Mold-Masters Fusion Series User manual

version 14
User Manual
Original Instrucons

Table of 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 .............................................................................................................1-2
1.5 Returned Goods Policy.......................................................................................1-2
1.6 Movement or Resale of Mold-Masters Products or Systems .............................1-2
1.7 Copyright ............................................................................................................1-3
1.8 Units of Measure and Conversion Factors .........................................................1-3
1.9 Trademarks and Patents ....................................................................................1-4
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 Operator Training and Safety .............................................................................3-1
3.2 Safety Hazards ...................................................................................................3-2
3.3 Operational Hazards...........................................................................................3-5
3.4 General Safety Symbols.....................................................................................3-7
3.5 Wiring Check ......................................................................................................3-8
3.6 Lockout Safety....................................................................................................3-9
3.6.1 Electrical Lockout.....................................................................................3-10
3.6.2 Energy Forms and Lockout Guidelines....................................................3-11
3.7 Disposal............................................................................................................3-12
3.8 FUSION SERIES®G2 Safety Hazards.............................................................3-13
Section 4 - Preparation ....................................................4-1
4.1 Tools Required....................................................................................................4-1
4.2 Screw Lengths....................................................................................................4-1
4.3 Unpacking...........................................................................................................4-2
4.4 Cleaning .............................................................................................................4-2
4.5 Hydraulic Cylinder Assembly ..............................................................................4-3
4.6 Pneumatic Cylinder Assembly ............................................................................4-9
4.7 Waterless Hydraulic Actuator Assembly ...........................................................4-14
4.7.1 Assemble the Piston Assembly of the Waterless Hydraulic Actuator.......4-15
4.7.2 Assemble the Cylinder Body Assembly of the Waterless Hydraulic Actuator .
4-17
4.7.3 Assemble the Cylinder Assembly of the Waterless Hydraulic Actuator ...4-19
4.7.4 Assemble the Anti-Rotation Waterless Hydraulic Actuator ......................4-20
4.8 Waterless Pneumatic Actuator Assembly .........................................................4-21
4.9 Piston Assembly for Waterless Pneumatic Actuator.........................................4-22
4.10 Adjust Valve Pin Length for Waterless Actuator (Optional).............................4-23
4.11 Cylinder Body Assembly for Waterless Pneumatic Actuator...........................4-24
4.12 Cylinder Assembly for Waterless Pneumatic Actuator....................................4-28
4.13 Cylinder Assembly for Waterless Pneumatic Actuator - Anti-Rotation Version4-30
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FSG2 User Manual

