Table of Contents

Die Statistics

Section 1: Safety
OSHA and the National Electrical Code 1-3
NEC Reference 1-3

Section 2: Start-Up/Operation
Tighten Body Bolts 2-1
Torque Rating Chart (For Dies Running 0°F/17.8°C - 550°F/288°C) 2-4
Torque Rating Chart (For Dies Running 550°F/288°C and Above) 2-5
18-8 Stainless Steel Cap Screws 2-6
End Seal Materials 2-7
Desirable End Seal Materials 2-8
Styles of End Seals and Seal Plates 2-8
End Seal Torque Procedure 2-9
Push-Only Lip Adjustment 2-10

Section 3: Maintenance
The Maintenance of Flat Film and Sheet Dies 3-1
Cleaning and Preventative Maintenance 3-2
Operating Procedures 3-4
Die Body Disassembly 3-6
Die Clean Up 3-7
Die Reassembly 3-7

Section 4: Options
Die Clean Up Kit 4-1
EDI Taper Gauge 4-2

Section 5: Parts
Recommended Spare Parts List 5-1
5%DU

i
 911 Kurth Road

Statistics Chippewa Falls, WI 54729 USA

(P) 715-726-1201
(F) 715-726-2205

Customer: Tecnolaminas IBG C.A.

Customer Purchase Order 331-11

Number:

Die Serial Number: 11-31338

Type of Die: 59” Ultraflex RC100 Die

Special Features on Die: Do Not Plate R-Bar

Spare Parts Per EDI JO#11-31339
Ships with EDI JO#11-31340
Torque Body Bolts to 1400 Ft/Lbs @ Assembly
Cleaning Kit
Assembly Drawings: 4MR5925_EU (Sheets 1-3)
R-Bar Drawing: 2AJ1612_RBA
Die Wiring: 4WD2125_338
ii
 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 f nd 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 suff cient time to melt any solidif ed
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 hygroscopic f ller 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 f atness distor-
tion of the die halves. Distortion of the die halves could result in gage bands, f ow 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 Autof ex® heater blocks reach operating temperature should the Fast Gap® (if provided), or
conventional lip be preset.

Before Autof ex® 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 f ow 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 specif ed a plug for your equipment which does not comply with the national electrical code, Extru-
sion Dies Industries, LLC, CANNOT assemble this item for your use.

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

NEC Reference

SECTION 200-10 “Identif cation 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
identif cation...”

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 suff ciently 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 Ultraf ex® 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 f nish 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 f nish does not get damaged, please follow the cleaning instructions below.

• For internal cleaning, saturate the f ow 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 f ow surface.

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

NOTE
The use of any felt type pens to mark on the f nished surfaces will also cause damage to the f ow 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 f nal 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 f nal 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 f nal 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 f nal
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 specif cations listed in the fol-
lowing charts. Start from center and work out to the die ends alternating either side of center line during f nal
tightening.

2-2
NOTE

Bolts MUST be tightened to the cold torque values specif ed. Failure to do so will allow the antiseize compound
to f ow 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 Autof ex® 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

English Metric English Metric Lb-Ft Kg-Meter Newton-Meter

10-24 M5-.8 5/32 4mm 4.0 .6 5.4
*1/4-20 M6-1 3/16 5mm 9 1.2 12.2
5/16-18 M8-1.25 1/4 6mm 19 3.0 25.7
3/8-16 M10-1.5M 5/16 8mm 34 5.0 46
3/8-24 M10-1 5/16 8mm 39 5.5 52.8
7/16-14 M12-1.75 3/8 10mm 54 7.5 73.2
1/2-13 M14-2 3/8 12mm 83 11.5 112.5
1/2-20 M14-1.25 3/8 12mm 93 13 126
5/8-11 M16-2 1/2 14mm 165 23 222.3
3/4-10 M20-2.5 5/8 17mm 291 40 394.5
7/8-9 3/4 470 65 637.2
1-8 M24-3 3/4 19mm 775 110 1050
1 1/4-7 M30-3.5 7/8 22mm 1400 195 1895
1 1/2-6 M36-4 1 27mm 2315 320 3140
1 3/4-5 M42-4.5 1 1/4 32mm 3840 530 5210
2-4 1/2 M48-5.0 1 1/2 36mm 5770 800 7820

