Mold Maintenance & Repair

OCT 2016

Mold Maintenance & Repair

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C A S E S T U D Y 18 Mold Maintenance & Repair How much time do your maintenance personnel spend tracing wiring issues or identifying faulty heaters and thermocouples? Are they frustrated with old-school methods and the time it takes to identify the problem? How many hours do they waste checking a mold for issues only to find that a faulty cable is to blame? Clack Corp.'s Rogers, Arizona, injection mold- ing facility encountered this issue many times and found a solution in the CableXChecker cable testing system, distributed by Milacron's DME Co. brand. "Before, the best way to test a cable (either thermocouple or power) was to hold the cable between your legs and touch a multimeter to each contact point/pin," says Michael McCutcheon, product manager for DME Industrial Supplies. "This required 576 point-to-point contacts to diagnose a 24-pin cable. Then, once the cable was repaired, this process had to be repeated to confirm the repair was completed correctly." The CableXChecker, manufactured for DME by Fast Heat Inc., enables maintenance personnel to cycle through a 24-pin cable in less than one minute, he says. "This will allow them to quickly rule out cable issues by confirming positive con- nection between the controller and mold on all zones quickly and safely." Gary Ash, Clack's main- tenance supervisor, confirms that the device speeds the diagnostic process. "In the real world, a mold setup person sets the mold, plugs in the hot runner and turns it on. Then, when a zone is not heating, what is the first thing you do? Where do you start? Do you start checking at the mold for shorted or open heaters, the cable, or the controller?" With the CableXChecker, he simply plugs it in and turns the selector switch from zone to zone, and it tests the conti- nuity of the entire cable. It can also identify shorted cables. "I can check thermocouple cables and power cables in just a minute or two, and I can eliminate or prove cable or plug failure in a couple of minutes instead of the 30 to 45 minutes it takes to get out a meter, jumper cables and alligator clips, and painfully check, pin for pin, each end of the plug," he says. "Six times out of 10, the failure may not present itself until the cable is jiggled or moved." According to McCutcheon, the device was developed to help molders simply and quickly Quickly Getting to the Root of the Problem Diagnostic device helps molders simply check hot runner cables to ensure connectivity. When replacing cable ends, connect the controller side of the cable to the CableXChecker. Before terminating the cable wire into the connector insert, touch the end of the wire with the probe to confirm the correct zone number. When you touch the wire with the probe, an LED will illuminate the correct zone into which that wire needs to be terminated. Images courtesy of DME Industrial Supplies/Milacron.

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