Mold-masters Dura plus User manual

version 2

Dura+ User Manual

Original Instrucons

User Manual

iii

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

Dura+ User Manual

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

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

Dura+ User Manual

Section 12 - Troubleshooting .............................................1

Section 13 - Glossary of Terms .................................... 13-1

Index ......................................................................................I

1-1INTRODUCTION

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

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

and the Mold-Masters logo are trademarks of Mold-Masters..

1-3INTRODUCTION

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

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: +86 512 86162882

fax: +86 512-86162883

[email protected]

JAPAN

Mold-Masters K.K.

1-4-17 Kurikidai, Asaoku Kawasaki,

Kanagawa

Japan, 215-0032

tel: +81 44 986 2101

fax: +81 44 986 3145

[email protected]

GLOBAL HEADQUARTERS

CANADA

Mold-Masters (2007) Limited

233 Armstrong Avenue

Georgetown, Ontario

Canada L7G 4X5

tel: +1 905 877 0185

fax: +1 905 877 6979

[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: +55 19 3518 4040

[email protected]

UNITED KINGDOM & IRELAND

Mold-Masters (UK) Ltd Netherwood

Road

Rotherwas Ind. Est.

Hereford, HR2 6JU

United Kingdom

tel: +44 1432 265768

fax: +44 1432 263782

[email protected]

EUROPEAN

HEADQUARTERS

GERMANY /

SWITZERLAND

Mold-Masters Europa GmbH

Neumattring 1

76532 Baden-Baden, Germany

tel: +49 7221 50990

fax: +49 7221 53093

[email protected]

INDIAN HEADQUARTERS

INDIA

Milacron India PVT Ltd. (Mold-

Masters Div.)

3B,Gandhiji Salai,

Nallampalayam, Rathinapuri

Post, Coimbatore T.N. 641027

tel: +91 422 423 4888

fax: +91 422 423 4800

[email protected]

USA

Mold-Masters Injectioneering

LLC, 29111 Stephenson

Highway, Madison Heights, MI

48071, USA

tel: +1 800 450 2270 (USA

only) tel: +1 (248) 544-5710

fax: +1 (248) 544-5712

[email protected]

Mold-Masters Regional Offices

AUSTRIA / EAST &

SOUTHEAST EUROPE

Mold-Masters Handelsges.m.b.H.

Pyhrnstrasse 16

A-4553 Schlierbach

Austria

tel: +43 7582 51877

fax: +43 7582 51877 18

[email protected]

ITALY

Mold-Masters Italia

Via Germania, 23

35010 Vigonza (PD)

Italy

tel: +39 049/5019955

fax: +39 049/5019951

[email protected]

CZECH REPUBLIC

Mold-Masters Europa GmbH

Hlavni 823

75654 Zubri

Czech Republic

tel: +420 571 619 017

fax: +420 571 619 018

[email protected]

KOREA

Mold-Masters Korea Ltd. E

dong, 2nd floor, 2625-6,

Jeongwang-dong, Siheung

City, Gyeonggi-do, 15117,

South Korea

tel: +82-31-431-4756

korea@moldmasters.com

FRANCE

Mold-Masters France

ZI la Marinière,

2 Rue Bernard Palissy

91070 Bondoufle, France

tel: +33 (0) 1 78 05 40 20

fax: +33 (0) 1 78 05 40 30

[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: +52 442 713 5661 (sales)

tel: +52 442 713 5664 (service)

[email protected]

2-2

Dura+ User Manual

GLOBAL SUPPORT

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: +34 93 575 41 29

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: +90 216 577 32 44

fax: +90 216 577 32 45

[email protected]

SINGAPORE*

Mold-Masters Singapore PTE. Ltd.

No 48 Toh Guan Road East

#06-140 Enterprise Hub

Singapore 608586

Republic of Singapore

tel: +65 6261 7793

fax: +65 6261 8378

[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: +54 11 4786 5978

fax: +54 11 4786 5978 Ext.

35 [email protected]

Denmark*

Englmayer A/S

Dam Holme 14-16

DK – 3660 Stenloese

Denmark tel: +45 46 733847

fax: +45 46 733859

[email protected]

*Coverage includes Norway

and Sweden

Israel

ASAF Industries Ltd. 29 Habanai

Street

PO Box 5598 Holon 58154 Israel

tel: +972 3 5581290

fax: +972 3 5581293

s[email protected]

Russia

System LLC

Prkt Marshala Zhukova 4

123308 Moscow

Russia

tel: +7 (495) 199-14-51

[email protected]

Belarus

HP Promcomplect

Sharangovicha 13

220018 Minsk

tel: +375 29 683-48-99

fax: +375 17 397-05-65

e:[email protected]

Finland**

Oy Scalar Ltd.

Tehtaankatu

10 11120 Riihimaki

Finland

tel: +358 10 387 2955

fax: +358 10 387 2950

[email protected]

**Coverage includes Estonia

Portugal

Gecim LDA

Rua Fonte Dos Ingleses, No 2

Engenho

2430-130 Marinha Grande

Portugal

tel: +351 244 575600

fax: +351 244 575601

[email protected]

Slovenia

RD PICTA tehnologije d.o.o.

Žolgarjeva ulica 2

2310 Slovenska Bistrica

Slovenija

+386 59 969 117

[email protected]

Bulgaria

Mold-Trade OOD

62, Aleksandrovska

St. Ruse City

Bulgaria

tel: +359 82 821 054

fax: +359 82 821 054

[email protected]

Greece

Ionian Chemicals S.A.

21 Pentelis Ave.

15235 Vrilissia, Athens

Greece

tel: +30 210 6836918-9

fax: +30 210 6828881

[email protected]

Romania

Tehnic Mold Trade SRL

Str. W. A Mozart nr. 17 Sect. 2

020251 Bucharesti

Romania

tel: +4 021 230 60 51

fax : +4 021 231 05 86

[email protected]

Ukraine

Company Park LLC

Gaydamatska str., 3, office 116

Kemenskoe City Dnipropetrovsk

Region 51935, Ukraine

tel: +38 (038) 277-82-82

[email protected]

3-1SAFETY

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

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

Top View with Guards Removed

769

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

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

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

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

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

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

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

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