Safety Requirements

for the Design, Manufacture,

Maintenance and Operation
of Die Casting Machine
TABLE OF CONTENTS

Abstract pp. iii

Personnel pp. iii

Foreword pp. iv

Explanation of Standard Format pp. iv

1. Scope, Purpose and Application pp. 1

1.1 Scope 1
1.2 Purpose 1
1.3 Application 1
1.3.1 New Installations 1
1.3.2 Former Installations 1
1.3.3 All Installations 1
1.4 Exclusions 2
1.5 Responsibilities 2
1.5.1 Manufacturer or Remanufacturer 2
1.5.2 Rebuilder or Modifier 2
1.5.3 System Integrator 2

2. Normative References pp. 2

3. Definitions pp. 3-11

4. Die Casting Machine Requirements pp. 11

4.1 Die Space 11

4.1.1 Operator’s Door 12
4.1.2 Additional Requirements for Powered Door 12
4.1.3 Rear Guard 12
4.1.4 Top Guard 13
4.1.5 Ratchet Bar 13
4.1.6 Hardwired Electrical Interlock(s) 14
4.1.7 Clamp Hydraulic or Pneumatic Interlock 14
4.1.8 Timed Opening 15
4.1.9 Area Between the Rear Guard and the Die Space 15
4.1.10 Cycle Initiation Control Location 15
4.1.10.1 Clear View of the Die Space 15
4.1.10.2 Obstructed View of the Die Space 15
4.2 Other Pinch Points 16
4.3 Powered Tie Bar Pulling Systems 16
4.4 Shot End 16
4.4.1 Cold Chamber 16
4.4.2 Hot Chamber 17
4.4.3 Vertical Shot Cylinder 17
4.4.4 Injection Interlock 18
4.5 Electrical Controls 18
4.5.1 Two-Hand Control Device 18
4.5.1.1 Unintentional Operation 18
4.5.1.2 Concurrent Control 19
4.5.1.3 Control Location 19

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 4.5.1.4 Concurrent Pressure 19
4.5.1.5 Control Release 19
4.5.1.6 Next Cycle Initiation 19
4.5.2 Control Interlock Circuit 19
4.5.2.1 Fail-Safe Control 19
4.5.2.2 Operator Intervention 19
4.5.2.3 Machine Suspension 19
4.5.2.4 Additional Actions 19
4.5.3 Emergency Stops 20
4.5.3.1 Unobstructed Emergency Stop Device 20
4.5.3.2 Emergency Stop Button Design 20
4.5.3.3 Emergency Stop Button Restrictions 20
4.5.3.4 Start-Up Procedure 20
4.5.4 Power Source 20
4.5.5 Power Loss 20
4.5.6 Electrical Requirements 21
4.6 Hydraulic Fluids and Compressed Gases 21
4.6.1 Nitrogen 21
4.6.2 Air 21
4.6.3 Hose and Tubing 21
4.6.4 Accumulators 21
4.6.5 Hydraulic Fluids 21
4.7 Manual Mode 22
4.8 Safety Signs 22

5. Die Requirements pp. 22

5.1 Design, Construction, and Use 22

5.1.1 Size 22
5.1.2 Broken Parts 22
5.1.3 Weight 22
5.1.4 Mounting 22
5.1.5 Handling 22
5.2 Die Setting 23
5.3 Flash or Die Spitting 23
5.4 Die Changing System 23

6. System Requirements pp. 24

6.1 Ancillary Equipment 24

6.1.1 Metal Delivery System 24
6.1.2 Plunger Lubrication System 24
6.1.3 Die Lubrication System 25
6.1.4 Casting Extraction System 25
6.2 Emergency Stop Circuitry 25
6.3 Control Interlocks 26
6.3.1 Timers 26
6.3.2 Interlock Resets 26

7. User Requirements pp. 26

7.1 Training 26
7.2 Lockout/Tagout 26
7.3 Risk Assessment 26
7.4 Work Area 26
7.5 Personal Protective Equipment 26

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 7.6 Ventilation 27

8. Maintenance Requirements pp. 27

8.1 Training 27
8.2 Lockout/Tagout 27
8.3 Maintenance Operations While Under Power 27
8.4 Stuck Plunger - Cold Chamber Machine 27
8.5 Stuck Casting 27

9. General Information pp. 28

9.1 Equipment Identification 28

9.2 Machine Manual 28

Annexes

A. Cold Chamber Die Casting Machine, Top & Side View 30

B. Hot Chamber Die Casting Machine, Top & Side View31
C. Vertical Die Casting Machine, Side View 32
D. Die Area & Die Space, Top & Side View 33
E. Typical Die Casting System 34

ABSTRACT

This safety standard governing die casting machines was prepared by a committee made up of
industry representatives from the following areas: suppliers, users, and general interest, under the
direction of the North American Die Casting Association Board of Governors.

This safety standard governing die casting machines was approved by the American National
Standards Institute (ANSI) on April 25, 2000 and updated for electornic distribution on November
30, 2000. In the following document, explanatory information is identified with the prefix E.

PERSONNEL - NADCA SAFETY COMMITTEE

V. L. Mangold, Jr., Chairman, KOHOL, Incorporated G. Loots, Chicago White Metal Casting
J. Rexford, Vice Chairman, HPM Corp.
H. Bakemeyer, DCD Consulting
D. Celek, Rimrock Corporation
W. Damian, Prince Machine Corp.
S. DeBartolo, EPCO
T. Dyer, Southern Die Casters, Inc.
B. Eggleston, Drion Safety Services Inc.
A. Eichhof, Prima Die Casting Inc.
B. Garner, UBE Machinery Inc.
J. Hoenle, Parker Hannifin Corp.
J. O’Brien, O’Brien Mfg. Consulting
D. Robb, NADCA Secretariat
J. Prei, Briggs & Stratton Corp.
M. Savard, Husky Injection Molding Systems
D. Teeples, GMTI Lester PDC Inc.
J. Thornburg, Diversified Diemakers Inc.
P. Vertin, GMPT Bedford Plant
R. Wagner, Premier Tool & Die Casting Corp.
J. Wilkey, Leggett & Platt Aluminum Group

iii
FOREWORD
This Foreword is not a part of the following standard, ANSI/NADCA B152.1-2000, Safety
Requirements for the Design, Manufacture, Maintenance and Operation of Die Casting Machines, but
is included for information.

