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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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
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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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
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

1.6 Copyright
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Mold-Masters®
and the Mold-Masters logo are trademarks of Mold-Masters.
1.7 Units of Measure and Conversion Factors
NOTE
The dimensions given in this manual are from original manufacturing
drawings.
All values in this manual are in S.I. units or subdivisions of these units.
Imperial units are given in parenthesis immediately after the S.I. units.
Table 1-2 Units of Measure and Conversion Factors
Abbreviation Unit Conversion Value
bar Bar 14.5 psi
in. Inch 25.4 mm
kg Kilogram 2.205 lb
kPa Kilopascal 0.145 psi
gal Gallon 3.785 l
lb Pound 0.4536 kg
lbf Pound force 4.448 N
lbf.in. Pound force inch 0.113 Nm
l Litre 0.264 gallon
min Minute
mm Millimeter 0.03937 in.
mΩ Milli Ohm
N Newton 0.2248 lbf
Nm Newton Meter 8.851 lbf.in.
psi Pound per square inch 0.069 bar
psi Pound per square inch 6.895 kPa
rpm Revolutions per minute
s Second
°Degree
°CDegree Celsius 0.556 (°F -32)
°FDegree Fahrenheit 1.8 °C +32
1-2
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INTRODUCTION
E-Multi Controller User Manual

1.8 Trademarks and Patents
ACCU-VALVE, DURA, E-MULTI, FLEX-DURA FLEX-SERIES, FUSION-SERIES, HOT
EDGE, MASTERPROBE, MASTER-SHOT, MOLD-MASTERS, MELT-DISK, MOLD-
MASTERS ACADEMY, MASTER-SERIES, MASTERSOLUTION, MASTERSPEED, MERLIN,
MOLD-MASTERS SYSTEM, MPET, STACK-LINK, are the registered trademarks of MOLD-
MASTERS (2007) LIMITED.
Information contained herein is, to our best knowledge, true and accurate, but all
recommendations or suggestions are made without guarantee. Since the conditions of
use are beyond our control, Mold-Masters disclaims any liability incurred in connection
with the use of our products and information contained herein. No person is authorized to
make any statement or recommendation not contained herein, and any such statement or
recommendation so made shall not bind Mold-Masters. Furthermore, nothing contained herein
shall be construed as a recommendation to use any product in conict with existing patents
covering any products or its use, and no license implied or in fact granted herein under the
claims of any patents.
No part of this publication may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopy, recording, or any information storage and
retrieval system without permission in writing from the publisher. All details, standards
and specications may be altered in accordance with technical development without prior
notication.
May be manufactured under one or more of the following U.S. Patents:
5792493, 5795599, 5820899, 5843361, 5849343, 5853777, 5935615, 5935616, 5935621, 5942257,
5952016, 5980236, 6009616, 6017209, 6030198, 6030202, 6062841, 6074191, 6077067, 6079972,
6095790, 6099780, 6113381, 6135751, 6162043, 6162044, 6176700, 6196826, 6203310, 6230384,
6270711, 6274075, 6286751, 6302680, 6318990, 6323465, 6348171, 6350401, 6394784, 6398537,
6405785, 6440350, 6454558, 6447283, 6488881, 6561789, 6575731, 6625873, 6638053, 6648622,
6655945, 6675055, 6688875, 6701997, 6739863, 6752618, 6755641, 6761557, 6769901, 6776600,
6780003, 6789745, 6830447, 6835060, 6840758, 6852265, 6860732, 6869276, 6884061, 6887418,
6890473, 6893249, 6921257, 6921259, 6936199, 6945767, 6945768, 6955534, 6962492, 6971869,
6988883, 6992269, 7014455, 7018197, 7022278, 7025585, 7025586, 7029269, 7040378, 7044191,
7044728, 7048532, 7086852, 7105123, 7108502, 7108503, 7115226, 7118703, 7118704, 7122145,
7125242, 7125243, 7128566, 7131832, 7131833, 7131834, 7134868, 7137806, 7137807, 7143496,
7156648, 7160100, 7160101, 7165965, 7168941, 7168943, 7172409, 7172411, 7175419, 7175420,
7179081, 7182591, 7182893, 7189071, 7192268, 7192270, 7198740, 7201335, 7210917, 7223092,
7238019, 7244118, 7252498, 7255555, 7258536, 7270538, 7303720, 7306454, 7306455, 7314367,
7320588, 7320589, 7320590 7326049, 7344372, 7347684, 7364425, 7364426, 7370417,7377768,
7381050, 7396226, 7407379, 7407380, 7410353, 7410354, 7413432, 7416402, 7438551,
7462030, 7462031, 7462314, 7465165, 7470122, 7507081, 7510392, 7513771, 7513772, 7517214,
7524183, 7527490, 7544056, 7547208, 7553150, 7559760, 7559762, 7565221, 7581944, 7611349,
7614869, 7614872, 7618253, 7658605, 7658606, 7671304, 7678320, 7686603, 7703188, 7713046,
7722351, 7731489, 7753676, 7766646, 7766647, 7775788, 7780433, 7780434, 7794228, 7802983,
7803306, 7806681, 7824163, 7845936, 7850442, 7874833, 7877163, 7891969, 7918660, 7918663,
7931455, 7963762, 7988445, 7998390, 8062025, 8066506, 8113812, 8142182, 8152513, 8167608,
8202082, 8206145, 8210842, 8241032, 8280544, 8282386, 8308475, 8308476, 8328546, 8353697,
8414285, 8425216, 8449287, 8465688, 8469687, 8475155, 8475158, 8480391, 8568133, 8690563,
8715547,8753102, 8757998, 8758002, 8845321, 8899964, 8940202, 8985997, 9004906, 9028243,
9073246, 9186830, 9186833, 9227351,9248593, 9272455, 9327436, D525592, RE38265, RE38396,
RE38920, RE39935, RE40478, RE40952, RE41536E, RE41648E+ Pending.
© 2019 MOLD-MASTERS (2007) LIMITED, ALL RIGHTS RESERVED
1-3
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
E-Multi Controller User Manual

