Mold-Masters E-Multi EM1 User manual

Controller User Manual
version 2
Original Instrucons

Table of Contents
Section 1 - Introduction ...................................................1-1
1.1 Intended Use ......................................................................................................1-1
1.2 Release Details ..................................................................................................1-1
1.3 Warranty .............................................................................................................1-1
1.4 Returned Goods Policy.......................................................................................1-1
1.5 Movement or Resale of Mold-Masters Products or Systems .............................1-1
1.6 Copyright ............................................................................................................1-2
1.7 Units of Measure and Conversion Factors .........................................................1-2
1.8 Trademarks and Patents ....................................................................................1-3
Section 2 - Global Support ..............................................2-1
2.1 Manufacturing Facilities......................................................................................2-1
2.2 Regional O󰀩ces .................................................................................................2-1
2.3 International Representatives.............................................................................2-2
Section 3 - Safety..............................................................3-1
3.1 Introduction.........................................................................................................3-1
3.2 Safety Hazards ...................................................................................................3-2
3.3 Operational Hazards...........................................................................................3-5
3.4 General Safety Symbols.....................................................................................3-7
3.5 Wiring Check ......................................................................................................3-8
3.6 Lockout Safety....................................................................................................3-9
3.6.1 Electrical Lockout.....................................................................................3-10
3.6.2 Energy Forms and Lockout Guidelines....................................................3-11
3.7 Grounded Earth Connections ...........................................................................3-12
3.8 Disposal............................................................................................................3-12
3.9 E-Multi Controller Safety Hazards ....................................................................3-13
3.9.1 Operational Environment.........................................................................3-13
3.9.2 Cabinet Push / Tip Forces .......................................................................3-13
3.10 E-Multi Injection Unit Safety Labels................................................................3-15
3.11 E-Multi Injection Unit Safety Hazards .............................................................3-16
3.12 E-Multi Injection Unit Safety Symbols.............................................................3-18
3.13 E-Multi Injection Unit Safety Guards...............................................................3-19
3.14 E-Multi Weight Specications.........................................................................3-20
3.15 Unpack the E-Multi Controller.........................................................................3-21
3.16 Lift the E-Multi Controller ................................................................................3-23
3.16.1 Preparation ............................................................................................3-23
3.17 Lift the E-Multi Injection Unit...........................................................................3-25
3.17.1 Prior to Lifting the E-Multi Injection Unit.................................................3-25
3.18 EM1 / EM2 / EM3 Lift Connections.................................................................3-26
3.18.1 EM1 / EM2 / EM3 Vertical Lift Connections...........................................3-26
3.18.2 EM1 / EM2 / EM3 Horizontal Lift Connections.......................................3-27
3.19 E-Multi Injection Unit Stand Safety .................................................................3-28
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E-Multi Controller User Manual

Section 4 - Overview ........................................................4-1
4.1 Controller Front...................................................................................................4-1
4.2 Controller Back - Connections Side....................................................................4-2
4.3 Cable Holders.....................................................................................................4-3
Section 5 - Installation .....................................................5-1
5.1 Introduction.........................................................................................................5-1
5.2 Connect the Controller to the E-Multi .................................................................5-2
5.3 Connect a Robot to the Controller ......................................................................5-2
5.4 Connect the Controller to the Molding Machine .................................................5-3
5.5 Connect a Handheld HMI (Optional) ..................................................................5-4
5.6 Connect Diagnostic Computer (Optional)...........................................................5-4
Section 6 - Operation .......................................................6-1
6.1 Introduction.........................................................................................................6-1
6.2 Isolate the Controller ..........................................................................................6-1
6.3 Switch On ...........................................................................................................6-2
6.4 Switch O󰀨 (Shutdown)........................................................................................6-2
6.4.1 Shutdown the Heating ...............................................................................6-2
6.4.2 Shutdown the Controller ............................................................................6-2
Section 7 - E-Multi Controller HMI Interface...................7-1
7.1 Introduction.........................................................................................................7-1
7.2 Cabinet Mounted Control Buttons ......................................................................7-2
7.3 E-Multi Touchscreen Interface ............................................................................7-3
7.3.1 Top Bar - Status Display ............................................................................7-4
7.3.2 Active Movement Icons..............................................................................7-5
7.3.3 Status Icons...............................................................................................7-5
7.3.4 Bottom Bar - Screen Navigation Buttons...................................................7-6
7.3.5 Print Functionality ......................................................................................7-7
7.4 Screen Descriptions ...........................................................................................7-8
7.5 Overview Screen ................................................................................................7-9
7.6 Injection Settings Screen..................................................................................7-13
7.7 Hold Settings Screen........................................................................................7-16
7.8 Recovery Settings Screen ................................................................................7-18
7.9 Barrel Temperature Settings - Legacy Controllers* ..........................................7-21
7.10 Barrel Temperature Settings - Mold-Masters Screen .....................................7-23
7.11 Integrated Hot Runner Temperature Control (Option).....................................7-26
7.11.1 Monitor Screen.......................................................................................7-27
7.11.2 Setup Screen (Supervisor Level)...........................................................7-31
7.11.3 Utilities Screen (Supervisor Level).........................................................7-35
7.12 Integrated E-Drive Control (Option)................................................................7-37
7.12.1 E-Drive Control Buttons.........................................................................7-38
7.13 Overview Screen ............................................................................................7-39
7.13.1 Homing ..................................................................................................7-40
7.14 Settings Screen (Supervisor Level) ................................................................7-41
7.15 Valve Gate Settings Screen............................................................................7-43
7.16 Shuto󰀨-Nozzle Settings Screen......................................................................7-45
7.17 7.17 Shuto󰀨-Nozzle Settings Screen—Kortec................................................7-48
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E-Multi Controller User Manual

