Husky Unify User manual

Unify Manifold System
Hot Runner Installation Manual
Original Instructions

Issue: v 2.2 — March 2021
Document No.: 7593574
This product manual is intended to provide information for safe operation and/or maintenance.
Husky reserves the right to make changes to products in an eort to continually improve the
product features and/or performance. These changes may result in dierent and/or additional
safety measures that are communicated to customers through bulletins as changes occur.
This document contains information which is the exclusive property of Husky Injection Molding
Systems Limited. Except for any rights expressly granted by contract, no further publication or
commercial use may be made of this document, in whole or in part, without the prior written
permission of Husky Injection Molding Systems Limited.
Notwithstanding the foregoing, Husky Injection Molding Systems Limited grants permission to its
customers to reproduce this document for limited internal use only.
Husky®product or service names or logos referenced in these materials are trademarks of Husky
Injection Molding Systems Ltd. and may be used by certain of its aliated companies under
license.
All third-party trademarks are the property of the respective third-party and may be protected by
applicable copyright, trademark or other intellectual property laws and treaties. Each such third-
party expressly reserves all rights into such intellectual property.
©2016 – 2021 Husky Injection Molding Systems Ltd. All rights reserved.
v 2.2 — March 2021 Unify Manifold System
ii

General Information
Telephone Support Numbers
North America Toll free 1-800-465-HUSKY (4875)
Europe EC (most countries) 008000 800 4300
Direct and Non-EC + (352) 52115-4300
Asia Toll Free 800-820-1667
Direct: [phone]
Latin America Brazil [phone]
Mexico [phone] option 5
For on-site service, contact your nearest Husky Regional Service and Sales oce.
For non-emergency questions and issues you may also e-mail Husky at [e-mail].
Husky Regional Service and Sales Oces
For the location closest to you, please visit www.husky.co.
Product Upgrades
Upgrades are available that can improve your output, reduce cycle times, and add functionality to
your Husky equipment.
To see what upgrades are available for your Husky equipment, visit our website at www.husky.co
or call your nearest Husky Regional Service and Sales Oce.
Ordering Spare Parts
All spare parts for Husky equipment can be ordered through your nearest Husky Parts
Distribution Center or online at www.husky.co.
Hot Runner Installation Manual v 2.2 — March 2021
Telephone Support Numbers iii

Hot Runner Refurbishing
Husky oers services for repairing, modifying, and retrotting Husky hot runners. Contact your
Husky Regional Service and Sales oce for details.
v 2.2 — March 2021 Unify Manifold System
iv Hot Runner Refurbishing