Section 5 - Assembly .......................................................5-1
5.1 Typical FUSION SERIES®G2 Systems..............................................................5-1
5.1.1 FUSION SERIES®G2 Drop-in System......................................................5-3
5.1.2 FUSION SERIES®G2 Lite System............................................................5-3
5.2 Gate Seal Finishing ............................................................................................5-4
5.2.1 Hot Valve / Hot Sprue / F Type ..................................................................5-4
5.3 Re-torque at Process Temperature ....................................................................5-5
5.4 Check Nozzle Core to Manifold Fit .....................................................................5-5
5.5 Assemble Nozzle to Manifold .............................................................................5-7
5.6 Nozzle Assembly for Systems with Protective Sleeves ......................................5-8
5.6.1 Heater Retaining Clip Installation ............................................................5-11
5.7 Nozzle Assembly for Systems without Protective Sleeves ...............................5-13
5.7.1 Install Nozzle Heaters and Sleeves.........................................................5-13
5.7.2 Install Thermocouple ...............................................................................5-13
5.7.3 Install Thermocouple onto Nozzle Body (Optional) .................................5-14
5.7.4 Install the Thermocouple onto the Nozzle Body (F3000/4000 nozzles) ..5-15
5.7.5 Heater Retaining Clip Installation ............................................................5-16
5.7.6 Flange Nozzle Assembly .........................................................................5-17
5.8 Gate Seal and Nozzle Assembly ......................................................................5-19
5.8.1 Check Gate Seal to Nozzle Fit.................................................................5-19
5.8.2 Assemble Gate Seals to Nozzle ..............................................................5-20
5.9 Install Manifold Locator.....................................................................................5-21
5.10 Install Support Bushings.................................................................................5-21
5.11 Install Manifold Thermocouple........................................................................5-23
5.12 Install Inlet ......................................................................................................5-24
5.12.1 Install Inlet Thermocouple......................................................................5-26
5.12.2 Install Inlet Extension Tip .......................................................................5-26
5.13 Install Valve Insert or Valve Disk.....................................................................5-28
5.13.1 Install Valve Insert (Valve Insert Design) ...............................................5-28
5.13.2 Install Valve Disk (Valve Disk Design) ...................................................5-31
5.14 Install Cylinder on Manifold ............................................................................5-33
5.14.1 Pneumatic System.................................................................................5-33
5.14.2 Hydraulic System...................................................................................5-38
5.15 Waterless Hydraulic and Pneumatic Actuator Systems..................................5-40
5.16 Install Wiring ...................................................................................................5-45
5.16.1 Install Wire Armor to Manifold................................................................5-45
5.16.2 Install Wiring ..........................................................................................5-46
5.16.3 Electrical Routing into Electrical Box .....................................................5-46
5.16.4 Solenoid Valve Wiring............................................................................5-47
5.17 Connect Solenoid Valve Bank ........................................................................5-50
5.17.1 Hydraulic Valvebank Connection ...........................................................5-50
5.17.2 Pneumatic Valve Bank Connection........................................................5-51
5.18 Install Hydraulic Flow Control Valve ...............................................................5-52
5.19 Install Actuator Position Sensor......................................................................5-54
5.20 Water Cooled Gate Insert Installation.............................................................5-59
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FSG2 User Manual

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 FUSION SERIES® Systems .........................................6-1
6.4 SeVG Plus Models .............................................................................................6-2
6.4.1 SE40-20 Actuator - Non Cooled ................................................................6-2
6.4.2 SE40-20C Actuator - Cooled .....................................................................6-3
6.5 Manifold Mounted Systems ................................................................................6-4
6.5.1 SE40-20 Model..........................................................................................6-4
6.5.2 SE40-20C Model .......................................................................................6-5
6.6 SeVG Plus in Manifold Mounted Systems..........................................................6-6
6.7 Assembly and Installation ...................................................................................6-7
6.8 Disassembly .....................................................................................................6-12
Section 7 - Electrical Testing...........................................7-1
7.1 Safety .................................................................................................................7-1
7.2 Electrical Wiring Check.......................................................................................7-1
7.3 Electrical Safety Testing .....................................................................................7-2
7.3.1 Verify Equipment to its Technical Documentation......................................7-2
7.3.2 Insulation Resistance Test.........................................................................7-2
7.3.3 Verication of Conditions for Protection by Automatic Disconnection of Supply
7-2
7.3.4 Verication of Continuity of Protective Bonding Circuit..............................7-2
7.3.5 Verication of Fault Loop Impedance ........................................................7-3
7.4 Thermocouple Continuity Test ............................................................................7-3
7.5 Pinch Point Test..................................................................................................7-3
7.6 Heating Element Check......................................................................................7-4
7.7 Thermocouple Wiring Guidelines .......................................................................7-4
7.8 Functional Test with a Temperature Controller ...................................................7-4
7.9 Retesting ............................................................................................................7-4
Section 8 - System Installation........................................8-1
8.1 Unpacking...........................................................................................................8-1
8.2 Pre-Installation....................................................................................................8-2
8.3 Install Manifold Locator Dowel............................................................................8-2
8.4 System Installation .............................................................................................8-3
8.4.1 Installation of a System with Flanged Nozzles ..........................................8-4
8.5 System Test ........................................................................................................8-5
Section 9 - System Startup and Shutdown ....................9-1
9.1 Pre-Startup .........................................................................................................9-1
9.2 Startup ................................................................................................................9-2
9.2.1 Shutdown...................................................................................................9-3
Section 10 - Color Change............................................ 10-1
10.1 Introduction.....................................................................................................10-1
10.2 Color Change for a Hot Tip / Sprue System ...................................................10-1
10.3 Color Change for a Valve Gate System..........................................................10-2
10.4 Locating a Source of Contamination ..............................................................10-2
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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
FSG2 User Manual