7.18 Production Graph Screen ...............................................................................7-51
7.18.1 Lower Menu Buttons..............................................................................7-53
7.19 Software Oscilloscope ....................................................................................7-54
7.19.1 Measure Parameter...............................................................................7-54
7.19.2 Trigger....................................................................................................7-55
7.19.3 Parameter..............................................................................................7-55
7.19.4 Line Color ..............................................................................................7-56
7.20 Process Data (PD) Protocol Screen ...............................................................7-57
7.20.1 Lower Menu Buttons..............................................................................7-58
7.21 Main Settings Screen .....................................................................................7-59
7.22 System Settings Screen .................................................................................7-61
7.22.1 Lower Menu Buttons..............................................................................7-63
7.23 E-Multi Radial / Servo Carriage Screen..........................................................7-64
7.24 Auto Purge Screen .........................................................................................7-66
7.25 Info-Log Screen ..............................................................................................7-68
7.26 Programmable I/O ..........................................................................................7-70
7.26.1 I/O Monitor Screen.................................................................................7-72
7.27 Production Settings Screen ............................................................................7-73
7.28 Drive Monitor Screen......................................................................................7-74
7.29 Task Monitor Screen.......................................................................................7-76
7.30 Drive Parameter Monitor Screen ....................................................................7-77
7.31 PID Settings....................................................................................................7-78
7.32 Reference Settings Screen.............................................................................7-79
7.32.1 Reference Settings Screen - continued.................................................7-80
7.33 Machine Data Screen .....................................................................................7-81
7.34 Variable Monitor Screen .................................................................................7-82
7.35 Delay Settings Screen ....................................................................................7-84
7.36 Calibration Settings Screens ..........................................................................7-85
7.37 Alarms Screen ................................................................................................7-86
7.38 Mold Data Screen...........................................................................................7-88
7.38.1 Lower Menu Buttons..............................................................................7-89
7.39 Euromap E67 Screen .....................................................................................7-90
7.40 Legacy E67 Screen ........................................................................................7-91
Section 8 - Maintenance...................................................8-1
8.1 Clean the HMI Screen ........................................................................................8-1
8.2 Preventative Maintenance ..................................................................................8-1
8.3 Verify Injection Pressure Oil Circuit
(Preload Pressure)..............................................................................................8-2
8.3.1 Check the Preload Oil Pressure ................................................................8-2
8.4 Nozzle Protrusion Adjustment - Automatic Adjustment.......................................8-3
8.4.1 Carriage Home Position Calibration ..........................................................8-3
8.4.2 Manual Calibration.....................................................................................8-3
8.4.3 Automatic Calibration.................................................................................8-4
8.5 Injection Axis Referencing ..................................................................................8-5
8.6 Service and Repair The Controller .....................................................................8-6
8.6.1 Replacement Parts ....................................................................................8-6
8.6.2 Cleaning and Inspection ............................................................................8-6
8.7 Update Software.................................................................................................8-7
8.7.1 Save Mold Data .........................................................................................8-7
8.7.2 Save Machine Data ...................................................................................8-8
8.7.3 Install New Software..................................................................................8-9
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E-Multi Controller User Manual

