Mold-Masters TempMaster M3 Series User manual

User Manual
version 1
Original Instrucons

REMOVE AND RETAIN
Every machine leaves our factory with two levels of
password protection. We recommend that you remove
this sheet in order to establish your own security.
User Password - unix
System Password - linux

Contents
Section 1 - Introduction ...................................................1-1
1.1 Intended Use ......................................................................................................1-1
1.2 Release Details ..................................................................................................1-1
1.3 Warranty Details .................................................................................................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
Section 2 - Global Support ..............................................2-1
2.1 Corporate O󰀩ces................................................................................................2-1
2.2 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
3.7 Electrical Lockout .............................................................................................3-10
3.7.1 Energy Forms and Lockout Guidelines....................................................3-11
3.8 Ground Connections.........................................................................................3-12
3.9 Disposal............................................................................................................3-12
3.10 M3 Controller Safety Hazards ........................................................................3-13
3.10.1 Operational Environment.......................................................................3-13
3.10.2 Cabinet Push / Tip Forces .....................................................................3-14
Section 4 - Overview ........................................................4-1
4.1 Specication .......................................................................................................4-1
4.2 Front View of Controller......................................................................................4-2
4.3 Back View of Controller ......................................................................................4-3
4.4 Screen Layout and Navigation ...........................................................................4-4
4.4.1 Navigation Menu Buttons...........................................................................4-5
4.4.2 Quick Access Buttons................................................................................4-6
4.4.3 The Information Button ..............................................................................4-7
4.4.4 Control Action Buttons ...............................................................................4-8
4.4.5 The Information Bar...................................................................................4-8
4.5 Choose a Screen Theme....................................................................................4-8
4.6 Modern Theme ...................................................................................................4-9
4.6.1 Light Theme...............................................................................................4-9
4.6.2 Classic Theme .........................................................................................4-10
4.7 Zone Display Options (TS8 Console) ...............................................................4-11
4.7.1 TS8 Console: 36 Zones on Screen..........................................................4-11
4.7.2 TS8 Console: 54 Zones on Screen..........................................................4-12
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4.7.3 TS8 Console: 96 Zones on Screen..........................................................4-12
4.8 Zone Display Options (TS12 Console) .............................................................4-13
4.8.1 TS12 Console: 40 Zones on Screen........................................................4-13
4.8.2 TS12 Console: 60 Zones on Screen........................................................4-14
4.8.3 TS12 Console: 96 Zones on Screen........................................................4-14
4.8.4 TS12 Console: 144 Zones on Screen......................................................4-15
4.9 Zone Display Options (TS17 Console) .............................................................4-15
4.9.1 TS17 Console: 78 Zones on Screen........................................................4-15
4.9.2 TS17 Console: 105 Zones on Screen......................................................4-16
4.9.3 TS17 Console: 165 Zones on Screen......................................................4-16
4.10 Resize Zones..................................................................................................4-16
4.11 The User Interface ..........................................................................................4-17
4.12 Screensaver ...................................................................................................4-17
4.13 Choose Zones ................................................................................................4-18
4.14 Set and Measured Parameters.......................................................................4-19
4.15 The Display Screen ........................................................................................4-20
4.16 Display Screen Options ..................................................................................4-21
4.16.1 Zone Panel Display................................................................................4-22
4.16.2 Table Display .........................................................................................4-23
4.16.3 Bar Graph Display .................................................................................4-24
4.16.4 EasyView Screen Display......................................................................4-25
4.17 Modes of Operation ........................................................................................4-26
4.17.1 Mode Window........................................................................................4-27
4.17.2 Status Window.......................................................................................4-27
4.18 The ToolStore Screen .....................................................................................4-28
4.18.1 Side Menu Buttons of ToolStore Screen................................................4-29
4.19 The Apps Screen ............................................................................................4-30
4.19.1 Apps Screen Icons.................................................................................4-31
4.20 The Settings Screen .......................................................................................4-32
4.20.1 Settings: Screen Side Menu Buttons.....................................................4-32
4.20.2 System Settings Icons ...........................................................................4-33
4.20.3 Tool Settings Icons.................................................................................4-33
4.21 The Graph Screen ..........................................................................................4-34
4.21.1 Graph Screen Side Menu Buttons.........................................................4-35
4.22 The Pictures Screen .......................................................................................4-36
4.22.1 Pictures Screen Side Menu Buttons......................................................4-36
4.22.2 Access the Pictures Screen: TS8 Console ............................................4-37
4.22.3 The Picture View Screen .......................................................................4-38
4.22.4 Menu Buttons of Picture View Screen Top ............................................4-39
4.22.5 Zoom Screen .........................................................................................4-40
4.22.6 Interpret the Zoom Screen.....................................................................4-41
4.22.7 Zoom Screen Side Menu Buttons..........................................................4-42
Section 5 - Setup ..............................................................5-1
5.1 Introduction.........................................................................................................5-2
5.2 Create a New Tool ..............................................................................................5-2
5.2.1 Cards That May Be Detected ....................................................................5-4
5.3 Congure the Control Cards...............................................................................5-5
5.3.1 Set Zone Types..........................................................................................5-5
5.4 Set Chillers, Cavities and Water Flow Zones .....................................................5-7
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5.4.1 Precongured Zone Values .......................................................................5-9
5.5 Congure the Parameters and Settings ...........................................................5-10
