Mold-Masters Dura PLUS User manual

version 2
Dura+ User Manual
Original Instrucons
User Manual

iii
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual
Contents
Section 1 - Introduction ...................................................1-1
1.1 Intended Use ......................................................................................................1-1
1.2 Documentation ...................................................................................................1-1
1.3 Release Details ..................................................................................................1-1
1.4 Warranty .............................................................................................................1-1
1.5 Returned Goods Policy.......................................................................................1-2
1.6 Movement or Resale of Mold-Masters Products or Systems .............................1-2
1.7 Copyright ............................................................................................................1-2
1.8 Units of Measure and Conversion Factors .........................................................1-3
Section 2 - Global Support ..............................................2-1
2.1 Corporate O󰀩ces................................................................................................2-1
2.2 International Representatives.............................................................................2-2
Section 3 - Safety..............................................................3-1
3.1 Safety Hazards ...................................................................................................3-2
3.2 Operational Hazards...........................................................................................3-5
3.3 General Safety Symbols.....................................................................................3-7
3.4 Wiring Check ......................................................................................................3-8
3.5 Lockout Safety....................................................................................................3-9
3.5.1 Electrical Lockout.....................................................................................3-10
3.5.2 Energy Forms and Lockout Guidelines....................................................3-11
3.6 Disposal............................................................................................................3-12
3.7 Dura Plus Safety Hazards ................................................................................3-13
Section 4 - Preparation ....................................................4-1
4.1 Tools Required....................................................................................................4-1
4.2 Screw Lengths....................................................................................................4-2
4.3 Unpacking...........................................................................................................4-2
4.4 Cleaning .............................................................................................................4-3
Section 5 - Assembly .......................................................5-1
5.1 Typical Dura Plus System...................................................................................5-1
5.2 Pre-Assembly Checks of Gate Seals and Nozzle ..............................................5-2
5.3 Assembly of Gate Seals to Nozzle .....................................................................5-3
5.4 Thermocouple Installation for 01 Nozzle ............................................................5-4
5.4.1 Nozzle Flange Assembly ...........................................................................5-6
5.5 Sub-Manifold Assembly for Drop-In System.......................................................5-9
5.5.1 Install Valve Disk (Valve Disk Design) .......................................................5-9
5.5.2 Pneumatic System Installation.................................................................5-12
5.5.3 Hydraulic System Installation...................................................................5-15
5.6 Actuator Assembly ............................................................................................5-20
5.6.1 Install Pneumatic Actuator Assembly.......................................................5-20
5.6.2 Install Hydraulic Actuator Assembly.........................................................5-24
5.7 Install Sub-Manifold Heater Plates (Option) .....................................................5-30

