Eng M Xmsi Standardmold

xMS-i
Standard Mold Manual
TABLE OF CONTENTS
1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 MAIN COMPONENTS OF THE MOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 TYPE PLATE AND ENGRAVED CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4.1 Fico tool kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4.2 Plunger seal cracker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.3 Plunger disassembly tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.4 Top mold removal tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.5 Mold carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.6 Mold oven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.7 Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.8 Temperature meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.9 RBS cleaning set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 HANDLING THE MOLD AND PLUNGER BEAM . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 SWITCHING TO A DIFFERENT COMPOUND TYPE . . . . . . . . . . . . . . . . . . . . . . 9
1.7 XMS-I MOLD VERSUS XMS-XX-M2 MOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.7.1 Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.7.2 xMS-xx-M2 to xMS-i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7.3 xMS-i to xMS-xx-M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. BOTTOM MOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 BOTTOM MOLD PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 BOTTOM MOLD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.1 Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Table of contents xMS-i
2.2.2 Preparing for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.2.3 Removing the plunger beam and plungers . . . . . . . . . . . . . . . . . . . . 13
2.2.4 Removing the covers and components. . . . . . . . . . . . . . . . . . . . . . . 14
2.2.5 Removing the ejector cams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.6 Removing the center pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.7 Removing the dowel pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.8 Removing the bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.9 Removing the ejector set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.10 Dismantling the mold plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 BOTTOM MOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3.2 Preparing for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.3 Assembling a solid cavity plate (design 2) . . . . . . . . . . . . . . . . . . . . 27
2.3.4 Assembling cavity strips and cull strip (design 5) . . . . . . . . . . . . . . . 27
2.3.5 Refitting the dowel pins and center nocks . . . . . . . . . . . . . . . . . . . . 30
2.3.6 Refitting the ejector set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3.7 Refitting the bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.8 Refitting the center pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3.9 Refitting the ejector cams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3.10 Refitting the components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3.11 Assembling the mold covers and handle . . . . . . . . . . . . . . . . . . . . . 35
2.3.12 Refitting the plungers and plunger beam . . . . . . . . . . . . . . . . . . . . . 36
3. TOP MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 TOP MOLD PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 TOP MOLD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2.1 Preparing for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2.2 Removing the covers and components. . . . . . . . . . . . . . . . . . . . . . . 38
3.2.3 Removing the DTC mold components . . . . . . . . . . . . . . . . . . . . . . . 40
3.2.4 Removing the top plate assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.2.5 Disassembling the top plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.2.6 Removing the ejector set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2.7 Disassembling the mold plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3 TOP MOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.3.1 Assembly precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.3.2 Assembling the mold plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.3.3 Refitting the ejector set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3.4 Refitting the top plate assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.3.5 Refitting the components and covers . . . . . . . . . . . . . . . . . . . . . . . . 49
4. EJECTOR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1 EJECTOR STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2 DISASSEMBLING THE EJECTOR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.3 ASSEMBLING THE EJECTOR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5. PLUNGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.1 PLUNGER BEAM AND PLUNGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.2 REPLACE THE TEFLON PLUNGER RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.3 DISASSEMBLING A PLUNGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.4 PLUNGER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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xMS-i Table of contents
5.5 CALCULATING THE TRANSFER END POSITION . . . . . . . . . . . . . . . . . . . . . . . 59

5.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.5.2 Transfer movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.5.3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.5.4 Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.5.5 Process monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6. SLEEVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.1 DISASSEMBLING THE SLEEVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.2 ASSEMBLING THE SLEEVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7. GATE INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.1 (DIS)ASSEMBLING THE GATE INSERTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8. CENTER PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.1 CHECKING CENTER PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2 ADJUSTING LONG CENTER PIN HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.1 MACHINE AND MOLD TYPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.2 HEATER ELEMENTS STANDARD MOLD (TOOLID V1). . . . . . . . . . . . . . . . . . . 74
9.2.1 The standard mold (ToolId V1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.2.2 Heater connector standard mold (ToolId V1) . . . . . . . . . . . . . . . . . . 76
9.3 HEATER ELEMENTS STANDARD MOLD (TOOLID V2). . . . . . . . . . . . . . . . . . . 78
9.3.1 The standard mold (ToolId V2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.3.2 Heater connector standard mold (ToolId V2) . . . . . . . . . . . . . . . . . . 80
9.4 HEATER ELEMENTS SPECIAL DTC MOLD (TOOLID V2) . . . . . . . . . . . . . . . . . 82
9.4.1 The DTC mold (ToolId v2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.4.2 Heater connector DTC mold (ToolId v2). . . . . . . . . . . . . . . . . . . . . . 84
9.5 CHECKING THE TEMPERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.6 CHECKING THE ELECTRICAL CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.7 CHECKING THE RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.8 EXCHANGING THE HEATER ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.9 PT-100 AND CLIXON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.9.2 PT-100 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.9.3 Checking the resistance of the PT-100 and clixon . . . . . . . . . . . . . . 88
9.9.4 Exchanging the PT-100 and clixon . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9.10 AUTOMATIC TOOL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.10.2 Using an xxy mold in an xMS-i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10. CLEANING, CONDITIONING AND STORING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

10.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.2 COMPRESSION CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.2.2 Compression cleaning with rubber sheets . . . . . . . . . . . . . . . . . . . . 92
10.2.3 Compression cleaning with melamine tablets. . . . . . . . . . . . . . . . . . 93
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Versions xMS-i
10.3 TRANSFER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

10.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
10.3.2 Transfer cleaning with melamine cleaning pellets . . . . . . . . . . . . . . 94
10.4 CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.4.2 Conditioning with conditioning compound. . . . . . . . . . . . . . . . . . . . . 95
10.4.3 Conditioning with wax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.5 MANUAL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.6 RBS-25 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.7 STORING THE MOLD LONG-TERM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.8 PACKING THE MOLD FOR TRANSPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
12. INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
VERSIONS
Version Changes
V1.0 First release. (June 16, 2003).
V1.1 Changed lay-out; several minor text and figure changes; end position
calculation changed (July 23, 2003).
V1.2 Changed to Besi-layout. Top mold information extended. Minor text
changes (February 18, 2004).
V1.3 Heater element, tool-ID and Transfer end position calculation information
changed (June 18, 2004).
V1.4 Changed heater connection pin lay-out (January 7, 2005).
V1.5 Added DTC option (July 20, 2005).
V1.6 Added all possible machine and mold heater configurations (September
20, 2005).
V1.7 Removed the return spring bottom mold information, as it is not used in
the AMS-i molds with clamp ejector system. Added information about the
teflon plunger ring and rewrote the assy/dis-assy procedure of the
plunger. Added exchange info about xMS-i/xMS-xx-M2 molds. (January
31, 2005)
Liability and Copyright: See page ii of the Main Table of Contents of this manual.
Page iv of iv xMS-i Standard Mold - V1.7 January 31, 2006

xMS-i General information 1
1. GENERAL INFORMATION
1.1 INTRODUCTION
This manual describes how to clean, pack and store, disassemble and re-assemble the top
and bottom mold halves. It also gives information on the various mold parts including the
heater elements, PT-100 temperature sensor, mold identification and the mold connectors.
This manual applies to a standard mold on the Fico xMS-i molding machine. For
information on non-standard mold types (BGA), refer to other manuals. The following
standard xMS-i mold designs are present:
• Mold design 2: solid cavity plate without cull strip (bottom mold) and top strip (top
mold). This design has no wedges, but only dowel pins, and is fitted with mold
vacuum.
• Mold design 5: separate cavity strips with cull strip (bottom mold) and top strip (top
mold). This design has both wedges and dowel pins.
• Mold design 5-2: a combination of design 5 and 2. The bottom mold is design 5 and
the top mold is design 2.
In this manual, mold design 5 is described and visualized in the figures. Keep in mind that the
exact configuration of a mold depends on the product, which is why the illustrations should be
taken as reference only. The same applies to the (dis)assembly actions. Due to configuration
differences, they may slightly differ from the procedures described in this document. In case of
doubt, consult your Fico Service engineer.
The Table Of Contents and the Index are useful aids to find relevant information.
January 31, 2006 xMS-i Standard Mold - V1.7 Page 1 of 106

1.2 Main components of the mold xMS-i
1.2 MAIN COMPONENTS OF THE MOLD

The following figure shows the main components of the mold:
Figure 1 Molds and plunger beam on mold slide

A: Top mold D: Plunger beam G: Connectors top mold
B: Bottom mold E: Ejector cam H: Handle
C: Mold slide F: Connectors bottom mold
1.3 TYPE PLATE AND ENGRAVED CODES

In each mold part, the mold code and/or mold order number are engraved. All codes are
engraved on the front side of the mold. Additionally each mold half has a type plate that is
attached to the side cover. The following information can be found on the plate:
Figure 2 Mold type plate

A: Product type for which the mold is suitable. For example: TSOP 48 lds
B: Mold order number.
C: Mold code.The mold code is a unique number.
D: The total weight of the mold half.
Page 2 of 106 xMS-i Standard Mold - V1.7 January 31, 2006

xMS-i Tools 1.4
1.4 TOOLS
1.4.1 Fico tool kit
Figure 3 Fico tool kit
Unless specified differently, all tools and materials below are present in the standard Fico
tool kit.
• screw driver no. 2
• set of metric allen keys
• dowel pin puller (M5) - to remove the dowel pins
• whet stone (red, 100 x 25 x 10 mm)
• punch, copper (Ø 14 x 60 mm)
• punch, copper (Ø 20 x 150 mm)
• plug, brass - to loosen the sleeves
• strip, brass (flat, 20 x 3 x 150 mm)
• pin, brass (square, 6 x 6 x 60 mm)
• pin, brass (round, Ø 4 x 150 mm)
• brush (flat, width 25 mm)
• brush, steel (round, Ø 3 mm)
• brush, copper (round)
• brush, bronze (flat)
• brush, steel
• cavity strip holder - to loosen the gate inserts
• brackets - to place the mold on for mold (dis)assembly

1.4.2 Plunger seal cracker xMS-i
• special screws M6 - to (dis)assemble the ejector pin bed

• socket screws M4 and M5
• Loctite, no 648
• “never seez” paste
• heatsink paste
The following items are required, but are not included in the Fico tool kit:
• pincers
• dry-cleaning naphtha
• cloth
• plastic bags
• wooden blocks - to (dis)assemble the ejector pin bed
1.4.2 Plunger seal cracker
Figure 4 Plunger seal cracker
During molding the plunger groove is filled with compound material. This ring of epoxy is
used as a seal to prevent compound flowing into other parts of the mold. Before placing a
dismounted plunger into the sleeve again, remove this compound ring with the plunger seal
cracker. This cracker can be ordered at the Fico spare parts shop. Please indicate the
plunger diameter (∅).

xMS-i Plunger disassembly tool 1.4.3
1.4.3 Plunger disassembly tool
Figure 5 Plunger disassembly tool
The plunger springs are fitted under tension. To disassemble and assemble the plungers
use this tool. When assembling the plunger, the plunger spring needs to be put under a
certain tension, called preload tension. This tension comes very precise as the product
quality depends on it. The tool is available for different spring diameters and can be
ordered at the Fico Spare parts shop.
1.4.4 Top mold removal tool
Figure 6 Top mold removal tool
To lift up and remove the top mold half from the bottom mold half, use the Fico top mold
removal tool. This tool is screwed into the top mold half with two screws. Make sure the
screws are attached properly and lift the top mold with two persons. This tool can be
ordered at the Fico spare parts shop.

1.4.5 Mold carrier xMS-i
1.4.5 Mold carrier
Figure 7 Mold carrier
To exchange and transport the mold and plunger beam (mold conversion), a mold carrier is
needed. To transport the mold, the carrier can be lowered. For more information on this
carrier, refer to its manual. This carrier can be ordered at the Fico spare parts shop.
1.4.6 Mold oven

To preheat the mold before placing it back in the press station, use a mold oven. Different
oven types are available and can be ordered at the Fico spare parts shop.

xMS-i Multimeter 1.4.7
1.4.7 Multimeter
Figure 8 Multimeter
To measure the tension (in Volt) or resistance (in Ohms) of the heater elements and
PT100, a suitable temperature meter is required. This meter can be ordered at the Fico
spare parts shop.
1.4.8 Temperature meter
Figure 9 Temperature meter with probe
To measure the temperatures of the mold surfaces, a suitable temperature meter with
probe is required. This sensor can be ordered at the Fico spare parts shop.

