Mold-Masters Sprint User manual

Hot Runner User Manual
Gen 2
User Manual
version 1
Original Instrucons

IMPORTANT
Before proceeding you must Identify your system. Using the wrong User Manual may result in
damage to your hot runner system.
There are two Sprint hot runner systems:
• Generation 1: Standard design 2019 or earlier (ID orders). Please refer to the Mold-Masters
Hot Runner User Manual.
• Generation 2: Standard design as of 2019 and later. Please refer to this Sprint User Manual
only.
This user manual focuses on Generation 2. Do not refer to any other user manual. Doing so may result
in performance issues and/or damage to your hot runner system.
How To Identify Your Sprint Generation 2 Hot Runner System
Identify MasterSHIELD Leak Protection Technology
Only Generation 2 Sprint hot runner systems are supplied with MasterSHIELD Leak Protection
Technology, which is a spring pack that sits on the nozzle ange. This can be identied by referencing
your GA drawings or by disassembling the hot runner system. If your Sprint hot runner system is
equipped with these components you have a Generation 2 system and you must use this user manual.

Contents
Section 1 - Introduction ...................................................1-1
1.1 Intended Use ......................................................................................................1-1
1.2 Documentation ...................................................................................................1-1
1.3 Release Details ..................................................................................................1-1
1.4 Warranty .............................................................................................................1-1
1.5 Returned Goods Policy.......................................................................................1-2
1.6 Movement or Resale of Mold-Masters Products or Systems .............................1-2
1.7 Copyright ............................................................................................................1-2
1.8 Units of Measure and Conversion Factors .........................................................1-3
Section 2 - Global Support ..............................................2-1
2.1 Corporate O󰀩ces................................................................................................2-1
2.2 International Representatives.............................................................................2-2
Section 3 - Safety..............................................................3-1
3.1 Safety Hazards ...................................................................................................3-2
3.2 Operational Hazards...........................................................................................3-5
3.3 General Safety Symbols.....................................................................................3-7
3.4 Wiring Check ......................................................................................................3-8
3.5 Lockout Safety....................................................................................................3-9
3.5.1 Electrical Lockout.....................................................................................3-10
3.5.2 Energy Forms and Lockout Guidelines....................................................3-11
3.6 Disposal............................................................................................................3-12
3.7 Hot Runner Safety Hazards..............................................................................3-13
Section 4 - Preparation ....................................................4-1
4.1 Tools Required....................................................................................................4-1
4.2 Screw Lengths....................................................................................................4-2
4.3 Unpacking...........................................................................................................4-3
4.4 Cleaning .............................................................................................................4-3
Section 5 - Assembly .......................................................5-1
5.1 System with a Sprint Nozzle...............................................................................5-1
5.2 Cutaway of a SPRINT System ...........................................................................5-2
5.3 Nozzle Insertion..................................................................................................5-3
5.3.1 Nozzle Insertion.........................................................................................5-3
5.4 Nozzle Wire Layout ............................................................................................5-7
5.4.1 Front Mounted Thermocouples..................................................................5-7
5.5 Optional Emergency Heater Sleeve ...................................................................5-8
5.5.1 Installation of Emergency Heater Sleeve...................................................5-8
5.5.2 Removal of Emergency Heater Sleeve....................................................5-11
5.6 Mount the Manifold ...........................................................................................5-12
5.6.1 Manifold Locator ......................................................................................5-13
5.6.2 Manifold Locating Dowel Pin ...................................................................5-14
5.6.3 Manifold and Slot Locator........................................................................5-14
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Sprint User Manual
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5.7 Manifold Thermocouple Installation..................................................................5-15
5.8 Main Manifolds .................................................................................................5-16
5.8.1 Inlet Seal Installation - Without Step.......................................................5-16
5.8.2 Inlet Seal Installation - With Step.............................................................5-17
5.9 Support Bushing Installation.............................................................................5-18
5.10 Inlet Components Installation .........................................................................5-19
5.10.1 Back Plate Installation ...........................................................................5-19
5.10.2 Center Heater Installation......................................................................5-20
5.10.3 Three-Piece Center-Heater Installation .................................................5-20
5.10.4 EcoDisk Installation ...............................................................................5-21
5.10.5 Clamp Plate Assembly (B-Screws) ........................................................5-22
5.11 Thermocouple Installation...............................................................................5-23
Section 6 - Electrical Testing...........................................6-1
6.1 Safety .................................................................................................................6-1
6.2 Electrical Wiring Check.......................................................................................6-2
6.3 Electrical Safety Testing .....................................................................................6-2
6.3.1 Verify Equipment to its Technical Documentation......................................6-2
6.3.2 Insulation Resistance Test ........................................................................6-2
6.3.3 Verication of Conditions for Protection by Automatic Disconnection of Supply
6-3
6.3.4 Verication of Continuity of Protective Bonding Circuit..............................6-3
6.3.5 Verication of Fault Loop Impedance ........................................................6-3
6.3.6 Thermocouple Continuity Test ...................................................................6-3
6.3.7 Pinch Point Test .........................................................................................6-4
6.3.8 Heating Element Check.............................................................................6-4
6.3.9 Ungrounded Thermocouple Continuity Test ..............................................6-5
6.4 Thermocouple Wiring Guidelines .......................................................................6-5
6.5 Functional Test with a Temperature Controller ...................................................6-5
6.6 Re-testing ...........................................................................................................6-5
Section 7 - Hot Half Assembly.........................................7-1
7.1 Hot Half Assembly ..............................................................................................7-1
Section 8 - System Startup and Shutdown ....................8-1
8.1 Pre-Startup .........................................................................................................8-1
8.2 Startup ................................................................................................................8-2
8.3 Shutdown............................................................................................................8-3
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: More Comprehensive ...................................................................9-2
Section 10 - Maintenance.............................................. 10-1
10.1 Terminal End Removal and Installation ..........................................................10-2
10.1.1 Terminal End Removal...........................................................................10-2
10.1.2 Terminal Installation ...............................................................................10-2
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Sprint User Manual