iv
Dura+ User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
5.8 Install Bridge Heater Plates (Optional) .............................................................5-30
5.8.1 Install Heater Plate Thermocouple ..........................................................5-30
5.8.2 Install Heater Plates.................................................................................5-31
5.9 Tubular Heater Installation and Replacement for Bridge..................................5-32
5.9.1 Storage ....................................................................................................5-32
5.9.2 Remove a Heater Element ......................................................................5-33
5.9.3 Install a New Heater Element ..................................................................5-33
5.10 Bridge Assembly.............................................................................................5-36
5.10.1 Installation of Inlet Components ............................................................5-36
5.10.2 Heated Back Plate Installation...............................................................5-36
5.10.3 Inlet Extension with Heater Sleeves ......................................................5-37
5.10.4 Wiring Channel ......................................................................................5-41
5.11 Sub-Manifold Wiring .......................................................................................5-43
5.11.1 Power Wiring..........................................................................................5-43
5.11.2 Thermocouple Wiring.............................................................................5-44
5.11.3 Prepare to Wire the Bridge ....................................................................5-44
5.11.4 Wiring Channel Installation ....................................................................5-45
5.11.5 Electrical Box .........................................................................................5-47
5.11.6 Solenoid Valve Wiring ............................................................................5-47
Section 6 - SeVG Plus Actuator ......................................6-1
6.1 Introduction.........................................................................................................6-1
6.2 SeVG Plus Actuator Models ...............................................................................6-1
6.3 SeVG Plus Actuator in Dura Plus Systems ........................................................6-1
6.4 SeVG Plus Model Options..................................................................................6-2
6.4.1 SE40-20 Actuator - Non Cooled ................................................................6-2
6.4.2 SE40-20C Actuator - Cooled .....................................................................6-3
6.4.3 SE20-15 Model - Non Cooled....................................................................6-4
6.5 Plate Mounted Systems......................................................................................6-5
6.6 SE40-20 / SE40-20C ModelS.............................................................................6-5
6.6.1 SE20-15 Model..........................................................................................6-5
6.7 Assembly and Installation ...................................................................................6-6
6.7.1 Attach the Water Lines (Cooled Models Only)...........................................6-7
6.7.2 Assemble and Install the Valve Pin Holder ................................................6-8
6.7.3 Install the Motor and Valve Pin Assembly..................................................6-8
6.8 Disassembly .....................................................................................................6-11
6.8.1 SE40-20 and SE40-20C Models:.............................................................6-11
6.8.2 SE20-15 Model........................................................................................6-12
6.9 Manifold Mounted Systems ..............................................................................6-13
6.9.1 SE40-20 Model........................................................................................6-13
6.9.2 SE40-20C Model .....................................................................................6-14
6.10 SeVG Plus in Manifold Mounted Systems......................................................6-15
6.11 Assembly and Installation ...............................................................................6-16
6.11.1 Assemble and Install the Valve Pin Holder ............................................6-17
6.11.2 Install the Motor and Valve Pin Assembly ..............................................6-18
6.11.3 Attach the Water Lines (Cooled Models Only) .......................................6-19
6.11.4 Install Cables .........................................................................................6-20
6.12 Disassembly ...................................................................................................6-21

v
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual
Section 7 - Accu-Line™ ...................................................7-1
7.1 Accu-Line™ with Valve Insert - Assembly ..........................................................7-2
Section 8 - Electrical Testing...........................................8-1
8.1 Safety .................................................................................................................8-1
8.2 Electrical Wiring Check.......................................................................................8-1
8.3 Ground Shorts Test.............................................................................................8-2
8.4 Thermocouple Continuity Test ............................................................................8-2
8.5 Pinch Point Test..................................................................................................8-3
8.6 Heater Continuity................................................................................................8-3
8.7 Thermocouple Wiring Guidelines .......................................................................8-3
8.8 Heating Test with a Temperature Controller........................................................8-4
8.9 Retesting ............................................................................................................8-4
Section 9 - System Installation........................................9-1
9.1 Prior to Assembly................................................................................................9-1
9.2 System Installation .............................................................................................9-1
9.2.1 Water Cooling Nozzle Jacket Assembly ....................................................9-1
9.2.2 Install Sub-Manifold Assembly...................................................................9-2
9.2.3 Install Manifold Locator and Anti-Rotation Dowel ......................................9-2
9.2.4 Install Bridge Assembly..............................................................................9-3
9.2.5 Final Installation Steps...............................................................................9-4
Section 10 - System Startup and Shutdown ............... 10-1
10.1 Pre-Startup .....................................................................................................10-1
10.2 Startup ............................................................................................................10-2
10.2.1 Standard Hot Runner Systems..............................................................10-2
10.2.2 Stack Mold Systems ..............................................................................10-3
10.3 Shutdown........................................................................................................10-3
10.3.1 Standard Hot Runner Systems..............................................................10-3
10.3.2 Stack Mold System................................................................................10-4
Section 11 - Maintenance Procedures..........................11-1
11.1 Repair Kits and Crimping Tools.......................................................................11-1
11.2 Terminal End Removal.................................................................................... 11-2
11.3 Terminal Assembly ..........................................................................................11-3
11.4 Heater Plate Power Lead Replacement .........................................................11-6
11.4.1 Removal.................................................................................................11-6
11.4.2 Installation..............................................................................................11-6
11.5 Gate Seal Maintenance .................................................................................. 11-7
11.6 Multi-Cavity Systems ...................................................................................... 11-7
11.7 Gate Seal Removal......................................................................................... 11-8
11.8 Gate Seal Replacement.................................................................................. 11-9
11.9 Checking Nozzle Tip Height.......................................................................... 11-11
11.10 Nozzle Thermocouple Removal.................................................................. 11-12
11.11 Torque Settings ...........................................................................................11-12
11.11.1 Gate Seal Torque Settings .................................................................11-12
11.11.2 System and Plate Screw Torques ......................................................11-13

vi
Dura+ User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
Section 12 - Troubleshooting .............................................1
Section 13 - Glossary of Terms .................................... 13-1
Index ......................................................................................I