1.4.9 RBS cleaning set xMS-i
1.4.9 RBS cleaning set
Figure 10 RBS cleaning set
The RBS cleaning set is needed when cleaning the disassembled mold parts with RBS-25
solution. The set can be ordered at the Fico spare parts shop.
1.5 HANDLING THE MOLD AND PLUNGER BEAM
Only use original Fico bolts in the mold.
The mold halves, plunger beam and plungers are precision tools and should be handled
with care. Take the following general remarks into account:
• Only use qualified and suitable tools to handle the mold (see paragraph 1.4).
• When (dis)assembling the plunger springs, always use the Fico plunger removal
tool.
• When removing the epoxy seal ring at the plunger top, always use the Fico plunger
seal cracker.
• Make sure that the mold is cool before (dis)assembling or handling it.
• When working on the mold, make sure to work in a clean room with sufficient space and
always place the mold with the surface down on a soft surface to prevent damages.

xMS-i Switching to a different compound type 1.6
• The bottom mold weighs approximately 45 kg (99 lb) and the top mold 55 kg (121 lb).
Always lift the mold with two people to avoid dropping, or use a suitable carrier or tool to
handle the mold and plunger beam.
• When replacing the top mold half on the bottom mold half again, make sure that the
mold is placed correctly and that the mold surfaces cannot be damaged.
• The front side of the mold halves and parts can be recognized by the engraved mold
code. When assembling the mold parts again, make sure that the engraved mold code
is positioned at the front side.
• Never use tools - not even copper ones - on the cavities, runners, gate inserts,
clamping area, sleeves and plungers. This damages the material (layer). If these parts
are heavily polluted, use brass tools, but be very carefully and never use excessive
force.
• When (dis)assembling, work in a logical sequence and follow the step-by-step
instructions in this manual.
• When (dis)assembling the plunger beam and plungers, be careful not to damage the
carbide plunger top and the spiral shaped shaft. Carbide easily chips off or breaks.
• When (dis)assembling the mold remove all personal jewelry (rings, watch, etc.) as this
may scratch and damage the mold surface, or may cause personal injury.
1.6 SWITCHING TO A DIFFERENT COMPOUND TYPE

When changing to a different compound type, first make a few conditioning shots while
using the new compound type. If this is not done, the release agent from the first
compound may affect the second compound in such a way that the mold becomes quickly
contaminated. See paragraph 10.4.
When changing the compound type, consult Fico as this affects the process settings.
1.7 XMS-I MOLD VERSUS XMS-XX-M2 MOLD
1.7.1 Possibilities
An xMS-i mold can be used on an xMS-xx-M2 machine provided that some changes have
to be carried out. These changes fall apart in once only changes and changes that have to
be carried out each time a mold is switched over from one machine type to the other.

1.7.2 xMS-xx-M2 to xMS-i xMS-i
1.7.2 xMS-xx-M2 to xMS-i

Following points must be carried out one time only to adapt an xMS-xx-M2 mold to be
able to use it on an xMS-i molding machine:
1. The toolID connectors are exchanged with a new connector with the electronics for the
toolID.
2. A Fico Molding Systems service engineer has to determine the proper recipe
parameters, especially the mold temperature control has to be adjusted correctly to
achieve an even temperature of the mold.
For Heater elements standard mold (ToolId v2) (p. 78), the heating parameters can be
copied from the xMS-xx-M2.
After that, each time you switch over from an xMS-xx-M2 to an xMS-i, the ejector cams
need to be exchanged (see paragraph 2.2.5) and the return springs of the bottom mold
must be removed (refer to the xMS-xx-M2 mold manual).
1.7.3 xMS-i to xMS-xx-M2

Following points must be carried out one time only to adapt an xMS-i mold to be able to
use it on an xMS-xx-M2 molding machine:
1. In the toolID connectors a so called MIC (Mold Identification Code) must be
implemented (see also paragraph 9.10). The MIC can be either:
• a new (unique) MIC
• an existing MIC of a compatible mold
• MIC 1, which allows the use of the mold on any machine (no safety check)
2. A Fico Molding Systems service engineer has to determine the proper recipe
parameters, especially the mold temperature control has to be adjusted correctly to
achieve an even temperature of the mold.
After that, each time you switch over from an xMS-i to an xMS-xx-M2 , the ejector cams
need to be exchanged (see paragraph 2.2.5) and the return springs of the bottom mold
must be mounted if applicable (refer to the xMS-xx-M2 mold manual).

xMS-i Bottom mold 2
2. BOTTOM MOLD
2.1 BOTTOM MOLD PARTS

The bottom mold parts and the mold surface are indicated in the figures below. Figures of
detail parts (of a partly disassembled mold) can be found in the procedures.
Figure 11 Bottom mold: parts

A: Ejector cam G: Heater element
B: Push plate H: Mold plate
C: Isolation plate I: Vacuum strip
D: Bottom plate J: Return pins
E: Ejector plate K: Support plugs (fixed to bottom plate)
F: Ejector holder plate M: Ejector set

2.2 Bottom mold disassembly xMS-i
2.2 BOTTOM MOLD DISASSEMBLY
2.2.1 Precautions
Do NOT mix up the various parts of the mold. When disassembling the mold, store the parts in
a logical sequence. If needed, name or number the separate parts.
When the ejector pins stick out, push the ejector pin bed back in by gently tapping down the
return pins with a copper tool.
Before starting dissassembly, take notice of the general notes in paragraph 1.5.
2.2.2 Preparing for disassembly

To prepare the mold for disassembly, proceed as follows:
1. On the machine, run operation mode Conversion to remove the mold. See Operating
Procedures. Use a mold carrier for this purpose.
Figure 12 Molds and plunger beam on mold slide

A: Top mold D: Plunger beam G: Connectors top mold
B: Bottom mold E: Ejector cam H: Handle
C: Mold slide F: Connectors bottom mold

xMS-i Removing the plunger beam and plungers 2.2.3
2. Attach the top mold removal tool (see paragraph 1.4.4) with two screws to the top
mold. Make sure the screws are tightened correctly. Lift up and turn the top mold until
the cavity surface faces upwards (position for disassembly). Always handle the mold
half with two persons and always place it on a clean soft surface.
3. Turn the bottom mold with mold slide until the mold cavity surface rests on a clean soft
surface. While turning, cover the bottom mold surface with a thick cloth to prevent
damaging.
Always handle the mold half with two persons and always place it on a clean soft
surface.
4. Remove the mold slide.
2.2.3 Removing the plunger beam and plungers
Never take out the plunger beam and plungers together. The plunger tops are made of
carbide and can break easily . When taking out the plungers one by one, turn the
plungers clockwise and pull them out in a straight line. Do not rock the plungers from
side to side.
To remove the plungers, proceed as follows:

1. Remove the two halves (A) of the plunger beam by unscrewing the socket screws (B),
and -if present- the dust cover of each plunger.
Figure 13 Plunger beam

A: Plunger beam B: Socket screws

2.2.4 Removing the covers and components xMS-i
2. Carefully pull the plungers one-by-one out of the mold.

3. Turn the bottom mold until the mold cavity surface faces upward (position to start
disassembly). The bottom mold rests on the two ejector cams. Handle the mold half
with two persons and always place it on a clean soft surface.
4. Remove the mold handle by unscrewing the two socket screws.
2.2.4 Removing the covers and components
Figure 14 Cover disassembly

A: Type plate D: PT-100 Connector
B: Covers E: Heaters Connector
C: Vacuum strip
To remove the covers and loose components, proceed as follows:

1. Unscrew the three screws inside the fitting of the heater connector (E). There is no
need to loosen the fitting of the second connector (D).
2. Unscrew the cover screws and remove all covers (B) except for the cover with the
connectors.
Due to the attached electrical component wires, this cover can be loosened but not yet
be removed.
Be careful not to damage the wires and electrical components when removing the
mold covers.

xMS-i Removing the covers and components 2.2.4
Figure 15 Components
A: Heater elements D: PT-100
B: Earthlead E: Vacuum strips
C: Clixon
3. Remove the vacuum strips (E).
There are different types of PT-100:. The used PT-100 depends on the mold design. Some
mold types do not have a clixon.
4. Unscrew the PT-100 (D) screws and pull out the sensor. Remove all heatsink
compound from the sensor and clean the surface around the hole with a clean cloth.
The sensor is connected to the PT-100 connector.
5. Remove the clixon (C) by unscrewing the two socket screws. This clixon is an over-
temperature protection switch which is screwed to the mold plate. The sensor is
covered with a white plastic cover and is connected to the PT-100 connector.
6. Twist the connector wires in such a way that the heater connector fitting can be pushed
through its housing.
The front cover with the PT-100 connector (and attached elements) can now be
removed.
THE HEATER ELEMENTS ARE SECURED BY SPRING CLIPS. TO REMOVE THESE

SPRING CLIPS, USE A SPECIAL TOOL. IF NOT, THE SPRING CLIP MAY JUMP IN ANY
DIRECTION AND MAY CAUSE PERSONAL INJURY.
7. Remove the cable clamps, if present.

2.2.5 Removing the ejector cams xMS-i
8. Remove the spring clips and carefully pull out the heater elements without bending or
damaging them. In some cases (no heater problems, no long-term storage), there is no
need to remove the heater elements. The heater connector can stay attached to the
mold plate. Remove all heatsink compound from the elements and clean the
surrounding.
9. Remove the earthlead (green/yellow cable (B)) by unscrewing its socket screw.
The heater connector can now be removed.
The heater connector and the attached elements need NO further disassembling
unless a heater (wire) problem has occured.
2.2.5 Removing the ejector cams
Figure 16 Ejector cam disassembly

A: Ejector cams C: Dowel pins
B: Socket screws D: Grinding plate
To remove the ejector cams, proceed as follows:

1. Unscrew the two M4 socket screws (B), remove the ejector cam (A), the loose grinding
plate (D) (if present), and the two dowel pins (C) that are inserted in the mold plate.
2. Do the same for the other ejector cam.

xMS-i Removing the center pins 2.2.6
2.2.6 Removing the center pins

The center pins on the mold surface ensure that the leadframe is placed correctly in the
cavity and cannot shift during the molding process. In general, six center pins are present
at a mold surface. Three types of center pins are developed depending on the mold
configuration. Check which type is used and follow the corresponding procedure to
disassemble.
• long center pins: pins which run all the way through the bottom mold. They can be
recognized by their adjustment screw at the bottom of the mold. This pin type is fitted
with springs to adjust the pin height.
• short center pins with inserts: pins with are fitted to an inserted block in the cavity strip.
They can be recognized by the inserted block with screw.
• short center pins without inserts (standard): pins which are fitted directly into the cavity
strip.
When taking out the center pins, be careful not to bend or damage them. Store the
pins by pinching them into foam or wrapping them carefully.
Long center pin
Figure 17 Long center pin

A: Center pin B: Adjustment screw
To remove a long center pin, proceed as follows:

1. At the mold bottom, unscrew the adjustment screw (B) that locks the center pin.
2. When turning the mold, the center pins (including the spring) should fall out. If needed,
gently tap the tapered end with a copper punch to loosen the pin somewhat.

2.2.6 Removing the center pins xMS-i
Short center pin with insert
Figure 18 Short center pin with insert

A: Socket screw B: Insert block
To remove a short center pin with insert, proceed as follows:

1. At the mold surface, unscrew the M3 socket screw (A) of the center pin block.
2. In the M3 screw hole, insert a M4 socket screw and turn this screw until the inserted
block (B) with center pin is pushed out of the cavity surface.
Short center pin without insert
Figure 19 Short center pin without insert
This type of center pin is fitted in the cavity strip. The pins can only be removed when
disassembling the cavity strip.

xMS-i Removing the dowel pins 2.2.7
2.2.7 Removing the dowel pins

Two dowel pins run through the mold plate to align and position the mold layers. They are
mounted opposite each other under the side center nocks. To remove the dowel pins, use
the dowel pin puller in the Fico tool kit. A third dowel pin is present under the cull strip and
should be removed when removing the cull strip.
To remove the dowel pins, proceed as follows:

1. At the mold surface, unscrew the center nock M5 screw and remove the center nock.
The dowel pin becomes visible underneath.
2. Screw the dowel pin puller into the threaded hole of the dowel pin, and pull up the
dowel pin.
3. Do the same for the second dowel pin.
2.2.8 Removing the bottom plate
The bottom plate assembly consists of three layers, i.e. the push plate, the isolation plate and
the bottom plate. Support plugs are screwed into the bottom plate. The three layers are
removed together and need NO further disassembling. The isolation plate is made of a
composite material that acts (shrinks, bends, etc.) which makes it difficult to assemble again.
Figure 20 Bottom plate disassembly
To remove the bottom plate assembly, proceed as follows:

2.2.9 Removing the ejector set xMS-i
1. Unscrew the M6 socket screws (A in figure 20) at both sides of the bottom plate. These
long socket screws are countersunk in the bottom plate, run through ’loose’ support
plugs and are screwed into the bottom plate.
Figure 21 Bottom plate and support plugs
2. Lift up and remove the bottom plate assembly (A in figure 21). Do NOT disassemble
the bottom plate assembly any further unless this is necessary. The isolation plate
material acts which makes it difficult to reassemble again. There is no need to loosen
the support plugs (B) either, unless they are damaged.
3. Remove the ’loose’ support plugs (C). The plugs rest freely on the ejector plate.
2.2.9 Removing the ejector set
The ejector set consists of the ejector plate and the ejector holder plate. The last one holds the
ejector pins. The pin bed needs NO further disassembling unless the ejector pins are bent or
damaged.

xMS-i Dismantling the mold plate 2.2.10
Figure 22 Ejector set

A: Special screw C: Ejector pin bed
B: Mold plate D: Plunger sleeve
To remove the ejector set, proceed as follows:

1. Use the special M6 bent screws (A) in the Fico tool kit and screw them in the four
threaded holes until they touch the mold plate (B).
2. Turn the bent screws (A) one at a time to raise the ejector pin bed (C) gradually and
evenly. When resistance is no longer sensed, the ejector pin bed can be removed.
3. Lift up and remove the ejector pin bed (C).
4. The sleeves (D) in the mold plate can NOT yet be taken out. They are taken out
together with the cull strip. See paragraph 2.2.10.
When taking out the ejector pin bed, be careful not to bend or damage the pins. Store
the pin bed in a safe place with the pins facing upward.
2.2.10 Dismantling the mold plate