Section 2 - Global Support
2.1 Manufacturing Facilities
2.2 Regional Ofces
ASIAN HEADQUARTERS
CHINA/HONG KONG/TAIWAN
Mold-Masters (KunShan) Co, Ltd
Zhao Tian Rd
Lu Jia Town, KunShan City
Jiang Su Province
People’s Republic of China
tel: [phone]
fax: [phone]
[email protected]
JAPAN
Mold-Masters K.K.
1-4-17 Kurikidai, Asaoku
Kawasaki, Kanagawa
Japan, 215-0032
tel: [phone]
fax: [phone]
[email protected]
GLOBAL HEADQUARTERS
CANADA
Mold-Masters (2007) Limited
233 Armstrong Avenue
Georgetown, Ontario
Canada L7G 4X5
tel: [phone]
fax: [phone]
[email protected]
SOUTH AMERICAN
HEADQUARTERS
BRAZIL
Mold-Masters do Brasil Ltda.
R. James Clerk Maxwel,
280 – Techno Park, Campinas
São Paulo, Brazil, 13069-380
tel: [phone]
[email protected]
UNITED KINGDOM & IRELAND
Mold-Masters (UK) Ltd
Netherwood Road
Rotherwas Ind. Est.
Hereford, HR2 6JU
United Kingdom
tel: [phone]
fax: [phone]
[email protected]
EUROPEAN HEADQUARTERS
GERMANY / SWITZERLAND
Mold-Masters Europa GmbH
Neumattring 1
76532 Baden-Baden, Germany tel:
[phone]
fax: [phone]
[email protected]
INDIA
Mold-Masters Technologies Private
Limited
# 247, Alagesan Road,
Shiv Building, Saibaba Colony.
Coimbatore T. N.
India 641 011
tel: [phone]
fax: [phone]
[email protected]
USA
Mold-Masters Injectioneering LLC
29111 Stephenson Highway
Madison Heights, MI 48071, USA
tel: [phone] (USA only)
tel: [phone]
fax: [phone]
[email protected]
Mold-Masters Regional Offices
AUSTRIA / East and South
East Europe
Mold-Masters Handelsges.m.b.H.
Pyhrnstrasse 16
A-4553 Schlierbach
Austria
tel: [phone]
fax: [phone]
[email protected]
ITALY
Mold-Masters Italia
Via Germania, 23
35010 Vigonza (PD)
Italy
tel: [phone]
fax: [phone]
[email protected]
CZECH REPUBLIC
Mold-Masters Europa GmbH
Hlavni 823
75654 Zubri
Czech Republic
tel: [phone]
fax: [phone]
[email protected]
KOREA
Mold-Masters Korea Ltd.
E dong, 2nd floor, 2625-6,
Jeongwang-dong, Siheung
City, Gyeonggi-do, 15117,
South Korea
Tel: [phone]
[email protected]
FRANCE
Mold-Masters France
ZI la Marinière,
2 Rue Bernard Palissy
91070 Bondoufle, France
tel: [phone]
fax: [phone]
[email protected]
MEXICO
Milacron Mexico Plastics Services
S.A. de C.V.
Circuito El Marques norte #55
Parque Industrial ElMarques
El Marques, Queretaro C.P. 76246
Mexico
tel: [phone] (sales)
tel: [phone] (service)
[email protected]
2-1
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
GLOBAL SUPPORT
E-Multi Controller User Manual

