Mold-Masters TempMaster MT Series User manual

version 4
Original Instrucons
User Manual

REMOVE AND KEEP THIS
SHEET SOMEWHERE SAFE
MT Controllers come with a xed password which is
entered via the two arrow keys.
The Password is:
(up, down, up, up, down)
followed by a check mark

Table of 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
1.8 Trademarks and Patents ....................................................................................1-3
Section 2 - Global Support ..............................................2-1
2.1 Manufacturing Facilities ......................................................................................2-1
2.2 Regional O󰀩ces .................................................................................................2-1
2.3 International Representatives .............................................................................2-2
Section 3 - Safety..............................................................3-1
3.1 Introduction .........................................................................................................3-1
3.2 Safety Hazards ...................................................................................................3-2
3.3 Operational Hazards ...........................................................................................3-5
3.4 General Safety Symbols .....................................................................................3-7
3.5 Wiring Check ......................................................................................................3-8
3.6 Lockout Safety ....................................................................................................3-9
3.7 Electrical Lockout .............................................................................................3-10
3.7.1 Energy Forms and Lockout Guidelines....................................................3-11
3.8 Disposal ............................................................................................................3-12
3.9 MT/MT2 Controller User Hazards .....................................................................3-13
Section 4 - Overview ........................................................4-1
4.1 Specication .......................................................................................................4-2
4.2 TMXL/MT Compatibility ......................................................................................4-2
4.3 Tool Connections ................................................................................................4-3
4.4 Controller Power Supplies ..................................................................................4-3
4.5 Filter Option ........................................................................................................4-3
4.6 Switch On and O󰀨...............................................................................................4-3
4.6.1 Switch On ..................................................................................................4-3
4.6.2 Switch O󰀨 Individual Modules ....................................................................4-3
4.6.3 Switch O󰀨 the Whole Controller .................................................................4-3
4.6.4 Switch O󰀨 Individual Zones .......................................................................4-4
4.7 Controller Cabinet ...............................................................................................4-4
4.7.1 Controller Modules ....................................................................................4-5
4.8 How the MT Controller Works .............................................................................4-6
4.8.1 Set the Ramp Feature (On / O󰀨) ...............................................................4-6
4.9 Program Menus ..................................................................................................4-7
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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
MT Controller User Manual

Section 5 - Setup ..............................................................5-1
5.1 Introduction .........................................................................................................5-2
5.2 Set Zone Numbering ..........................................................................................5-3
5.3 Set the Temperature Scale .................................................................................5-5
5.4 Change Zone PID Characteristics ......................................................................5-7
5.5 Set the Ramp Feature .......................................................................................5-9
5.6 Set Boost Value ................................................................................................5-11
5.7 Set Standby Value ............................................................................................5-13
5.8 Monitor Temperature Limits ..............................................................................5-15
5.8.1 Warning and Alarm Limits ........................................................................5-15
5.9 Set Ground Fault Detection ..............................................................................5-17
5.10 Set Mold Leak Detection ................................................................................5-19
5.11 Set Response to Thermocouple Failure .........................................................5-21
5.12 Restrict Access to Manual, Standby or Boost .................................................5-23
5.13 Extend Alarms for Manual, Standby or Boost Operation ................................5-25
5.14 Language ........................................................................................................5-27
5.15 Set the Required Zone Temperatures ............................................................5-28
Section 6 - Operation .......................................................6-1
6.1 Run Mode ...........................................................................................................6-1
6.2 OFF Mode (Single Zone) ....................................................................................6-2
6.3 O󰀨 Mode (Single Module) ...................................................................................6-2
6.4 Manual Mode ......................................................................................................6-3
6.5 Manual Mode - Power Level ...............................................................................6-4
6.6 Slave Mode .........................................................................................................6-5
6.7 Standby and Boost Mode ...................................................................................6-7
6.7.1 Standby – Whole Cabinet ..........................................................................6-7
6.7.2 Boost – Whole Cabinet ..............................................................................6-7
6.7.3 No Standby or Boost Option ......................................................................6-7
6.8 Standby Mode – Individual Zones ......................................................................6-8
6.9 Leaving Standby Mode .......................................................................................6-9
6.10 Boost Mode – Individual Zones ......................................................................6-10
6.11 Change Set Temperature (Auto or Manual) .................................................... 6-11
Section 7 - Maintenance...................................................7-1
7.1 Service and Repair The Controller .....................................................................7-1
7.1.1 Replacement Parts ....................................................................................7-1
7.1.2 Cleaning and Inspection ............................................................................7-1
7.2 Restore Factory Settings and Recalibration .......................................................7-2
7.2.1 Default Settings .........................................................................................7-3
7.2.2 Calibration Routine ....................................................................................7-3
7.2.3 Calibration Sequence ................................................................................7-3
7.2.4 M.Dis Option ..............................................................................................7-4
7.3 Fuses and Overcurrent Protection ......................................................................7-5
7.3.1 Fans ...........................................................................................................7-5
7.3.2 Controller Cards .........................................................................................7-6
7.3.3 Onboard Power Supply ..............................................................................7-6
7.3.4 Output Fuse Type: HRC High Speed .........................................................7-6
7.3.5 Input Fuse Type: Surface-Mount Quick-Blow ............................................7-6
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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
MT Controller User Manual