Two different mold plate designs are available:
• Mold design 2: mold plate with one solid cavity plate (no cull strip).
• Mold design 5: mold plate with two separate cavity strips and a cull strip.
Dismantling a solid cavity pate (design 2)

2.2.10 Dismantling the mold plate xMS-i
If tapping is needed to loosen the mold plate, make sure to tap carefully and always
use brass or copper tools. Tap the mold plate loose from the backside, through the
screw holes. NEVER tap at the plate surface or edges.
At the bottom mold plate, unscrew all socket screws and remove the cavity plate from the
mold plate.
Dismantling the separate cavity strips and cull strip (design 5)
If tapping is needed to loosen the mold parts, make sure to tap carefully and always
use brass or copper tools. Tap the mold parts loose from the backside, through their
screw holes. NEVER tap at the part surface or edges.
Remove the strips one-by-one. Beware that the strips cannot fall and get damaged.
When removing, never use force or rock the strips too much as the strip edges may
get damaged.
Figure 23 Mold on brackets
To disassemble the cavity strips, proceed as follows:

1. Use the two brackets (B) in the Fico tool kit and attach them to the bottom of the mold
plate.
When attaching the brackets make sure that the socket screws in the mold plate are

not covered. It is also possible to remove these socket screws before attaching the
brackets.
2. Unscrew the socket screws of the upper cavity strip (A) and remove the strip.
When short center pins without insert are used, take these pins out of the cavity strip.
Figure 24 Mold plate design 5
3. Use the brass pin in the Fico tool kit to remove the location keys/ wedges (A) in the
slots (B). The keys are fitted into the mold plate slots by pins.
4. When the cavity strip inserts are worn-out or damaged, remove the gate inserts in the
cavity strip. See paragraph 7.
Figure 25 Location pins

2.2.10 Dismantling the mold plate xMS-i
When removing the cull strip, make sure that the sleeves and (if present) the location
pins do NOT fall out or get damaged.
5. Unscrew the socket screws of the cull strip and remove the strip and sleeves.
6. Under the cull strip a third dowel pin (A in figure 25) (in some cases a location key) is
mounted. Use the dowel pin puller or otherwise the brass pin and copper punch (in the
Fico tool kit) to remove this one.
Figure 26 Cull Strip: location pins disassembly
7. Carefully remove the locations pins (A in figure 26) in the cull strip. If needed, use the
brass pin and copper punch to tap the pin out of the strip. The location pins are
inserted to position the leadframe correctly.
8. Remove the sleeves from the cull strip. See paragraph 6.
9. Remove the lower cavity strip. See step 2 to 5.
Figure 27 Fill plates

If fill plates are present under the cull strip, record their location. This information is
required when assembling the mold again.
10. Remove the small and large fill plates (A) under the cull bar. Fill plates are used to fill
up the minor irregularities between the sleeve holes. In most cases, the fill plates are
placed loose.
11. To clean the mold parts, refer to paragraph 10.1.

2.3 Bottom mold assembly xMS-i
2.3 BOTTOM MOLD ASSEMBLY
2.3.1 Precautions
The different mold parts have engraved codes. If the mold is assembled properly, all codes
should be at the same side.
When screwing screws or bolts back in, always use NeverSeez when metal touches
metal and always use Loctite no. 646 when metal touches non-metal materials. In the
mold, the vacuum strips and the isolation plate are made of a non-metal material, i.e. a
composite material.
Wear toolmakers gloves when assembling the mold halves. This will prevent the
moisture on your hands from contaminating the mold. Moisture may cause rust.
Always tighten the screws diagonally and evenly to prevent pulling mold parts out of
alignment.
If tapping is needed to fit the mold parts in place, make sure to tap carefully and always
use brass or copper tools. NEVER tap at the part surface or edges. The parts should
fit without force. Clean the area afterwards with the brush available in the Fico tool kit.
NEVER use a whet stone (not even the red one) on the cavities and clamping area of
the cavity strip, or on the plungers and sleeves.
Before starting assembly, take notice of the general notes in paragraph 1.5.

xMS-i Preparing for assembly 2.3.2
2.3.2 Preparing for assembly

Make the following preparations to prepare the mold for assembly:
1. Clean all parts before assembling the mold. It is recommended that all parts are
cleaned with RBS-25. See paragraph 10.6.
2. Check all parts for wear and damage. It is advisable to record this information as this
may help to plan preventive maintenance actions.
3. Make sure that the surfaces are flat, i.e. no burrs or (small) irregularities.
When checking the mold surfaces for burrs and irregularities, only use the red whet
stone. The others are too abrasive.
Before placing back the support plugs and return springs into the mold, clean their
surface with the black whet stone.
4. Grease all socket screws and dowel pins with NeverSeez paste and apply Loctite no.
648 to socket screws which are used for the plastic parts.
2.3.3 Assembling a solid cavity plate (design 2)

To assemble a solid cavity plate, follow the procedure in paragraph 2.3.4, except for the
steps related to the cull strip.
2.3.4 Assembling cavity strips and cull strip (design 5)
Figure 28 Mold on brackets
To assemble the separate cavity strips, proceed as follows:

1. Use the two brackets in the Fico tool kit to attach them to the bottom of the mold plate.

2.3.4 Assembling cavity strips and cull strip (design 5) xMS-i
Figure 29 Mold plate

A: Dowel pin (3) B: Slots for keys
2. Refit the middle dowel pin (A in figure 29) (in some cases it is replaced by a location
key). The two outer dowel pins are fitted later on.
Figure 30 Bottom Mold: cull strip location pins assembly
3. Refit the leadframe location pins (A) in the cull strip.. See figure 30.
4. Refit the sleeves in the cull strip. See paragraph 6.
5. Refit the cull strip with sleeves in the mold plate and make sure that the cavity strip
makes contact with the mold plate surface. When inserting the sleeves, be careful not
to damage them. Hand tighten the M4 socket screws of the cull strip.
6. Refit the fill plates and location keys. Make sure to position them correctly. If needed,
tap the keys in place with the copper punch.
7. If needed, refit the gate inserts in the cavity strip. See paragraph 7.

xMS-i Assembling cavity strips and cull strip (design 5) 2.3.4
Figure 31 Bottom Mold: short center pin
8. If short center pins without insert are used, insert the pins in the cavity strip.
Short center pins with insert and long center pins are refitted later on. See
paragraph 2.3.8.
9. Place the cavity strip on the mold plate and make sure that the cavity strip makes
contact with the mold plate surface. Hand tighten the M4 socket screws.
10. Do the same for the other cavity strip.
11. Place the mold on a soft cloth with the surface downwards and remove the brackets.
12. Verify if all (M4) socket screws are fitted, and fully tighten the screws diagonally and
evenly from the outside to the inside.
13. Check at the mold surface if the strips are correctly placed, i.e. no level differences and
gaps.

2.3.5 Refitting the dowel pins and center nocks xMS-i
2.3.5 Refitting the dowel pins and center nocks
Figure 32 Dowel pin and center nock assembly

Dowel pin in image is not inserted completely in the mold plate
To refit the center nocks, proceed as follows:

1. At the mold surface, refit the two dowel pins (A) under the side center nocks. Make
sure that the threaded hole of the dowel pin faces upward.
2. Refit the four center nocks (B) and tighten the M4 screw. If needed, tap the center nock
in place with the brass tool and copper punch.

xMS-i Refitting the ejector set 2.3.6
2.3.6 Refitting the ejector set
NEVER rotate the bed. The correct positioning of the bed can be traced back to the
engraved code on the pin bed. The bed’s engraved code should be at the same side
as the mold plate’s code.
To install the ejector set, proceed as follows:

1. Make sure that the surfaces of the mold plate (B), the ejector plate (C) and the pins (A)
are clean and free of compound rests. This applies equally to the sleeves (D) and
sleeve holes in the ejector plate.
Figure 33 Ejector set

A: Ejector pins C: Ejector pin plate
B: Mold plate D: Sleeve
2. Carefully lower the ejector pin bed into the mold plate. Be careful not to damage the
pins and the sleeves.
3. If the ejector pin bed does not fit easily, disassemble the ejector set (see paragraph 4)
and clean the pins. If needed, push the pins in one-by-one before reassembling the
ejector pin bed again.

2.3.7 Refitting the bottom plate xMS-i
2.3.7 Refitting the bottom plate

To instal the bottom plate, proceed as follows:
1. Clean the support plug surfaces with the black whet stone in the Fico tool kit.
Figure 34 Bottom plate and return springs
2. Place the loose support plugs (C in figure 34) on the bottom plate in the openings of
the ejector plate.
3. Place the bottom plate assembly (A) on the ejector plate. Make sure that the plate’s
engraved code is at the same side as the ejector bed’s code.
Figure 35 Bottom plate

xMS-i Refitting the center pins 2.3.8
2.3.8 Refitting the center pins

For information on the different center pin types, refer to paragraph 2.2.6.
Long center pin

To assemble the long center pin, proceed as follows:
1. Check if the pins are clean and straight.
2. At the mold bottom, carefully insert the long center pin (A) with spring (B) in the bottom
mold.
Figure 36 Long center pin
3. Insert the M4 set screw (C) and hand tighten the screw to lock the pin.
4. Adjust the center pin height. See paragraph 8.2.
Short center pin with insert
Figure 37 Short center pin with insert

2.3.9 Refitting the ejector cams xMS-i
To assemble the short center pin with inserts, proceed as follows:

1. At the mold surface, insert the center pin in the inserted block (B) and press the block
with pin in the mold.
2. In the screw hole, insert a M3 socket screw and turn this screw to secure the block.
Short center pin without insert

This pin type must be pressed into the cavity strip before refitting the cavity strip. See
paragraph 2.3.3 or paragraph 2.3.4.
2.3.9 Refitting the ejector cams
Figure 38 Ejector cams

A: Ejector cam C: Dowel pins
B: Socket screws D: Grinding plate
To install the ejector cam, proceed as follows:

1. Insert the two dowel pins (C) in the ejector plate. Make sure that the threaded hole of
the dowel pin faces upward.
2. If present, place the grinding plate (D) over the dowel pins. Some ejector cams have
loose grinding plate, some come without grinding plate.
3. Place the ejector cam (A) on top of the grinding plate and secure it with the two M4
socket screws (B).
4. Do the same for the other ejector cam.

xMS-i Refitting the components 2.3.10
2.3.10 Refitting the components

Install the loose components acoording to the following procedure:
1. If removed, refit the cable clamps.
Except for the Cull Bar Heater (CBH) element in the top mold, all other heater
elements need to be rubbed with heatsink compound. As the CBH element is pressed
between two mold parts, the heatsink compound may flow between the parts when
heated.
2. Rub the heater elements with heatsink paste and carefully insert them in the mold
plate.
Make sure that enough heatsink paste is used to ensure a good contact. Clean the
surface around the hole.
3. Refit the spring clips that secure the heaters.
4. Rub the PT-100 with heatsink paste and carefully insert the sensor in the mold plate.
Tighten the screws. Make sure that enough heatsink paste is used to ensure a good
contact. Clean the surface around the hole.
5. Refit the clixon and tighten the screws.
6. Refit the earthlead to the covers by tightening its socket screw.
7. Refit the vacuum strips by tightening the socket screws. Start with the long sides, and
next the short sides. One strip has an opening for the PT-100 sensor.
2.3.11 Assembling the mold covers and handle

To complete the assembly, proceed as follows:
1. Refit the protective shielded cable around the heater element wires.
2. Twist the heater wires in such a way that the heater connector fitting can be pushed
through the connector housing in the front cover. Tighten the screws of the connector
fitting.
3. Refit the covers by tightening the socket screws.
4. Refit the handle by tightening the socket screws.

2.3.12 Refitting the plungers and plunger beam xMS-i
2.3.12 Refitting the plungers and plunger beam
Be careful when refitting the plungers. The tops are made of carbide and can easily
break. Only turn the plungers clockwise and fit them in a straight line. Do not rock the
plungers from side to side and NEVER use tools (not even brass or copper ones) to
tap the plungers back in.
Do not grease the transfer beam assembly and make sure that no grease is present on
the outside. Mixed grease and pellet dust may clog on the parts and obstruct the
movement.
To refit the plungers and the plunger beam, proceed as follows:

1. Insert the plungers one at a time into the bottom mold.
2. Refit the two halves of the plunger beam and, if present, the dust cover.
3. Place the mold slide on the bottom mold and turn the assembly 180 degrees, until the
mold rests on the mold slide. Always handle the mold with two persons.
4. Make sure that the ejector pins are fully retracted (not sticking out). Use the copper
punch to tap down the return pins of the ejector pin bed.
5. Make sure that the plunger tops are level with the mold surface. If not, carefully push
the plungers back in until the plunger beam touches the mold slide.

xMS-i Top mold 3
3. TOP MOLD
3.1 TOP MOLD PARTS

Figures of detail parts (of a partly disassembled mold) can be found in the different
procedures.
Figure 39 Top mold: parts (covers removed)

A: Support plug F: Top plate M: Earth terminal
B: Push plate G: Ejector plate N: Clixon (optional)
C: Hook H: Ejector holder plate O: PT-100 sensor
D: Connector K: Mold plate
E: Isolation strip L: Vacuum strip
Do NOT mix up the various parts of the mold. When disassembling the mold, store the parts in
a logical sequence. If needed, name or number the separate parts.
Before starting dissassembly, read the general notes in paragraph 1.5.

