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Mold-Masters MILACRON E-Multi User Manual

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E-Multi User Manual
version 04
Original Instructions

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Summary of Contents for Mold-Masters MILACRON E-Multi

  • Page 1 E-Multi User Manual version 04 Original Instructions...

  • Page 3: Table Of Contents

    Table of Contents Section 1 - Introduction ...........1-1 1.1 INTENDED USE ....................1-1 1.2 OPERATOR TRAINING AND SAFETY ..............1-1 1.3 DOCUMENTATION ....................1-1 1.4 WARRANTY ......................1-1 1.5 RELEASE DETAILS ...................1-2 1.6 TRADEMARKS AND PATENTS .................1-3 Section 2 - Global Support ..........2-1 2.1 MANUFACTURING FACILITIES ................2-1 2.2 REGIONAL OFFICES ..................2-1 2.3 INTERNATIONAL REPRESENTATIVES ............2-2 Section 3 - Safety..............3-1...
  • Page 4 Section 7 - System Set-Up ..........7-1 7.1 CONNECTING THE CONTROLLER TO THE E-MULTI ........7-1 7.1.1 Routing and Connecting Servo Cables............7-1 7.1.2 Routing and Connecting Heater, I/O, IMM Cables........7-2 7.2 CONNECTING A ROBOT TO THE CONTROLLER ...........7-4 7.3 CONNECTING THE CONTROLLER TO THE MOLDING MACHINE ....7-4 7.4 CONNECTING A HAND-HELD HMI (OPTION) ..........7-4 7.5 CONNECTING PNEUMATIC CONNECTIONS ..........7-5 7.6 COOLING WATER CONNECTIONS ..............7-6...
  • Page 5 9.20 FEED ASSEMBLY REMOVAL AND REPLACEMENT ........9-26 9.20.1 Feed Assembly Removal ...............9-26 9.20.2 Install the Feed Block ................9-28 9.21 FEED SCREW CLEANING AND REPLACEMENT ........9-29 9.21.1 Preparing for Feed Screw Removal ............9-29 9.21.2 Feed Screw Removal ................9-30 9.21.3 Cleaning ....................9-32 9.21.4 Install the Feed Screw ................9-32 9.22 BARREL REMOVAL AND INSTALLATION .............9-34 9.22.1 Removing the Barrel ................9-34...
  • Page 6 12.4.2 Unpacking ....................12-2 12.4.3 Receiving inspection ................12-2 12.4.4 Installation ....................12-2 12.5 CALIBRATE HOME POSITION ..............12-2 12.6 AUTO PURGE ....................12-3 12.7 MAINTENANCE .....................12-3 12.7.1 Checking the Lubrication of the Ball Screw ...........12-3 12.8 SPARE PARTS ....................12-3 Section 13 - Servo Cooling Option ......13-1 13.1 OPERATION AND SPECIFICATIONS ............13-1 13.1.1 Closed loop specification ...............13-1 13.1.2 External loop specification ..............13-1...
  • Page 7 List of Figures FIGURE 3-1 INJECTION MOLDING MACHINE HAZARD AREAS......3-2 FIGURE 3-2 E-MULTI SAFETY HAZARDS ..............3-6 FIGURE 3-3 GUARDS LAYOUT. EM1 SHOWN.............3-12 FIGURE 3-4 DO NOT USE THE MOTOR AS A LIFTING POINT......3-14 FIGURE 3-5 EM1/EM2 VERTICAL LIFTING CONNECTIONS (EM3 SIMILAR) ...3-15 FIGURE 3-6 EM3 HORIZONTAL LIFT CONNECTIONS.
  • Page 8 List of Tables TABLE 1-1 RELEASE DETAILS ................1-2 TABLE 3-1 SAFETY HAZARDS ................3-3 TABLE 3-2 TYPICAL SAFETY SYMBOLS ...............3-5 TABLE 3-3 SAFETY SYMBOLS USED ON THE E-MULTI ........3-7 TABLE 3-4 E-MULTI SAFETY HAZARD DETAILS ...........3-8 TABLE 3-5 ENERGY FORMS, ENERGY SOURCES, AND GENERAL LOCKOUT GUIDELINES ....................3-10 TABLE 3-6 E-MULTI SHIPPING DIMENSIONS &...
  • Page 9 Units of measure and conversion factors NOTE The dimensions given in this manual are from original manufacturing draw- ings. All values in this manual are in S.I. units or subdivisions of these units. Im- perial units are given in parenthesis immediately after the S.I. units. Abbreviation Unit Conversion value...

  • Page 11: Section 1 - Introduction

    Before unpacking, moving, integrating or using the equipment, please read the manual, especially “Section 3 - Safety”,for important information. Please also be aware that the safety information provided by Mold-Masters does not absolve the integrator and employer from understanding and following inter- national and local standards for safety of machinery.

  • Page 12: Release Details

    INTRODUCTION 1.5 Release Details Table 1-1 Release Details Document # Release Date Version AIU-UM-EN-00-04 01 August 2016 E-Multi User Manual v4 © 2016 Milacron LLC. All Rights Reserved.

  • Page 13: Trademarks And Patents

    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.

  • Page 15: Section 2 - Global Support

    EUROPEAN HEADQUARTERS ASIAN HEADQUARTERS CANADA GERMANY / SWITZERLAND CHINA/HONG KONG/TAIWAN Mold-Masters (2007) Limited Mold-Masters Europa GmbH Mold-Masters (KunShan) Co, Ltd 233 Armstrong Avenue Postfach/P.O. Box 19 01 45 Zhao Tian Rd Georgetown, Ontario 76503 Baden-Baden, Germany Lu Jia Town, KunShan City...

