Safety Information

Working around plastic extrusion equipment requires the operator to use caution. Operators MUST be trained
properly in the use of tools and safety equipment.

You will find various types of safety information on the following pages and on the labels attached to the equip-
ment. This section explains their meaning.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
EDI IS NOT responsible for damage or injury caused by improper use!

DANGER means that failure to follow this safety statement will result in serious personal injury or death.

WARNING means that failure to follow this safety statement will result in serious personal injury or death.

CAUTION means that failure to follow this safety statement will result in
minor or moderate personal injury or property damage.

NOTE: Use of the word “NOTE” will alert you to key information or instructions.

BEFORE attaching power, make sure die body has ground wire attached.

To avoid electrical shock, DO NOT remove any wire covers, conduit or plugs while power is connected to the
die.

BEFORE connecting this tooling to any electrical power source, make certain that the unit is externally ground-
ed (use #12 wire minimum).

NEVER stand in front of the exit opening of a die while it is heating or during start-up as molten material may
spurt out.

Touching hot die surfaces will cause burns.

Die surfaces may become extremely hot during operation.

• Wear protective gloves, glasses and clothing when working around die.
• Die insulation jackets are designed to retain die heat, not to protect the operator. Outer surfaces will be-
come extremely hot.
1-1
Dies are heavy and must be supported from the proper attach points while in operation or during handling.

• Lift points are indicated by “LP” stamped on die near attach point taps.
• Jack bolt taps are indicated by “JB” stamped on the die near the taps.

Dies, adaptors and co-extrusion feedblocks MUST be “heat soaked” for a sufficient time to melt any solidified
material (cold slug) BEFORE starting extruder.

Back die away from roll nip area before doing any maintenance or adjustment on deckle system.

Die bolts MUST be tightened per torque values shown. Over torque could cause harm to operator or damage
to equipment. Under torque will cause leaks. Use only Grade 8 (U.S. threads), Grade 12.9 (Metric) or better
fasteners and high quality tools.

Thermocouple taps and adaptors are provided for customers to provide a method of over temperature protec-
tion. EDI DOES NOT provide over temperature protection as part of the die.

All cartridge heaters and lip heaters contain a hydroscopic filler material around the heater coils. If the die has
been stored for any time, the heater could contain moisture. Before starting up your die, it must be brought up
to temperature very slowly to drive off the moisture without shorting out the heaters. Failure to do this WILL
cause heaters to fail.

The body bolt manufacturer highly recommends that the body bolts are replaced whenever the bolts are
untorqued due to the nature of the heating and cooling process. Body bolts are considered to be a wearable,
replaceable product. DO NOT replace body bolts with a lower Grade of bolt as operator injury may occur due
to bolt breakage.

Protect the lips when reassembling die. Leave lip protection in place until die is ready to heat.

End seals MUST be left loose until after die is hot.

Body bolts should be installed and tightened to the recommended cold torque levels when the die is cold.

To promote safe handling of hot dies, a procedure manual should be developed by your safety committee to
establish safe working conditions within your particular environment.

Final tightening of body bolts MUST be made with die at full operating temperature. Avoid seal material or for-
eign material from being pinched between the metal to metal main body seals. This can cause flatness distor-
tion of the die halves. Distortion of the die halves could result in gage bands, flow cavity degradation, increase
the chances of seal leakage and/or cause permanent damage to the metal-to-metal main body seal area.

NEVER use “helpers”, such as pipes, on lip adjustment bolts.

DO NOT tighten pressure screws to the point where the deckle block could be deformed or the seal material
destroyed.

Moisture In heaters WILL cause premature failure.

1-2
Only after the Autoflex® heater blocks reach operating temperature should the Fast Gap® (if provided), or
conventional lip be preset.

Before Autoflex® heaters are turned on, care MUST be taken to insure that premature heater failure does not
occur.

DO NOT use torch or extreme high temperatures to remove plastics from die, deckle, lips, etc. Heating above
die operating temperature may cause damage.

Place paper, cardboard or plastic sheets between the lips before die reassembly to guard against lip damage.
This protective material should be thin enough to slide out easily when the halves are connected.

Prior to lip removal, place soft protective shim between lips to prevent lip damage.

A piece of template paper or other suitable nonmetallic material should be placed in the lip gap between lip and
adjacent side of die to prevent damage to flow surface.

OSHA and the National Electrical Code

OSHA has established the national electrical code as its basic standard of electrical safety. The code in turn
imposes many demands upon wiring devices and their use.

If you have specified a plug for your equipment which does not comply with the national electrical code, Extru-
sion Dies, Inc., CANNOT assemble this item for your use.

Extrusion Dies, Inc., will not be responsible for any damage, injury or penalty imposed by OSHA, if the custom-
er installs non-conforming plugs or connectors.

NEC Reference

SECTION 200-10 “Identification of terminals. All devices provided with terminal for the attachment of conduc-
tors and intended for connections to more than one side of the circuit shall have terminals properly marked for
identification...”

SECTION 210-7(F) “Receptacles connected to circuits having different voltages, frequencies or types of cur-
rent (AC or DC) on the same premises shall be of such design that attachment plugs used on such circuits are
not interchangeable.”

SECTION 210-7(A) “Grounding-type receptacles shall be installed only on circuits of the voltage class and cur-
rent for which they have been approved.”

SECTION 250-45 “Equipment Connected by Cord and Plug. Under any of the following conditions, exposed
non-current-carrying metal parts of cord and plug connected equipment, which are liable to become energized,
shall be grounded:
(a) Hazardous location...
(b) When operated at more the 150 Volts to ground
(c) ...”

SECTION 250-51 “Effective Grounding. The path to ground from circuits, equipment and conductor enclosures
shall (a) be permanent and continuous and (b) have capacity to conduct safely any fault current liable to be
imposed on it and (c) shall have sufficiently low impedance to limit to voltage to ground and to facilitate the
operation of the circuit protective devices in the circuit.”

1-3
 Set-Up / Operation

As shipped, the Ultraflex® die is completely assembled with all necessary fasteners in place. Power leads to
connect the die zones to a power source are in a reusable crate with the die, as are the lugs for lifting the die.

The highest quality finish has been provided on this product. If the die has a rust inhibitor coating applied, the
coating must be removed from the internal and external surfaces before heating or oeprating the die. To assure
that this finish does not get damaged, please follow the cleaning instructions below.

• For internal cleaning, saturate the flow surface area to be cleaned with lacquer thinner to remove
any particles that have collected on the surface.

• For external cleaning, soak the tissue or clean, soft cotton cloth with lacquer thinner and wipe the
die surface from one side to the other. Only wipe in one direction. Discard the tissue or soft, cotton
cloth after one pass. (Using the tissue or cloth more than one time will damage the flow surface.

NOTE
The use of any other materials to clean this die will result in a damaged finish that could affect the integrity of
your product.

NOTE
The use of any felt type pens to mark on the finished surfaces will also cause damage to the flow surface.

To inspect the internal surfaces of the die before use, follow disassembly and reassembly instructions in the
Maintenance section of this manual.

Leave lip protection in place until die is ready to heat.

1. Using the provided eye bolts, lift die from crate to its operating position.
2. Mount the die to its cart or overhead support.
3. Mount adaptor to die and extruder clamp, leveling as necessary. This provideds a stable platform for
tightening fasteners.

Tighten Body Bolts

The body bolt manufacturer highly recommends that the body bolts are replaced whenever the bolts are
untorqued do to the nature of the heating and cooling process. Body bolts are considered to be a wearable,
replaceable product. DO NOT replace body bolts with a lower Grade or length of bolt as operator injury
may occur due to body bolt breakage.