Table of Contents
General Information..........................................................................................................................................iii
Telephone Support Numbers..................................................................................................................................................iii
Husky Regional Service and Sales Oces...........................................................................................................................iii
Product Upgrades........................................................................................................................................................................iii
Ordering Spare Parts...................................................................................................................................................................iii
Hot Runner Refurbishing.......................................................................................................................................................... iv
Chapter 1: Introduction..................................................................................................................................... 9
1.1 Purpose of the Equipment................................................................................................................................................9
1.2 Restrictions of Use............................................................................................................................................................... 9
1.3 Unauthorized Modications............................................................................................................................................ 9
1.4 Auxiliary Equipment........................................................................................................................................................... 9
1.5 Documentation..................................................................................................................................................................10
1.5.1 Manuals................................................................................................................................................................ 10
1.5.2 Engineering Drawings and Schematics....................................................................................................11
1.5.3 Safety Alert Conventions............................................................................................................................... 11
1.6 Training................................................................................................................................................................................. 12
1.7 Nameplates..........................................................................................................................................................................12
1.7.1 Hot Runner Nameplate...................................................................................................................................12
1.8 Special Tools........................................................................................................................................................................14
1.8.1 Nozzle Tip Sockets and Heater Removal Tools.......................................................................................14
1.8.2 Standard Nozzle Tip Sockets.........................................................................................................................14
1.8.3 Thermocouple Wire Stripping Tools.......................................................................................................... 15
1.8.4 Single Probe Thermocouple Removal Tools........................................................................................... 15
1.8.5 Crimping Tools for Contact Pins (25 or 64 Pin Connectors)...............................................................15
1.8.6 Unify Nozzle Assembly Tool..........................................................................................................................16
1.8.7 Unify Hydraulic Actuator Seal Installation Tools....................................................................................16
Chapter 2: Safety Summary.............................................................................................................................17
2.1 Qualied Personnel.......................................................................................................................................................... 17
2.2 Safety Guidelines...............................................................................................................................................................17
2.3 Safety Hazards.................................................................................................................................................................... 17
2.3.1 Mechanical Hazards.........................................................................................................................................18
2.3.2 Burn Hazards...................................................................................................................................................... 18
2.3.3 High Pressure Hazards.................................................................................................................................... 19
2.3.3.1 Hydraulic System Pressure Hazards...........................................................................................20
2.3.4 Electrical Hazards..............................................................................................................................................20
2.3.5 Gas, Vapor and Dust Emissions....................................................................................................................20
2.3.6 Slip, Trip or Fall Hazards..................................................................................................................................21
2.3.7 Lifting Hazards...................................................................................................................................................21
2.4 Safety Signs......................................................................................................................................................................... 21
2.5 Lockout and Tagout..........................................................................................................................................................23
2.6 Personal Protective Equipment and Safety Equipment...................................................................................... 24
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2.6.1 Personal Protective Equipment (PPE)........................................................................................................24
2.6.2 Safety Equipment............................................................................................................................................. 25
2.7 Material Safety Data Sheet (MSDS)............................................................................................................................. 25
2.8 Materials, Parts and Processing....................................................................................................................................26
2.9 Safety Latch Bars................................................................................................................................................................26
2.10 Lift Bars and Swivel Hoist Rings................................................................................................................................. 27
Chapter 3: Specications................................................................................................................................. 29
3.1 Weight................................................................................................................................................................................... 29
3.2 Operating Temperature.................................................................................................................................................. 29
3.3 Electrical System Specications................................................................................................................................... 29
3.3.1 Controller Requirements................................................................................................................................29
3.3.2 Nozzle Heaters................................................................................................................................................... 30
3.3.3 Manifold Heaters...............................................................................................................................................30
3.3.3.1 Spare Thermocouple Wires.......................................................................................................... 30
3.3.4 Power Fluctuation............................................................................................................................................ 31
3.4 Operating Specications................................................................................................................................................ 31
3.4.1 Hydraulic Manifold Operating Limits........................................................................................................ 31
3.4.2 Pneumatic Manifold Operating Limits......................................................................................................32
3.5 Hydraulic Fluid Specications.......................................................................................................................................32
3.6 Pneumatic Specications............................................................................................................................................... 32
3.7 Hydraulic Cooling Water Specications.................................................................................................................... 33
3.8 Pneumatic Cooling Water Specications..................................................................................................................33
3.9 Recommended Lubricants.............................................................................................................................................34
3.10 Rust Inhibitor Specications....................................................................................................................................... 35
3.11 Torque Specications.................................................................................................................................................... 35
3.12 Hydraulic and Pneumatic Actuator Component Specications.................................................................... 36
3.12.1 Large Hydraulic Actuator Components................................................................................................. 36
3.12.2 Small Hydraulic Actuator Components..................................................................................................37
3.12.3 Large and Small Pneumatic Actuator Components.......................................................................... 39
3.12.4 Large and Small Pneumatic Actuator with Thermal Regulator Components..........................40
Chapter 4: Installation and Removal.............................................................................................................. 43
4.1 Lifting and Handling........................................................................................................................................................ 43
4.1.1 Lifting and Handling Using a Single Lifting Point.................................................................................44
4.1.1.1 Laying Down Plates Using a Single Lifting Point..................................................................44
4.1.1.2 Picking Up Plates Using a Single Lifting Point.......................................................................45
4.1.2 Lifting and Handling Using Multiple Lifting Points..............................................................................46
4.1.3 Lifting Using a Lift Bar..................................................................................................................................... 47
4.1.4 Lifting Using Swivel Hoist Rings..................................................................................................................48
4.2 Installing and Removing the Manifold Assembly..................................................................................................49
4.2.1 Installing the Manifold into the Plates......................................................................................................49
4.2.2 Removing the Manifold assembly from the Mold................................................................................ 52
Chapter 5: Startup and Operation.................................................................................................................. 55
5.1 Preparing the Hot Runner.............................................................................................................................................. 55
5.2 Heating Up the Hot Runner, Mold and Machine....................................................................................................56
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vi