10.1.3 Terminal Assembly.................................................................................10-3
10.2 Gate Seal Maintenance ..................................................................................10-6
10.2.1 Nozzle Tip Removal...............................................................................10-7
10.3 Nozzle Tip Installation.....................................................................................10-8
10.4 Clean the Nozzle Insulator Cap......................................................................10-9
10.5 Install the Nozzle Insulator Cap......................................................................10-9
10.6 Check Nozzle Tip Height ..............................................................................10-10
10.7 Latches .........................................................................................................10-11
10.8 Latch the Cavity Plate to the Core Half (Cold Half) ......................................10-11
10.9 Latch the Cavity Plate to the Manifold Plate (Hot Half) ................................10-13
10.10 Torque Settings...........................................................................................10-15
10.10.1 Torque Settings of Gate Seals ...........................................................10-15
10.10.2 System and Plate Screw Torques......................................................10-16
Section 11 - Troubleshooting ........................................11-1
Section 12 - Glossary of Terms .................................... 12-1
Index ......................................................................................I
iii
Sprint User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

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 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
When ordering this manual, please reference the document number below.
Table 1-1 Release Details
Document Number Release Date Version
SPT-UM-EN-00-01 November 2020 01
1.4 Warranty
For current warranty information please refer to the documents available from our website:
https://www.moldmasters.com/index.php/support/warranty or contact your Mold-Masters
representative.
1-1INTRODUCTION
Sprint User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

1.5 Returned Goods Policy
Please do not return any parts to Mold-Masters without pre-authorization and a return
authorization number supplied by Mold-Masters.
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
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Mold-Masters®and the Mold-
Masters logo are trademarks of Mold-Masters.
1-2
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
Sprint 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
Sprint User Manual
© 2020 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
Sprint User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

2.2 International Representatives
Corporate Ofces - continued
Mold-Masters Regional Offices (cont.)
SPAIN
Mold-Masters Europa GmbH
C/ Tecnología, 17
Edificio Canadá PL. 0 Office A2
08840 – Viladecans
Barcelona
tel: [phone]
e: [email protected]
TURKEY
Mold-Masters Europa GmbH
Merkezi Almanya Türkiye
İstanbul Şubesi
Alanaldı Caddesi Bahçelerarası
Sokak No: 31/1
34736 İçerenköy-Ataşehir
Istanbul, Turkey
tel: [phone]
fax: [phone]
[email protected]
SINGAPORE*
Mold-Masters Singapore PTE. Ltd.
No 48 Toh Guan Road East
#06-140 Enterprise Hub
Singapore 608586
Republic of Singapore
tel: [phone]
fax: [phone]
[email protected]
*Coverage includes Southeast
Asia, Australia, and New Zealand
Mold-Masters International Representatives
Argentina
Sollwert S.R.L.
La Pampa 2849 2∫ B
C1428EAY Buenos Aires
Argentina
tel: [phone]
fax: [phone] Ext.
35 [email protected]
Denmark*
Englmayer A/S
Dam Holme 14-16
DK – 3660 Stenloese
Denmark tel: [phone]
fax: [phone]
[email protected]
*Coverage includes Norway
and Sweden
Israel
ASAF Industries Ltd. 29 Habanai
Street
PO Box 5598 Holon 58154 Israel
tel: [phone]
fax: [phone]
s[email protected]
Russia
System LLC
Prkt Marshala Zhukova 4
123308 Moscow
Russia
tel: [phone]
[email protected]
Belarus
HP Promcomplect
Sharangovicha 13
220018 Minsk
tel: [phone]
fax: [phone]
e:[email protected]
Finland**
Oy Scalar Ltd.
Tehtaankatu
10 11120 Riihimaki
Finland
tel: [phone]
fax: [phone]
[email protected]
**Coverage includes Estonia
Portugal
Gecim LDA
Rua Fonte Dos Ingleses, No 2
Engenho
2430-130 Marinha Grande
Portugal
tel: [phone]
fax: [phone]
[email protected]
Slovenia
RD PICTA tehnologije d.o.o.
Žolgarjeva ulica 2
2310 Slovenska Bistrica
Slovenija
[phone]
[email protected]
Bulgaria
Mold-Trade OOD
62, Aleksandrovska
St. Ruse City
Bulgaria
tel: [phone]
fax: [phone]
[email protected]
Greece
Ionian Chemicals S.A.
21 Pentelis Ave.
15235 Vrilissia, Athens
Greece
tel: [phone]
fax: [phone]
[email protected]
Romania
Tehnic Mold Trade SRL
Str. W. A Mozart nr. 17 Sect. 2
020251 Bucharesti
Romania
tel: [phone]
fax : [phone]
[email protected]
Ukraine
Company Park LLC
Gaydamatska str., 3, office 116
Kemenskoe City Dnipropetrovsk
Region 51935, Ukraine
tel: [phone]
[email protected]
For support in regions not listed above, please contact the nearest headquarters and they will connect
you with the appropriate representative.
2-2
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
GLOBAL SUPPORT
Sprint 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
Sprint User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

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

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

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