  • Page 16: International Representatives

    TURKEY Ferromatik Milacron / Mold-Masters Europa GmbH INDONESIA / THAILAND Mold Masters Europa GmbH Merkezi Almanya Türkiye İstanbul Mold-Masters Singapore PTE. Ltd. C/. Enric Morera, 7 Şubesi No 48 Toh Guan Road East Polig. Ind. Foinvasa Alanaldı Caddesi Bahçelerarası #06-140 Enterprise Hub...

  • Page 17: Section 3 - Safety

    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 in- ternational and local standards for safety of machinery. It is the responsibility...

  • Page 18: Safety Hazards

    SAFETY 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.

  • Page 19: Table 3-1 Safety Hazards

    SAFETY Table 3-1 Safety Hazards Hazard Area Potential Hazards Mold Area Mechanical Hazards Area between the Crushing and/or shearing and/or impact hazards caused by: platens. Movement of the platen See Figure 3-1 area 1 Movements of the injection barrel(s) into the mold area Movements of cores and ejectors and their drive mechanisms Tie bar motion Thermal Hazards...
  • Page 20 SAFETY Table 3-1 Safety Hazards Hazard Area Potential Hazards Feed Opening Pinching and crushing between injection screw movement and housing. See Figure 3-1 area 6 Area of the heater Burns and/or scalds due to operating temperature of: bands of the plasti- The plasticizing and/or injection unit.

  • Page 21: Safety Symbols Typical To Injection Molding Machines

    SAFETY 3.3 Safety Symbols Typical to Injection Molding Machines Table 3-2 Typical Safety Symbols Symbol General Description General – Warning Indicates an immediate or potentially hazardous situation, which if not avoided, could result in a serious injury or death, and/or damage to equip- ment.

  • Page 22: E-Multi Safety Hazards

    SAFETY Table 3-2 Typical Safety Symbols Symbol General Description Warning – Read manual before operation Personnel should read and understand all instructions in the manuals be- fore working on equipment. Only properly trained personnel should operate the equipment. Warning – Slip, Trip, or Fall Hazard Do not climb on equipment surfaces.

  • Page 23: Table 3-3 Safety Symbols Used On The E-Multi

    SAFETY Table 3-3 Safety Symbols Used on the E-Multi Symbol General Description General – Warning Indicates an immediate or potentially hazardous situation, which if not avoided, could result in a serious injury or death, and/or damage to equip- ment Warning – Body Crush Hazard End of motor moves back during hold or recovery.

  • Page 24: Table 3-4 E-Multi Safety Hazard Details

    SAFETY Table 3-4 E-Multi Safety Hazard Details Hazard Type Potential Hazards Mechanical Hazards Body Crushing Hazard End of motor moves back during hold or recovery. A hazard may exist between the end of the injection unit motor assembly and a nearby solid obstacle.

  • Page 25: Lockout Safety

    SAFETY Table 3-4 E-Multi Safety Hazard Details Hazard Type Potential Hazards Hazards generated by materials or substances Hazards from contact Hot plastic could result in harmful gases being emitted from the purged with or inhalation of material or feed inlet. harmful gases Fire or explosion Hot surfaces of the barrel heaters could ignite flammable liquids or dust.

  • Page 26: Table 3-5 Energy Forms, Energy Sources, And General Lockout

    SAFETY 3-10 Table 3-5 Energy Forms, Energy Sources, and General Lockout Guidelines Energy Form Energy Source Lockout Guidelines Electrical Energy Power transmission lines; Turn off power at machine first (i.e., Machine power cords; at point of operation switch), and Motors; then at the main disconnect switch Solenoids;...

  • Page 27: Electrical Lockout

    SAFETY 3-11 3.5.1 Electrical Lockout Employers must provide an effective Lockout / Tagout program. WARNING - READ MANUAL Refer to all machine manuals and local regulations and codes. 1. Shut down machine using normal operational shutdown procedure and controls. This should be done by, or in consultation with the machine operator.

  • Page 28: Safety Guards

    SAFETY 3-12 3.6 Safety Guards WARNING Guards should not be removed unless maintenance is required, and should be replace after maintenance is complete. Do no run the machine with guards removed. CAUTION When installing the barrel covers, check that the covers do not pinch the CAUTION heater or thermocouple wires, and that the covers will not crush or shear the heater or thermocouple wires when the unit moves.

  • Page 29: Handling

    SAFETY 3-13 3.7 Handling Dimensions and weights shown are for packed wooden crates containing standard-optioned units. Additional options may add weight or require addi- tional crates. Specifications subject to changes without notice. Table 3-6 E-Multi Shipping Dimensions & Weight Model Length mm (in.) Width mm (in.) Height mm (in.) Weight kg (lb) EM1/EM2...

  • Page 30: Figure 3-4 Do Not Use The Motor As A Lifting Point

    SAFETY 3-14 Prior to Lifting the E-Multi 1. Choose lift equipment that is rated for the prescribed load (see equipment tag). 2. Define the load path (the path and orientation the item will move in while it is being lifted, and the location and orientation where it will be set down). 3.

  • Page 31: Em1/Em2/Em3 Lift Connections

    SAFETY 3-15 3.8 EM1/EM2/EM3 Lift Connections NOTE Review the information in “3.7 Handling” on page 3-13 before performing any lifting procedure. 3.8.1 EM1/EM2/EM3 Vertical Lift Connections Table 3-8 EM1/EM2/EM3 Vertical Lift Connections EM1 / EM2 Connect sling to motor end of the Connect sling to motor end support beam using one 16 mm (5/8 of the support beam using a...