5.3 Precharging the Hot Runner..........................................................................................................................................57
5.4 Producing Test Parts.........................................................................................................................................................58
Chapter 6: Maintenance...................................................................................................................................61
6.1 Scheduled and Non-Scheduled Maintenance........................................................................................................61
6.1.1 Preventive Maintenance.................................................................................................................................62
6.1.2 Service Procedures...........................................................................................................................................62
6.2 Removing and Installing Nozzle Stacks.....................................................................................................................63
6.2.1 Removing the Nozzle Stack...........................................................................................................................63
6.2.2 Installing the Nozzle Stack.............................................................................................................................63
6.3 Changing the Resin Color...............................................................................................................................................66
6.4 Extending Nozzle and Sprue Heater Wire Leads....................................................................................................67
6.5 Removing and Installing the Hydraulic Actuator ................................................................................................. 69
6.5.1 Removing the Hydraulic Actuator from the Manifold.........................................................................69
6.5.2 Installing the Hydraulic Actuator on the Manifold...............................................................................70
6.6 Removing and Installing the Pneumatic Actuator ...............................................................................................72
6.6.1 Removing the Pneumatic Actuator from the Manifold...................................................................... 72
6.6.2 Installing the Pneumatic Actuator to the Manifold..............................................................................73
6.7 Adjusting the Valve Stem Preload for Hydraulic Actuators................................................................................74
6.8 Replacing the Hydraulic and Pneumatic Seals....................................................................................................... 78
6.9 Removing and Installing Valve Stems........................................................................................................................78
6.9.1 Removing a Valve Stem..................................................................................................................................78
6.9.2 Installing a Valve Stem....................................................................................................................................79
6.10 Removing and Installing Nozzle Heaters............................................................................................................... 79
6.10.1 Removing and Installing Ultra Nozzle Heaters (UNH) on U750 Systems................................... 80
6.10.1.1 Removing Ultra Nozzle Heaters (UNH) on U750 Systems...............................................80
6.10.1.2 Installing Ultra Nozzle Heaters (UNH) on U750 Systems.................................................80
6.10.2 Removing and Installing Ultra Nozzle Heaters (UNH) With Ring Thermocouples..................83
6.10.2.1 Removing Ultra Nozzle Heaters (UNH) With Ring Thermocouples............................. 83
6.10.2.2 Installing Ultra Nozzle Heaters (UNH) With Ring Thermocouples............................... 84
6.10.3 Removing and Installing Bi-Metal Heaters on U750 and U1000 Systems................................. 89
6.10.3.1 Removing Bi-Metal Nozzle Heaters on U750 and U1000 Systems...............................89
6.10.3.2 Installing Bi-Metal Nozzle Heaters on U750 and U1000 Systems.................................89
6.10.4 Removing and Installing Triton Heaters on U750-UP Systems......................................................92
6.10.4.1 Removing Triton Nozzle Heaters on U750-UP Systems...................................................92
6.10.4.2 Installing Triton Nozzle Heaters on U750-UP Systems.....................................................93
6.10.5 Removing and Installing HTM Nozzle Heaters for U1000 Systems.............................................. 95
6.11 Replacing the Hydraulic or Pneumatic Manifold Hoses ...................................................................................95
6.12 Grounding the Unify System...................................................................................................................................... 96
6.13 Testing Heaters................................................................................................................................................................ 97
6.14 Removing and Installing the Cavity Plate.............................................................................................................. 97
6.14.1 Removing the Cavity Plate On a Work Bench...................................................................................... 98
6.14.2 Installing the Cavity Plate On a Work Bench........................................................................................ 99
6.14.3 Removing the Cavity Plate In the Machine........................................................................................ 101
6.14.4 Installing the Cavity Plate In the Machine.......................................................................................... 103
6.15 Inspecting and Cleaning Manifolds.......................................................................................................................104
6.15.1 Cleaning Using a Fluidized Bed Process.............................................................................................. 105
6.15.1.1 Assistance...................................................................................................................................... 106
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vii

