The inner scale isfor the 1.00 inch mold assembly; the middle scale is for the1.25 inch mold assembly; the out scale is for the 1.50 inchmold assembly. The red dots represent 4200 psi within therespective mold assemblies. All of the scales are represented in"psi x 1000" and "bars x 70."

Timer—The timer is a mechanical-type timer and is adjustablefrom 0 to 20 minutes. There will be an audible ring when presettime has expired.

Power Light—This red light, located on the heater coolerassembly, indicates that power is on to the heater coolerassembly.

Heater Light—This amber light will only be lit when the heaterelements are on and working. The heater elements areregulated by a thermostat, so the heater light will flicker on andoff periodically.

Cool/Heat Knob—Used as a power switch for the heater cooler.Turn clockwise to heat; turn counterclockwise to cool.

Note


Figure 3–1Pressure Gauge

Figure 3–2Controls and Indicators

807-540COLLAR

807-426 - 230V806-951 - 115V

AMBER INDICATORHEAT

807-427 - 230V806-952 - 115VRED INDICATOR

POWER

807-533PRESSURE

GAUGE

808-711TIMER KNOB

808-713RAM DOWN

KNOB

808-712COOL/HEAT

KNOB

803-435PRESSURE

REGULATOR

807-573RAM CONTROL


Operation

• All installation steps must be completed before operatingthis instrument.

• Hydraulic fluid may have been dispersed in shipment.Before using:

1. Set the pressure control knob clockwise to full close.

2. Operate the pressure handle until the mold cylinder isfully extended.

3. Set the pressure control knob one full turncounterclockwise and push the mold cylinder down innecessary.

4. Repeat this process several times.

• LECO recommends using the silicone release agent for thefirst 25 mounts, thereafter, only occasionally.

1. Make sure the instrument air and water supplies areturned on, and the power on/off switch is in the offposition.

• To avoid the cottonball effect when processing Lucite(thermoplastic) mounts, disconnect the water inlet on theback of the mounting press via the quick disconnect prior tomaking a mount. Process mounts as outlined and allowgradual cooling. Reconnect the water inlet when processingthermosetting mounting media.

2. Plug the unit into the proper facility power. Refer to theSpecifications section, page 1–16, for additionalinformation.

3. Before making a mount, test the unit as follows:

A. Turn the power switch to heat.

B. Set the timer to 5 minutes. The indicator lights on theheater assembly should immediately light. The powerlight should stay lighted throughout the entire heatcycle. The heater light should regulate with thetemperature of the heater.

C. Once the heat cycle is expired, turn the power switchto the cool position.

Notes

Note


D. Set the timer to 5 minutes.

E. During the cooling cycle, check the rear fittingconnections for leaks. If there are no leaks, the unitis ready for operation.

4. With the top enclosure removed, rotate the pressure knobapproximately 1 full turn counterclockwise to assure thatthe bottom ram is in the down position.

5. Turn the ram down knob clockwise until the closed positionis reached.

6. Turn the ram control selector knob to the up position.

7. Position the sample on the bottom ram.

8. Rotate the ram down knob counterclockwise one full turnto place the bottom ram in the down position.

9. Add mounting media (powder and preform). Refer tofigure 3-3, page 3–9, for additional information.

10. Thread the top enclosure all the way down onto the moldcylinder and then back to top enclosure off one-quarterturn.

• It is very important to back the top enclosure off one-quarter turn. This will reduce the stress on the moldcylinder threads and eases the removal of the topenclosure.

11. Rotate the ram down knob clockwise to the full closeposition.

12. Operate the pressure handle to the desired pressure forthe mold assembly being used.

POSSIBLE MACHINE DAMAGEDo not allow pressure to reach overload range.Pressure can be adjusted using the front panelpressure control knob.

• There will be a definite decrease in pressure as thethermosetting materials are heated through the curingstage. Pressure must be maintained throughout this stage.Pressure will become constant when cure stage temperatureis reached.

Note

CAUTION

!

