Mold-Masters Hot Runner User manual

Hot Runner
User Manual
version 32
Original Instructions

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 ............................................................................................................1-2
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 Overview.............................................................................................................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 Hot Runner Safety Hazards..............................................................................3-13
Section 4 - Preparation ....................................................4-1
4.1 Tools Required....................................................................................................4-1
4.2 Screws ...............................................................................................................4-2
4.2.1 Length........................................................................................................4-2
4.2.2 Grade.........................................................................................................4-2
4.3 Torque Settings...................................................................................................4-3
4.3.1 Master-Series Gate Seals..........................................................................4-3
4.3.2 Summit-Series Gate Seals ........................................................................4-3
4.3.3 Dura Gate Seals ........................................................................................4-3
4.3.4 Others........................................................................................................4-4
4.4 Unpacking...........................................................................................................4-5
4.5 Cleaning .............................................................................................................4-5
4.6 Overview of System Types .................................................................................4-6
4.6.1 Non-Valved System ...................................................................................4-6
4.6.2 Valve Gate System ....................................................................................4-7
4.6.3 Valve Gate System with Bridge .................................................................4-8
4.6.4 Non-Valved System with MasterShield Technology...................................4-9
4.6.5 Valved System with MasterShield Technology ........................................4-10
4.7 System Cutaways...............................................................................................5-1
4.7.1 Brazed-in/Paste-in System ........................................................................5-1
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4.7.2 Bolt-in System............................................................................................5-2
4.7.3 MasterShield System.................................................................................5-3
Section 5 - Assembly .......................................................5-4
5.1 Finishing a Gate Seal .........................................................................................5-4
5.2 Installing a Water-Cooled Gate Insert.................................................................5-4
5.3 Thermocouples...................................................................................................5-5
5.3.1 Installing a Master Series-style Thermocouple..........................................5-5
5.3.2 Installing a Dura Line Thermocouple.........................................................5-8
5.3.3 Removing a Non-Front Mounted Thermocouple .....................................5-10
5.4 Installing a Nozzle ............................................................................................5-11
5.4.1 Master-Series and Dura Lines.................................................................5-11
5.4.2 MasterShield Centi, Deci, and Pico .........................................................5-12
5.4.3 MasterShield Femto.................................................................................5-15
5.5 Installing a Nozzle Step ....................................................................................5-19
5.6 Nozzle Wire Layout ..........................................................................................5-20
5.6.1 Back Mounted Thermocouples................................................................5-20
5.6.2 Front Mounted Thermocouples................................................................5-20
5.7 Installing a Valve Bushing.................................................................................5-21
5.7.1 Types .......................................................................................................5-21
5.7.2 Installing...................................................................................................5-21
5.8 Mounting a Manifold .........................................................................................5-23
5.8.1 Manifold Locator ......................................................................................5-24
5.8.2 Manifold Locating Dowel Pin ...................................................................5-25
5.8.3 Installing a Manifold Thermocouple.........................................................5-26
5.9 Mounting a Main Manifold ................................................................................5-27
5.9.1 Installing an Inlet Seal..............................................................................5-27
5.9.2 Installing a Manifold Step.........................................................................5-28
5.10 Installing a Pressure Disk or a Valve Disk in a Master-Series System...........5-28
5.10.1 Pressure Disk: Final Grinding Required ................................................5-29
5.10.2 Installing a Pressure Disk ......................................................................5-31
5.10.3 Pressure Disk: Final Grinding Not Required..........................................5-31
5.10.4 Installing a Valve Disk............................................................................5-32
5.11 Installing a support bushing or a valve disk in a MasterShield System ..........5-33
5.11.1 Installing a Support Bushing ..................................................................5-33
5.11.2 Installing a Valve Disk ............................................................................5-34
5.12 Installing a Heater Plate .................................................................................5-36
5.13 Installing Inlet Components ............................................................................5-38
5.13.1 Unheated Back Plate.............................................................................5-38
5.13.2 Heated Back Plate.................................................................................5-39
5.13.3 Center Heater (Direct mount) ................................................................5-40
5.13.4 Center Heater (Indirect mount)..............................................................5-41
5.13.5 Inlet Extension .......................................................................................5-42
5.13.6 Inlet Extension with Pressure Sleeves...................................................5-43
5.14 Slimstack Actuator ..........................................................................................5-44
5.15 Hydraulic and Pneumatic Actuators................................................................5-45
5.15.1 Valve Actuator Assembly .......................................................................5-45
5.15.2 Pre-Installation.......................................................................................5-46
5.15.3 Assembling a Cylinder Bottom...............................................................5-46
5.15.4 Piston Assembly ....................................................................................5-47
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Hot Runner User Manual