Our torque chart shows the typical recommended values. These values are for torquing at ambient
temperatures. If you would like to hot torque, reduce by 10%. 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 20% 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 20% 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. 3 10/17/2011

EDI 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

English Metric English Metric Lb-Ft Kg-Meter Newton-Meter

10-24 M5-.8 5/32 4mm 3 .46 4.47
*1/4-20 M6-1 3/16 5mm 8 1.1 11
5/16-18 M8-1.25 1/4 6mm 16 2.2 22
3/8-16 M10-1.5M 5/16 8mm 29 4 40
3/8-24 M10-1 5/16 8mm 33.2 4.6 45
7/16-14 M12-1.75 3/8 10mm 47 6.5 64
1/2-13 M14-2 3/8 12mm 71 9.8 96
1/2-20 M14-1.25 3/8 12mm 80 11 108
5/8-11 M16-2 1/2 14mm 142 19.6 193
3/4-10 M20-2.5 5/8 17mm 250 34.5 330
7/8-9 3/4 403 56 546
1-8 M24-3 3/4 19mm 670 90 900
1 1/4-7 M30-3.5 7/8 22mm 1200 165 1625
1 1/2-6 M36-4 1 27mm 1985 275 2690
1 3/4-5 M42-4.5 1 1/4 32mm 3295 455 3420
2-4 1/2 M48-5.0 1 1/2 36mm 4945 680 6700

Our torque chart shows the typical recommended values. These values are for torquing at ambient
temperatures. If you would like to hot torque, reduce by 10%. 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 20% 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 20% 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 # 1RE0007
Rev. 3 10/17/2011

2-5
EDI
 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 # 1RE0009
Rev. 2 10/23/2008

EDI 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 specif ed 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 f ow 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 f t a specif c 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 f ow surface for the polymer.
5. Torque applied to pressure screws should be held closely to values listed below. Insuff cient 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 f ush 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 diff cult 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 f lled Tef on® 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 f ve minute intervals. This will properly seat the seal
material.

2-9
 Set-Up / Operation

Push Only Lip Adjustment Operating Instructions

Typical Push Only Lip Adjustment Components

Push Only Lip Adjustment

1. A T-Allen wrench included in the die tool kit provides adequate torque to adjust any lip adjuting screw 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 (1mm) of motion at the lip. A slight adjust-
ment is signif cant. 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.
2-10
5. If the die is equipped with a f eixble lip, it is set to its maximum opening. If you wish you 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.
(0.025mm to 0.050mm) larger than the blade of the internal deckle. Tighten the adjusting bolts in a clockwise
direction. Make several passes along the 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.

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

Push Only Lip Adjustment Disassembly / Reassembly Procedure

The following are the instructions for the disassembly/reassembly of the lip adjustment system from the die.

Please make sure all personnel carrying out these operations are wearing personal protective equipment, as
these components may be HOT.

1. To remove lip adjusting screws, unscrew the lip adjusting screw from each lip adjusting block, taking care as
these components are HOT.

2. You can remove the lip adjusting blocks only after the lip adjusting screws have been removed from each lip
adjusting block.

3. Replacement of the components is the reverse of the above.

NOTE
Please make sure that when all lip adjusting screws are being reassembled that no damaged lip adjusting
screws are ref tted to the die as this will limit lip gap movement.