  • Page 32: Em1/Em2/Em3 Horizontal Lift Connections

    SAFETY 3-16 3.8.2 EM1/EM2/EM3 Horizontal Lift Connections Table 3-9 EM1/EM2/EM3 Horizontal Lift Connections EM1 / EM2 *Note: For best results use an adjustable two leg chain bridle. Connect one sling (A) to motor end of Connect one sling (A) to motor the support beam by feeding it through end of the support beam by feed- the lifting hole, with sling on either side...

  • Page 33: Em4 Vertical Lift Procedures

    SAFETY 3-17 3.9 EM4 Vertical Lift Procedures NOTE Review the information in “3.7 Handling” on page 3-13 before performing any lifting procedure. The general procedure for lifting the EM4 unit vertically onto the injection molding machine is: 1. Lay the EM4 horizontally on the floor from either a) the shipping crate (see 3.9.1) , or b) a horizontal stand (see 3.9.2) 2.

  • Page 34: Lay The Em4 Horizontally On The Floor From A Horizontal Stand

    SAFETY 3-18 3.9.2 Lay the EM4 Horizontally on the Floor from a Horizontal Stand 1. Purge plastic from the system. See “Purging Plastic from System” on page 9-8. 2. Retract the carriage so that the nozzle does not protrude past the adapter plate.
  • Page 35 SAFETY 3-19 Attach the Lifting Bar - continued 3. Place the lifting bar under the motor and secure in place with the two hitch pins provided. 4. Secure the hitch pins with the provided hitch pin clips. 5. Attach and tighten the two M16 screws to the holes in the lifting bar. Torque to 101 Nm (75 ft-lbs).

  • Page 36: Raise The Em4 To A Vertical Orientation With Two Lifting Machines

    SAFETY 3-20 3.9.4 Raise the EM4 to a Vertical Orientation with Two Lifting Machines This is the preferred method to raise the EM4 to a vertical position. 1. Attach the slings from the lifting bar to the lifting machine. 2. Connect slings to the barrel end of the support beam using two 25 mm (1 in.) shackles in the lifting holes.
  • Page 37 SAFETY 3-21 Raise the EM4 to a Vertical Orientation with Two Lifting Machines - continued 7. Continue slowly until the unit is vertical and there is slack in the lower slings. 8. Rest the E-Multi on the adapter plate. Place the E-Multi on a surface that will not mar the adapter plate (wood, cardboard, etc.) 9.

  • Page 38: Raise The Em4 To A Vertical Orientation With One Lifting Machine

    SAFETY 3-22 3.9.5 Raise the EM4 to a Vertical Orientation with One Lifting Machine It is preferred to use two lifting machines to raise the E-Multi to a vertical posi- tion. Use this procedure if only one lifting machine is available. 1.

  • Page 39: Raise And Install The E-Multi Onto The Injection Molding Machine

    SAFETY 3-23 Raise the EM4 to a Vertical Orientation with One Lifting Machine - continued 5. Continue to slowly raise the E-Multi until it is in a vertical orientation, keeping the lifting machine centered over the E-Multi. WARNING Do not leave the E-Multi standing vertically without support. This is danger- ous and can result in serious injury if the unit falls over.

  • Page 40: Em4 Horizontal Lift Connections

    SAFETY 3-24 3.10 EM4 Horizontal Lift Connections Table 3-10 EM4 Horizontal Lift Connections Connect one sling (A) to motor end of the support beam by feeding it through the lifting hole, with sling on either side of the motor. Connect other sling (B) to barrel end of the support beam us- ing two 25 mm (1 in.) shackles in lifting holes.

  • Page 41: Section 4 - Overview

    OVERVIEW Section 4 - Overview 4.1 E-Multi Models Figure 4-1 E-Multi models. E-Multi User Manual v4 © 2016 Milacron LLC. All Rights Reserved.

  • Page 42: E-Multi Components

    OVERVIEW 4.2 E-Multi Components 1. Support beam: The back- bone of machine. All compo- nents connect to the support beam. 2. Injection housing: Provides injection pressure for ma- chine. 3. Injection motor: Provides power to injection housing. 4. Barrel housing: Provides material to barrel for injection.

  • Page 43: Section 5 - Preparation

    OVERVIEW Section 5 - Preparation WARNING When doing any work that requires lifting the machine, connect all lifting de- vices 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.

  • Page 44: Unpacking

    OVERVIEW 5.2 Unpacking 1. The crate should be moved using a forklift or pallet truck. If using a crane, the crate must be slung from underneath. Do not lift from the top of the crate. 2. Remove accessory boxes, manual and anything other than the E-Multi. 3.

  • Page 45: Section 6 - Installation

    OVERVIEW Section 6 - Installation HAZARD WARNINGS See “Section 3 - Safety” on page 3-1. It is the responsibility of the integrator to understand and follow international and local standards for safety of machinery when integrating the E-Multi into the molding system. This includes providing necessary e-stop connec- tions, safety interlocks and guarding to protect operators.

  • Page 46: Attaching E-Multi To Mold / Machine

    OVERVIEW 6.1 Attaching E-Multi to Mold / Machine IMPORTANT Please refer to the installation drawing supplied with unit for complete infor- mation on services and connections. WARNING - BODY CRUSH HAZARD The end of the injection motor moves back 210 mm (8 in.) max stroke dur- ing hold or recovery.

  • Page 47: Controller Installation

    The E-Multi controller supply should have a fused disconnect or main circuit breaker according to local safety codes. Refer to the serial plate on the controller cabinet for confirmation of the supply requirements. If the local supply is outside the specified range, please contact Mold-Masters for advice. •...