5.15.4.1 5500 Series .............................................................................5-47
5.15.4.2 6X00 and 7100 Series .............................................................5-47
5.15.5 Assembling a Cylinder Top ....................................................................5-48
5.15.6 Finishing the Tip of a Valve Pin..............................................................5-48
5.15.6.1 5500 Series .............................................................................5-48
5.15.6.2 6X00 Series .............................................................................5-50
5.15.6.3 7100 Series .............................................................................5-50
5.15.6.4 8X00 Series .............................................................................5-52
5.15.6.5 8600—AR Series.....................................................................5-53
5.15.7 Lapping a Tapered Valve Pin—5500 and 6X00 Series.........................5-54
5.15.8 Finishing the Head of a Valve Pin—5500 Series ..................................5-55
5.16 Valve Pin Assembly ........................................................................................5-56
5.16.1 5500 Series............................................................................................5-56
5.16.2 6X00 Series ...........................................................................................5-56
5.16.3 7100 Series............................................................................................5-57
5.17 Installing a Valve Actuator in a Hydraulic Plate ..............................................5-58
5.17.1 5500 Series............................................................................................5-58
5.17.2 6X00 Series ...........................................................................................5-59
5.18 Installing a Hydraulic Limit-Switch Option—6500 and 6600 Series................5-60
5.18.1 Installing a Proximity Sensor .................................................................5-61
5.18.2 Cutout Options Based on Stroke ...........................................................5-62
5.19 Testing the Proximity Sensor of a Hydraulic Limit-Switch Option ...................5-63
5.20 SeVG Plus Actuator........................................................................................5-64
5.21 E-Drive............................................................................................................5-65
5.21.1 Typical System.......................................................................................5-65
5.21.2 Components ..........................................................................................5-67
5.21.3 Safety.....................................................................................................5-68
5.21.4 Assembly ...............................................................................................5-69
5.21.5 Attaching a Hot Runner Assembly .........................................................5-70
5.21.6 Attaching a Plate Assembly ...................................................................5-70
5.21.7 Assembling a Synchro-Plate..................................................................5-71
5.21.8 Preparing a Ball Screw ..........................................................................5-72
5.21.9 Lubricating a Ball Screw ........................................................................5-72
5.21.10 Assembling a Ball Screw .....................................................................5-73
5.21.11 Maintaining a Ball-Screw .....................................................................5-74
5.21.12 Assembling a Top Plate .......................................................................5-74
5.21.13 Attaching a Synchro-Plate to a Top Plate Assembly ............................5-74
5.21.14 Assembling a Tension Belt...................................................................5-74
5.21.15 Assembling an Insulation Plate and a Locating Ring...........................5-77
5.21.16 Doing E-Drive Controller Checks.........................................................5-78
5.21.17 Installing a Hot Half in a Mold..............................................................5-78
5.21.18 Installing or Replacing a Belt ...............................................................5-78
5.21.19 Doing a Check for Misalignment..........................................................5-80
5.22 Mag-Pin Option...............................................................................................5-81
5.22.1 Assembly ...............................................................................................5-82
5.22.2 Safety.....................................................................................................5-82
5.22.3 Operation...............................................................................................5-83
5.22.4 Handling Magnets..................................................................................5-85
5.22.5 Summary of the Assembly Procedure ...................................................5-86
