Mold-masters E-multi er1-15 User manual

version 5

User Manual

Original Instrucons

Contents

Section 1 - Introduction ...................................................1-1

1.1 Intended Use ......................................................................................................1-1

1.2 Documentation ...................................................................................................1-1

1.3 Release Details ..................................................................................................1-1

1.4 Warranty .............................................................................................................1-1

1.5 Returned Goods Policy.......................................................................................1-1

1.6 Movement or Resale of Mold-Masters Products or

Systems..............................................................................................................1-2

1.7 Copyright ............................................................................................................1-2

1.8 Units of Measure and Conversion Factors .........................................................1-3

1.9 Trademarks and Patents ....................................................................................1-4

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 Disposal............................................................................................................3-12

3.8 E-Multi Injection Unit Safety Hazards ...............................................................3-13

3.9 E-Multi Servo Carriage Safety Hazard .............................................................3-15

3.10 E-Multi Radial Unit Hazards ...........................................................................3-16

3.11 Safety Symbols on the E-Multi Injection Unit..................................................3-18

3.12 Safety Guards.................................................................................................3-19

3.13 E-Multi Weight Specications .........................................................................3-20

3.14 Lift the E-Multi Injection Unit...........................................................................3-21

3.14.1 Pre Lift Procedures................................................................................3-21

3.15 EM1 / EM2 / EM3 Lift Connections.................................................................3-22

3.15.1 EM1 / EM2 / EM3 Vertical Lift Connections...........................................3-22

3.15.2 EM1 / EM2 / EM3 Horizontal Lift Connections.......................................3-23

3.16 EM4 Vertical Lift Procedures ..........................................................................3-24

3.16.1 Horizontal Placement from the Shipping Crate......................................3-24

3.16.2 Horizontal Placement from a Horizontal Stand......................................3-25

3.16.3 Attach the Lifting Bar..............................................................................3-25

3.16.4 Vertical Orientation with Two Lifting Machines ......................................3-27

3.16.5 Vertical Orientation with One Lifting Machine........................................3-29

3.16.6 E-Multi Injection Unit Installation onto the Molding Machine .................3-30

3.17 EM4 Horizontal Lift Connections ....................................................................3-31

E-Multi User Manual

Section 4 - Overview ........................................................4-1

4.1 E-Multi Injection Unit Models ..............................................................................4-1

4.2 E-Multi Injection Unit Components .....................................................................4-2

Section 5 - Preparation ....................................................5-1

5.1 Shipping Contents ..............................................................................................5-1

5.2 Unpacking...........................................................................................................5-2

5.3 Inspection ...........................................................................................................5-2

Section 6 - Installation .....................................................6-1

6.1 Attach E-Multi Injection Unit to the Mold / Machine ............................................6-2

6.2 Controller Installation..........................................................................................6-3

6.3 Operational Environment....................................................................................6-4

Section 7 - System Setup.................................................7-1

7.1 Connection of the Controller to the E-Multi Injection

Unit .....................................................................................................................7-1

7.1.1 Route and Connect Servo Cables .............................................................7-1

7.1.2 Route and Connect Heater, I/O, Injection Molding Machine Cables..........7-2

7.2 Connection to a Robot........................................................................................7-4

7.3 Connection of the Controller to the Molding Machine.........................................7-4

7.4 Connection a Handheld HMI (Optional)..............................................................7-4

7.5 Air Connections ..................................................................................................7-5

7.6 Water Connections .............................................................................................7-6

7.6.1 Cooling Water Schematic ..........................................................................7-7

7.6.2 Corrosion Caused by Condensation..........................................................7-7

7.6.3 Cooling Water Quality................................................................................7-7

7.6.4 Coolant and Additives................................................................................7-8

7.7 Connection to a Diagnostic Computer (Optional) ...............................................7-9

Section 8 - Operation .......................................................8-1

8.1 Introduction.........................................................................................................8-1

8.2 Controller Startup and Shutdown .......................................................................8-1

8.3 Switch On ...........................................................................................................8-2