3.2 Top mold disassembly xMS-i
3.2 TOP MOLD DISASSEMBLY
3.2.1 Preparing for disassembly

To prepare the mold for disassembly, proceed as follows:
1. On the machine, run the operation mode "conversion" to remove the mold. Refer to the
operating procedures in the user manual. Use a mold carrier for this purpose.
2. Use the top mold removal tool (see paragraph 1.4.4) to remove the TOP mold from the
bottom mold.
3.2.2 Removing the covers and components

To remove the covers, proceed as follows:
1. Place the mold with the connectors facing upward. Make sure to place the cavity
surface on a soft clean surface.
Be careful not to damage the wires and electrical components when removing the
mold covers or turning the mold.
2. Remove the covers by loosening their screws (A).

3. Loosen the four M4 socket screws of the connectors (B).
Figure 40 Top mold with covers

A: Cover screws B: Connector screws

xMS-i Removing the covers and components 3.2.2
4. Place the connector beside the mold. The electrical components are still attached to it.
A: Clixon (optional) C: Earth terminal
B: PT-100 sensor D: Vacuum strip
5. Remove the vacuum strips (D) by loosening their screws.

6. Remove the PT-100 sensor (B). Remove all heatsink paste from the sensor and clean
the surface around the hole with a clean cloth. The sensor is connected to the PT-100
connector.
7. If applicable, remove the DTC mold components as described in paragraph 3.2.3.
8. If applicable, remove the clixon (A) by unscrewing the two socket screws. This clixon is
an over-temperature protection switch which is screwed to the mold plate. The sensor
is covered with a white plastic cover and is connected to the PT-100 connector.
9. Pull the earth lead (yellow-green cable) from the earth terminal (C) and remove the
terminal if necessary.
10. Remove the spring clips that secure the heater elements.
11. Carefully pull out all heater elements without bending or damaging them. In some
cases (no heater problems, no long-term storage), there is no need to remove the
heater elements. The heater connector can stay attached to the mold plate.
The heater connector and the attached elements need NO further disassembling
unless a heater (wire) problem has occurred.

3.2.3 Removing the DTC mold components xMS-i
3.2.3 Removing the DTC mold components

Removing DTC mold components is only necessary when you have a specal DTC mold. In
case of doubt, please consult the Fico customer service department.
Figure 42 Extra components in the DTC mold

D: Vacuum strip F: Fuse H: PT-100 DTC
E: Center nock G: DTC heater elements
In case the top mold contains DTC mold components, remove the heater elements, PT-100
and fuse as follows:
1. Remove the two center nocks (E) at the front and back side of the mold.
2. At one side, remove the heater elements and the PT-100.
At the other side, remove the fuse.
3. Continue removing the other components as described in paragraph 3.2.2.

xMS-i Removing the top plate assembly 3.2.4
3.2.4 Removing the top plate assembly

In case the top mold contains center pins, these have to be removed before the top plate
assembly can be removed, to avoid damage.
Proceed as follows:
• Loosen the set screws
• Take care that the spring do not jump out
• Push the pins up and remove them from the mold
To remove the top plate assembly from the mold, proceed as follows:
1. Remove the shoulder bolts (A) from the mold:
Figure 43 Top plate (top view)

A: Shoulder screw B: Support plug
2. Carefully remove the top plate assembly and put it aside.

For further disassembly of the top plate, refer to paragraph 3.2.5.
If no disassembly of the top plate is necessary, continue with paragraph 3.2.6.

3.2.5 Disassembling the top plate xMS-i
3.2.5 Disassembling the top plate
The following steps are only needed in case of damaged or worn-out parts. In all other cases,
skip this paragraph.
The top plate assembly consists of several layers, i.e. the push plates (C), the isolation
plates (H) and the top plate (B). On top of the top plate, four support plugs (A) and two
centre rings (E) are attached to position the mold correctly in the top block. One centre ring
has a slot hole and the other a round hole. To secure the top mold in the press, two hooks
grip behind the two blocks (F) mounted at each side of the top mold.
Figure 44 Top plate: parts

A: Support plug E: Centre ring
B: Top plate F: Hook
C: Push plate H: Isolation plate
Remove all parts from the top plate.
If removal of parts is not necessary, leave them on the assembly. The isolation plate is made of
a composite material that works (shrinks, bends, etc.) which makes it difficult to assemble
again.

xMS-i Removing the ejector set 3.2.6
3.2.6 Removing the ejector set

Remove the ejector set as follows:
1. Lift the ejector set (figure 45) from the mold.
When lifting the ejector set, be careful not to bend or damage any of the ejector pins or
return pins.
Store the ejector set in a safe place with the return pins facing upward. There is NO
need to disassemble the ejector set any further unless the ejector pins are damaged
(see paragraph 4.2 for the disassembly procedure).
Figure 45 Ejector pin bed

A: Ejector plate C: Return pin
B: Ejector holder plate D: Distance nock

3.2.7 Disassembling the mold plate xMS-i
3.2.7 Disassembling the mold plate
If tapping is needed to loosen the mold parts, make sure to tap carefully and always
use brass or copper tools. Tap the mold parts loose from the backside, through their
screw holes. NEVER tap at the part surface or edges.
To disassemble the mold plate, proceed as follows:

1. If necessary, remove the distance nocks.
2. Loosen all mold plate screws (B in figure 46) and remove the mold plate.
Figure 46 Mold plate

A: Distance nocks D: Vacuum plate
B: Fixing bolts E: Center nock
C: Mold plate F: Vacuum strip
3. If necessary remove the wedges or dowel pins from the mold plate.
4. Turn over the vacuum plate (see figure 47).

xMS-i Disassembling the mold plate 3.2.7
Figure 47 Vacuum plate and vacuum o-ring

A: Vacuum O-ring (if applicable) C: Vacuum strip
B: Center nock
5. Remove the vacuum O-ring (A) out of its slot (if applicable).
6. If necessary, remove the center nocks (B) and vacuum strip (C).

3.3 Top mold assembly xMS-i
3.3 TOP MOLD ASSEMBLY
3.3.1 Assembly precautions

Read and follow the precautions as written in paragraph 2.3.1, "Precautions", on page 26.
3.3.2 Assembling the mold plate

To assemble the mold plate, proceed as follows:
1. Insert the wedges or dowel pins into the mold plate.
Make sure they are aligned correctly, to be able to fit the vacuum plate to it.
2. Use all the fixing bolts (B in figure 46) to fasten the vacuum plate to the mold plate (C).
3. Refit the four center nocks (E).
To prevent damage to the O-ring, it will be fitted later on (if applicable).
Figure 48 Mold plate and distance nocks

A: Distance nocks D: Vacuum plate
B: Fixing bolts E: Center nock
C: Mold plate F: Vacuum strip
4. If they were removed, refit the distance nocks (B).

xMS-i Refitting the ejector set 3.3.3
3.3.3 Refitting the ejector set

Disassembly and assembly of the ejector set is explained in paragraph 4.2 and
paragraph 4.3.
Before refitting the ejector set, check the pins. If necessary, replace damaged pins and/or clean
them. The pins should fit without force in their holes in the mold plate.
To refit the ejector set to the mold plate, proceed as follows:
Figure 49 Ejector set and mold plate

A: Ejector plate C: Return pin
B: Ejector holder plate D: Ejector pin
1. Carefully lower the ejector set (A, B, C and D) on the mold.
Be careful not to bend or rock the pins, as these are extremely delicate and get
damaged very easily.

3.3.4 Refitting the top plate assembly xMS-i
3.3.4 Refitting the top plate assembly

To refit the top plate assembly, proceed as follows:
1. If the top plate was disassembled, re-assemble it again.
Lower the top plate on the mold.
2. Slide the 4 support plugs (B in figure 50) between the mold plate and the top plate and
fasten them with the shoulder screws (A).
3. Refit the center pins as follows:
- insert the pin
- refit the spring
- tighten the set screw
- check if the center pin springs by pressing it with a brass tool.
Figure 50 Dowel pins

A: Shoulder screw B: Support plug

xMS-i Refitting the components and covers 3.3.5
3.3.5 Refitting the components and covers

Refit the components and covers as follows:
1. Carefully insert the heater elements into the correct hole in the mold.
2. Secure the heater elements with the spring clips.
A: Clixon (optional) C: Earth terminal
B: PT-100 sensor D: Vacuum strip
3. Refit the earth terminal (C) and connect the earth lead to it.
4. Refit the clixon (A) (if applicable).
5. Apply heatsink paste to the PT-100 (B) sensor and insert it into the mold.
6. Refit the vacuum strips (D) at the front and back of the mold.
7. Refit the plastic block that is mounted behind the connector and install the connector.
8. Check the electrical connections and adjust them if necessary (refer to paragraph 9,
"Electrical system", on page 72).
9. Refit the covers around the mold.
10. Carefully put the mold on its side.
11. Insert a new rubber vacuum O-ring in the groove of the vacuum plate (if applicable).

3.3.5 Refitting the components and covers xMS-i

xMS-i Ejector set 4
4. EJECTOR SET
4.1 EJECTOR STROKE

The ejector set in the top mold is mechanically driven. When the mold opens the ejector
pins are pushed down by compression spings. The ejector pins stick out about 2 mm (the
so-called ejector stroke) and prevent the product from sticking to the top mold surface.
Attached to the top ejector pin bed are return pins, which are slightly longer than the ejector
pins. When the mold closes, the bottom mold pushes up the return pins which take the
ejector pins with them up.
4.2 DISASSEMBLING THE EJECTOR SET
All ejector pins are fitted in a specific pattern. During disassembly, always mark their
place or record the pattern to ensure that they are refitted at the correct place. When
they are numbered, their individual length and thickness may differ. When they are not
numbered, the pins (or groups of pins) have the same length and thickness.
Figure 52 Ejector set on blocks
To disassemble the ejector set, proceed as follows:

1. Place the ejector set on two blocks with the pins facing downwards. See figure 52.
2. Unscrew all socket screws and remove the ejector plate (A).
3. Carefully remove the ejector pins one-by-one by pulling them out of the ejector holder
plate (B). Make sure that they cannot bend or get damaged.
4. Take the return pins out of the ejector holder plate.
5. Clean the pins and remove possible compound. If needed, clean them with RBS-25.
See paragraph 10.6.

4.3 Assembling the ejector set xMS-i
4.3 ASSEMBLING THE EJECTOR SET

To assemble the ejector set, proceed as follows:
1. Place the ejector holder plate on two blocks so that the pins can be pushed in. See
figure 52.
2. Check the pins on bendings and damages.
3. Carefully refit all ejector and return pins in the ejector holder plate. Make sure that they
are refitted in the original pattern.
4. Place the ejector plate and hand tighten the socket screws.
5. Tighten the screws fully, from the outside to the inside.
6. Turn the ejector set upside down and check if the pins can still move slightly.

xMS-i Plungers 5
5. PLUNGERS
5.1 PLUNGER BEAM AND PLUNGERS
Figure 53 Plunger beam

A: Plunger beam halves E: Socket screw (M5 x 90)
B: Plunger holder ring F: Shoulder pin
C: Lock ring G: Plunger spiral
D: Compression spring H: Epoxy groove
The head of each plunger has an epoxy groove (H), which fills with molding compound
during the first molding stroke. Every time the bottom mold is disassembled for
maintenance, the epoxy groove must be cleaned before re-assembly. The plungers are
fitted under a pre-defined tension (preload tension) by means of the compression spring
(D). Different spring diameters (recognizable by their color) are used, depending on the
required spring force and transfer pressure. The higher part of the plunger (plunger spiral
(G)) is screwed to the lower plunger part (shoulder pin (F) and spring (D)) by means of a
long socket screw (E). Information on the
and process can be found in the Press general information manual.

5.2 Replace the teflon plunger rings xMS-i
The plunger spring is set under tension, which is why the Fico plunger removal tool (see
paragraph 1.4.3) must be used to disassemble or assemble the plunger compression
spring. Use the correct split center bush (B) in the removal tool. The split center bush must
correspond with the spring diameter which is indicated by the spring color. Adjusting the
spring preload tension is a precise job and the product quality depends on it.
The springs are pre-loaded to ensure that:

• the plungers move up evenly and without ’hesitation’,
• the required transfer end pressure can be reached.
A plunger spring needs dismantling in the following cases:

• to replace a (broken, worn-out) part in the plunger assembly,
• to clean the plunger assembly thoroughly.
5.2 REPLACE THE TEFLON PLUNGER RINGS

To replace the teflon plunger ring, proceed as follows:
1. Use a sharp knife to cut the old teflon plunger ring.
Figure 54 Cut the teflon ring
2. Thoroughly clean the plunger.

3. Apply a new teflon ring.

xMS-i Replace the teflon plunger rings 5.2
Figure 55 Applying the teflon ring
4. Wait a few minutes so that the teflon ring can settle.

