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PR-25

Mounting Press

PR-25 Instruction Manual

Patents are pending in U.S.A.


and other countries.
Minor revisions may not be reflected
in this manual.
1999 LECO Corporation

Part Number 200-262


November 1999

This page intentionally left blank.

12

PR-25

Introduction

Introduction

Introduction
Illustrations .......................................................................... 14
Warranty.............................................................................. 15
Warning and Caution Symbols.................................................. 17
Interference to Other Devices .................................................. 18
Major Equipment and Accessories List ....................................... 19
Components and Accessories List ........................................... 112
Options .............................................................................. 113
Consumables ...................................................................... 114
Specifications...................................................................... 116

Installation
Illustrations .......................................................................... 22
Installation ........................................................................... 23
Mount Heights....................................................................... 27

Operation
Illustrations .......................................................................... 32
Controls and Indicators........................................................... 33
Operation............................................................................. 35
Molding Pressures and Times ................................................... 38

Maintenance
Molding Defects..................................................................... 43
Heater Cooler Removal........................................................... 45

Illustration

Index

Introduction

PR-25

13

Illustrations
Figure 11......... PR-25 Mounting PressFront View................117
Figure 21......... PR-25 Mounting PressBack View ................25
Figure 22......... Heater Cooler Assembly Alignment ...............26
Figure 23......... Heater Cooler Assembly at 45o .....................26
Figure 24......... Heater Cooler Assembly Positioned Correctly ..26
Figure 31......... Pressure Gauge .........................................34
Figure 32......... Controls and Indicators...............................34
Figure 33......... Double Mount Cross-Section ........................39
Figure 51......... InteriorLeft Side View ..............................53
Figure 52......... InteriorRight Side View ............................54
Figure 53......... Exploded View1 ......................................55
Figure 54......... Exploded View2 ......................................56
Figure 55......... Exploded View3 ......................................57
Figure 56......... Heater Cooler Assembly ..............................58
Figure 57......... Switch Assemblies .....................................59
Figure 58......... PR-25 Flow Diagram...................................510

14

PR-25

Introduction

Warranty
Equipment manufactured by LECO Corporation, St. Joseph,
Michigan is warranted free from defect in material and
workmanship for a period of six months from the date of
installation. Equipment not manufactured by LECO is covered to
the extent of warranty provided by the original manufacturer
and this warranty does not cover any equipment, new or used,
purchased from anyone other than LECO Corporation. All
replacement parts shall be covered under warranty for a period
of thirty days from date of purchase. LECO makes no other
representation or warranty of any other kind, expressed
or implied, with respect to the goods sold hereunder,
whether as to merchantability, fitness for purpose, or
otherwise.
Expendable items such as crucibles, combustion tubes,
chemicals, and items of like nature are not covered by this
warranty.
LECO's sole obligation under this warranty shall be to repair or
replace any part or parts which, to our satisfaction, prove to be
defective upon return prepaid to LECO Corporation, St. Joseph,
Michigan. This obligation does not include labor to install
replacement parts, nor does it cover any failure due to
accident, abuse, neglect, or use in disregard of instructions
furnished by LECO. In no event shall damages for defective
goods exceed the purchase price of the goods, and LECO shall
not be liable for incidental or consequential damages
whatsoever.
All claims in regard to the parts or equipment must be made
within ten (10) days after Purchaser learns of the facts upon
which the claim is based. Authorization must be obtained from
LECO prior to returning any other parts. This warranty is voided
by failure to comply with these notice requirements.

Introduction

PR-25

15

Notice
The warranty on LECO equipment remains valid only when
genuine LECO replacement parts are employed. Since LECO has
no control over the quality or purity of consumable products not
manufactured by LECO, the specifications for accuracy of
results using LECO instruments are not guaranteed unless
genuine LECO consumables are employed in conjunction with
LECO instruments. If purchaser defaults in making payment for
any parts or equipment, this warranty shall be void and shall
not apply to such parts and equipment. No late payment or
cure of default in payment shall extend the warranty period
provided herein.
LECO Corporation is not responsible for damage to any
associated instruments, equipment, or apparatus nor will LECO
be held liable for loss of profit or other special damages
resulting from abuse, neglect, or use in disregard of
instructions. The Buyer, their employees, agents, and
successors in interest assume all risks and liabilities for the
operation, use, and/or misuse of the product(s) described
herein and agree to indemnify, hold harmless, and defend the
seller from any and all claims and actions arising from any
cause whatsoever, including seller's negligence for personal
injury incurred in connection with the use of said product(s)
and any and all damages proximately resulting therefrom.

