Clause 5.3.2

Q.1   Can a hopper satisfy this requirement?

A.1   Interpretation: A hopper can serve as a guard for the feed throat to prevent inadvertent insertion of hands.

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Clause 5.3.5

Q.1   Is a purge guard interlock required to be hardwired?

A.1   Interpretation: No

Q.2   Is a purge guard required for a thermoset machine where splatter is not an issue.

A.2   Interpretation: Yes

Q.3. Can perforated material (such as 3/16" dia. holes, 16 Ga. sheet metal, staggered hole centers) be used as purge guards?

A.3. Specific component design approval is outside the scope of the SPI committee. In general, if any hot plastic spray can penetrate a perforated purge guard material and potentially contact personnel, then this material does not meet the purgeguard performance requirements.

Q.4. If the injection unit is enclosed on all sides by fixed guards and gates is this considered purging protection?

A.4. Fixed guards and moveable guards that enclose all side of the injection unit may be considered purging protection if the fixed guards and gates provide the protection as required by clause 5.3.5 and are interlocked per that clause.

Q.5. If the injection unit is enclosed on all sides by fixed guards and gates (at least the machine perimeter), is a purging area top guard required?

A.5. Guarding around the sides of the injection unit would not fulfill the requirements of 5.3.5 to protect the top of the purge area.

Clause 5.3.5

Q.1   Is the purge guard required to meet conditions of both clauses 5.3.1 & 5.3.5)? For example, guard shall be interlocked to prevent screw rotation, screw forward and injection carriage forward when guard is not in position (5.3.5) and (movable) guard shall be interlocked to stop hazardous motion exposed by moving or removing the guard (5.3.1).

A.1   Interpretation: The interlock requirements for a purge guard are listed in clause 5.3.5. Clause 5.3.1 provides requirements for guards that do not have specific interlock requirements listed in the standard.

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Clause 5.3.7

Q.1   On older IMMs where the injection unit rotates manually is it necessary to retrofit with an interlock so that injection forward is limited to .5 in/sec. travel speed?

A.1   Interpretation: No. The swivel interlock on the injection unit is only required on new machines and remanufactured machines according to clause 5.3.7.

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Clause 5.4

Does Lockout/Tagout satisfy large machine requirements?

Interpretation: No, Lockout/Tagout is exclusively for service and/or maintenance.

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Clause 5.4.1

Q.1   Where it is possible to stand between the operator's gate and the mold area, an emergency stop or emergency reverse button shall be provided in a location that is readily accessible from this area. Don't you mean where it is not possible…?

A.1   Interpretation: The clauses are stated correctly.

Q.2   Do the requirements in 5.4.1 and 6.4.1 also apply to large machines with manual gates?

A.2   Interpretation: Yes.

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Clause 5.4.2

Q.1   Where it is possible to stand between the rear guard and the mold area, an emergency stop or emergency reverse button shall be provided in a location that is readily accessible from this area. Don't you mean where it is not possible…?

A.1   Interpretation: The clauses are stated correctly.

Q.2   If the machine has two interlocks and the pump stops when the rear guard is opened, an emergency stop or emergency reverse button is not required?

A.2   Interpretation: The requirement for the E-stop does not depend on the interlocks used on the rear guard. The E-stop must be used when it is possible to stand between the rear guard and the mold area.

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Clause E5.4.2

Q.1   Does this clause eliminate the need for an e-stop as specified in 5.4.2 and 6.4.2?

A.1   Interpretation: No

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Clause 5.4.3

Q.1   When a platform is provided in the mold area, presence sensing shall be used. When a platform is not provided, a gate block or double acknowledgement system shall be used. If the HIMM is being operated in semi-auto mode during production, why are there restrictions on which additional device is permitted due to the use of a platform?

A.1   Interpretation: The choice of safety devices in Clause 5.4.3 is based on whether there is an expectation of whole body entry of the operator into the mold area during normal production. A working platform is an indication of the expectation of whole body entry of the operator into the mold area during normal production.

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Clause 5.4.3.2

"When the Large HIMM is not supplied with a working platform in the mold for the purpose of operator access during normal production, one of the following devices shall be provided:"

Correction: "Mold" should be "mold area".