Section 9 - Troubleshooting ............................................9-1
9.1 Thermocouple Electrical Check..........................................................................9-1
9.2 Heater Continuity Check.....................................................................................9-1
9.3 Transducer Output Check...................................................................................9-1
9.4 Vibrator Valve Check ..........................................................................................9-1
9.5 Servo Motor Temperature Check........................................................................9-2
9.6 Troubleshoot the Control System .......................................................................9-2
9.6.1 Fault and Warning Messages ....................................................................9-3
Index ......................................................................................I
Section 10 - Index.................................................................I
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E-Multi Controller User Manual

List of Tables
Table 1-1 Release Details.........................................................................................1-1
Table 1-2 Units of Measure and Conversion Factors ...............................................1-2
Table 3-1 Safety Hazards .........................................................................................3-3
Table 3-2 Typical Safety Symbols.............................................................................3-7
Table 3-3 Energy Forms, Energy Sources and General
Lockout Guidelines ...........................................................................................3-11
Table 3-4 Cabinet Push / Tip Forces ......................................................................3-13
Table 3-5 E-Multi Injection Unit Safety Hazard Details ...........................................3-16
Table 3-6 Safety Symbols Used on the E-Multi Injection Unit ................................3-18
Table 3-7 E-Multi Injection Unit Shipping Dimensions and
Weight...............................................................................................................3-20
Table 3-8 E-Multi Injection Unit Lifting Kits .............................................................3-25
Table 3-9 EM1 / EM2 / EM3 Vertical Lift Connections ............................................3-26
Table 3-10 EM1 / EM2 / EM3 Horizontal Lift Connections......................................3-27
Table 7-1 Control Buttons .........................................................................................7-2
Table 7-2 Top Bar - Status Display ...........................................................................7-4
Table 7-3 Active Movement Icons.............................................................................7-5
Table 7-4 Status Icons ..............................................................................................7-5
Table 7-5 Screen Navigation Buttons .......................................................................7-6
Table 7-6 Printer Settings .........................................................................................7-7
Table 7-7 Overview Screen Components ...............................................................7-10
Table 7-8 Overview Screen Context Menu Buttons................................................7-12
Table 7-9 Injection Settings Screen Components...................................................7-13
Table 7-10 Injection Settings Screen Context Menu Buttons .................................7-15
Table 7-11 Hold Setting Screen Components.........................................................7-16
Table 7-12 Hold Settings Screen Context Menu Buttons .......................................7-17
Table 7-13 Recovery Settings Screen Components...............................................7-18
Table 7-14 Recovery Settings Screen Context Menu Buttons................................7-20
Table 7-15 Legacy Style Barrel Temperature Setting Screen
Components .....................................................................................................7-21
Table 7-16 Legacy Style Barrel Temperature Setting Screen
Context Menu Buttons ......................................................................................7-22
Table 7-17 Mold-Masters Barrel Temperature Screen
Components .....................................................................................................7-24
Table 7-18 Mold-Masters Temperature Settings Screen
Context Menu Buttons ......................................................................................7-25
Table 7-19 Monitor Screen Control Buttons............................................................7-27
Table 7-20 Heat Zone Display ................................................................................7-28
Table 7-21 Utility Screen Elements.........................................................................7-36
Table 7-22 E-Drive Control Buttons ........................................................................7-38
Table 7-23 E-Drive Overview Screen Elements .....................................................7-39
Table 7-24 E-Drive Screen Context Menu Buttons.................................................7-40
Table 7-25 E-Drive Settings Screen Elements .......................................................7-42
Table 7-26 Valve Gate Settings Screen Elements..................................................7-44
Table 7-27 Production Graph Screen Elements .....................................................7-46
Table 7-28 Production Graph Screen Context Menu Buttons.................................7-46
Table 7-29 Production Graph Screen Lower Menu Buttons ...................................7-47
Table 7-30 Measure Parameter Tab Fields.............................................................7-48
Table 7-31 Process Data Screen Components ......................................................7-51
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E-Multi Controller User Manual