Caution
The instrument should be operated only by technically qualified
individuals who have fully read and understand these
instructions. The instrument should be operated only in
accordance with these instructions.
The operator should follow all of the warnings and cautions set
forth in the manual and the operator should follow and employ
all 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.

16

PR-25

Introduction

Warning and Caution Symbols


The following symbols may be found on LECO equipment or
their components. These symbols indicate the use of specific
safety guidelines. Important safety information is highlighted in
this manual by one of the following symbols as well as
WARNING and CAUTION statements. Operator and service
personnel must follow these instructions for personal safety and
to prevent damage to the equipment.

WARNING

This symbol indicates a risk of electrical shock.


Refer to the manual for specific instructions.

WARNING

This symbol indicates a high temperature


surface. Refer to the manual for specific
instructions.

!
CAUTION

This symbol indicates a caution. Refer to the


manual for specific instructions.

LECO equipment should be operated only by technically


qualified individuals who have fully read and understand the
instructions detailed in this manual. The equipment should be
operated only in accordance with these instructions.
The operator should follow all of the warnings and cautions set
forth in this manual and the operator should follow and employ
all applicable standard laboratory safety procedures.

Introduction

PR-25

17

Interference to Other Devices


This equipment has been tested and found to comply with the
limits for a Class A digital device, pursuant to Part 15 of the
FCC Rules and Regulations. These limits are designed to
provide reasonable protection against harmful interference
when this equipment is operated in a commercial environment.
This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accordance
with the instructions, may cause interference to radio
communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own
expense.

18

PR-25

Introduction

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:

200-262

Instruction Manual

814-200-050

Component Pack (for complete listing, see


Components and Accessories List, page 112)

807-543

Power Cord

807-927-100

Heater Cooler Assembly

811-308

Bakelite Black Preform (1.00 inch)

807-922*

Hazard Materials Pack (for complete listing, see


Components and Accessories List, page 112)

814-200-125 PR-25 115V with 1.25 inch Heater Cooler Package


1

814-200

PR-25 115V Mounting Press including:

200-262

Instruction Manual

814-200-050

Component Pack (for complete listing, see


Components and Accessories List, page 112)

807-543

Power Cord

807-927-125

Heater Cooler Assembly

811-304

Bakelite Black Preform (1.25 inch)

807-922*

Hazard Materials Pack (for complete listing, see


Components and Accessories List, page 112)

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

Introduction

PR-25

19

814-200-150 PR-25 115V with 1.50 inch Heater Cooler Package


1

814-200

PR-25 115V Mounting Press including:

200-262

Instruction Manual

814-200-050

Component Pack (for complete listing, see


Components and Accessories List, page 112)

807-543

Power Cord

807-927-150

Heater Cooler Assembly

811-312

Bakelite Black Preform (1.50 inch)

807-922*

Hazard Materials Pack (for complete listing, see


Components and Accessories List, page 112)

814-300-100 PR-25 230V with 1.00 inch Heater Cooler Package


1

814-300

PR-25 230V Mounting Press including:

200-262

Instruction Manual

814-200-050

Component Pack (for complete listing, see


Components and Accessories List, page 112)

807-928-100

Heater Cooler Assembly

811-308

Bakelite Black Preform (1.00 inch)

807-922*

Hazard Materials Pack (for complete listing, see


Components and Accessories List, page 112)

814-300-125 PR-25 230V with 1.25 inch Heater Cooler Package


1

814-300

PR-25 230V Mounting Press including:

200-262

Instruction Manual

814-200-050

Component Pack (for complete listing, see


Components and Accessories List, page 112)

807-928-125

Heater Cooler Assembly

811-304

Bakelite Black Preform (1.25 inch)

807-922*

Hazard Materials Pack (for complete listing, see


Components and Accessories List, page 112)

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

110

PR-25

Introduction

814-300-150 PR-25 230V with 1.50 inch Heater Cooler Package


1

814-300

PR-25 Mounting Press including:

200-262

Instruction Manual

814-200-050

Component Pack (for complete listing, see


Components and Accessories List, page 112)

807-928-100

Heater Cooler Assembly

811-312

Bakelite Black Preform (1.50 inch)

807-922*

Hazard Materials Pack (for complete listing, see


Components and Accessories List, page 112)

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

Introduction

PR-25

111

Components and Accessories List


814-200-050

Component Pack

163-021

Insert

537-103

Tubing (15 Ft)

774-672

Plastic Tubing (6 Ft)

805-757

Fitting

805-758

Fitting

807-615

Fitting

811-110

Powder Bakelite (1/Lb)

807-922*
1

811-271

Hazardous Material Pack


Silicon Aerosol Release Agent

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

112

PR-25

Introduction

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)

Introduction

PR-25

113

Consumables

Note

For a complete list of all LECO metallographic consumable,


request catalog number 203-826.