Q.2   The safety key switch located at the control box -- If the operator turns this switch to the position and pulls it out, the pump stops immediately and can not start the pump again without this switch -- can satisfy this requirement?

Q.2   Interpretation: No, the provisions in Clause 5.4.3.2 and 6.4.3.2 are intended for use in normal production. If a key switch is used that shuts off the pumps, this is not a safety device that would be used in normal production.

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Clauses 5.6 and 6.6

Q1.   Is wire mesh compliant with requirements of ANSI Z97.1?

A1.   No per definition of glazing in the Z97.1 standard, (e.g.: all opening for viewing in guards must use material compliant with ANSI Z97.1.)

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Clause 6.2.1

Correction: The following should have been underlined:

When an opening movement of the movable platen is possible with the operator's gate open, access to pinching and shearing points behind the mold mounting surface of the movable platen shall be prevented.

Q.1   Can existing piping etc. be considered an adequate guard?

A.1   Interpretation: Existing piping may provide some or all of the guarding function to prevent access to pinching and shearing points behind the mold mounting surface when the opening movement of the platen is possible with the operator's gate open. Existing piping is not considered an adequate guarding replacement for the operator gate(s).

Q2.   The injection molding machine in question does allow the movable platen to open with the operator gate open. We are providing a jam bar on the movable platen to prevent the operator gate from opening past the movable platen and thus preventing access to shearing and pinching points. Can this jam bar be hinged to allow a bypass? Thus, you could have access to the shearing and pinching points if you opened the door and lifted the jam bar. Is this still in compliance?

A2.   The special "jam bar" that is described may be hinged to allow a by-pass for set-up and maintenance of the ejectors. It is understood that the "jam bar" that is described in the question provides a physical obstruction to prevent the operators gate from opening past the moving platen and is not performing the function of the device described in clause 6.2.3.

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Clause 6.2.1.1

Q.1   Once the gate if fully closed, is there any need for it to open by actuation of the presence-sensitive switch?

A.1   Interpretation: No

Question 1 (from B151.1 survey)- Does the question mean "start the machine cycle from stop positon" or "re-cycle" the machine after the robot is clear and safe during a production run"?

Interpretation:The robot exception in 6.2.1.1 means that when a robot is used with an HIMM and a power operated gate is opened and closed for each cycle, that a signal from the robot is permitted to start the next cycle after the gate is closed and the robot is clear.

Under this heading, it states that closing a power operated gate shall not directly initiate the machine cycle. Does this point apply to a molding machine with a hand-closing gate, i.e. gate start for semi-automatic allowed or not?

Interpretation: For an HIMM that is not large: In accordance with 6.2.1.1 closing a power-operated operator's gate may not directly initiate a cycle. Closing a manually operated operator's gate may start a cycle because it is not prohibited by 6.2.1.1.

For a large HIMM: Clause 6.4.4 makes no distinction between a power operated or a manually operated gate, therefore, the clause applies to both. Closing either a manually operted or a power-operated operator's gate many not directly initiate a cycle.

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Clause 6.2.2

Clarifying the statement "…shall allow open motion to continue to its adjusted open position."

Q.1   Does this only count on the way open?

A.1   Interpretation: No

Q.2   What if you are on the way closed?

A.2   Interpretation: Yes, it applies

Q.3   What if you are closed (at low end pressure)?

A.3   Interpretation: If the mold is fully closed platen opening is not required.

Q.4   Does it matter if in manual cycle, mold set or auto cycle?

A.4   Interpretation: In manual or mold set mode the HIMM shall allow platen open motion under the control of the operator with the operator gate open.

Q.5   For machines not equipped with a ratchet or friction style of mechanical device, upon mold opening when the operator gate is opened, the mold must continue to open to its mold open stop position so that the drop/jam bar is in position to prevent the mold from closing Is this the correct interpretation of this clause?

A.5   Interpretation: Yes

Q.6   Exception: What happens if the operators gate is opened after that jam bar has passed its full traverse? i.e. if the machine is starting the injection process and the door is opened, what happens? Should the platens go to full open whenever the door is opened or should the machine just stop?

A.6   Interpretation: If injection has started, the machine should stop.