Section 8 - Troubleshooting ............................................8-1
8.1 Individual Card Diagnostics ................................................................................8-1
8.2 Other Possible Fault Conditions .........................................................................8-3
8.2.1 Rapid Temperature Fluctuations ................................................................8-3
8.2.2 Ground Fault Detection ..............................................................................8-3
8.3 Module Removal .................................................................................................8-3
Section 9 - Wiring Details ................................................9-1
9.1 Single Phase Supply Cable ................................................................................9-1
9.2 Three Phase Designation ...................................................................................9-2
9.2.1 Five Wire Star 380VAC ..............................................................................9-2
9.2.2 Set Power Terminal Block to STAR Conguration .....................................9-3
9.2.3 For Four Wire Delta 240V ..........................................................................9-4
9.2.4 Set Power Terminal Block To DELTA Conguration ...................................9-5
9.3 Filter Option ........................................................................................................9-6
9.4 Alarm Output .......................................................................................................9-6
9.5 Standard Tool Connections ................................................................................9-7
9.5.1 MT-02-02 ...................................................................................................9-7
9.5.2 MT-02-02 For UK and Europe ...................................................................9-7
9.5.3 MT-02-02 For India ....................................................................................9-8
9.5.4 MT-02-02 For North America .....................................................................9-9
9.5.5 MT-04-04 .................................................................................................9-10
9.5.6 MT-06-06 ................................................................................................. 9-11
9.5.7 MT-12-12 and MT-18-xx ..........................................................................9-12
9.5.8 MT-12-12 and MT-18-xx for UK and Europe............................................9-12
9.5.9 MT-12-12 and MT-18-xx for North America .............................................9-14
Index ......................................................................................I
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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
MT Controller User Manual

viii
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
MT Controller User Manual
List of Tables
Table 1-2 Units of Measure and Conversion Factors ...............................................1-2
Table 3-1 Safety Hazards .........................................................................................3-3
Table 3-2 Typical Safety Symbols .............................................................................3-7
Table 3-3 Energy Forms, Energy Sources and General
Lockout Guidelines ...........................................................................................3-11
Table 4-1 General Specications ..............................................................................4-2
Table 5-1 Factory Settings ........................................................................................5-2
Table 7-1 Factory Settings ........................................................................................7-3
Table 7-2 Fan Fuses .................................................................................................7-6
Table 7-3 Onboard Power Supply Fuse ....................................................................7-6
Table 7-4 Output Fuse Type .....................................................................................7-6
Table 7-5 Input Fuse Type ........................................................................................7-6
Table 8-1 Alarm Conditions .......................................................................................8-1
Table 9-1 Cable Markings for Single Phase Supply Cable
(MT-02-02) ..........................................................................................................9-1
Table 9-2 Cable Markings - 5 Wire Star ....................................................................9-1
Table 9-3 Cable Markings for Four Wire Star ...........................................................9-3
Table 9-4 HAN4A Pin Connections ...........................................................................9-5
Table 9-5 MT-02-02 Pin Conguration for UK and Europe .......................................9-6
Table 9-6 MT-02-02 Pin Conguration for India ........................................................9-7
Table 9-7 MT-02-02 Pin Conguration for North America .........................................9-8
Table 9-8 MT-04-04 Pin Conguration ......................................................................9-9
Table 9-9 MT-06-06 Pin Conguration ....................................................................9-10
Table 9-10 MT-12-12 / MT-18-xx Pin Conguration for UK
and Europe .......................................................................................................9-12
Table 9-11 MT-12-12 / MT-18-xx Pin Conguration for
North America (Plug 1) .....................................................................................9-13
Table 9-12 MT-12-12 / MT-18-xx Pin Conguration for
North America (Plug 2) .....................................................................................9-14