The die is provided with Grade 8 (U.S. thread) or Grade 12.9 (Metric thread) body bolts. Twisting bolts off is
not a problem unless inferior Grade bolts are substituted. DO NOT substitue grade or length of bolt. Only high
strength wrenches should be used when applying bolt torque.

2-1
NOTE
Careful adherence to the following information will ensure leak free extrusion die operation.

Torque levels are for clean tooling with undamaged threads that have been lubricated with high temperature
anti-seize compound similar to that provided in the tool kit. The bolt head seating surface must also be lubri-
cated.

NOTE
Clean, lubricated bolts are essential to leak free operation.

During assembly, foreign matter may fall onto seal surface and prevent total seal contact. All dowel pins, push
bolt and body bolt holes must be clean. Inspect seal areas just prior to final seal contact.

1. Clean and inspect all parts.

2. Lubricate threads and bolt head seats with high temperature anti-seize lubricant.

Protect the lips when reassembling die.

3. Clean die seal surfaces just prior to final assembly.

End seals MUST be left loose until after die is hot at operating temperature and lip has been adjusted
to the proper gap and operating temperature, then tighten end seals.

Body bolts should be installed and tightened to the recommended cold torque levels when the die is
cold.

Per customer specifications, not all dies manufactured at EDI have been torqued completely at our
factory, please refer to your torquing procedure in the startup operations section of the manual.

NOTE
When tightening body bolts to their final stage, a suitable torque wrench or torque multiplying device is to be
used. Recommended torque levels MUST be reached and held for a moment allowing bolts to seat. This final
stage must be carried out at least twice to ensure leak free operations.

4. Tighten body bolts, adapter bolts and lip mounting bolts to the cold torque specifications listed in the fol-
lowing charts. Start from center and work out to the die ends alternating either side of center line during final
tightening.

2-2
NOTE

Bolts MUST be tightened to the cold torque values specified. Failure to do so will allow the antiseize compound
to flow over the seal surface and possibly create operational problems. DO NOT touch lip adjustment bolts at
this time. If this die has the upper lip bolts located under the Autoflex® adjustment system, they have been pre-
torqued at the factory.

BEFORE connecting this tooling to any electrical power source, make certain the unit is EXTERNALLY
GROUNDED. Use #12 wire minimum. Ground lug is located on the adjustment body and is marked with
a ground symbol/stamping. There is also a ground wire located in the power leads. Due to the possibil-
ity that the customer socket is not grounded at the power panel, the external ground wire MUST NOT
be omitted. See Figure 2-1.

Figure 2-1
Ground Lug

5. Connect power leads and thermocouples from die to power panel. Make certain that each power lead and
its corresponding thermocouple are properly matched at the panel.
6. Check and recalibrate die and adaptor controllers.

NOTE

When installing a die into an existing system, it is recommended that temperature controllers be tuned to the
new die. New thermocouples should be installed and care taken to make sure these are completely seated in
the thermocouple well. If the replacement die is of a different design, new operating conditions most likely will
be required.

All cartridge heaters contain a hygroscopic filler material around the heater coils. If the die has been
stored for any time, the heater could contain moisture. Failure to bring die up to temperature as direct-
ed WILL cause heater failure.

To promote safe handling of hot dies, a procedure manual should be developed by your safety commit-
tee to establish safe working conditions within your particular environment.

2-3
 TORQUE RATING CHART
(FOR DIES RUNNING 0°F/17.8°C - 550°F/288°C)

Recommended torque to be applied to socket head cap screws on E.D.I. plastics extrusion dies
for optimum results (assuming bolts are lubricated).
BOLT SIZE SOCKET SIZE RECOMMENDED TORQUE
Lb-Ft Kg-Meter Newton-Meter
English Metric English Metric Cold Hot Cold Hot Cold Hot
10-24 M5-.8 5/32 4mm 2.4 4.0 .36 .6 3.2 5.4
*1/4-20 M6-1 3/16 5mm 5.4 9 .72 1.2 7.3 12.2
5/16-18 M8-1.25 1/4 6mm 11 19 1.8 3 15.4 25.7
3/8-16 M10-1.5M 5/16 8mm 20 34 3 5 28 46
3/8-24 M10-1 5/16 8mm 23 39 3.3 5.5 31.6 52.8
7/16-14 M12-1.75 3/8 10mm 32 54 4.5 7.5 43.9 73.2
1/2-13 M14-2 3/8 12mm 50 83 6.9 11.5 67.5 112.5
1/2-20 M14-1.25 3/8 12mm 56 93 7.8 13 76 126
5/8-11 M16-2 1/2 14mm 98 165 13.8 23 133 222.3
3/4-10 M20-2.5 5/8 17mm 175 291 24 40 237 394.5
7/8-9 3/4 282 470 39 65 382 637.2
1-8 M24-3 3/4 19mm 424 706 59 98 574 957.2
1 1/4-7 M30-3.5 7/8 22mm 763 1271 106 176 1034 1723
1 1/2-6 M36-4 1 27mm 1263 2105 175 291 1712 2854
1 3/4-5 M42-4.5 1 1/4 32mm 2095 3493 290 483 2842 4736
2-4 1/2 M48-5.0 1 1/2 36mm 3146 5243 435 725 4265 7108

Our torque chart shows the typical recommended values. In some instances additional torque may be re-
quired. For example, applications operating at a high output rate, using tight operating lip gaps, or colder melt
temperatures.

A maximum value of 30% above our standard torque values can be used without causing damage to the bolt
threads or die body threads. EDI has performed testing to ensure that the 30% higher torque values are within
the safety limitations of the bolt. These increased torque values are still significantly below the maximum val-
ues recommended by the bolt manufacturer.

*NOTE: On dies w/lip inserts we must use 9 lb.ft.

(English bolts = Grade 8; Metric bolts = Grade 12.9)
(Pounds-Foot x .1383 = KG.-Meters)
(Pounds-Foot x 1.355818 = Newton-Meter)

Drawing # 1RE0008
Rev. 2 10/23/2008

2-4
 TORQUE RATING CHART
(FOR DIES RUNNING 550°F/288°C - AND ABOVE)

Recommended torque to be applied to socket head cap screws on E.D.I.

plastics extrusion dies for optimum results (assuming bolts are lubricated).
BOLT SIZE SOCKET SIZE RECOMMENDED TORQUE
Lb-Ft Kg-Meter Newton-Meter
English Metric English Metric Cold Hot Cold Hot Cold Hot
10-24 M5-.8 5/32 4mm 2 3 .27 .46 2.7 4.47
*1/4-20 M6-1 3/16 5mm 5 8 .66 1.1 7 11
5/16-18 M8-1.25 1/4 6mm 10 16 1.32 2.2 13 22
3/8-16 M10-1.5M 5/16 8mm 17 29 2.4 4 24 40
3/8-24 M10-1 5/16 8mm 20 33.2 2.8 4.6 27 45
7/16-14 M12-1.75 3/8 10mm 28 47 4 6.5 38 64
1/2-13 M14-2 3/8 12mm 43 71 5.8 9.8 58 96
1/2-20 M14-1.25 3/8 12mm 48 80 6.6 11 65 108
5/8-11 M16-2 1/2 14mm 85 142 11.8 19.6 116 193
3/4-10 M20-2.5 5/8 17mm 150 250 20.7 34.5 198 330
7/8-9 3/4 242 403 34 56 328 546
1-8 M24-3 3/4 19mm 363 605 51 84 492 820
1 1/4-7 M30-3.5 7/8 22mm 654 1090 91 151 887 1478
1 1/2-6 M36-4 1 27mm 1083 1805 150 250 1468 2447
1 3/4-5 M42-4.5 1 1/4 32mm 1796 2994 248 414 1866 3110
2-4 1/2 M48-5.0 1 1/2 36mm 2696 4494 373 621 3656 6093

Our torque chart shows the typical recommended values. In some instances additional torque may be re-
quired. For example, applications operating at a high output rate, using tight operating lip gaps, or colder melt
temperatures.

