Minebea MPC-203-25 User manual

Molding Pressure Conversion Module
MPC-203-25
Instruction Manual
EN294-1982

I
Introduction
Thank you for purchasing the MPC-203-25 Molding Pressure Conversion Module.
This instruction manual describes how to operate the device, as well as noteworthy points.
Note that handling or operating the device incorrectly may result in malfunctions. Read this manual
thoroughly before use for safety and optimal results.
Keep this instruction manual in a location where it is readily accessible to end users.
Pictograms and conventions used in this manual
This manual uses the following pictograms to indicate actions to avoid at all times, aspects requiring
caution, and other noteworthy matters.
Be sure to read the descriptions provided alongside these pictograms.
WARNING
This indicates circumstances in which incorrect handling may result in death or serious injury to
users. Avoid the actions described here at all times.
CAUTION
This indicates circumstances in which incorrect handling may result in injury to users or damage to
property.
This indicates operating or procedural precautions or restrictions.
Always read the details included here to avoid malfunctioning.

II
Safety Precautions
Please be sure to read this manual before attempting to use the equipment.
1. Installation location
CAUTION
Install in a location where temperature and humidity conditions are within the ranges described
below.
 Amplifier
Environmental temperature: －10° C to 50° C
Environmental humidity: 85 % RH or less (Non-condensing)
 Relay box : MPC-304
Environmental temperature: 0 °C to 70 °C (0 °C to 100 °C when not using magnets)
Environmental humidity: 85 % RH or less (Non-condensing)
 Relay box : MRB-304-BI , MRB-304-CV
Environmental temperature: 0 °C to 100 °C
Environmental humidity: 85 % RH or less (Non-condensing)
WARNING
To minimize the risk of unforeseen accidents, avoid installing equipment in the following locations.
(1)
Do not install in the following locations:
 Hot locations or locations exposed to direct sunlight
 Damp locations
 Dusty locations
 Environments containing corrosive gases or salt
 Locations subject to sudden temperature or humidity fluctuations
 Close to equipment that generates magnetic or electromagnetic radiation
 Locations subject to the effects of radiation and radioactive materials
 Locations such as laboratories where chemical changes may occur

III
(2) When installing the amplifier
The individual component dimensions are as shown below:
The amplifier is held in place by sticking the magnetic sheet on the bottom of the device to the surface
on which it is to be installed.
The following conditions must be complied with when installing the amplifier.
 The surface on which it is installed must be flat and must be a strongly magnetic material (e.g., iron or
ferritic stainless steel) at least 5 mm thick.
 The magnetic sheet must be fully in contact with the surface.
CAUTION
Take care, as there is a risk of injury if your fingers become trapped between the magnetic sheet and
the equipment or rig on which the device is mounted.
CAUTION
Keep credit cards and cash cards away from the magnetic sheet, as the magnetism may render them
unusable.
Likewise, the magnetic sheet may also cause malfunctions if precision equipment such as PCs and
mobile phones are close by.
Unit: mm

IV
(3) When installing MPC-304 relay box
(For more information on installing the MRB-304-BI or MRB-304-CV, see the separate instruction
manuals.)
MRB-304-BI instruction manual EN294-1959
MRB-304-CV instruction manual EN294-1960
The individual component dimensions are as shown below:
The relay box can be mounted using the magnets or bolt-mounted using the mounting holes.
When mounting using the magnets, attach to the moving part (platen) of the mold clamping unit. Make
sure operating temperatures do not exceed 70 °C here.
Mount with bolts if the magnets provide insufficient magnetic attraction; if ambient temperatures at the
installation location exceed 70 °C; or if the relay box is mounted to the mold.
Unit: mm
Minimum bending radius: 50 mm
1
Magnet

V
CAUTION
Make sure ambient temperatures around the box are between 0 °C and 70 °C when mounting using
the magnets and between 0 °C and 100 °C when bolt-mounting.
CAUTION
When mounting using the magnets, check to confirm that magnetic attraction is adequate. If the
magnetic attraction is insufficient due to mounting surface conditions or if the relay box is to be
used for extended periods, mount using the bolts.
CAUTION
Keep credit cards and cash cards away from the magnets; the magnetic force may render them
unusable.
Likewise, the magnets may also cause malfunctions if precision equipment such as PCs and mobile
phones are located close by.
CAUTION
Remove the magnets before mounting the box with the bolts.
Otherwise, the box will not mount flush with the mounting surface.
M4 hex socket head bolts × 4
Magnet mounting screws × 2
Magnets × 2
Mount using the M4 hex socket head bolts in two of
the three holes on each side. (M4 tapped holes must
be drilled in the mounting surface.)
Remove the magnets before mounting using the bolts.
The magnets can be removed by removing the screws
in the center of the magnets.