5.22.6 Assembling ............................................................................................5-86
5.22.6.1 Placing a Magnet on Top of the Magnet Retainer ...................5-86
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5.22.6.2 Checking the Polarity of a Magnet...........................................5-87
5.22.6.3 Cleaning a Magnet Holder.......................................................5-87
5.22.6.4 Installing a Magnetic Retainer in a Magnet Holder..................5-88
5.22.6.5 Placing a Magnet Holder and Magnet into a Housing .............5-88
5.22.6.6 Assembling a Nut and a Lock Magnet Holder .........................5-89
5.22.6.7 Installing a Valve Pin in a Valve Pin Holder .............................5-89
5.22.6.8 Installing an O-Ring in a Valve Pin Holder...............................5-90
5.22.6.9 Installing a Valve Pin in a Housing Assembly ..........................5-90
5.22.6.10 Installing a Mag-Pin Assembly in a Synchro-Plate ................5-91
5.23 Single Nozzle Valve System (Accu-Line) .......................................................5-92
5.23.1 Centi Accu-Line with Valve Bushing ......................................................5-92
5.23.1.1 Pre-Assembly ..........................................................................5-93
5.23.1.2 Assembling an Accu-Line System ...........................................5-93
5.23.2 Deci and Hecto Accu-Line with Valve Insert ........................................5-100
5.23.2.1 Pre-Assembly ........................................................................5-101
5.23.2.2 Assembling an Accu-Line System .........................................5-102
5.24 TIT Edge-Gated System ...............................................................................5-113
5.24.1 Removing TIT Edge Gate Seals ..........................................................5-113
5.25 Melt-Disk System..........................................................................................5-114
5.25.1 Identifying a Reverse Melt-Link ...........................................................5-114
5.25.2 Example...............................................................................................5-115
5.25.3 Preparing and Cleaning.......................................................................5-116
5.25.4 Assembling a Melt-Disk Thermocouple ...............................................5-118
5.25.5 Installing a Melt Disk in a Nozzle.........................................................5-120
5.25.5.1 Reverse Two-Piece Melt-Link................................................5-120
5.25.5.2 One-piece Melt-Link ..............................................................5-121
5.25.6 Optional Quick Disconnect Terminal Ends...........................................5-122
5.25.6.1 Crimping the Quick Disconnects ...........................................5-123
5.26 Melt-Cube Systems ......................................................................................5-124
5.26.1 Identifying Your Melt-Cube Design ......................................................5-124
5.26.2 Melt-Cube Design A (Angled version)..................................................5-124
5.26.3 Melt-Cube Design B (Horizontal version) ............................................5-125
5.26.4 Example...............................................................................................5-126
5.26.5 Melt-Cube Design A.............................................................................5-127
5.26.5.1 Gate Seal Assembly ..............................................................5-128
5.26.5.2 Maintenance Toolkit ...............................................................5-128
5.26.5.3 Dual Nozzle Assembly...........................................................5-129
5.26.5.4 Inspecting ..............................................................................5-129
5.26.5.5 Cleaning ................................................................................5-129
5.26.5.6 Assembling a Melt-Cube Thermocouple................................5-130
5.26.5.7 Assembling a Ground Wire....................................................5-130
5.26.5.8 Installing a Melt Transfer Link................................................5-131
5.26.5.9 Installing in a Cavity Block.....................................................5-132
5.26.5.10 Assembling (Cold Condition) ...............................................5-132
5.26.5.11 Retightening Wedge Screws (Hot Condition) ......................5-137
5.26.5.12 Replacing a Transfer-Seal/Torpedo .....................................5-139
5.26.6 Melt-Cube Design B.............................................................................5-142
5.26.6.1 Components ..........................................................................5-142
5.26.6.2 Maintenance Toolkit ...............................................................5-143
5.26.6.3 Inspecting ..............................................................................5-143
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Hot Runner User Manual