8.4 Switch O󰀨 (Shutdown)........................................................................................8-2

8.4.1 Shutdown the Heating ...............................................................................8-2

8.4.2 Shutdown the Controller ............................................................................8-2

Section 9 - Maintenance...................................................9-1

9.1 Preventive Maintenance Schedule .....................................................................9-1

9.2 Screw Torque Specications ..............................................................................9-1

9.3 Other Torque Specications ...............................................................................9-2

9.4 Belt Tension Specications.................................................................................9-2

9.5 Lubrication Guidelines ........................................................................................9-3

9.6 Preload Oil Pressure Verication........................................................................9-4

9.6.1 Check the Preload Oil Pressure ................................................................9-4

9.6.2 Assemble the Injection Pressure Oil Fill Kit ...............................................9-4

9.6.3 Charge the High Pressure Oil Circuit with the Oil Kit.................................9-5

9.7 E-Multi Preload Pressures..................................................................................9-6

E-Multi User Manual

9.8 Check the Oil Bath Level ....................................................................................9-7

9.9 Check Lubrication of Linear Guides and Injection Ball

Screws................................................................................................................9-7

9.10 Purge Plastic from System ...............................................................................9-8

9.11 Purge Cooling Water from System ...................................................................9-8

9.12 Move the E-Multi Injection Unit for Maintenance ..............................................9-9

9.13 Clean Servo Motor Cooling Lines.....................................................................9-9

9.13.1 Indications of Cooling Line Contamination ..............................................9-9

9.14 Adapter Plate Removal and Installation..........................................................9-10

9.13.2 Cleaning Recommendations..................................................................9-10

9.15 Injection Nozzle Replacement ........................................................................9-13

9.16 Nozzle Protrusion Adjustment - Toggle Link Models ......................................9-13

9.16.1 Introduction............................................................................................9-13

9.16.2 Adjust the Nozzle Protrusion Manually ..................................................9-15

9.17 Nozzle Protrusion Adjustment - Automatic Adjustment...................................9-17

9.17.1 Calibrate the Carriage Home Position ...................................................9-17

9.17.2 Calibrate Manually.................................................................................9-17

9.17.3 Automatic Calibration.............................................................................9-18

9.18 Injection Axis Referencing ..............................................................................9-19

9.19 Bolt Type Shut O󰀨 Nozzle Maintenance .........................................................9-20

9.20 Barrel Head Removal and Replacement ........................................................9-22

9.21 Heater Replacement.......................................................................................9-23

9.22 Feed Assembly Removal and Replacement...................................................9-27

9.22.1 Remove Feed Assembly........................................................................9-27

9.22.2 Install the Feed Block ............................................................................9-29

9.23 Feed Screw Cleaning and Replacement ........................................................9-30

9.23.1 Prepare for Feed Screw Removal .........................................................9-30

9.23.2 Remove the Feed Screw .......................................................................9-31

9.23.3 Cleaning.................................................................................................9-33

9.23.4 Install the Feed Screw ...........................................................................9-33

9.24 Barrel Removal and Installation......................................................................9-36

9.24.1 Remove the Barrel Assembly ................................................................9-36

9.24.2 Transfer Heaters and Thermocouples to a New Barrel .........................9-38

9.24.3 Install the Barrel Assembly ....................................................................9-39

9.25 Belt Tension Adjustment .................................................................................9-41

9.26 Belt Removal and Installation .........................................................................9-42

9.27 Servicing and Repairing your Controller.........................................................9-44

Section 10 - Component Tests and System Alarms... 10-1

10.1 Thermocouple Electrical Test..........................................................................10-1

10.2 Heater Continuity Test ....................................................................................10-1

10.3 Transducer Output Alarm................................................................................10-1

10.4 Vibrator Valve Test..........................................................................................10-2

10.5 Control System Alarms ...................................................................................10-2

10.6 Servo Motor Temperature Alarms...................................................................10-3

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E-Multi User Manual

Section 11 - E-Multi Radial Option ................................11-1

11.1 Introduction .....................................................................................................11-1

11.2 E-Multi Radial Specications ..........................................................................11-1

11.3 E-Multi Radial Components ............................................................................11-2

11.4 Unpacking.......................................................................................................11-3

11.5 Inspection ....................................................................................................... 11-4

11.6 E-Multi Radial Installation (EM1 and EM2 Models) ........................................11-5

11.6.1 Install onto an Injection Molding Machine .............................................. 11-9

11.7 Manual Position Adjustment .........................................................................11-10

11.8 Home Position Calibration ............................................................................11-13

11.9 Auto Purge ....................................................................................................11-13

11.10 E-Multi Radial Maintenance........................................................................11-14

11.10.1 Lubricate the E-Multi Radial Carriage Ball Screw and Linear

Guides ......................................................................................................11-14

11.11 Service of the E-Multi Radial Carriage Assembly and

Servo Motor ....................................................................................................11-17

11.12 ER3 / ER4 Installation.................................................................................11-18

11.13 Spare Parts for the E-Multi Radial ..............................................................11-26

Section 12 - Servo Carriage Option ............................. 12-1

12.1 Introduction.....................................................................................................12-1