Q.7   This clause includes an exception which says that when a jam bar is used which is effective only in the platen adjusted open position, the electrical interlock shall allow the platen to open to its adjusted open position so that the jam bar engages. Is this platen motion required or is it an option?

A.7   Interpretation: It is a requirement. This platen motion is specified to ensure that when the mechanical device is a jam bar, which can only engage in the platen adjusted open position, that it will engage when the operator's gate is opened.

Q.8   Our machines are equipped with a jam bar as a mechanical device for platen close prevention. When the operator's gate is opened, the jam bar does not engage until the platen opens all the way. We have updated our machines, so that all the motion stops with the operator's gate open, but it does not kill the pump in semi-automatic mode. In auto mode it kills the pump. Does this comply with the standard?

A.8   Interpretation: The system that is described does not allow platen open motion to continue so that the jam bar is engaged when the operator's gate is open and, therefore, would not be in compliance with clauses 6.2.2 and 6.2.3 of the standard.

Q.9   If a gate limit switch operates a gate control relay that in turn stops machine motion, is this considered a "hardwired electrical interlock"?

A.9   Interpretation: The wording of the question does not provide enough detail to indicate whether the switch and relay contacts are stopping machine motion without depending on software. If they stop motion without depending on software, it would be a hardwired interlock.

Q.10   If the above mentioned gate relay inhibits power to an output module of a PLC, is this considered a "hardwired electrical interlock"?

A.10   Interpretation: Yes.

Q.11   We have 3 30-ton machines that do not have ratchet or jam bars. Do these machines need to comply with 6.2.2 and 6.2.3?

A.11   Interpretation: Yes, a ratchet bar, friction device or jam bar must be used according to Clause 6.2.3. A hardwired electrical interlock is required according to Clause 6.2.2.

Q.12   The following interpretation has been previously given: "In manual or mold set mode the HIMM shall allow platen open motion under the control of the operator with the operator gate open." does this last part mean that if we drop to manual mode when the gate is opened, the press shall stop motion?

A.12   Interpretation: Yes, all motion shall stop.

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Clause 6.2.3

Q.1   When hydraulic pneumatic or electrical means are used to disengage the pawl on a ratchet bar, is a separate limit switch required for this function…?

A.1   Interpretation: No

Q.2   If an older machine does not have a mechanical bar and there is no room to install one, are there any provisions in the standard to account for this?

A.2   Interpretation: No, there are no provisions to account for this. A mechanical device has been required on new machines since the 1976 standard. It is now required on all machines, including existing machines.

Q.3   We have 3 30-ton machines that do not have ratchet or jam bars. Do these machines need to comply with 6.2.2 and 6.2.3?

A.3   Interpretation: Yes, a ratchet bar, friction device or jam bar must be used according to 6.2.3. A hardwired electrical interlock is required according to Clause 6.2.2.

Q.4   Is a monitoring device required on existing machines for the mechanical device (i.e., jame bar or ratchet bar)?

A.4   Interpretation: Monitoring is not required for the mechanical device on an existing HIMM.

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Clause 6.2.4

Q.1   Calls for a monitoring device to be provided when a hydraulic or pneumatic platen movement interlock is electrically actuated and the HIMM cycle shall be inhibited and an alarm activated should improper operation occur. Our internal HIMM specifications calls for a mechanically actuated interlock via a ratchet type jam bar or a jam bar flag. Is this compliant?

A.1   Interpretation: A mechanical device is required according to clause 6.2.3 and a hydraulic/pneumatic interlock is required according to clause 6.2.4.

Q.2   Specifically what type of monitoring is required for electrically actuated interlocks and what are we trying to verify?

A.2   Interpretation: The exact form of monitoring is not specified in order to allow a variety of design solutions. The intent of the monitoring is to verify that the platen close circuit has been interrupted.

Q.3   Is a monitoring device required on existing machines for the hydraulic interlock that is actuated by mechanical means?

A.3   Interpretation:Monitoring of the hydraulic interlock on an existing HIMM is not required when the hydraulic interlock is mechanically actuated.

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Clause 6.2.6

Q.1   If an older machine is in the "mold set" mode, is motion of the platen allowed when an interlocked top guard is open.

A.1   Interpretation: No, an interlocked top guard must prevent all motion when it is open or removed.