Table 7-32 Process Data Screen Lower Menu Buttons..........................................7-52
Table 7-33 Process Data Screen Context Menu Buttons .......................................7-52
Table 7-34 Systems Settings Screen Components ................................................7-55
Table 7-35 System Settings Screen Lower Menu Buttons .....................................7-57
Table 7-36 E-Multi Radial / Servo Carriage Screen Components ..........................7-58
Table 7-37 E-Multi Radial / Servo Carriage Screen Context
Menu Buttons....................................................................................................7-59
Table 7-38 Auto Purge Screen Elements................................................................7-61
Table 7-39 Info-Log Screen Elements ....................................................................7-62
Table 7-40 Info-Log Menu Buttons .........................................................................7-63
Table 7-41 Info-Log Filter Elements........................................................................7-63
Table 7-42 Programmable I/O Screen Components...............................................7-64
Table 7-43 I/O Monitor Screen Components ..........................................................7-66
Table 7-44 Production Settings Screen Components.............................................7-67
Table 7-45 Drive Manager Screen Components ....................................................7-68
Table 7-46 Drive Parameter Monitor Screen Components.....................................7-71
Table 7-47 PID Settings Screen Components ........................................................7-72
Table 7-48 Reference Settings Screen Elements...................................................7-73
Table 7-49 Reference Settings Screen Context Menu Buttons ..............................7-74
Table 7-50 Machine Data Screen Components......................................................7-75
Table 7-51 Variable Monitor Screen Components ..................................................7-77
Table 7-52 Delay Setting Screen Components.......................................................7-78
Table 7-53 Calibration Settings Screen Components.............................................7-79
Table 7-54 Alarms Screen Components .................................................................7-81
Table 7-55 Mold Data Screen Components............................................................7-82
Table 7-56 Mold Data Screen Menu Buttons..........................................................7-83
Table 7-57 Euromap E67 Screen Components ......................................................7-84
Table 8-1 Preventive Maintenance Schedule ...........................................................8-1
Table 9-1 Fault and Warning Messages ...................................................................9-3
Table 9-2 Integrated HRC Warning Messages .........................................................9-4
List of Tables
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E-Multi Controller User Manual

List of Figures
Figure 3-1 Injection molding machine hazard areas.................................................3-2
Figure 3-2 E-Multi controller safety hazards...........................................................3-14
Figure 3-3 E-Multi injection unit safety labels .........................................................3-15
Figure 3-4 Guards layout........................................................................................3-19
Figure 3-5 Correct side of crate to open.................................................................3-21
Figure 3-6 Remove top row of screws....................................................................3-21
Figure 3-7 Remove cross brace screws .................................................................3-22
Figure 3-8 Remove screws from side and bottom..................................................3-22
Figure 3-9 Eyebolts and washers ...........................................................................3-23
Figure 3-10 Install eyebolts and washers ...............................................................3-24
Figure 3-11 Attach slings to all four eyebolts ..........................................................3-24
Figure 3-12 Do not use the motor as a lifting point.................................................3-25
Figure 4-1 Controller front ........................................................................................4-1
Figure 4-2 Controller back connections....................................................................4-2
Figure 4-3 Diagnostic kit (option)..............................................................................4-2
Figure 4-4 Cable holders ..........................................................................................4-3
Figure 4-5 Attach cable holders................................................................................4-3
Figure 5-1 EM3 servo cable routing .........................................................................5-2
Figure 5-2 Robot jumper plug...................................................................................5-2
Figure 5-3 E-Multi connection locations ...................................................................5-3
Figure 5-4 Handheld HMI and connection................................................................5-4
Figure 5-5 Wireless network icon .............................................................................5-5
Figure 6-1 E-Multi main power switch ......................................................................6-1
Figure 6-2 Button strip below controller display (HMI)..............................................6-2
Figure 7-1 Cabinet mounted control buttons ............................................................7-2
Figure 7-2 Print functionality screen .........................................................................7-7
Figure 7-3 Overview screen .....................................................................................7-9
Figure 7-4 Injection settings screen........................................................................7-13
Figure 7-5 Hold settings screen..............................................................................7-16
Figure 7-6 Recovery settings screen......................................................................7-18
Figure 7-7 Legacy style barrel temperature settings screen ..................................7-21
Figure 7-8 Mold-Masters barrel temperature settings
screen...............................................................................................................7-23
Figure 7-9 Integrated hot runner controller overview
screen...............................................................................................................7-26
Figure 7-10 Hot runner controller monitor screen...................................................7-27
Figure 7-11 Setup screen (supervisor level)...........................................................7-31
Figure 7-12 Utilities screen (supervisor level) ........................................................7-35
Figure 7-13 E-Drive control screen components ....................................................7-37
Figure 7-14 E-Drive controller overview screen .....................................................7-39
Figure 7-15 E-Drive setting screen.........................................................................7-41
Figure 7-16 Valve gate settings screen ..................................................................7-43
Figure 7-17 Production graph screen ....................................................................7-45
Figure 7-18 Production graph screen lower menu buttons.....................................7-47
Figure 7-19 Process data protocol screen..............................................................7-51
Figure 7-20 Process data screen lower menu buttons ...........................................7-52
Figure 7-21 Main setting screen .............................................................................7-53
Figure 7-22 Machine specication screen icons.....................................................7-54
Figure 7-23 System settings screen .......................................................................7-55
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E-Multi Controller User Manual