  • Page 49: Section 7 - System Set-Up

    SYSTEM SET-UP Section 7 - System Set-Up 7.1 Connecting the Controller to the E-Multi There are 3 sets of cables that connect the controller to the E-Multi: 1. servo power cables 2. servo feedback cables 3. heater - I/O - IMM cables. The correct sequence must be followed when installing the cables.

  • Page 50: Routing And Connecting Heater, I/O, Imm Cables

    SYSTEM SET-UP Routing and Connecting Heater, I/O, IMM Cables - continued 4. Once cables have been routed, use cable ties to hold cables in place. See below for correct connector alignment. Figure 7-2 Cables held with wire ties. Align arrows on connector halves Figure 7-3 Correct connector alignment.

  • Page 51: Figure 7-4 E-Multi Connection Locations

    SYSTEM SET-UP E-Multi side connections 1. E-Multi End Barrel Heat Connection 2. E-Multi End Aux. Inj. I/O Connection 3. EM4 barrel heater and thermocouple connection 4. Zone Connections for Hot Runner Control Option 5. Remote HMI Connection 6. EM1/2/3 barrel heater and thermocouple connection 7.

  • Page 52: Connecting A Robot To The Controller

    SYSTEM SET-UP 7.2 Connecting a Robot to the Controller E-Multi units are compatible with both E67 and SPI robots. In all cases, the controller is shipped with a robot jumper plug. If no robot is used, connect the robot jumper plug to the “ROBOT E67”...

  • Page 53: Connecting Pneumatic Connections

    SYSTEM SET-UP 7.5 Connecting Pneumatic Connections WARNING Hoses fitted to the E-Multi will contain high or low temperature 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. 1.

  • Page 54: Cooling Water Connections

    SYSTEM SET-UP 7.6 Cooling Water Connections All units have water-cooled housings to prevent over-heating of the injection unit. The EM3 and EM4 have water cooled servo motors. Figure 7-7 below shows the water inlet and outlet manifolds on the support beam. 1.

  • Page 55: Cooling Water Schematic Diagram

    CAUTION channels. It may result in decreased cooling performance and necessitate replacement of the servos. Mold-Masters recommends the use of our optional closed loop cooling sys- tem. Contact your Mold-Masters representative for more information. Table 7-2 Basic Water Quality Specification...

  • Page 56: Coolant And Additives

    SYSTEM SET-UP Cooling water quality - continued A more detailed water quality specification is found in “Water Quality” on page B-1. The values in Table 7-2 and represent conditions that will prevent most problems associated with poor water quality. These recommended val- ues do not guarantee that corrosion won’t occur.

  • Page 57: Connecting Diagnostic Computer (Option)

    SYSTEM SET-UP 7.7 Connecting Diagnostic Computer (option) 1. Connect one end of the crossover cable to Ethernet port on the controller. The Ethernet cable can be connected with the power on. 2. Connect the other end of the crossover cable to the Ethernet port on the diagnostic computer.

  • Page 58: Figure 7-11 Wireless Network Icon

    The diagnostic computer must be connected to the internet using its wire- less network adapter. The wired connection must be used to connect to the controller. Mold-Masters does not support alternate network configurations. Connection problems when using alternate configurations are not covered under warranty and may result in increased support times and additional costs.

  • Page 59: Section 8 - Operation

    OPERATION Section 8 - Operation WARNINGS Also see “Section 3 - Safety” on page 3-1. • Ensure that extreme caution is observed in the operation and mainte- nance of the injection molding machines. • Only fully trained personnel should operate or maintain equipment. •...

  • Page 60: Start Up And Shut Down

    OPERATION WARNINGS - CONTINUED • 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. • Hair could become entangled in the drive belt or screw of the injection unit.

  • Page 61: Switching On

    The E-Multi controller can be used in “Manual”, “Setup” and “Auto/Ready” mode. 8.1.2 Switching Off (or Shutting Down) Mold-Masters recommends that you use the console to shut down the heat- ing load, and only use the main current breaker switch to turn off the dormant controller.

  • Page 63: Section 9 - Maintenance

    MAINTENANCE Section 9 - Maintenance WARNING Before performing maintenance procedures be aware of the safety warn- ings. See “Section 3 - Safety” on page 3-1. 9.1 Preventive Maintenance Schedule Table 9-1 Preventive Maintenance Schedule Preventive Maintenance Frequency Verify injection pressure oil circuit Check preload pressure on controller at start of ev- ery shift.

  • Page 64: Other Torque Specifications

    MAINTENANCE 9.3 Other Torque Specifications Description Model lb-ft Nozzle Tip 99.5 Eccentric Shaft EM1/EM2 Locking Plate Description Model / Screw lb-ft Size Feed Block EM1 / M8 EM2 / M8 20.5 EM3 / M10 EM4 / M12 9.4 Belt Tension Specifications Table 9-2 Belt Tension Specifications Description Model...

  • Page 65: Table 9-3 E-Multi Lubrication

    MAINTENANCE Table 9-3 E-Multi Lubrication Location MM P/N Type Manufacturer Manufacturer’s P/N Drive Shaft Bearings 104L1111I Spindle Bearing Kluber Lubrica- ISOFLEX NBU 15 Grease tion Linear Guides Ball Nuts Carriage Spring Pack Oil Bath Level (Ball Screw 104L11081 75W-90 EP Synthet- Mobil Mobil Delvac 75W-90 Spindle Bearings)

  • Page 66: Verifying Injection Pressure Oil Circuit(Pre-Load Pressure)

    NOTE The Oil Fill Kit may have been supplied with the E-Multi injection unit and is also available from Mold-Masters. The Fill Kits are supplied without oil. The oil circuit requires 75W-90 synthetic gear oil. High Pressure Oil Fill Kit components: •...