Q.2   Is an interlocked top guard required to shut off the hydraulic pump motor when it is opened?

A.2   Interpretation:No, an interlocked top guard must prevent all motion when it is open or removed. Shutting off the hydraulic pump motor is not required.

Q.3   Under what circumstances is a top guard a necessity?

A.3   Interpretation: A top guard shall be installed when it would be possible for a person standing on the floor or working surface to reach over the tope of the operator's gate or guard and into a hazardous area. No specific dimensions are provided.

This standard reads an inter lock shall be provided to prevent platen movement if the top guard is open. If a mechanical interlock is provided do we require an electrical interlock as well.

Interpretation: If the mechanical interlock requires tools to remove the top guard, the top guard would qualify as a fixed guard and would not require an interlock. If the top guard can be moved or removed without the use of tools, it is a movable guard and must be interlocked (to stop all hazardous motion).

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Clause 6.2.7

Q.1   Does Compliance with clause 6.2.7 for existing HIMMs require meeting the dimensions given in clause 5.2.8 for new HIMMs?

A.1   Interpretation: No, the dimensions given in clause 5.2.8 for new HIMMs were not repeated in clause 6.2.7 to allow more freedom in guarding concepts for existing HIMMs.

Q.2   If the rear parts discharge area on an older machine is inaccessible due to hoses and hydraulic tubing, is a guard required?

A.2   Interpretation: Hoses alone do not provide an adequate guard for this area, since they may be easily moved. Permanent tubing may provide some or all of the guarding requirement.

Q.3   6.2.7 parts dischard opening. For the opening, we are placing a CAUTION sign which states that this machinery is not to be operated without a part drop area guard unless a chute or conveyor is used. Is this enough to bring this area into compliance with the standard?

A.3   Interpretation:The chute may provide some or all of the guarding required by clause 6.2.7. Depending on the design of the conveyor or chute, the parts discharge opening may require additional guarding, even with a conveyor or chute. If the additional guarding would render the conveyor or chute unusable, prominent warning means shall be provided in lieu of such guarding. See Clause 7.3

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Clause 6.2.8

Q.1   What does "default to the open position" mean for a nozzle valve?

A.1   Interpretation: In manual mode, the nozzle valve is closed when the screw is rotating and the nozzle valve is open when the screw is not rotating.

Q.2   Does "the default to the open position" apply to gas assist, two stage, co-injection or other special processes?

A.2   Interpretation: No

Q.3   Is monitoring required for the nozzle shut-off device?

A.3   Interpretation: No

Q.4   Is a nozzle shut-off device required on an HIMM by this clause?

A.4   Interpretation: No

Q.5   If the machine closes the nozzle shutoff device when the operator's gate is opened in all modes of operation, does this comply with the standard?

A.5   Interpretation: Determining whether it complies or not depends on the process that is in use on the machine. The nozzle shutoff device must default to the open position in manual mode unless gas assist, co-injection, or other special processes are in use. The exception for these processes has been provided in a previous interpretation.

Q.6   How should the nozzle shut-off respond to opening of the safety guard/purge guard?

A.6   Interpretation: The nozzle shut-off device is not affected by the purge guard. There is no specific requirement.

A.7   Define the nozzle shut-off with regards to:

a. Switching the machine from automatic mode to manual mode (open=default?)
b. Automatic Mode - opening safety/purge guard.
c. Manual Mode - opening safety/purge guard.

InterpretationThe nozzle shut-off device will default to the open position unless it is a "special application."(This interpretation also applies to b. and c.)*See response at top of section

Q.8   Does this require the valve to open in the event of a power failure?

A.8   Interpretation:No

Q.9   Is a hot runner system an example of a "special application"?

A.9   Interpretation:Yes

Q.10   How should the nozzle shut-off respond to opening of the safety guard/purge guard?

A.10   Interpretation: The nozzle shut-off device is not affected by the purge guard. There is no specific requirement.

Q.11   Does this require the valve to open in the event of a power failure?

A.11   Interpretation:No

Q.12   Is a hot runner system an example of a "special application"?

A.12   Interpretation:Yes

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Clause 6.3.2

Q.1   Can a hopper satisfy this requirement?