The NADCA Safety Committee was organized in 1996 to provide a centralized source for the
exchange of technical information between manufacturers and users of die casting machines.

The following standard, ANSI/NADCA B152.1-2000, Safety Requirements for the Design,
Manufacture, Maintenance and Operation of Die Casting Machines, provides recommendations for the
safe use of die casting machines and the ancillary equipment that is routinely used in conjunction with
die casting machines.

Emphasis is placed on conformance of this process with prevailing industry standards for hazard
analysis and proper safeguarding of foundry equipment.

Comments and suggestions for the improvement of this standard are welcome. They should be sent
to the Secretary of the NADCA Safety Committee, North American Die Casting Association, 9701
West Higgins Road, Suite 880, Rosemont, Illinois 60018-4721.

Official interpretations of any of the technical requirements of this standard may be obtained by
sending a request, in writing, to the Secretary of the NADCA Safety Committee. A formal reply will be
issued after it has been reviewed by the appropriate personnel following established procedures.
Explanation of Standard Format
This standard uses a two-column format to provide both specific requirements and supporting
information.
The left column, designated "Standard Requirements," is confined solely to these requirements and is
printed in bold type.
The right column, designated "Explanatory Information," contains only information that is intended to
clarify the standard. This column is not a part of the standard.
The "Annex Information," designated Annex A through E contains only information that is intended to
clarify the Standard. This information is not part of the standard.
Operating rules (safe practices) are not included in either column unless they are of such a nature as
to be vital safety requirements, equal in weight to other requirements, or guides to assist in compliance
with the standard.

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CLAUSE 1: SCOPE, PURPOSE, AND
APPLICATION
1.1 Scope
The requirements of this standard apply to
machines that inject molten metal under
pressure into a reusable die. This type of
machine is commonly referred to as a die
casting machine. The scope of this standard
includes metal delivery systems, plunger
lubrication systems, die lubrication systems,
and casting extraction systems.

Mechanically powered die casting machines,

permanent mold machines, low pressure
casting machines, and green sand casting
machines are not covered by this standard.

1.2 Purpose
The purpose of this standard is to establish
safety requirements with respect to the
design, manufacture, maintenance, and
operation of die casting machines and use of
ancillary equipment.
E1.2 Purpose
The intention of this standard is to minimize
hazards involved in maintaining, operating,
and die setting while working on or adjacent
to a die casting machine.

1.3 Application

1.3.1 New Installations

The requirements of this standard pertaining
to design and manufacture shall apply to all
new, rebuilt, or remanufactured die casting
machines, dies, and ancillary equipment
manufactured for installation or installed in
the United States after the compliance date
subsequent to the approval of this standard.
Compliance to the standard shall be 12
months after the approval date.

1.3.2 Former Installations E1.3.2 Former Installations

Within 48 months after the approval date of
this standard, all die casting machines, dies
and ancillary equipment, as described in this
standard, shall be modified by the employer
to the extent required to bring them into
conformity with the requirements of this
standard.
The useful life of a die casting machine, dies,
and ancillary equipment that is specified in this
standard may extend over several decades.
Existing machines that are sub-standard by
current safety standards should be modified in
accordance with the requirements of this
standard.

1.3.3 All Installations

The requirements of Clauses 7 and 8 of this
standard pertaining to the use and
maintenance of die casting machines shall
apply to all users subsequent to the approval
of this standard.

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1.4 Exclusions
This standard applies to die casting
machines and die casting systems only and
is not intended to apply to the following
machines:
1. mechanically powered
2. permanent molding
3. low pressure casting
4. green sand casting
This list is not intended to be all-inclusive.

1.5 Responsibilities
The responsibility for the application of this
standard is defined by this standard.

1.5.1 Manufacturer or Remanufacturer

It shall be the responsibility of the die casting
machine manufacturer or remanufacturer to
design and construct die casting machines
in accordance with Clause 4 of this standard.

1.5.2 Rebuilder or Modifier

It shall be the responsibility of any person
rebuilding or modifying die casting machines
to do so in accordance with portions of
Clause 4 of this standard applicable to
components being rebuilt or modified.

1.5.3 System Integrator E1.5.3 System Integrator

The system integrator shall ensure that the When a guard is removed or modified to
system complies with Clause 6 of this accommodate a casting extraction system,
standard. The System Integrator has the alternate interlocked perimeter guarding
responsibility to ensure that any should be incorporated.
modifications made to the die casting
machine shall conform to Clause 4. The
employer shall be the system integrator
unless another party contractually accepts
responsibility as the system integrator.

CLAUSE 2: NORMATIVE REFERENCES

2.0 Normative Reference E2.0 Normative References

The following standards contain provisions,
which, through reference in this text,
constitute provisions of this American
National Standard. At the time of publication,
the editions indicated were valid. All
standards are subject to revision, and parties
are encouraged to investigate
1. ANSI/ASME B15.1-1992, “Safety
Standard for Mechanical Power
Transmission Apparatus.”
2. ANSI C2, “National Electrical Safety
Code.”

2
the possibility of applying the most recent
editions of the standards indicated below.
1. NFPA 79-1997, “Electrical Standard for
Industrial Machinery.”
2. ANSI/NFPA T2.13.8-1997, “Hydraulic Fluid
Power - Fire Resistant Fluids -
Definitions, Classifications, and Testing.”
3. ANSI Z535.1-1998, “Safety Color Code.”
4. ANSI Z535.2-1998, “Environmental and
Facility Safety Signs.”
5. ANSI Z535.3-1998, “Criteria for Safety
Symbols.”
6. ANSI Z535.4-1998, “Product Safety Signs
and Labels.”
7. ANSI Z535.5-1998, “Accident Prevention
Tags.”

CLAUSE 3: DEFINITIONS

3.1 Alarm
Alarm means an indication that a failure or
misadjustment of a device has occurred.

3.2 Anti-repeat E3.2 Anti-repeat

Anti-repeat means the part of the machine There shall be no inference that the purpose
control system designed to limit the die of Anti-repeat is to prevent an inadvertent
casting machine to a single cycle if the cycle closing of the machine. An inadvertent
actuating means are held operated or tied closing is the result of a malfunction.
down. Anti-repeat requires release of all
cycle actuating mechanisms before another
cycle can be initiated.

3.3 Anti-tie Down

Anti-tie Down means a circuit designed to
prevent machine operation in case a control
is permanently actuated.