12.2 E-Multi Servo Carriage Specications ............................................................12-1

12.3 Material Handling............................................................................................12-2

12.3.1 Preparation ............................................................................................12-2

12.3.2 Unpacking..............................................................................................12-2

12.3.3 Inspection ..............................................................................................12-2

12.3.4 Installation..............................................................................................12-2

12.4 Calibrate Home Position.................................................................................12-2

12.5 Auto Purge......................................................................................................12-3

12.6 Maintenance ...................................................................................................12-3

12.6.1 Check the Lubrication of the Ball Screw................................................12-3

12.7 Spare Parts.....................................................................................................12-3

Section 13 - Servo Cooling Option .............................. 13-1

13.1 Operation and Specications..........................................................................13-1

13.1.1 Closed Loop Specication .....................................................................13-1

13.1.2 External Loop Specication ...................................................................13-1

13.1.3 Materials in Contact with Coolant ..........................................................13-1

13.2 Maintenance ...................................................................................................13-2

13.2.1 Drain the Coolant...................................................................................13-2

13.2.2 Clean / Replace the Heat Exchanger ....................................................13-3

13.2.3 Troubleshooting .....................................................................................13-3

E-Multi User Manual

Section 14 - E-Multi Stands .......................................... 14-1

14.1 Introduction.....................................................................................................14-1

14.2 Stand Options.................................................................................................14-1

14.3 Compact Stand...............................................................................................14-2

14.3.1 Main Components..................................................................................14-2

14.3.2 Horizontal Position Adjustment..............................................................14-3

14.3.3 Assembly ...............................................................................................14-3

14.4 Heavy Duty Stand...........................................................................................14-4

14.4.1 Main Components..................................................................................14-4

14.4.2 Horizontal Position Adjustment..............................................................14-5

14.4.3 Front or Back Leg Position ....................................................................14-5

14.4.4 Counter Weight Kit (Optional)................................................................14-6

14.4.5 Assembly ...............................................................................................14-7

14.5 Leveling Castors.............................................................................................14-8

14.6 Mold Installation..............................................................................................14-8

14.7 Mold Removal...............................................................................................14-11

14.8 Disassembly .................................................................................................14-11

Section 15 - Euromap 67............................................... 15-1

15.1 Scope and Application ....................................................................................15-1

15.2 Description......................................................................................................15-1

15.3 Plug and Socket Outlet...................................................................................15-1

Section 16 - Water Quality ............................................ 16-1

Index ......................................................................................I

E-Multi User Manual

Figures

Figure 3-1 Injection molding machine hazard areas.................................................3-2

Figure 3-2 E-Multi safety hazards...........................................................................3-13

Figure 3-3 E-Multi Radial safety hazard locations ..................................................3-16

Figure 3-4 Guards layout .......................................................................................3-19

Figure 3-5 Do not use the motor as a lifting point...................................................3-21

Figure 3-6 EM1 / EM2 vertical lifting connections (EM3 similar) ............................3-22

Figure 3-7 EM3 horizontal lift connections. EM1 / EM2 similar ..............................3-23

Figure 3-8 EM4 horizontal lift connections .............................................................3-31

Figure 4-1 E-Multi injection unit models ...................................................................4-1

Figure 4-2 E-Multi injection unit components ...........................................................4-2

Figure 5-1 Oil ll kit (optional)...................................................................................5-1

Figure 7-1 EM3 Servo cable routing.........................................................................7-1

Figure 7-2 Cables held with wire ties........................................................................7-2

Figure 7-3 Correct connector alignment ...................................................................7-2

Figure 7-4 E-Multi connection locations ...................................................................7-3

Figure 7-5 Hand-held HMI and connection...............................................................7-4

Figure 7-6 Robot jumper plug...................................................................................7-4

Figure 7-7 EM3 / EM4 water supply and return manifolds .......................................7-6

Figure 7-8 EM3 / EM4 Servo motor cooling connections .........................................7-6

Figure 7-9 Water cooling schematic diagram ...........................................................7-7

Figure 7-10 Water quality specication tag on E-Multi .............................................7-8

Figure 7-11 Wireless network icon..........................................................................7-10

Figure 8-1 E-Multi main power switch ......................................................................8-1

Figure 8-2 Button strip below controller display (HMI)..............................................8-2

Figure 9-1 Comparison of clean and contaminated cooling

lines ....................................................................................................................9-9

Figure 9-2 Protrusion adjustment parts. EM1 shown,

other models are similar. ................................................................................9-14