5.5.1 Congure Tool Parameters Zone by Zone...............................................5-11
5.5.2 Congure Tool Settings for the Whole Tool..............................................5-15
5.5.3 Congure System Settings ......................................................................5-21
5.6 Set Zone Temperature......................................................................................5-26
5.7 Manual Mode....................................................................................................5-27
5.7.1 Set Manual Mode.....................................................................................5-28
5.8 Melt Leakage Detection....................................................................................5-30
5.8.1 Enable Melt Leakage Detection...............................................................5-30
5.8.2 Set Automatic Leakage Detection............................................................5-32
5.8.3 Set Manual Leakage Detection................................................................5-35
5.8.4 Set Smart Leakage Detection..................................................................5-37
5.9 View or Print Tool Settings................................................................................5-39
5.10 Import a Picture ..............................................................................................5-41
5.11 Setup the Picture View Screen .......................................................................5-42
5.11.1 Link a Picture in the Picture View Screen ..............................................5-43
5.11.2 Unlink a Picture in the Picture View Screen...........................................5-43
5.11.3 View Linked Pictures..............................................................................5-44
5.11.4 Add a Mini Panel to the Tool Picture ......................................................5-45
5.11.5 Remove a Mini Panel from the Tool Picture...........................................5-46
5.11.6 Backup a Picture from the Picture View Screen ....................................5-46
5.11.7 Delete a Picture Using the Picture View Screen....................................5-47
5.12 Set Date and Time..........................................................................................5-48
5.13 Congure a Printer .........................................................................................5-50
5.14 Set the Storage Locations ..............................................................................5-53
Section 6 - Operation .......................................................6-1
6.1 Switch On the Controller.....................................................................................6-1
6.1.1 Mold Heating..............................................................................................6-2
6.2 Switch O󰀨 the Controller.....................................................................................6-2
6.2.1 Shut Down the Console.............................................................................6-2
6.2.2 Shut down the Controller ...........................................................................6-4
6.3 Login or Logout...................................................................................................6-5
6.3.1 Login..........................................................................................................6-5
6.3.2 Logout........................................................................................................6-6
6.4 Quick Start Guide ...............................................................................................6-7
6.5 Control Modes for All Zones ...............................................................................6-9
6.6 Boost Mode ......................................................................................................6-11
6.6.1 Enter Boost Mode Manually.....................................................................6-11
6.6.2 Enter Boost Mode Remotely....................................................................6-11
6.7 Slave Mode.......................................................................................................6-12
6.7.1 Enter Slave Mode ....................................................................................6-12
6.8 Purge Function .................................................................................................6-14
6.8.1 The Purge Process..................................................................................6-14
6.8.2 Chemical Purge .......................................................................................6-17
6.8.3 Mechanical Purge....................................................................................6-18
6.8.4 Print the Purge Results............................................................................6-19
6.9 Turn Zones O󰀨 or On........................................................................................6-20
6.10 Rename an Existing Tool................................................................................6-22
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6.11 Save a Tool .....................................................................................................6-23
6.11.1 Overwrite Tool Settings ..........................................................................6-24
6.11.2 Save Changes as a New Tool................................................................6-25
6.12 Load a Tool Locally.........................................................................................6-27
6.13 Load a Tool Remotely.....................................................................................6-28
6.14 Search for a Tool ............................................................................................6-28
6.15 Delete a Tool...................................................................................................6-30
6.16 Backup Tool Settings ......................................................................................6-32
6.16.1 Backup a Single Tool .............................................................................6-32
6.16.2 Backup the Tool Bank............................................................................6-33
6.17 Restore Tool Settings .....................................................................................6-34
6.17.1 Restore a Single Tool.............................................................................6-34
6.17.2 Restore the Tool Bank ...........................................................................6-35
6.18 Sequence Tools and Settings .........................................................................6-36
6.18.1 Example of a Sequence.........................................................................6-36
6.18.2 Program a Sequence ...........................................................................6-37
6.18.3 Start a Sequence - Locally.....................................................................6-39
6.18.4 Start a Sequence - Remotely.................................................................6-40
6.19 Use the Picture View Screen as the Display Screen......................................6-41
6.19.1 Lock and Unlock the Screen..................................................................6-41
6.19.2 Choose Zones with the Picture View Screen.........................................6-42
6.19.3 Set or Change Temperature with the Picture View Screen....................6-43
6.19.4 Set Manual Mode with the Picture View Screen....................................6-44
6.19.5 Set a Zone to Slave on the Picture View Screen...................................6-45
6.19.6 Open the Zoom Screen from the Picture View Screen..........................6-47
6.20 Monitor Energy Usage - Energy Screen.........................................................6-48
6.20.1 Congure the Energy Screen ................................................................6-49
6.20.2 Print the Graphs from the Energy Screen..............................................6-51
6.21 Export Tool Data - Export Screen ...................................................................6-51
6.22 Monitor Controller Changes - Actions Screen ................................................6-54
6.23 Monitor Alarms - Alarms Screen .....................................................................6-58
6.24 Connect Remotely - Remote Screen..............................................................6-62
6.24.1 Stop the VNC.........................................................................................6-63
Section 7 - User Access and Networking.......................7-1
7.1 User Access Screen ...........................................................................................7-1
7.2 Congure User Limitations .................................................................................7-2
7.2.1 Add a Function for a User..........................................................................7-2
7.2.2 Remove a Function from a User................................................................7-3
7.2.3 Import System Security Settings................................................................7-4