2-11
 Maintenance

The Maintenance of Flat Film and Sheet Dies

Rising costs, material shortages, and highly competitive markets are continually forcing sheet and f lm extrud-
ers to maximize operating eff ciency. 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 f lm 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 f lm die is nor-
mally hot, heavy, and awkward, yet the critical surfaces are very precisely and highly f nished, 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
justif cation 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 amplif ed 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 f nger-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.

3-1
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 f ow 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 diff culty
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 f ow 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 specif c cleaning suggestions. After the bulk of the plastic has
been scraped away, the remaining f lm 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.

3-2
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 f ow 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 coeff cient of thermal expansion that is slightly
higher than the body steel, f nal 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.

3-3
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 f nal tightening is best done with the die clamped securely
to the extruder.

NOTE
When tightening body bolts to their f nal 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 f nal
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 specif cations listed in the fol-
lowing charts. Start from center and work out to the die ends alternating either side of center line during f nal
tightening.

NOTE
Bolts MUST be tightened to the cold torque values specif ed f rst. Failure to do so will allow the anti-seize com-
pound to f ow 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 inf exible and will not conform to tight bends. The relative inf exibility
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 f ghting 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.

3-4
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 signif cant wear to a die,
even in the course of several years of operation. Thus the useful life of a die is nearly indef nite, limited only by
obsolescence or physical damage. While design or product changes may make obsolescence unavoidable, die
life and performance certainly should not be sacrif ced 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).

3-5
 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 f ve 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 Autof ex® 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.

3-6
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 f ow 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 Autof ex® 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 f ashing 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 f ow 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 f ow 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.

3-7
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 f ashed 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 f ve minute inter-
vals. This will properly seat the seal material.

NOTE
Dies manufactured with the Autof ex® 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 f ve minute intervals. This will properly seat the seal material.

3-8
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 Autof ex® 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

3-9
 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

4-1
4-2
 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 Autof ex™ Adjust. Screws/Heater
Lip Adjusting Nuts Cleaning Scrapers Autof ex™ 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.

5-1
5-2
 Restrictor Bar Operating Instructions

Certain dies, are equipped with restrictor bars. This module presents an introduction.

Restrictor Bar Function

A restrictor bar (R-Bar) is used to distribute polymer f ow uniformly across the full width of the die. It is neces-
sary because of the variables commonly found in extrusion processes, namely throughput rate and polymer
viscosity. In general, as the rate of throughput, or the polymer viscosity increases, more restriction will be
needed in the center of the die to force the polymer to f ow to the ends of the die. For this reason, the restrictor
bar is adjustable, to allow compensation in changes in viscosity or throughput rate.
This style of die contains two adjusting systems, an internal restrictor bar and a f exible lip. The restrictor bar is
treated as a coarse adjustment, bringing the sheet thickness to approximate uniformity. Finally, precise adjust-
ments are made at the lip.

A Typical Restrictor Bar Assembly


Setup/Operation
Perform the Setup and Operation instructions as detailed in Section 2 of the Instruction Manual. In particular,
follow the steps for End Seal Torque Procedure exactly as stated.

1) Bring the die and extruder up to processing temperature with the die temperatures at a uniform setting. Re-
fer to Section 2 - Setup/Operation in the Instruction Manual.
2) Tighten all fasteners to the torque ratings listed in Section 2 - Setup/Operation of the Instruction manual.
3) Set die lips to a uniform opening.
4) Start the extruder and bring the throughput rate up to production level.

Restrictor Bar Adjustment

When the die is received, the restrictor bar is in the fully opened position. Figure RB-1 shows a typical f ow pat-
tern from a die with the restrictor bar in the fully opened position, and the corresponding gap under the bar. Set
the restrictor bar in the following manner:

Figure RB-1

The restrictor bar is a push-pull stud and spool design. A counter-clockwise turn on the spool reduces the
opening under the bar to reduce the f ow in the area. Clockwise adjustment increases the opening under the
bar. There is a neutral zone when the direction of adjustment is reversed.
The f ow pattern from the die after equilibrium extrusion conditions are reached will indicate the bar adjust-
ments necessary to achieve approximately uniform thickness. With the bar in the full open position the top of
the stud will be f ush with the top of the spool. As adjustments are made, the distance from the top of the stud
to the top of the spool will indicate the relative position of the bar at each adjusting point. This feature should
be used to make sure that the bar is adjusted in a smooth continuous curve. Small local adjustments should
not be attempted with the restrictor bar. Efforts to do this usually result in one adjustment working against an-
other and may result in stud breakage. The socket wrench provided in the die tool kit will give suff cient torque
for any proper restrictor bar adjustment. Longer handles on the wrench for added torque should not be used.

DO NOT use a longer wrench handle than what is provided in the die tool kit for restrictor bar adjustment.

When sheet thickness uniformity is within about 10% of target, the restrictor bar setting should be left as is, and
f nal adjustments made on the f exible lip.


5. Check the sheet thickness uniformity (on heavy sheet an observation of the “bank” at the roll nip will normal-
ly suff ce). Figure RB-2 shows a typical gauge prof le when the bar is partially adjusted, but not enough to give
full f ow to the die ends. The ends of the bar are still in the fully opened position.

Figure RB-2

6. Begin decreasing the restrictor bar gap at the points where the sheet is thickest.
7. Continue to adjust the bar, decreasing the gap at the heavy points in the sheet until the full sheet width is
uniform within about 15% (depending upon sheet thickness). Figure RB-3 shows a typical bar prof le when the
sheet thickness is uniform.
Normally, the ends of the bar will be fully opened, and the center 60% of the bar will be fairly straight.
There should not be any abrupt irregularities in the bar prof le.

Figure RB-3

NOTE
The standard lip adjusting system on Ultraf ex R-75 and HR-75 dies is a push only adjustment which f exes
the adjustable lip to change the die opening. A clockwise motion on a bolt reduces the opening in the area of
that bolt. A counter-clockwise motion permits the spring action of the lip to bring it to a larger opening.

At maximum opening, further counter-clockwise motion will simply cause the bolt to f oat off its bearing sur-
face. No further opening will take place. At minimum opening the bolt head will contact the die body, prohib-
iting further closing. Forcing the bolts beyond this point will damage threads. In normal operation, all bolts
should be run between these two extremes to
give positive adjustment in either direction.

8. Adjust the lips to achieve f nal sheet thickness uniformity. Refer to Lip Adjustment in Section 2 of the In-
struction Manual.

Adjustment of any f at f lm and sheet die is designed to bring broad areas of heavy and light sheet to a uni-
form thickness. Very narrow gauge bands are generally initiated elsewhere in the extrusion system and can-
not be adjusted out with the die.


Although the lip adjusting bolts of the Ultraf ex die are closely spaced and the lip is f exible, the lip is still a steel
bar and will not assume extreme contours over short distance. Adjustment of a single bolt will f ex the lip in
a smooth curve over a length of 3 to 5 inches (76.2 to 127 mm). Given a uniform melt from the extruder, and
proper setting of the restrictor bar, the lip setting at uniform sheet thickness should be a smooth, symmetrical
curve from one end of the die to the other.

Possible Restrictor Bar Adjustment Problems

If the bar does not have a smooth contour when adjusted, the temperature or rate variation is probably causing
the problem. Check the following:

(a) A die temperature controller may be malfunctioning. A controller which is out of calibration will cause a hot
(or cold) zone in the die which will produce non-uniform f ow. If the operator tries to correct this with the bar,
severe distortion of the bar may result.

(b) If a die temperature controller is not tuned properly, the zone temperature will f uctuate due to the long on/
off time of the controller. In this case, the f ow through the die will continually vary. It is impossible for the opera-
tor to correct this condition with the die, and if he tries, severe distortion of the bar may result.

(c) If the extruder rate is varying, the effect will be much the same. The operator will not be able to stabilize
sheet thickness, and any attempt to do so will lead to severe distortion of the R-Bar.