List of Figures
Figure 7-24 System settings screen lower menu buttons.......................................7-57
Figure 7-25 E-Multi Radial / Servo carriage screen................................................7-58
Figure 7-26 Auto purge screen ...............................................................................7-60
Figure 7-27 Info-log screen ....................................................................................7-62
Figure 7-28 Programmable I/O screen ...................................................................7-64
Figure 7-29 I/O monitor screen...............................................................................7-66
Figure 7-30 Production settings screen..................................................................7-67
Figure 7-31 Drive monitor screen ...........................................................................7-68
Figure 7-32 Task monitor screen ............................................................................7-70
Figure 7-33 Drive parameter monitor screen..........................................................7-71
Figure 7-34 Reference settings screen ..................................................................7-73
Figure 7-35 Machine data screen...........................................................................7-75
Figure 7-36 Variable monitor screen ......................................................................7-76
Figure 7-37 Delay settings screen..........................................................................7-78
Figure 7-38 Calibration settings screen..................................................................7-79
Figure 7-39 Alarms screen .....................................................................................7-80
Figure 7-40 Mold data screen.................................................................................7-82
Figure 7-41 Mold data screen lower menu buttons ................................................7-83
Figure 7-42 Euromap E67 screen ..........................................................................7-84
Figure 8-1 Nozzle protrusion adjustment - Radial and
Servo carriage models........................................................................................8-4
Figure 9-1 Alarms screen with motor temperature alarm .........................................9-2
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E-Multi Controller User Manual

Section 1 - Introduction
The purpose of this manual is to assist users in the integration, operation
and maintenance of the E-Multi controller. This manual is designed to cover
most system congurations. If you need additional information specic to your
system please contact your representative or a Mold-Masters o󰀩ce whose
location can be found in the “Global Support” section.
1.1 Intended Use
The E-Multi controller is an electrical switching device designed for use with
the E-Multi Auxiliary Injection Unit (AIU). It is designed to be safe during
normal operation. Any other uses would fall outside the engineered intent
of this machine which may be a safety hazard and would void any and all
warranties.
This manual is written for use by skilled persons who are familiar with
injection molding machinery and their terminology. Operators should be
familiar with plastic injection molding machines and the controls of such
equipment. Maintenance persons should have su󰀩cient understanding of
electrical safety to appreciate the dangers of 3-phase supplies. They should
know how to take appropriate measures to avoid any danger from electrical
supplies.
1.2 Release Details
Table 1-1 Release Details
Document Number Release Date Version
AIU-UM-EN-01-02-11 May 2019 02-11
AIU-UM-EN-01-03 August 2020 03
1.3 Warranty
For current warranty information please refer to the documents available from
our website: https://www.milacron.com/mold-masters-warranty/ or contact
your Mold-Masters representative.
1.4 Returned Goods Policy
Please do not return any parts to Mold-Masters without pre-authorization and
a return authorization number supplied by Mold-Masters.
Our policy is one of continuous improvement and we reserve the right to alter
product specications at any time without giving notice.
1.5 Movement or Resale of Mold-Masters
Products or Systems
This documentation is intended for use in the country of destination for which
the product or system was purchased.
Mold-Masters takes no responsibility for documentation of products or
systems if they are relocated or resold outside the intended country of
destination, as stated on the accompanying invoice and/or waybill.
1-1
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
E-Multi Controller User Manual