BALA VALVE SYSTEM

Instruction Manual

YUDO BALA VALVE GATE SYSTEM

Ver. 4.5 MN BALA VALVE English

 Greetings

Thank you for using YUDO Hot Runner System.

YUDO fabricated Hot Runner System with its best efforts so

that customers can use it most easily. However, there are many

parts for customers to pay attention because it is a technical product.

Please read this manual well and use it.

YUDO reserves the right to change the provisions of these descriptions

and specifications at any time without notification to customers.

Please discuss with YUDO in advance when technical support is needed.

2
 Contents
1. Basic Structure of YUDO Hot Runner System
1-1 Basic Structure of Cylinder
1-2 Basic Structure of Nozzle
2. Outline of Hot Runner System
3. Kinds of Hot Runner System
3-1 Open Gate, Shut Off Gate, Valve Gate
3-2 Comparison of features between hydraulic and pneumatic type in Valve Gate
3-3 Comparison of features between Valve Gate and Open Gate
4. Features and Use Effect of Valve System
5. Meaning of YUDO Open Nozzle Standard
5-1 BALA 45 Series (Valve VV Type) Specification
5-2 Shape and symbol of gate 5-3 Machining of Cylinder Part
5-4 Nozzle part machining
5-5 Gate part machining 5-6 Machining of Locating Ring Part
5-7 Machining of Lead Wire Slot Part
5-8 MODU Plate Machining (Clamping Plate, Spacer Block, Hold Plate)
5-9 Machining of Sequence System Part
5-10 Machining of Connecting System Part
6. Check Items of Hot Runner System
6-1 Check of Hot Runner System Part 6-2 Electric Check of Hot Runner System
6-3 Dimensional Check of Hot Runner System
6-4 Check items of Gate Park
7. Assembly of Hot Runner System (MODU System)
8. Operation of Hot Runner System
8-1 Installation 8-2 Caution before operation
8-3 Maintenance
9. Disassembly and Assembly
9-1 Disassembly and assembly when replacing various “O” rings of cylinder
9-2 Disassembly and assembly when replacing nozzle heater and T/C
10. How to Recognize Product Standard and System
11. Trouble and Countermeasure
11-1 Not being heated 11-2 Valve pin is not operating or not smooth
11-3 Occurrence of carbonization 11-4 Defect in gate mark 11-5 Resin leakage
11-6 In case that resin leaks on manifold but heater is not disconnected.
11-7 In case that resin leaks on manifold, heater is not disconnected, and coolant leaks
to destroy insulation of heater.
11-8 In case that manifold heater is disconnected.

3
1. Basic Structure of YUDO Hot Runner System

PLAN VIEW

4
SIDE VIEW

5
 Hot Runner and Mold Parts List

No Description No Description
1 Locating Ring 31 Gate Bush
2 Socket Head Cap Bolt 32 Cylinder Cover
3 Clamping Plate 33 Housing
4 Spacer Plate 34 Piston Out
5 Holding Plate 35 Piston In
6 Cavity Plate 36 Snap Ring
7 MODU Ass’y Bolt(B2) 37 “O” Ring
8 Mold Ass’y Bolt(B1) 38 Glyd Ring
9 Socket Head Cap Bolt 39 Wear Ring
10 Center Pin Cover 40 Valve Pin
11 Center Pin 41 Power +T/C Connector
12 Nozzle Locator 42 Solenoid Valve
13 Socket Head Cap Bolt 43 Signal Connector
14 Support Pad 44 One Touch Nipple
15 Pin Guide Bush 45 Silencer
16 Upper Insulation Pad
17 Manifold Block
18 Lock Pin
19 Socket Head Cap Bolt
20 Lower Insulation Pad
21 Dowel Pin
22 Dowel Pad
23 Manifold Thermocouple
24 Sheath Heater
25 Seal Ring
26 Nozzle Body
27 Tube Heater
28 Snap Ring
29 Nozzle Tip
30 Nozzle Thermocouple

6
1) Basic Structure of Cylinder

The role of cylinder is very important in valve gate system.

Cylinder is installed on clamping plate and is operated by signal from injection machine.
Cylinder opens and closes gate by moving valve pin forward and back, which is fixed on piston.
The cylinder provided by YUDO is basically for use of air pressure, and a minimum of 6bar is
necessary.
When it should be needed to use oil pressure, make decision after consulting with YUDO, then
maximum oil pressure, must not exceed 30bar

Cylinder Parts List

No Description VC5804G VC6806G VC7810G
1 Bolt M6*15-4EA
2 Housing Ø 57.9*51 Ø 67.9*54.8 Ø 77.9*59.5
3 Cylinder Cover Ø 80*16.5 Ø 90*18 Ø 110*18
4 Snap Ring C42 C32 C42
5 Piston Out Ø 39.6*21.5 Ø 49.6*23.5 Ø 59.6*23.5
6 Valve Pin Ø4 Ø6 Ø 10
7 Piston In Ø 25.9*33.4 Ø 31.9*34 Ø 36.9*36
8 Viton “O” Ring ARP 221 ARP 224 ARP 228
9 Viton “O” Ring ARP 226 ARP 229 ARP 232
GS55044-0400 GS55044-0500 GS55044-0600
10 Glyd Ring ARP 216 ARP 222 ARP 228
11 Viton “O” Ring ARP 115 ARP 120 ARP 123
12 Viton “O” Ring ARP 219 ARP 223 ARP 227
13 Viton “O” Ring ARP 225 ARP 228 ARP 231
14 Viton “O” Ring ARP 114 ARP 115 ARP 115
15 Wear Ring B=2.5 T=1.55
16 Viton “O” Ring ARP 212 ARP 212 ARP 212

7
2) Basic Structure of Nozzle

Nozzle serves a route to feed the resin injected by injector to cavity, and is a device to maintain
resin at constant temperature until it is injected. Nozzle may be used by selecting proper
specification according to injection amount, and selecting proper type of nozzle according to shape
or characteristics of gate part.

VV Type

Nozzle Parts List

No Description BALA 18 BALA 25 BALA 35 BALA 45 Qty Remark

1 Cu Ring Ø 22×2.3t Ø 32×2.3t 1
2 Nozzle Ø 38×L Ø 50×L Ø 60×L Ø 70×L 1
3 Nozzle T/C NZTPIC□ □ □ □ □ □ or NZTPCA□ □ □ □ □ □ 1
Nozzle
4 HTFR1518□ □ □ HTFR3625□ □ □ HTFR3635□ □ □ HTFR3645□ □ □ 1
Heater
5 Valve Pin Ø 4*L Ø 4×L Ø 6×L Ø 10×L 1
6 Valve Tip Ø 12.5*44 Ø 16×51.5 Ø 22×62 Ø 30×71.5 1
7 Snap Ring ACRICS000180 ACRICS000250 ACRICS000350 ACRICS000450 1
8 VV Type None None None None 1
9 VA Type Ø 25×15 Ø 35×20 Ø 45×25 Ø 55×32 1
10 VAE Type Ø 25×30 Ø 35×50 Ø 45×65 Ø 55×77 1
11 VF Type Ø 25×18 Ø 38×25 Ø 48×30 Ø 58×35 1
12 LVA Type Ø 44×30 Ø 54×40 Ø 64×50 Ø 74×60 1
13 LVF Type Ø 44×30 Ø 54×40 Ø 64×50 Ø 74×60 1
14 TVA Type None Ø 25×30 Ø 35×40.5 None
15 TVL Type None Ø 25×62 Ø 35×83 None

8
3) Basic Structure of Sequence System

Sequence System is a device to regulate opening and closing of gate arbitrarily, which is operated
by set time on sequence timer after receipt of injection signal.

When applying sequence system, it shall be determined how many zones will be controlled and
how many gates will be controlled.

Refer to sequence system manual for other detailed matters.

Sequence System Parts List

No Description Specification Q’ ty Remark

1 Bolt M5*70 4
2 Air Manifold Flat head Cap M3*8 1
3 Air Nipple PT 1/4” Coupler 1
4 Silencer PT 1/4” 2
5 Sealing Plate 50*26*1.5T 1 Quantity per Sol Valve
6 Bolt M4*40 4 Quantity per Sol Valve
7 Solenoid Valve SF-2120 1
8 Sealing Plate 80, 140*45*1.5T 1 For 2, 4Zone
9 Insert (Male) 56*23*33, 72.4*23*33 1 Screw Terminal (10P 16P)
10 Bolt M4*12 4
11 Housing 74.5*50*52, 91*50*57 1 Use of 10P 16P

9
2. Outline of Hot Runner System

Hot runner system is a method devised to produce product continuously without spure and
runner by heating sprue and runner which serve as a route of melted resin in order to fill cavity
in plastic injection mold and by maintaining it as melted state.