VI
2. Power supply
WARNING
Turn off power before connecting or disconnecting cables.
Leaving power on may result in electric shock or equipment damage.
WARNING
Before turning on power, confirm that the power supply specifications match the power supply
specifications for the equipment.
Contact with us if the specifications do not match. Using an unconfirmed power supply may result in
electric shock or equipment damage.
CAUTION
Always ground the equipment.
Failure to ground the equipment may result in electric shock or malfunctions.
3. Precautions
CAUTION
Always set the sensor or pressure transmitting pin using the software before first use or after
replacing them. Failure to set the equipment may result in incorrect measurements, equipment
malfunctions, and damage to peripheral equipment. Likewise, reset the equipment if it has been set
once but gives incorrect results.
CAUTION
Confirm that the wiring is correctly connected before attempting to use the equipment. Incorrect
wiring of the equipment may lead to incorrect measurements, equipment malfunctions, damage to
peripheral equipment, and serious accidents.
CAUTION
Altering the settings while carrying out measurements using the equipment will result in incorrect
measurements, equipment malfunctions, and damage to peripheral equipment.
CAUTION
Protect the equipment from impact or shock—for example, impact or shock caused by striking
against other objects.
Impact or shock may damage the equipment and lead to failures in the electrical circuits.
CAUTION
Do not remove the equipment case cover or attempt to disassemble the equipment.
Doing so may damage the case and affect durability and operations.
This system saves measurement data to a PC memory storage device (e.g., hard disk drive).
Periodically sort out stored data to prevent freezing or degradation of PC performance.
To prevent communication errors, always shut down the measurement software before turning off
the equipment power or disconnecting the USB cable connecting the equipment and PC.

VII
Do not open numerical data or alarm history csv files while acquiring data with the PC.
Opening such files while acquiring data with the PC will result in an error, and will turn the PC
interface off-line without updating the numerical data or alarm history.
Set the start trigger signal interrupt interval to at least 1 s.
Leave an interval of at least 1 s before starting measurement after changing the conditions or
aborting measurement using the [Stop] button.
Always make sure that the latest version of the measurement software is installed and used. Older
versions of the software will not operate with the latest version of the amplifier updated with
additional features.
The latest software version supports all previous amplifiers.
When upgrading the measurement software, always uninstall the old software version first before
installing the new version.
For details on how to attach the sensor to the mold, see Section 25 "Appendix".

VIII
4. Compatible standards
This equipment conforms to the following standards:
EN61326-1: 2013
"Electrical equipment for measurement, control, and laboratory use - EMC
requirements"
"Immunity requirements for equipment intended to be used in industrial locations"
EN IEC 63000: 2018
"Technical documentation for the assessment of electrical and electronic products with
respect to the restriction of hazardous substances" (RoHS Directive)
CAUTION
The following usage conditions must be strictly adhered to ensure that this equipment complies with
the above standards. The equipment may not be compliant if these conditions are not followed.
 Power supply
A "CE mark compliant" 24 V DC power supply must always be used.
 Cables
Always use shielded cables, except for power cables.
The USB cable must be fitted with a ferrite core as described in Section 5-2-4 "USB Connection".
 Shielding
The shield wire of the I/O cable must be connected to the protective ground terminal.
The shield wire of the V-OUT cable must be connected to the F.G. terminal.
The opposing shield wires of the I/O cable and V-OUT cable must be grounded (grounded at both
ends).
 Grounding
Ground the equipment based on single grounding using a protective ground terminal.
For details of the protective ground terminal and F.G. terminal, see Section 4 "Equipment Part Names
and Functions".