  • Page 67: Charging The High Pressure Oil Circuit With The Oil Kit

    MAINTENANCE 9.5.3 Charging the High Pressure Oil Circuit with the Oil Kit WARNING Never run the E-Multi with the fill kit attached. Serious injury to the operator may result as well as damage to the machine. 1. Connect the oil gun to the oil manifold on the E-Multi injection unit using the flexible hose quick connect.

  • Page 68: Table 9-4 E-Multi Preload Pressures (1.34 Software)

    MAINTENANCE Table 9-4 E-Multi Preload Pressures (1.34 Software) Screw Calibration (melt) Preload oil pressure on HMI Preload oil pressure Preload Diameter pressure at 10V on gauge pressure transducer voltage Max Min Max Min Max Min 3 521 51 063 2 250 1 953 2 587 37 515...

  • Page 69: Checking Oil Bath Level

    MAINTENANCE 9.6 Checking Oil Bath Level 1. The E-Multi should be in horizontal or vertical position and the injection unit moved fully back. 2. The oil fill port is positioned so that the oil level may be checked with the E-Multi mounted vertically, horizontally, or at any angle in between.

  • Page 70: Purging Plastic From System

    MAINTENANCE 9.8 Purging Plastic from System WARNING Material purged from machine will be extremely hot. Ensure protec- tive guards are in place around the nozzle to prevent molten plastic from splashing. Use proper personal protective equipment. 1. Retract the carriage from the mold. 2.

  • Page 71: Moving The E-Multi To A Work Surface For Maintenance

    9.11 Clean Servo Motor Cooling Lines Mold-Masters recommends using closed loop cooling to avoid hard water de- posits that may clog the thin cooling channels inside the motors. However if open loop cooling has been used, and there are indications of contamination (see below), follow those recommendations to clean the servo motor cooling channels.

  • Page 72: Adapter Plate Removal And Installation

    MAINTENANCE 9-10 9.11.2 Cleaning Recommendations • Use a pump capable of 4.5 bar (65 PSI) minimum pressure in a 45 m (147 ft) water head. CAUTION The motor inlet pressure must not exceed 6 bar. CAUTION • Set the flow rate to 3 l/min (0.75 gal/min) minimum •...
  • Page 73 MAINTENANCE 9-11 Adapter Plate Removal and Installation - continued 4. Remove replacement adapter plate shipping bracket, if necessary. 5. With solvent, clean the mating surfaces of the replacement adapter plate, adapter blocks (if used) and support beam. Wipe with a clean, lint free cloth.
  • Page 74 MAINTENANCE 9-12 Adapter Plate Removal and Installation - continued 10. Tighten bolts lightly so adapter plate can be moved by tapping with a rub- ber mallet. 11. Measure the distance from the nozzle to the adapter plate bore at 12, 3, 6 and 9 o’clock and align the plate by tapping so the distance is equal at all positions.

  • Page 75: Injection Nozzle Replacement

    MAINTENANCE 9-13 9.13 Injection Nozzle Replacement 1. Clean the nozzle and barrel area. Remove any plastic residue, using soft brass tools only. 2. Remove the nozzle tip and clean plastic from the nozzle opening and in- ner cone. 3. Apply anti-seize to the nozzle tip threads and re-install the nozzle tip. See “Other Torque Specifications”...

  • Page 76: Figure 9-1 Protrusion Adjustment Parts. Em1 Shown, Other Models

    MAINTENANCE 9-14 Nozzle Protrusion Introduction - continued 1. Clamping screw 2. Adjuster screw 3. Clevis link 4. Forward stop pin Figure 9-1 Protrusion adjustment parts. EM1 shown, other models are similar. CAUTION The nozzle should not touch the mold during installation before the adapter CAUTION plate bolts are tight.

  • Page 77: Nozzle Protrusion Adjustment Procedure - Manual Protrusion Adjustment

    MAINTENANCE 9-15 9.14.2 Nozzle Protrusion Adjustment Procedure - Manual Protrusion Adjustment This procedure is used to correctly adjust the carriage linkage for optimum nozzle contact force. 1. Loosen the carriage adjuster clamping screw. 2. Put the controller in Setup mode. 3.
  • Page 78 MAINTENANCE 9-16 Nozzle Protrusion Adjustment Procedure - Manual Protrusion Adjustment - cont. 5. With the clevis link touching the stop pin, use the adjuster screw to move the nozzle forward until it just touches the mold as shown below. Nozzle touching mold Clevis link touching stop pin 6.

  • Page 79: Nozzle Protrusion Adjustment - Automatic Adjustment

    MAINTENANCE 9-17 9.15 Nozzle Protrusion Adjustment - Automatic Adjustment 9.15.1 Carriage Home Position Calibration The first time the E-Multi is installed, and any time it is transferred to a new machine with a different mold, the carriage home position and contact force must be set.

  • Page 80: Automatic Calibration

    MAINTENANCE 9-18 9.15.3 Automatic Calibration 1. Put the controller in setup mode 2. Make sure barrel heaters are at operating temperature 3. Touch the start reference button If the nozzle is adjusted correctly, the routine will complete and the nozzle tip position graphic will show the nozzle tip in the green region.

  • Page 81: Injection Axis Referencing

    MAINTENANCE 9-19 9.16 Injection Axis Referencing CAUTION The injection referencing routine verifies the injection stroke by moving the CAUTION screw fully back and then fully forward. Referencing will fail if the screw cannot achieve the full stroke. 1. Controller must be in setup mode with heats on and up to operating tem- perature, carriage referenced and carriage retracted from the mold.