3.4 Automatic Mode

Automatic Mode means a selectable mode of
operation of the die casting machine, which
allows it to perform more than one cycle
without cycle actuation by an operator.

3.5 Biscuit
Biscuit means the cylindrical plug of metal
formed by the excess metal in the cold
chamber machine after a shot has been
made.

3
3.6 Casting
1. n. Casting means the product that results
from the solidification of molten metal in
a mold or die.
2. v. Casting means the process by which
molten metal is poured or injected into a
metal mold or die.

3.7 Casting Extraction System

Casting Extraction System means the device
or devices used to remove a casting from the
die area.

3.8 Cold Chamber

Cold Chamber means the shot system by
which molten metal is delivered to the mold
or die; this mechanism is also separated
from the reservoir of molten metal.

3.9 Cold Chamber Machine

Cold Chamber Machine means a die casting
machine in which the injection mechanism is
separated from the reservoir of molten metal.

3.10 Concurrent
Concurrent means acting in conjunction and
is used to describe a situation wherein two
or more controls exist in an operated
condition at the same time.

3.11 Device
Device means an invention or contrivance
designed to perform a particular objective.

3.12 Die
Die means the tooling used in a die casting
machine for imparting the shape to the
casting.

3.13 Die Area E3.13 Die Area

Die Area means the space and the area See Annex D.
adjacent to the die that presents hazard(s)
during operation.

3.14 Die Lubrication System E3.14 Die Lubrication System

Die Lubrication System means the device Die Lubrication System includes spray
used to apply die release material to the wands, fixed mounted sprayers, and
casting die. mechanized spray devices.

4
3.15 Die Casting Machine
Die Casting Machine means a machine that
injects molten metal under pressure into a
reusable die.

3.16 Die Space E3.16 Die Space

Die Space is defined as the working area of See Annex D.
the die casting die between the stationary
and moving machine platens.

3.17 Door
Door means a movable barrier that when
closed prevents the entry of any portion of a
person’s body into the die space.

3.18 Ejector
Ejector means a mechanism for forcing
castings from the die cavity.

3.19 Emergency Stop

Emergency Stop means operation of a circuit
that overrides all machine control, removes
drive power, and causes all moving parts to
stop.

3.20 Employer
Employer means any person who contracts,
hires, or is responsible for the personnel
associated with the operation, maintenance,
and setup of die casting machinery.

3.21 Fixed Guard

Fixed Guard means a guard that cannot be
moved except with the use of tools.

3.22 Former Installation

Former Installation means a currently
existing die casting machine installed prior
to the compliance date of this standard.

3.23 Gate
Gate means a movable barrier that when
closed prevents the exposure of any portion
of a person’s body to a hazard.

3.24 Gooseneck
Gooseneck means that part of the metal
delivery system for a hot chamber machine
containing the sleeve and metal flow path
immersed in the metal bath.

5
3.25 Guard
Guard means a physical barrier, which
protects personnel from exposure to a
hazardous area.

3.26 Hardwired
Hardwired means the components of an
electrical circuit that are permanently
electrically wired together, and the electrical
circuit is independent of electronic logic
(hardware or software).

3.27 Hot Chamber Machine

Hot Chamber Machine means a die casting
machine in which the injection mechanism is
immersed in the reservoir of molten metal.

3.28 Injection
Injection means the process of forcing
molten metal into the die.

3.29 Interlock
Interlock means an arrangement whereby the
status of one control or mechanism allows or
prevents the operation of another.

3.30 Interlock Switches

Interlock Switches are an electrical or
mechanical means by which operation of a
component is prevented or maintained
unless required conditions are met.

3.31 Locked
1. Locked means the secured state of a
device used to secure a switch, door, or
gate.
2. Locked means the clamping mechanism
of the die casting machine is in the ready
to cast position.

3.32 Maintenance Personnel

Maintenance Personnel means an individual
who has been trained and authorized by the
employer to inspect, repair, and maintain die
casting machines and ancillary equipment.

3.33 Manual
1. Manual means a mode of operation that
requires a deliberate and continuous act
to initiate and sustain an individual
function of the die casting machine.

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2. Manual means a text document for use as
a guide or reference.

3.34 Manual Mode E3.34 Manual Mode

Manual Mode means a machine operational Manual Mode is commonly referred to as inch
control method that requires a deliberate and or jog.
continuous act to initiate and sustain
movement of any portion of the die casting
machine.

3.35 Manufacturer E3.35 Manufacturer

Manufacturer means any person who A Manufacturer may also be a modifier or
manufactures a die casting machine, rebuilder.
ancillary equipment or both for installation in
the United States.

3.36 Metal Delivery System

Metal Delivery System means a device used
to transfer metal from the holding furnace to
the cold chamber.

3.37 Modifier
Modifier means any person who converts,
changes or otherwise alters a die casting
machine.

3.38 Monitoring Device

Monitoring Device means a device, which
may be used to verify the function of another
device.

3.39 Movable Guard

Movable Guard means a guard, which may be
moved or removed without the use of tools.

3.40 New Installation E3.40 New Installation

New Installation means a new, rebuilt, or New Installations include equipment rebuilt or
remanufactured die casting machine remanufactured on site by the user.
installation.

3.41 One-hand Control, Remotely

Located
One-hand control, remotely located means a
one-hand actuator that requires maintained
pressure from one-hand of the operator to
sustain or initiate hazardous motion. The
actuator shall be located far enough away
from the hazardous area so that the
hazardous motion has stopped before the
area can be accessed by personnel.

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3.42 Operator
Operator means an individual who has been
trained and authorized by the employer to
perform production work with the die casting
machine.

3.43 Operator Door

Operator Door means a moveable barrier that
when closed prevents the entry of any
portion of a person’s body into the
operator’s side of the die space.

3.44 Parting Line

Parting Line means the surface formed by
the separation of the die halves and/or
movable sections.

3.45 Perimeter Guarding

Perimeter Guarding means guarding placed
around a die casting machine or machine
cell.

3.46 Physical Barrier E3.46 Physical Barrier

Physical Barrier means a rigid boundary to Cages, gates, walls, shields, and fences are
safeguard personnel access. all examples of Physical Barriers.

3.47 Pinch Point

Pinch Point means any point where it is
possible to be caught between moving parts
or between a moving and stationary part.

3.48 Platen
Platen means the moving or stationary
members of a die casting machine to which
the die is fastened.

3.49 Plunger
Plunger means the piston which forces metal
from the shot sleeve into the die and applies
pressure during solidification.