IX
Revision History
Date Manual No. Revision reason (details)
Dec. 2021 DRW. No. EN294-1982 1st issue

X
Contents
Page
Introduction ....................................................................................................... I
Pictograms and conventions used in this manual .................................................... I
Safety Precautions ............................................................................................. II
1. Installation location ........................................................................................................... II
(1) Do not install in the following locations. ..................................................................................II
(2) When installing the amplifier .................................................................................................. III
(3) When installing MPC-304 relay box .................................................................................... IV
2. Power supply ................................................................................................................... VI
3. Precautions ...................................................................................................................... VI
4. Compatible standards .................................................................................................... VIII
Revision History ............................................................................................... IX
1. Overview....................................................................................................... 1
2. Software System Operating Requirements ......................................................... 1
3. System Configuration ..................................................................................... 2
4. Equipment Part Names and Functions ............................................................... 3
4-1. Amplifier ....................................................................................................................... 3
4-2. Relay box and relay cable ............................................................................................ 4
5. System Setup ................................................................................................ 6
5-1. Installation on Molding Machine ................................................................................... 7
5-1-1. Relay Box Installation ..................................................................... 7
5-1-2. Amplifier Installation....................................................................... 8
5-2. Terminal Board Connections......................................................................................... 9
5-2-1. Power and Ground Connections....................................................... 9
5-2-2. External Control Input/Output Connection ...................................... 10
5-2-3. Analog Voltage Output Connection ................................................ 11
5-2-4. USB Connection ........................................................................... 12
5-2-5. Sensor Connection ....................................................................... 12
5-3. Installing the Software ................................................................................................ 13
5-4. Installing the Driver Software ...................................................................................... 16
6. Starting to Use the Software .......................................................................... 21
7. Launching the Software ................................................................................ 22
7-1. To Launch the Software .............................................................................................. 22
8. Explanation of the Measurement Screen ......................................................... 23
8-1. Menu Bar.................................................................................................................... 24
8-2. Measurement Buttons ................................................................................................ 30
8-3. Measurement Data Display ........................................................................................ 30
8-4. Alarm Display ............................................................................................................. 30
8-5. Error Display .............................................................................................................. 31
8-6. No. of Shots Display ................................................................................................... 31
8-7. Waveform Display ...................................................................................................... 32

XI
8-7-1. Using Graph Zoom, In/Out, Move ................................................... 34
8-7-2. Adjust Scale Automatically ............................................................ 39
8-8. Measurement Conditions Display................................................................................ 40
8-9. Display Channel Selection .......................................................................................... 40
8-10. Status Display 1 .......................................................................................................... 41
8-11. Status Display 2 .......................................................................................................... 41
9. Change Condition Screen .............................................................................. 42
9-1. Measurement Conditions Tab ..................................................................................... 42
9-1-1. Measurement Mode ...................................................................... 43
9-1-2. Sensor Channels .......................................................................... 44
9-1-3. Measurement ............................................................................... 47
9-1-4. Start Trigger ................................................................................ 48
9-1-5. Eject Detection Range .................................................................. 49
9-2. Alarm Conditions Tab .................................................................................................. 50
9-2-1. Alarm Detection Enabled Setting ................................................... 50
9-2-2. Graph .......................................................................................... 51
9-2-3. Alarm Condition Setting Channel ................................................... 51
9-2-4. Alarm Output Condition Settings.................................................... 52
9-2-5. Alarm Setting Examples ................................................................ 55
9-2-6. Alarm Signal Output Settings ........................................................ 57
9-2-7. Alarm Cancel Conditions Settings .................................................. 58
9-3. Graph Tab ................................................................................................................... 59
9-3-1. Real Time Graph and Overlay Graph.............................................. 59
9-3-2. Trend Graph ................................................................................ 61
9-3-3. Template ..................................................................................... 62
9-4. Analog Output Tag ...................................................................................................... 63
9-4-1. Analog Output Settings ................................................................. 63
9-5. Operating Buttons ....................................................................................................... 64
10. Data Processing Screen ............................................................................ 65
10-1. Menu Bar .................................................................................................................... 66
10-1-1. File ............................................................................................. 66
10-1-2. Print ............................................................................................ 66
10-1-3. Display ........................................................................................ 66
10-1-4. Window ....................................................................................... 66
10-2. Operating Buttons ....................................................................................................... 67
10-3. Waveform Display Area............................................................................................... 68
10-3-1. Using Graph Zoom, In/Out, Move ................................................... 68
10-3-2. Adjust Scale Automatically ............................................................ 68
10-3-3. Analyzing Waveform Data ............................................................. 69
10-4. Information Display Area ............................................................................................. 76
10-4-1. Explanation of Display Area .......................................................... 77
11. Statistics Screen ...................................................................................... 78
11-1. Display Selection ........................................................................................................ 78
11-2. Operating buttons ....................................................................................................... 78
12. Administrator Setup Screen ....................................................................... 79