6.15.1.2 Disassembling the Hot Runner for Fluidized Bed Cleaning.........................................106
6.15.1.3 Removing the PEEK Bushings.................................................................................................108
6.16 Removing Insulating Gate Bubbles (If Equipped)............................................................................................ 108
6.17 Removing and Installing the Sprue Heater (If Equipped)..............................................................................112
6.17.1 Removing a Sprue Heater with a Built-In Thermocouple............................................................. 112
6.17.2 Removing a Sprue Heater with a Separate Thermocouple.......................................................... 112
6.17.3 Installing a Sprue Heater with a Built-In Thermocouple................................................................113
6.17.4 Installing a Sprue Heater with a Separate Thermocouple............................................................ 114
6.18 Removing and Installing the Sprue Bushing......................................................................................................115
6.18.1 Removing the Sprue Bushing..................................................................................................................116
6.18.2 Installing the Sprue Bushing....................................................................................................................116
6.19 Removing and Installing Nozzle Tip Insulators (If Equipped).......................................................................118
6.19.1 Removing the Nozzle Tip Insulators..................................................................................................... 118
6.19.2 Installing Nozzle Tip Insulators............................................................................................................... 119
Chapter 7: Storage and Shipping..................................................................................................................121
7.1 Corrosion Protection......................................................................................................................................................121
7.2 Short Term Storage........................................................................................................................................................ 121
7.2.1 Storing in the Machine.................................................................................................................................122
7.2.2 Storing Outside the Machine.....................................................................................................................122
7.3 Long Term Storage......................................................................................................................................................... 123
7.4 Shipping the Hot Runner............................................................................................................................................. 123
v 2.2 — March 2021 Unify Manifold System
viii

Chapter 1 Introduction
This chapter describes the manifold system, training opportunities, and the available equipment
manuals.
1.1 Purpose of the Equipment
Husky equipment and systems are designed for injection molding applications only, using
approved materials and operating within design guidelines.
Contact your nearest Husky Regional Service and Sales oce if you plan to use a Husky product
for anything other than its intended use.
1.2 Restrictions of Use
Husky injection molding equipment must never be:
• operated by more than one person
• used for any purpose other than that described in Section 1.1, unless otherwise approved by
Husky
• used to extrude any materials not outlined in the scope of the harmonized EN201 or ANSI
B151.1 standard
• operated or serviced by personnel unfamiliar with the inherent risks and necessary
precautions related to injection molding equipment
• operated at temperatures higher than the maximum permissible temperature for the resin
1.3 Unauthorized Modications
Unauthorized modications or reconstruction of any Husky injection molding system is strictly
prohibited. Modications can be unsafe and/or void warranty.
Contact your nearest Husky Regional Service and Sales oce to discuss modications or
requirements for Husky systems.
1.4 Auxiliary Equipment
Husky is only responsible for the interaction of Husky equipment and systems with auxiliary
equipment when Husky is the system integrator. If auxiliary equipment is removed, the user must
install proper safeguards to prevent access to the hazards.
Hot Runner Installation Manual v 2.2 — March 2021 Introduction
Purpose of the Equipment 9