Advantage and Disadvantage of Hot Runner System

◈ Advantage

1) Because product must be produced using 100% of new resin without any loss at all the time,
defect or trouble due to foreign material can be prevented.

2) Filling up cavity is needed only, because resin is always being melted up to gate, thus the
time of injection, measurement, cooling and frame opening/closing is shortened as well as
the time to take out sprue and runner.

3) Improvement of product quality

Because the injection pressure of injection molder is directly transferred to cavity, the
problem of product shrinkage, weld, and deformation due to internal stress can be solved.

4) Increase of mechanical efficiency

Efficiency of molder is enhanced because injection quantity, pressure, mold opening
distance may be decreased as much as the amount of sprue and runner.

5) Extension of mold life

The pressure exerted on the mold is decreased due to decrease of injection pressure and 3-
stage mold of large type may be converted into 2-stage mold in case of using hot runner
system, so that the trouble which can occur in 3-stage mold may be prevented.

◈ Disadvantage

1) Increase of mold cost : Hot runner components and controller are necessary.

2) Technical manpower is necessary for maintenance and repair.

3) Sufficient review is necessary for mold design depending on shape of resin and product
used.

10
3. Kinds of Hot Runner System

1) OPEN GATE
a. Direct Gate : This is the most basic system where flow route is equipped with heater.
(There are BALA series in YUDO.)
b. Pin Point Type Gate : Gate mark may be minimized, but a little more pressure is required.

Type Basic Shape Product Shape of Gate Part Nozzle Type

Direct Gate BALA TOE,
TOL System

Pin Point Type BALA CC, CA,

Gate CF System

SHUT – OFF GATE

a. Spring Type Valve Gate : This is the most simple valve gate system, but much injection
pressure is required, so that gate mark is unstable.(There are no related products in YUDO)

b. Electrical Shut–off Gate : This may be mainly used for small products, but special
temperature control device is required, and high technology is required for management of
function.(LOVO Series Nozzles of YUDO)
2)Valve Gate
Hydraulic Valve Gate
Advantage Disadvantage
a. High pressure can be obtained by using a. Hydraulic unit is required.
relatively small cylinder. b. Because oil is used, there is much possibility of oil
b. The life of “0” ring used is long relatively. leakage and surrounding is not clean when oiling.
c. Operation and management is difficult.
d. There are many elements of troubles due to
carbonization of oil.
e. Response speed is slow relatively.

Pneumatic Valve Gate

Advantage Disadvantage
a. Structure is simple. a. Relatively large cylinder is required.
b. Response speed is relatively fast. b. The life of “0” ring is shorter than hydraulic type.
c. Operation and management are easy.
d. Equipment investment cost is relatively small.
e. Because air is used, damaging of “0” ring does not
cause contamination of surrounding.

11
3) Comparison of features between hydraulic and pneumatic type in valve gate
For Valve system of YUDO, pneumatic system is used as standard, hydraulic system as special
option. If you want to use hydraulic system, you should consult YUDO in advance in order to
regulate system changes. The problem occurring due to misuse of hydraulic system on valve
system will not covered under quality guarantee of YUDO.
Even in case of using hydraulic system, YUDO standard is designed to apply 30 bar or less
pressure, and is designed to be operated smoothly under maximum 30 bar or less pressure.
But also, the problem caused by less than specified pressure is out of quality guarantee scope.
Major specification difference between pneumatic type and hydraulic type is as follows:
① The gap in “0” ring part which is installed on piston, cylinder, etc. is different.

In case of hydraulic In case of pneumatic

Drawing
system system

A minimum of 0.08 and a A minimum of 0.39 and a

maximum of 0.13 are used maximum of 0.46 are used
for gap between piston and for gap between piston and
housing of YUDO cylinder. housing of YUDO cylinder.

② Compression quantity of “0” ring installed on piston, cylinder, etc. is different.

In case of hydraulic In case of pneumatic

Drawing
system system

A minimum of 0.65 and a A minimum of 0.37 and a

maximum of 0.72 are used maximum of 0.44 are used
for compression quantity of for compression quantity of
“O” ring used in YUDO “O” ring used in YUDO
cylinder. cylinder.

Maximum allowable pressure of YUDO hydraulic valve : 30 bar

12
③ The length of valve pin is different. In case of hydraulic valve, the length of valve pin should
coincide with the normal dimension of mold. but The dimension of pneumatic valve is 1mm
longer than normal dimension. There is allowance space where piston could advance 1mm
more. Therefore, applying hydraulic system on YUDO system without adjusting valve pin
causes damage on piston cover of gate or causes bending phenomenon of valve pin.
In case of hydraulic system In case of pneumatic system

The length of hydraulic valve pin should be adjusted

to normal dimension. Allowance may cause damage of
gate.

④ The machining angle of gate and the machining angle of valve pin nose are different.
(Gate of taper type)
In case of hydraulic system In case of pneumatic system

⑤ Gate machining shape is same in case of straight type. It is better to use straight type gate in
case of using hydraulic system.
In case of hydraulic system In case of pneumatic system

13
 4) Comparison of features between valve gate and open gate
Division Open Gate Valve Gate
Gate - Not clean - Beautiful
Mark
- There is drool problem. - There is no drool phenomenon
- It is necessary to remove the drooled resin
(after pause)
Drool - Nozzle should be operated at relatively
problem high temperature.
- There is possibility of problem when
changing mold.

- Change of injection condition pursuant to - Low pressure injection is possible with

Injection gate temperature large gate
pressure - Decrease of twisting and stress due to
decrease of stress within cavity
- Change of injection speed pursuant to - Constant injection speed
gate temperature - High-speed injection is possible.
Injection
- Shortening of cycle time
speed
- Pressure compensation time may be
removed or minimized.
- Increase and decrease of efficiency - possible to be widely used in all heat-plastic
Resin
pursuant to resin characteristics resin
used

4. Features and Use Effect of Valve System

Valve pin may be closed while injection pressure is maintained in mold after injection and help
plasticizing for the next shot material supply, then afterwards injection pressure may be transferred
to cavity at the opening of gate as soon as mold closes.

If the quantity and shape of molding product are composed of several different cavities or in case
that large mold product is composed of several gates, it is possible to regulate filling amount of
each cavity through sequence operation in order to improve or move weld line and so on.

Valve gate system enables to make gate larger, so that low-pressure molding and high-speed
molding are possible for this system, and molding may be performed without difficulty up to the
end of product.

Because gate is plugged up by valve pin, it is possible to make gate seal perfect, which enables
product to gain good surface with clean gate mark, to improve product quality by decreasing of
internal stress and reducing of molding deformation, and extending life time of mold.

As gate may be made relatively larger, it is possible to make product thickness thin and to shorten
cooling time.

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 5. Meaning of YUDO Valve Nozzle Standard

1) BALA Series (Valve Type) Specification

BALA 18 Series
HEATER T/C HEATER T/C
Nozzle Model L Nozzle Model L
MODEL MODEL MODEL MODEL
BIM18-□□□-075 75 HTFR180350 NZTP[CA,IC]100450 BIM18-□□□-125 125 HTFR180850 NZTP[CA,IC]100950
BIM18-□□□-085 85 HTFR180450 NZTP[CA,IC]100550 BIM18-□□□-135 135 HTFR180950 NZTP[CA,IC]101050
BIM18-□□□-095 95 HTFR180550 NZTP[CA,IC]100650 BIM18-□□□-145 145 HTFR181050 NZTP[CA,IC]101150
BIM18-□□□-105 105 HTFR180651 NZTP[CA,IC]100750 BIM18-□□□-155 155 HTFR181150 NZTP[CA,IC]101250
BIM18-□□□-115 115 HTFR180751 NZTP[CA,IC]100850 BIM18-□□□-165 165 HTFR181250 NZTP[CA,IC]101350

♦ Nozzle length “L” : Minimum = 75mm Maximum = 175mm

♦ T/C Type : IC or CA

15
 BALA 25 Series
HEATER T/C HEATER T/C
Nozzle Model L Nozzle Model L
MODEL MODEL MODEL MODEL
BIM25-□□□-090 90 HTFR36250430 NZTP[CA,IC]160550 BIM25-□□□-140 140 HTFR36250930 NZTP[CA,IC]161050