3.50 Plunger Lubrication System

Plunger Lubrication System means a system
by which a plunger lubricant is introduced to
the shot system of the die casting machine
through either automatic or manual means.

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3.51 Point of Operation
Point of Operation means the area of the die
casting machine, which is between the die
faces.

3.52 Pour Hole

Pour Hole means the hole in the shot sleeve
into which the metal is poured.

3.53 Presence Sensing Device

Presence Sensing Device means a device
capable of detecting an intrusion into a
specified area.

3.54 Ratchet Bar

Ratchet Bar means a notched bar or rack
used to prevent inadvertent die casting
machine closure.

3.55 Rear Guard

Rear Guard means a guard placed to prevent
entry into the die space at the side of the
machine opposite the operator’s control
panel.

3.56 Rear Side

Rear Side means the side of the die casting
machine opposite the operator’s control
panel.

3.57 Rebuilder
Rebuilder means any person who rebuilds all
or a portion of a die casting machine for
installation in the United States. The
rebuilding may consist of any restoration of
the machine to its original specification and
capability.

3.58 Remanufacturer
Remanufacturer means any person who
remanufactures a die casting machine for
installation in the United States. The
remanufacturer is not limited to the original
equipment specification or capability.

3.59 Restraint
Restraint means a mechanism, which
prevents the die casting machine from
inadvertent movement.

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3.60 Safeguarding
Safeguarding means a device or procedure
used to protect personnel from hazard(s).

3.61 Semi-Automatic Mode

Semi-Automatic Mode means a die casting
machine operational control sequence,
which allows it to perform one complete
cycle and then stop.

3.62 Shall
Shall means a mandatory requirement.

3.63 Shield E3.63 Shield

Shield means a barrier that protects against A Shield may be a moving barrier as when
the hazards of spitting or splashing metal. mounted on the die or a stationary barrier as
when mounted on the floor.
3.64 Should
Should means a recommended safe practice,
but does not mean a mandatory requirement.

3.65 Shot
Shot means the injection of metal into the die
casting die. The shot end portion of the
machine causes the injection of metal to
occur.

3.66 Shot Sleeve

Shot Sleeve means the portion of the shot
system, which guides the plunger and
contains the molten metal prior to being
injected into the mold or die.

3.67 Signage
Signage means graphic communication
whose functions include direction,
identification, information, regulation,
warning, or restriction.

3.68 Suspended State

Suspended State means an operation that is
stopped.

3.69 System Integrator

System Integrator means the party that is
responsible for assuring the system design
and control interlocking of the die casting
machine and other ancillary equipment into a
system that conforms with the requirements
of this standard.

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3.70 Timed Opening
Timed Opening means the initiation of the
opening of the die casting machine is
controlled by an independent timer during
the automatic or semi-automatic machine
cycle mode.
E3.70 Timed Opening
The Timed Opening time may be either a
hardwire or software timer. This timer is
often referred to as the “dwell” timer.

3.71 Toggle
Toggle means the series of connected arms
and pivots mounted between the adjustable
and moving platens, which when actuated,
causes the platens to open or close.

3.72 Top Guard

Top Guard means a guard placed to prevent
entry into the die space at the top of the
machine.

3.73 Two-Hand Control E3.73 Two-Hand Control

Two-Hand Controls means a two-hand
actuator that requires simultaneous or
concurrent pressure from both hands of the
operator to sustain or initiate the motion.
The initiation of motion by a Two-Hand
Control may be permissible when additional
safety devices are in place such as guards,
electronic light curtains, or other devices
which would stop the motion of the machine
when the safety guarding and operation has
been compromised.

3.74 User
User means the owner or operator of a die
casting facility.

3.75 Work Level

Work Level means the surface from which
the die casting machine and ancillary
equipment are operated.

CLAUSE 4: DIE CASTING MACHINE

REQUIREMENTS

4.1 Die Space E4.1 Die Space

The die space on the operator’s side of the
die casting machine shall have a physical
barrier to safeguard the operator from the
following:
1. Burn hazard associated with die spitting,
bursting biscuits, and hot surfaces.
2. Impact and pinch point hazards
associated with motion within the die
space area.
See Clause 5 for alternate methods for
safeguarding burn hazards and Clause 6 for
alternate methods for safeguarding ancillary
equipment. For further requirements
pertaining to ancillary equipment see Clause
6.

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4.1.1 Operator’s Door
An operator’s door shall be provided to
guard the die space.
Where a die casting machine, equipped with
ancillary equipment, is operated in automatic
mode and an operator is not present,
interlocked perimeter guarding, see clause
6.1, and other safeguarding, see clauses 5.3
and E5.3, may be used in place of an
operator's door.
The operator’s door shall be closed and
locked before the die casting machine close
cycle can be initiated. The operator’s door
shall remain closed and locked until the burn
hazard associated with a bursting biscuit or
die spitting no longer exits.
E 4.1.1 Operator’s Door
An operator’s door should be locked during
the following sequences:
1. Once the operator’s door is closed in
“Semi-Automatic” or “Automatic” Mode.
2. During clamp closing.
3. During metal injection cycle, including die
close time.
4. Until all pressure from injection forward
has been removed from the biscuit.
An operator's door is locked when the
operator is prevented from opening the
operator's door.

Locking of the operator’s door shall be

achieved using an electrical interlock and a
hydraulic, pneumatic, or mechanical device.

Closure of the operator’s door shall not

directly initiate die closing.

4.1.2 Additional Requirements for

Powered Door
Hazards created by the motions of the door
shall be safeguarded with a presence
sensing device or other means to eliminate
the hazards.

The presence sensing device shall be

designed into the circuit such that a failure of
the device duplicates the actuation of the
device. The power assist mechanism shall
not lessen the effectiveness of the operator’s
door.

4.1.3 Rear Guard E4.1.3 Rear Guard

The die space opposite the operator’s side of A rear guard is designed to open and close
the die casting machine shall have a rear during setup and maintenance functions only.
guard with two interlocks. The interlocks
shall separately interrupt the control circuit
and the power circuit to prevent all machine
movements if the guard is opened or
removed.

When a die casting machine, equipped with

ancillary equipment on the rear side, is

12
operated in automatic mode and an operator
is not present, interlocked perimeter
guarding, see clause 6.1, and other
safeguarding, see clauses 5.3 and E5.3, may
be used in place of a rear guard.