(d) Often, the melt stream entering the die will have "channels" of polymer which are not at the same tempera-
ture as the rest of the melt. These temperature differentials may be as high as 40°F (22°C).

These channels will consistently pass through the die in the same area, resulting in a lack of thickness uni-
formity. If the operator adjusts the die to compensate for these hot streaks, the bar may be severely stressed.
Figure RB-4 demonstrates this problem. The problem can be identif ed by checking melt temperature exiting
from the die with a pyrometer with a needle tip or with an optical pyrometer.

Figure RB-4


Possible Restrictor Bar System Damage
Two components of the bar adjusting system are subject to failure; the adjusting stud and the bar itself.
The Krupa Stud® is designed to break at a stress value low enough to protect the bar in most normal situa-
tions.
However, it is important to note the stud will only break when it is in tension, that is, when the bar is being
opened. In compression, when the bar is being closed, the stud will not fail and, hence, will not protect the bar.
Figure RB-5 shows how it is possible to break the bar when closing it. The studs "A" in tension adjacent to the
break will share the load and, hence, will not break.
Exerting high forces on studs "B" in compression may cause the bar to fracture at point "C".

Figure RB-5

Preventing Restrictor Bar System Damage

In our experience, most damage to the restrictor bar system is due to one problem, the use of excessive torque
on the adjusting spools. We normally furnish a wrench with a 17" (438 mm) handle with our tool kits.
Under no circumstances should it be necessary to use a wrench with a longer handle. It is extremely diff cult
for an average operator to break an adjusting stud with a 17" (438 mm) wrench handle. However, many opera-
tors are allowed to use extensions on the adjusting wrench, and the result is often a broken stud.

Use ONLY the wrenches supplied in the toolkit. Using longer wrenches could lead to damaging the
restrictor bar system.

The second most common problem to be encountered, is the "locking up" of the adjusting system.
Please refer to Figure RB-5 and note that two adjacent studs, "A" and "B", are exerting opposite forces.
Stud "A" is opening the bar gap and stud "B" is closing it. If excessive force is exerted on stud "B", stud "A" will
become locked because of the high loading.
In order to free stud "A", it is necessary to relieve some of the pressure on "B".
To prevent this situation, the operator must refrain from using excessive torque on any single adjustment point.
The operator should be able to adjust any point in the system with one hand on a wrench with a 17" (438 mm)
handle. If an operator is using an extension on the wrench handle, a high rate of stud breakage is to be expect-
ed, and there is a risk that the restrictor bar may be broken.


Lubrication
Like any working-thread system, the restrictor bar adjustments require lubrication. When the die was assem-
bled, it was carefully lubricated with a molybdenum base lubricant designed for high temperature applications.
Any time the adjusting system is dismantled, or when replacing a stud, make certain the parts are lubricated.
Lubricant should be applied to the stud threads and the upper and lower f anges of the spool. EDI suggests a
molybdenum base lubricant designed for at least 1000°F (538°C) service temperature.

Restrictor Bar Stud Replacement

The Ultraf ex die is equipped with the Krupa Stud® restrictor bar adjustment system. This system is designed
to permit easy replacement of the studs and to prevent damage to the restrictor bar resulting from over stress-
ing the adjustments. Follow these steps to replace broken studs:

1. Remove the spool retainer over the broken stud.

2. Remove the stud locking plate from the stud.
3. Carefully measure the location of the top of the square stud section in relation to the die body.
4. Remove the broken stud by turning counter clockwise on the wrench f ats.
5. Screw in the new stud to the point where the top of the square section is the same distance from the die
body as the original stud as determined by Step 3.

NOTE:
Failure to follow this procedure carefully will result in loss of available adjustment and binding of the adjust-
ments.

6. Replace locking plate, spool, and spool retainer. Re-lubricate all threads and the skirt on the spool.
7. If the preceding steps are followed the restrictor bars settings will be nearly as before, allowing for a faster
restart.