BIM25-□□□-100 100 HTFR36250530 NZTP[CA,IC]160650 BIM25-□□□-150 150 HTFR36251030 NZTP[CA,IC]161150

BIM25-□□□-110 110 HTFR36250630 NZTP[CA,IC]160750 BIM25-□□□-160 160 HTFR36251130 NZTP[CA,IC]161250

BIM25-□□□-120 120 HTFR36250730 NZTP[CA,IC]160850 BIM25-□□□-170 170 HTFR36251230 NZTP[CA,IC]161350

BIM25-□□□-130 130 HTFR36250830 NZTP[CA,IC]160950 BIM25-□□□-180 180 HTFR36251330 NZTP[CA,IC]161450

♦ Length of “L” : Minimum = 90mm Maximum = 320mm

♦ T/C Type : IC or CA

BALA 35 Series
HEATER T/C HEATER T/C
Nozzle Model L Nozzle Model L
MODEL MODEL MODEL MODEL
BIM35-□□□-090 90 HTFR36350380 NZTP[CA,IC]160450 BIM35-□□□-140 140 HTFR36350880 NZTP[CA,IC]160950

BIM35-□□□-100 100 HTFR36350480 NZTP[CA,IC]160550 BIM35-□□□-150 150 HTFR36350980 NZTP[CA,IC]161050

BIM35-□□□-110 110 HTFR36350580 NZTP[CA,IC]160650 BIM35-□□□-160 160 HTFR36351080 NZTP[CA,IC]161150

BIM35-□□□-120 120 HTFR36350680 NZTP[CA,IC]160750 BIM35-□□□-170 170 HTFR36351180 NZTP[CA,IC]161250

BIM35-□□□-130 130 HTFR36350780 NZTP[CA,IC]160850 BIM35-□□□-180 180 HTFR36351280 NZTP[CA,IC]161350

♦ Length of “L” : Minimum = 90mm Maximum = 390mm

♦ Two Heaters and Two T/C are applied for over “L” 320mm.
♦ T/C Type : IC or CA

♦
BALA 45 Series
HEATER T/C HEATER T/C
Nozzle Model L Nozzle Model L
MODEL MODEL MODEL MODEL
BIM45-□□□-110 110 HTFR36450530 NZTP[CA,IC]160550 BIM45-□□□-160 160 HTFR36451030 NZTP[CA,IC]161050

BIM45-□□□-120 120 HTFR36450630 NZTP[CA,IC]160650 BIM45-□□□-170 170 HTFR36451130 NZTP[CA,IC]161150

BIM45-□□□-130 130 HTFR36450730 NZTP[CA,IC]160750 BIM45-□□□-180 180 HTFR36451230 NZTP[CA,IC]161250

BIM45-□□□-140 140 HTFR36450830 NZTP[CA,IC]160850 BIM45-□□□-190 190 HTFR36451330 NZTP[CA,IC]161350

BIM45-□□□-150 150 HTFR36450930 NZTP[CA,IC]160950 BIM45-□□□-200 200 HTFR36451430 NZTP[CA,IC]161450

♦ Length of “L” : Minimum =100mm Maximum =320mm

♦ Two Heaters and Two T/C are applied for over “L” 320mm.
♦ T/C Type : IC or CA

16
2) Shape and symbol of gate

Model and
Gate Shape Application
Symbol
BIM □ □ VV - Common gate with the widest application scope
(Gate is directly machined on cavity plate)

BIM □ □ VA - Insertion of gate bush into “VV” type

- Solution of machining difficulty on gate part

BIC □ □ VAE - Used for color change and the resin with large heat
deformation

BIM □ □ VF - Insertion of gate bush into “BAC” type

- Used for color change and the resin with large heat
deformation
- Solution of machining difficulty on gate part
BIM □ □ LVA - Circulation of coolant in nozzle nose
- Maintenance of temperature around gate
- Solution of machining difficulty around gate

3) Machining of cylinder part

1) Because the dimension around * mark is important, exact machining is required.
2) Entrance part and side part where “0” ring is inserted should be machined by taking care of
roughness. If roughness is not smooth, it may cause damage of “0” ring when assembling cylinder.
3) Tolerance and dimension should be observed in order to fix cylinder exactly and to maintain
valve pin protrusion quantity constant.
4) In case of gun drill type, the entrance part ⓐ where cylinder is inserted and the entrance
part ⓑ in air line hole should be rounded or chamfered. If rounding or chamfering is not
carried out, it may cause damage in “0” ring when assembling cylinder.

ⓐ part machining detail

17
◈ Cylinder Area Machining – VC 58, 68, 78 (Pneumatic Cylinder)

Nozzle
VCD1 VCD2 VCD3 VCD4 VCH1 VCH2 VCH3 VCH4 VCH5 VCG1 VCG2 PCD
Model
VC 58 55 58 80 7 10 1 26.5 50 2.5 20 42 67
VC 68 65 68 90 7 11.5 1.5 29.5 55 2.7 22.5 47 77
VC 78 75 78 100 8 11.5 1.5 31.5 58 4 23 50 87
VC 88 85 88 110 8 11.5 1.5 31.5 58 4 23 50 97

◈ Cylinder Area Machining – VCH 78 (Hydraulic Cylinder)

18
◈ Cylinder Area Machining – VC 85 (Pneumatic Cylinder)

◈ Cylinder Area Machining – VC 29, 35, 40, 50 (Pneumatic Cylinder)

Cylinder Model VCD1 VCD2 VCD3 N PCD VCH1 T1 CT A1 A2

VCM29□ □ GP 29.5 55.5 4 22.25 44.5 2 6.5 50 55 45
6.5 50
VCM35□ □ GP 35 61 4 25 50 2
10 60
6.5 50
60
VCM40□ □ GP 40 66 5 27 54 2
10 65 35 45
70
6.5 50
VCM50□ □ GP 50 76 5 32 64 3 65
10
70

19
4) Nozzle part machining
1) The part with * mark should be precisely machined.
2) YUDO requires hold plate by all means in using hot runner. Of course, there is no problem
in using YUDO system by directly attaching nozzle to cavity plate. However, hot runner
disambling and assembling is repeated on the way of test injection and correction of mold,
this may cause of resin leakage, heater line blockage, etc. But also increase of manhour
causes more cost than addition of hold plate in terms of total cost in the end, and causes
drop in reliability of mold.
Structure of general hot runner Structure with hold plate required by YUDO

3) Machine the space where nozzle

flange part will be inserted in hold
plate.
4) Machine lead wire slot.
Machine heater so that lead wire may
be come out of the lower surface of
hold plate. Only such arrangement
makes it possible to change heater
directly on ianjection machine
without disambling and assembling of
hot runner in case of line
disconnection.
5) Use M8-P1.25 tap for manifold
clamping bolt.
Bolt position is 68mm in manifold
width direction and 60mm in length direction as shown in the drawing below.

MODEL L ØD ØD1 ØD2 H1

BIM 18 V□ □ □ □ □□□ 32 38 40 2.5
BIM 25 V□ □ □ □ □□□ 40 50 55 3
BIM 35 V□ □ □ □ □□□ 50 60 65 3
BIM 45 V□ □ □ □ □□□ 60 70 75 3

20
5) Gate part machining
(1) VV Type Gate
The most important dimension is ØD1. It is designed so that
inflow of resin into heater part may be prevented by side
contact of ØD1 and nozzle end part.
L2 dimension is important, but there is thermal expansion, so
that L2 section is not major point of resin leakage.
There should be coolant hole within a maximum of 20mm
from gate center.
Unit : mm
MODEL VVD1 VVD2 VVD3 VVD4 VVH1 VVH2 VVH3 VVH4 VVH5 VVR1
BALA 18 5.68 14 18 32 2 9.21 12 14.5 46 1.5
BALA 25 7.42 20 25 40 2.5 13.4 15 18 20 2
BALA 35 10.31 82 35 50 3 18.32 20 23 25 2.5
BALA 45 14.89 38 45 60 4 24.02 25 28 30 3

(2) VA Type Gate

There should be coolant hole within

A maximum of 20mm from gate center.