During maintenance and/or setup operations,

when the rear guard or perimeter guarding is
opened or removed and motion is needed,
this motion shall be controlled by two-hand
control or by a one-hand control, remotely
located on the rear side of the machine. The
one-hand control, remotely located, shall be
located within a clear view of the die area.
For any motion to occur, the operator’s two-
hand control and the two- hand control or
one-hand control, remotely located, on the
rear side must be activated simultaneously
and remain depressed during any motion.

4.1.4 Top Guard E4.1.4 Top Guard

A top guard shall be installed when it is
possible for a person standing on the floor or
work level to reach over the top of the
operator’s door or rear guard and into a
hazardous area or where a spit hazard exists.
When the top guard is movable, it shall be
interlocked.
The intent of this Clause is to require
safeguarding of the parting line which can
spit metal to areas accessible to personnel.
A low profile machine would require
safeguarding at both sides and across the
top; a larger machine would require
safeguarding at both sides.

During die setting, the top guard may be

open only when the die casting machine is
operated in the manual mode, see Clause 4.7.

4.1.5 Ratchet Bar E4.1.5 Ratchet Bar

All die casting machines shall be equipped
with a ratchet bar or equivalent device to
prevent inadvertent platen closure whenever
the operator’s door is not fully closed and
whenever power to the machine is lost.
Some platen motion may occur before the
ratchet bar or equivalent device is fully
engaged. The ratchet bar or equivalent
device is not intended to resist the lock-up
force.

A monitoring device shall be provided to

verify the proper operation of the ratchet bar
or equivalent device. If improper operation is
detected, the die casting machine cycle shall
be inhibited and an alarm shall be activated.

Limited platen closing motion is permitted

with ratchet bar or equivalent device not
engaged only during manual operation; see
Clause 4.7.

4.1.6 Hardwired Electrical Interlock(s)

Independent hardwired electrical interlock(s)
shall be provided to prevent the following

13
motions when the operator’s door is not fully
closed:
1. die closing
2. core setting
3. injection forward
4. ejector reset

The interlock(s) shall be so located or

protected to prevent accidental actuation.

The exception to hardwired electrical

interlock(s) shall be as follows:

Core setting, and ejector reset motions are

allowed when the operator’s door is open,
only when one or more of the following
conditions exist:

Condition 1: The hazardous motion is

controlled by a two-hand control that
complies with Clause 4.5.1.

Condition 2: The hazardous motion is

activated by a remote switch that is located
far enough away from the hazardous area so
that the motion has stopped before the area
can be accessed by personnel.

The hardwired electrical interlock(s) may be

bypassed in the manual mode (see Clause
4.7) to provide limited platen closing motion
for the setting of dies.

4.1.7 Clamp Hydraulic or Pneumatic E 4.1.7 Clamp Hydraulic or Pneumatic

Interlock
If hydraulic or pneumatic power is used to
cause platen motion, then a hydraulic or
pneumatic interlock shall be provided such
that the platen close circuit is interrupted
unless the operator’s door is closed.
The clamp hydraulic or pneumatic interlock
may be bypassed in the manual mode (see
Clause 4.7) to provide limited platen closing
motion for the setting of dies.
This hydraulic or pneumatic interlock shall
be actuated by mechanical or electrical
Interlock
The hydraulic or pneumatic valve which, interrupts
the flow to the cylinder for platen closing motion
should be one of the following:
1. Positively and directly actuated by the operator’s
door.
2. Controlled by an independent hardwired limit
switch which is positively and directly actuated
by the operator’s door.
3. Controlled by a pilot valve, which is positively
and directly actuated by the operator’s door.
4. Controlled by a pilot valve, which is controlled
by an independent hardwired limit switch, which
is positively and directly actuated by the
operator’s door.

14
means, which are independent of all other
interlocks.

A monitoring device shall be provided to

verify the operation of this hydraulic or
pneumatic interlock. If improper operation is
detected, the die casting machine cycle shall
be inhibited and an alarm shall be activated.

When a die casting machine is powered by

sources other than hydraulics or pneumatics,
an additional independent interlock shall be
provided.

4.1.8 Timed Opening E4.1.8 Timed Opening

The minimum opening time of a die after the Timed opening is often referred to as "dwell"
injection of metal has been initiated shall be time.
a function of an independent timer for that
purpose. Die opening shall be inhibited until
this timer has timed out.

4.1.9 Area Between the Rear Guard

and the Die Space
Where it is possible to stand between the
rear guard and the die space and a hazard
exists, an emergency stop pushbutton shall
be provided in a location that is readily
accessible from this area.

4.1.10 Cycle Initiation Control

Location

4.1.10.1 Clear View of the Die Space

If the position from which the operator
initiates the machine cycle allows a clear
view of the die space, a two-hand control
device or a one-hand control, remotely
located shall be used to initiate the machine
cycle.

4.1.10.2 Obstructed View of the Die

Space
If the position from which the operator
initiates the machine cycle does not allow a
clear view of the die space, one of the
following devices shall be provided:
1. Acknowledgment system: An
acknowledgment system shall consist of
a pushbutton located in a position,
which provides full view of the die
space. To start a cycle, the following

15
 sequence shall be completed within a time
interval prescribed by the die casting
machine manufacturer:
a. Acknowledgment pushbutton
activation.
b. Close operator’s door.
c. Two-hand control device or one-hand
control, remotely located, device
actuation.
A monitoring circuit shall be provided to
check the operation of each pushbutton.
If improper operation or sequencing is
detected, the die casting machine cycle
shall be inhibited and an alarm shall be
activated.
2. Presence sensing device: A presence
sensing device which, when activated,
shall prevent, stop, or reverse the closure
of the operator’s door, and in turn, the
movement of the die.

4.2 Other Pinch Points E4.2 Other Pinch Points

Hazards associated with other pinch point Other pinch point locations include, but are
locations that are not otherwise identified not limited to, the toggle area, die height
shall be safeguarded. If a movable guard is adjust systems, etc.
used, it shall be interlocked.

4.3 Powered Tie Bar Pulling

Systems
Where present, powered tie bar pulling
systems shall be designed to address the
following hazards:
1. Pinch point hazards created between the
tie bar and platens.
2. Burn hazard associated with the spitting
due to unbalanced locking force on the
die.

The tie bar shall be in a properly secured

position prior to commencement of
operation. The system shall be mechanically
interlocked to ensure that the tie bar is
secure.