1-1INTRODUCTION
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual
Section 1 - Introduction
The purpose of this manual is to assist users in the integration, operation
and maintenance of a Dura Plus Hot Runner. This manual is designed to
cover most system congurations. If you need additional information specic
to your system, or information in another language, please contact your
representative or a Mold-Masters o󰀩ce.
1.1 Intended Use
Mold-Masters Dura Plus Hot Runner systems have been built to process
thermoplastic material at the required temperature for injection molding and
must not be used for any other purpose.
This manual is written for use by skilled persons who are familiar with
injection molding machinery and their terminology. Operators should be
familiar with plastic injection molding machines and the controls of such
equipment. Maintenance persons should have su󰀩cient understanding of
electrical safety to appreciate the dangers of 3-phase supplies. They should
know how to take appropriate measures to avoid any danger from electrical
supplies.
1.2 Documentation
This manual is part of the documentation package for your order and should
be referenced along with the following documents included in the package:
• The Bill of Materials (BOM). Together with the General Assembly drawing,
the Bill of Materials should be referenced when ordering spare parts.
• General Assembly drawing used to integrate your Hot Runner system into
the mold.
• Hot half drawing used to integrate Hot Half to cavity plate if applicable.
• CE declaration of conformity and declaration of incorporation (EU only)
NOTE
This manual should also be used in conjunction with other relevant
manuals, e.g. Mold Machine Manual and Controller Manual.
1.3 Release Details
When ordering this manual, please reference the document number below.
Table 1-1 Release Details
Document Number Release Date Version
DP-UM-EN-00-02-2 July 2019 02-2
DP--UM--EN--00--02-3 May 2021 02-3
1.4 Warranty
For current warranty information please refer to the documents available from
our website www.moldmasters.com/support/warranty or contact your Mold-
Masters representative.

1-2
Dura+ User Manual
INTRODUCTION
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
1.5 Returned Goods Policy
Please do not return any parts to Mold-Masters without pre-authorization and
a return authorization number supplied by Mold-Masters Limited.
Our policy is one of continuous improvement and we reserve the right to alter
product specications at any time without giving notice.
1.6 Movement or Resale of Mold-Masters
Products or Systems
This documentation is intended for use in the country of destination for which
the product or system was purchased.
Mold-Masters takes no responsibility for documentation of products or
systems if they are relocated or resold outside the intended country of
destination, as stated on the accompanying invoice and/or waybill.
1.7 Copyright
© 2021 Mold-Masters (2007) Limited. All Rights Reserved. Mold-Masters®
and the Mold-Masters logo are trademarks of Mold-Masters..

1-3INTRODUCTION
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual
1.8 Units of Measure and Conversion Factors
NOTE
The dimensions given in this manual are from original manufacturing
drawings.
All values in this manual are in S.I. units or subdivisions of these units.
Imperial units are given in parenthesis immediately after the S.I. units.
Table 1-2 Units of Measure and Conversion Factors
Unit Abbreviation Conversion value
bar Bar 14.5 psi
in. Inch 25.4 mm
kg Kilogram 2.205 lb
kPa Kilopascal 0.145 psi
lb Pound 0.4536 kg
lbf Pound force 4.448 N
lbf.in. Pound force inch 0.113 Nm
min Minute
mm Millimeter 0.03937 in.
mΩ Milliohm
N Newton 0.2248 lbf
Nm Newton meter 8.851 lbf.in.
psi Pound per square inch 0.069 bar
psi Pound per square inch 6.895 kPa
rpm Revolutions per minute
s Second
°Degree
°CDegree Celsius 0.556 (°F -32)
°FDegree Fahrenheit 1.8 °C +32