5. Push the plunger into a sleeve to scrape off the excess teflon.
Figure 56 Scraping off excess teflon from the plunger

A: Plunger B: Sleeve

5.3 Disassembling a plunger xMS-i
5.3 DISASSEMBLING A PLUNGER

For disassembly of a plunger a special tool is necessary.
To disassemble a plunger, proceed as follows:

1. Clamp the bottom piece of the special tool in a vice.
Apply a small amount of NeverSeez to the screw thread of the bottom piece, to prevent
grating.
Figure 57 Place the bottom piece in a vice
2. Place the two bush halves over the end of the plunger.
Figure 58 For each spring diameter (color) there is a special bush

xMS-i Disassembling a plunger 5.3
3. Place the plunger in the bottom piece and turn the plunger so that it falls into the slot in
the bottom.
Figure 59 Lock the plunger in position
4. Fasten the cap of the tool to relief the tension from the plunger spring.
Figure 60 Fasten the cap completely

5.3 Disassembling a plunger xMS-i
5. Stick an allen key through the hole in in the cap and loosen the long plunger screw.
Figure 61 Hold the plunger while loosening the screw
While unscrewing the long plunger socket screw, hold the plunger to make sure that
the carbide plunger cannot fall out of the tool. The plungers are very brittle and can
break easily.
6. Take out the spiral plunger.

7. Loosen the cap to release the tension from the spring.
8. Remove the individual parts from the tool.
Figure 62 Plunger parts

xMS-i Plunger assembly 5.4
5.4 PLUNGER ASSEMBLY

Assemble the plunger in the reverse order as described in paragraph 5.3. After having
assembled the plunger, always check if the plunger spiral (B) fits exactly to the shoulder pin
(C), and that the long socket screw (E) is screwed in correctly. Check if all plungers are at
the same height in the topedge strip.
Figure 63 Plunger parts

A: Teflon ring E: Socket screw
B: Plunger spiral F: Lock ring
C: Shoulder pin G: Plunger holder ring
D: Plunger spring
5.5 CALCULATING THE TRANSFER END POSITION
5.5.1 General
The desired transfer pressure is a setting in each MMI recipe. The actual transfer pressure
is only measured in the machine if the option FTPC is available and activated. In all other
situations a calculation is used to convert the desired transfer pressure to a transfer end
position. Understanding the calculations used for the transfer end position is important for
process engineers.
5.5.2 Transfer movement

The transfer makes a movement that is determined by the recipe parameters of the
product.
This movement has following important positions.

5.5.2 Transfer movement xMS-i
Figure 64 Plunger beam and plunger positions

A: Sleeve D: Plunger beam
B: Plunger S: Spring compression
C: Spring
1. The starting position.

The plunger beam and plungers are in pellet load position.
2. The pellet crunch position.
Here the plunger beam waits until the pellet preheat time has finished.
3. The position "Cull Height".
This is the position at which the plunger tips cannot move up any higher.
The cavities are completely filled but the transfer movement is not yet applying
pressure to the epoxy.
The plunger beam moves up from position "cull height" to the calculated "End
Position". The plungers themselves can NOT go higher because the culls are blocking
this.
The plungers springs are the flexible connection between the transfer beam and the
plungers. Since the plunger tips are blocked by the culls the springs will be
compressed by the up movement of the transfer beam.
4. The end position.
The transfer beam is at the position where the springs apply the pressure to the epoxy.
Since the transfer beam movement stopped, the plungers keep the desired transfer

xMS-i Parameters 5.5.3
pressure to each plunger and thus to the epoxy.
Hardware determines parameter settings like spring constant and plunger diameter.
Your product determines parameter settings like cull height and transfer pressure.
The parameters can be found and modified in the MMI Recipe screen, and differ per
product.
5.5.3 Parameters
• SPRING CONSTANT: This parameter is the spring constant, i.e. the force needed to
compress the spring 1mm. This parameter is determined by the material and
dimensions of the spring. See the table below.
Spring color Spring diameter (mm) Spring constant (N/mm) Free spring length (mm)
Yellow 20.5 95 68.8
Green 24.2 159 64.9
Blue 20.5 191 66.8
Black 21.5 320 66.8
• SPRING PRELOAD: This parameter is the force the spring produces when it is fitted to
the plunger. The spring’s free length is longer than the plunger’s shoulder pin. When
assembling the plunger spring, the spring is therefore compressed. This compression is
called the mounted spring length (in mm). To calculate the spring preload, measure this
mounted spring length.
Calculation: Pre-load = (Free spring length - Mounted spring length) x spring constant
Example: if the mounted spring length for the yellow spring is 63mm,
the pre-load becomes: (68.8 - 63) x 95 = 551 N
• PLUNGER DIAMETER: Standard plunger diameters are used, i.e. either 15mm or
11.6mm. Check by measuring the diameter. The plunger area (mm2) is derived from the
plunger diameter.
Calculation: (PI / 4) x plunger diameter^2
Example: 0.785 x 11.6^2 = 105.63 mm2
• MOLDSURFACE TO CULL TOP: The mold surface to cull top is the distance between
the top strip and the surface of the parting line (i.e. the cull strip). This parameter is
expressed in mm.

5.5.3 Parameters xMS-i
Figure 65 Mold surface to cull top

A: Top mold E: Cull strip
B: Bottom mold F: Sleeve
C: Cull G: Cull height
D: Plunger H: Mold surface to cull top
• CULL HEIGHT: The thickness of the cull. A correct cull height value is essential when
FTPC is not used. Measure several culls and calculate the average height. When the
cull height parameter is set lower than the actual cull height, this may transform your
product and deform the dambar. When changing the end position, make sure that its
height is always lower than the cull height. If not, the maximum transfer pressure can
not be attained.
• TRANSFER END PRESSURE: When raising the transfer pressure, the transfer end-
position becomes higher. The transfer pressure is a software parameter that can be
changed in the MMI Recipe screen. Different transfer end pressure ranges can be
reached depending on the used spring type. In general, three ranges are identified: from
40 to 70 Bar, from 70 to 120 Bar and from 120 to 150 Bar. When calculating the transfer
end position, convert the value into MPa (e.g. 70 Bar = 7 MPa). When the transfer
pressure is too low, this may cause an incomplete fill and air in the package. When the
pressure is too high, this may cause die damage or compound leakage.
The MMI calculates how far the transfer must move up to reach the pre-set transfer
pressure. This transfer end position indicates the plunger tip position (above) the mold
surface if no cull would be present. To check if the pre-set transfer pressure is reached,
read the realtime values in the Process Monitoring screen (graph pressure vs. transfer
position). The transfer time can also be read here.

xMS-i Calculation 5.5.4
5.5.4 Calculation
Example 1: end position calculation:
• Desired transfer pressure: 8.4 MPa = 8.4 N/mm^2
• Measured cull height: 6 mm
• Plunger diameter: 15 mm
• Spring preload: 922 N
• Spring constant: 159 N/mm (green spring)
• Calculation of the force needed to reach the end pressure:

Force (N) = pressure (N/mm^2) x Area (= Surface = mm^2)
Force (N) = pressure (N/mm^2) x (PI / 4 x diameter x diameter)
Force (N) = 8.4 N/mm^2 x 0.785 x 15 mm x 15 mm
Force (N) = 1484 N
• The total force is 1484 N.
Part of this force is required to overcome the spring preload.
Part of this force is required to compress the spring extra, going to the endposition.
The spring preload is 922 N.
For the compression remains: 1484 - 922 = 562 N
• Extra force = Compression x spring constant
562 N = Compression (mm) x 159 N/mm.
The compression is 562 N / 159 N/mm = 3.5 mm.
This means that the transfer travels 3.5 mm further after cull height is reached.
Example 2: end position calculation:

• Desired transfer pressure: 8.4 MPa = 8.4 N/mm^2
• Measured cull height: 1.5 mm
• Plunger diameter: 11.6 mm
• Spring preload: 480 N
• Spring constant: 95 N/mm (yellow spring)
• Calculation of the force needed to reach the end pressure is:

F = p x A = 8.4 x 0.785 x 11.6^2 = 888 N
• The spring is already compressed with the spring preload, which means the spring will
be compressed after the preload force is overcome.
For the compression remains: 888 - 480 = 408 N
• The compression of the spring with a spring constant of 95 N/mm is: 408 / 95 = 4.3 mm.
This means that the transfer travels 4.3 mm further after cull height is reached.

5.5.5 Process monitoring xMS-i
5.5.5 Process monitoring

To check if the desired transfer pressure is reached, read the real-time values in the
Process Monitoring screen (graph pressure vs. transfer position). The actual transfer time
can also be read here.
If Final Transfer Pressure Control (FTPC) is present on your machine, and is switched ON, the
plunger end position is not calculated. Instead, load cells read the actual transfer pressure and
the transfer movement stops when the desired final transfer pressure is reached.

xMS-i Sleeves 6
6. SLEEVES
6.1 DISASSEMBLING THE SLEEVES
The cull strip (steel) and the sleeves (carbide) are made of different materials, and when
heated they expand differently. As a result, the tolerance between the sleeves and the cull strip
hole is maximum which makes the disassembly easier.
The sleeves are made of carbide, which is very brittle and can easily break. Be careful
when handling the sleeves.
Figure 66 Tapping the sleeve out of the cull strip

A: Brass pin B: Sleeve C: Cull strip
To disassemble the sleeves, proceed as follows:

1. Heat up the cull strip with the sleeves to approximately 200ºC. Use the RBS cleaning
set for this purpose or place the cull strip on the preheat table in the loader/service
module.
2. Place the cull strip with the sleeves downwards on two blocks and place a cotton cloth
between the blocks. The cloth is there to avoid damages to the sleeves.
3. Use the round brass pin (same diameter as sleeves) and the copper punch from the
tool kit to carefully tap the sleeves out of the cull strip. As a result of the heating, the
sleeves should come out easily.

6.2 Assembling the sleeves xMS-i
6.2 ASSEMBLING THE SLEEVES
Figure 67 Cull strip with sleeves
NEVER use a copper punch to force the sleeves into the cull strip and NEVER rock the
sleeves from side to side. This may damage or break the carbide sleeves.
To assemble the sleeves, proceed as follows:

1. Use the copper brush to remove any dirt or epoxy from the outside of the sleeves and
from the holes in the cull strip.
There is a small tolerance between the sleeves and the cull strip when the sleeves are
cold, which is why the parts should be cleaned thoroughly.
2. Heat up the cull strip. Use the RBS cleaning set for this purpose or place the cull strip
on the preheat table in the Service module.
3. Push the cold sleeves into the cull strip and turn them by hand until they are in the
correct position. The sleeve edge should be level with the cull strip surface.

xMS-i Gate inserts 7
7. GATE INSERTS
7.1 (DIS)ASSEMBLING THE GATE INSERTS
Only disassemble the gate inserts when they are worn out or damaged.
The cavity strip (steel) and the gate inserts (carbide) are made of different materials, and when
heated, they expand differently. As a result, the tolerance between the inserts and the cavity
strip is maximum which eases the disassembly.
If needed, use the brass tools of the tool kit to tap the inserts. Always tap very
carefully. Never use other tools - not even the copper tools - on the cavities, clamping
area, runners and gate inserts.
Figure 68 Cavity strip gate inserts
To (dis)assemble the inserts, proceed as follows:

1. Remove the cavity strip. Refer to paragraph 2.2.
2. If present, remove the pin at the side of the cavity strip which locks the gate inserts.
Use the square brass pin in the tool kit to do this.
3. Use the RBS cleaning system to heat the cavity strip to approximately 200ºC. Another
way to heat up the cavity strip is to place it on the preheat table in the Service module.

7.1 (Dis)assembling the gate inserts xMS-i
4. Use heat resistant gloves to place the cavity strip (with cavity facing upwards) on a
holder with space underneath the gate inserts.
Make sure that the gate inserts fall on a soft surface, e.g. a cloth or rubber mat.
Always tap the gate insert from the top to the bottom as shown in figure 68. If not, this
can damage the cavity strip and the gate insert
5. Use the brass punch to carefully tap the gate inserts out of the cavity strip
Figure 69 Refitting the gate inserts
Before assembling the strip, the cavity strip and gate inserts must be thoroughly cleaned.
6. Insert the new gate insert in the cavity strip from the side as shown in figure 69. The
insert is made to fit without using much force.
7. If present, insert the pin which locks the gate inserts.

xMS-i Center pins 8
8. CENTER PINS
8.1 CHECKING CENTER PINS

For information on the different center pin types, refer to paragraph 2.2.6. Regularly check
if the center pins are not broken, damaged or bend. A center pin problem may result in
misplaced leadframes in the cavities or package off-center. If needed, replace the pin(s).
One center pin type can be adjusted in height, i.e. the long center pin. See paragraph 8.2.
8.2 ADJUSTING LONG CENTER PIN HEIGHT

Only long center pins can be adjusted in height. The other two types have a fixed length.
The height of the center pin is adjusted by removing material from the adjustment screw at
the bottom of the mold.
Figure 70 Long center pin height
A: the center pin is correctly adjusted when the tapered part (A) of the center pin begins at
75% of the leadframe thickness (B).
B: the center pin is too low when the tapered part (A) of the center pin is inside the cavity
hole (C). If so, the leadframe can move on the mold surface, which might cause off-center.
C: the center pin is too high when the parallel part of the center pin is visible above the
cavity hole (C). If so, this will damage the leadframe when the pick & place wagon removes
it from the mold surface. After the leadframe has been ejected it also shrinks slightly due to
cooling down.