A.1   Interpretation: A hopper can serve as a guard for the feed throat to prevent inadvertent insertion of hands.

Q.2   Are there any depth or diameter requirements for guarding the feedthroat? What is meant by "inadvertent insertion of hands"?

A.2   Interpretation: No, there are no specific dimensions required to guard the feedthroat opening. The words"...guarded against inadvertent insertion of hands" means that someone would not be able to insert their hands or fingers into the screw through the feedthroat in an unintentional action.

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Clause 6.3.4

Q.1   This clauses states that electrical systems shall be in accordance with the requirements of ANSI/NFPA 79. Are all doors on electrical enclosures required to be interlocked or can the doors just require a special tool to open them?

A.1   Interpretation: The question requires an interpretation of NFPA 79 and should be submitted to the NFPA 79 committee.

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Clause 6.3.5

Q.1   Is a purge guard interlock required to be hardwired?

A.1   Interpretation: No

Q.2   What does "electrically actuated" mean? Is it a sled driven by an electric motor?

A.2   Interpretation: No, "electrically actuated" means that the injection carriage is operated by electrical signals. The electrical signals could operate a hydraulic motor, hydraulic cylinder, or an electric drive system. It was explicitly stated to exclude injection carriages that were controlled by manual hydraulic valves which would be difficult to interlock.

Q.3   Regarding the requirement that "all electrically actuated carriage forward motion shall have the carriage motion inhibited when the purge guard is open in addition to inhibiting purging motions…" Does the term "electrically" in this sentence only concern electrical presses or does it include hydraulic presses that are electrically controlled?

A.3   Interpretation: The term "electrically actuated" in clause 6.3.5 includes hydraulic HIMMs that are electrically controlled.

Q.4   Is a purge guard required for a thermoset machine where splatter is not an issue?

A.4   Interpretation: Yes

This standard states a guard shall be provided to protect front, rear and top behind the platen. What provision are tere in place for multi-component machines with an "L unit" or vertical unit on the fixed platen? "L unit" meaning an injection unit attached through the rear door of a HIMM.

Interpretation: The HIMM configuration described in your question is not addressed by the standard.

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Clause 6.3.6

Q.1   Can a blanket serve as an injection barrel cover?

A.1   Interpretation: Yes, if the thermal barrier blanket protects against inadvertent contact with high voltage and high temperature.

Q.2   Must barrel covers/guards provide protection from intentional reaching over/under/around to touch barrel?

A.2   Interpretation: No.

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Clause 6.4

Q.1   Does Lockout/Tagout satisfy large machine requirements?

A.1   Interpretation: No, Lockout/Tagout is exclusively for service and/or maintenance.

Q.2   If we a 1,000 ton press or larger and the distance between tie bars is less than 47", are we to assume it is not considered a large tonnage machine?

A.2   Interpretation: Any horizontal injection molding machine, regardless of tonnage, is not large unless the horizontal or vertical distance between tie bars is greater than 47 inches.

Q.3   On a large tonnage machine, is there a defined distance between the gate or rear guard and the mold area which triggers the necessity for an emergency stop or reverse button? If so, please elaborate.

A.3   Interpretation: The intent of the wording in 6.4.1 "Where it is possible to stand between the operator's gate and the mold area..." is that if a person could be reasonably expected to stand on a horizontal surface (either the floor or a platform) and the operator's gate could be closed with the person standing in this area, then the requirements of 6.4.1 apply. No specific dimensions for this area are provided.

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Clause 6.4.1

Q.1   Where it is possible to stand between the operator's gate and the mold area, an emergency stop or emergency reverse button shall be provided in a location that is readily accessible from this area. Don't you mean where it is not possible…?

A.1   Interpretation: The clauses are stated correctly.

Q.2   Do the requirements of these clauses also apply to large machines with manual gates?

A.2   Interpretation: Yes

Q.3   Does this section require a height dimension?

A.3   Interpretation: No, there is no dimensional criteria.

Q.4   Does standing between the gate and the mold area mean a work platform inside the press for the operator to work from? My plant manager is concerned with all of our HIMM machines (not just the large ones) with being able to stand inside the press period. This includes mold changes and even standing on the tie bars. Can you give me a little more clarity on this section of the standard?