Section 11 - Maintenance...............................................11-1
11.1 Recommended Torque Settings......................................................................11-1
11.2 Tubular Heater Installation and Replacement.................................................11-3
11.2.1 Storage ..................................................................................................11-3
11.2.2 Removing a Heater Element..................................................................11-3
11.2.3 Installing a New Heater Element............................................................ 11-3
11.2.4 New Heater Startup ............................................................................... 11-6
11.3 Solenoid Valve Bank.......................................................................................11-6
11.3.1 Hydraulic Solenoid Valve Bank ..............................................................11-6
11.3.2 Components of a Hydraulic Solenoid Valve Bank.................................. 11-7
11.3.3 Pneumatic Solenoid Valve Bank ............................................................11-9
11.3.4 Components of a Hydraulic Solenoid Valve Bank.................................. 11-9
11.4 Recommended Spare Parts .........................................................................11-13
Section 12 - Troubleshooting ....................................... 12-1
12.1 Introduction.....................................................................................................12-1
12.2 Moisture Related Issues .................................................................................12-2
12.2.1 Resin Moisture Contamination...............................................................12-2
12.2.2 Resin Drying Issues...............................................................................12-2
12.2.3 Importance of Pre-Drying Resin ............................................................12-2
12.3 Pre-Molding Precautions ................................................................................12-3
12.4 Establishing Root Cause ................................................................................12-4
12.4.1 Fault Identication..................................................................................12-4
12.5 Troubleshooting Typical Problems..................................................................12-5
12.5.1 Dark Specks ..........................................................................................12-5
12.5.2 Blisters or Bubbles.................................................................................12-6
12.5.3 Flow Marks ............................................................................................12-7
12.5.4 Burn Marks ............................................................................................12-8
12.5.5 Delaminating Parts ................................................................................12-9
12.5.6 Dimensional Irregularities ....................................................................12-10
12.5.7 Discolored Parts ..................................................................................12-11
12.5.8 Flash....................................................................................................12-12
12.5.9 Jetting ..................................................................................................12-13
12.5.10 Pitted Parts ........................................................................................12-14
12.5.11 Rough Surface ...................................................................................12-15
12.5.12 Parts Sticking to Cavity......................................................................12-16
12.5.13 Parts Sticking to Core........................................................................12-17
12.5.14 Short Parts.........................................................................................12-18
12.5.15 Sinks or Voids ....................................................................................12-19
12.5.16 Splay..................................................................................................12-20
12.5.17 Streaks...............................................................................................12-21
12.5.18 Stringing.............................................................................................12-22
12.5.19 Warped Parts.....................................................................................12-23
12.5.20 Weld Lines.........................................................................................12-24
Index ......................................................................................I
Section 13 - Index.................................................................I
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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
FSG2 User Manual

List of Tables
Table 1-1 Release Details.........................................................................................1-1
Table 1-2 Units of Measure and Conversion Factors ...............................................1-3
Table 3-1 Safety Hazards .........................................................................................3-3
Table 3-2 Typical Safety Symbols.............................................................................3-7
Table 3-3 Energy Forms, Energy Sources and General
Lockout Guidelines ...........................................................................................3-11
Table 4-1 Valve Pin and Spacer Combinations ......................................................4-16
Table 5-1 Typical Contact Length .............................................................................5-4
Table 6-1 SEVG Plus Actuator Models .....................................................................6-1
Table 6-2 FUSION SERIES® Systems: SeVG Plus Actuator
Selection.............................................................................................................6-1
Table 11-1 Recommended Torque Settings............................................................ 11-2
Table 11-2 Actuator Spare Seal Kits .....................................................................11-13
Table 11-3 Nozzle Spring Clip ..............................................................................11-13
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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
FSG2 User Manual

