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
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E-Multi User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

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
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E-Multi User Manual
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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
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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
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E-Multi User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

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
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E-Multi User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

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
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E-Multi User Manual
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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
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E-Multi User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

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
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E-Multi User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

Section 1 - Introduction
The purpose of this manual is to assist users in the integration, operation and
maintenance of an E-Multi Auxiliary Injection Unit. This manual is designed to
cover most system congurations. This manual should be used in conjunction
with E-Multi Controller User Manual. If you need additional information
specic to your system, or information in another language, please contact
your representative or a Mold-Masters o󰀩ce.
1.1 Intended Use
Mold-Masters’ E-Multi systems have been built to process thermoplastic
material at the required temperature for injection molding and must not be
used for any other purpose. The E-Multi injection unit is to be integrated with
a host injection molding machine and not used as a standalone device. Any
other uses would fall outside the engineered intent of this machine, which
may be a safety hazard and will void any and all warranties.
1.2 Documentation
This manual is part of the documentation package for your order and should
be referenced along with the following documents included in the package:
• The Bill of Materials (BOM). Together with the General Assembly drawing,
the Bill of Materials should be referenced when ordering spare parts.
• General Assembly drawing
• Electrical drawings
• CE declaration of conformity and declaration of incorporation (EU only)
1.3 Release Details
Table 1-1 Release Details
Document Number Release Date Version
AIU-UM-EN-00-05-7 May 2019 05-7
1.4 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.
1.5 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.
1-1INTRODUCTION
E-Multi User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

1.6 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.
1.7 Copyright
© 2020 Mold-Masters (2007) Limited. All Rights Reserved. Mold-Masters®
and the Mold-Masters logo are trademarks of Mold-Masters.
1-2
E-Multi User Manual
INTRODUCTION
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

1.8 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
1-3INTRODUCTION
E-Multi User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

1.9 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:
5421716, 5427519, 5429491, 5437093, 5441197, 5443381, 5460510, 5474440, 5494433, 5496168,
5507635, 5507636, 5536165, 5591465, 5599567, 5614233, 5641526, 5644835, 5652003, 5658604,
5695793, 5700499, 5704113, 5705202, 5707664, 5720995, 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, D525592, RE38265, RE38396, RE38920,
RE39935, RE40478, RE40952, RE41536E, RE41648E+ Pending.
© 2019 MOLD-MASTERS (2007) LIMITED, ALL RIGHTS RESERVED
1-4
E-Multi User Manual
INTRODUCTION
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

Section 2 - Global Support
2.1 Manufacturing Facilities
2.2 Regional Ofces
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]
EUROPEAN HEADQUARTERS
GERMANY / SWITZERLAND
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]
Mold-Masters Europa GmbH
Postfach/P.O. Box 19 01 45
76503 Baden-Baden, Germany
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, MI48071, USA
tel: [phone] (USA only)
tel: [phone]
fax: [phone]
[email protected]
2-1GLOBAL SUPPORT
E-Multi User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

2.3 International Representatives
Regional Ofces - continued
Mold-Masters Regional Offices (cont.)
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
SPAIN
Ferromatik Milacron /
Mold Masters Europa GmbH
C/. Enric Morera, 7
Polig. Ind. Foinvasa
08110 Montcada iReixac
Barcelona, Spain
tel: [phone]
fax: [phone]
s[email protected]
POLAND
Mold-Masters Europa GmbH
Skr. Pocztowa 59
00-908 Warszawa
Poland
tel: [phone]
fax: [phone]
[email protected]
TURKEY
Mold-Masters Europa GmbH
Merkezi Almanya Türkiye
İstanbul Şubesi
AlanaldıCaddesi Bahçelerarası
Sokak No: 31/1
34736 İçerenköy-Ataşehir
Istanbul, Turkey
tel: [phone]
fax: [phone]
[email protected]
Mold-Masters International Representatives
ARGENTINA
Sollwert S.R.L.
tel: [phone]
e: [email protected]
BULGARIA
Mold-Trade OOD
tel: [phone]
e: [email protected]
GREECE
Ionian Chemicals S.A.
tel: [phone]
e: [email protected]
ROMANIA
Tehnic Mold Trade SRL
tel: [phone]
e: [email protected]
DENMARK*
Englmayer A/S
tel: [phone]
e: [e-mail]
*Coverage includes Norway and
Sweden.
ISRAEL
ASAF Industries
tel: [phone]
e: [email protected]
RUSSIA
System LLC
tel: [phone]
e: [email protected]
SLOVENIA
RD Picta Tehnologije d.o.o.
tel: [phone]
e: [email protected]
BELARUS
HP Promcomplect
tel: +375 29
683-48-99 e:
[email protected]
FINLAND
Oy Scalar Ltd.
tel: [phone]
e: [e-mail]
PORTUGAL
Gecim LDA
tel: [phone]
e: [e-mail]
2-2
E-Multi User Manual
GLOBAL SUPPORT
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

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 select 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.
3-1SAFETY
E-Multi User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

3.2 Safety Hazards
The following safety hazards are most commonly associated with plastic
injection molding equipment (see European Standard EN201 or American
Standard ANSI/SPI B151.1).
WARNING
Also refer to all machine manuals and local regulations and codes for safety
information.
Refer to the illustration of hazard areas below when reading the Safety
Hazards Table 3-1 on page 3-3.
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
E-Multi User Manual
SAFETY
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

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.
Plasticized material released from / through the mold.
Clamping
Mechanism Area
See Figure 3-1 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.
Plasticized 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 plasticized 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.
3-3SAFETY
E-Multi User Manual
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.

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 plasticized 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.
Plasticized 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
E-Multi User Manual
SAFETY
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.