XII
13. I/O Test Screen ........................................................................................ 83
14. Analog Output Test Screen ........................................................................ 84
15. Monitor Screen ........................................................................................ 84
16. Analog Output Fine Adjustment Screen ....................................................... 85
17. Check ERROR LED Details ........................................................................ 88
18. File Output Destinations ............................................................................ 89
18-1. Error Log File Output Destination ............................................................................... 89
18-2. Measurement Results Auto File Output Destination .................................................... 89
18-3. Manual File Output Destination .................................................................................. 90
19. Software Condition Setting Precautions ....................................................... 91
19-1. Maximum Number of Overlay Shots Setting ............................................................... 91
20. Software Uninstall Procedure ..................................................................... 92
20-1. Uninstalling the Software ............................................................................................ 92
21. Troubleshooting ....................................................................................... 94
21-1. General ...................................................................................................................... 94
21-2. Measurement Problems ............................................................................................. 95
21-3. External Control Input/Output Problems ..................................................................... 96
21-4. Analog Voltage Output Problems ................................................................................ 96
21-5. Amplifier Error Problems (ERROR LED Illuminated)................................................... 97
21-6. PC Personalization ..................................................................................................... 98
22. Hardware Specifications ............................................................................ 99
22-1. Analog Specifications ................................................................................................. 99
22-2. Digital Specifications .................................................................................................. 99
22-3. Interface ..................................................................................................................... 99
22-4. General Specifications...............................................................................................100
22-5. Accessories ...............................................................................................................100
22-6. Options ......................................................................................................................100
22-6-1. Relay box .................................................................................. 100
22-6-2. Relay cable ................................................................................ 101
22-6-3. Analog voltage output cable ........................................................ 102
22-6-4. External control input/output cable .............................................. 102
23. Warranty ............................................................................................... 102
23-1. Warranty ....................................................................................................................102
23-2. Repairs ......................................................................................................................102
23-3. Component Service Lives ..........................................................................................102
24. Appendix ............................................................................................... 103
24-1. Embedding the sensor...............................................................................................103
24-2. Counterboring the sensor embedding hole ................................................................104
24-3. Anchoring the sensor cable .......................................................................................105
24-4. Opening for the sensor cable .....................................................................................106
24-5. Vertically positioning the ejector plate ........................................................................106
24-6. Removing a sensor ...................................................................................................106

1
1. Overview
This equipment is an four-channel input digital conversion module for measuring resin pressure inside
molds in injection molding machines.
The pressure input from force sensors is monitored in accordance with preset parameters, and the
results are output in the form of an alarm signal.
Pressure waveforms converted to analog voltages can be transmitted to the molding machine.
PC software can also be used to display the pressure waveforms in real time, save, export and
analyze them, and perform various settings. The PC can be disconnected after setting performed by
the software, enabling the pressure to be monitored continuously using the module itself.
2. Software System Operating Requirements
PC PC/AT compatible machine
Operating system Windows 7, 8, 8.1, 10
CPU 2 GHz or higher
RAM 4.0 GB or higher
USB port 1 port required
CD-ROM drive Required
Mouse or similar input device Required
Keyboard Required
Monitor At least 1,280 x 768 resolution
* Software is not guaranteed to run on all PCs.
Spreadsheet software such as Microsoft Excel should be used for complex analysis work, plotting
data for multiple waveforms, and other works.

2
3. System Configuration
Configuration Example
The MPC-203-25 (this equipment), relay box, and relay cable are all sold separately.
For further details on optional items, see Section 22-6 “Options”.
For details on how to attach the sensor to the mold, see Section 24 "Appendix".
Relay cable
FA409-567-*M
USB
Analog voltage output (4 channels)
Relay box
MPC-304
START (Start trigger input)
ALARM RESET (Alarm cancel input)
ALARM (Alarm output)
DC24 V
4-channel amplifier
Mold interior
Force sensors (LSMS,LSMSB × 4)
...