List of Figures
Figure 3-1 Injection molding machine hazard areas.................................................3-2
Figure 4-1 Screw length ...........................................................................................4-1
Figure 4-2 Hydraulic cylinder components ...............................................................4-3
Figure 4-3 Pneumatic cylinder components .............................................................4-9
Figure 4-4 Waterless pneumatic components ........................................................4-14
Figure 4-5 Install piston seals and guide ring .........................................................4-15
Figure 4-6 Install valve pin and spacers .................................................................4-15
Figure 4-7 Install O-ring for rod seal.......................................................................4-18
Figure 4-8 Install rod seal .......................................................................................4-18
Figure 4-9 Rod seal assembly................................................................................4-19
Figure 4-10 Install O-ring for wiper seal .................................................................4-19
Figure 4-11 Install wiper seal..................................................................................4-19
Figure 4-12 Rod seal and wiper seal assemblies...................................................4-20
Figure 4-13 Install the piston ..................................................................................4-21
Figure 4-14 Install the top seal ...............................................................................4-21
Figure 4-15 Assembled cylinder - note ports ..........................................................4-22
Figure 4-16 Install piston seals and guide ring .......................................................4-23
Figure 4-17 Anti rotation dowel...............................................................................4-23
Figure 4-18 Install valve pin and spacers ...............................................................4-24
Figure 4-19 Anti rotation version: install the piston.................................................4-24
Figure 4-20 Anti rotation version: install the top seal..............................................4-25
Figure 4-21 Anti rotation version: assembled cylinder............................................4-25
Figure 5-1 FUSION SERIES®G2 system with thread nozzle...................................5-1
Figure 5-2
FUSION SERIES® G2 ange nozzle...................................................................5-1
Figure 5-3 FUSION SERIES®G2 hydraulic system .................................................5-2
Figure 5-4 FUSION SERIES®drop-in system ..........................................................5-3
Figure 5-5 FUSION SERIES®lite system.................................................................5-3
Figure 5-6 Example contact length “H”.....................................................................5-4
Figure 5-7 Completed protective sleeve assembly.................................................5-12
Figure 5-8 Nozzle center guiding ring.....................................................................5-15
Figure 5-9 Pneumatic actuator mounted on top of valve disk ange......................5-35
Figure 5-10 Hydraulic actuator mounted on top of valve disk ange......................5-36
Figure 5-11 Waterless actuator models: valve disk and
valve insert........................................................................................................5-38
Figure 5-12 Install valve insert or valve disk...........................................................5-38
Figure 5-13 Valve insert design: install support pillars ...........................................5-38
Figure 5-14 Valve disk design: install support pillars..............................................5-39
Figure 5-15 Screw shoulder bolts into support pillar ..............................................5-40
Figure 5-16 Torque shoulder bolts..........................................................................5-40
Figure 5-17 Check tooling pocket...........................................................................5-41
Figure 5-18 Bolt clamp plate...................................................................................5-42
Figure 5-19 Hydraulic ow control valve - connections ..........................................5-50
Figure 5-21 Actuator with position sensor ..............................................................5-51
Figure 5-20 Top sensor mounting assembly installation.........................................5-54
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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
FSG2 User Manual