A.4   Interpretation: Clause 6.4.1 applies only to large machines. The intent of the wording in 6.4.1 "Where it is possible to stand between the operator's gate and the mold area..." is that if a person could be reasonably expected to stand on a horizontal surface (either the floor or a platform) and the operator's gate could be closed with the person standing in this area, then the requirements of 6.4.1 apply. No specific dimensions for this area are provided.

Q.5   E-stops that are required inside the machine, is this an e-stop between the gate and mold area or something that would be mounted inside the mold area itself?

A.5   Interpretation: The intent of this e-stop is that it is inside of the operator's gate, not outside like other e-stops. The requirement for position of this e-stop is only that it must be readily accessible from the area between the operator's gate and the mold area. No specific dimensions are provided.

Q.6   When auditing an 1100 ton HIMM that has a manual gate (the operator physically opens and closes the gate when in manual and semi-cycle modes), how does the second part of standard 6.4.1 apply and any other standards that may differ given this situation.

A.6   Interpretation: This clause applies to both a power operated and a manually operated operator's gate. Clause 6.4.1 applies when it is possible to stand between the operator's gate and the mold area. If this is true for the HIMM in question, then it would comply with Clause 6.4.1, if the E-stop is accessible from the area between the operator's gate and the mold area and if a gate block, a double acknowledgement system, or presense sensing is used.

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Clause 6.4.2

Q.1   Where it is possible to stand between the rear guard and the mold area, an emergency stop or emergency reverse button shall be provided in a location that is readily accessible from this area. Don't you mean where it is not possible…?

A.1   Interpretation: The clauses are stated correctly.

Q.2   If the machine has two interlocks and the pump stops when the rear guard is opened, an emergency stop or emergency reverse button is not required?

A.2   Interpretation: The requirement for the E-stop does not depend on the interlocks used on the rear guard. The E-stop must be used when it is possible to stand between the rear guard and the mold area.

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Clauses E6.4.2

Q.1   Does this clause eliminate the need for an e-stop as specified in 5.4.2 and 6.4.2?

A.1   Interpretation: No, it does not.

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Clause 6.4.3

Q.Q   When a platform is provided in the mold area, presence sensing shall be used. When a platform is not provided, a gate block or double acknowledgement system shall be used. If the HIMM is being operated in semi-auto mode during production, why are there restrictions on which additional device is permitted due to the use of a platform?

A.Q   Interpretation: The choice of safety devices in Clause 5.4.3 is based on whether there is an expectation of whole body entry of the operator into the mold area during normal production. A working platform is an indication of the expectation of whole body entry of the operator into the mold area during normal production.

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Clause 6.4.3.1

Q.1   What is considered "normal production"?

A.1   Interpretation: As the machine is operating in semi-automatic or full automatic mode and is producing product(s).

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Clause 6.4.3.2

Q.1   "When the Large HIMM is not supplied with a working platform in the mold for the purpose of operator access during normal production, one of the following devices shall be provided:"

A.1   Correction: "Mold" should be "mold area".

Q.2   The safety key switch located at the control box -- If the operator turns this switch to the position and pulls it out, the pump stops immediately and can not start the pump again without this switch -- can satisfy this requirement?

A.2   Interpretation: No, the provisions in Clause 5.4.3.2 and 6.4.3.2 are intended for use in normal production. If a key switch is used that shuts off the pumps, this is not a safety device that would be used in normal production.

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Clause 7.3

Q.1   Does this clause require that a conveyor be interlocked to the machine such that if the conveyor is removed the machine stops?

A.1   Interpretation: It does not require that a conveyor be interlocked to the machine.

Q.2a. Is "parts discharge area" guarding required for raised HIMM's, for example free drop parts discharge from the underside of the HIMM?

A.2a. Interpretation: YES

Q.2b. Can "presence sensing" devices be used to guard the "parts discharge area"?

A.2b. Interpretation: YES

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Clause 7.5

Q.1   When venting during purging do you need a vent cover over the nozzle?

A.1   Interpretation: Yes, see clause 7.5

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Clause 8

Q.1   Does this section mean that all signs on existing machines must be changed to comply with ANSI Z535?

A.1   Interpretation: No

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