A maximum value of 30% above our standard torque values can be used without causing damage to the bolt
threads or die body threads. EDI has performed testing to ensure that the 30% higher torque values are within
the safety limitations of the bolt. These increased torque values are still significantly below the maximum val-
ues recommended by the bolt manufacturer.

*NOTE: On dies w/lip inserts we must use 9 lb.ft.

(English bolts = Grade 8; Metric bolts = Grade 12.9)
(Pounds-Foot x .1383 = KG.-Meters)
(Pounds-Foot x 1.355818 = Newton-Meter)

Drawing # RE0008
Rev. 2 10/23/2008

2-5
 18-8 STAINLESS STEEL CAP SCREWS
Recommended torque to be applied to socket head cap screws on E.D.I. plastics extrusion dies
for optimum results (assuming bolts are lubricated).

BOLT SIZE SOCKET SIZE RECOMMENDED TORQUE

Lb-Ft Kg-Meter Newton-Meter
English Metric English Metric Cold Hot Cold Hot Cold Hot
10-24 M5-.8 5/32 4mm 1.1 1.6 .15 .22 1.5 2.2
*1/4-20 M6-1 3/16 5mm 2.8 4.0 .39 .55 3.8 5.4
5/16-18 M8-1.25 1/4 6mm 5 7.1 .6 1 6.7 9.6
3/8-16 M10-1.5M 5/16 8mm 8.8 12.5 1.2 1.7 12 17
3/8-24 M10-1 5/16 8mm 10.1 14.4 1.4 2 13.7 19.5
7/16-14 M12-1.75 3/8 10mm 14.1 20.2 1.7 2.8 18.9 27
1/2-13 M14-2 3/8 12mm 21.9 31.2 3.0 4.3 29.4 42
1/2-20 M14-1.25 3/8 12mm 24.8 35.4 3.4 4.9 33.6 48
5/8-11 M16-2 1/2 14mm 37 53 5.1 7.3 50.4 72
3/4-10 M20-2.5 5/8 17mm 66 94 9 13 89 127
7/8-9 3/4 110 158 15 21.8 149 214
1-8 M24-3 3/4 19mm 166 237 23 32.7 225 321
1 1/4-7 M30-3.5 7/8 22mm 400 572 55 79 542 775
1 1/2-6 M36-4 1 27mm 697 995 96 138 945 1348

HOT TORQUE RATING ARE LISTED AT 50% OF THE SEATING TORQUE RECEMMENDED FOR 1960 SE-
RIES SOCKET HEAD CAP SCREWS. COLD TORQUE IS 70% OF HOT TORQUE RATINGS.

(Pounds-Foot x .1383 = KG-Meters)

(Pounds-Foot x 1.355818 = Newton-Meters)

Drawing # RE0008
Rev. 2 10/23/2008

2-6
7. At start up the die MUST be brought up to temperature very slowly to drive off moisture without shorting out
the heaters. Heat progressively from room temperature as follows:

Room temp. to 100°F/38°C Hold for 30 minutes

100°F/38°C to 150°F/65°C Hold for 30 minutes
150°F/65°C to 250°F/120°C Hold for 15 minutes
250°F/120°C to Die Operating Temperature

Final tightening of body bolts MUST be made with die at full operating temperature. Dies manufactured
at EDI have not been torqued completely at our factory, please refer to your torquing procedure in the
startup operations section of the manual.

8. With die at full operating temperature, repeat step 4 and tighten body bolts to specified hot torque rating.

End Seal Materials

The die body ends have micro-grooves, resulting from machining operations. These grooves must be sealed
by end seal material, and in fact, present the advantage of a labyrinth type seal. The seal is created by the
resiliency of the seal material which permits flow into the crevices. Metal-to-metal seals have proven ineffective
because they lack this capability.

EDI has carefully selected end seal materials to possess the proper characteristics needed to provide an
adequate seal. The seal material must be soft enough to “hob” into the die ends, while providing the proper
amount of compressive force without excessive “creep” under load.

Procedure to be used in applying end seals should include:-

1. Always make sure surfaces to be sealed are clean and free of polymer or other foreign material. If die body
has seal grooves make sure seal material is positioned in the grooves properly before putting die halves to-
gether.
2. Always use new end seal gasket material. Old gaskets have been “hobbed” to fit a specific placement and
relocating them may cause problems.
3. If substitute gasket materials must be used, match the properties of our recommended materials.
4. Never add additional backing material or use softer backing material, since this will cause the seal material
to be overextended and split into the polymer stream. This will not necessarily cause a leak but will present a
poor flow surface for the polymer.
5. Torque applied to pressure screws should be held closely to values listed below. Insufficient torque may per-
mit leakage, while excessive torque is unnecessarily destructive to the end seal components. Pressure screws
should be periodically lubricated with adequate high temperature lubricant to avoid thread binding. Torque to
24 lb ft (3.3 kg-m), let stand for 5 minutes at operating temperature and then re-torque. This value may change
with different process materials and operating pressure.
6. If external deckles are to be used on the die lips, special care must be taken to ensure that end seal assem-
bly is flush with die lips.

Avoid seal material or foreign material from being pinched between the metal to metal main body seals.
This can cause flatness distortion of the die halves. Distortion of the die halves could result in gage
bands, flow cavity degradation, increase the chances of seal leakage and/or cause permanent damage
to the metal to metal main body seal area.

2-7
 Figure 2-2
End Plate Types

Desirable End Seal Material Properties

Thermal Resistance: Normal processing temperatures range from 350°F to 650°F (177°C to 343°C). Seal
materials MUST be capable of maintaining seal pressure throughout this range without excessive “creep” or
thermal decomposition.

Release Properties: Materials in contact with die surfaces must not adhere to the die surfaces after prolonged
use, thus permitting rapid replacement.

Stability Under Load: The most critical and most difficult property to achieve in a gasket material. As the end
seal is installed and tightened, the seal material must compress and deform slightly to “hob” into the surface of
the die and effect a tight seal. It must then retain this deformation and not compress further, which would allow
the sealing pressure to decrease and create a leak.

Styles of End Seals and Seal Plates

The most frequently used type is a combination of pressure plate, seal plate and a compressible seal material.
See Figure 2-3. The seal material often is a special filled Teflon® composite available through EDI, spare parts
department. A variety of seal materials are available for various applications. Refer to your assembly prints for
the type of seal material used in the manufacturing of the die.

NOTE

The temperature range of this material is from ambient to 650°F (343°C). If your die operates above this range
a special seal material may be necessary.

2-8
 Figure 2-3
Styles of End Seals and Seal Plates

End Seal Torque Procedure

(Dies With Or Without Restrictor Bars)

As received, your EDI die will not have the end seal screws tightened to proper torque values. They will only be
snug enough to retain the seals and seal plates. The end seal screws should be torqued to approximately 24
lb ft. (3.3 kg-m) only after the lip has been adjusted to the proper gap and the die has been heated to operat-
ing temperature. Repeat this tightening procedure twice at five minute intervals. This will properly seat the seal
material.