5.26.6.4 Cleaning ................................................................................5-144
5.26.6.5 Installing a Thermocouple......................................................5-145
5.26.6.6 Attaching a Ground Wire .......................................................5-146
5.26.6.7 Installing a Melt Transfer Link ...............................................5-146
5.26.6.8 Assembling ............................................................................5-148
5.26.6.9 Installing Gate Seals and Cavity Inserts................................5-151
5.26.6.10 Installing a Melt Block..........................................................5-152
5.26.6.11 Disassembling a Transfer-Seal/Torpedo and a Melt Block ..5-153
5.26.6.12 Installing a Melt-Cube in a Cavity Block ..............................5-155
Section 6 - Hot Half Assembly.........................................6-1
6.1 Assembling a Hot Half ........................................................................................6-1
6.2 Installing a Stack Mold Cavity Plate ...................................................................6-3
Section 7 - Electrical Testing...........................................7-1
7.1 Safety .................................................................................................................7-1
7.2 Doing a Check of the Electrical Wiring ...............................................................7-2
7.3 Electrical Safety Testing .....................................................................................7-2
7.3.1 Doing a Check of Equipment.....................................................................7-2
7.3.2 Doing a Test of the Insulation Resistance.................................................7-2
7.3.3 Doing a Test of the Conditions for Protection by Automatic Disconnection of
the Power Supply..........................................................................................7-3
7.3.4 Doing a Test of the Continuity of the Protective Bonding Circuit ...............7-3
7.3.5 Doing a Test of the Impedance of the Fault Loop......................................7-3
7.3.6 Doing a Test of the Continuity of a Thermocouple.....................................7-4
7.3.7 Doing a Pinch Point Test............................................................................7-4
7.3.8 Doing a Check of the Heating Element......................................................7-4
7.3.9 Doing a Test of the Continuity of the Ungrounded Thermocouple .............7-5
7.4 Thermocouple Wiring Guidelines .......................................................................7-5
7.5 Doing a Functional Test with a Temperature Controller ......................................7-5
7.6 Re-testing ...........................................................................................................7-5
Section 8 - System Startup and Shutdown ....................8-1
8.1 Pre-Startup .........................................................................................................8-1
8.2 Startup ................................................................................................................8-2
8.2.1 Standard Hot Runner Systems..................................................................8-2
8.2.2 Stack Mold Systems ..................................................................................8-3
8.2.3 Melt-Disk ...................................................................................................8-3
8.2.3.1 Melt-Link ......................................................................................8-3
8.2.3.2 Reverse Melt-Link........................................................................8-4
8.2.4 Melt Cube ..................................................................................................8-5
8.3 Shutdown............................................................................................................8-6
8.3.1 Standard Hot Runner Systems..................................................................8-6
8.3.2 Stack Mold Systems ..................................................................................8-6
8.3.2.1 Shutdown manifolds, submanifolds, inlets and nozzles. .............8-6
8.3.3 Melt-Disk....................................................................................................8-6
8.3.3.1 Melt Link ......................................................................................8-7
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Hot Runner User Manual
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8.3.3.2 Reverse Melt Link........................................................................8-7
8.3.4 Melt-Cube ..................................................................................................8-7
Section 9 - Color Change.................................................9-1
9.1 General Tips .......................................................................................................9-1
9.2 Procedure A: Simple and E󰀨ective .....................................................................9-1
9.3 Procedure B: Comprehensive ............................................................................9-2
Section 10 - Maintenance.............................................. 10-1
10.1 Valve Disks .....................................................................................................10-1
10.1.1 Removing a 1-piece Valve Disk .............................................................10-2
10.1.2 Removing a 2-piece Valve Disk .............................................................10-4
10.1.3 Overview of Valve Disk Extraction Tools................................................10-6
10.2 Terminal Ends .................................................................................................10-8
10.2.1 Removing...............................................................................................10-8
10.2.2 Installing.................................................................................................10-8
10.2.3 Assembling ............................................................................................10-9
10.3 Heater Plates................................................................................................10-11
10.3.1 Removing Power Leads.......................................................................10-11
10.3.2 Installing Power Leads.........................................................................10-12
10.4 Gate Seals....................................................................................................10-12
10.4.1 Heating the System .............................................................................10-12
10.4.2 Removing.............................................................................................10-13
10.4.3 Replacing.............................................................................................10-14
10.5 Nozzle Tips ...................................................................................................10-16
10.5.1 Checking the Height of a Nozzle Tip....................................................10-16
10.6 Melt-Disk/Melt-Cube .....................................................................................10-17
10.6.1 Disassembling the Melt Link................................................................10-17
10.6.2 Disassembling the Reverse Melt Link..................................................10-17
10.6.3 Reassembling the Melt-Disk/Melt-Cube ..............................................10-17
10.7 Actuators.......................................................................................................10-18
10.7.1 Extraction Tools for Hydraulic and Pneumatic Actuators .....................10-18
10.7.2 5500 Series, 6X00 Series, and 7100 Series........................................10-21
10.7.2.1 Hydraulic Systems.................................................................10-21
10.7.2.2 Pneumatic Systems...............................................................10-21
10.8 Extracting a Mag-Pin ....................................................................................10-23
10.9 Latches .........................................................................................................10-27
10.9.1 Latching a Cavity Plate to a Core Half (Cold Half)...............................10-27
10.9.2 Latching a Cavity Plate to a Manifold Plate (Hot Half).........................10-29
Section 11 - Troubleshooting ........................................11-1
Section 12 - Glossary of Terms .................................... 12-1
Index ......................................................................................I
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Hot Runner User Manual