2-1GLOBAL SUPPORT
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual
Section 2 - Global Support
2.1 Corporate Ofces
ASIAN HEADQUARTERS
CHINA/HONG KONG/TAIWAN
Mold-Masters (KunShan) Co, Ltd
Zhao Tian Rd
Lu Jia Town, KunShan City
Jiang Su Province
People’s Republic of China
tel: [phone]
fax: [phone]
[email protected]
JAPAN
Mold-Masters K.K.
1-4-17 Kurikidai, Asaoku Kawasaki,
Kanagawa
Japan, 215-0032
tel: [phone]
fax: [phone]
[email protected]
GLOBAL HEADQUARTERS
CANADA
Mold-Masters (2007) Limited
233 Armstrong Avenue
Georgetown, Ontario
Canada L7G 4X5
tel: [phone]
fax: [phone]
[email protected]
SOUTH AMERICAN
HEADQUARTERS
BRAZIL
Mold-Masters do Brasil Ltda.
R. James Clerk Maxwel,
280 – Techno Park, Campinas
São Paulo, Brazil, 13069-380
tel: [phone]
[email protected]
UNITED KINGDOM & IRELAND
Mold-Masters (UK) Ltd Netherwood
Road
Rotherwas Ind. Est.
Hereford, HR2 6JU
United Kingdom
tel: [phone]
fax: [phone]
[email protected]
EUROPEAN
HEADQUARTERS
GERMANY /
SWITZERLAND
Mold-Masters Europa GmbH
Neumattring 1
76532 Baden-Baden, Germany
tel: [phone]
fax: [phone]
[email protected]
INDIAN HEADQUARTERS
INDIA
Milacron India PVT Ltd. (Mold-
Masters Div.)
3B,Gandhiji Salai,
Nallampalayam, Rathinapuri
Post, Coimbatore T.N. 641027
tel: [phone]
fax: [phone]
[email protected]
USA
Mold-Masters Injectioneering
LLC, 29111 Stephenson
Highway, Madison Heights, MI
48071, USA
tel: [phone] (USA
only) tel: [phone]
fax: [phone]
[email protected]
Mold-Masters Regional Offices
AUSTRIA / EAST &
SOUTHEAST EUROPE
Mold-Masters Handelsges.m.b.H.
Pyhrnstrasse 16
A-4553 Schlierbach
Austria
tel: [phone]
fax: [phone]
[email protected]
ITALY
Mold-Masters Italia
Via Germania, 23
35010 Vigonza (PD)
Italy
tel: [phone]
fax: [phone]
[email protected]
CZECH REPUBLIC
Mold-Masters Europa GmbH
Hlavni 823
75654 Zubri
Czech Republic
tel: [phone]
fax: [phone]
[email protected]
KOREA
Mold-Masters Korea Ltd. E
dong, 2nd floor, 2625-6,
Jeongwang-dong, Siheung
City, Gyeonggi-do, 15117,
South Korea
tel: [phone]
[e-mail]
FRANCE
Mold-Masters France
ZI la Marinière,
2 Rue Bernard Palissy
91070 Bondoufle, France
tel: [phone]
fax: [phone]
[email protected]
MEXICO
Milacron Mexico Plastics Services
S.A. de C.V.
Circuito El Marques norte #55
Parque Industrial El Marques
El Marques, Queretaro C.P. 76246
Mexico
tel: [phone] (sales)
tel: [phone] (service)
[email protected]