Note


13. Set the timer to the desired heating time.

14. Once the heat cycle time has expired, turn the powerswitch from the heat position to the cool position.

15. Set the timer to the desired cooling time.

• Continue to keep mold pressure stable.

16. Once the cooling cycle time has expired, rotate the ramdown knob counterclockwise one turn to release thepressure inside the mold cylinder.

17. Turn the ram control selector knob to the neutral position.

18. Unscrew the top enclosure from the mold cylinder. Thespring inside the top enclosure will hold the threads apartthroughout the ejection process.

19. Rotate the ram down knob clockwise to full closure.

20. Turn the ram control selector knob to the up position.

21. Remove the top enclosure and place it in the holder ring.

HIGH TEMPERATURE HAZARDMounted specimens may be hot.LECO recommends wearing hear resistant gloveswhen removing mounted specimens.

22. Remove mounted specimens.

23. After each mount, clean the flashing off of the bottom ramto ensure movement of the bottom ram inside the moldcylinder.

Note

WARNING


Molding Pressures and Times

Time(Minutes)

MountingMaterial Temperature Pressure 1.25 inch

(3.18 cm)Mold

1.50 inch(3.82 cm)

Mold

2.00 inch(5.08 cm)

Mold

Thermosetting Powder Preform Powder Preform Powder

Bakelite4200 psi

(289.58 bars) 8 7 10 8 12

Epoxy1000 to 2000 psi(68.95 to 137.89

bars)8 N/A 10 N/A 12

DiallylPhthalate

285oF to 300oF(140oC to 150oC)

3000 psi(206.84 bars) 9 N/A 12 N/A 12

ThermoplasticTime

(Minutes)

Heat285oF to 300oF

(140oC to 150oC)

100 psi(6.89 bars) 30

LuciteCool

100oF(38oC)

4200 psi(289 bars)

30 Air Cool20 Water Cool


• When making a double mount, make sure that the powdermedia is approximately even across the cylinder beforeinserting the spacer and the top enclosure. This will reducethe forces on the rams and spacer, which in turn will makeit easier to remove the sample

Figure 3–3Double Mount Cross-Section

HANDLE TOP807-842 - 1.25"807-843 - 1.50"807-844 - 2.00"

PIGGY BACK SPACER807-919 - 1.25"807-920 - 1.50"807-921 - 2.00"

MOUNT

Note

Maintenance PR-25 4–1

4 Molding Defects..................................................................... 4–3

Thermosetting Materials ................................................ 4–3

Thermoplastic Materials ................................................. 4–4

Heater Cooler Removal........................................................... 4–5

Maintenance

4–2 PR-25 Maintenance



Molding Defects

Thermosetting MaterialsDefect Cause Remedy

Section too large for moldarea.Sharp corner on specimen.

Reduce specimen size.Use larger mold size.Eliminate sharp corners ifpossible.

Material has absorbedmoisture.Gases released bychemical reaction.

Use preheated powderor preforms.Momentarily releasepressure during flowstage.

Poor adhesion to samplesurface.Excessive shrinkage atinterface.

Use lower moldingtemperature.

Insufficient pressureand/or cure time.

Adjust molding pressure.Increase cure time.

Insufficient pressureand/or cure time.Curing or powder particlesprior to flow stage.

Adjust pressure and/orcure time.Rapidly seal mold closureand apply pressure toeliminate localized curing.

Excessive moldtemperature.

Decrease moldtemperature.Momentarily releasepressure during flowstage.

• If mold temperature is too high, the following difficultiesmay also be encountered:

1. Mounts sticking to mold surface regardless of finish orapplication or release agent.

2. Dull surfaces on mounts.

3. Excessive flash.

4. Mold staining.

Note

4–4 PR-25 Maintenance

Thermoplastic MaterialsDefect Cause Remedy

Center portion of mediumdid not reach maximumtemperature prior to curestage.

Increase holding time atmaximum temperature.

Inherent stresses relievedupon or after ejection ofmount.

Cool to a lowertemperature prior toejection.Decrease pressure duringcure stage.Stress relieve mounts inboiling water.


