SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 1 of 17 ASSEMBLY INSTRUCTIONS, MODEL SR-1.0 EXTRUSION HEAD STREAMLINE EXTRUSION, INC. Following is a set of photos and verbal descriptions for assembling the Model SR-1.0 extrusion head subassembly and flange subassembly. Upon receipt of the extrusion head and flange subassemblies, completely disassemble both, and then re-assemble with these instructions before use. This is done to familiarize the line operators with the construction, assembly and disassembly of this extrusion head. Numbers in parentheses (##) refer to item numbers related to the related subassembly drawings. The acronym ASC refers to high temperature anti-seize compound, 800 F minimum temperature resistance. SEI recommends that fasteners to be tightened to 70-75% of full load torque as specified in the Unbrako engineering guide. This will be the recommended torque value (RTV). The following web link will allow you to download the PDF guide. See page 7 of this guide to find full load torque values for each screw diameter. http://www.unbrako.com/engineer_guide.htm Step1 Figure 1 All the following item numbers refer to subassembly SEI ST46183. Find clamp flange (1), insert hub adapter (4), nipple (6), nipple nut (5), 2-pcs. transducer port plugs (7), 2-pcs. tightening bars (ST28645, not shown on assembly drawing). Insure that all mating surfaces are clean, smooth, flat, and burr-free. Add a small amount of ASC to the mating surfaces. See Figure 1.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 2 of 17 Step 2 Figure 2 Insert the insert hub adapter into the clamp flange. See Figure 2. Step 3 Figure 3 Place band heater (3) 400W/240V on the insert hub OD. Tighten band heater around the insert hub. Do not over-tighten. Band heaters must be checked for tightness after heating to operating temperature to insure good metal-to-metal contact. Insufficient contact of the band heater to the heated item will cause premature band heater failure due to overheating. Insert thermocouple adapter (8) to pipe tapped hole and tighten with a flat-bladed screwdriver. See Figure 3.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 3 of 17 Step 4 Figure 4 Find and install spring-loaded bayonet temperature control thermocouple (2) to the thermocouple adapter (8). Adjust spring tension to insure contact of the probe with the bottom of the thermocouple port. Find melt thermocouple probe Locate 8,000 psi rupture disk assembly, transducer port plug (7), melt temperature thermocouple probe and adapter. The insert hub adapter has two standard pressure/melt transducer ports, diametrically opposite on the main diameter, also 1 pipe threaded port for the temperature control zone thermocouple. For the two transducer ports, one each of an adjustable-depth melt temperature thermocouple, an 8,000 psi rupture disk, and a 2 port plugs are provided. Select two of the three to insert in the extruder flange. Do not operate the die head and flange without one of these items in the two transducer ports. The melt probe, adapter, and rupture dick assemblies are not shown in the assembly drawing. See Figure 4 and 5.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 4 of 17 Figure 5 All the following item numbers refer to subassembly SEI ST46184. Step 5 Figure 6 Locate main spiral die body (2). See Figure 6.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 5 of 17 Step 6. Figure 7 Locate the inlet tail cone (12) and 1 socket head cap screw (16) ¼ -20 x ½ lg. See Figure 7. Step 7. Figure 8 From the upstream end of the manifold, insert the tail cone into the counterbored hole. Be sure the face of the tailcone and bottom face of the counterbore are clean, flat and smooth. Add a small amount of ASC to the face and diameter surfaces of the tailcone. The threads in the tailcone and the underside of the cap screw head before installing.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 6 of 17 Use the socket head screw, inserted from the downstream end of the manifold to fasten the tailcone into place. Do not over tighten the screw. See Figure 8. Step 8. Figure 9 Find the spiral body end plate (20), the end nose (9), and 4-pcs. socket head cap screws (15) #10-24 x ½ lg. See Figure 9. Step 9. Figure 10
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 7 of 17 Make sure the upstream face of the end plate and counterbore face surface of the spiral manifold are both smooth, flat, and burr-free. Apply a small amount of ASC to the four threaded holes and the underside of the cap screw heads. See Figure 10. Step 10. Figure 11 Apply a small amount of ASC to the threaded hole at the center of the end plate. Be sure the mating surfaces of the end nose and the manifold are smooth, flat, and burrfree. Thread the end nose into the end plate by hand. Tighten with the provided 5/8 hex wrench. Do not over tighten.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 8 of 17 Step 11 Figure 12 Locate the head cartridge, (10).Step 12 Step 12 Figure 13 Locate the inlet adapter bushing (11). Make sure that the sealing surfaces are smooth, flat and burr-free. Insert the bushing into the upscream counterbore hole of the manifold. Apply a small amount of ASC to the engagement diameter. Make sure the push our bolt holes of the bushing align with the spotface locations on the upstream face of the manifold.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 9 of 17 Step 13 Figure 14 Locate 6 pcs. socket head cap screws, (19) 3/8-16 x 1-3/4 lg. Apply a small amount of ASC to the fastener threads and to the underside of the bolt heads. Step 14 Figure 15 Tighten the socket head cap screws in a cross-diameter pattern incrementally to the RTV (see page 1 for RTV definition).