2-2
Dura+ User Manual
GLOBAL SUPPORT
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
2.2 International Representatives
Corporate Ofces - continued
Mold-Masters Regional Offices (cont.)
SPAIN
Mold-Masters Europa GmbH
C/ Tecnología, 17
Edificio Canadá PL. 0 Office A2
08840 – Viladecans
Barcelona
tel: [phone]
e: [email protected]
TURKEY
Mold-Masters Europa GmbH
Merkezi Almanya Türkiye
İstanbul Şubesi
Alanaldı Caddesi Bahçelerarası
Sokak No: 31/1
34736 İçerenköy-Ataşehir
Istanbul, Turkey
tel: [phone]
fax: [phone]
[email protected]
SINGAPORE*
Mold-Masters Singapore PTE. Ltd.
No 48 Toh Guan Road East
#06-140 Enterprise Hub
Singapore 608586
Republic of Singapore
tel: [phone]
fax: [phone]
[email protected]
*Coverage includes Southeast
Asia, Australia, and New Zealand
Mold-Masters International Representatives
Argentina
Sollwert S.R.L.
La Pampa 2849 2∫ B
C1428EAY Buenos Aires
Argentina
tel: [phone]
fax: [phone] Ext.
35 [email protected]
Denmark*
Englmayer A/S
Dam Holme 14-16
DK – 3660 Stenloese
Denmark tel: [phone]
fax: [phone]
[email protected]
*Coverage includes Norway
and Sweden
Israel
ASAF Industries Ltd. 29 Habanai
Street
PO Box 5598 Holon 58154 Israel
tel: [phone]
fax: [phone]
s[email protected]
Russia
System LLC
Prkt Marshala Zhukova 4
123308 Moscow
Russia
tel: [phone]
[email protected]
Belarus
HP Promcomplect
Sharangovicha 13
220018 Minsk
tel: [phone]
fax: [phone]
e:[email protected]
Finland**
Oy Scalar Ltd.
Tehtaankatu
10 11120 Riihimaki
Finland
tel: [phone]
fax: [phone]
[email protected]
**Coverage includes Estonia
Portugal
Gecim LDA
Rua Fonte Dos Ingleses, No 2
Engenho
2430-130 Marinha Grande
Portugal
tel: [phone]
fax: [phone]
[email protected]
Slovenia
RD PICTA tehnologije d.o.o.
Žolgarjeva ulica 2
2310 Slovenska Bistrica
Slovenija
[phone]
[email protected]
Bulgaria
Mold-Trade OOD
62, Aleksandrovska
St. Ruse City
Bulgaria
tel: [phone]
fax: [phone]
[email protected]
Greece
Ionian Chemicals S.A.
21 Pentelis Ave.
15235 Vrilissia, Athens
Greece
tel: [phone]
fax: [phone]
[email protected]
Romania
Tehnic Mold Trade SRL
Str. W. A Mozart nr. 17 Sect. 2
020251 Bucharesti
Romania
tel: [phone]
fax : [phone]
[email protected]
Ukraine
Company Park LLC
Gaydamatska str., 3, office 116
Kemenskoe City Dnipropetrovsk
Region 51935, Ukraine
tel: [phone]
[email protected]

3-1SAFETY
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual
Section 3 - Safety
Please be aware that the safety information provided by Mold-Masters
does not absolve the integrator and employer from understanding and
following international and local standards for safety of machinery. It is the
responsibility of the end integrator to integrate the nal system, provide
necessary e-stop connections, safety interlocks and guarding, to select the
appropriate electrical cable for the region of use and to ensure compliance
with all relevant standards.
It is the responsibility of the employer to:
• Properly train and instruct its personnel in the safe operation of
equipment, including the use of all the safety devices.
• Provide its personnel with all necessary protective clothing, including
a face shield and heat resistant gloves.
• Ensure the original and continuing competence of personnel
caring for, setting up, inspecting and maintaining injection molding
equipment.
• Establish and follow a program of periodic and regular inspections of
injection molding equipment to ensure it is in safe operating condition
and proper adjustment.
• Ensure that no modications, repairs, or rebuild of portions are made
to the equipment that reduces the level of safety existing at time of
manufacture or remanufacture.

3-2
Dura+ User Manual
SAFETY
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
3.1 Safety Hazards
WARNING
Refer to all machine manuals and local regulations and codes for safety
information.
The following safety hazards are most commonly associated with plastic
injection molding equipment (see European Standard EN201 or American
Standard ANSI/SPI B151.1).
Refer to the illustration of hazard areas below when reading the “Table 3-1
Safety Hazards” on page 3-3
Figure 3-1 Injection molding machine hazard areas
Top view with guards removed
Front view with guards removed
210 5
3
Top View with Guards Removed
2
5
9
1
4
769
8
Front View with Guards Removed
1. Mold area
2. Clamping mechanism area
3. Area of movement of
core and ejector drive
mechanisms outside areas
1 and 2
4. Machine nozzle area
5. Plasticating and / or
injection unit area
6. Feed opening area
7. Area of the heater bands
of the plasticizing and / or
injection cylinders
8. Parts discharge area
9. Hoses
10. Area inside the guards and
outside the mold area