List of Figures
Figure 3-1 Injection molding machine hazard areas .................................................3-2
Figure 4-1 MT controller ...........................................................................................4-1
Figure 4-2 MT2 controller .........................................................................................4-1
Figure 4-3 MT Menu .................................................................................................4-7
Figure 4-4 MT2 Menu ...............................................................................................4-7
Figure 7-1 Fuse location on a controller card ...........................................................7-5
Figure 9-1 Connect the neutral - position shown by blue
arrow ...................................................................................................................9-2
Figure 9-2 Install the three way link ..........................................................................9-2
Figure 9-3 Remove the neutral wire - position shown by the
blue arrow ...........................................................................................................9-4
Figure 9-4 Install the three 2-way links .....................................................................9-4
Figure 9-5 HAN4A connector ....................................................................................9-5
Figure 9-6 Harting Han 10 A® insert for MT-02-02 ....................................................9-6
Figure 9-7 Harting Han 10 A® cut out dimensions ....................................................9-6
Figure 9-8 Harting Han 16 E® insert for MT-02-02 ....................................................9-7
Figure 9-9 Harting Han 16 E® cut out dimensions ....................................................9-7
Figure 9-10 Harting Han 10 E® insert for MT-02-02 .................................................9-8
Figure 9-11 Harting Han 10 E® cut out dimensions ..................................................9-8
Figure 9-12 Insert for MT-04-04 ................................................................................9-9
Figure 9-13 MT-04-04 cut out dimensions ................................................................9-9
Figure 9-14 Insert for MT-06-06 ..............................................................................9-10
Figure 9-15 MT-06-06 cut out dimensions ..............................................................9-10
Figure 9-16 Inserts for MT-12-12 and MT-18-xx ..................................................... 9-11
Figure 9-17 MT-12-12 AND MT-18-xx cut out dimensions -
UK and Europe .................................................................................................9-12
Figure 9-18 MT-12-12 and MT-18-xx inserts (Plug 1 and Plug 2) ..........................9-13
Figure 9-19 MT-12-12 AND MT-18-xx cut out dimensions -
North America ...................................................................................................9-14
ix
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
MT Controller User Manual

Section 1 - Introduction
The purpose of this manual is to assist users in the integration, operation and
maintenance of the MT and MT2 controller. This manual is designed to cover
most system congurations. If you need additional information specic to your
system please contact your representative or a Mold-Masters o󰀩ce whose
location can be found in the “Global Support” section.
1.1 Intended Use
The MT Series controllers have been designed as a multi-channel
temperature controllers for use in hot runner plastic molding equipment. They
use feedback from thermocouples within the nozzles and manifolds to give
precise closed-loop temperature control, and they are 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
MT-UM-EN-00-04-5 July 2019 04-5
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
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
MT Controller User Manual

1.6 Copyright
© 2019 Milacron LLC. All Rights Reserved. Mold-Masters® and the Mold-
Masters logo are trademarks of Milacron LLC and/or its a󰀩liates Mold-
Masters (2007) Limited, DME Company LLC, and Cimcool Fluid Technology.
(collectively, “Milacron”).
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
lLitre 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
sSecond
°Degree
°CDegree Celsius 0.556 (°F -32)
°FDegree Fahrenheit 1.8 °C +32
1-2
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
MT Controller User Manual