7.2.4 Export System Security Settings ...............................................................7-5
7.3 User Admin Screen.............................................................................................7-6
7.3.1 View User Details ......................................................................................7-7
7.3.2 Edit User Details........................................................................................7-7
7.4 Add a New User..................................................................................................7-8
7.5 Delete a User....................................................................................................7-10
7.6 User Admin Settings .........................................................................................7-10
7.6.1 Auto Login User .......................................................................................7-11
7.6.2 Login Mode..............................................................................................7-11
7.6.3 Logout Time.............................................................................................7-11
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7.6.4 Import User List .......................................................................................7-11
7.6.5 Export User List .......................................................................................7-12
7.7 Congure a Network Connection......................................................................7-13
7.7.1 Congure a Wired Connection.................................................................7-13
7.7.2 Congure a Wireless Network .................................................................7-15
7.7.3 Add a Hidden Wireless SSID...................................................................7-17
7.8 Share Files on a Network .................................................................................7-18
7.9 Linked Controllers.............................................................................................7-20
Section 8 - Maintenance...................................................8-1
8.1 Upgrade Software...............................................................................................8-1
8.2 Check the Touchscreen Alignment .....................................................................8-4
8.3 Self Diagnostic Tests ..........................................................................................8-7
8.3.1 Fast Test ..................................................................................................8-10
8.3.2 Full Test ...................................................................................................8-10
8.3.3 Power Test ...............................................................................................8-11
8.4 Interpret the Test Results..................................................................................8-12
8.4.1 Satisfactory Test ......................................................................................8-12
8.4.2 Unsatisfactory Test ..................................................................................8-12
8.5 System Diagnosis Error Messages ..................................................................8-14
8.6 Print the Test Results........................................................................................8-15
8.7 Training and Demonstration Mode ...................................................................8-16
8.7.1 Enter or Leave Demo Mode.....................................................................8-16
8.8 Remove or Reconnect the Console..................................................................8-18
8.8.1 Remove the Console ...............................................................................8-18
8.8.2 Reconnect the Console ...........................................................................8-18
8.9 Service and Repair The Controller ...................................................................8-19
8.9.1 Replacement Parts ..................................................................................8-19
8.9.2 Cleaning and Inspection ..........................................................................8-19
8.9.3 Replacement Fuses.................................................................................8-20
8.9.4 Protection of Power Supply Unit..............................................................8-20
8.9.5 Ancillary Components..............................................................................8-20
8.9.6 Controller Card Fuses..............................................................................8-20
Section 9 - Troubleshooting ............................................9-1
9.1 Controller Card Indicators...................................................................................9-1
9.3 Beacon and Sounder Extension .........................................................................9-2
9.2 System Warning Messages ................................................................................9-2
9.4 Fault and Warning Messages .............................................................................9-3
9.5 M3 Comm Board Troubleshooting......................................................................9-6
9.6 TC Module Troubleshooting ...............................................................................9-6
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Section 10 - Controller Wiring...................................... 10-1
10.1 Three Phase Designation - Star / Delta Option ..............................................10-1
10.2 Connect the Star / Delta Option......................................................................10-2
10.2.1 Set Power Rail to Star Conguration.....................................................10-2
10.2.2 Star Supply Wiring.................................................................................10-3
10.2.3 Set Power Rail to Delta Conguration ...................................................10-4
10.2.4 Delta Supply Wiring ...............................................................................10-5
10.3 Loom Thermocouple Cables ..........................................................................10-5
10.4 Loom Power Cables .......................................................................................10-5
10.5 Alarm Output / Auxiliary Input .........................................................................10-6
10.6 Serial Port.......................................................................................................10-6
10.7 USB Port.........................................................................................................10-7
10.8 Filter Option ....................................................................................................10-7
10.9 Touchscreen Schematic .................................................................................10-8
Section 11 - Quad IO Options......................................11-10
11.1 Quad IO Screen............................................................................................ 11-10
11.2 Quad IO Card Reset Timer ...........................................................................11-12
11.2.1 Set the Quad IO Reset Timer............................................................... 11-12
11.3 Quad IO - Inputs ........................................................................................... 11-14
11.4 Quad IO - Outputs ........................................................................................11-15
11.5 Quad IO - Default Connections..................................................................... 11-16
11.6 Remote Tool Selection.................................................................................. 11-17
11.7 Remote Tool Loading.................................................................................... 11-17
11.7.1 Static Remote Tool Load...................................................................... 11-17
11.7.2 Dynamic Remote Tool Load................................................................. 11-18
Index ......................................................................................I
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Section 1 - Introduction
The purpose of this manual is to assist users in the integration, operation and
maintenance of the M3 controller with a touchscreen console. 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 M3 controller together with the console is an electrical distribution and control device
designed as a multi channel temperature controller for use in hot runner plastic molding
equipment. It uses feedback from thermocouples within the nozzles and manifolds to
give precise closed loop temperature control, and 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
M3-UM-EN-00-01 October 2020 01
M3--UM--EN--00--01-1 April 2021 01-1
1.3 Warranty Details
Warranty details are provided with your order documentation.
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
M3 Controller User Manual
© 2021 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION

1.6 Copyright
© 2021 Mold-Masters. All Rights Reserved. Mold-Masters®and the Mold-Masters logo are
trademarks of Mold- Masters (2007) Limited.
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 M3 Controller User Manual
© 2021 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION

Section 2 - Global Support
2.1 Corporate 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]
INDIAN HEADQUARTERS
INDIA
Milacron India PVT Ltd. (Mold-
Masters Div.)
3B,Gandhiji Salai,
Nallampalayam, Rathinapuri
Post, Coimbatore T.N. 641027
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 &
SOUTHEAST 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]
[e-mail]
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 El Marques
El Marques, Queretaro C.P. 76246
Mexico
tel: [phone] (sales)
tel: [phone] (service)
[email protected]
2-1
M3 Controller User Manual
© 2021 Mold-Masters (2007) Limited. All Rights Reserved.
GLOBAL SUPPORT

2.2 International Representatives
Corporate Ofces - continued
Mold-Masters Regional Offices (cont.)
SPAIN
Mold-Masters Europa GmbH
C/ Tecnología, 17
Edificio Canadá PL. 0 Office A2
08840 – Viladecans
Barcelona
tel: [phone]
e: [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]
[email protected]
2-2 M3 Controller User Manual
© 2021 Mold-Masters (2007) Limited. All Rights Reserved.
GLOBAL SUPPORT

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
M3 Controller User Manual
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SAFETY

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 Hazard areas of an injection molding machine
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 M3 Controller User Manual
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SAFETY

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 3-1 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.
• 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.
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SAFETY

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 M3 Controller User Manual
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SAFETY

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.
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SAFETY