  • Page 82: Cleaning The Bolt-Type Shut Off Nozzle's Bolt

    MAINTENANCE 9-20 9.17 Cleaning The Bolt-Type Shut Off Nozzle’s Bolt When the E-Multi is installed in the horizontal orientation the well surrounding the shut off nozzle bolt needs to be cleaned of accumulated plastic mate- rial regularly. A build-up of plastic material can cause the bolt to seize or not function properly.
  • Page 83 MAINTENANCE 9-21 Cleaning The Bolt-Type Shut Off Nozzle’s Bolt - continued WARNING Compressed air will cause the molten plastic to splash. Wear appropriate protective clothing. 3. Use a small pick to remove the residual plastic from the well surrounding the pin. Compressed air can be used to blow the plastic from the bolt. 4.

  • Page 84: Barrel Head Removal & Replacement

    MAINTENANCE 9-22 9.18 Barrel Head Removal & Replacement The procedure applies to EM3 and EM4 units only. The barrel head must be removed to change the barrel, the screw or the check-ring. If the entire screw and barrel assembly is being changed, barrel head removal is not necessary.

  • Page 85: Heater Replacement

    MAINTENANCE 9-23 9.19 Heater Replacement WARNING Contact with the barrel can cause severe burns. Exercise caution and wear appropriate PPE when working on or around a hot barrel. 1. Move the carriage to the fully back position. 2. Remove the front and rear guards. Remove the outer barrel cover and the inner barrel cover.
  • Page 86 MAINTENANCE 9-24 Heater Replacement - continued 3. Number all heaters and thermocouples and note orientation of connectors and wires. Heaters and thermocouples are numbered starting with #1 at the housing end of the barrel. Heater 1 Thermocouples 4. Remove any plastic residue and clean the end of the barrel. 5.
  • Page 87 MAINTENANCE 9-25 Heater Replacement - continued 14. Using the old heater as a template, cut new heater wires to the same length. Cut the braided shield back from the wire 50 mm (2 in.). Strip the insulation off the heater wires to 10 mm (0.4 in.). Install ferrules using fer- rule crimper.

  • Page 88: Feed Assembly Removal And Replacement

    MAINTENANCE 9-26 Feed Assembly Removal and Replacement - continued 27. Test heater resistance using a multi-meter on the connector insert pins. 28. Reinstall the front and rear guards. Ensure the gap between the guards and the injection housing is the same all around the housing. Also make sure there is no interference with heater and thermocouple wires.
  • Page 89 MAINTENANCE 9-27 Feed Assembly Removal - continued 6. Remove screws attaching feed tube to feed block and lift the feed tube away and remove the feed tube. If a vibrator is used, disconnect air sup- ply from the vibrator. 7. If pellets are not purged from the unit, use a vacuum cleaner to remove pellets from feed block and barrel.

  • Page 90: Install The Feed Block

    MAINTENANCE 9-28 9.20.2 Install the Feed Block 1. Install the feed block into barrel housing. 2. Apply a light coat of synthetic grease to the screws, install and finger tighten. 3. In a cross pattern, torque the screws in steps, ensuring that the gap for the entire contact surface remains uniform as the screws are tightened.

  • Page 91: Feed Screw Cleaning And Replacement

    MAINTENANCE 9-29 9.21 Feed Screw Cleaning and Replacement 9.21.1 Preparing for Feed Screw Removal 1. Move the machine to a work surface. See “Moving the E-Multi to a Work Surface for Maintenance” on page 9-9. WARNING This procedure is done in the hot condition. Wear appropriate personal protective equipment such as heat resistant gloves and goggles or a face shield.

  • Page 92: Feed Screw Removal

    MAINTENANCE 9-30 9.21.2 Feed Screw Removal NOTE Step 1 is different for EM1/EM2 units and for EM3/EM4 units. Refer to the correct Step 1 for your system. The remaining steps are the same for all units. EM1/EM2 Units 1. Release the feed screw from the drive shaft a) With the drive power on, unscrew the collet securing the feed screw to the feed drive shaft.

  • Page 93: All Units

    MAINTENANCE 9-31 Feed Screw Removal - continued EM3/EM4 Units 1. Release the feed screw from the drive shaft a) Remove screws securing screw collar to feed drive shaft. b) Push the screw towards the barrel until the bolt securing the screw- retaining bushing is accessible.

  • Page 94: Cleaning

    MAINTENANCE 9-32 9.21.3 Cleaning Use a brass bristled brush to clean plastic from the feed screw. 9.21.4 Install the Feed Screw 1. Insert the feed screw into barrel. NOTE Step 2 is different for EM1 / EM2 units and for EM3 / EM4 units. Refer to the correct Step 2 for your system.
  • Page 95 MAINTENANCE 9-33 Install the Feed Screw - continued d) Apply anti-seize compound. Tighten the collet securing the feed screw to drive. EM3/EM4 Units a) Insert the feed screw into the barrel. Once the end protrudes past the barrel end far enough to install the screw collar, install the splined ring. b) Install the screw collar, retaining bushing and bolt.

  • Page 96: Barrel Removal And Installation

    MAINTENANCE 9-34 9.22 Barrel Removal and Installation WARNING Contact with the barrel can cause severe burns. Exercise caution and wear appropriate PPE when working on or around a hot barrel. CAUTION Thermocouple connections on the barrel are easily damaged. Do not allow CAUTION the weight of the barrel to rest on the thermocouples.
  • Page 97 MAINTENANCE 9-35 Removing the Barrel - continued 3. Remove the feed block. See “Feed Assembly Removal and Replacement” on page 9-26. 4. Remove the feed screw. See “Feed Screw Cleaning and Replacement” on page 9-29. 5. Remove the large barrel nuts securing the barrel to the barrel housing. 6.