8.2 Adjusting long center pin height xMS-i
Figure 71 Long center pin adjustment screw
To adjust the height, proceed as follows:

1. If the center pin is too high remove material from the area indicated by A in figure 71.
This will lower the center pin.
2. If the center pin is too low remove material from the area indicated by B in figure 71.
This will raise the center pin.

xMS-i Adjusting long center pin height 8.2

9 Electrical system xMS-i
9. ELECTRICAL SYSTEM
9.1 MACHINE AND MOLD TYPES

In the machine, the heating of the mold can be connected in two different ways:
• Mk1 heating.
• Mk2 heating.
Three different mold types can be distinguished:

• Standard mold (ToolId V1)
• Standard mold (ToolId V2)
• DTC mold (ToolId V2)
Not all molds can be used on all machines.
Machine with: Mk1 heating Mk2 heating

Standard mold (ToolId V1) OK NO
Standard mold (ToolId V2) NO OK
DTC mold (ToolId V2) NO OK
To check which heating systems is used on your machine, select the MMI maintenance
screen and press on the Machine Config button on the soft key bar.
Figure 72 Machine Configuration

xMS-i Machine and mold types 9.1
If the machine configuration list shows the parameter PR2N_MOLDHEATINGMK2, then

the machine is equipped for the Standard mold (ToolId V2). If parameter
PR2N_DYNAMICTEMPERATURECONTROL can be found in the list the machine can
also be used for DTC molds (ToolID V2).
If none of the above parameters can be found, the machine can only run with Standard
molds (ToolId V1).
To check the heating system version of the mold, the mold must be in the press (use
operation mode conversion to enter the mold in the press).
Proceed as follows:
1. In the MMI maintenance screen, press the button of the press in which the mold was
entered.
2. Press the General button.
The tool number buttons appear in the command list.
3. In the command list, press on one of the buttons with the tool number.
4. In the tool parameter screen, check the value of parameter Major version number.
For a V1 mold this can be either 0 or 1.
For a V2 mold this is 2.
Figure 73 Major version number

9.2 Heater elements standard mold (ToolId v1) xMS-i
9.2 HEATER ELEMENTS STANDARD MOLD (TOOLID V1)
9.2.1 The standard mold (ToolId V1)
Figure 74 Heater elements standard mold

MC: Main Channel CBH: Cull Bar Heating element
Fn: Follow channel n PT100: Temperature sensor
The bottom mold contains 6 heater elements. The top mold contains 5 heater elements
and an element above the cull bar, called the ’Cull bar heater element’ (CBH). This CBH
element (600 W) is not controlled by the PT-100, but is switched on for a specified time by
the parameter "Cull bar heating time" in the Recipe tab of the MMI.

xMS-i The standard mold (ToolId V1) 9.2.1
The individual heater elements all have two wires which are connected to the mold
connector (see figure 74). The properties of the heater elements are stored in the tool-ID.
The heater elements are set by specifying their "P-factor follow channel ’x’" in the MMI
Maintenance screen. The time the CBH is switched on is specified in seconds.
STANDARD TOP MOLD (ToolId V1)

Channel Tool parameter Electro code Power (W)
MC Main channel ET1C 250
F1 Follow channel 1 ET1B 250
F2 Follow channel 2 ET1A 250
F3 Follow channel 3 ET1E 100
F4 Follow channel 4 ET1F 100
CBH * ET1Z 600
*Cull bar heating is controlled by the recipe parameter Cull bar heating time.
STANDARD BOTTOM MOLD (ToolId V1)

MC Main channel EB1D 250
F1 Follow channel 1 EB1C 250
F2 Follow channel 2 EB1B 250
F3 Follow channel 3 EB1A 250
F4 Follow channel 4 EB1E 100
F5 Follow channel 5 EB1F 100

9.2.2 Heater connector standard mold (ToolId V1) xMS-i
9.2.2 Heater connector standard mold (ToolId V1)

The heater connector has two rows of eight pins, numbered from 1 to 16. Each individual
heater element is connected to the heater connector by two wires and can be identified by
color coded labels. Besides the heater elements, the earth lead (green/yellow wiring) is
also connected to the heater connector. In general to pin number 15.
Figure 75 Heater connector standard mold (ToolId V1)

xMS-i Heater connector standard mold (ToolId V1) 9.2.2

Heater Electro Controller Power Resistance Color code Pin
element code channel (Watt) (Ohm) numbers
MC ET_C 2 250 184-226 Green 3 and 11

F1 ET_B 13 250 184-226 Brown 2 and 10
F2 ET_A 14 250 184-226 White 1 and 9
F3 ET_E 15 100 462-564 Blue 5 and 13
F4 ET_F 16 100 462-564 Red 6 and 14
CBH ET_Z 4 600 78-94 Brown/Black 8 and 16

MC EB_D 1 250 184-226 White 4 and 12

F1 EB_C 8 250 184-226 Brown 3 and 11
F2 EB_B 9 250 184-226 Green 2 and 10
F3 EB_A 10 250 184-226 Yellow 1 and 9
F4 EB_E 11 100 462-564 Red 5 and 13
F5 EB_F 12 100 462-564 Blue 6 and 14
Always check the Mold electrical drawings for the correct colors and connector pin numbers.

9.3 Heater elements standard mold (ToolId v2) xMS-i
9.3 HEATER ELEMENTS STANDARD MOLD (TOOLID V2)
9.3.1 The standard mold (ToolId V2)
Figure 76 Heater elements standard mold (ToolId V2)

MC: Main Channel CBH: Cull Bar Heating element
Fn: Follow channel n PT100: Temperature sensor
The bottom mold contains 6 heater elements. The top mold contains 5 heater elements
and an element above the cull bar, called the ’Cull bar heater element’ (Z). This Z element
(600 W) is not controlled by the PT-100, but is switched on for a specified time by the
parameter "Cull bar heating time" in the Recipe tab of the MMI.

xMS-i The standard mold (ToolId V2) 9.3.1
The heater elements are set by specifying their Duty cycle channel ’x’ in the MMI
Maintenance screen. The time the cull bar heating is switched on is specified in seconds.

A Duty cycle channel A ET1A 250
B Duty cycle channel B ET1B 250
C Duty cycle channel C ET1C 250
E Duty cycle channel E ET1E 100
F Duty cycle channel F ET1F 100
Z * ET1Z 600
*Cull bar heating is controlled by the recipe parameter Cull bar heating time.

A Duty cycle channel A EB1A 250
B Duty cycle channel B EB1B 250
C Duty cycle channel C EB1C 250
D Duty cycle channel D EB1D 250
E Duty cycle channel E EB1E 100
F Duty cycle channel F EB1F 100

9.3.2 Heater connector standard mold (ToolId V2) xMS-i
9.3.2 Heater connector standard mold (ToolId V2)

Figure 77 Heater connector standard mold (ToolId V2)

xMS-i Heater connector standard mold (ToolId V2) 9.3.2
STANDARD TOP MOLD (ToolId v2)

A ET_A 14 250 184-226 Green 1 and 9

B ET_B 13 250 184-226 Brown 2 and 10
C ET_C 5 250 184-226 White 3 and 11
E ET_E 15 100 462-564 Blue 5 and 13
F ET_F 16 100 462-564 Red 6 and 14
Z ET_Z 4 600 78-94 Brown/Black 8 and 16
STANDARD BOTTOM MOLD (ToolId v2)

A EB_A 10 250 184-226 White 1 and 9

B EB_B 9 250 184-226 Brown 2 and 10
C EB_C 8 250 184-226 Green 3 and 11
D EB_D 7 250 184-226 Yellow 4 and 12
E EB_E 11 100 462-564 Blue 5 and 13
F EB_F 12 100 462-564 Red 6 and 14

9.4 Heater elements special DTC mold (ToolId v2) xMS-i
9.4 HEATER ELEMENTS SPECIAL DTC MOLD (TOOLID V2)
9.4.1 The DTC mold (ToolId v2)

Some AMS-i molding machine are equipped with a special DTC (Dynamic Temperature
Control) mold. The heating of this mold is controlled differently from the standard mold. The
machine is adapted to these molds.
Figure 78 Heater elements DTC mold (ToolId v2)

A-F Heater element PT100: Temperature sensor
The DTC bottom mold contains 6 heater elements. The top mold contains 7 heater
elements.
The heater elements are set by specifying their Duty cycle. These factors are stored int he
ToolID of the mold.

xMS-i The DTC mold (ToolId v2) 9.4.1
DTC TOP MOLD (ToolId V2)

Element Tool parameter Electro code Power (W)
A Duty cycle channel A ET1A 250
B Duty cycle channel B ET1B 250
C Duty cycle channel C ET1C 250
E Duty cycle channel E ET1E 100
F Duty cycle channel F ET1F 100
MA P, I and D factor* and Bias ET1MA 600
MB P, I and D factor* and Bias ET1MB 600
* The P, I and D factors may only be changed by Fico
DTC BOTTOM MOLD (ToolId V2)

Element Tool parameter Electro code Power (W)
A Duty cycle channel A EB1A 250
B Duty cycle channel B EB1B 250
C Duty cycle channel C EB1C 250
D Duty cycle channel D EB1D 250
E Duty cycle channel E EB1E 100
F Duty cycle channel F EB1F 100

9.4.2 Heater connector DTC mold (ToolId v2) xMS-i
9.4.2 Heater connector DTC mold (ToolId v2)

Figure 79 Heater connectors DTC mold (ToolId v2)

xMS-i Checking the temperature 9.5
DTC TOP MOLD (ToolId v2)

A ET_A 14 250 184-226 Green 1 and 9

B ET_B 13 250 184-226 Brown 2 and 10
C ET_C 5 250 184-226 White 3 and 11
E ET_E 15 100 462-564 Blue 5 and 13
F ET_F 16 100 462-564 Red 6 and 14
MA ET_MA 4 600 78-94 Brown/Black 8 and 16
MB ET_MB 4 600 78-94 Brown/Black 4 and 12
DTC BOTTOM MOLD (ToolId v2)

A EB_A 10 250 184-226 White 1 and 9

B EB_B 9 250 184-226 Brown 2 and 10
C EB_C 8 250 184-226 Green 3 and 11
D EB_D 7 250 184-226 Yellow 4 and 12
E EB_E 11 100 462-564 Blue 5 and 13
F EB_F 12 100 462-564 Red 6 and 14
9.5 CHECKING THE TEMPERATURE

The temperature of the heater elements can be checked by measuring the temperature at
the mold surface. The temperature pattern at the mold surface should be as equal as
possible. Use a temperature sensor (see paragraph 1.4.8) with probe for this purpose. For
the procedure, refer to the Press Preventive Maintenance manual.
9.6 CHECKING THE ELECTRICAL CURRENT

See Press Preventive Maintenance manual.

9.7 Checking the resistance xMS-i
9.7 CHECKING THE RESISTANCE

The heater element can be checked by measuring the resistance between the pins in the
heater connector. This can be done with a hot or cold mold. The table below lists the heater
element power (Watt) and the resistance value that should be measured. The resistance
value can also be calculated by using the following formula: R= U^2 / P (R= resistance in
Ohms, U = Voltage (230Vdc), P = Power (in Watt)). For the procedure, see the Press
Preventive Maintenance manual.
Power Resistance
Watt Ohms
100 513 ± 51
250 205 ± 21
600 86 ± 8
Always check the electrical drawings of the mold for the correct power (in Watt), and connector
pin numbers.
9.8 EXCHANGING THE HEATER ELEMENTS

To exchange a heater element, proceed as follows:
1. Remove the mold covers. See paragraph 2.2.
2. Unscrew the screws of the heater connector fitting.
3. Remove the protective plastic shielding around the heater element wire, and loosen
the cable clamps.
4. Loosen the lock screws in the heater connector and disconnect the heater element
wires.
5. Slowly pull the heater elements out of the mold plate. Verify if the wires and elements
are not damaged or bend.
6. Rub heatsink paste on the new heater element before pushing it back in the mold
plate.
7. Fasten the cable clamps and place a new piece of protective shielding around the
element wires.
8. Refit the element wires to the heater connector, and refit the connector.
9. Refit the mold covers. See paragraph 2.3.

xMS-i PT-100 and clixon 9.9
9.9 PT-100 AND CLIXON
9.9.1 Introduction
To measure the mold temperature a Platinum (PT-100) sensor is mounted just below the
surface of the mold. Each mold half has a PT-100 in the mold plate. The PT-100 signal is
used to switch on and off the heating elements in order to keep the mold at target
temperature, and within the allowed deviation range. The PT-100 has four wires which are
connected to the mold PT-100 connector.
To prevent overheating, an optional Clixon bimetal safety switch is attached to the mold.
This device switches off all heating elements when the temperature exceeds a preset
value. The Clixon is interconnected to the mold PT-100 connector by two wires. Mold with
special DTC heating have a fuse in series with the clixon. The fuse is mounted in the top
strip behind the center nock. If the fuse is blown, it has to be replaced.
9.9.2 PT-100 connector
Figure 80 PT-100 connector for the standard (left) and special DTC (right) mold
A: MIC D: ToolId
B: PT-100 E: PT-100 DTC
C: Clixon

9.9.3 Checking the resistance of the PT-100 and clixon xMS-i
Each PT-100 connector has three (A, B, C) rows of pins (25 pins in total). The pin numbers
are marked from 1 to 9, except for row B which has seven pins which are numbered from 2
to 8.
In general, the pin numbers in row A and B are used for Mold Identification Code (MIC). Pin
numbers 1C up to and including 4C are used for the PT-100, and 5C and 6C for the Clixon.
If ToolID is present on the mold, the remaining pin numbers are used for this feature, and
one from MIC (i.e. 9A). For more information on MIC and ToolID, see paragraph 9.10.
Special DTC molds have no MIC code. As these molds have an extra PT100, it is
connected to pins 1A through 4A.
Always check the electrical drawings of the mold for the correct connector pin numbers.
9.9.3 Checking the resistance of the PT-100 and clixon