For information about integrating non-Husky auxiliary equipment, contact your nearest Husky
Regional Service and Sales oce.
1.5 Documentation
A full set of manuals, drawings, schematics, certicates and other documentation are available for
every Husky hot runner.
The following describes the documentation provided with each system, along with common
conventions all readers should be familiar with.
IMPORTANT!
Keep all manuals in a convenient location for future reference.
1.5.1 Manuals
Husky manuals aid in the safe and proper use of Husky products. Where applicable, the manuals
provide instructions on installation, operation and maintenance.
Personnel should thoroughly review all manuals provided with their Husky equipment prior to
performing any tasks. Proceed with tasks only if all instructions are understood and always follow
applicable workplace safety requirements.
IMPORTANT!
Images in the manuals are for reference only and may not represent specic equipment details.
Refer to engineering drawings and schematics and the HMI for specic details.
The following manuals are provided with each Husky machine upon delivery:
Installation
Manual
Describes the basic installation of the manifold system.
Service Manual Describes the installation, startup, operation, shut down and maintenance of the
hot runner system.
NOTE:
Refer to the hot runner Service Manual for specic removal and maintenance
instructions.
These manuals are available online through www.husky.co.
v 2.2 — March 2021 Unify Manifold System
10 Documentation

IMPORTANT!
Some manuals may contain addendums that detail new or updated information. Before reading a
manual, make sure to review all available addendums located at the end of the manual.
1.5.2 Engineering Drawings and Schematics
Each Husky hot runner is provided with a set of drawings and schematics specic to the hot
runner. These are used for troubleshooting the hot runner and ordering spare parts.
NOTE:
Each drawing and schematic is specic to the hot runner it is provided with.
1.5.3 Safety Alert Conventions
Safety alerts highlight hazardous conditions that may arise during installation, operation or
maintenance and describe methods for avoiding personal injury and/or property damage.
Depending on the severity of the hazard, safety alerts start with one of the following signal words:
Danger, Warning or Caution.
DANGER!
The DANGER safety alert indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING!
The WARNING safety alert indicates a potentially hazardous situation that, if not avoided,
could result in death or serious injury.
CAUTION!
The CAUTION safety alert indicates a potentially hazardous situation that, if not avoided,
could result in property damage.
Other non-safety related alert types used in the manuals highlight important information needed
by the user to install, operate or maintain the equipment properly. They may also, in some cases,
describe best practices, oer an expanded explanation, or reference a related section in the
manual.
Non-safety related alerts start with one of the following signal words: Note or Important.
Hot Runner Installation Manual v 2.2 — March 2021 Introduction
Documentation 11

NOTE:
The NOTE alert is used to add information to a subject that does not t within the general ow of
the document.
IMPORTANT!
The IMPORTANT alert is used to highlight important steps, conditions, or considerations related to
the subject.
1.6 Training
All designated operators and maintenance personnel must be fully trained before using or
servicing Husky injection molding systems.
If training is required, visit www.husky.co or contact your nearest Husky Regional Service and
Sales oce to learn more about Husky’s training solutions.
IMPORTANT!
It is the obligation of the employer to properly train and instruct all personnel in the safe methods
of operation and maintenance. Manuals and other reference material, which have been prepared
by Husky for the operation and maintenance of Husky equipment, do not in any way absolve the
employer from fullling these obligations and Husky disclaims liability for injury to personnel
which is attributable to the employer's failure to do so.
1.7 Nameplates
Nameplates are axed to the operator’s side of the mold and hot runner for quick identication
of the equipment type, source and general specications.
IMPORTANT!
The mold and hot runner nameplates must never be removed. The information on the
nameplates is necessary for mold selection, setup, parts ordering and troubleshooting.
Immediately order a new nameplate for the mold or hot runner if it is missing or damaged.
1.7.1 Hot Runner Nameplate
Every hot runner nameplate lists the following information:
v 2.2 — March 2021 Unify Manifold System
12 Training