2-9
 Autoflex VI or VI-R Operating Instructions

The Autoflex® VI or VI R Feature

This die is fitted with an Autoflex® VI or VI R thermal lip adjusting feature. The Autoflex® VI or VI R system
uses thermal expansion and contraction of the lip adjusting unit to make finer adjustments to the flexible lip
than are possible by strictly mechanical means.
Each lip adjusting position is fitted with a translator containing a heater and an air cooling path. Also provided
is a manual override, so that the approximate gauge uniformity is established prior to switching to automatic
control. The adjusting system utilizes an electrical source for each adjusting point to increase or decrease the
temperature of the adjusting translator, thereby changing the lip opening.

A Typical Autoflex VI-R Assembly Fitted to a Contour Die

3-1
A Typical Autoflex VI-R Assembly

3-2
The Autoflex® VI or VI R Die
With the exception of the Autoflex® VI or VI R feature, the die is a completely conventional flexible lip die. All of
the procedures and precautions described in all sections of this manual should be closely followed.
The Autoflex® VI or VI R heaters are pre-wired to multiple pin connectors located near the ends of the die. The
female half of the multiple pin connectors must be mounted by the customer and wired to the control source. A
schematic correlating the electrical pins with the corresponding adjusting screw is included.

Electrical
Refer to control interface instructions by system supplier.

Push Only or Push/Pull Lip Adjustment System

Due to the inherent design of a mechanical lip adjusting system it is possible to set the die lips mechanically
and have it be nonfunctional in the automatic mode.

This is due to non-contact of the adjusting screw to the lip with push only adjustment (Figure 3-1) or the me-
chanical backlash being in a pull mode in a push/pull adjustment system. See Figure 3-2.

Due to the limited thermal expansion of the adjusting system, if all of the adjusters are not set up in compres-
sion (pushing), the automatic mode may move through its complete travel without effecting the lip opening.

Figure 3-1 Figure 3-2

Push Only Adjustment Push/Pull Adjustment

It is very important to make sure:

1. All adjusters are in contact with the lip (push system only).
2. All Adjusters are in compression (push/pull adjusting system).

3-3
Autoflex® VI or VI R Design Features

Autoflex® VI, VI-A, and VI-R

Low mass translators which provide improved reaction time of both the heating and cooling cycles with
proper control algorithm.
Working threaded parts are easily replaced and serviced.
Manual adjusting system can be provided with:

A. DIFFERENTIAL PUSH/PULL LIP ADJUSTMENT.

U.S.: One turn of adjusting screw = 0.008 in. lip movement.

Metric: One turn of adjusting screw = 0.250 mm lip movement.

Translators are mounted above die and heat from translators does not affect die body.
Adjustments are typically on 1-1/8 in. (28 mm) centers.
A stainless steel cover is installed over adjustment system to prevent external drafts from influencing the
adjustments and vapor residue from condensing on adjustment components.
Translator blocks can have thermocouples incorporated into each adjustment position, if a temperature feed-
back system is to be used to control the Autoflex® system.
Adjustment system has low profile, allowing close approach into nip.
Autoflex® VI Travel = 0.030” or 0.762mm (Long stroke design)

At 50% Power 0.015” or 0.381mm movement (Long stroke design)

3-4
Autoflex® Operation

Moisture In heaters WILL cause premature failure.

1. Supply air to Autoflex® air/wire box prior to powering up Autoflex® system. See Figures 3-3 and 3-4 for
examples of air supply piping.

NOTE:
1) Regenerative Blower MUST be blowing air into Autoflex® air/wire box, as the Autoflex® air/wire box is de-
signed to run under pressure (EDI recommends 1.2psi).

2) All Flexible Piping MUST be the same Length.

3) The number of fittings will vary depending on the length of the die.

Figure 3-3
Blower Assembly for Autoflex®

3-5
NOTE:
1) Air Supply MUST be blowing air into Autoflex® air/wire box, as the Autoflex® air/wire box is designed to run
under pressure EDI recommends 1.2psi).

2) All Flexible Piping MUST be the same Length.

3) The number of fittings will vary depending on the length of the die.

Figure 3-4
Other Air source for Autoflex®

2. Allow the Autoflex® system to reach die body operating temperature, using the die body heat only, for one
hour before powering up Autoflex®. This will assure no moisture is in the heater element.

3. While the die is being heated and prepared for operation, per the Setup/Operation section of this manual,
set up the Autoflex® control using instructions provided by the system supplier.

3-6
Only after the Autoflex® heater blocks reach operating temperature should the Fast Gap® (if provided),
or conventional lip be preset.

4. Allow die body to stabilize at operating temperature for at least 30 minutes, then preset lip gap.

Various Wire / Air Box Fitting Styles

3-7
AUTOFLEX® VI or VI R

Push/Pull Lip Adjustment

1. A T-Allen wrench included in the die tool kit provides adequate torque to adjust any lip bolt at any opening
within the design range.

NEVER use “helpers”, such as pipes, on lip adjustment bolts.

2. All lip bolts in a push/pull system may not be in compression at all times. Care must be taken so as not to
force one screw down against adjacent screws, holding in tension. Any adjustment to close or open the lip
must be spread across many screws.

3. One full turn of a lip bolt represents about 0.008 in. (0.2 mm) of motion at the lip with English threads and
0.010 in., (0.25 mm), travel using metric threads.

4. This system has a neutral point between the push function and the pull function. Slack must be overcome
when changing rotation before the lip will be moved.

NOTE
An effective technique for maintaining all bolts in compression is to open bolt positions corresponding to “thin”
areas in the product to the point where “thick” areas are created. Then, close these positions to reach product
thickness specifications.

5. Do not try to correct extrusion problems with die adjustment. An extruder surge, for example, cannot be cor-
rected at the die.

6. Generally temperatures should be constant across the entire die. Occasionally a 5°F-10°F (3°C - 6°C)
increase of end zone temperatures is used to compensate for end heat losses of low throughputs which may
cause sheet to run light at the ends.

NOTE
If lip adjustment system has been disassembled, special attention must be given to the distance between the
bottom of the adjusting screw collar and the top of the micro nut (see sketch below). This dimension allows the
lip to be flexed the proper amount before the safety collar limits over-travel and must be set before the adjust-
ment nut retainer is bolted down.

The chart below shows the proper gap (X) required for a specific lip opening. Check your die assembly drawing
for lip opening, (amount of flex required). Gap “X” to be used only when lip gap is at maximum opening. See
Figure 2-4.

3-8
AUTOFLEX® VI or VI R

Push Only Lip Adjustment

1. A T-Allen wrench included in the die tool kit provides adequate torque to adjust any lip bolt at any opening
within the design range.

NEVER use “helpers”, such as pipes, on lip adjustment bolts.

2. All lip adjusting screws should be maintained in compression at all times. Any adjusting screws which
become slack due to movement of neighboring adjusting screws should be brought back into contact with the
bearing surface. Adjustment of lip adjusting screws in groups and in smooth patterns tends to do this automati-
cally.

3. One full turn of a lip adjusting screw represents about 0.040 in. (1 mm) of motion at the lip. A slight adjust-
ment is significant. Keep individual lip adjusting screw adjustments small.

4. There is no neutral point through which the threads pass upon a change on direction. Every turn of an ad-
justing bolt represents a change in the die opening.

NOTE
An effective technique for maintaining all bolts in compression is to open bolt positions corresponding to “thin”
areas in the product to the point where “thick” areas are created. Then, close these positions to reach product
thickness specifications.

5. Do not try to correct extrusion problems with die adjustment. An extruder surge, for example, cannot be cor-
rected at the die.

6. If the die is equipped with a flexible lip, it is set to its maximum opening. If you wish to preset the lip to a
smaller opening, do so at this point. A die with an internal deckle should have a lip gap 0.001 in. to 0.002 in.
(0.025 mm to 0.050 mm) larger than the blade of the internal deckle. Tighten the adjusting bolts in a clockwise
direction. Make several passes along entire length of the die, turning each bolt only slightly on each pass.
Make uniform adjustments on each bolt, rather than a large adjustment on any single bolt.