  • Page 98: Transferring Heaters And Thermocouples To A New Barrel

    MAINTENANCE 9-36 Removing the Barrel - continued 8. Disconnect the barrel housing thermocouple. Barrel Housing Thermocouple 9. Slide the barrel out of the barrel housing. 9.22.2 Transferring Heaters and Thermocouples to a New Barrel See “Heater Replacement” on page 9-23. E-Multi User Manual v4 ©...

  • Page 99: Installing The Barrel

    MAINTENANCE 9-37 9.22.3 Installing the Barrel 1. Apply anti-seize to load surfaces and thread. Lift the barrel into position and slide it into the barrel housing with the flat face facing up. 2. Install the large barrel nuts onto the end of the barrel and tighten finger tight.
  • Page 100 MAINTENANCE 9-38 Installing the Barrel - continued 5. In a cross pattern, re-install the heater connector screws. See “Screw Torque Specifications” on page 9-1. 6. Secure the feed screw to the drive shaft. See “Feed Screw Cleaning and Replacement” on page 9-29. 7.

  • Page 101: Belt Tension Adjustment

    MAINTENANCE 9-39 9.23 Belt Tension Adjustment WARNING Lock out / tag out machine before performing a belt tension adjustment. 1. Remove front and rear guards. 1. Rear Guard 2. Front Guard 2. Loosen, but do not remove, the screws securing the eccentric shaft lock- ing plate.

  • Page 102: Belt Removal And Installation

    MAINTENANCE 9-40 9.24 Belt Removal and Installation CAUTION Do not rotate the ball screws with the belt removed, otherwise realignment CAUTION will be necessary. EM1/EM2 Models: 1. Purge plastic from the machine. See “Purging Plastic from System” on page 9-8. 2.
  • Page 103 MAINTENANCE 9-41 Belt Removal and Installation - continued 15. Remove the screws securing the cable track bracket to the shaft cover on the injection housing. Cable Track Bracket 16. Unfold the cable track. 17. Position the new belt as shown below. 18.

  • Page 104: Servicing And Repairing Your Controller

    MAINTENANCE 9-42 Servicing and Repairing your Controller - continued 21. Move the old belt over the injection housing, all the way to the barrel housing and remove it. 22. Clean the pulleys and the idler surface with solvent and a clean cloth. 23.

  • Page 105: Section 10 - Troubleshooting

    TROUBLESHOOTING 10-1 Section 10 - Troubleshooting 10.1 Thermocouple Electrical Check The controller system has functionality to monitor thermocouple performance. 1. A working thermocouple will show a realistic temperature based on the environment it is in. Defective thermocouples will read -100ºC (-148ºF) on the controller.

  • Page 106: Servo Motor Temperature Check

    10-2 10.5 Servo Motor Temperature Check The motor warning and alarm temperatures are factory settings that can only be changed by a Mold-Masters technician. The default values are: Warning temperature: 75°C (167°F) Alarm temperature: 80°C (176°F) The E-Multi controller automatically disables the motors when the alarm tem- perature is reached.

  • Page 107: Section 11 - E-Multi Radial Option

    E-MULTI RADIAL OPTION 11-1 Section 11 - E-Multi Radial Option 11.1 Introduction This section provides information that is special to the E-Multi Radial ma- chine-mounted solution for E-Multi Auxiliary Injection Units. WARNING Refer the full user manual for important safety, setup and operation informa- tion.

  • Page 108: Figure 11-1 Main Components Of The E-Multi Radial

    E-MULTI RADIAL OPTION 11-2 1. Vertical beam assembly (with E-Multi) 2. Horizontal beam assembly 3. X-axis brake 4. Clamping bolts 5. Adapter plate Figure 11-1 Main components of the E-Multi Radial E-Multi User Manual v4 © 2016 Milacron LLC. All Rights Reserved.

  • Page 109: E-Multi Radial Safety Hazards

    E-MULTI RADIAL OPTION 11-3 11.3 E-Multi Radial Safety Hazards In addition to the E-Multi safety hazards found in “Section 3 - Safety” on page 3-1, Note the hazards that follow. 1. Mandatory lift point 2. Entanglement hazard 3. Hot surface hazard 4.

  • Page 110: Table 11-2 E-Multi Radial Safety Hazards Details

    E-MULTI RADIAL OPTION 11-4 Table 11-2 E-Multi Radial Safety Hazards Details (In addition to the E-Multi Safety Hazards found in “Section 3 - Safety” on page 3-1). Hazard Type Potential Hazards Body Crushing Hazard End of motor moves back during hold or recovery or during carriage return.

  • Page 111: Unpacking

    E-MULTI RADIAL OPTION 11-5 11.4 Unpacking WARNING When doing any work that requires lifting the machine, connect all lifting devices and support the machine using a crane of adequate capacity be- fore commencing work. Failure to support the machine can result in severe injury or death.

  • Page 112: Receiving Inspection

    E-MULTI RADIAL OPTION 11-6 Receiving Inspection - continued 8. Remove any rust inhibiting material that may be on the four machined surfaces of the horizontal and vertical beam interface. Apply a light coating of oil on these four surfaces. Figure 11-4 Forward sling attachment Figure 11-5 Rear sling attachment 11.5 Receiving Inspection 9.

  • Page 113: E-Multi Radial Installation (Em1 And Em2 Models)

    E-MULTI RADIAL OPTION 11-7 11.6 E-Multi Radial Installation (EM1 and EM2 models) WARNING See “Safety” on page 3-1. It is the responsibility of the integrator to understand and follow international and local standards for safety of machinery when integrating the E-Multi Radial system into the molding system.
  • Page 114 E-MULTI RADIAL OPTION 11-8 E-Multi Radial Installation (EM1 and EM2 models) - continued 1. In preparation for mounting the E-Multi Radial to the injection molding machine, clean the stationary platen surface where the E-Multi Radial will be mounted. 2. The E-Multi Radial was shipped with the injection unit in the horizontal position.