Compression Mounting Supplies


Description
Bakelite
Thermosetting
Powder and
Pellets

Powder

Qty

5 lb
(2.27 kg)

250 lb Drum
(113 kg)
Filler

Mineral
Epoxy
Thermosetting
Powder

Mineral
(-20 Mesh)
Glass

Filler

Mineral

Diallyl Phthalate
Thermosetting
Powder
Glass Fiber

Copper

114

PR-25

Qty
1 lb
(.454 kg)
5 lb
(2.27 kg)
5 lb
(2.27 kg)
1 lb
(.454 kg)
5 lb
(2.27 kg)
Qty
1 lb
(.454 kg)
5 lb
(2.27 kg)
50 lb
(22.5 kg)
1 lb
(.454 kg)
5 lb
(2.27 kg)
50 lb
(22.5 kg)
1 lb
(.454 kg)
5 lb
(2.27 kg)

Color
Black
Red
Green
Green/
Brown
Black
Green
Color

LECO
Part Number
811-111
811-118
811-123
811-128
811-111-250
811-154-110
LECO
Part Number
811-144

Black

811-145
811-145-120
811-140

Green
811-141
Color

LECO
Part Number
811-134
811-135
811-633

Blue
811-136
811-137
811-277
811-138*
Copper
811-139*

Introduction

Preforms
Thermosetting

Lucite
Thermoplastic
Powder

Introduction

Black

LECO
Part Number
811-301

Red
Green

811-313
811-325

Black

811-305

Red
Green

811-317
811-32

Black

811-309

Red
Green

811-321
811-333

Qty

Color

LECO
Part Number

1 lb
(.454 kg)
5 lb
(2.27 kg)
50 lb
(22.5 kg)

Clear
(For
Transparent
Mounts)

Mold Size

Qty

1.00 inch

100

1.25 inch

100

1.50 inch

100

Lucite is a
registered
trademark of
DUPONT

PR-25

Color

811-132
811-133
811-625

115

Specifications
The PR-25 is an automatic mounting press that incorporates a
unique, pneumatic-hydraulic system. The PR-25 incorporates
an integral, 1200-watt heater cooler and a larger mold height
to 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 and
non-restricting gravitational drain.

116

PR-25

Introduction

Figure 11
PR-25 Mounting PressFront View

Introduction

PR-25

117

Installation

Illustrations .......................................................................... 22
Installation ........................................................................... 23
Mount Heights....................................................................... 27

Installation

PR-25

21

Illustrations
Figure 21......... PR-25 Mounting PressBack View ................25
Figure 22......... Heater Cooler Assembly Alignment ...............26
Figure 23......... Heater Cooler Assembly at 45o .....................26
Figure 24......... Heater Cooler Assembly Positioned Correctly ..26

22

PR-25

Installation

Installation

WARNING

ELECTRICAL SHOCK HAZARD


This equipment uses 115 or 230 VAC power
supplies. Contact with these voltages can be
lethal. Do not apply power until instructed to
do so.

1.

Place the instrument on a work surface that has a


convenient air supply, water supply, electrical power
supply, and gravitational drain. Refer to the Specifications
section, page 116, for more information.

2.

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

3.

Turn the regulator control knob, located on the front panel


of the PR-25, all the way to the left (counterclockwise).

4.

Turn the ram down knob clockwise to the full close


position.

!
CAUTION

Note

Installation

POSSIBLE JACK DAMAGE


Do not over turn the knob. Turning the knob too
far 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 be


used. Tube push rod should be 1 to 2 inches above the
unit.

8.

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

Make sure that the bottom ram, heater cooler assembly,


and mold assembly are clean to assure proper fit and ease
of assembly.

PR-25

23

9.

Note

Note

Hold the heater cooler assembly in position over the


bottom ram (figure 2-2, page 26, and rotate the heater
cool assembly 45-degrees to the left (figure 2-3,
page 26).

This rotation matches the collar with the bottom mold


assembly configuration.

10.

Once the heater cooler assembly and the collar are aligned
properly, push the heater cooler assembly down into the
collar (figure 2-4, page 26).

11.

When the heater cooler assembly is down into the collar


correctly, turn the heater cooler assembly
counterclockwise until it locks in position. The heater
cooler assembly is now captive and cannot rotate.

12.

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

Connect the electrical outlet connector (already connected


to the PR-25) to the electrical inlet on the back of the
heater cooler assembly.

!
CAUTION

24

POSSIBLE MACHINE DAMAGE


To prevent overheating, make sure this
connector is on all the way and the locking ring is
engaged.

13.