• the location where the hot runner was manufactured
• the project number
• the material type allowed to be used in the hot runner
• the melt and mold temperatures
• electrical requirements and specications
NOTE:
Other details and specications may be required.
IMPORTANT!
Each hot runner is designed to process a specic type and grade of resin/ller based on the
customer’s requirements. Use of any other type or grade of resin/ller could aect part quality
and/or the performance of the hot runner. Before using a dierent type or grade of resin/ller,
contact Husky.
CAUTION!
Mechanical hazard – risk of damage to the hot runner. Never operate the hot runner
outside of the melt and mold temperatures indicated on the nameplate. Internal resin
leakage or component damage could occur.
1234 1
2
3
4
5
6
Figure 1-1: Hot Runner Nameplate (Sample)
1. Project Number 2. Resin Type Allowed 3. Melt and Mold Temperatures 4. Power Requirements
5. Temperature Warning 6. Product Information
Hot Runner Installation Manual v 2.2 — March 2021 Introduction
Nameplates 13

1.8 Special Tools
The following sections list various component-specic tools developed by Husky for use during
maintenance of hot runner systems. Contact Husky to order special tools applicable to your hot
runner system.
1.8.1 Nozzle Tip Sockets and Heater Removal Tools
Nozzle Tip Part Number
Nozzle Tip Socket Heater Removal Tool
U750 VG-R 531983 535160
VG 2338059
VX 3253170
U1000 VG 2449784 2410903 (Bi-Metal)
VX 2816672
1.8.2 Standard Nozzle Tip Sockets
Size Points Drive Part Number
4 mm 6 (Allen Key) 3/8 inch 622974
6 mm 6 (Allen Key) 3/8 inch 622972
6mm 6 3/8 inch 533942
8 mm 6 1/4 inch 2996145
8 mm 12 1/4 inch 3436695
8 mm 6 3/8 inch 1501813
10 mm 12 3/8 inch 3253169
11 mm 6 3/8 inch 3320712
11 mm 12 3/8 inch 531983
12 mm 6 3/8 inch 2338059
13 mm 6 3/8 inch 536678
14 mm 12 3/8 inch 533533
v 2.2 — March 2021 Unify Manifold System
14 Special Tools

Size Points Drive Part Number
15 mm 6 3/8 inch 2449784
15 mm 12 3/8 inch 3253170
16 mm 6 3/8 inch 2402461
16 mm 12 3/8 inch 2816670
17 mm 6 3/8 inch 2308879
20 mm 6 1/2 inch 3722920
21 mm 12 1/2 inch 3274535
22 mm 6 1/2 inch 3311845
22 mm 12 1/2 inch 2816672
29 mm 6 1/2 inch 1502743
30 mm 6 1/2 inch 535571
1/2 inch 6 3/8 inch 2192309
1.8.3 Thermocouple Wire Stripping Tools
Description Part Number
Strippers for Thermocouple Wires 4240042
1.8.4 Single Probe Thermocouple Removal Tools
Description Part Number
11 mm Split Socket 4395427
1.8.5 Crimping Tools for Contact Pins (25 or 64 Pin Connectors)
Description Part Number
Crimp Tool 2292562
Locator 2292574
Hot Runner Installation Manual v 2.2 — March 2021 Introduction
Special Tools 15