7. Opening should be checked with a soft (aluminum, brass, or other soft, but rigid material) shim of the de-
sired thickness. DO NOT adjust lip with shim between lips, but slide it in after each adjustment, until a snug fit
is obtained all the way across the die.

8. Generally temperatures should be constant across the entire die. Occasionally a 5°F-10°F (3°C - 6°C)
increase of end zone temperatures is used to compensate for end heat losses of low throughputs which may
cause sheet to run light at the ends.

NOTE
If lip adjustment system has been disassembled, special attention must be given to the distance between the
bottom of the adjusting screw collar and the top of the micro nut (see sketch below). This dimension allows the
lip to be flexed the proper amount before the safety collar limits over-travel and must be set before the adjust-
ment nut retainer is bolted down.

The chart below shows the proper gap (X) required for a specific lip opening. Check your die assembly drawing
for lip opening, (amount of flex required). Gap “X” to be used only when lip gap is at maximum opening. See
Figure 2-4.

3-9
“X” Dimension Diagram & Chart
Lip Flex Req’d *X English *X Metric

0.010 0.092 0.080 (2.03mm)

0.020 0.155 0.130 (3.30mm)
0.030 0.217 0.180 (4.57mm)
0.040 0.280 0.230 (5.84mm)
0.050 0.342 0.280 (7.11mm)
0.060 0.405 0.330 (8.38mm)
0.075 0.500 0.400 (10.16mm)
0.100 0.655 0.530 (13.46mm)

*Numbers shown above include 0.030 allowance thread for

thread backlash.

Figure 2-4
Push/Pull Adjustment Screw

“X” Dim Measured with Vernier Calipers

3-10
Autoflex® VI or VI R Start Up

Checking the autoflex system before powering up any components.

1. The individual bolt wiring should be checked to make sure that when the controller calls for a power level /
temperature change to a given bolt, that the correct bolt is the one seeing the change.

2. The Autoflex® blower air piping should be checked to confirm air supply to the Autoflex® air/wire box is cor-
rect. The air being supplied to the Autoflex® air/wire box MUST be blowing air into Autoflex® air/wire box, as
the Autoflex® air/wire box is designed to run under pressure (EDI recommends 1.2psi). (See Figures 3-3 and
3-4 for examples of air supply piping).

3. Check the Autoflex® air/wire box for air leakage’s.

Before Autoflex® heaters are turned on, care MUST be taken to insure that premature heater failure
does not occur.

1. Supply air to Autoflex® air/wire box prior to powering up Autoflex® system.

2. Heat die to operating temperature per Setup/Operation section of this manual.

3. Allow the Autoflex® system to reach die body operating temperature, using the die body heat only, for one
hour before powering up Autoflex®. (This will assure no moisture is in the heater element).

4. After the die body is at set point, the Autoflex® system must be brought up to heat slowly as follows:-

• 10% power for 15 minutes

• 20% until setup power level is reached and maintained for 15 minutes
• 30% until setup power level is reached and maintained 15 minutes
• 40% until setup power level is reached and maintained 15 minutes
• 50% until setup power level is reached and maintained 30 minutes

5. After reaching the setup power level (usually 40% or 50%), the die lip must be re-gapped to process set lip
opening. Re-gapping accomplished by manually adjusting die bolts (See Setup/Operation), or by Fast Gap®
Features (if provided).

6. Tune the open/close response ramp as follows: (Typically tune 40% to 60% or 50% to 70%).

• Bring power level to 40% or 50% and let bolt temperature stabilize.
• Raise power level to 60% or 70%. Using one of the thermocouples provided on the Autoflex® System
and a handheld pyrometer check the heat up response. Record the temperature every minute until the
temperature stabilizes.
• Bring power levels back to 40% or 50% and check the cooling response time as the lip opens up.
• Adjust the cooling air flow to approximate the heating ramp time/temperature. If more convenient the
same test can be run recording lip opening rather than bolt temperature.

3-11
Important Note:

• If the Autoflex® system is to run using temperature control instead of percentage (%) power control
then further tests must be performed to find out at what temperature will give the same output as 50%
power.
• A temperature feedback system is where the use of thermocouples to control the temperature of each
individual Autoflex® heaters & NOT percentage (%) electrical power output on each individual Autoflex®
heaters is used to control the gauge thickness.
• In a temperature feedback system the starting set point of the Autoflex® heaters is very important as too
high a temperature will not allow the Autoflex® translators to do their jobs correctly. i.e. at 50% power out-
put you still have 50% movement each way, but if a temperature feedback system is used & the starting
set point temperature is set too high then you immediately lose Autoflex® movement to close the lip gap.

a) Set all Autoflex® heater blocks to 50% power output. Making sure that the air is being supplied to
the Autoflex® air/wire box and let bolt temperature stabilize.
b) Record all Autoflex® heater block temperatures at this setting.
c) Set all Autoflex® heaters to 75% power output and let bolt temperature stabilize.
d) Record all Autoflex® heaters temperatures at this setting
e) Set all Autoflex® heaters to 25% power output and let bolt temperature stabilize.
f) Record all Autoflex® heater temperatures at this setting.
g) This will give you three Autoflex® temperature curves, from this data an ideal Autoflex® heater set
point (50%) can be arrived at.

7. The Autoflex® bolt should at no time exceed 600°F (316°C). A power temperature test should be made at
this time to set up a maximum bolt power level.

8. The die bolt system is now ready to be put into operation.

9. An operator should rough adjust the gauge to within ±10%, then the system can be turned over to auto
control.

10. Check the “DIE BOLT MAP” to make sure the Autoflex® adjusters are correctly aligned to the gauging
head position.

11. The gauging control system manufacturer will fine tune the system at this point.

12. At shutdown turn the Autoflex® control off before die body temperature is shut off.

13. The lip adjusting screws should be backed off allowing the lip to open to its maximum setting.

NOTE
Your Autoflex® die is equipped with thermocouple taps in both the Autoflex® and fixed body side. When oper-
ating die in Autoflex® mode, thermocouples MUST be installed on Autoflex® side.

After the extruder is started and brought up to operating speed and allowed to stabilize, the die can be
adjusted in the conventional fashion, that is the film measured and necessary corrections made by manually
turning the adjusting screws.

Preventive Maintenance
The Autoflex® system requires no special maintenance procedures. Adjusting screws should be periodically
cleaned and lubricated for smooth functioning. A list of recommended spare parts is included in Parts section
of this manual.

3-12
REPLACEMENT OF FAILED AUTOFLEX® VI or VI R CARTRIDGE HEATERS

Use the following instruction for replacement of your thermal die bolt cartridge heater element. Reference
the cross-section drawing located in the back of your manual.

1. Disconnect the power supplied to the Autoflex system by shutting power off and unplugging receptacle. Use
obligatory Lockout Tagout procedure as directed by your company safety policy.

2. Remove the cover on the air/wire box to access the terminal inside. The heater lead is terminated to one
side of the block, with the power lead wires on the other side.

3. Locate the heater lead to be replaced and loosen lugs.

4. Remove the screw cap and grommet holding the lead into the box and remove the lead from the box. Slide
the grommet off the lead and retain for use on the replacement heater.

5. Pull the heater from the translator. It should not be necessary to remove any components from the adjust-
ment position. If the heater is stuck, remove the retainer screws and retainer. If the heater still will not move,
clamp locking pliers onto the element for additional pulling force. If you still cannot remove the element from
the translator with locking pliers, the adjustment position will need to be disassembled. (See Assembly proce-
dure or call your EDI representative).