Heater Cooler Removal

• Remove the heater cooler assembly only when the unit is atambient temperature. Due to thermal expansion, the heatercooler may slide off the mold cylinder if removed whenwarm. If this happens, warm the heater cooler and adjust itback onto the mold cylinder.

1. Before removing the heater cooler assembly, spray themold cylinder with silicone release agent.

2. Run the bottom ram up and down inside the mold cylindera few times. This will help release the mold assembly fromthe bottom ram and will also treat the inside diameter ofthe mold cylinder for storage.

3. Install the top enclosure onto the heater cooler assemblyand set the mold pressure to zero.

4. Disconnect all connections from the rear of the heatercooler assembly.

5. Pull the locking pin out and turn the assembly to a 45degree angle (figure 2-3, page 2-6).

6. Place the ram control lever in the up position.

7. Slowly increase the pressure until you hear the pumpcycling slowly. Do not pull up on the heater coolerassembly shroud. Let the pump do the work.

8. If the heater cooler assembly is properly located, it shouldbegin to extend out of the collar. Once the base of theheater cooler assembly is out of the collar, turn the heatercooler assembly back to its center position (figure 2-4,page 2-6).

9. Position the ram control lever to the down position. Whenthe pump stops running, the ram is out of the moldcylinder and the heater cooler assembly can now beremoved.

Note

Illustrations PR-25 5–1

5 Figure 5–1......... Interior—Left Side View ..............................5–3

Figure 5–2......... Interior—Right Side View ............................5–4




Figure 5–6......... Heater Cooler Assembly ..............................5–8

Figure 5–7......... Switch Assemblies .....................................5–9

Figure 5–8......... PR-25 Flow Diagram...................................5–10

Illustrations

5–2 PR-25 Illustrations



Figure 5–1Interior—Left Side View

814-006CYLINDER MOUNT

AND BEARINGASSEMBLY

814-001AIR

CYLINDER

807-593TOP PANELASSEMBLY

807-533HYDRAULICPRESSURE

GAUGE

807-534ADAPTERFITTING

803-435PRESSURE

REGULATOR

807-502SUPERSTRUCTURE

ASSEMBLY

190-018SHOULDER

SCREW807-564

4 WAY AIRPILOT VALVE

805-798-110ROTARY SWITCH

807-525LOWER FRONT

PANEL ASSEMBLY


Figure 5–2Interior—Right Side View

803-254MECHANICAL

TIMER

807-573PNEUMATICCONTROL

VALVE

807-888FILTER

807-523 (115V)807-550 (230V)TIMER RELAY

807-520 (115V)807-548 (230V)WATER VALVE

ASSEMBLY

805-798-1102 POSITION

ROTARY SWITCH


Figure 5–3Exploded View—1

807

-567

FIT

TIN

G

807-

598

INS

UL

AT

ION

193-

110

WA

SH

ER

(7 R

EQ

'D)

193

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WA

SH

ER

(7 R

EQ

'D)

190-

269

SC

RE

W(1

0 R

EQ'D

)80

7-59

5R

IGH

T PA

NE

L

767-

866

FITT

ING

603-

061

FIT

TIN

G

544-

184

RE

DU

CE

R 807-

581

PL

UG

772-

710

RE

DU

CE

R

800-

299

FITT

ING

(W/ N

UT) 80

7-54

3 (1

15V

)80

7-55

1(23

0V)

PO

WE

R C

OR

D

804-

711

AD

AP

TE

R

900-

259

NU

TF

ITTI

NG

807-

591

RE

AR

PA

NE

L

780-

397

FIT

TIN

G

807

-47

1F

ITTI

NG

772-

614

FITT

ING

807

-598

INS

UL

ATI

ON

807-

594

LE

FT P

AN

EL

807-

533

GA

UG

E(W

/HA

RD

WA

RE

)

807-

596

UP

PE

R F

RO

NT

PAN

EL 80

7-53

4N

IPP

LE

807-

888

AIR

FIL

TE

R80

3-43

5R

EGU

LA

TOR 80

7-57

3C

ON

TR

OL

VA

LVE

(W/ N

UT)