Connect the water tubing that is already connected to the


rear of the PR-25 to the back of the heater cooler
assembly (figure 2-1, page 25).

14.

Connect the water supply tubing between the water supply


inlet on the rear of the PR-25 and the facility water supply.

15.

Connect the drain tubing to the water drain outlet on the


rear of the heater cooler and slop the tubing downward to
the laboratory drain.

PR-25

Installation

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

ELECTRICAL
CONNECTOR

HEATER COOLER
WATER INLET

807-538
HANDLE HOLDER

DRAIN OUTLET

774-672
DRAIN TUBING
(TO FACILITY DRAIN)

772-614
WATER OUTLET
ELBOW

537-103
WATER SUPPLY
TUBING
(TO FACILITY
WATER SUPPLY)

AIR INLET
WATER INLET

807-543 115V
807-551 230V
POWER CORD

Figure 21
PR-25 Mounting PressBack View

Installation

PR-25

25

LOCKING PIN HOLE


LOCATION ON MOLD
ASSEMBLY

BOTTOM RAM
(SELECT PROPER
RAM FOR HEATER / COOLER
1.25, 1.50, OR 2.00)

ALIGNMENT COUPLING
HYDRAULIC
CYLINDER ROD

LOCKING PIN CONSISTING OF:


807-541 BODY
803-456 SPRING
807-540 COLLAR
807-542 KNOB

807-539
MOLD COLLAR

Figure 22
Heater Cooler Assembly Alignment

Figure 23
Heater Cooler Assembly at 45o

Figure 24
Heater Cooler Assembly Positioned Correctly

26

PR-25

Installation

Mount Heights
For relatively consistent mount heights, the graph below lists
suggested parameters. This graph represents cured mount
heights for mounting media only. The volume of the sample has
not yet been considered. To compensate for sample volume,
the following table is given as an example.

Mold Diameter
1.00 inch
(2.54 cm)
1.25 inch
(3.18 cm)
1.50 inch
(3.82 cm)

Powder or
Premold
Weight

Sample
Dimensions

Mold Height

8 grams

/2 d x 3/8 t

13.5 grams

18.6 grams

15

/8 inch

/8 d x 3/8 t

/8 inch

/16 d x 3/8 t

/8 inch

1.5

1.0

MOUNTING
HEIGHT
(INCHES)
0.5

0
0

10

15

20

25

WEIGHT (GRAMS)
POWDER OR PREFORMS

Installation

PR-25

27

Operation

Illustrations .......................................................................... 32
Controls and Indicators........................................................... 33
Operation............................................................................. 35
Molding Pressures and Times ................................................... 38

Operation

PR-25

31

Illustrations
Figure 31......... Pressure Gauge .........................................34
Figure 32......... Controls and Indicators...............................34
Figure 33......... Double Mount Cross-Section ........................39

32

PR-25

Operation

Controls and Indicators

Note

Refer to figure 3-2, page 34, for control and indicator


locations.

Ram Down KnobTurning the knob clockwise closed the


hydraulic cylinder. Turning the knob counterclockwise releases
the applied pressure.
Ram Control KnobThis knob is used to raise and lower the
ram piston.
Pressure Regulator Control KnobUsed for adjusting mold
pressure. Rotate clockwise to increase pressure,
counterclockwise to decrease pressure. Use the outside lock
ring to lock unit at desired pressure.
Pressure GaugeIndicates the proper pressure setting for each
available mold size (figure 3-1, page 34). The inner scale is
for the 1.00 inch mold assembly; the middle scale is for the
1.25 inch mold assembly; the out scale is for the 1.50 inch
mold assembly. The red dots represent 4200 psi within the
respective mold assemblies. All of the scales are represented in
"psi x 1000" and "bars x 70."
TimerThe timer is a mechanical-type timer and is adjustable
from 0 to 20 minutes. There will be an audible ring when preset
time has expired.
Power LightThis red light, located on the heater cooler
assembly, indicates that power is on to the heater cooler
assembly.
Heater LightThis amber light will only be lit when the heater
elements are on and working. The heater elements are
regulated by a thermostat, so the heater light will flicker on and
off periodically.
Cool/Heat KnobUsed as a power switch for the heater cooler.
Turn clockwise to heat; turn counterclockwise to cool.

Operation

PR-25

33

Figure 31
Pressure Gauge

807-426 - 230V
806-951 - 115V
AMBER INDICATOR
HEAT

807-427 - 230V
806-952 - 115V
RED INDICATOR
POWER
807-533
PRESSURE
GAUGE
807-540
COLLAR

808-711
TIMER KNOB

807-573
RAM CONTROL

803-435
PRESSURE
REGULATOR

808-712
COOL/HEAT
KNOB

808-713
RAM DOWN
KNOB

Figure 32
Controls and Indicators

34

PR-25

Operation

Operation

Notes

All installation steps must be completed before operating


this 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 is
fully extended.
3. Set the pressure control knob one full turn
counterclockwise and push the mold cylinder down in
necessary.
4. Repeat this process several times.