2.3 International Representatives
Regional Ofces - continued
Mold-Masters Regional Offices (cont.)
SPAIN
Ferromatik Milacron /
Mold Masters Europa GmbH
C/. Enric Morera, 7
Polig. Ind. Foinvasa
08110 Montcada i Reixac
Barcelona, Spain
tel: [phone]
fax: [phone]
[email protected]
TURKEY
Mold-Masters Europa GmbH
Merkezi Almanya Türkiye
İstanbul Şubesi
Alanaldı Caddesi Bahçelerarası
Sokak No: 31/1
34736 İçerenköy-Ataşehir
Istanbul, Turkey
tel: [phone]
fax: [phone]
[email protected]
SINGAPORE*
Mold-Masters Singapore PTE. Ltd.
No 48 Toh Guan Road East
#06-140 Enterprise Hub
Singapore 608586
Republic of Singapore
tel: [phone]
fax: [phone]
[email protected]
*Coverage includes Southeast
Asia, Australia, and New Zealand
Mold-Masters International Representatives
Argentina
Sollwert S.R.L.
La Pampa 2849 2∫ B
C1428EAY Buenos Aires
Argentina
tel: [phone]
fax: [phone] Ext.
35 [email protected]
Denmark*
Englmayer A/S
Dam Holme 14-16
DK – 3660 Stenloese
Denmark tel: [phone]
fax: [phone]
[email protected]
*Coverage includes Norway
and Sweden
Israel
ASAF Industries Ltd. 29 Habanai
Street
PO Box 5598 Holon 58154 Israel
tel: [phone]
fax: [phone]
s[email protected]
Russia
System LLC
Prkt Marshala Zhukova 4
123308 Moscow
Russia
tel: [phone]
[email protected]
Belarus
HP Promcomplect
Sharangovicha 13
220018 Minsk
tel: [phone]
fax: [phone]
e:[email protected]
Finland**
Oy Scalar Ltd.
Tehtaankatu
10 11120 Riihimaki
Finland
tel: [phone]
fax: [phone]
[email protected]
**Coverage includes Estonia
Portugal
Gecim LDA
Rua Fonte Dos Ingleses, No 2
Engenho
2430-130 Marinha Grande
Portugal
tel: [phone]
fax: [phone]
[email protected]
Slovenia
RD PICTA tehnologije d.o.o.
Žolgarjeva ulica 2
2310 Slovenska Bistrica
Slovenija
[phone]
[email protected]
Bulgaria
Mold-Trade OOD
62, Aleksandrovska
St. Ruse City
Bulgaria
tel: [phone]
fax: [phone]
[email protected]
Greece
Ionian Chemicals S.A.
21 Pentelis Ave.
15235 Vrilissia, Athens
Greece
tel: [phone]
fax: [phone]
[email protected]
Romania
Tehnic Mold Trade SRL
Str. W. A Mozart nr. 17 Sect. 2
020251 Bucharesti
Romania
tel: [phone]
fax : [phone]
[email protected]
Ukraine
Company Park LLC
Gaydamatska str., 3, office 116
Kemenskoe City Dnipropetrovsk
Region 51935, Ukraine
tel: [phone]
[e-mail]
2-2
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
GLOBAL SUPPORT
E-Multi Controller User Manual

Section 3 - Safety
3.1 Introduction
Please be aware that the safety information provided by Mold-Masters
does not absolve the integrator and employer from understanding and
following international and local standards for safety of machinery. It is the
responsibility of the end integrator to integrate the nal system, provide
necessary e-stop connections, safety interlocks and guarding, to choose the
appropriate electrical cable for the region of use and to ensure compliance
with all relevant standards.
It is the responsibility of the employer to:
• Properly train and instruct its personnel in the safe operation of
equipment, including the use of all the safety devices.
• Provide its personnel with all necessary protective clothing, including such
items as a face shield and heat resistant gloves.
• Ensure the original and continuing competence of personnel caring for,
setting up, inspecting and maintaining injection molding equipment.
• Establish and follow a program of periodic and regular inspections of
injection molding equipment to ensure it is in safe operating condition and
proper adjustment.
• Ensure that no modications, repairs or rebuild of portions are made
to the equipment that reduces the level of safety existing at time of
manufacture or remanufacture.
3-1
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
E-Multi Controller User Manual