Description Part Number
Removal Tool 534645
Crimp Dies 0.5 to 1.5 mm2(20 to 16 AWG)[1] 238569
4.0 to 10 mm2(12 to 8 AWG)[1] 2292575
0.14 to 4.0 mm2(26 to 12 AWG)[2] 2292576
0.14 to 0.5 mm2(26 to 20 AWG)[1] 2748316
1.5 to 2.5 mm2(16 to 14 AWG)[1] 2748326
[1] Stamped crimp pins.
[2] Machined crimp pins.
1.8.6 Unify Nozzle Assembly Tool
Nozzle Part Number
Ultra 750 6685641
Ultra 1000 6611265
1.8.7 Unify Hydraulic Actuator Seal Installation Tools
Nozzle Description Part Number
Ultra 750 / Ultra 1000 Tool Sub Assembly 6618499
This part is included in the sub assembly Seal Base 6618449
Rod Seal Spacer 6396598
Seal Installation Tool 6469572
Seal Mandrel 6469607
Calibration Mandrel 6402092
Piston Seal Resizing Tool 6467523
Piston Seal Installation
Tool
6396301
v 2.2 — March 2021 Unify Manifold System
16 Unify Nozzle Assembly Tool

Chapter 2 Safety Summary
This chapter describes the general requirements and conditions for safe installation, operation
and maintenance of the manifold system.
IMPORTANT!
Personnel must read, understand and follow all safety precautions.
IMPORTANT!
Personnel must follow applicable industry and regulatory safety requirements for safe
installation, operation and maintenance of equipment.
2.1 Qualied Personnel
Only fully trained and qualied personnel should be permitted to maintain equipment. Qualied
personnel must have demonstrated skills and knowledge related to the construction, installation
and operation of the injection molding equipment and have received safety training on the
hazards involved.
2.2 Safety Guidelines
Personnel operating, installing, maintaining or servicing Husky equipment must adhere to safe
working practices that are in compliance with the following guidelines:
• Lockout and tag electrical, pneumatic and hydraulic energy sources before servicing the
mold/hot runner or entering the mold area
• Do not operate the mold/hot runner if scheduled preventive maintenance has not been
performed
• Do not use a magnetic platen without approval from Husky and the magnetic platen
supplier/manufacturer
• Do not operate a hot runner outside the maximum melt and mold temperatures specied on
the hot runner nameplate
2.3 Safety Hazards
Some common safety hazards associated with injection molding equipment are:
Hot Runner Installation Manual v 2.2 — March 2021 Safety Summary
Qualied Personnel 17

• Mechanical
• Electrical
• Burn
• High pressure (hydraulic system pressure and molten material spray)
• Slip, trip or fall
• Lifting
• Gas, vapor and dust emissions
• Noise
2.3.1 Mechanical Hazards
•Worn Hoses and Safety Restraints
Regularly inspect and replace all exible hose assemblies and restraints.
•Cooling Water Hoses
Cooling water hoses degrade over time and need to be replaced on a yearly basis. Degraded hoses
become brittle and can break or separate from the tting when manipulated. To minimize the risk
of failure, inspect the hoses regularly and replace as required.
Wait until the machine has cooled down before servicing cooling water hoses.
•Seized Screws or Plugs
If screws or plugs cannot be removed by normal methods using standard tooling and force, there is
a high possibility these items have become seized; contact Husky for repair recommendation.
WARNING!
Mechanical and/or ying debris hazard - Tool breakage: risk projectile debris, serious injury
and/or mechanical damage. Do not use excessive force and/or use tools beyond their
designated limits. Do not use torque multiplying bars. Failure of tools may produce
fragments that can become projectiles that may cause injury. For seized parts, consult
Husky for safe disassembly instructions.
NOTE:
Manifold plugs are not a eld repairable item and should never be removed. These items can only
be serviced at a Husky manufacturing location.
2.3.2 Burn Hazards
•Hot Surfaces
The mold area, auxiliary mold equipment, and injection unit heating elements have numerous high
temperature surfaces. At normal operating temperatures, contact with these surfaces will cause
severe skin burns. These areas are clearly marked with safety signs. Wear personal protective
equipment when working in these areas.
v 2.2 — March 2021 Unify Manifold System
18 Mechanical Hazards