Figure 6-1 SE40-20 actuator ....................................................................................6-2
Figure 6-2 SE40-20C actuator..................................................................................6-3
Figure 6-3 SE40-20 actuator ....................................................................................6-4
Figure 6-4 SE40-20C actuator..................................................................................6-5
Figure 6-5 SE40-20 actuator in a manifold mounted system ...................................6-6
Figure 6-6 Bulkhead connectors and template.........................................................6-7
Figure 6-7 Motor rod ats .........................................................................................6-8
Figure 6-8 Valve pin holder components ..................................................................6-9
Figure 6-9 Motor locating spigot ...............................................................................6-9
Figure 6-10 Insert the screws to fasten the assembly ............................................6-10
Figure 6-11 Place cables into insulated sheath ......................................................6-10
Figure 6-12 Attach cables to wiring channel...........................................................6-11
Figure 6-13 Remove B screws ...............................................................................6-13
Figure 11-1 Pressure reducing and relieving valve ................................................11-7
Figure 11-2 Manometer mounting port ................................................................... 11-8
Figure 11-3 Solenoid connector.............................................................................. 11-9
Figure 11-4 Manual override switch...................................................................... 11-12
List of Figures
vii
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
FSG2 User Manual

The purpose of this manual is to assist users in the integration, operation
and maintenance of Mold-Masters systems. 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
FUSION SERIES®G2 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.
• 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
Table 1-1 Release Details
Document Number Release Date Version
FSG2-UM-EN-00-13-2 July 2019 13-2
FSG2-UM-EN-00-13-3 January 2020 13-3
FSG2-UM-EN-00-13-4 June 2020 13-4
FSG2-UM-EN-00-14 July 2020 14
FSG2-UM-EN-00-14-1 September 2020 14-1
Section 1 - Introduction
1-1
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
FSG2 User Manual

1.4 Warranty
For current warranty information please refer to the documents available from
our website: https://www.milacron.com/mold-masters-warranty/ or contact
your Mold-Masters representative.
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.
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.
1-2
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
FSG2 User Manual

1.7 Copyright
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Mold-Masters®
and the Mold-Masters logo are trademarks of Mold-Masters.
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
1-3
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
FSG2 User Manual