3.2 Safety Hazards
WARNING
Also refer to all machine manuals and local regulations and codes for safety
information.
The following safety hazards are most commonly associated with injection
molding equipment. See European Standard EN201 or American Standard
ANSI/SPI B151.1.
Refer to the illustration of hazard areas below when reading the Safety
Hazards Figure 3-1 on page 3-2.
Figure 3-1 Injection molding machine hazard areas
Top view with guards removed
Front view with guards removed
210 5
3
Top View with Guards Removed
25
91
4
769
8
Front View with Guards Removed
1. Mold area
2. Clamping mechanism area
3. Area of movement of
core and ejector drive
mechanisms outside areas
1 and 2
4. Machine nozzle area
5. Plasticating and / or
injection unit area
6. Feed opening area
7. Area of the heater bands
of the plasticizing and / or
injection cylinders
8. Parts discharge area
9. Hoses
10. Area inside the guards and
outside the mold area
3-2
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
E-Multi Controller User Manual

Safety Hazards - continued
Table 3-1 Safety Hazards
Hazard Area Potential Hazards
Mold Area
Area between the
platens.
See Figure 3-1 area 1
Mechanical Hazards
Crushing and / or shearing and / or impact hazards caused by:
• Movement of the platen.
• Movements of the injection barrel(s) into the mold area.
• Movements of cores and ejectors and their drive mechanisms.
• Tie bar motion.
Thermal Hazards
Burns and / or scalds due to operating temperature of:
• The mold heating elements.
• Material released from/through the mold.
Clamping
Mechanism Area
See Figure 3-12 area
2
Mechanical Hazards
Crushing and / or shearing and / or impact hazards caused by:
• Movement of the platen.
• Movement of the drive mechanism of the platen.
• Movement of the core and ejector drive mechanism.
Movement of
Drive Mechanisms
Outside the Mold
Area and Outside
the Clamping
Mechanism Area
See Figure 3-1 area 3
Mechanical Hazards
Mechanical hazards of crushing, shearing and / or impact caused by the
movements of:
• Core and ejector drive mechanisms.
Nozzle Area
The nozzle area is
the area between the
barrel and the sprue
bushing.
See Figure 3-1 area 4
Mechanical Hazards
Crushing, shearing hazards and / or impact hazards caused by:
• Forward movement of the plasticizing and / or injection unit including
nozzle.
• Movements of parts of the power-operated nozzle shuto󰀨 and their
drives.
• Over pressurization in the nozzle.
Thermal Hazards
Burns and or scalds due to operating temperature of:
• The nozzle.
• Material discharging from the nozzle.
Plasticizing and / or
Injection Unit Area
Area from the adapter
/ barrel head / end cap
to the extruder motor
above the sled
including the carriage
cylinders.
See Figure 3-1 area 5
Mechanical Hazards
Crushing, shearing and / or drawn-into hazards caused by:
• Unintentional gravity movements e.g. for machines with plasticizing
and / or injection unit positioned above the mold area.
• The movements of the screw and / or the injection plunger in the
cylinder accessible through the feed opening.
• Movement of the carriage unit.
Thermal Hazards
Burns and / or scalds due to operating temperature of:
• The plasticizing and / or injection unit.
• The heating elements e.g. heater bands.
• The material and / or vapors discharging from the vent opening, feed
throat or hopper.
Mechanical and / or Thermal Hazard
• Hazards due to reduction in mechanical strength of the plasticizing and
/ or injection cylinder due to overheating.
Feed Opening
See Figure 3-1 area 6
Pinching and crushing between injection screw movement and housing.
3-3
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
E-Multi Controller User Manual