4.4 Shot End

4.4.1 Cold Chamber E4.4.1 Cold Chamber

The shot end of the die casting machine shall
be safeguarded to prevent personnel
exposure to the following hazards:
See Clause 6.1 for Ancillary Equipment.
Burn hazard safeguards can include, but are
not limited to, the following:
1. Physical guarding.
2. Perimeter guarding.
3. Personal Protective Equipment.

16
1. Impact hazards caused by the movement
of the shot rod and associated equipment
shall be guarded with an appropriate
physical barrier as follows:
a. Hazards associated with a shot end
equipped with a metal delivery
system shall be safeguarded with
physical barriers or perimeter
guarding to prevent operators from
accessing the plunger, tail rod, piston
rod, and metal delivery system.
b. Hazards associated with a shot end
that uses manual ladling shall be
safeguarded with physical barriers or
perimeter guarding to prevent
operators from accessing the tail rod
and piston rod. Access to the shot
end from the side opposite the
operator shall be safeguarded with a
physical barrier. Additionally, hazards
associated with the cold chamber
and molten metal shall be
safeguarded with appropriate
operator training, equipment, and
personal protective equipment.
2. Burn hazards resulting from metal splash
from the pour hole during the start of the
injection while the plunger passes the
pour hole shall be safeguarded.

4.4.2 Hot Chamber

The shot end of the die casting machine shall
be safeguarded to prevent personnel from
exposure to the following hazards:
1. Burn hazard from molten metal
associated with blow-out due to nozzle
alignment, nozzle rupture, or breakaway.
2. Pinch point hazards between the nozzle
and the platen.
3. Burn hazards due to plunger drift shall be
safeguarded through the use of an
interlocked and monitored mechanical
device, which inhibits unintended plunger
movement.

4.4.3 Vertical Shot Cylinder

A die casting machine equipped with a
vertical shot cylinder shall be safeguarded to
prevent personnel exposure to the following
hazards:

17
1. Impact and pinch point hazards caused
by the movement of the shot cylinder
piston and attached equipment shall be
safeguarded with appropriate guards.
2. Burn hazards from molten metal in the
area below the shot cylinder caused by
spilling or metal splash shall be
safeguarded with a physical barrier.
3. Impact and pinch point hazards
associated with releasing stored potential
energy in the mechanism or system used
to move the shot cylinder assembly with
each machine cycle shall be safeguarded
using one of the following methods:
a. A system that automatically
releases all stored potential energy
in a safe manner.
b. A locking mechanism that prevents
the shot cylinder assembly from
motion.
4. Burn hazards due to plunger drift shall be
safeguarded using an interlocked and
monitored mechanical device, which
inhibits unintended plunger movement.

4.4.4 Injection Interlock

The injection stroke of a die casting machine
shall be interlocked to prevent the injection
of metal unless the machine is locked.

4.5 Electrical Controls

4.5.1 Two-Hand Control Device E4.5.1 Two-Hand Control Device

A die casting machine should be equipped with a
two-hand control device that initiates the closing
and locking of the dies.
Two examples of this process are provided as
follows:
1. A two-hand control device has pressure
maintained until the dies are closed.
2. A two-hand control device has pressure
maintained until the powered operator door is
closed and interlocked during manual or semi-
automatic mode.

4.5.1.1 Unintentional Operation

Each hand control shall be protected against
unintentional operation.

18
4.5.1.2 Concurrent Control
Each hand control shall be arranged by
design, construction, and/or separation to
require the use of both hands to actuate the
controls concurrently.

4.5.1.3 Control Location

The hand controls shall be located to prevent
exposure to the hazard.

4.5.1.4 Concurrent Pressure

Each hand control shall require continuous
and concurrent pressure while the hazard
exists.

4.5.1.5 Control Release

The hazardous machine motion shall stop or
reverse, if reverse motion does not create a
hazard, when either control is released.

4.5.1.6 Next Cycle Initiation

The control system shall require an anti-
repeat/anti-tie down feature so that each
button must be released, and reactivated, to
initiate the next cycle.

4.5.2 Control Interlock Circuit

4.5.2.1 Fail-Safe Control

Control interlock circuits shall be designed
to operate in a fail-safe manner.

4.5.2.2 Operator Intervention

Control interlock circuits shall inhibit
automatic or operator initiated actions when
all safe conditions are not met.

4.5.2.3 Machine Suspension

When safe conditions are not met control
interlock circuits shall suspend further or
additional actions and shall notify the
operator of the suspended state of the
machine.

4.5.2.4 Additional Actions

Control interlock circuits shall require the
operator to acknowledge the suspended
state of the machine before additional
actions can take place.

19
4.5.3 Emergency Stops
Every die casting machine shall have an
emergency stop circuit using hardware
based components. The emergency stop
circuit, when activated, shall override all
other controls and cause all motion to stop.

4.5.3.1 Unobstructed Emergency

Stop Device
Each die casting machine operator control
station shall be provided with a readily
accessible, unobstructed emergency stop
device.

4.5.3.2 Emergency Stop Button

Design
Pushbuttons that activate an emergency stop
circuit shall be red and unguarded, and shall
have a yellow background. Emergency stop
pushbuttons shall be palm or mushroom
head type. All emergency stop pushbuttons
shall be of the type requiring manual
resetting.

4.5.3.3 Emergency Stop Button

Restrictions
Red palm type or red mushroom head type
pushbuttons shall not be used for any
function except emergency stop.

4.5.3.4 Start-Up Procedure

Following an emergency stop, restarting
operation shall require a deliberate action to
follow a prescribed start-up procedure
outside the safeguarded space.

4.5.4 Power Source

The power source of the die casting machine
shall be clearly identified and shall be
provided with electrical disconnect and
lockout for the purpose of maintenance or
repair of the die casting machine or its
ancillary equipment.

4.5.5 Power Loss

Safeguards shall be implemented to ensure
that a loss of power shall not result in an
operator hazard. Safeguards must be
designed to ensure that a loss of power shall
produce an emergency stop condition that
shall immediately de-energize all
equipment that is potentially hazardous in
the die casting area.

20
4.5.6 Electrical Requirements
New die casting machines shall be built in
accordance with NFPA 79-1997.

4.6 Hydraulic Fluids and

Compressed Gases

4.6.1 Nitrogen
Machines and systems that require
compressed nitrogen shall be designed in
accordance with applicable industry
standards.