3-3SAFETY
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual
Table 3-1 Safety Hazards
Hazard Area Potential Hazards
Mold Area
Area between the
platens
See Figure 3-1 area 1
Mechanical Hazards
Crushing and / or shearing and / or impact hazards caused by:
• Movement of the platen.
• Movements of the injection barrel(s) into the mold area.
• Movements of cores and ejectors and their drive mechanisms.
• Tie bar motion.
Thermal Hazards
Burns and / or scalds due to operating temperature of:
• The mold heating elements.
• Plasticized material released from / through the mold.
Clamping
Mechanism Area
See Figure 3-1 area 2
Mechanical Hazards
Crushing and / or shearing and/or impact hazards caused by:
• Movement of the platen.
• Movement of the drive mechanism of the platen.
• Movement of the core and ejector drive mechanism.
Movement of Drive
Mechanisms Outside
the Mold Area
and Outside the
Clamping Mechanism
Area
See Figure 3-1 area 3
Mechanical Hazards
Mechanical hazards of crushing, shearing and / or impact caused by the
movements of:
• Core and ejector drive mechanisms.
Nozzle Area
The nozzle area is
the area between the
barrel and the sprue
bushing.
See Figure 3-1 area 4
Mechanical Hazards
Crushing, shearing hazards, and / or impact hazards caused by:
• Forward movement of the plasticizing and / or injection unit including
nozzle.
• Movements of parts of-the power operated nozzle shuto󰀨 and their
drives.
• Over pressurization in the nozzle.
Thermal Hazards
Burns and or scalds due to operating temperature of:
• The nozzle.
• Plasticized material discharging from the nozzle.
Plasticizing and / or
Injection Unit Area
Area from the adapter
/ barrel head / end cap
to the extruder motor
above the sled
including the carriage
cylinders.
See Figure 3-1 area 5
Mechanical Hazards
Crushing, shearing and / or drawn-into hazards caused by:
• Unintentional gravity movements e.g. for machines with plasticizing and
/ or injection unit positioned above the mold area.
• The movements of the screw and / or the injection plunger in the
cylinder accessible through the feed opening.
• Movement of the carriage unit.
Thermal Hazards
Burns and or scalds due to operating temperature of:
• The plasticizing and / or injection unit.
• The heating elements e.g. heater bands.
• The plasticized material and / or vapors discharging from the vent
opening, feed throat or hopper.
Mechanical and / or Thermal Hazard
Hazards due to reduction in mechanical strength of the plasticizing and / or
injection cylinder due to overheating.
Feed Opening
See Figure 3-1 area 6
Pinching and crushing between injection screw movement and housing.
Safety Hazards - continued

3-4
Dura+ User Manual
SAFETY
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
Table 3-1 Safety Hazards
Hazard Area Potential Hazards
Area of the Heater
Bands of the
Plasticizing and / or
Injection Cylinders
See Figure 3-1 area 7
Burns and / or scalds due to operating temperature of:
• The plasticizing and / or injection unit.
• The heating elements e.g. heater bands.
• The plasticized material and / or vapors discharging from the vent
opening, feed throat or hopper.
Parts Discharge Area
See Figure 3-1 area 8
Mechanical Hazards
Accessible through the discharge area
Crushing, shearing and / or impact hazards caused by:
• Closing movement of the platen.
• Movements of cores and ejectors and their drive mechanisms.
Thermal Hazards
Accessible through the discharge area
Burns and or scalds due to operating temperature of:
• The mold.
• Heating elements of the mold.
• Plasticized material released from / through the mold.
Hoses
See Figure 3-1 area 9
• Whipping action caused by hose assembly failure.
• Possible release of uid under pressure that can cause injury.
• Thermal hazards associated with hot uid.
Area Inside the
Guards and Outside
the Mold Area
See Figure 3-1 area 10
Crushing and / or shearing and / or impact hazards caused by:
• Movement of the platen.
• Movement of the drive mechanism of the platen.
• Movement of the core and ejector drive mechanism.
• Clamp opening movement.
Electrical Hazards • Electrical or electromagnetic disturbance generated by the motor
control unit.
• Electrical or electromagnetic disturbance that can cause failures in the
machine control systems and adjacent machine controls.
• Electrical or electromagnetic disturbance generated by the motor
control unit.
Hydraulic
Accumulators
High pressure discharge.
Power Operated Gate Crush or impact hazards caused by the movement of the power operated
gates.
Vapors and Gases Certain processing conditions and / or resins can cause hazardous fumes
or vapors.
Safety Hazards - continued