1.9 Trademarks and Patents
ACCU-VALVE, DURA, E-MULTI, FLEX-DURA FLEX-SERIES, FUSION SERIES®-SERIES,
HOT EDGE, MASTERPROBE, MASTER-SHOT, MOLD-MASTERS, MELT-DISK, MOLD-
MASTERS ACADEMY, MASTER-SERIES, MASTERSOLUTION, MASTERSPEED, MERLIN,
MOLD-MASTERS SYSTEM, MPET, STACK-LINK, are the registered trademarks of MOLD-
MASTERS (2007) LIMITED.
Information contained herein is, to our best knowledge, true and accurate, but all
recommendations or suggestions are made without guarantee. Since the conditions of
use are beyond our control, Mold-Masters disclaims any liability incurred in connection
with the use of our products and information contained herein. No person is authorized to
make any statement or recommendation not contained herein, and any such statement or
recommendation so made shall not bind Mold-Masters. Furthermore, nothing contained herein
shall be construed as a recommendation to use any product in conict with existing patents
covering any products or its use, and no license implied or in fact granted herein under the
claims of any patents.
No part of this publication may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopy, recording, or any information storage and
retrieval system without permission in writing from the publisher. All details, standards
and specications may be altered in accordance with technical development without prior
notication.
May be manufactured under one or more of the following U.S. Patents:
5421716, 5427519, 5429491, 5437093, 5441197, 5443381, 5460510, 5474440, 5494433, 5496168,
5507635, 5507636, 5536165, 5591465, 5599567, 5614233, 5641526, 5644835, 5652003, 5658604,
5695793, 5700499, 5704113, 5705202, 5707664, 5720995, 5792493, 5795599, 5820899, 5843361,
5849343, 5853777, 5935615, 5935616, 5935621, 5942257, 5952016, 5980236, 6009616, 6017209,
6030198, 6030202, 6062841, 6074191, 6077067, 6079972, 6095790, 6099780, 6113381, 6135751,
6162043, 6162044, 6176700, 6196826, 6203310, 6230384, 6270711, 6274075, 6286751, 6302680,
6318990, 6323465, 6348171, 6350401, 6394784, 6398537, 6405785, 6440350, 6454558, 6447283,
6488881, 6561789, 6575731, 6625873, 6638053, 6648622, 6655945, 6675055, 6688875, 6701997,
6739863, 6752618, 6755641, 6761557, 6769901, 6776600, 6780003, 6789745, 6830447, 6835060,
6840758, 6852265, 6860732, 6869276, 6884061, 6887418, 6890473, 6893249, 6921257, 6921259,
6936199, 6945767, 6945768, 6955534, 6962492, 6971869, 6988883, 6992269, 7014455, 7018197,
7022278, 7025585, 7025586, 7029269, 7040378, 7044191, 7044728, 7048532, 7086852, 7105123,
7108502, 7108503, 7115226, 7118703, 7118704, 7122145, 7125242, 7125243, 7128566, 7131832,
7131833, 7131834, 7134868, 7137806, 7137807, 7143496, 7156648, 7160100, 7160101, 7165965,
7168941, 7168943, 7172409, 7172411, 7175419, 7175420, 7179081, 7182591, 7182893, 7189071,
7192268, 7192270, 7198740, 7201335, 7210917, 7223092, 7238019, 7244118, 7252498, 7255555,
7258536, 7270538, 7303720, 7306454, 7306455, 7314367, 7320588, 7320589, 7320590, 7326049,
7344372, 7347684, 7364425, 7364426, 7370417, 7377768, 7381050, 7396226, 7407379, 7407380,
7410353, 7410354, 7413432, 7416402, 7438551, 7462030, 7462031, 7462314, 7465165, 7470122,
7507081, 7510392, 7513771, 7513772, 7517214, 7524183, 7527490, 7544056, 7547208, 7553150,
7559760, 7559762, 7565221, 7581944, 7611349, 7614869, 7614872, 7618253, 7658605, 7658606,
7671304, 7678320, 7686603, 7703188, 7713046, 7722351, 7731489, 7753676, 7766646, 7766647,
7775788, 7780433, 7780434, 7794228, 7802983, 7803306, 7806681, 7824163, 7845936, 7850442,
7874833, 7877163, 7891969, 7918660, 7918663, 7931455, 7963762, 7988445, 7998390, 8062025,
8066506, 8113812, 8142182, 8152513, 8167608, 8202082, 8206145, 8210842, 8241032, 8280544,
8282386, 8308475, 8308476, 8328546, 8353697, 8414285, 8425216, 8449287, 8465688, 8469687,
8475155, 8475158, 8480391, 8568133, 8690563, 8715547, D525592, RE38265, RE38396, RE38920,
RE39935, RE40478, RE40952, RE41536E, RE41648E+ Pending.
© 2019 MOLD-MASTERS (2007) LIMITED, ALL RIGHTS RESERVED
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INTRODUCTION
FSG2 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]
INDIA
Mold-Masters Technologies Private
Limited
# 247, Alagesan Road,
Shiv Building, Saibaba Colony.
Coimbatore T. N.
India 641 011
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 and South
East 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]
[email protected]
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 ElMarques
El Marques, Queretaro C.P. 76246
Mexico
tel: [phone] (sales)
tel: [phone] (service)
[email protected]
2-1
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GLOBAL SUPPORT
FSG2 User Manual

Corporate Ofces - continued
2.2 International Representatives
Mold-Masters Regional Offices (cont.)
SPAIN
Ferromatik Milacron /
Mold Masters Europa GmbH
C/. Enric Morera, 7
Polig. Ind. Foinvasa
08110 Montcada i Reixac
Barcelona, Spain
tel: [phone]
fax: [phone]
[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]
[e-mail]
2-2
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
GLOBAL SUPPORT
FSG2 User Manual

Section 3 - Safety
3.1 Operator Training and 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 such
items as 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.
3-1
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
FSG2 User Manual

3.2 Safety Hazards
WARNING
Also 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 Safety
Hazards Table 3-1 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
3-2
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
FSG2 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
3-3
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
FSG2 User Manual

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
3-4
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
FSG2 User Manual