1.

Note

Operation

LECO recommends using the silicone release agent for the


first 25 mounts, thereafter, only occasionally.
Make sure the instrument air and water supplies are
turned on, and the power on/off switch is in the off
position.

To avoid the cottonball effect when processing Lucite


(thermoplastic) mounts, disconnect the water inlet on the
back of the mounting press via the quick disconnect prior to
making a mount. Process mounts as outlined and allow
gradual cooling. Reconnect the water inlet when processing
thermosetting mounting media.

2.

Plug the unit into the proper facility power. Refer to the
Specifications section, page 116, for additional
information.

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 the


heater assembly should immediately light. The power
light should stay lighted throughout the entire heat
cycle. The heater light should regulate with the
temperature of the heater.

C.

Once the heat cycle is expired, turn the power switch


to the cool position.

PR-25

35

Note

D.

Set the timer to 5 minutes.

E.

During the cooling cycle, check the rear fitting


connections for leaks. If there are no leaks, the unit
is ready for operation.

4.

With the top enclosure removed, rotate the pressure knob


approximately 1 full turn counterclockwise to assure that
the bottom ram is in the down position.

5.

Turn the ram down knob clockwise until the closed position
is 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 turn


to place the bottom ram in the down position.

9.

Add mounting media (powder and preform). Refer to


figure 3-3, page 39, for additional information.

10.

Thread the top enclosure all the way down onto the mold
cylinder and then back to top enclosure off one-quarter
turn.

It is very important to back the top enclosure off onequarter turn. This will reduce the stress on the mold
cylinder threads and eases the removal of the top
enclosure.

11.

Rotate the ram down knob clockwise to the full close


position.

12.

Operate the pressure handle to the desired pressure for


the mold assembly being used.

!
CAUTION

Note

36

POSSIBLE MACHINE DAMAGE


Do not allow pressure to reach overload range.
Pressure can be adjusted using the front panel
pressure control knob.

There will be a definite decrease in pressure as the


thermosetting materials are heated through the curing
stage. Pressure must be maintained throughout this stage.
Pressure will become constant when cure stage temperature
is reached.

PR-25

Operation

Note

13.

Set the timer to the desired heating time.

14.

Once the heat cycle time has expired, turn the power
switch from the heat position to the cool position.

15.

Set the timer to the desired cooling time.

16.

Once the cooling cycle time has expired, rotate the ram
down knob counterclockwise one turn to release the
pressure inside the mold cylinder.

17.

Turn the ram control selector knob to the neutral position.

18.

Unscrew the top enclosure from the mold cylinder. The


spring inside the top enclosure will hold the threads apart
throughout 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.

WARNING

Operation

Continue to keep mold pressure stable.

HIGH TEMPERATURE HAZARD


Mounted specimens may be hot.
LECO recommends wearing hear resistant gloves
when removing mounted specimens.

22.

Remove mounted specimens.

23.

After each mount, clean the flashing off of the bottom ram
to ensure movement of the bottom ram inside the mold
cylinder.

PR-25

37

Molding Pressures and Times

Mounting
Material

Temperature

Pressure

Thermosetting

Bakelite

Epoxy

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

Diallyl
Phthalate

1.25 inch
(3.18 cm)
Mold

38

2.00 inch
(5.08 cm)
Mold

Powder

Preform

Powder

Preform

Powder

4200 psi
(289.58 bars)

10

12

1000 to 2000 psi


(68.95 to 137.89
bars)

N/A

10

N/A

12

3000 psi
(206.84 bars)

N/A

12

N/A

12

Time
(Minutes)

Thermoplastic

Lucite

Time
(Minutes)
1.50 inch
(3.82 cm)
Mold

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

100 psi
(6.89 bars)

30

Cool
100oF
(38oC )

4200 psi
(289 bars)

30 Air Cool
20 Water Cool

PR-25

Operation

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

MOUNT

Note

PIGGY BACK SPACER


807-919 - 1.25"
807-920 - 1.50"
807-921 - 2.00"

When making a double mount, make sure that the powder


media is approximately even across the cylinder before
inserting the spacer and the top enclosure. This will reduce
the forces on the rams and spacer, which in turn will make
it easier to remove the sample

Figure 33
Double Mount Cross-Section

Operation

PR-25

39

Maintenance

Molding Defects..................................................................... 43
Thermosetting Materials ................................................ 43
Thermoplastic Materials ................................................. 44
Heater Cooler Removal........................................................... 45

Maintenance

PR-25

41

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42

PR-25

Maintenance

Molding Defects

Thermosetting Materials
Defect

Note

Cause

Remedy

Section too large for mold


area.
Sharp corner on specimen.