MODEL VAD1 VAD2 VAD3 VAH1 VAH2

BALA 18 8 20 32 2 10
BALA 25 12 28 40 2.5 12
BALA 35 14 38 50 3 17
BALA 45 20 48 60 3.5 20

(3) TVA Type Gate

MODEL TVD1 TVH1 TVAD TVLD E

BALA 18
BALA 25 40 2.5 14 12 30
BALA 35 50 3 18 14 40
BALA 45

21
 (4) VF Type Gate

There should be coolant hole within a maximum of

35mm from gate center.

Unit :mm
MODEL VFD1 VFD2 VFD3 VFD4 VFD5 VFH1 VFH2 VFH3 VFH4 VFH5
BALA 18 8 20 28 32 3 2 9.5 10 18 11.5
BALA 25 12 28 39 40 6 2.5 11 12 25 15.5
BALA 35 14 38 48 50 6 3 16 17 30 20
BALA 45 20 48 58 60 6 3.5 19 20 35 24.5

(5) LVA, LVF Type Gate

There should be coolant hole within a maximum

of 35mm from gate center.

Unit: mm
MODEL LVD1 LVD2 LVD3 LVD4 LVD5 LVH1 LVH2 LVH3 LVH4
BALA 18 8 20 38 45 4 2 10 20 11.5
BALA 25 12 28 48 55 6 2.5 12 30 15.5
BALA 35 14 38 58 65 6 3 17 38 20
BALA 45 20 48 68 75 8 3.5 20 45 24.5
LVH5 = Cavity Thickness – LVH3

Standard Length of
MODEL
Long Gate Bush
BALA 18 30
BALA 25 40
BALA 35 50
BALA 45 60

22
(6) VV Type Gate Machining Method
a. Cut and rough the part while nozzle will be assembled on cavity plate
with machining center.
ⓐ part should be cut as circular machining at first so that reference may
be caught during discharging machining of gate part.
ⓑ part should be machined with drill or end mill as roughing concept.

b. Cut the part where nozzle end part will be assembled.(ⓒ part in the

drawing).
Adjust depth while machining circle at machining
center because this part has precise tolerance.
Circle machining method is shown in the drawing.

c. Machine ⓓ part by machining shape with end mill.

d. Machine the gate in rough state using end mill with 0.5mm
side allowance.

e. Machine the gate part with electric discharge. Discharge electricity with sufficient time in order
to make it smooth as far as possible because gate part is a flow route of resin. Machine the gate
part with electric discharge by all means.The reasion is that precise machining is necessary to
avoid gate deformation to product surface direction due to machining force in case that cavity is
weak. But also when tool swings, the concentricity between ⓒ
part and gate will not coincide with each other, in case that
machining is performed with end mill or drill. Shape of jig for
electric discharge is shown in the drawing.
It is possible to maintain surface hardness of gate and to lengthen
the life of gate through heat-treatment of gate surface by electric
discharge machining.

23
6) Machining of Locating Ring Part
Use of MNL 35

① Locating ring fixes mold and nozzle locator to mold and functions as a guide to set the mold
center at center of injection machine holding plate. Locating ring seat should be fixed so as not to
be moved by machined hole on clamping plate by all means. And, some part(a part) of locating
ring should be designed so as to be pressed by injection machine fixing plate. Fixing of locating
ring with only locating ring fixing bolt may be a cause of resin leakage by injection back pressure.
Moving of locating ring may be a cause of resin leakage between nozzle locator and manifold.
② Machine locating ring seat on
clamping plate.
③ Machine seat of nozzle locator on
clamping plate in order to assemble
nozzle locator.
④ Locating ring should be machined
in accordance with specification of
injection machine.
⑤ Refer to the drawing in the right
side for machining method.

7) Machining of Lead Wire Slot Part

① Machine the lead wire slot by selecting a hole of proper size according to wire quantity.
② Wire surface should be prevented from being damaged by machining the solt in the proper
round(minimum R10) at the part where wire slot is bent.
③ Lead wire slot should be machined differently according to quantity of wire.
④ Wire slot machining size pursuant to the quantity of wire is as follows.

Nozzle Lead Wire Slot Machining Detail

W = 26 W=46

DP Zone DP Zone

10 1~2 10 1~4

15 3~4 15 5~8

20 5~6 20 9~12

25 7~8 25 13~15

30 9~10 30 16~18

24
8) MODU Plate Machining(Clamping Plate, Spacer Block, Hold Plate)
① Machine the guide pin hole for fixing MODU plate position. It is more advantageous to
machine those 3 MODU plates and cavity plate simultaneously when machining guide pin
hole. Simultaneous machining can reduce error due to machining during MODU plate
assembly.
② Machine the dimension by referring to the drawing.
③ Machine the bolt hole for fixing
MODU plate. Machine the hole in
clamping plate and spacer block, and
machine tap in hold plate.
④ Bolt(B2) standard differs according to
mold base standard. If the size of mold
base is 600mm or less, install 4 or more
M16 bolts ; and if the size of mold base
is 600mm or more, install more than 6
units of M16 bolts or 4 units of M20
bolts.
⑤ Machine bolt hole(B1) for fixing
MODU plate and cavity plate.Machine
the hole on MODU plate and machine
the tap on cavity plate.Follow the
dimension specification for machining
position and bolt specification, and the
enterprise should provide exact location
and specification when ordering
MODU.
⑥ The length of ØD H7g6 part of guide
pin should be H+5mm or more longer
from the hold plate face(cavity plate
position should be fixed in advance of
fixing the end part of nozzle when assembling MODU), and the length of ØD-3 part should
be fabricated 10~15mm longer than the longest nozzle(cavity plate position is guided first,
rather than nozzle tip end part when assembling mold first). Otherwise, the end part of nozzle
tip contacts with mold and is damaged when assembling MODU plate on mold.
⑦ Guide pin specification is as follows
Standard used D D1 D2 D3 H H1 Mb
CPN30L 30 35.5 46 60 10 8 M6
CPN40L 40 45.5 67 90 20 10 M12
CPN254L 25.4 30.5 46 60 10 8 M6
CPN3175L 31.75 35.5 46 60 10 10 M6

25
⑧ Guide pin is 10~15mm longer than nozzle to be assembled to cavity plate first, so that nozzle
is guided by cavity plate.

⑨ Because precise fitting is made when assembling ⓐ part of nozzle, guide pin must be
assembled to cavity plate first to play a role of guide.

26
9) Machining of Sequence System Part

Machine mold by referring to the drawing in order to use YUDO sequence system.
Machine clamping plate, spacer block, and hold plate after selecting solenoid valve attaching
position on mold.
It is more convenient to install it on the upper side of mold or to the opposite surface of worker.
Refer to YUDO timer manual for detailed use method.
square Connector 16P

square Connector 10P

Each of L and L1 is a dimension of position

to be processed according to each zone
use of 64

use of 48

Each of 1,2,3 and 4 zone is a quantity of hole

to be processed according to each zone

27
10) Machining of Connecting System Part

Connector is a component used to make electric connection smooth with the mold, and is
essentially used in the mold equipped with hot runner system.
24P connector is used as standard connector in YUDO.
It is generally more convenient to install connector at the upper surface of mold or on the
opposite surface of worker.
The drawing below shows on example of machining, and the machining size differs according
to quantity of connector.
- In processing of machining of mold, the datum base plane will be the base plane of the hold plate

28
6. Check Items of Hot Runner System

1) Check of Hot Runner System Part

Check if the quantity of component is accurate by checking part list of the system. In the event
that the quantity of component is not accurate in system assembly, the assembly schedule may
be delayed due to lack of component.
Especially, check if the quantities of “0” ring, pin and bolt coincide with the necesary quantities.
In case of MODU type, check if the component to be assembled on MODU plate which should
be is attached. (Connecting Box, Solenoid Valve, Wiring Name Plate)

(1) Check if heater and T/C are properly assembled to the nozzle. Give number to heater and
T/C and bind lead wire together, so as to prevent from wrong wiring, between heater and
T/C wires.

(2) Check if the component are attached exactly on manifold.

(Upper, Lower Riser Pad, Nozzle Locator, Thermocouple, etc.)
Give number to heater and T/C and bind lead wire together, so as to prevent from confused
wiring.

(3) Check assembly state and operation state of cylinder component.