Section 1 - Introduction
The purpose of this manual is to assist users in the integration, operation and
maintenance of a 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 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 into 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
When ordering this manual, please reference the document number below.
Table 1-1 Release Details
Document Number Release Date Version
HR-UM-EN-00-30-1 July 2019 30-1
HR-UM-EN-00-30-6 September 2020 30-6
HR--UM--EN--00--31-3 June 2021 31-3
HR--UM--EN--00--32 December 2022 32
1-1INTRODUCTION
Hot Runner User Manual
© 2022 Mold-Masters (2007) Limited. All Rights Reserved.

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.
1.5 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.
1.7 Copyright
© 2022 Mold-Masters (2007) Limited. All Rights Reserved. Mold-Masters®
and the Mold-Masters logo are trademarks of Mold-Masters.
1-2
© 2022 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
Hot Runner 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
1-3INTRODUCTION
Hot Runner User Manual
© 2022 Mold-Masters (2007) Limited. All Rights Reserved.

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]
2-1GLOBAL SUPPORT
Hot Runner User Manual
© 2022 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]
Ukraine
Company Park LLC Gaydamatska
str., 3, office 116 Kemenskoe City
Dnipropetrovsk Region 51935,
Ukraine
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]
South Africa
Plastic & Chemical Trading (P&CT)
23 Orange Road
Johannesburg 2192
tel: [phone]
[email protected]
2-2
© 2022 Mold-Masters (2007) Limited. All Rights Reserved.
GLOBAL SUPPORT
Hot Runner 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.
3-1SAFETY
Hot Runner User Manual
© 2022 Mold-Masters (2007) Limited. All Rights Reserved.

3.1 Overview
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
3-2
© 2022 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
Hot Runner 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 Out-
side 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 ex-
truder 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.
3-3SAFETY
Hot Runner User Manual
© 2022 Mold-Masters (2007) Limited. All Rights Reserved.

Table 3-1 Safety Hazards
Hazard Area Potential Hazards
Feed Opening
See Figure 3-1 area 6
Pinching and crushing between injection screw movement and housing.
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 • Electric shock or burns due to contact with live conductive parts.
• 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.
3-4
© 2022 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
Hot Runner 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.
3-5SAFETY
Hot Runner User Manual
© 2022 Mold-Masters (2007) Limited. All Rights Reserved.

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.
3-6
© 2022 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
Hot Runner User Manual