3
4. Equipment Part Names and Functions
4-1. Amplifier
(1) Sensor connection D-sub connector
Allows up to four sensors to be connected via the relay cable and relay box.
Only Minebea dedicated sensors are supported.
(2) Status LEDs
Indicate the equipment status.
The POWER LED illuminates when the power is on, the ALARM LED illuminates when an alarm
occurs, and the ERROR LED illuminates when an amplifier error occurs.
(3) Terminal board
Used to connect the 24 V DC power supply and external control input/output (I/O).
(4) USB connector
A mini-B type USB connector for connecting to a PC.
(5) V-OUT D-sub connector
Connects the analog voltage output (V-OUT) to an external control device.
(6) Ground terminal
Connect this to ground to eliminate static electricity or noise. Also connect the shield wire of the I/O
cable. This terminal is internally linked to F.G. on the terminal board.
(7) F.G. terminal
Use this terminal to connect the V-OUT cable shield wire to prevent noise effects. The F.G. terminal is
internally linked to the F.G. terminal on the terminal board.
(8) Magnetic sheet
Used to secure the amplifier to the surface on which it is installed. For further details, see "1.
Installation location" in "Safety Precautions".
If this equipment is to comply with CE mark applicable standards, connect the correct cable and
ground properly. For further details, see Section 4 "Compatible standards" in "Safety Precautions".
(4) USB connector
(3) Terminal board
(6) Ground terminal
(2) Status LEDs
(1) Sensor connection D-sub connector (5) V-OUT D-sub connector
(8) Magnetic sheet
(7) F.G. terminal

4
4-2. Relay box and relay cable
MPC-304
MRB-304-BI
MRB-304-CV
(3) Magnetic sheet
(2) Relay cable
(1) Sensor connectors CH1 to CH4
(4) Bolt mounting holes
(1) Sensor connectors CH1 to CH4
(2) Relay cable
(4) Bolt mounting holes
(4) Bolt mounting holes
(2) Relay cable
(1) Sensor connectors CH1 to CH4
(4) Bolt mounting holes
(4) Bolt mounting holes

5
(1) Sensor connectors CH1 to CH4
Allows up to four sensors to be connected. Only our dedicayed sensors are supported.
(2) Relay cable
Connects the sensor connection D-sub connector on the amplifier to the D-sub connector on the relay
box. The cable is available in 2 m, 5 m, and 10 m lengths and is sold separately, as with the relay box.
(3) Magnets
Mount the MPC-304 on the installation location using magnets. For further details, see "1. Installation
location" in "Safety Precautions".
(4) Bolt mounting holes
Mount MPC-304 using M4 hex socket head bolts in the holes on either side of the relay box. (M4
tapped holes must be drilled into the mounting surface.)
Mount the MRB-304-BI or MRB-304-CV by securing M5 bolts in the holes on either side of the relay
box. (M5 tapped holes must be drilled in the mounting surface.)
For further details, see "1. Installation location" in "Safety Precautions".
CAUTION
Remove the magnets before mounting using the bolts. Otherwise, the box will not mount flush with
the mounting surface.
CAUTION
When connecting the relay cable to the relay box, be sure to securely tighten the screws on both
sides of the D-sub connector.
The MPC-203-25 (this equipment), relay box, and relay cable are all sold separately. For further
details on optional items, see Section 22-6 “Options”.
Waveform data cannot be loaded when using the MPC-308B relay box, even if sensors are installed
for channels 5 to 8.
Changing the relay cable length will change the excitation voltage acting on the sensor due to the
change in cable resistance, resulting in discrepancies in sensor output values. Take care to avoid
altering the cable length when comparing data: for example, when transferring between molds.
*For details on sensor output discrepancies due to cable length changes, see the following table.
2 m → 5 m 2 m → 10 m 5 m → 10 m
Percentage
change Approx. -0.3 % Approx. -0.8 % Approx. -0.5 %

6
5. System Setup
The procedure for configuring the molding pressure system using the module is outlined below.
Install the module close to the molding machine
Connect the module power supply, I/O, and V-OUT cables, and
connect the module to a PC using a USB cable.
Turn on the power to the module.
Install the measurement software and module driver software on the
PC.
Use the software to set the molding pressure measurement and
monitoring conditions for the module.
Example settings:
 Sensor rated capacity and pressure sensing area
 Span and sampling frequency for one shot
 Alarm output conditions
 Alarm cancel conditions
 Analog output conditions
Measurement and monitoring is started by the start signal.
If the waveform from the measuring software is not required, the PC
can be disconnected from the module, enabling alarm monitoring of
the molding pressure using the module on its own.
Only alarm monitoring is performed with independent module operation, and waveform data is not
acquired.
To install the driver software, connected the amplifier to the PC by a USB cable, and turn on the
power to the amplifier.
(4) Software and driver
installation
(2) Wiring
(1) Installation
(6) Molding pressure
monitoring
(5) Setup
(3) Power on