Check if “0” ring is attached to the outside in case of gun drill type, and check if nipple is
attached to housing in case of nipple type.
And check if snap ring is properly assembled on the upper side of housing.
Wrong assembly of snap ring may cause serious personal injuries owing to cylinder cap
bouncing out, when inserting air in order to check operation.
Check the operation state by inserting air into air line of each cylinder.
(3~4Kgf/㎠ air pressure is proper for test.)
In case of MODU type, check the operation state by connecting air line to one touch air
nipple of solenoid valve. (4~6Kgf/㎠ air pressure is proper for test.)

(4) Check connecting box.

Check if there is connector and solenoid valve and if the quantity is proper.
Check if silencer and one touch nipple are attached to solenoid valve.

29
2) Electric Check of Hot Runner System
Because hot runner is equipped with electric components as compared with other mold
components, thorough check is necessary. Especially, the insulation state and division between
heater wire and T/C wire are very important in heater part. It should be checked by all means.

(1) Check of Nozzle Heater and T/C

Check insulation state by connecting
power line of nozzle heater to + or – of
tester and by contacting the other side of
tester to body of nozzle. At this time,
resistance should be selected for selection
switch of tester. Needle of tester should
not move for insulation state.

Check resistance of heater and existence

of line disconnection by connecting two
lines of tester to power line of nozzle heater.
The checked resistance value may be basis
of determining capacity of heater and
capacity of controller. At this time, select
resistance for selection switch of tester.

- Calculation method is as follows.

Diagram of Ω law

If the measured resistance value and the voltage are known, it may be calculated with E2/R.
Ex) If R=60Ω E=220 V
I = current (A)
W=E2/R
E = voltage (V)
2202/60=806.66 W
R = resistance (Ω)
W= power
consumption (W)

Table: ②-1

30
 Check if line is disconnected by connecting two
lines of thermocouple(T/C) to + and – of tester.
There are ground and non-ground type in T/C.
Generally, ground type is used. However, non-
ground type T/C should be used in case of ultra-
precise injection. T/C and nozzle are grounded in
case of ground type, and it is insulated in case of
non-ground type.

Check if T/C type is IC or CA by checking

coating color of T/C.

How to identify polarity of T/C is as follows.

Division + - YUDO Sleeve Color
Coating color Red stripe Yellow stripe
IC (J) Material Iron Constantan Yellow
Magnetism Magnetic Non-magnetic
Coating color Red stripe Blue stripe
CA (K) Material Chromel Alumel Blue
Magnetism Non-magnetic Magnetic
Table : ④-1

(2) Check of manifold Heater and T/C

- Check insulation state by connecting + or – of tester to power line of manifold heater and
then contacting another side of tester to manifold block.
(Same as how to test insulation of nozzle)
- Check resistance of heater and existence of disconnection by connecting two lines of tester
to power line of nozzle heater. (Same as how to test disconnection of nozzle)
- Check existence of disconnection by connecting two lines of thermocouple(T/C) to + and
of tester. (Same as how to tester disconnection of nozzle)
- Check whether T/C type is IC or CA by checking coating color of T/C.
How to identify polarity of T/C is as table ④-1.
- Check resistance value by connecting power line of manifold heater to + and – of tester.
The checked resistance value becomes a basis to determine heater capacity and controller
capacity. (Same as how to check resistance value of nozzle) The maximum value of
induction controller is 15A, and maximum average capacity is proper to use up to 10~12A.

31
3) Dimensional Check of Hot Runner System
Dimension inspection of hot runner system has close relationship with mold, and dimension
measurement is used as important data when assembling mold, so that it should be exactly
measured.
(1) Dimension check of manifold
Check manifold thickness and riser pad thickness.
Manifold thickness is usually 45T(tolerance: +0.05~0), and may be 50T(tolerance: +0.05~0) in
some cases. Riser pad thickness is usually 10T(tolerance: 0~-0.02) in upper side of manifold
and 15T(tolerance: +0.05~0) in lower side. Tolerance scope of measured dimension including
riser pad is 70T or 75T(tolerance: -0.04~+0.05).

Check the distance between dowel pin center and gate center for gate position.
Manifold gate distance is a dimension to consider thermal expansion quantity, so that it differ
from gate distance on mold drawing. Thermal expansion quantity is calculated by using the
following formula.
◈ Formula
Δ L = (1.23*10-5)*L*Δ T Δ T = (To-Tm) Δ L = Thermal expansion quantity
-5
(1.23*10 ) = Thermal expansion coefficient
To = Manifold temperature Tm = Mold temperature L = Distance between manifold Center and gate
Ex) L = 127mm
To = 280℃
Tm = 60℃
Δ T = (280-60) = 220℃
Δ L = (1.23*10-5)
*127*220 =0.34366mm
The distance between manifold center
and gate is 126.6563mm.

Thermal expansion quantity diagram

pursuant to the length is as follows.

32
(2) Check of nozzle dimension
- Check BALA nozzle by using the same thermal
expansion quantity as manifold.
- Check dimension of nozzle ØD and ØD1 part and
30mm part.
- Check dimension of nozzle L1. The dimension of L1
is machined short by considering thermal expansion
quantity. Because the normal dimension on the drawing
is a dimension after thermal expansion, the product is as
short as thermal expansion quantity.
◈ Formula
Δ L = (1.08*10-5)*L*Δ T Δ T = (Tn-Tm)
Δ L = Thermal expansion quantity
(1.08*10-5)=Thermal expansion coefficient
Tn = Nozzle temperature Tm = Mold temperature L = Mold size of nozzle touch part

- Nozzle length, where thermal expansion quantity by model and temperature is considered, is as
follows. (Nozzle length is machined as short as thermal expansion quantity based on 220℃
which is a temperature usually used for nozzle.) In case of using special resin, nozzle length
should be adjusted by specifying injection temperature and mold temperature.

[ Reference Data ]
L1(L-Δ L)
MODEL L ØD ØD1
Δ T:200℃ Δ T:250℃ Δ T:300℃
BIM18VV075 075 32.93 32.91 32.89
BIM18VV085 085 52.89 52.86 52.83
38 18
BIM18VV095 095 72.84 72.80 72.76
BIM18VV105 105 92.80 92.75 92.70
BIM25VV090 090 44.90 44.88 44.86
BIM25VV100 100 64.86 64.83 64.79
BIM25VV110 110 50 25 84.82 84.77 84.73
BIM25VV120 120 104.77 104.72 104.66
BIM25VV130 130 124.73 124.66 124.60
BIM35VV090 090 39.91 39.89 39.87
BIM35VV100 100 59.87 59.84 59.81
BIM35VV110 110 60 35 79.83 79.78 79.74
BIM35VV120 120 99.79 99.73 99.68
BIM35VV130 130 119.74 119.68 119.61
BIM45VV110 110 54.88 54.85 54.82
BIM45VV120 120 74.84 74.80 74.76
BIM45VV130 130 70 45 94.79 94.74 94.69
BIM45VV140 140 114.75 114.69 114.63
BIM45VV150 150 134.71 134.64 134.56

33
3) Check of valve pin dimension
① Check the size of valve pin end part according to the size of gate. The size of pin end part is
smaller than gate size because valve pin is protruded 0.5mm from gate surface.

Model Gate Ø Ød1 Ød ØD L1

1.2 0.9
BIM 18 4 7 4
1.5 1.2
BIM 25 1.5 1.2 4 7 4
2,5 2,2
3.0 2.7
BIM 35 6 9 4
3.5 3.2
4.0 3.7
4.0 3.7
5.0 4.7
BIM 45 10 15 6
6.0 5.7
7.0 6.7

Model Gate Ø Ød1 Ød ØD L1

BIM 18 2.0 1.7 4 7 4
2,5 1.7
BIM 25 6 9 4
2.5 2.2
BIM 35 4.0 3.7 6 9 4
BIM 45 8.0 7.7 10 15 6

Model Gate Ø Ød1 Ød ØD L1

2,5 2,2
3.0 2.7
BIM 35 6 9 4
3.5 3.2
4.0 3.7
4.0 3.7
5.0 4.7
BIM 45 6.0 5.7 10 15 6
7.0 6.7
8.0 7.7

34
② Check valve pin length.
③ Valve pin length is checked as nozzle nominal length +0.5 + Spacer Block thickness + A
dimension (Dimension A in diagram is a dimension including allowance stroke 1mm.)
Dimension A diagram by each cylinder
Ex) Cylinder : VC5504 used
Cylinder Model A
VC5504N 30
Nozzle nominal dimension: BIM 25-095
VC6506N 30
Spacer Block : 70T VC8510N 36
95+0.5+70+30=195.5mm VC58□ □ G 30
Valve pin length is protruded 0.5mm from VC68□ □ G 30
gate surface. (Refer to the drawing of page 5) VC78□ □ G 32

4. Check Items of Gate Part

(1) Check of gate machining state (Using valve pin)
Joint state of valve pin in normal state
Valve pin machining angle of normal product is 38˚and gate machining angle is 40˚.