1.8 Trademarks and Patents
ACCU-VALVE, DURA, FLEX-DURA FLEX-SERIES, FUSION-SERIES, HOT EDGE, INJECTION-
EERING, MASTERPROBE, MASTER-SHOT, MOLD-MASTERS, MELT-DISK, MOLD-MASTERS
ACADEMY, MASTER-SERIES, MASTERSOLUTION, MASTERSPEED, MERLIN, MOLD-MASTERS
SYSTEM, MPET, SCAN-MASTER, 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 ac-
cordance with technical development without prior notication.
May be manufactured under one or more of the following U.S. Patents:
5792493, 5795599, 5820899, 5843361, 5849343, 5853777, 5935615, 5935616, 5935621, 5942257,
5952016, 5980236, 6009616, 6017209, 6030198, 6030202, 6062841, 6074191, 6077067, 6079972,
6095790, 6099780, 6113381, 6135751, 6162043, 6162044, 6176700, 6196826, 6203310, 6230384,
6270711, 6274075, 6286751, 6302680, 6318990, 6323465, 6348171, 6350401, 6394784, 6398537,
6405785, 6440350, 6454558, 6447283, 6488881, 6561789, 6575731, 6625873, 6638053, 6648622,
6655945, 6675055, 6688875, 6701997, 6739863, 6752618, 6755641, 6761557, 6769901, 6776600,
6780003, 6789745, 6830447, 6835060, 6840758, 6852265, 6860732, 6869276, 6884061, 6887418,
6890473, 6893249, 6921257, 6921259, 6936199, 6945767, 6945768, 6955534, 6962492, 6971869,
6988883, 6992269, 7014455, 7018197, 7022278, 7025585, 7025586, 7029269, 7040378, 7044191,
7044728, 7048532, 7086852, 7105123, 7108502, 7108503, 7115226, 7118703, 7118704, 7122145,
7125242, 7125243, 7128566, 7131832, 7131833, 7131834, 7134868, 7137806, 7137807, 7143496,
7156648, 7160100, 7160101, 7165965, 7168941, 7168943, 7172409, 7172411, 7175419, 7175420,
7179081, 7182591, 7182893, 7189071, 7192268, 7192270, 7198740, 7201335, 7210917, 7223092,
7238019, 7244118, 7252498, 7255555, 7258536, 7270538, 7303720, 7306454, 7306455, 7314367,
7320588, 7320589, 7320590 7326049, 7344372, 7347684, 7364425, 7364426, 7370417,7377768,
7381050, 7396226, 7407379, 7407380, 7410353, 7410354, 7413432, 7416402, 7438551, 7462030,
7462031, 7462314, 7465165, 7470122, 7507081, 7510392, 7513771, 7513772, 7517214, 7524183,
7527490, 7544056, 7547208, 7553150, 7559760, 7559762, 7565221, 7581944, 7611349, 7614869,
7614872, 7618253, 7658605, 7658606, 7671304, 7678320, 7686603, 7703188, 7713046, 7722351,
7731489, 7753676, 7766646, 7766647, 7775788, 7780433, 7780434, 7794228, 7802983, 7803306,
7806681, 7824163, 7845936, 7850442, 7874833, 7877163, 7891969, 7918660, 7918663, 7931455,
7963762, 7988445, 7998390, 8062025, 8066506, 8113812, 8142182, 8152513, 8167608, 8202082,
8206145, 8210842, 8241032, 8280544, 8282386, 8308475, 8308476, 8328546, 8353697, 8414285,
8425216, 8449287, 8465688, 8469687, 8475155, 8475158, 8480391, 8568133, 8690563,
8715547,8753102, 8757998, 8758002, 8845321, 8899964, 8940202, 8985997, 9004906, 9028243,
9073246, 9186830, 9186833, 9227351,9248593, 9272455, 9327436, D525592, RE38265, RE38396,
RE38920, RE39935, RE40478, RE40952, RE41536E, RE41648E+ Pending.
© 2019 MOLD-MASTERS (2007) LIMITED. ALL RIGHTS RESERVED
1-3
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
MT Controller User Manual

Section 2 - Global Support
2.1 Manufacturing Facilities
2.2 Regional Ofces
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]
Mold-Masters Regional Offices
AUSTRIA / East and South
East Europe
Mold-Masters Handelsges.m.b.H.
Pyhrnstrasse 16
A-4553 Schlierbach
Austria
tel: [phone]
fax: [phone]
[email protected]
ITALY
Mold-Masters Italia
Via Germania, 23
35010 Vigonza (PD)
Italy
tel: [phone]
fax: [phone]
[email protected]
CZECH REPUBLIC
Mold-Masters Europa GmbH
Hlavni 823
75654 Zubri
Czech Republic
tel: [phone]
fax: [phone]
[email protected]
KOREA
Mold-Masters Korea Ltd.
E dong, 2nd floor, 2625-6,
Jeongwang-dong, Siheung
City, Gyeonggi-do, 15117,
South Korea
Tel: [phone]
[email protected]
FRANCE
Mold-Masters France
ZI la Marinière,
2 Rue Bernard Palissy
91070 Bondoufle, France
tel: [phone]
fax: [phone]
[email protected]
MEXICO
Milacron Mexico Plastics Services
S.A. de C.V.
Circuito El Marques norte #55
Parque Industrial ElMarques
El Marques, Queretaro C.P. 76246
Mexico
tel: [phone] (sales)
tel: [phone] (service)
[email protected]
2-1
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
GLOBAL SUPPORT
MT Controller User Manual

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
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
GLOBAL SUPPORT
MT Controller User Manual

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

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

Safety Hazards - continued
Table 3-1 Safety Hazards
Hazard Area Potential Hazards
Mold Area
Area between the
platens.
See Figure 3-1 area 1
Mechanical Hazards
Crushing and / or shearing and / or impact hazards caused by:
• Movement of the platen.
• Movements of the injection barrel(s) into the mold area.
• Movements of cores and ejectors and their drive mechanisms.
• Tie bar motion.
Thermal Hazards
Burns and / or scalds due to operating temperature of:
• The mold heating elements.
• Material released from/through the mold.
Clamping
Mechanism Area
See Figure 3-1 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.
3-3
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
SAFETY
MT Controller User Manual

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.
Safety Hazards - continued
3-4
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SAFETY
MT Controller User Manual

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.
• It is highly recommended that all operators wear 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.
• Make sure that the cables are connected to the correct motors. Cables
and motors are clearly labeled. Reversing the cables can result in
unexpected and uncontrolled motion causing a safety risk or damage to
the machine.
3.3 Operational Hazards
3-5
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SAFETY
MT Controller User Manual

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