•Molten Material
Never touch process material purged or otherwise owing from the nozzle, mold, hot runner or
feed throat area. Molten material can appear cool on the surface, but remain very hot on the inside.
Wear personal protective equipment when handling purged material.
2.3.3 High Pressure Hazards
WARNING!
Burn and hot resin spray hazard – risk of death, serious injury and/or damage to the hot
runner. All nozzle and sprue heaters (if equipped) must be turned on when manifold
heaters are turned on. Failure to do so could result in generation of dangerous pressure
levels in the manifold, resulting in component failure and/or sudden release of hot resin.
Pressure inside the hot runner manifold(s) can increase to dangerous levels if the nozzle and
sprue heaters (if equipped) are not turned on before or at the same time as the nozzle sprue.
The pressure is generated when the injection nozzle sprue is plugged with frozen resin and the
residual resin in the manifold is heated. This pressure can release suddenly causing the resin plug
to eject from the sprue and hot resin to spray from the nozzle tips. The risk of serious burn injuries
as a result is increased.
Moisture that inltrates and is trapped in the hot runner molten material can also increase the
risks of this potential hazard. If the temperature of the water in the molten material becomes
greater than 400 °C (725 °F) , the pressure of this trapped water can be signicant enough to
rupture the metal housing and cause serious injury to personnel.
To avoid this hazard, do the following:
1. Always make sure all nozzle and sprue heaters (if equipped) are turned on any time manifold
heaters are turned on outside of the mold. The nozzle and sprue heaters can be turned on
independently of the manifold heaters, however, it is recommended that they be heated rst
or slaved to the manifold heaters so they heat up in unison.
2. Always make sure the nozzle tips are open and the nozzle housings are dry prior to applying
heat to the manifold.
IMPORTANT!
In the event of water leaking onto or into the hot runner, the nozzle tips must be removed (cold)
and the plastic in the nozzles drilled out to ensure they are open to atmosphere. This can be done
using a standard twist drill with the cutting edges removed to prevent damage to the melt
channel.
Replace the cavity plate prior to heating the system.
Hot Runner Installation Manual v 2.2 — March 2021 Safety Summary
Safety Hazards 19

2.3.3.1 Hydraulic System Pressure Hazards
•Hydraulic System
Flexible hose connections and piping in hydraulic systems must be properly tightened to
prevent the release of uids or gases under pressure. Hoses must be inspected periodically
for signs of sweating and/or blistering. Rubber hoses naturally age with time and require
replacement at regular intervals as per the manufacturer's specications and Husky
maintenance requirements. Steel tubes should be tested using dye penetrant.
WARNING!
High pressure spray hazard – risk of death or serious injury. High pressure hydraulic
oil spray could penetrate human tissue and cause extensive injuries. Lock out and tag
the machine before servicing any hydraulic component.
WARNING!
High pressure spray hazard – risk of death or serious injury. Depressurize each
individual hydraulic circuit using an oil sampling kit before servicing any hydraulic
component.
•Skin Puncture Injuries
High pressure hydraulic spray can penetrate human tissue and cause severe bodily injury.
Seek immediate medical help in any event of skin puncture by uid spray.
2.3.4 Electrical Hazards
•Power Supply
Molding equipment draws high amperage current at high voltage. The electrical power
requirements are indicated on the nameplate and in the electrical schematics. Connect equipment
to a suitable power supply as specied in the electrical schematics and in compliance with all
applicable local regulations.
•Water
Water on the hot runner can be in close proximity to electrical connections and equipment. This
can lead to a short circuit, resulting in serious electrical damage to the equipment. Always keep
water lines, hoses, and hose ttings in good condition to avoid leaks.
2.3.5 Gas, Vapor and Dust Emissions
Certain processed materials release harmful gas, vapors or dust. Install an exhaust system
according to local codes.
v 2.2 — March 2021 Unify Manifold System
20 Hydraulic System Pressure Hazards