Shape of product gate part

Cavity side

(2) Grind the end part of pin as much as protrusion amount and make it coincide with
product surface in order to make product surface coincide with the end side of valve pin.
(3) Standard valve pin is delivered with protrusion quantity(0.5mm) plus 1mm allowance
length. Therefore, it is 1.5mm longer than normal dimension. It is possible to cope with gate
machining defect.(Allowance tolerance to be handled is +0.4~-0.2mm.)
(4) If valve pin joint machining angle(40。±30’) and gate size(ØG) are improper, the
following phenomenon occurs.
(5) If the end part of valve pin does not reach the product surface,
◈ This occurs when gate diameter is smaller than the end part of valve pin.

Shape of product gate part

Cavity side

- Machine gate so that valve pin may coincide with the product surface.
Check the nose angle of gate and the machining angle of pin.
◈ This occurs when the gate taper angle is smaller than the taper angle of valve pin

35
 over specified angle.

Shape of product gate part

Cavity side

- Machine gate so that valve pin may coincide with the product surface.
Check the nose angle of gate and the machining angle of pin.

◈ This occurs when the length of valve pin is short or the taper angle of gate is larger
than the taper angle of valve pin over specified angle.

Shape of product gate part

Cavity side

- Machine gate so that valve pin may coincide with the product surface.
Check the nose angle of gate and the machining angle of pin.

7. Assembly of Hot Runner System (MODU System)

1) Put hold plate on assembly table, and then check the thickness ofplate and the position and size
of flange part and various pins.
① The thickness of hold plate should be
ground as ±0.01 tolerance.
② Check if flange part is properly machined.
(Refer to 5-3 flange part machining)
③ Check if various pin holes are machined.
(Dowel Pin, Lock Pin, Guide Pin, etc.)
④ Remove foreign material, chip and so on
from frame plate.

36
2) Install manifold lock pin. This is easy to
ignore, but plays very important roles, so
this must be omitted by no means.
Abnormal wear of gate and pin guide
bush may be direct
cause of resin leakage.
3) Measure the thickness of spacer block,
and then put it on hold plate. At this time,
the withdrawal groove part of lead line
for manifold should be oriented upward.
(Basic reason for resin leakage is
determined from the thickness of
spacer block.)
※ Thickness tolerance(T) : 0 ∼ -0.03

The thickness of spacer block is the most important reason of resin leakage. Minus(-) tolerance must be
maintained by all means.

4) Assemble nozzle(protrusion height : 15 ㎜

+0.04) Give gate number to the end part of
lead wire(because it is difficult in the
completely assembled state), and draw it
through withdrawal groove of lead wire of
spacer block. Insert Cu ring into the groove of
nozzle. Because the used Cu ring has
possibility of resin leakage in case of re-use,
replace Cu ring with new one by all means
when re-assembling it after disassembly.

37
 5) Check if dowel pin and disc are attached
to manifold, and install manifold by
adjusting the position of manifold lock pin.-
Caution : Take care so that dust or foreign material
may not inserted in the surface where manifold and
nozzle contact each other. Take care so that lead wire
may not be pushed between nozzle and manifold.

6) Tighten the bolt for fixing manifold.

(M8×P1.25, length 60∼65 ㎜) Give
number to the end part of lead wire, and
draw it through lead withdrawal groove of
lead wire. At this time, bind heater wire and
T/C wire together so that they may not be
mixed with other wires.

7) Check thickness of clamping plate,

position/size of cylinder, and so on, and
then put it on spacer block.

38
8) Adjust the position of clamping plate, spacer
block and hold plate with guide pin(2 places).
Assemble guide pin and then assemble guide
pin cover.

9) Fix clamping plate and hold plate by

tightening bolt(B2). Block all the air hole
except for air hole (2 places) in sky direction of
mold.(PT 1/4”)

10) Insert cylinder housing into cylinder hole

of clamping plate.

39
11) Assemble the piston furnished with valve pin to
cylinder housing, Push piston completely to the
arrow(b) direction, check if valve pin closes
gate completely in gate side, and then measure
the height(a) of the upper surface of piston and
the upper surface of cylinder housing.
The normal dimension of a pursuant to the
standard of cylinder is shown in the following
diagram.

CYLINDER MODEL a
VC5404N 21.5 ~ 22
VC6506N 23.5 ~ 24
VC8510N 26.5 ~ 27
VC58□ □ G 17.6
VC68□ □ G 20.6
VC78□ □ G 24.0

12) Install cylinder cover. The bolt for tightening

cylinder cover is a M5*15 range bolt.

13) Install locating ring. The bolt for tightening

locating ring is a M8 range bolt.

40
14) Attach connector.

15) Install PT 1/4” ring elbow nipple(2 places) for air line pipe on the upper side of mold.
* When transporting and handling the assembled MODU system, handle it after retreating (open)

valve pin by all means.

16) Perform wiring in accordance with the following rule.

The point to be considered in wiring is to check if heater and T/C to detect its temperature are
coupled. Therefore, it is very important to arrange heater lead wire and T/C lead wire and give
numbers before wiring.

① The wiring diagram shows manifold shape and gate position which
are seen from fixing side of mold.

② Give gate number first to the gate which is in the center of mold.

③ Wire gate(nozzle) part first and then wire manifold when using
manifold.

④ Wiring sequence : Wire gate(nozzle) located at the 1/4 quarter surface(X :

+ , Y ; +) in sky direction as seen from fixed side (machine nozzle side)
first in counterclockwise direction according to sequence, and then
wire manifold in the same sequence.

41
 ⑤ In case that gate is multi-point when using I type manifold,
wire gate(nozzle) in operator side first when manifold is
installed horizontally, and then wire it from upper side to
down side according to sequence when installing it vertically.

17) Wire hot runner system at connector.

Diagram Pursuant to Quantity of YUDO Hot Runner System Gate

▶ WIRING & ZONE DIAGRAMS

CONFIGURATION & GATE POSITION WIRING

42
▶ WIRING & ZONE DIAGRAMS

CONFIGURATION & GATE POSITION WIRING

43
▶ WIRING & ZONE DIAGRAMS

CONFIGURATION & GATE POSITION WIRING

44
18) Inspect wiring state after completing wiring to connector.

▶ Wiring inspection

① Wire the lead line of each heater and sensor at the connector in the upper side of mold
according to wiring diagram, and then fix it.
② Check if there is line disconnection or electric leakage by measuring the resistance
between heater terminals at connector. Measurement method is the same as 6.2.1)②.
③ Calculate capacity of heater by calculating the measured resistance of each nozzle
heater according to the method of 6.2.1)②. If the calculated capacity is the same as the
capacity indicated in the following table(deviation ±10%), the wiring is normal.

④ If the checked resistance value is remarkably smaller than the numerical value in the
table, there is a possibility of lead wire shorting, and so connecting of power line at this
time may damage thermostat.
⑤ Because sensor and mold contact each other(in case of ground type T/C) in electric
leakage check, there is no abnormality.

45
19) Assemble sequence system.
① Insert sealing plate between solenoid valve and
air manifold, and then assemble it.(M4*35)

② Tighten blocking bolt into air manifold.

③ Assemble one touch nipple and silencer to

air manifold.

④ Put sealing plate and the assembled air

manifold on the mold, and then tighten
it using M5*70 flat head cap bolt.

46
⑤ Connect solenoid valve magnet power cable to 10P or 16P square connector.

Connection Sequence
Square Connector No Sol Valve No. Connector Specification
1, 2 No.1 Sol
3, 4 No.2 Sol
Han 10 A
5, 6 No.3 Sol
250V 16A
7, 8 No.4 Sol
9, 10 No.5 Sol
11, 12 No.6 Sol
Han 16 A
13, 14 No.7 Sol
250V 16A
15, 16 No.8 Sol

⑥ Assemble the connected square

connector to mold using M4*12 bolt.

⑦ The completely assembled shape is as follows.