807-

566

FIT

TIN

G(2

RE

Q'D

)

193-

113

WA

SH

ER

193-

055

WA

SH

ER

(2 R

EQ

’D)

193-

055

WA

SHE

R(2

RE

Q’D

)

193-

110

WA

SH

ER

(3 R

EQ

’D)

190-

824

SC

RE

W(3

RE

Q’D

)

803-

254

TIM

ER

(W/ N

UT

)

805-

798-

110

SE

LEC

TO

R S

WIT

CH

194-

055

NU

T(4

RE

Q'D

)

194-

110

NU

T(3

RE

Q'D

)

194-

056

NU

T(2

RE

Q'D

)

194-

056

NU

T(2

RE

Q'D

)

807

-631

SL

EE

VE

808-

523

RE

LIE

F VA

LVE

807-

565

FIT

TIN

G(2

RE

Q'D

)

808-

711

KN

OB

(W/ S

CR

EW

S)

808-

713

KN

OB

808-

712

KN

OB

807-

887

SH

AF

T(W

/ HA

RD

WA

RE

)

190-

886

SC

RE

W(4

RE

Q'D

)

807-

525

LO

WE

RF

RO

NT

PAN

EL

190-

926

SC

RE

W(2

RE

Q'D

)

778-

523

FITT

ING

(3 R

EQ

'D)

(OP

TIO

NA

L)W

AS

HER

(2 R

EQ

'D)

193-

008

WA

SH

ER

(3 R

EQ'D

)

801-

238

PL

UG



780-970LEVELING FOOT

(4 REQ'D)

193-010WASHER(2 REQ'D)



190-929SCREW

(2 REQ'D)

190-753SCREW

(4 REQ'D)

807-590BASE

807-565FITTING

(3 REQ'D)

589-855FITTING

800-271MUFFLER(2 REQ'D)

602-167ELBOW

(2 REQ'D)

190-750SCREW

193-127WASHER

807-523 (115V)807-550 (230V)

RELAY

807-521 (115V)807-549 (230V)

SOLENOID

807-522FILTER

193-110WASHER

773-41RESISTOR

807-5644 WAY VALVE

190-750SCREW

(2 REQ'D)

778-523FITTING

807-763VALVE

778-523FITTING

(2 REQ'D)

807-539COLLAR

807-575COLLAR WASHER

807-593TOP PANEL

807-542PLUNGER

807-538HANDLE HOLDER

806-764BOX HOLDER


190-269SCREW

(2 REQ'D)

190-324SCREW

(4 REQ'D)

807-447WARNING LABEL



AB



814-004TOP PLATE

807-565FITTING

807-565FITTING

190-643SCREW

(4 REQ'D)

190-643SCREW

(4 REQ'D)

807-504SUPPORT ROD

(4 REQ'D)

814-002CYLINDER MOUNT

(2 REQ'D)

814-001AIR CYLINDER

803-234EYE BOLT

807-511SPRING

(4 REQ'D)

190-908SCREW

(2 REQ'D)



807-508PUSH ROD

190-018SCREW

807-506JACK CLEVIS

194-109NUT

807-505JACK

190-837SCREW

814-003BEARING(2 REQ'D)

190-908SCREW

(4 REQ'D)

807-510SCREW

(8 REQ'D)

807-509SPRING PLATE

807-503BOTTOM PLATE

808-499CYLINDERRELEASEADAPTOR

773-705ROLL PIN

807-764LIMIT SWITCH

(2 REQ'D)

190-881SCREW

(2 REQ'D)


194-056NUT

(4 REQ'D)

807-761BRACKET


190-706SCREW

(4 REQ'D)

194-162JAM NUT

190-353SCREW

775-322CAP NUT

773-661FITTING

(2 REQ'D)

773-661FITTING

(2 REQ'D)

RUBBER WASHERINCLUDED WITH FITTING

RUBBER WASHERINCLUDED

WITH FITTING

782-401ELBOWFITTING


Figure 5–6Heater Cooler Assembly

806-549PANEL TOP

807-643BASE HEATER COOLER

ASSEMBLY

190-229SCREW

(4 REQ'D)