Reduce specimen size.


Use larger mold size.
Eliminate sharp corners if
possible.

Material has absorbed


moisture.
Gases released by
chemical reaction.

Use preheated powder


or preforms.
Momentarily release
pressure during flow
stage.

Poor adhesion to sample


surface.
Excessive shrinkage at
interface.

Use lower molding


temperature.

Insufficient pressure
and/or cure time.

Adjust molding pressure.


Increase cure time.

Insufficient pressure
and/or cure time.
Curing or powder particles
prior to flow stage.

Adjust pressure and/or


cure time.
Rapidly seal mold closure
and apply pressure to
eliminate localized curing.

Excessive mold
temperature.

Decrease mold
temperature.
Momentarily release
pressure during flow
stage.

If mold temperature is too high, the following difficulties


may also be encountered:
1. Mounts sticking to mold surface regardless of finish or
application or release agent.
2. Dull surfaces on mounts.
3. Excessive flash.
4. Mold staining.

Maintenance

PR-25

43

Thermoplastic Materials
Defect

44

Cause

Remedy

Center portion of medium


did not reach maximum
temperature prior to cure
stage.

Increase holding time at


maximum temperature.

Inherent stresses relieved


upon or after ejection of
mount.

Cool to a lower
temperature prior to
ejection.
Decrease pressure during
cure stage.
Stress relieve mounts in
boiling water.

PR-25

Maintenance

Heater Cooler Removal

Note

Maintenance

Remove the heater cooler assembly only when the unit is at


ambient temperature. Due to thermal expansion, the heater
cooler may slide off the mold cylinder if removed when
warm. If this happens, warm the heater cooler and adjust it
back onto the mold cylinder.

1.

Before removing the heater cooler assembly, spray the


mold cylinder with silicone release agent.

2.

Run the bottom ram up and down inside the mold cylinder
a few times. This will help release the mold assembly from
the bottom ram and will also treat the inside diameter of
the mold cylinder for storage.

3.

Install the top enclosure onto the heater cooler assembly


and set the mold pressure to zero.

4.

Disconnect all connections from the rear of the heater


cooler assembly.

5.

Pull the locking pin out and turn the assembly to a 45


degree 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 pump


cycling slowly. Do not pull up on the heater cooler
assembly shroud. Let the pump do the work.

8.

If the heater cooler assembly is properly located, it should


begin to extend out of the collar. Once the base of the
heater cooler assembly is out of the collar, turn the heater
cooler assembly back to its center position (figure 2-4,
page 2-6).

9.

Position the ram control lever to the down position. When


the pump stops running, the ram is out of the mold
cylinder and the heater cooler assembly can now be
removed.

PR-25

45

Illustrations

Figure 51......... InteriorLeft Side View ..............................53


Figure 52......... InteriorRight Side View ............................54
Figure 53......... Exploded View1 ......................................55
Figure 54......... Exploded View2 ......................................56
Figure 55......... Exploded View3 ......................................57
Figure 56......... Heater Cooler Assembly ..............................58
Figure 57......... Switch Assemblies .....................................59
Figure 58......... PR-25 Flow Diagram...................................510

Illustrations

PR-25

51

This page intentionally left blank.

52

PR-25

Illustrations

814-006
CYLINDER MOUNT
AND BEARING
ASSEMBLY

807-593
TOP PANEL
ASSEMBLY

814-001
AIR
CYLINDER

807-533
HYDRAULIC
PRESSURE
GAUGE

807-534
ADAPTER
FITTING

803-435
PRESSURE
REGULATOR

807-502
SUPERSTRUCTURE
ASSEMBLY

807-525
LOWER FRONT
PANEL ASSEMBLY

190-018
SHOULDER
SCREW

807-564
4 WAY AIR
PILOT VALVE

805-798-110
ROTARY SWITCH

Figure 51
InteriorLeft Side View

Illustrations

PR-25

53

803-254
MECHANICAL
TIMER

807-573
PNEUMATIC
CONTROL
VALVE

805-798-110
2 POSITION
ROTARY SWITCH

807-888
FILTER
807-520 (115V)
807-548 (230V)
WATER VALVE
ASSEMBLY

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

Figure 52
InteriorRight Side View

54

PR-25

Illustrations

Figure 53
Exploded View1

Illustrations

PR-25

55

808-713
KNOB

190-886
SCREW
(4 REQ'D)