The PT-100 and Clixon can be checked by measuring the resistance between the pins in
the PT-100 connector. This can be done with a hot or cold mold. For the checking
procedure, see the Press Preventive Maintenance manual.
9.9.4 Exchanging the PT-100 and clixon

To exchange a PT-100 sensor or clixon, proceed as follows:
1. Remove the mold covers and pull out the PT-100. See paragraph 2.2.
2. Use a pin pusher to remove the electrical component pins from the PT-100 connector.
3. Remove the protective plastic shielding around the wires of the PT-100 and loosen the
cable clamps.
4. Rub heatsink paste on the new PT-100 and the new Clixon and attach them to the
mold plate.
5. Refit the protective plastic shielding around the wires of the PT-100 and attach the
cable clamps.
6. Refit the mold covers. See paragraph 2.3.

xMS-i Automatic tool identification 9.10
9.10 AUTOMATIC TOOL IDENTIFICATION
9.10.1 Introduction
Two different Automatic Tool Identification systems can be present on the xMS-i mold. This
means that xMS-i molds can be used in both xMS-i and xMSxx-M(2) (shortly xxy) press
stations. Depending on the machine type, one of the systems is activated and read. If
needed, xxy molds can also be made suitable for use in both the xMS-i and xxy press
stations. This requires some changes.
The xxy system uses a unique binary code in the range of 0 to 2047 that is checked during
mold exchange. No further validations or parameter downloading takes place. This system
is called Mold Identification Code or shortly MIC.
In the xMS-i system, the mold parameters are stored in an EEPROM memory chip. This is
referred to as ToolID. ToolID streamlines a product change over. It allows to exchange
molds between press stations and machines without having to adjust the MMI parameters
manually. Instead, the MMI software is informed on the hardware change by the EEPROM,
and the parameters are automatically downloaded to the machine. When the mold is
inserted in the machine, the mold parameters are checked by the software. If the mold
parameters do not match the machine parameters, the MMI software will ask the user to
remove the mold. Mold parameters that are changed are automatically stored in the
EEPROM or can be stored manually. For information on how to read and modify the
EEPROM parameters, refer to the MMI Maintenance manual.
Figure 81 ToolID EEPROM (A) and printed circuit board (B)
The ToolID EEPROM (A) is mounted on the PT-100 mold connector. The EEPROM is
connected to a printed circuit board (PCB) (B) in the back of the press station. This PCB is
at its turn connected to the Berghof module by means of an I2C bus cable. One PCB
serves one mold half, except for the bottom molds where one PCB serves two bottom
molds. This means that in a three press configuration, five PCBs are present: three for the
top molds, one for one single bottom mold and one for two bottom molds. Each PCB has a
unique hardware code which is set by means of the switches (jumpers) on the PCB itself.

9.10.2 Using an xxy mold in an xMS-i xMS-i
Information on these hardware codes, the PCB lay-out and the PT-100 connector pins can
be found in the Electrical manual (drawings "I/O-temperature control Bottom / Top mold
Station x").
In general, the PT-100 connector pin numbers 1A up to and including 9A, and 2B up to and
including 6B are used for MIC (see figure 80). These pins are connected to each other at
the back of the connector to produce the unique binary code. Pin numbers 7B and 8B
detect if the MIC mold is present. These 2 pins are connected to each other at the back of
the connector. In general, pin numbers 7C, 8C, 9C and 9A are connected to the ToolID
EEPROM. This means that PT-100 connector pin 9A is shared by the two systems, which
serves as Ground for ToolID and as one bit for MIC.
In general, the four digits of the MIC code correspond with the last four digits of the mold
electrical drawings.
9.10.2 Using an xxy mold in an xMS-i

To adapt an xxy mold for use on the xMS-i, the ’open’ ejector cams need to be replaced by
’closed’ ejector cams. The ToolID EEPROM must be mounted on the PT-100 connector
and the heating parameters have to be determined. Consult your Fico Service engineer for
this upgrade.
To use an xMS-i mold in an xxy-machine, the same procedure has to be followed in

reverse order.
Refer to paragraph 1.7 for more information.
ALWAYS consult your Fico service engineer for these change overs. Only then full
warranty can be given.

xMS-i Cleaning, conditioning and storing 10
10. CLEANING, CONDITIONING AND STORING
10.1 INTRODUCTION
The molds must be regularly cleaned and conditioned. Cleaning and conditioning can be
done with the mold still in the machine (MMI program) or by taking out the mold. In the
latter case the mold needs disassembling. The following cleaning and conditioning
methods are present:
• By MMI program ON the machine:
• Transfer cleaning : this cleaning program is used to clean the surfaces of the mold
that are directly affected by the production process, i.e. the sleeves, the gates, the
cavities, etc. Like in Normal Production leadframes and pellets are used. The used
leadframes may be dummy ones. The cleaning pellets are however made of a
combination of melamine, wax and epoxy.
• Compression cleaning : this cleaning program is used to clean a larger surface of
the mold than is done in Transfer cleaning. It includes the clamping area and the
lower surfaces around the cavities. Melamine tablets or rubber sheets are used as a
cleaning medium.
• Conditioning: this program is used to wax the mold chases surfaces and must be
done each time a press station has been cleaned, either by transfer or compression
cleaning. The pellets that are used in conditioning are made of wax (in combination
with other materials).
• By a cleaning solvent OUTSIDE the machine:
• RBS-25 cleaning: for very dirty molds with difficult stains. All mold parts and
surfaces are cleaned.
• Manual cleaning. To remove thick layers of compound.
It is better to keep the mold clean by frequent cleaning, rather than let the stain build up to such
a level that a major cleaning operation is required.
Compression cleaning and transfer cleaning are complementary to each other as they clean
different mold parts. It is therefore best to run both programs. Start with transfer cleaning and
finish with compression cleaning as during compression cleaning the left particles of transfer
cleaning will be removed.

10.2 Compression cleaning xMS-i
The cleaning and conditioning material that can be used depends on the compound
type used in production. Consult your compound supplier to find out what type(s) give
the best results.
For the process settings of conditioning, transfer and compression cleaning, refer to
the data sheet of the cleaning/conditioning compound supplier.
Condition the mold after each cleaning action. If this is not done, the leadframes and
culls may stick to the mold surface. Before starting conditioning or resuming
production, verify if all traces of the cleaning compound are removed. Any small
pollutions may result in staining. Small particles in gates can lead to incomplete fillings
and associated problems.
Before starting production, make sure that the mold surface is free of compound
particles. Cured compound particles in the cavities or on the clamping area make
bumps in the surface which may result in product problems.
MAKE SURE THAT THE WORKING AREA IS SUFFICIENTLY VENTILATED AND

EXHAUSTED DURING MOLD CLEANING. THE FUMES CONTAIN AMMONIA AND
FORMALDEHYDE, WHICH MAY DAMAGE YOUR HEALTH.
10.2 COMPRESSION CLEANING
10.2.1 Introduction
To run the Compression Cleaning program on the MMI, refer to the Operating Procedures.
The parameter settings for compression cleaning should be determined by running trials. In
general, the temperature should be close to the molding temperature and the clamp
pressure should be reduced. Overcuring should be avoided as this can result in a very dry
mold. See also Operating Procedures manual.
10.2.2 Compression cleaning with rubber sheets

Rubber sheets are preformed long strips with grooves to break. They are placed adjacent
to each other over the cavity areas and runner area, avoiding the center pins if possible.

xMS-i Compression cleaning with melamine tablets 10.2.3
Advantages
• less cleaning shots required.
• cleans the mold quickly.
• used material can be removed in one piece.
• mold does not have to be conditioned after cleaning.
• material is less toxic than melamine.
Disadvantages
• does not always remove all dirt and stains, in which case the mold also has to be
cleaned with melamine.
• produces an unpleasant smell.
• the rubber sheets are more expensive.
10.2.3 Compression cleaning with melamine tablets

Tablets are preformed squares. The squares are placed adjacent to each other over the
cavity areas and runner area, avoiding the center pins if possible.
Advantages
• removes difficult stains from the cavities and runners.
• the melamine tablets are less expensive than the rubber sheets.
Disadvantages
• requires more cleaning shots than the rubber sheets.
• takes longer to clean the mold.
• produces small particles which can be difficult to remove from the cavities and
runners.
• the mold must be conditioned after cleaning.
• melamine is more toxic than the rubber sheets.

10.3 Transfer cleaning xMS-i
10.3 TRANSFER CLEANING
10.3.1 Introduction
To run the Transfer Cleaning program on the MMI, refer to the Operating Procedures. In
general, the settings for Transfer cleaning should be as close to production as possible,
only with an increased cure time. See also Operating Procedures manual.
10.3.2 Transfer cleaning with melamine cleaning pellets

Advantages
• less cleaning material required
• the mold can be cleaned with a higher clamping pressure
• better for cleaning small details
• smaller chance of compound forcing its way between cavity strips and mold parts
• pellets and leadframes can be loaded with a special tool
Disadvantages
• uses leadframes as well as cleaning compound
• does not always clean the vents thoroughly
• a greater chance to sticking plungers after cleaning
• more expensive than compression cleaning
When using cleaning pellets, the best results are achieved with the following settings.
- high transfer speed of 4 to 4.5 mm/s
- high transfer pressure of 90 to 120 bar
Check the leadframes for flash when using these high transfer pressure values.

xMS-i Conditioning 10.4
10.4 CONDITIONING
10.4.1 Introduction
During cleaning, the stains and dirt are removed from the mold surface. This leaves the
mold surface very dry and may cause the leadframes and culls to stick during product
ejection.
Therefore, after the mold has been cleaned it needs to be conditioned. The conditioning
shots leave a release agent on the mold surface which prevents the leadframes from
sticking. When the mold has been cleaned and conditioned, preferably make a number of
dummy shots before starting with the production. This will ensure that there is no excess
wax on the mold surface.
Following on conditioning, immediately run production (preferably start with a few

dummy shots). This prevents staining on the mold surface.
10.4.2 Conditioning with conditioning compound

Run the Conditioning program on the MMI to condition the molds with conditioning
compound. See Operating Procedures. The conditioning compound leaves a release agent
on the mold surface which prevents the leadframes from sticking to the mold surface.
In normal conditions, two to three conditioning shots should be sufficient.
10.4.3 Conditioning with wax

To run the Conditioning program, refer to the Operating Procedures. When the mold
opens, spray the top and bottom mold with wax. Conditioning with spray wax is however
not recommended as it has three main disadvantages:

10.5 Manual Cleaning xMS-i
Disadvantages
• It is difficult to see if all corners of the cavities are correctly waxed.
• Wax conditioning leaves more wax in the mold than with conditioning compound.
Therefore you will have to process more dummy leadframes to make sure that all
excess wax is removed.
• The mold will soon become dirty because a lot of spray wax will cover areas where
it is not required.
The use of solid wax may eliminate these disadvantages, but solid wax has other
complications, e.g. an uneven wax distribution.
10.5 MANUAL CLEANING

For the cavities, clamping area, runners, gate inserts, sleeves and plungers only use the
brass tool in the Fico tool kit to remove thick epoxy. Be very careful and avoid scratches or
other damages. For all other parts, use the copper tools and use the copper brush to clean
afterwards.
10.6 RBS-25 CLEANING

The RBS-25 solution is used to thoroughly clean the various mold parts and to remove
difficult stains from the mold surface. The cleaning solution is alkaline-based which affects
on zinc aluminum and galvanic iron.
In case of very dirty molds, increase the RBS-25 solution percentage with maximum 50%. The
higher the RBS-25 concentration, the lower the required soaking time.
In general, only the parts that come into contact with compound (e.g. mold plate, ejector pins,
cavity strips, center pins) need to be cleaned with RBS-25.
PREVENT CONTACT BETWEEN RBS-25 AND EYES AND/OR SKIN AND NEVER DRINK
THE SOLUTION. IN CASE OF CONTACT WASH THE SKIN WITH PLENTY OF WATER.
ALWAYS WEAR RUBBER GLOVES WHEN WORKING WITH RBS-25. RBS-25 IS A FULLY
BIODEGRADABLE, NON-TOXIC SOLUTION AND CAN BE DISPOSED OF IN THE SEWAGE
SYSTEM. ALWAYS REFER TO THE SUPPLIER INSTRUCTIONS.

xMS-i RBS-25 cleaning 10.6
Figure 82 RBS-25 cleaning set
Clean parts with the RBS-25 solution according to the following procedure:
1. Disassemble the mold. See paragraph 2.2.
2. Make sure that there is no thick epoxy on the mold parts because this will not be
removed by the solution. See paragraph 10.5.
3. Add approximately 1 part RBS-25 to 50 parts tap water at a temperature of 50°C into
the stainless steel tray.
Example: add 20 grams of RBS-25 to 1 liter of tap water.
NEVER set the temperature of the heater plate higher than 60°C. This results in
unnecessary vapors of the cleaning solution.
4. Place the tray on the heater plate and set the temperature to 60°C.
Place a cover over the tray to prevent excessive evaporation.
NEVER immerse the non-metal parts (e.g. isolation plate, vacuum strips), the heater
elements, the electrical parts (e.g. sensors, connectors) in the RBS-25 solution.
5. Immerse the mold part(s) in the solution. Make sure that they are completely immersed
and use gloves when handing the parts.