6. Replace the element with EDI supplied OEM heaters of the correct size and wattage. Perform a resistance
check on the heater prior to installation. Apply a thin coating of Infra kote, heat transfer paste to the heater and
insert it into the translator.

7. Put the grommet on the lead. Locate the grommet where the braiding ends. Insert the leads into the provi-
sion on the Air/Wire box and connect the leads to the terminal.

8. Replace the cap over the grommet and check the resistance at the receptacle. Replace the cover on the
Air/Wire box. Do not over tighten the cover, taking care to assure a good air seal is achieved.

9. Connect the power and slow heat the new element at 10% power increments over 30 minutes. Restore
required nominal power settings.

3-13
Autoflex VI or VI R removal & reassembly Procedure

The following is the procedure for setting and assembling the Autoflex VI system.
Reference your drawings and manual for additional information.

1. Disconnect the power supplied to the Autoflex system by shutting power off and unplugging receptacle. Use
obligatory Lockout Tagout procedure as directed by your company safety policy.

2. Remove cartridge heaters from the translator blocks.

3. Remove all retainer bolts.

4. Remove all lip adjusting nut retainers.

5. Remove all lip adjusting screws & nuts.

6. Remove the retainer bar & flex cover.

7. Remove all lip adjusting blocks.

8. Clean all threads, re-lubricate with anti-seize compound.

9. With the die lip gap in a neutral position (No lip adjustment assembles fitted to the die & no polymer effect-
ing the lip gap).

10. Set the gap between the lip adjusting screw and the lip adjusting nut (“X” dimension). (Reference your
drawings and manual for your dies specific dimension).

11. If the lip adjusting blocks have been removed. Refit the lip adjusting blocks onto the lip adjustment groove
on the die. (Confirm the block is seated in the groove on the die).

12. Then thread the lip adjusting screw and nut into the lip adjusting inserts until the lip adjusting nut seats
onto the die body.

13. Re-check the gap between the lip adjusting screw and lip adjusting nut after the lip adjusting block is
installed. (A gap as per your die drawings or slightly more, never should the gap be less then your dies specific
dimension).

14. Install all lip adjusting nut retainers.

15. Install all retainer bolts.

16. Lubricate all cartridge heaters with Infra-Kote Heat Transfer Lube.

17. Install cartridge heaters into the translator blocks.

18. Check the movement of all lip adjusting screws. (If any are tight disassembly & check components).

3-14
 Maintenance

The Maintenance of Flat Film and Sheet Dies

Rising costs, material shortages, and highly competitive markets are continually forcing sheet and film extrud-
ers to maximize operating efficiency. With extruder machine time costing upwards of $200/hour, it is essential
that unscheduled or excessively long shut-downs be minimized. All too often, excessive downtime is the result
of failures in the die, which could be avoided by adopting sensible and inexpensive die maintenance and
cleaning practices.

Because of the continuous nature of the extrusion process, sheet and film dies are rarely subject to wear or
damage while in operation. Most cases of die failure can be traced directly to careless or improper handling
during maintenance, cleaning, or set-up. This is somewhat understandable in that a sheet or film die is nor-
mally hot, heavy, and awkward, yet the critical surfaces are very precisely and highly finished, and must be
handled with care. A sound die maintenance and training program can eliminate the majority of costly errors.

Recognizing the cost of extruder time, and the part that die care plays in downtime, there is a strong economic
justification to keep a back-up die on hand. Should a die become unusable, repair costs may run from 30 to
60 percent of new die cost. In addition, a complete rework often requires 2 to 8 weeks. Obviously 8 weeks
of downtime could justify a back-up die. Less obvious, but also important, is the time that a back-up die can
save in routine day-to-day operations. The case for a back-up die and sound die program is amplified in most
specialized applications, such as PVC extrusion, where frequent clean-ups and occasional die reworks are
routine.

Turn-around time to stop, clean-up and restart a die can be 4 to 8 hours. If a back-up die is preheated and pre-
set, this time can often be reduced to 1 hour or less. With minimum time loss, the clean die is placed in produc-
tion while the original die is moved to a work area to be thoroughly cleaned and inspected. Disassembly and
cleaning can be done by select personnel responsible for the maintenance of die systems. Persons involved in
this work should be familiar with the design, construction, and function of each die. They should also be sup-
plied with individual assembly drawings, parts lists, and instruction manuals for each die.

When a new die arrives in the plant, it is a good practice to take it apart while it is still clean and cold. This pro-
cedure not only services as an incoming inspection, but it is also an excellent way to familiarize maintenance
people with the die. Working with a clean, cold die can be very good for training new personnel.

The Die Shop

Whether die work is done on or near the extrusion line, or in a separate work area adequate equipment is
required for rapid, safe handling. First and foremost is a good lifting device. A slow-speed electric hoist, which
can be readily positioned over the die, is ideal for this application, allowing the operator to guide the die while
maintaining finger-tip control of the hoist. Lift speed should be less than 15 ft./minute, preferably 6 to 8 ft./
minute. Manually operated chain hoists should be avoided as the loose chain, carelessly handled, can easily
damage the die lips. Fork lift trucks and other portable lifts have the disadvantage of not being controlled at the
point of lift, thus requiring the close coordination of two men. Also, these portable devices are often tied up with
other plant work when needed in the die shop.

In addition to the hoist, a means to grasp the die is needed. A simple set of hooks and eye bolts can be easily
fabricated to grasp and balance the die. These hooks are more convenient and safe than the chains, cables
and clevises often used. Because of the danger of fraying, melting, or charring, non metallic ropes and slings
must be avoided.

4-1
A sturdy portable cart or bench is useful as a work table and to hold die parts during cleaning. The table should
have a wooden surface and padding such as felt or paperboard. The padding must be renewed when dirty to
prevent scratching of polished surfaces.

Tools required for die work are not numerous, consisting mainly of various hexagon keys and a mechanic’s
common tools. A complete tool box containing all of the required tools and cleaning materials should be kept
close at hand and reserved for this purpose. A small impact wrench to speed insertion and removal of fasten-
ers is time-saving convenience, but a tool large enough to bring large body bolts to full torque is generally
impractical except in large shops. Two sizes of manual torque wrenches, one to 1580 ft./lb (2142 N/m). Capac-
ity and one of 1000 to 1200 ft./lb (1355 to 1627 N/m) capacity, should be considered essential.

A most valuable installation is a die pre-heat station, which is used to reheat dies for ease of cleaning and to
pre-heat the clean dies prior to installation on line.

Precise multi-zone temperature control is not required for simple single manifold dies so there is no need for
an elaborate, multi-zone panel. A single on-off control is adequate to handle simple single manifold dies. Of
course, the unit must be properly fused and grounded to protect both equipment and people. The addition of a
simple timer to turn the heat on at a predetermined time can increase the utility of the unit and save energy.

Precise multi-zone temperature control is required for multi-manifold dies so an elaborate, multi-zone panel
should be purchased. Of course, the unit must be properly fused and grounded to protect both equipment
and people. The addition of a simple timer to turn the heat on at a predetermined time can increase the utility
of the unit and save energy.

If the physical layout of the extrusion line permits, a die cart is most useful. In operation, the cart supports the
weight of the die system, preventing undue strain on the extruder barrel. In many cases it can provide a work-
ing platform for the operator. The cart also provides a means to transport the die and support for at least part of
it during cleaning.