807- 887
SHAFT
(W/ HARDWARE)

808-711
KNOB
(W/ SCREWS)

193-055
WASHER
(2 REQD)

194-056
NUT
(2 REQ'D)

807-565
FITTING
(2 REQ'D)

808-712
KNOB

193- 110
WASHER
(3 REQD)

193-113
WASHER

807- 566
FITTING
(2 REQ'D)

194-055
NUT
(4 REQ'D)

190-824
SCREW
(3 REQD)

807-573
CONTROL
VALVE
(W/ NUT)

808-523
RELIEF
VALVE

801-238
PLUG

803-435
REGULATOR

807-594
LEFT PANEL

194-110
NUT
(3 REQ'D)

805-798-110
SELECTOR SWITCH
807-525
LOWER
FRONT PANEL

190-926
SCREW
(2 REQ'D)

803-254
TIMER
(W/ NUT)

807-534
NIPPLE

807-596
UPPER FRONT
PANEL

807-631
SLEEVE

807- 533
GAUGE
(W/HARDWARE)

190-269
SCREW
(10 REQ'D)

193-127
WASHER
(7 REQ'D)

807-598
INSULATION

193-008
WASHER
(3 REQ'D)

807-567
FITTING

767-866
FITTING

807-595
RIGHT PANEL

807-598
INSULATION

193-110
WASHER
(7 REQ'D)

778-523
FITTING
(3 REQ'D)

807-888
AIR FILTER

772-710
REDUCER

(OPTIONAL)
WASHER
(2 REQ'D)

194-056
NUT
(2 REQ'D)

603-061
FITTING

780-397
FITTING
807-471
FITTING

807-591
REAR PANEL

804-711 807-543 (115V)


ADAPTER 807-551(230V)
POWER CORD

800-299
FITTING
(W/ NUT)

807-581
PLUG

544-184
REDUCER

900-259
NUT
FITTING

772-614
FITTING

193-055
WASHER
(2 REQD)

190-324
SCREW
(4 REQ'D)

807-539
COLLAR

807-542
PLUNGER

807-447
WARNING LABEL

807-538
HANDLE HOLDER

807-575
COLLAR WASHER

807-593
TOP PANEL

806-764
BOX HOLDER

193-127
WASHER
(2 REQ'D)

190-269
SCREW
(2 REQ'D)

807-521 (115V)
807-549 (230V)
SOLENOID
773-41
RESISTOR

807-522
FILTER

190-750
SCREW
193-127
WASHER

602-167
ELBOW
(2 REQ'D)

780-970
LEVELING FOOT
(4 REQ'D)

193-110
WASHER

807-590
BASE

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

190-750
SCREW
(2 REQ'D)
193-127
WASHER
(2 REQ'D)

800-271
MUFFLER
(2 REQ'D)

193-110
WASHER
(2 REQ'D)

807-565
FITTING
(3 REQ'D)

778-523
FITTING
807-564
4 WAY VALVE

778-523
FITTING
(2 REQ'D)
B

807-763
VALVE

190-929
SCREW
(2 REQ'D)

193-010
WASHER
(2 REQ'D)

193-033
WASHER
(4 REQ'D)

193-108
WASHER
(4 REQ'D)

190-753
SCREW
(4 REQ'D)

589-855
FITTING

Figure 54
Exploded View2

56

PR-25

Illustrations

190-643
SCREW
(4 REQ'D)
190-908
SCREW
(4 REQ'D)

814-004
TOP PLATE

814-002
CYLINDER MOUNT
(2 REQ'D)

814-003
BEARING
(2 REQ'D)

807-565
FITTING

814-001
AIR CYLINDER

807-565
FITTING

194-162
JAM NUT
807-504
SUPPORT ROD
(4 REQ'D)

803-234
EYE BOLT

807-509
SPRING PLATE

807-510
SCREW
(8 REQ'D)
190-353
SCREW

807-511
SPRING
(4 REQ'D)
807-508
PUSH ROD

194-109
NUT

190-908
SCREW
(2 REQ'D)

807-505
JACK

807-506
JACK CLEVIS

193-033
WASHER
(2 REQ'D)

190-837
SCREW
190-018
SCREW

190-881
SCREW
(2 REQ'D)
193-033
WASHER
(2 REQ'D)
807-761
BRACKET
807-764
LIMIT SWITCH
(2 REQ'D)

193-058
WASHER
(2 REQ'D)

808-499
CYLINDER
RELEASE
ADAPTOR

775-322
CAP NUT

RUBBER WASHER
INCLUDED
WITH
FITTING

782-401
ELBOW
FITTING

773-705
ROLL PIN

773-661
FITTING
(2 REQ'D)