3-5SAFETY
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual
3.2 Operational Hazards
WARNINGS
• Refer to all machine manuals and local regulations and codes for safety
information.
• The equipment supplied is subjected to high injection pressures and high
temperatures. Ensure that extreme caution is observed in the operation
and maintenance of the injection molding machines.
• Only fully trained personnel should operate or maintain equipment.
• Do not operate the equipment with unconned long hair, loose clothing
or jewelry, including name badges, neckties, etc. These may get caught
in the equipment and can cause death or serious injury.
• Never disable or bypass a safety device.
• Ensure that the protective guards are placed around the nozzle to
prevent the material from splashing or drooling.
• A burn hazard exists from material during routine purging. Wear heat-
resistant personal protective equipment (PPE) to prevent burns from
contact with hot surfaces or splatter of hot material and gases.
• Material purged from machine may be extremely hot. Ensure protective
guards are in place around the nozzle to prevent material from
splashing. Use proper personal protective equipment.
• All operators should wear personal protective equipment, such as face
shields and use heat resistant gloves when working around the feed
inlet, purging the machine or cleaning the gates of the mold.
• Remove purged material from the machine immediately.
• Decomposing or burning material could result in noxious gases being
emitted from the purged material, feed inlet or mold.
• Ensure proper ventilation and exhaust systems are in place to help
prevent inhalation of harmful gases and vapors.
• Consult manufacturer’s Material Safety Data Sheets (MSDS).
• Hoses tted to the mold will contain high or low temperature uids or air
under high pressure. The operator must shut down and lockout these
systems as well as relieving any pressure before performing any work
with these hoses. Regularly inspect and replace all exible hoses and
restraints.
• Water and / or hydraulics on the mold may be in close proximity to
electrical connections and equipment. Water leakage may cause an
electrical short circuit. Hydraulic uid leakage may cause a re hazard.
Always keep water and / or hydraulic hoses and ttings in good condition
to avoid leaks.
• Never perform any work on the mold machine unless the hydraulic pump
has been stopped.
• Check frequently for possible oil leaks / water leaks. Stop the machine
and make repairs.

3-6
Dura+ User Manual
SAFETY
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
Operational Hazards - continued
WARNING
• Make sure that the cables are connected to the correct motors. Cables
and motors are clearly labeled. Reversing the cables can result in
unexpected and uncontrolled motion causing a safety risk or damage to
the machine.
• A crushing hazard exists between the nozzle and mold melt inlet during
carriage forward motion.
• A possible shearing hazard exists between the edge of the injection
guard and the injection housing during injection.
• The open feed port could present a hazard to a nger or a hand
inserted during operation of the machine.
• The electric servo motors could overheat presenting a hot surface which
could cause burns to someone touching it.
• The barrel, barrel head, nozzle, heater bands and mold components are
hot surfaces which could result in burns.
• Keep ammable liquids or dust away from the hot surfaces as they
could ignite.
• Follow good housekeeping procedures and keep oors clean to prevent
slips, trips and falls due to spilled material on the work oor.
• Apply engineering controls or hearing conservation programs as
necessary to control noise.
• When doing any work on the machine that requires moving and lifting
the machine, ensure that lifting equipment (eyebolts, fork lift truck,
cranes, etc.) will have su󰀩cient capacity to handle mold, auxiliary
injection unit or Hot Runner weight.
• Connect all lifting devices and support the machine using a crane of
adequate capacity before commencing work. Failure to support the
machine can result in severe injury or death.
• Mold cable from the controller to the mold must be removed before
servicing the mold.