47
20) Check item after assembling MODU system
① Check the operation state of cylinder and valve pin with 3~4Kgf/㎠ pressure by
connecting air line.
② Check if bolt head, cylinder cover, center pin cover, etc. is protruded on the upper side
of clamping plate.
③ Check if there is no damage in assemble process at the end part of valve tip.
④ Check if opening and closing of valve gate are normal.

21) Assemble the assembled MODU system

with cavity plate(mold). In order to assemble
it, put cavity plate(mold) on the assembly
table, remove foreign material from gate part
and cavity plate, and then assemble MODU
system based on guide pin.

* When assembling the assembled MODU system

with cavity plate or mold, assemble it after
retreating (open) valve pin by all means.

22) Fix MODU system and cavity plate with

bolt(B1).

48
8. Operation of Hot Runner System
Before connecting mold to injector, check if the connector terminal wiring of controller
coincides with the connector terminal wiring of hot runner mold. Check if wiring is proper and
heater and T/C operate jointly by putting power to each controller, and then install mold.

1) Installation
① Install mold on machine, and then connect the accessory assembly product of mold (cooling
line, core cylinder, etc.)
② Connect air line to solenoid(induction system is attached to connecting box). In case of
sequence system type, air manifold is equipped with air nipple.
③ Connect signal line connected to injector with solenoid valve. In case of sequence system type,
it is connected to timer controller case(refer to layout drawing).
④ In case of using timer unit, refer to YUDO timer manual(3. Operation pannel of timer unit SIT300).

⑤ Connect the trunk of controller to connecting box. At this time, fix it with care so that
connector may not be moved or removed.

⑥ Use the controller which is suitable for the number of heaters by each system. If the connector
terminal wiring of mold is different from the terminal wiring of controller, controller may be
destroyed or T/C of heater may be destroyed when inputting power. Be sure to recheck it
before inputting power.

49
 ⑦ Connect trunk to controller, turn on main switch, turn on the switch of each unit one by one
and soft start function, and then check temperature change.

2) Caution before operation

① Check if there is disconnection, electric leakage, or air leakage in heater and T/C by all means
before and after installing mold on machine.
② Check the operation state of valve pin by operating injection signal manually.
③ Start operation when there is no problem with all functions.
④ Check all the functions of mold and injector with cooling line of mold opened. In case of
checking it over long time, convert the temperature of controller to preheating function.
Especially, because the material which is sensitive to heat causes carbonization, care should be
taken.
⑤ If there is no problem with mold and machine operation, check injection quantity and pin
operation state by setting the temperature of nozzle 10℃ higher than injection temperature
and injecting it one or twice with mold opened.
⑥ Check flow valance of raw material while injecting it over three times(short-shot) with mold
closed.
⑦ Check the program in various products such as carbonization, gate mark, gas, etc. by injecting
it at the same temperature as injection.
⑧ Prevent carbonization due to stay in advance by lowering the temperature of controller about 70%
if it takes long time to review product.(Because engineering plastic or the material with additive
may be easily carbonized, temperature should be lowered by all means.)
⑨ Perform normal injection work.
⑩ In case of stopping mass production for the time being, lower setting temperature about 70%
by all means.
⑪ If carbonization occurs, open mold immediately and purge it 3 or 4 times.

3) Maintenance
Maintenance is very important because it extends the life of mold as well as the life of hot runner
system.
① When mass production is finished, remove raw material or foreign material attached to hot
runner system completely.
② Remove all moisture and oil, and spray antirust to prevent rusting.
③ Keep mold at a place where there is no moisture and ventilation is well done.
④ In case of keeping it for long time, take care so that moisture may not invade heater.
Remove moisture from system.
⑤ When entering re-mass production, check operation state of valve pin while raising the
temperature of hot runner system by 10℃. At this time, perform operation sequence in the
same way as 8-2-⑥.

50
9. Disassembly and Assembly
1) Disassembly and assembly when replacing various “0” rings of cylinder

① In order to replace “0” ring by disassembling cylinder with mold cooled completely after injection,
connect controller to nozzle and manifold first and then heat it. Heat it by setting heating
temperature by 20℃ higher than the minimum melting temperature of resin in the nozzle.

Note : Change of ”O” rings is recommended with new ones, when it is disassembled to prevent problems caused by

wearing of it.

② Remove cylinder cover bolt and then disassemble cover.

③ Remove snap ring for fixing piston cap, and then

disassemble cap.

④ Disassemble piston using the tap in

the upper side of piston-out.(At this
time, valve pin is disassembled
together.)

⑤ Remove snap ring which is in the

inside of piston-out using tool, and
then disassemble piston-in and
valve pin.

⑥ Disassemble housing from clamping plate.

⑦ Assemble it in the reverse order of disassembly.

51
2) Disassembly and assembly when replacing nozzle heater
and T/C

◈ Disassemble from the Manifold side

① Disassemble nozzle from mold. (Because Cu ring being
assembled at the upper side of nozzle may be used only once
at this time, replace it with new one during re-assembly.)

② Fix the flange part of the disassembled nozzle to fixing jig,

and then separate snap ring.

③ Disassemble heater from nozzle.

④ Disassemble thermocouple(T/C) from nozzle.

⑤ Assemble it in the reverse order of disassembly.

◈ Disassemble from the Cavity side

① Disassemble MODU system only from mold.(If B1 bolt is

removed, only MODU is separated.)

② Separate snap ring from nozzle.

③ Disassemble heater from nozzle.

④ Disassemble thermocouple(T/C) from nozzle.

⑤ Assemble in the reverse order of disassembly.

Note : Cu-ring must be replaced when it is disassembled.

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10. How to Recognize Product Standard and System
You can receive quicker service if you check and notify product item, standard and lot number
marked on the product in case that damage, additional purchase, or customer service occurs to
YUDO product. How to recognize product is as follows.

1) How to Recognize Product of Nozzle (BALA Nozzle Series)

For BALA nozzle, the mark can be seen on the flange by interval of 120˚ interval as show
n in the drawing.
A drawing : YUDO Logo Marking B drawing : Product Standard Marking C drawing : LOT No. Marking

2) How to Recognize Product of Heater (Tube Type)

For Tube heater, the mark is on the opposite end part of lead line as shown in the drawing.

A part : YUDO Logo Marking

B part : Product Standard Marking
C part : Voltage and Capacity Marking
D part : LOT NO Marking

3) How to Recognize Product of Manifold Block

The upper side of manifold block is marked as shown
in the drawing.
A part : YUDO Logo Marking B part : Order No. Marking

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4) How to Recognize Product of MODU System
In case of MODU system, order number is marked on the ID card attached to the side
of MODU plate.
Name plate attaching position and order number position (A) are same to the drawing.

ID Card plate attaching position on mold ID Card

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11. Trouble and Countermeasure
Phenomenon Cause Countermeasure and Check point
1. Heater disconnection 1. Checking of heater and T/C using tester
(Refer to 6. 2. 1.② and ③)
2. Mal-contacting of trunk and 2-1.Checking of all the trunks using tester
connecting system 2-2.Checking of connecting pin separation
A.
3. Mal-operation of controller 3. Checking of nozzle sensor and controller
Not being heated
sensor type (J or K) (Refer to 6. 2. 1.④)
4. Change of polarity of T/C 4. Controller gauge or visual check
5. Disconnection of T/C 5. No output of controller. Checking using
tester.(Refer to 6. 2. 1. ③)

2-1. Checking of all trunk

2-2. Separation of connecting pin

Figure

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 Phenomenon Cause Countermeasure and Check point
1. Mal-connection of signal 1-1 Check signal.(DC24V, AC110,220 V)
1-2 Check if signal is sensed at signal jack using
tester..

2. Damage to piston O-ring 2 Disassemble and check cylinder.(Refer to 9.

Disassembly and assembly)

3. Defect in air piping 3 Check all the connections with air connected.

4. Mal-function of solenoid valve 4-1 Loosen solenoid connections a little and then
check operation state.
4-2 Check if solenoid valve magnet power coincides
with injector signal power.(Refer to layout
drawing in 8-1. ③)
4-3 Check if solenoid valve magnet operation valve
is working.
4-4 Check if there is foreign materials in silencer.

5. Lack of air pressure 5-1 Check connection state of main compressor

and peripheral.
5-2 Install air booster if air pressure is 6.0kgf/㎠
or less.(Model: VABT10)

B. 6. The tolerance between valve 6 Remove raw material in system and then
Valve pin is not operating pin and pin guide bush is not separate mold to check operation state.
or not smooth. proper.
7. Damage to valve pin surface 7 In case of engineering plastic or a product
(sliding part) mixed with glass fiber, disassemble it and
then check sliding part.