807-503
BOTTOM PLATE

193-008
WASHER
(4 REQ'D)
190-706
SCREW
(4 REQ'D)
RUBBER WASHER
INCLUDED WITH FITTING

773-661
FITTING
(2 REQ'D)

194-056
NUT
(4 REQ'D)

190-643
SCREW
(4 REQ'D)

Figure 55
Exploded View3
Illustrations

PR-25

57

807-839
TOP PLUG
RAM TOP
(PART OF MOLD CYLINDER ASSEMBLY)

806-987
SPRING

807-841
SLIDE
SHAFT

770-233
ROLL PIN
(2 REQ'D)

190-851
SCREW
(2 REQ'D)

806-549
PANEL TOP
807-842
HANDLE
TOP
193-004
WASHER
(4 REQ'D)

774-016
HANDLE
KNOB
(2 REQ'D)

190-624
SCREW
(4 REQ'D)

807-656 - 1.00-INCH
807-656 - 1.25-INCH
807-659 - 1.50-INCH
TOP ISOLATION RING

806-956
L350
THERMOSTAT
806-958
L425
THERMOSTAT

807-645-030
807-645-030
807-645-030
HEATER

807-427 - 230V
806-952 - 115V
RED INDICATOR

807-555
BOTTOM
ISOLATION RING

807-426 - 230V
806-951 - 115V
AMBER INDICATOR

807-644
TRIM

- 1.00-INCH
- 1.25-INCH
- 1.50-INCH
COOLER

807-643
BASE HEATER COOLER
ASSEMBLY
194-056
NUT
(2 REQ'D)

521-028
BUTTON PLUG
190-229
SCREW
(4 REQ'D)

194-055
NUT
(4 REQ'D)

804-733
CONNECTOR

807-932-100 - 1.00-INCH
807-650-125 - 1.25-INCH
807-650-150 - 1.50-INCH
MOLD CYLINDER ASSEMBLY

193-055
WASHER
(4 REQ'D)
190-279
SCREW
(4 REQ'D)

Figure 56
Heater Cooler Assembly

58

PR-25

Illustrations

24
VDC
806-932

INDICATOR
LIGHT
CLEAR LENS CAP
806-769
LAMP
NO RESISTORS

120VAC
806-952

INDICATOR
LIGHT
RED LENS CAP
806-768
LAMP
1 RESISTOR

806-951

AMBER LENS CAP


806-768
LAMP
1 RESISTOR

240VAC
807-427

INDICATOR
LIGHT
RED LENS CAP
806-768
LAMP
2 RESISTORS

807-426

AMBER LENS CAP


806-768
LAMP
2 RESISTORS

Figure 57
Switch Assemblies

Illustrations

PR-25

59

14

13
807-764
3 WAY EXT
VALVE

803-435
PRESSURE
REGULATOR

807-564
AIR PILOT
4 WAY VALVE

807-888
AIR FILTER
AIR IN

807-573
PNEUMATIC
CONTROL
VALVE

814-001
CYLINDER
808-523
75 PSI
RELIEF VALVE
2
3
1

807-763
AND VALVE

14

807-764
3 WAY EXT
VALVE
13

Figure 58
PR-25 Flow Diagram

510

PR-25

Illustrations

Index

C
Caution Symbols ............................................................... 17
Caution, Operator.............................................................. 16
Component Pack............................................................... 112
Components and Accessories List ......................................... 112
Compression Mounting Supplies........................................... 114
Consumables.................................................................... 114
Controls and Indicators ...................................................... 33
D
Dimensions ...................................................................... 116
Double Mount Cross-Section ............................................... 39
E
Electrical Power Requirements............................................. 116
G
Gases Required................................................................. 116
H
Hazardous Material Pack..................................................... 112
Heater Cooler Assembly ..................................................... 58
Heater Light ..................................................................... 33
I
Illustrations List ................................................................ 14
Installation....................................................................... 23
Interference to Other Devices ............................................. 18
M
Major Equipment and Accessories List ................................... 19
Molding Defects................................................................ 43
Mount Heights.................................................................. 27

Index

PR-25

61

N
Notice, Operator ............................................................... 16
O
Options ........................................................................... 113
P
Power Light ...................................................................... 33
Pressure Gauge................................................................. 33
Pressure Regulator Control Knob.......................................... 33
S
Specifications ................................................................... 116
Switch Assemblies............................................................. 59
T
Thermoplastic Materials ...................................................... 44
Thermosetting Materials ..................................................... 43
U
Utilities Required............................................................... 116
W
Warning Symbols .............................................................. 17
Warranty......................................................................... 15

62

PR-25

Index