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 10 of 17 Step 15 Figure 16 Find the nipple (6), nipple nut (5) as shown in figure 1 and 16, 2-pcs. tightening bars (ST28645, not shown on assembly drawing). Insure that all mating surfaces are clean, smooth, flat, and burr-free. Add a small amount of ASC to the threads and the mating surfaces. Insert the nipple through the nipple nut as shown. See Figure 16.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 11 of 17 Step 16 Figure 17 Note that the nipple nut has two drilled hole patterns on the outer diameter. One is a two hole pattern with holes that extend through to the ID of the nut. The other is a six hole pattern of drilled blind holes. See Figures 16 and 17. Thread the nipple, with the nipple nut attached into the upstream threaded hole of the inlet adapter bushing Insert the two tightening rods into the holes of the two hole pattern and rotate the nipple nut until the tightening rods will engage further into the drilled holes in the outside of the nipple. Once properly engaged, it is possible to tighten the nipple into the back of the inlet adapter bushing. Caution: do not over tighten the nipple in the back of the inlet adapter bushing. If the mating surfaces are, clean, flat, smooth and burr-free, a large amount of torque will not be needed to create a polymer pressure seal, and the nipple will be loosened much easier after extended operation. Remove the rods after tightening. The six blind holes on the OD of the nipple nut will accept a regular pin spanner wrench (provided) or the tightening rods may also be used. Also shown in figure 17 is the mandrel pin (14).
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 12 of 17 Step 17 Figure 18 Apply a small amount of ASC to the external thread and the mating surface of the mandrel pin, being sure that the mating surfaces are smooth, flat and burr-free. The mandrel pin is threaded into the end cap. As a point of order of procedure, the mandrel pin should be threaded into the end cap prior to inserting the spiral manifold into the head cartridge. See step 10 and figure 11. The mandrel tip may be tightened into the end cap by using the shaft collar (provided). The shaft collar allows the large diameter of the mandrel tip to be gripped and tightened without damaging the melt flow surfaces. Do not use excessive torque when installing the mandrel tip.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 13 of 17 Step 18 Figure 19 Locate the upstream and downstream die bearings (5 and 6, respectively) and the die bushing (7). Install the upstream die bearing in the counterbored hole on the upstream face of the die bushing. Place the downstream die bearing over the downstream nose of the die bushing. Step 19 Figure 20 Locate 2 pcs. of band heater, 240v/750w (4) onto the OD of the head cartridge (10). Tighten band heater around the insert hub. Do not over-tighten. Band heaters must be checked for tightness after heating to operating temperature to insure good metal-to-
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 14 of 17 metal contact. Insufficient contact of the band heater to the heated item will cause premature band heater failure due to overheating. Insert thermocouple adapter (23) to pipe tapped hole and tighten with a flat-bladed screwdriver. Find and install spring-loaded bayonet temperature control thermocouple (22) to the thermocouple adapter. Adjust spring tension to insure contact of the probe with the bottom of the thermocouple port. Step 20 Figure 21 Locate 4 pcs. socket head cap screws, (19) 3/8-16 x 7/8 lg. Apply a small amount of ASC to the fastener threads and to the underside of the bolt heads. Locate die retainer plate (8). Fasten the die retainer plate to the front of the head cartridge. Be aware that the torque used to fasten the die retainer plate will directly affect the ease or difficulty of adjusting the die bushing when correcting the centering of the wall of the extruded product. The rule of thumb for this torque is to have the bolt torque high enough to prevent a polymer leak, and not so high that the die bushing becomes immovable. A polymer seal should be created with a fairly low torque value, provided that the mating surfaces are smooth, flat and burr-free.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 15 of 17 Step 21 Figure 22 Locate 4 pcs. socket head cap screws, (18) 3/8-16 x 1-1/4 lg. Apply a small amount of ASC to the fastener threads. Insert bolts into 4 radially located threaded holes for die bushing centering.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 16 of 17 Step 21 Figure 23 Locate 4 pcs. socket head cap screws, (18) 3/8-16 x 1-1/4 lg. Apply a small amount of ASC to the fastener threads. Locate die retainer plate (8). Place band heater (2) 150W/240V on the die bushing OD. Tighten band heater around the insert hub. Do not over-tighten. Band heaters must be checked for tightness after heating to operating temperature to insure good metal-to-metal contact. Insufficient contact of the band heater to the heated item will cause premature band heater failure due to overheating. A spade-type thermocouple can be placed under the band to allow for a separate temperature control zone.
SR-1.0 Manual, 20061108a.doc 11/14/2006 Page 17 of 17 Find air supply tube (1), ¼ OD flex tube connector (supplied), apply a small amount of ASC to the air tube screw threads and thread into the air supply port on the manifold flange outer diameter.. This completes the mechanical assembly of the extrusion head and flange subassemblies. This manual is copyright 2006, StreamLine Extrusion, Inc. and for use solely for StreamLine Extrusion, Inc. customers and not for general publication.