Safety Hazards - continued
Table 3-1 Safety Hazards
Hazard Area Potential Hazards
Area of the Heater
Bands of the
Plasticizing and / or
Injection Cylinders
See Figure 3-1 area 7
Burns and / or scalds due to operating temperature of:
• The plasticizing and / or injection unit.
• The heating elements e.g. heater bands.
• The material and / or vapors discharging from the vent opening, feed
throat or hopper.
Parts Discharge Area
See Figure 3-1 area 8
Mechanical Hazards
Accessible Through the Discharge Area
Crushing, shearing and / or impact hazards caused by:
• Closing movement of the platen.
• Movements of cores and ejectors and their drive mechanisms.
Thermal Hazards
Accessible through the discharge area
Burns and or scalds due to operating temperature of:
• The mold.
• Heating elements of the mold.
• Material released from / through the mold.
Hoses
See Figure 3-1 area 9
• Whipping action caused by hose assembly failure.
• Possible release of uid under pressure that can cause injury.
• Thermal hazards associated with hot uid.
Area Inside the
Guards and Outside
the Mold Area
See Figure 3-1 area
10
Crushing and / or shearing and / or impact hazards caused by:
• Movement of the platen.
• Movement of the drive mechanism of the platen.
• Movement of the core and ejector drive mechanism.
• Clamp opening movement.
Electrical Hazards • Electrical or electromagnetic disturbance generated by the motor
control unit.
• Electrical or electromagnetic disturbance that can cause failures in the
machine control systems and adjacent machine controls.
• Electrical or electromagnetic disturbance generated by the motor
control unit.
Hydraulic
Accumulators
High pressure discharge.
Power Operated
Gate
Crush or impact hazards caused by the movement of the power operated
gates.
Vapors and Gases Certain processing conditions and / or resins can cause hazardous fumes
or vapors.
3-4
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
E-Multi Controller User Manual

3.3 Operational Hazards
WARNINGS
• Refer to all machine manuals and local regulations and codes for safety
information.
• The equipment supplied is subjected to high injection pressures and high
temperatures. Ensure that extreme caution is observed in the operation
and maintenance of the injection molding machines.
• Only fully trained personnel should operate or maintain equipment.
• Do not operate the equipment with unconned long hair, loose clothing
or jewelry, including name badges, neckties, etc. These may get caught
in the equipment and can cause death or serious injury.
• Never disable or bypass a safety device.
• Ensure that the protective guards are placed around the nozzle to
prevent the material from splashing or drooling.
• A burn hazard exists from material during routine purging. Wear heat-
resistant personal protective equipment (PPE) to prevent burns from
contact with hot surfaces or splatter of hot material and gases.
• Material purged from machine may be extremely hot. Ensure protective
guards are in place around the nozzle to prevent material from
splashing. Use proper personal protective equipment.
• All operators should wear personal protective equipment, such as face
shields and use heat resistant gloves when working around the feed
inlet, purging the machine or cleaning the gates of the mold.
• Remove purged material from the machine immediately.
• Decomposing or burning material could result in noxious gases being
emitted from the purged material, feed inlet or mold.
• Ensure proper ventilation and exhaust systems are in place to help
prevent inhalation of harmful gases and vapors.
• Consult manufacturer’s Material Safety Data Sheets (MSDS).
• Hoses tted to the mold will contain high or low temperature uids or air
under high pressure. The operator must shut down and lockout these
systems as well as relieving any pressure before performing any work
with these hoses. Regularly inspect and replace all exible hoses and
restraints.
• Water and / or hydraulics on the mold may be in close proximity to
electrical connections and equipment. Water leakage may cause an
electrical short circuit. Hydraulic uid leakage may cause a re hazard.
Always keep water and / or hydraulic hoses and ttings in good condition
to avoid leaks.
• Never perform any work on the mold machine unless the hydraulic pump
has been stopped.
• Check frequently for possible oil leaks / water leaks. Stop the machine
and make repairs.
3-5
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
E-Multi Controller User Manual

Operational Hazards - continued
WARNING
• Make sure that the cables are connected to the correct motors. Cables
and motors are clearly labeled. Reversing the cables can result in
unexpected and uncontrolled motion causing a safety risk or damage to
the machine.
• A crushing hazard exists between the nozzle and mold melt inlet during
carriage forward motion.
• A possible shearing hazard exists between the edge of the injection
guard and the injection housing during injection.
• The open feed port could present a hazard to a nger or a hand
inserted during operation of the machine.
• The electric servo motors could overheat presenting a hot surface which
could cause burns to someone touching it.
• The barrel, barrel head, nozzle, heater bands and mold components are
hot surfaces which could result in burns.
• Keep ammable liquids or dust away from the hot surfaces as they
could ignite.
• Follow good housekeeping procedures and keep oors clean to prevent
slips, trips and falls due to spilled material on the work oor.
• Apply engineering controls or hearing conservation programs as
necessary to control noise.
• When doing any work on the machine that requires moving and lifting
the machine, ensure that lifting equipment (eyebolts, fork lift truck,
cranes, etc.) will have su󰀩cient capacity to handle mold, auxiliary
injection unit or Hot Runner weight.
• Connect all lifting devices and support the machine using a crane of
adequate capacity before commencing work. Failure to support the
machine can result in severe injury or death.
• Mold cable from the controller to the mold must be removed before
servicing the mold.
3-6
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
E-Multi Controller User Manual