Cleaning and Preventative Maintenance

When possible, the die clean-up crew should be alerted in advance of a shut-down, in order for tools and
supplies to be assembled. Upon shut-down, the major fasteners, such as end plate, adapter, and body bolts,
should be loosened but not removed. Because of the force required, this is best done with the die clamped
securely to the extruder. Once the all major fasteners have been opened, the die can be moved to the cleaning
area where the fasteners are completely removed and the die parts separated. (Remove only those parts nec-
essary to expose all flow surfaces for cleaning.) Whenever possible, lip and restrictor bar (R-Bar) (choker bar)
settings should remain undisturbed, allowing a faster re-start. Since thermoplastics clean up with least difficulty
when hot, disassembly should proceed as rapidly as possible to minimize heat loss. It is best to leave the die
heating until the very last possible moment before starting the disassembly process.

After the die is opened and flow surfaces exposed, the cleaning procedure will depend upon the type of mate-
rial being processed. Many thermoplastics can be readily removed by lifting the material away from the die,
while at the same time directing a jet of compressed air at the junction of the plastic and the die surfaces. If the
molten plastic cannot be removed in this manner, it can be scraped off using scrapers made of brass, copper
or soft aluminium; never use steel. Occasionally, solvents can be utilized to aid removal of stubborn materi-
als. The resin or die supplier can usually offer specific cleaning suggestions. After the bulk of the plastic has
been scraped away, the remaining film can be scrubbed off by scouring with brass wool and dry mild abrasive.
Household cleaners make an excellent and economical abrasive for this purpose, although the types designed
for very heavy scouring may cause scratching. Test a sample on a non-critical surface before proceeding. Pow-
er brushes or buggers should not be used as they can easily abrade through the chrome plating and round
off sharp edges. Extra care should be taken to meticulously clean all sealing surfaces to prevent subsequent
leakage.

4-2
Typical Die Sealing Surfaces are Shown Below

Figure 4

Between cleaning and reassembly, the die should be closely inspected. Minor problems such as damaged
threads should be repaired or replaced as necessary.

Damage that cannot be corrected on the spot should be evaluated as to the effect on performance. If it is de-
termined that immediate correction is not essential, the damage should be noted for future repair.

As a precautionary measure, the die flow surfaces should be lightly covered with a protective coating such as
silicone grease / oil. The coating protects against corrosion during prolonged storage and helps the initial, rela-
tively cold plastic to move cleanly through the die upon start-up.

During reassembly of the die bodies, a paper or plastic shim should be placed between the die lips to prevent
them from touching and causing damage. The shim can be slipped out as soon as the die bodies are securely
in place. Bolts should be replaced and lightly tightened. When reinstalling bolts or other threaded devices, it
is important that they go together smoothly and easily. Any thread that feels tight or sticky at reassembly will
probably be solidly seized after some time in production. Threads and the seat areas under bolt heads should
be thoroughly lubricated. Because extremes of temperature and pressure make high demands on lubricants,
only the best grades of high temperature grease should be used. Molybdenum or graphite based lubricants
have proven most satisfactory in this application. The die can now be re-set and reheated in preparation for the
next run. During heat up, all heaters should be checked for function.

Because the high-strength bolts used in most dies have a coefficient of thermal expansion that is slightly
higher than the body steel, final tightening of the bolts should be done only after the die has been allowed to
heat soak at operating temperature for 30 to 60 minutes. Torque requirements are supplied in the manual.

4-3
Any bolts providing a sealing function are normally brought to maximum torque and should be tightened by
starting at the die center and working outward. The final tightening is best done with the die clamped securely
to the extruder.

NOTE
When tightening body bolts to their final stage, a suitable torque wrench or torque multiplying device is to be
used. Recommended torque levels MUST be reached and held for a moment allowing bolts to seat. This final
stage must be carried out at least twice to ensure leak free operations.

1. Tighten body bolts, adapter bolts and lip mounting bolts to the cold torque specifications listed in the fol-
lowing charts. Start from center and work out to the die ends alternating either side of center line during final
tightening.

NOTE
Bolts MUST be tightened to the cold torque values specified first. Failure to do so will allow the anti-seize com-
pound to flow over the seal surface and possibly create operational problems. DO NOT touch lip adjustment
bolts at this time.

Operating Procedures

Proper operation is part of any good maintenance program. While in operation, a die can be considered to be
a solid, stable mass of steel with no moving parts. For this reason, product variations of a cyclic nature are
almost never related to the die. When cyclic variations do occur, variations in temperature, pressure, output,
and line speed should be investigated and corrected as necessary. Die adjustments to correct an extrusion
problem only increase wear.

Both die lips and choker bars are relatively inflexible and will not conform to tight bends. The relative inflexibility
of these members means that they neither cause nor correct very narrow gage bands, which usually have their
source upstream of the die. Adjustments to the die lips and restrictor bar (R-Bar) (choker bar) should be made
in smooth curves, using the adjusting bolts in pairs and groupings.

Making broad adjustments will prevent sharply bending the lip or bar and will distribute the stress evenly
among the bolts.

Care should be taken that adjacent adjustments are not fighting one another, which will eventually cause bolt
breakage. Use only the wrenches provided to make adjustments. The use of “cheaters” is unnecessary and
can cause damage. If it is necessary to scrape or clean the die lips during operation use only soft materials
such as brass or copper.

In addition to routine maintenance, a very thorough cleaning and inspection of all parts should be made period-
ically. The time interval depends on the type of service, but every six months would be a reasonable average.
All die parts and fasteners should be stripped and cleaned of polymer, carbon and lubricants.

4-4
Threaded holes should be re-tapped and all parts lubricated.

Electrical systems should be inspected for grounded heaters, frayed wires and cracked receptacles.

Any faulty or questionable parts must be replaced to insure a safe, operational die. Flow and seal surfaces
should be inspected for nicks and scratches.

Damage to these surfaces should be referred only to a shop experienced in extrusion die repair.

With the exception of corrosive or abrasive extrudates, most plastics will cause no significant wear to a die,
even in the course of several years of operation. Thus the useful life of a die is nearly indefinite, limited only by
obsolescence or physical damage. While design or product changes may make obsolescence unavoidable, die
life and performance certainly should not be sacrificed for want of proper care.

This die is supplied with cartridge heaters installed in holes which are precision drilled and reamed in the die
bodies. In the event of heater failure, it must be removed and replaced with another heater of equal wattage,
voltage and size.

To avoid electrical shock, DO NOT remove any wire covers, conduit or plugs while power is connected
to die.

1. Disconnect power to the die and remove the wire enclosure to expose the heater wiring.

2. Unfasten the wires which supply voltage to the heater being replaced.

3. A 5/16 in. (8 mm) diameter rod is inserted in the 3/8 in. (9.5 mm) diameter poke out hole and tapped gently
with a small hammer to push out heater.

NOTE
Most heaters have a 3/8 in. (9.5 mm) diameter poke out hole which exits the body on the side opposite the wir-
ing. (There may be a pipe plug sealing this hole).

4-5
 Slide

Driver Weight
Die Body

Note: If your die has heaters installed in blind holes (holes

that are not drilled through the piece), you will find a
removal tool in the tool box.

Removal Tool
Instructions: Thread the heater wire into the hollow pipe and screw
the threaded end into the collar on the heater. Slide the
Heater in Blind Hole driver weight away from the heater, with a rapping
motion, against the far end of the tool. Keep tool
screwed in tight in the heater collar.

EDI012
Figure 4-2
Heater Removal Tool

4. Apply a thin coat of heat transfer compound, like “Infra-Kote”, which will help conduct heat and help future
heater removal.

NOTE
Be sure push out plug is inserted in hole before the heater is installed.

5. Insert new heater.

6. Reconnect heater wires as installed by factory (Refer to die electrical wiring diagram).

7. Replace all electrical covers before restoring power to the die.

NOTE
To replace heaters without poke out holes refer to Figure 4-2.