Figure 9-3 Nozzle touching mold............................................................................9-16

Figure 9-4 Automatic calibration .............................................................................9-18

Figure 9-5 Linear guide position .............................................................................9-43

Figure 10-1 Motor temperature alarm - Alarms screen on

E-Multi controller...............................................................................................10-3

Figure 11-1 Main components of the E-Multi Radial...............................................11-2

Figure 11-2 Sling positions of the E-Multi Radial vertical beam ............................11-3

Figure 11-3 Forward sling attachment ...................................................................11-4

Figure 11-4 Rear sling attachment .........................................................................11-4

Figure 11-5 Oil ll kit (optional) ...............................................................................11-4

Figure 11-6 Tilting the E-Multi Radial from the horizontal to

vertical position ................................................................................................11-7

Figure 11-7 Install the barrel heats connector ........................................................11-9

Figure 11-8 Attach the servo motor cables .............................................................11-9

Figure 11-9 Install the I/O connector ....................................................................11-10

Figure 11-10 Gap between the rotating plate and lockring................................... 11-11

Figure 13-1 Bottom side of the cooling unit showing the

drain plug..........................................................................................................13-2

Figure 14-1 Compact stand ....................................................................................14-1

Figure 14-2 Heavy duty stand ................................................................................14-1

E-Multi User Manual

Figure 14-3 Compact stand main components.......................................................14-2

Figure 14-4 Compact stand horizontal position adjustment ...................................14-3

Figure 14-5 Compact stand assembly....................................................................14-3

Figure 14-6 Heavy duty stand main components ...................................................14-4

Figure 14-8 Heavy duty stand - front or back leg position ......................................14-5

Figure 14-7 Heavy duty stand horizontal position adjustment................................14-5

Figure 14-9 Heavy duty stand counter weight kit ...................................................14-6

Figure 14-10 E-Multi stand leveling castors ...........................................................14-8

Figure 14-11 E-Multi injection unit stand-to-mold installation .................................14-9

Figure 14-12 With the crane, lift the E-Multi injection unit

up and away from the stand. ..........................................................................14-11

vii

E-Multi User Manual

Tables

Table 1-1 Release Details.........................................................................................1-1

Table 1-2 Units of Measure and Conversion Factors ...............................................1-3

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 E-Multi Injection Unit Safety Hazard Details ...........................................3-14

Table 3-5 E-Multi Servo Carriage Safety Hazard Details........................................3-15

Table 3-6 E-Multi Radial Safety Hazards Details....................................................3-17

Table 3-7 Safety Symbols Used on the E-Multi ......................................................3-18

Table 3-8 Safety Symbols on the E-Multi Transport Stand .....................................3-20

Table 3-9 E-Multi Injection Unit Shipping Dimensions and Weight.........................3-20

Table 3-10 E-Multi Injection Unit Lifting Kits ...........................................................3-21

Table 3-11 EM1 / EM2 / EM3 Vertical Lift Connections ..........................................3-22

Table 3-12 EM1 / EM2 / EM3 Horizontal Lift Connections......................................3-23

Table 3-13 EM4 Horizontal Lift Connections ..........................................................3-31

Table 7-1 Cooling System Water Limits....................................................................7-6

Table 7-2 Basic Water Quality Specication.............................................................7-7

Table 9-1 Preventive Maintenance Schedule ...........................................................9-1

Table 9-2 Screw Torque Specications.....................................................................9-1

Table 9-3 Nozzle Tip and Locking Plate Torque Specications ................................9-2

Table 9-4 Feed Block Torque Specications.............................................................9-2

Table 9-5 Belt Tension Specications .......................................................................9-2

Table 9-6 E-Multi Injection Unit Lubrication ..............................................................9-3

Table 9-7 E-Multi Preload Pressures (1.34 Software) ..............................................9-6

Table 9-8 Grease Lubrication Mass - Injection Ball Screws .....................................9-6

Table 11-1 E-Multi Radial Specications ................................................................11-1

Table 11-2 Grease Lubrication Volume - Ball Screw Nut......................................11-14

Table 12-1 E-Multi Servo Carriage Specications ..................................................12-1

Table 13-1 Materials in Contact with Coolant .........................................................13-1

Table 13-2 Troubleshooting ....................................................................................13-3

Table 14-1 E-Multi Stand Options...........................................................................14-1

Table 15-1 Plug on the Injection Molding Machine .................................................15-1

Table 15-2 Plug on the Injection Molding Machine .................................................15-4

Table 16-1 Detailed Water Quality Specication.....................................................16-1

viii

E-Multi User Manual

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