4.6.2 Air
Machines and systems that require
compressed air shall be designed in
accordance with applicable industry
standards.

4.6.3 Hose and Tubing E4.6.3 Hose and Tubing

All hoses and tubing that transport gases An example of a restraint for hose or
and fluids that can produce potential hazards tubing is a mechanical clamp located to
shall be restrained in accordance with prevent “whipping” of loose hose or
applicable industry standards. tubing. A mechanical restraint should be
constructed to prevent premature hose
wear and failure.
4.6.4 Accumulators
Hydraulic accumulators shall be properly
restrained and charged in accordance with
manufacturer specifications. Charged
accumulators shall be identified with
appropriate signage for high pressure
potential hazard.

Barrier type piston accumulator systems

shall have a device that automatically
removes all stored hydraulic energy in a
controlled manner when electrical or control
power is removed.

All other accumulator systems shall have a

lockable manual energy isolating device that
blocks all stored hydraulic energy.

4.6.5 Hydraulic Fluids E4.6.5 Hydraulic Fluids

Hydraulic fluids used by the die casting
machine and its ancillary equipment shall
comply with ANSI/NFPA T2.13.8-97
requirements for Group I or Group II.
Flame retarding hydraulic fluids should
conform to local, state, federal and industry
requirements, such as, but not limited to,
OSHA, ANSI Standards, National Fluid
Power Association (NFPA), and Factory
Mutual Research Corporation, (FMRC).

21
4.7 Manual Mode E4.7 Manual Mode
All motions in manual mode shall be limited Maximum speed is to be based on
to a maximum speed that is less than full application; maximum safe recommended
machine speed. Any motion that creates a speed for Manual Mode is 250 mm/sec
hazard within the operator’s reach in manual (10in/sec).
mode shall be controlled with two-hand
control device. See Clause 4.5.1.

4.8 Safety Signs

All new signs shall conform to the color,
format, size, and content requirements of the
ANSI Z535 series, where feasible.

CLAUSE 5: DIE REQUIREMENTS

5.1 Design, Construction, and Use

Die hazards that shall be safeguarded
include the following:
1. Burn hazards associated with die spitting
and hot surfaces.
2. Impact and pinch points associated with
die motion, ejection motion, core motion,
and broken parts.

5.1.1 Size
Dies shall fit within the guarding provided on
the machine or machine cell.

5.1.2 Broken Parts E5.1.2 Broken Parts

Dies shall be guarded to prevent injury from
broken parts and/or springs. Dies equipped
with springs containing potential energy
shall be equipped with signs.
5.1.3 Weight
Die weight shall be permanently indicated on
the die to safeguard against overloading die
handling equipment.
Some ejector and core pull systems contain
springs, which may fail after extended usage.
To protect against such failure, resulting in
part of the mechanism becoming a flying
projectile, guards should be provided over all
such mechanisms.

5.1.4 Mounting
Die fastening provisions shall be made in
both die halves for securely mounting the die
to the platens.

5.1.5 Handling E5.1.5 Handling

Die casting dies and accessories shall have Metal straps should be provided to hold both
provisions to facilitate handling. halves of the die together during
transportation. Provisions for lifting the
halves of the die should be provided.

22
5.2 Die Setting
Impact and pinch point hazards associated
with die setting and handling shall be
safeguarded.

The employer shall establish procedures for

the installation and removal of dies from the
die casting machine. The safeguarding
procedure shall include, lockout/tagout
program, selection and use of die handling
equipment, and selection and use of
personnel safety equipment.

5.3 Flash or Die Spitting E5.3 Flash or Die Spitting

Intentional flashing of a die for whatever Over the life of the die, some spitting of the
reason is an unsafe practice and shall be die may occur. The parting line should be
prohibited. guarded to prevent burn hazards from spitting
metal.
Vents used for air to escape during filling
should be guarded or directed away from the
operator.
5.4 Die Changing System
When a die changing system is used in
conjunction with a die casting machine, it is
permissible for motion to occur in the die
area with the machine doors and/or guards
open or removed only if and when the
following conditions are met.
1. A key operated selector switch is provided
to enable the die changing process.
2. If the die changer is mobile, it shall act as
a barrier to the die area, replacing the
opened or removed gate and/or guard
when in position. The mobile unit shall
include an electrical interlock, plugged
into the machine when the unit is in
position. This interlock permits the die
changing process to be functional.
3. If the die changer is fixed, it shall act as a
barrier to the die area, essentially
replacing the opened or removed gate
and/or guard.
4. If the die changer, mobile or fixed, does
not act as a barrier to the die area, then
interlocked perimeter guarding shall be
used to guard the die area and the die
changing system.

23
CLAUSE 6: SYSTEM REQUIREMENTS

6.1 Ancillary Equipment

The installation and use of any ancillary
equipment shall not reduce the level of
safety embodied in this standard.

This standard describes the use of ancillary

equipment in conjunction with a die casting
machine. It is not intended to define the
design and construction of ancillary
equipment.

All ancillary equipment shall be interlocked

to achieve safe, controlled operation and to
prevent hazardous motion when the die
casting machine is not in a predetermined
ready state.

Any die casting machine safety device that is

removed or altered for the use of ancillary
equipment shall be replaced by one or more
of the following: modified guard, additional
guarding, presence sensing devices, or
perimeter guarding. These additional safety
devices shall comply with the safeguard
requirements described in Clause 4.0.

6.1.1 Metal Delivery System E6.1.1 Metal Delivery System

When using a metal delivery system, there The following are examples of metal delivery
shall be a perimeter guard designed to systems:
prevent burn hazards based on the 1. Automatic ladle.
temperature, velocity, and quantity of metal 2. Metal pump.
3. Metal siphon.
being handled. All access safeguards shall
4. Robotic ladle.
be interlocked to stop hazardous motion of
5. Gooseneck.
both the metal delivery system and the die
This list is not all inclusive of metal delivery
casting machine. systems.

6.1.2 Plunger Lubrication System

Safeguards shall be used to avoid pinch
point, collision, burn, and other hazards
when a plunger lubrication system is used.

If combustible liquids are used, protective

measures shall be taken to prevent the
spraying of combustible liquids on exposed
metal baths and heat sources in the event of
a hose or pipe failure.

24
6.1.3 Die Lubrication System
Safeguards shall be used to avoid pinch
point, collision, burn, and other hazards
when a die lubrication system is used.