3-7SAFETY
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual
3.3 General Safety Symbols
Table 3-2 Typical Safety Symbols
Symbol General Description
General – Warning
Indicates an immediate or potentially hazardous situation, which if not
avoided, could result in a serious injury or death, and / or damage to
equipment.
Warning – Barrel Cover Grounding Strap
Lockout / tagout procedures must be followed before removing the barrel
cover. Barrel cover can become energized upon removal of grounding
straps and contact can result in death or serious injury. Grounding straps
must be reconnected before reconnecting power to machine.
Warning – Crushing and / or Impact Points
Contact with moving parts can cause serious crushing injury. Always keep
guards in place.
Warning – Crush Hazard Closing Mold
Warning – Hazardous Voltage
Contact with hazardous voltages will cause death or serious injury. Turn o󰀨
power and review electrical schematics before servicing equipment. May
contain more than one live circuit. Test all circuits before handling to make
sure circuits have been de-energized.
Warning – High Pressure
Overheated uids may cause severe burns. Discharge pressure before
disconnecting water lines.
Warning – High Pressure Accumulator
Sudden release of high pressure gas or oil can cause death or serious
injury. Discharge all gas and hydraulic pressure before disconnecting or
disassembling accumulator.
Warning – Hot Surfaces
Contact with exposed hot surfaces will cause serious burn injury. Wear
protective gloves when working near these areas.
Mandatory – Lockout / Tagout
Ensure that all energies are properly locked out, and remain locked out
until the service work is completed. Servicing equipment without disabling
all internal and external power sources can cause death or serious injury.
De-energize all internal and external power sources (electrical, hydraulic,
pneumatic, kinetic, potential, and thermal).
Warning – Material Splashing Hazard
Material or high pressure gas can cause death or severe burns. Wear
personal protective equipment while servicing the feed throat, nozzle, mold
areas and when purging the injection unit.
Warning – Read Manual Before Operation
Personnel should read and understand all instructions in the manuals
before working on equipment. Only properly trained personnel should
operate the equipment.
Warning – Slip, Trip or Fall Hazard
Do not climb on equipment surfaces. Serious slip, trip or fall injuries can
result from personnel climbing on equipment surfaces.

3-8
Dura+ User Manual
SAFETY
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
Table 3-2 Typical Safety Symbols
Symbol General Description
CAUTION
Caution
Failure to follow instructions may damage equipment.
Important
Indicates additional information or used as a reminder.
3.4 Wiring Check
CAUTION
System Mains Supply Wiring:
• Before connecting the system to a power supply, it is important to check
that the wiring between the system and the power supply has been
done correctly.
• Particular attention must be given to the current rating of the power
supply. For example, if a controller is rated at 63A, then the power
supply must also be rated at 63A.
• Check that the phases of power supply are wired correctly.
Controller to Mold Wiring:
• For separate power and thermocouple connections, ensure that the
power cables are never connected to the thermocouple connectors and
vice-versa.
• For mixed power and thermocouple connections, ensure that the power
and thermocouple connections have not been wired incorrectly.
Communications Interface and Control Sequence:
• It is the customer’s responsibility to verify functionality of any custom
machine interface at safe speeds, prior to operating equipment in the
production environment at full speed in automatic mode.
• It is the customer’s responsibility to verify all required motion sequences
are correct, prior to operating equipment in the production environment
at full speed in automatic mode.
• Switching the machinery into Auto mode without having veried the
control interlocks and motion sequence are correct, may cause damage
to machinery and / or equipment.
Failure to do wiring or connections properly will result in equipment failure.
CAUTION
General Safety Symbols - continued

3-9SAFETY
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Dura+ User Manual
3.5 Lockout Safety
WARNING
DO NOT enter the cabinet without rst ISOLATING the supplies.
High voltage and amperage cables are connected to the controller and the
mold. Electrical power must be shut o󰀨 and lockout / tagout procedures
followed prior to installing or removing any cables.
Use lockout / tagout to prevent operation during maintenance.
All maintenance should be performed by properly trained personnel based
on local laws and regulation. Electrical products may not be grounded when
removed from the assembled or normal operating condition.
Ensure proper grounding of all electrical components before performing any
maintenance to avoid potential risk of electrical shock.
Often power sources are inadvertently turned on or valves are opened
mistakenly before maintenance work is completed, resulting in serious
injuries and fatalities. Therefore, it is important to ensure that all energies
are properly locked out and that they remain locked out until the work is
completed.
If a lockout is not performed, uncontrolled energies could cause:
• Electrocution from contact with live circuits
• Cuts, bruises, crushing, amputations or death, resulting from
entanglement with belts, chains, conveyors, rollers, shafts,
impellers
• Burns from contact with hot parts, materials or equipment such as
furnaces
• Fires and explosions
• Chemical exposures from gases or liquids released from pipelines