Removal And Installation Of Restrictor Bar

TOOLS AND ITEMS REQUIRED:

• The die tool kit as provided with your die includes all necessary items except wood block, plastic hammer,
and seal material.
• Threaded rod (14 inch long [356 mm] pieces, provided in tool kit).
• Restrictor bar seal material.
• Plastic or leather hammer.
• Hardwood block.
• Spray lubricant (Zep Dry Graphite®).
• High temperature anti-seize compound.

Die Body Disassembly

Follow the Die Body Disassembly and Die Clean Up procedures as detailed in Section 4 of the Instruction
Manual.

Restrictor Bar Removal

1. Remove the restrictor bar adjusting assembly (retainers, spools, and studs).
2. Install M16-2 or 5/8-11 threaded rods through die into R-bar, spaced equally.
3. Install spools on the threaded rods and mount a retainer over each spool with the mounting bolts. (These
are parts removed from the adjusting assembly.)
4. Lift the upper half with a forklift and straps.
5. Turning the spools counter clockwise will push the R-bar out. (Turn the spools equally until the R-bar is out
of the slot.)


6. With a person holding each end of the R-bar, remove the retainers and spools from the threaded rods
and remove the R-bar.
7. Set the upper half down.
8. Turn the upper half over.
9. Clean the R-bar, slot, internal f ow and seal surfaces. (Stone to remove any high spots with a f ne f at
stone.)
10. Set the upper half on an open support cart or the forks of a forklift.

Restrictor Bar Installation:

1. Cut (2 or 4) pieces of R-bar seal 6 (153 mm) inches longer than the R-bar.
2. Apply a light f lm of oil to the slot. (Dry Graphite spray works the best if available.)
3. With threaded rods in the R-bar, install the threaded rods through the die.
4. Put the spools on the threaded rods.
5. Install the downstream R-bar seal. (Do not stretch lengthwise).
6. Make sure the seal stays in the groove, and pull the R-bar into the slot by turning the spools clockwise.

NOTE:
For dies over 80” (2m) apply High temp RTV Silicone Adhesive in the groove with the Tef on seal to keep
it in place.
7. Pull the R-bar into the slot, by starting on one end working it in across the die, to the upstream seal
groove. (A block of wood and clamp may be needed to get it started into the slot.)
8. Install the R-bar seal in the upstream seal groove by laying it into the groove. (Do not pull on the seal.
This will stretch it and cause it to leak.)
9. Pull the R-bar in the slot past the seal. Start at one end and work across the die. A small even amount
of seal will be shaved off.)
10. Pull the R-bar all the way down into the slot.
11. Cut off the seals at room temperature. Leave approximately 1/16 to 1/8 inch of the seal extended out
of the R-bar.

NOTE:
For dies over 80” (2m) Cut off the seals at room temperature. Leave approximately 1/8 to 3/16 inch of the
seal extended out of the R-bar.
12. Install the end seal plate assembly without the gasket and tighten the seal screws to 30 lb-ft.
13. Remove the end seal assembly and trim the mushroomed excess off.
14. Install end plate seal assembly with the gasket and proceed with die heating procedure.

Die Reassembly

Follow the detailed instructions for Die Reassembly as covered in Section 4 of the Instruction Manual.
INSTALL THE RESTRICTOR BAR ADJUSTMENT SYSTEM

1. Lubricate all threads.

2. Install Krupa Stud®. (Top of the square f ange is to be 3/4 inch [19 mm] from the die body.)
3. Stud locking plate goes over the square f ange.
4. Install spool.
5. Install spool retainer and mounting bolts.

Set Up/Operation
Perform the Setup and Operation instructions as detailed in Section 2 of the Instruction Manual. In par-
ticular,
follow the steps for End Seal Torque Procedure exactly as stated. Setup and Operation should performed
as though your die is brand new.

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