If combustible liquids are used, protective

measures shall be taken to prevent the
spraying of combustible liquids on exposed
metal baths and heat sources in the event of
delivery hose or pipe failure.

One of the following conditions shall be

achieved prior to activation of a die
lubrication system:
1. The rear guard and operator's door shall
be closed.
2. Perimeter guarding shall be in place.
3. Motion shall be controlled through two-
hand control. The two-hand control shall
be located in a position, which provides a
clear line of sight to the die space.

6.1.4 Casting Extraction System

Safeguards shall be used to avoid pinch
point, collision, burn, and other hazards
when a casting extraction system is used.

If combustible liquids are used, protective

measures shall be taken to prevent the
spraying of combustible liquids on exposed
metal baths and heat sources in the event of
a hose or pipe failure.

One of the following conditions shall be

achieved prior to activation of a casting
extraction system:
1. Perimeter guarding shall be in place.
2. Motion shall be controlled through two-
hand control. The two-hand control shall
be located in a position, which provides a
clear line of sight to the die space.

6.2 Emergency Stop Circuitry

The emergency stop circuitry shall be
hardwired and act independently from the
electronic control systems.

All ancillary equipment shall have a

hardwired emergency stop circuit connected
in series with the die casting machine
emergency stop circuit.

25
6.3 Control Interlocks

6.3.1 Timers E6.3.1 Timers

Timers shall not be used in conjunction with Timers should not be used to delay or initiate
interlocks to control the die casting machine motion of an interlocked guard.
or ancillary equipment during automatic or
semi-automatic operation.

6.3.2 Interlock Resets

Resetting the die casting machine shall not
automatically reset ancillary equipment.

CLAUSE 7: USER REQUIREMENTS

7.1 Training E7.1 Training

The employer shall train and instruct The employer should document training and
personnel in the safe operation and assessment of personnel.
maintenance of the die casting machine and
ancillary equipment.

7.2 Lockout/Tagout E7.2 Lockout/Tagout

The employer shall establish a program and The isolating devices shall disable machines
components and other equipment to prevent
procedure for affixing lockout or tagout
unexpected start-up or release of stored energy.
devices.
7.3 Risk Assessment
The employer shall perform a risk
assessment on die casting machines and
ancillary equipment to determine the
safeguarding necessary to achieve and
maintain a safe work environment.

7.4 Work Area

The employer shall provide adequate work
areas for safe operation of machines,
maintenance, and material handling. All
walkways and working surfaces shall be kept
in good condition and free from debris and
fluids.

7.5 Personal Protective Equipment E7.5 Personal Protective

The employer shall establish a personal Equipment
protective equipment program for personal The Personal Protective Equipment program should
safety. Safety equipment selected as a result include, but not be limited to, these types of
of risk assessment shall be appropriate for equipment:
the task to be performed and in compliance 1. Eye protection.
with applicable state, federal, and ANSI 2. Hand protection.
standards. 3. Body protection.
4. Foot protection.
5. Hearing protection.

26
7.6 Ventilation
A means of ventilation shall be provided to
vent hazardous vapors away from work
areas.

CLAUSE 8: MAINTENANCE
REQUIREMENTS

8.1 Training
The employer shall train and instruct
personnel in the safe operation and
maintenance of the die casting machine and
its ancillary equipment.

Maintenance personnel shall be trained on

the electrical, hydraulic, and pneumatic
systems. Training shall include mechanical
operation of the die casting machine and
ancillary equipment through on the job
training or specialized training.

8.2 Lockout/Tagout E8.2 Lockout/Tagout

The employer shall establish a program and See E7.2.
procedure for affixing lockout/tagout
devices.

8.3 Maintenance Operations While E8.3 Maintenance Operations

Under Power While Under Power
When motion of the die casting machine is Maximum speed is to be based on
required for maintenance, it shall occur in application; maximum safe recommended
manual mode at a speed that is less than full speed for Manual Mode is 250 mm/sec (10
in/sec).
machine speed. Any motion that creates a
hazard within the operator’s reach in manual
mode shall be controlled with a two-hand
control device.

8.4 Stuck Plunger – Cold Chamber

Machine
When freeing a stuck plunger in a cold
chamber die casting machine, maintenance
personnel shall not enter the die space
unless the die casting machine is locked out;
see Clause 7.2.

If die casting machine motion is required, see

Clause 8.3.

8.5 Stuck Casting

When freeing a stuck casting, personnel
shall not enter the die space unless the die

27
casting machine is locked out. If die casting
machine motion is required, see Clause 8.3.

CLAUSE 9: GENERAL INFORMATION

9.1 Equipment Identification

The following indications shall be clearly and
durably attached to the die casting machine:
1. Name and address of manufacturer.
2. Type of machine.
3. Serial number/machine number.
4. Year of manufacture.
5. Electrical characteristics.
6. Weight.
7. Safety Signage.

9.2 Machine Manual

The manufacturer or remanufacturer shall
supply a manual. The machine manual shall
include the following information:
1. Equipment Identification.
2. Type of machine.
3. Installation and transport weight.
4. Intended use of the machine.
5. Machine hazard identification.
6. Safety instructions.
7. Machine operating specifications.
8. Operating Procedures.
9. The prohibition of unauthorized
reconstruction and modification of the
machine.
10. An instruction by the manufacturer that
only personnel properly trained in the
operation, setup, and/or maintenance of
the die casting machine, should be
authorized to operate the machine.
11. Alarm descriptions.
12. Troubleshooting information.
13. Recommended lockout procedures.

28
ANNEXES

ANNEX A: COLD CHAMBER DIE CASTING MACHINE, TOP & SIDE VIEW
ANNEX B: HOT CHAMBER DIE CASTING MACHINE, TOP & SIDE VIEW
ANNEX C: VERTICAL DIE CASTING MACHINE, SIDE VIEW
ANNEX D: DIE AREA & DIE SPACE, TOP & SIDE VIEW
ANNEX E: TYPICAL DIE CASTING SYSTEM

Drawings have been simplified for clarity and are meant

for reference only within the context of this document.

29
 Drawings have been simplified for clarity and are meant
for reference only within the context of this document.

30
Drawings have been simplified for clarity and are meant
for reference only within the context of this document.

31
 Drawings have been simplified for clarity and are meant
for reference only within the context of this document.

32
Drawings have been simplified for clarity and are meant
for reference only within the context of this document.

33
 Drawings have been simplified for clarity and are meant
for reference only within the context of this document.

34