10.7 Storing the mold long-term xMS-i
6. Leave the parts to soak for 2 to 12 hours.

The soaking time depends on the contamination degree.
Always rinse the parts carefully and thoroughly after a RBS-25 cleaning job. If not, dry
RBS-25 particles may form on the parts. This may trouble mold assembly and may
cause damage when the mold is heated.
7. Take out the parts and rinse them immediately and thoroughly with hot water. Repeat
the rinsing job several times. A final rinse with distilled or de-mineralized water is
recommended.
8. Dry the part(s) with compressed air and visually inspect them for remaining dirt.
10.7 STORING THE MOLD LONG-TERM

When storing the mold(s) for a long period of time, follow the procedure below:
1. On the machine, run the Transfer and/or Compression cleaning program. See
Operating Procedures in the manual.
2. On the machine, run the Conversion program to exchange the mold(s). See Operating
Procedures in the manual.
3. Disassemble the mold halves. See paragraph 2.2.
4. Clean the individual mold parts. If the mold parts are very dirty, clean them with RBS-
25. See paragraph 10.6. Make sure that the mold halves are cool before cleaning.
5. Remove the ring of cured compound from the groove of the plunger tip with the plunger
seal cracker. See paragraph 5.2.
6. Spray a thin layer of wax on the separate mold parts.
Only spray wax on the mold parts. Never use oil or oil containing products as this
produces unnecessary vapors when the mold is heated for the first time.
7. Assemble the mold halves again. See paragraph 2.3.

8. Spray a thin layer of wax over the outer surfaces of the mold halves, including the
cavity surfaces.
9. Wrap the mold halves in plastic sheet. Place moisture absorbing material (silicon gel)
on top of the mold halves and seal the packages with tape.

xMS-i Storing the mold long-term 10.7
The two mold halves (top and bottom) must always be wrapped SEPARATELY to
prevent damaging the mold surfaces.
Before using the mold again, clean it thoroughly with RBS-25 (see paragraph 10.6) as
left wax particles on the mold surface may cause product problems and stains.

10.8 Packing the mold for transport xMS-i
10.8 PACKING THE MOLD FOR TRANSPORT

When returning the molds to Fico make sure they are packed correctly.
Figure 83 Packing the mold

A: Plunger beam and spare parts B: Molds
Pack the mold according to the following procedure:

1. Follow paragraph 10.7, "Storing the mold long-term", on page 98, but make sure to
clean all mold parts with RBS-25.
2. For transport, use a wooden box with the dimensions and construction as indicated in
figure 83. The original mold box can be used for this purpose. If possible, use the
original wooden box with foam to transport the plunger beam and plungers.
3. Wrap each mold half in a thick cotton cloth. Place plastic sheet around the cotton cloth
and seal the packages with tape. Place the two mold halves in the box as indicated (B)
in figure 83.
The two mold halves (top and bottom) must always be wrapped SEPARATELY to
prevent damage to the mold surfaces.
Make sure that the mold surfaces do not face each other or touch the side walls of the
wooden box. This could cause damage to the mold surfaces.
xMS-i Packing the mold for transport 10.8
4. Wrap the plungers and the transfer beam in a thick cotton cloth and place them in the
box as indicated (A) in figure 83. Additional spare parts should also be stored here -
packed separately.
5. Place moisture absorbing material (silicon gel) in the wooden box.
6. Place filling material besides the packages to prevent the mold and spare parts from
moving. Make sure to fill up all empty holes in the box.
7. Seal the box.
10.8 Packing the mold for transport xMS-i
xMS-i Troubleshooting 11
11. TROUBLESHOOTING
The table below lists a number of molding problems and/or product defects, with possible
causes and solutions.
Problem Molding conditions Compound Mold material
Compound sticks Increase cure time Temperature too low
Incomplete fill • Insufficient epoxy • Too stiff in flow • Inadequate venting

• Cull height wrong • Too fast curing • Gate block
• Transfer pressure too • Polluted mold
low
• Mold temperature too
high
• Transfer speed too
slow
• Too much preheat
Wire sweep Transfer speed too high / Too stiff in flow Incorrect shape of gate
low
Voids • Insufficient epoxy Too easy in flow • Inadequate venting

• Air entrapment pellets • Polluted mold
used
• Transfer speed too
low
Dull spots on Stained mold

surface
Knitted lines Transfer speed too high Too stiff in flow
Side rail pinching • Insufficient

straightness
(chamber) of frames
• Location pin
missing
Off-set package Check position of frame

location pin
Flash on • Transfer pressure • Check flatness of

leadframes • Clamping fault mold
• Check thickness of
frames
• Check uniformity of
temperature
11 Troubleshooting xMS-i
xMS-i Index 12
12. INDEX
B G
Bimetal safety device . . . . . . . . . . . . . . . . . . . . 88 Grinding plate . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brass plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 H
Heater element . . . . . . . . . . . . . . . . . . . . . 11, 86
C cull bar heater . . . . . . . . . . . . . . . . . . . . . . . . 74
Cavity strip . . . . . . . . . . . . . . . . . . . . . . . . 17, 18 Heater elements
Centre pin special DTC mold . . . . . . . . . . . . . . . . . . . . . . 82
height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 standard mold (ToolId v1) . . . . . . . . . . . . . . . 74
long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 standard mold (ToolId v2) . . . . . . . . . . . . . . . 78
short with insert . . . . . . . . . . . . . . . . . . . . . . . 18 Heatsink compound . . . . . . . . . . . . . . . . . . . . . 15
short without insert . . . . . . . . . . . . . . . . . . . . . 18 Heatsink paste . . . . . . . . . . . . . . 35, 39, 86, 88
Cleaning compound . . . . . . . . . . . . . . . . . . . . . 94
Cleaning material I
melamine cleaning pellets . . . . . . . . . . . . . . . 94
Isolation plate . . . . . . . . . . . . . . . . . . . . . . . . . . 11
melamine tablets . . . . . . . . . . . . . . . . . . . . . . 93
RBS-25 . . . . . . . . . . . . . . . . . . . . . . . . . 91, 96
rubber sheets . . . . . . . . . . . . . . . . . . . . . . . . . 92 L
Clixon . . . . . . . . . . . . . . . . . . . . . . . . . 15, 39, 87 Leadframe off-center . . . . . . . . . . . . . . . . . . . . . 69
Compression cleaning program . . . . . . . . . . . . 91 Leadframe thickness . . . . . . . . . . . . . . . . . . . . . 69
Conditioning material Loctite no. 648 . . . . . . . . . . . . . . . . . . . . . . . . . 27
conditioning compound . . . . . . . . . . . . . . . . . 95
solid wax . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 M
spray wax . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
MIC (Mold Identification Code) . . . . . . . . . 89, 90
Conditioning program . . . . . . . . . . . . . . . . . . . . 91
Mold handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mold plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
heater elements . . . . . . . . . . . . . . . . . . . 76, 80
heater elements DTC mold . . . . . . . . . . . . . . 84
PT-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 N
Copper brush . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Never seez paste . . . . . . . . . . . . . . . . . . . . . . . 27
Copper punch . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cull strip . . . . . . . . . . . . . . . . . . . . . . . 28, 65, 66 P
Parameter
D cull height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Dowel pin . . . . . . . . . . . . . . . . . . . . . . . . . 16, 19 moldsurface to culltop . . . . . . . . . . . . . . . . . . 61
DTC mold . . . . . . . . . . . . . . . . . . . . . . . . . 40, 82 P-factor channel x . . . . . . . . . . . . . . . . . . . . . 75
plunger diameter . . . . . . . . . . . . . . . . . . . . . . 61
E spring constant . . . . . . . . . . . . . . . . . . . . . . . . 61
spring preload . . . . . . . . . . . . . . . . . . . . . . . . 61
Earthlead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Plastic strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Ejector cam . . . . . . . . . . . . . . . . . . . . . . . . 11, 16
Plunger
Ejector cams . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
sticking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Ejector holder plate . . . . . . . . . . . . . . . 11, 20, 52
Plunger area . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Ejector pin bed . . . . . . . . . . 11, 20, 21, 31, 36
Plunger beam . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ejector plate . . . . . . . . . . . . . . . . . . . . . . . 11, 20
Plunger holder ring . . . . . . . . . . . . . . . . . . . . . . 53
Ejector stroke . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Plunger lock ring . . . . . . . . . . . . . . . . . . . . . . . . 53
Epoxy groove . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Plunger shoulder pin . . . . . . . . . . . . . . . . . . . . . 53
Plunger sleeve . . . . . . . . . . . . . . . . . . . . . . . . . 21
F Plunger spiral . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Final transfer pressure . . . . . . . . . . . . . . . . . . . 62
12 Index xMS-i
Problem
dull spots on surface . . . . . . . . . . . . . . . . . . 103
flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
incomplete fill . . . . . . . . . . . . . . . . . . . . . . . . 103
knitted lines . . . . . . . . . . . . . . . . . . . . . . . . . 103
leadframe off-centre . . . . . . . . . . . . . . . . . . . . 69
package off-centre . . . . . . . . . . . . . . . . . . . . . 69
package off-set . . . . . . . . . . . . . . . . . . . . . . 103
side rail pinching . . . . . . . . . . . . . . . . . . . . . 103
sticking compound . . . . . . . . . . . . . . . . . . . . 103
sticking culls/leadframes . . . . . . . . . . . . . . . . 92
voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
wire sweep . . . . . . . . . . . . . . . . . . . . . . . . . . 103
PT-100 DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
PT-100 sensor . . . . . . . . . . . . . . . . . . 15, 87, 88
Punch
copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Push plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
R
RBS-25 cleaning set . . . . . . . . . . . . . . . . . . . . . 27
Return pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
S
Safety device, bimetal . . . . . . . . . . . . . . . . . . . . 88
Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Special brass plug . . . . . . . . . . . . . . . . . . . . . . . 65
Sticking plunger . . . . . . . . . . . . . . . . . . . . . . . . 94
Support plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 11
T
Temperature sensor . . . . . . . . . . . . . . . . . . . . . . 7
ToolID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Transfer cleaning program . . . . . . . . . . . . . . . . 91
Transfer end-position . . . . . . . . . . . . . . . . . . . . 59
type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
V
Vacuum strips . . . . . . . . . . . . . . . . . . . . . . 11, 15

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xMS-i

Standard Mold Manual

January 31, 2006 xMS-i Standard Mold - V1.7 Page i of iv

2.2.2 Preparing for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Page ii of iv xMS-i Standard Mold - V1.7 January 31, 2006

5.5 CALCULATING THE TRANSFER END POSITION . . . . . . . . . . . . . . . . . . . . . . . 59

10. CLEANING, CONDITIONING AND STORING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

January 31, 2006 xMS-i Standard Mold - V1.7 Page iii of iv

10.3 TRANSFER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

12. INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Page iv of iv xMS-i Standard Mold - V1.7 January 31, 2006

January 31, 2006 xMS-i Standard Mold - V1.7 Page 1 of 106

1.2 MAIN COMPONENTS OF THE MOLD

Figure 1 Molds and plunger beam on mold slide

1.3 TYPE PLATE AND ENGRAVED CODES

Figure 2 Mold type plate

Page 2 of 106 xMS-i Standard Mold - V1.7 January 31, 2006

1.4.1 Fico tool kit

Figure 3 Fico tool kit

January 31, 2006 xMS-i Standard Mold - V1.7 Page 3 of 106

• special screws M6 - to (dis)assemble the ejector pin bed

1.4.2 Plunger seal cracker

Figure 4 Plunger seal cracker

Page 4 of 106 xMS-i Standard Mold - V1.7 January 31, 2006

1.4.3 Plunger disassembly tool

Figure 5 Plunger disassembly tool

1.4.4 Top mold removal tool

Figure 6 Top mold removal tool

January 31, 2006 xMS-i Standard Mold - V1.7 Page 5 of 106

1.4.5 Mold carrier

Figure 7 Mold carrier

1.4.6 Mold oven

Page 6 of 106 xMS-i Standard Mold - V1.7 January 31, 2006

1.4.8 Temperature meter

Figure 9 Temperature meter with probe

January 31, 2006 xMS-i Standard Mold - V1.7 Page 7 of 106

1.4.9 RBS cleaning set

Figure 10 RBS cleaning set

1.5 HANDLING THE MOLD AND PLUNGER BEAM

Only use original Fico bolts in the mold.

Page 8 of 106 xMS-i Standard Mold - V1.7 January 31, 2006

1.6 SWITCHING TO A DIFFERENT COMPOUND TYPE

1.7 XMS-I MOLD VERSUS XMS-XX-M2 MOLD

January 31, 2006 xMS-i Standard Mold - V1.7 Page 9 of 106

1.7.2 xMS-xx-M2 to xMS-i

1.7.3 xMS-i to xMS-xx-M2

Page 10 of 106 xMS-i Standard Mold - V1.7 January 31, 2006

2.1 BOTTOM MOLD PARTS

Figure 11 Bottom mold: parts

January 31, 2006 xMS-i Standard Mold - V1.7 Page 11 of 106

2.2 BOTTOM MOLD DISASSEMBLY

2.2.2 Preparing for disassembly

Figure 12 Molds and plunger beam on mold slide

Page 12 of 106 xMS-i Standard Mold - V1.7 January 31, 2006

2.2.3 Removing the plunger beam and plungers

To remove the plungers, proceed as follows:

Figure 13 Plunger beam