807-932-100 - 1.00-INCH807-650-125 - 1.25-INCH807-650-150 - 1.50-INCH

MOLD CYLINDER ASSEMBLY

807-645-030 - 1.00-INCH807-645-030 - 1.25-INCH807-645-030 - 1.50-INCH

HEATER COOLER

190-279SCREW

(4 REQ'D)


804-733CONNECTOR

194-055NUT

(4 REQ'D)

194-056NUT

(2 REQ'D)

807-644TRIM

807-426 - 230V806-951 - 115V

AMBER INDICATOR

807-427 - 230V806-952 - 115VRED INDICATOR

190-624SCREW

(4 REQ'D)


806-956L350

THERMOSTAT

806-958L425

THERMOSTAT

807-656 - 1.00-INCH807-656 - 1.25-INCH807-659 - 1.50-INCHTOP ISOLATION RING

RAM TOP(PART OF MOLD CYLINDER ASSEMBLY)

807-555BOTTOM

ISOLATION RING

521-028BUTTON PLUG

770-233ROLL PIN(2 REQ'D)

774-016HANDLE KNOB

(2 REQ'D)

807-842HANDLE

TOP

190-851SCREW

(2 REQ'D)

807-841SLIDESHAFT

806-987SPRING

807-839TOP PLUG


Figure 5–7Switch Assemblies

24 VDC INDICATOR LIGHT806-932 CLEAR LENS CAP

806-769 LAMPNO RESISTORS

120VAC INDICATOR LIGHT806-952 RED LENS CAP

806-768 LAMP1 RESISTOR

806-951 AMBER LENS CAP806-768 LAMP1 RESISTOR

240VAC INDICATOR LIGHT807-427 RED LENS CAP

806-768 LAMP2 RESISTORS

807-426 AMBER LENS CAP806-768 LAMP2 RESISTORS


Figure 5–8PR-25 Flow Diagram

807-888AIR FILTER

803-435PRESSURE

REGULATOR

807-7643 WAY EXT

VALVE

807-7643 WAY EXT

VALVE

AIR IN

807-573PNEUMATICCONTROL

VALVE

808-52375 PSI

RELIEF VALVE

807-763‘AND’ VALVE

807-564AIR PILOT

4 WAY VALVE

814-001CYLINDER

14

14

13

13

2

1

3

Index PR-25 6–1

6 C

Caution Symbols ............................................................... 1–7

Caution, Operator.............................................................. 1–6

Component Pack............................................................... 1–12

Components and Accessories List ......................................... 1–12

Compression Mounting Supplies........................................... 1–14

Consumables.................................................................... 1–14

Controls and Indicators ...................................................... 3–3

D

Dimensions ...................................................................... 1–16

Double Mount Cross-Section ............................................... 3–9

E

Electrical Power Requirements............................................. 1–16

G

Gases Required................................................................. 1–16

H

Hazardous Material Pack..................................................... 1–12

Heater Cooler Assembly ..................................................... 5–8

Heater Light ..................................................................... 3–3

I

Illustrations List ................................................................ 1–4

Installation....................................................................... 2–3

Interference to Other Devices ............................................. 1–8

M

Major Equipment and Accessories List ................................... 1–9

Molding Defects................................................................ 4–3

Mount Heights.................................................................. 2–7

Index

6–2 PR-25 Index

N

Notice, Operator ............................................................... 1–6

O

Options ........................................................................... 1–13

P

Power Light ...................................................................... 3–3

Pressure Gauge................................................................. 3–3

Pressure Regulator Control Knob.......................................... 3–3

S

Specifications ................................................................... 1–16

Switch Assemblies............................................................. 5–9

T

Thermoplastic Materials ...................................................... 4–4

Thermosetting Materials ..................................................... 4–3

U

Utilities Required............................................................... 1–16

W

Warning Symbols .............................................................. 1–7

Warranty......................................................................... 1–5

Montador A

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Transcript of Montador A