8. Mixing of foreign material in 8 Because it is located near gate in most cases,

system check it visually with pin operated, and then
remove and disassemble it.

9. Leakage of raw material in 9-1 Disassemble and check it( Refer to 9.

piston Disassembly and assembly)
9-2 Check pin guide bush and pin gap.

10. Gas in resin is pushed to 10 Check the tolerance of valve pin and pin guide
valve pin and pin guide bush. bush, and then correct or change it.
(This occurs mainly in PP, non- combustible
resin, or engineering plastic.)

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 1-1 Check signal.(DC24, AC110,220 V)
Figure

1-2 Check injection signal at signal jack.

4 Check the state where air is connected.

4-4 Check foreign material in silencer.

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 Phenomenon Cause Countermeasure and Check point

1. Overheating 1-1 Check carbonization part in product.

1-2 Check it around gate.
1-3 Check T/C fixing state.
1-4 Change T/C polarity.
C. 1-5 Abnormality in controller unit – defect in Triac.
Occurrence of 1-6 Heater and T/C is changed to each other.
carbonization 2. Carbonization due to delay of 2 Check raw material change time in injector
raw material in cylinder itself. cylinder.

3. Carbonization in delay section 3 Check delay part of manifold and nozzle.

within hot runner.

1-1 Checking of carbonization part around the gate of product

- In case of the part near the gate as shown in the figure, it is carbonization due to delayed raw material around tip.

- In case of the part far from the gate as shown in the figure, it is carbonization due to delay within injector
cylinder or single V/G body.

- In case of long occurrence from the gate as shown in the figure, it is carbonization due to delay within
single V/G body and nozzle.

1-6 Heater and T/C are changed with each other.

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 Phenomenon Cause Countermeasure and Check point
1. Mal-function of pin 1-1 Check it by referring to the part where valve
pin operation is not smooth in clause B.
1-2 Check cooling line configuration of mold.
2. Lack of air pressure 2 Refer to No.5 of clause B.
3. Immaturity in injection control 3 In case that pressure compensation time is
unnecessarily long
D.
4. Defect in signal connection 4-1 Check if injection signal is connected together
Defect in gate mark
with other signals.
4-2 Make sure that one turn only is operated per
cycle.

- Gate machining state of mold

1) Taper Type

2) Straight Type
Figure

3) Gate mark pursuant to defect in gate machining

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 Phenomenon Cause Countermeasure and Check point
1. Gate is machined in straight type, and 1. Machine valve pin and gate in same type.
valve pin is machined in taper type.
2. Valve pin is closed with gate hardened 2. Set pressure compensation time short during
completely. injection.
3. Air pressure is deficient. 3. Use air booster if air pressure is 6.0kgf/cm2 or
less. (Model: VABT10)
4. Temperature around gate is too low. 4. Raise temperature of nozzle, or loosen cooling
5. Foreign material is mixed in gate part. condition of mold.
Shape of gate mark
5. Check it, and then remove it.

1. Gate is machined smaller than valve 1. Machine it again using gate bush. (Machine it
pin. again by referring 5.4 VA type gate machining
drawing.)
Shape of gate mark

1. Temperature of valve pin is high. 1-1 Improve cooling condition by adding cooling
cooling line around gate.

1-2 Lower temperature of nozzle.

Shape of gate mark

1. Gate diameter of mold is larger than 1. Change pin or reduce gate.

pin.

Shape of gate mark

1. Valve pin is short. 1. Check the length of valve pin.

2. Air pressure is low. 2. Use air booster if air pressure is less than
6.0Kgf/㎠. (Model: VABT10)
3. Injection time is too long. 3. Inject it while reducing injection time and
pressure compensation time.
Shape of gate mark

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 Phenomenon Cause Countermeasure and Check point
1. Defective assembly of mold. 1. Check defective machining dimension of mold.
2. Keep assembly sequence during assembly after
2. Defect in assembly of system itself disassembly of system, and check operation by all
means after assembly.
E. Resin leakage
3. Injector nozzle does not coincide 3. Adjust injector nozzle to nozzle locator “R” of
with nozzle locator “R” of manifold.
manifold.

Resin leakage points of hot runner system

Figure

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 2. Cause and countermeasure by resin leakage point

A part : This is a problem caused by wrong radius at the contact part between injector and nozzle locator. R of
injector nozzle should be 1R or more smaller then radius(R21) of nozzle, and the size of injector nozzle
gate should be smaller then the size of nozzle locator gate.

B part : This is a ring to prevent resin leakage in manifold and nozzle locator, and once nozzle locator is
disassembled, Cu ring having been used at this place should not be re-used. Replace it with new one by
all means. In order to prevent resin leakage at this place, assemble M8 bolt with even force until it
is completely pushed.

C part : Resin leakage occurs due to bad adherence state between manifold and pin guide bush. Resin leakage
occurs because clamping plate does not clamp pin guide bush. In order to make clamp complete,
the dimension of spacer block should maintain --- (Refer to clause 7. 7-3). Non-observance of this
dimension may be the largest cause of resin leakage.

D part : Resin leakage occurs due to the gap between valve pin and pin guide bush. If resin leakage occurs,
replace valve pin and pin guide bush simultaneously.

E part : This is a ring to prevent resin leakage in manifold and nozzle, and once nozzle is disassembled, Cu ring
having been used at this place should not be re-used. Replace it with new one by all means. The largest
cause of resin leakage is that clamping plate can not clamp nozzle completely. The dimension of spacer
Figure

block should maintain – in order that clamping may be complete (Refer to clause 7. 7-3). Non-observing
this dimension is the largest reason of resin leakage.

F part : This is a problem caused by incomplete contact between mold and nozzle end part, and this occurs
frequently when mold depth, diameter, etc. are unsuitable, so that thorough measurement should be
performed before assembling system to mold.

G part : This is a blocked place using end plug and blocking bolt in order to convert the direction of resin hole
machined at manifold, and resin leakage occurs due to bad adherence between manifold and end plug.

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 Phenomenon Countermeasures

1. Check if heater is disconnected by measuring resistance on manifold heater.

2. Check insulation state by measuring resistance on manifold heater. If insulation state is
good(5 ㏁), heat it using controller.
3. Heat manifold using controller, and then disassemble clamping plate.
4. Disassemble spacer block.
5. Remove the resin attached to the upper part and the side part of manifold. (When
removing resin, remove resin at the temperature of manifold where controller is turned
off and not cooled. If controller is not turned off, there is danger of electric shock.
Special care should be taken when removing resin at the lead line part. If the bolt in the
F. heater end part is cut or damaged, it can not be repaired and heater should be replaced.)
In case that resin leaks 6. Remove manifold clamping bolt and then disassemble manifold.
on manifold but heater is 7. Remove the resin in the lower part of the disassembled manifold. When removing
not disconnected. the resin in manifold lastly, wipe manifold surface with soft cloth so that it may not be
damaged. (Damage may cause water leakage on manifold surface and nozzle touch
surface during re-assembly.)
8. Cut lead wire attached to the end part of heater.
9. Remove bolt in the end part of heater, and perform wiring again.
10. Remove the resin attached to nozzle and lead wire.
11. Assemble the nozzle where resin is removed, replace Cu ring with new one and then
assemble it in the reverse sequence of disassembly.

1. Remove the coolant attached to mold using air and soft cloth.
2. Check if heater is disconnected by measuring resistance on manifold heater.
3. Check insulation state by measuring resistance on manifold heater. If insulation state is
checked to be 0.5 ㏁ or more, heat it using YUDO controller. Because there is soft
G. start function in YUDO controller, it improves insulation state of heater when inputting
In case that resin leaks power for the first time.
on manifold, heater is not 4. If insulation state is 0.5 ㏁ or less by measuring resistance on manifold heater, dry the
disconnected, and coolant end part of heater so that insulation state may be 0.5 ㏁ or more, and then heat it using
leaks to destroy insulation
YUDO controller.
of heater.
5. Heat manifold using controller, and then disassemble clamping plate.
6. Handle it in the same way as the content after No.4 of D.

1. Check if heater is disconnected by measuring resistance on manifold heater.

H. 2. If heater is disconnected, receive customer service by contacting the head office of
In case that manifold YUDO or each branch office.
heater is disconnected.

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