Die Body Disassembly

Torque on body bolts is most easily overcome with die mounted in its operating position. With extruder shut
off and adaptor locked in the clamp but die heat should still be on until just before removal from the line, break
loose all body bolts with a torque wrench or Allen wrench with four to five feet of pipe. Subsequent disassembly
steps may be made at or remote from the extruder. The adaptor and both die halves should be fully supported
throughout disassembly. (See exception below, for removable lip with Autoflex® feature.) Consult die drawings
found in this manual.

1. Shut off die and adaptor heater controllers.

2. Remove leads and thermocouples from the die.

3. Check dowel pin engagement.

4-6
NOTE
Dowel pins should be engaged no more the 3/8 in. (9.5 mm) in the half to be lifted away from mating half and
adaptor.

4. Remove end seal screws to drop out end seal gaskets and plates. If die has a one piece bolt-on end plate,
remove bolts and plate.

5. If adaptor bolt circle encompassed both die halves, remove adaptor bolts for the half to be lifted.

6. Place soft protective shim (paper or plastic shim) should be placed between the die lips to prevent them
from touching and causing damage. The shim can be slipped out as soon as the die bodies are parted.

DO NOT use torch or extreme high temperatures to remove plastics from die, deckle, lips, etc. Heating
above die operating temperature may cause damage.

7. Separate die halves using a lifting apparatus connected to provided lifting lugs.

NOTE
If the halves do not separate easily, Lubricate and install all jacking bolts in the main body. (Allow them to heat
soak before jacking the halves apart). Engage jack bolts provided. Jack the die apart, taking small turns on
alternate jack bolts until adhesion of the plastic between die halves is overcome.

8. All die and adaptor flow surfaces are now exposed for cleaning.

NOTE
It is not necessary to touch the lip adjusting system to disassemble the die. (Except as noted below.)
Dies manufactured with the Autoflex® feature as part of a removable lip must have all lip adjusting screws and
screw heater blocks removed to expose the lip retaining bolts.

Die Clean Up

Clean up procedure depends to some extent on the thermoplastic being processed. Some materials will form
a molded piece which lifts out easily when the die is opened, leaving only a little flashing to be scoured out.
Others will come off the die surface in a continuous piece with an assist from an air jet directed at the plastic by
gripping it with needle nose pliers and pulling steadily as the plastic peels away.

DO NOT use torch or extreme high temperatures to remove plastics from die, deckle, lips, etc. Heating
above die operating temperature may cause damage.

Some materials, unfortunately, grip the metal tenaciously and must be scraped out using brass or aluminium
tools. Once the bulk of the plastics is stripped or scraped from the die, the remaining material should be
scoured from all flow surfaces and seal surfaces using brass wool and a DRY mild abrasive such as Bon
Ami®.

NOTE
The last two cleaning operations are most easily performed while the die is still hot.

Die Reassembly

All flow and sealing surfaces should be spotlessly clean before die is reassembled. Check sealing surfaces
carefully for metal burrs or dirt which could separate these surfaces and induce leakage. Refer to Figure 4.

4-7
It is not necessary to touch the lip adjusting system to reassemble die. The adaptor and both halves should be
fully supported throughout reassembly. All fasteners should be cleaned and re-lubricated with high quality anti-
seize or equivalent before reassembly.

Make sure both die halves are same temperature before reassembling. If this precaution is not taken it
will create problems assembling die back together correctly.

1. Check dowel pins to make sure they are seated at the bottom of the hole, and will engage the removed
body a maximum of 3/8 in. (9.5 mm).

2. Make sure jack bolts have been removed.

Place paper, cardboard or plastic sheets between the lips before die reassembly to guard against lip
damage. This protective material should be thin enough to slide out easily when the halves are con-
nected.

3. Using a lifting apparatus connected to the lifting lugs provided, carefully bring die halves together using
dowel pins and, if applicable, adaptor pilot as guides.

4. With both halves engaged by the dowel pins, insert body bolts and tighten with an Allen wrench WITHOUT
pipe or other helper. Refer to Setup/ Operation section of this manual for body bolt tightening procedure.

5. Remove lifting device, eye bolts and protective shims.

NOTE
If die bodies have a seal groove and rod type seal between the halves, body bolts should be tightened to com-
press seal. Then carefully take apart die to check for seal alignment. If any seal material has flashed out onto
the seal surface, trim excess away with a razor blade or other sharp tool.

6. Insert and tighten any adaptor bolts which have been removed.

7. Insert end seal pressure plates and bolts, and tighten. The lip has been adjusted to the proper gap and the
die has been heated to the operating temperature. Repeat this torquing procedure twice at five minute inter-
vals. This will properly seat the seal material.

NOTE
Dies manufactured with the Autoflex® feature as part of a removable lip, should have lip adjusting screws and
screw heater blocks assembled to the die after lip is installed on body and tightened to recommended torque
rating.

NOTE
The end seal screws should be torqued to approximately 24 ft. lbs (3.3 kg-m). Only after the lip has been
adjusted to the proper gap and the die has been heated to the operating temperature. Repeat this torquing
procedure twice at five minute intervals. This will properly seat the seal material.

4-8
NOTE
New end seals should be used on each reassembly. These are available precut from EDI.

1. Refer to Setup/Operation section of this manual for start up information.

NOTE
Dies manufactured with the Autoflex® feature as part of a removable lip, should have lip adjusting screws and
screw heater blocks assembled to the die after lip is installed on body and tightened to recommended torque
rating.

Removal of Pull Dowel Pin

1. Thread the tool into the pull dowel pin.

2. Slide the driver weight away from the pull dowel pin, with a rapping motion, against the far end of the tool.

3. Keep too screwed in tight in the pull dowel pin until removed.

PULL DOWEL PIN REMOVAL TOOL

Figure 4-4
Pull Dowel Pin Removal Tool

4-9
 Options

Die Clean Up Kit

ITEM QUANTITY PARTS OR DWG # DESCRIPTION

1 2 Brass Scraper
1 1/4” Blade
2” Blade
2 1 set Brass Lip Gage Shims
(1) Each: 0.001, 0.0015,
0.002, 0.003, 0.004,
0.005, 0.007, 0.010,
0.012, 0.015, 0.020,
0.025, and 0.032
3 1 lb. #67-64 Anti-Seize Lube with
Applicator
4 100 ft. roll Copper Gauze
5 1 bar AA Die Soap

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 Parts

Recommended Spare Parts List

To assure a minimum of downtime, your EDI extrusion die should have an “on shelf” back up of certain parts
that are easily damaged, lost, or simply wear out through normal operation. Please check the spare parts
sheets or die assembly drawing for the items listed before, which you may need to order.

DIE MECHANICAL ACCESSORY EQUIPMENT ELECTRICAL

End Seal Gasket Deckle Seals Die Body Heaters
End Seal Plates Deckle Blocks *Adaptor Heaters
End Seal Screws Deckle Mounting Bar Electric Plugs
End Seal Pressure Plates Lifting Lugs High Temperature Wire
Lip Adjusting Screws Adjustment Wrench Wire Connectors
Lip Adjusting Blocks High Temperature Lubricant Autoflex™ Adjust. Screws/Heater
Lip Adjusting Nuts Cleaning Scrapers Autoflex™ Electric Plugs
Adjusting Nut Retainer Cleaning Brass Wool Thermocouples
Body Bolts Lip Adjusting Shims T.C. Adaptors
End Plate Bolts Die Soap *Lip Heaters
Jack Screws
Dowel Pins

*Four to six week delivery on these items.

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