  • Page 115: Figure 11-7 Tilting The E-Multi Radial From The Horizontal To Verti

    E-MULTI RADIAL OPTION 11-9 E-Multi Radial Installation (EM1 and EM2 models) - continued 1) lifting with tension in rear sling 2) approximate tipping point 3) lowering with tension in forward sling. Figure 11-7 Tilting the E-Multi Radial from the horizontal to vertical position. 5.
  • Page 116 E-MULTI RADIAL OPTION 11-10 E-Multi Radial Installation (EM1 and EM2 models) - continued 6. Install the lower end of both cable tracks and connect the water and air lines. 7. Release the orange X-Axis brake and slide the unit back until it is bal- anced and stable.

  • Page 117: Installation Onto Injection Molding Machine

    E-MULTI RADIAL OPTION 11-11 11.6.1 Installation onto Injection Molding Machine 1. Lift the assembly into place above the injection molding machine’s sta- tionary platen. Install all adapter plate mounting screws and torque in a crosswise pattern (See “Screw Torque Specifications” on page 9-1). 2.

  • Page 118: Manual Position Adjustment

    E-MULTI RADIAL OPTION 11-12 11.7 Manual Position Adjustment Manually use the E-Multi Radial range of movement to roughly align the E- Multi nozzle with the hot runner inlet. The controller will be used to fine tune the alignment and calibrate the carriage position in preparation for molding. NOTE The E-Multi Radial is designed to work with a spherical nozzle tip and a spherical hot runner inlet.
  • Page 119 E-MULTI RADIAL OPTION 11-13 Manual Position Adjustment - continued 3. Release the rotary stopper - a white band will show on the plunger when released. Rotate the E-Multi Radial to the approximate angle required. You may optionally depress the rotary stopper to prevent further rotation. NOTE The stopper can be depressed in rotational increments of 15°.
  • Page 120 E-MULTI RADIAL OPTION 11-14 Manual Position Adjustment - continued 10. Follow these steps to start to lock the Radial into position: a) Torque the two, rear-most M16 clamping bolts to 160 Nm (118 ft-lbs) b) Torque the two, forward-most M16 clamping bolts to 160 Nm (118 ft- lbs) c) Finger tighten the two M12 clamping bolts d) Tighten the X-Axis brake...

  • Page 121: Calibrate Home Position

    E-MULTI RADIAL OPTION 11-15 11.8 Calibrate Home Position NOTE Calibrate the carriage home position when you install the E-Multi for the first time and when you use the E-Multi with a newly installed mold. Mold must be closed and clamped and barrel must be at operating temperature before calibrating the home position.

  • Page 122: E-Multi Radial Maintenance

    E-MULTI RADIAL OPTION 11-16 11.10 E-Multi Radial Maintenance Follow the recommended maintenance in “Section 9 - Maintenance” on page 9-1. Additional E-Multi Radial maintenance instructions are listed here. The E-Multi Radial has linear guides attaching the upper assembly to the lower assembly and also has additional linear guides supporting the E-Multi barrel housing and injections housings.
  • Page 123 E-MULTI RADIAL OPTION 11-17 EM1 and EM2 Models - continued 2. Remove the plug. Ensure the fitting is lined up with the hole. 3. Press the E-Stop on the controller. Lock-out / tag-out the E-Multi system by following the procedures in “Lockout Safety” on page 3-9. 4.
  • Page 124 E-MULTI RADIAL OPTION 11-18 EM3 and EM4 Models - continued 5. Bring the carriage down approximately 130 mm (5 in.) from fully up to access the grease nipple for the ball screw nut. Apply the E-Stop on the controller. See Table 11-3 for lubrication specification. Carriage Ball Screw Nut Lubrication Position Carriage down 130 mm...

  • Page 125: Service Of The E-Multi Radial Carriage Assembly And Servo Motor

    WARNING The carriage assembly and, specifically, the servo motor, should never be removed for maintenance. If the carriage assembly, or the servo motor, must be removed, please contact your Mold-Masters representative for instructions. WARNING Removal of any of the carriage assembly, including the servo motor, any of...

  • Page 126: Er3 / Er4 Installation

    E-MULTI RADIAL OPTION 11-20 11.12 ER3 / ER4 installation 1. Remove adapter plate from shipping crate. 2. Place the adapter plate on the stationary platen. Install the bolts (M20X90) in a cross pattern and torque it to 339 Nm (250 ft-lbs). 3.
  • Page 127 E-MULTI RADIAL OPTION 11-21 ER3 / ER4 installation - continued 4. Install the horizontal beam on the adapter plate. Insert and hand tighten the 4 bolts (M20X90) in the accessible holes. 5. Unclamp the horizontal beam assembly with the clamping screw. Rotate the screw counter clockwise until the end of the head is flush with the support plate.
  • Page 128 E-MULTI RADIAL OPTION 11-22 ER3 / ER4 installation - continued 7. Use the rear hand crank and rotate the horizontal beam assembly so that it is in the home position (x-axis is parallel to tiebars). Torque the other two bolts to 339 Nm (250 ft-lbs). 8.
  • Page 129 E-MULTI RADIAL OPTION 11-23 ER3 / ER4 installation - continued 12. Attach lifting bar to vertical beam. Attach a 4 in. web sling (supplied) to each end of the lifting bar with a choker configuration. 13. Lift the vertical beam with two lifting devices. If a crane and forklift are used, the crane should lift the lifting bar end.
  • Page 130 E-MULTI RADIAL OPTION 11-24 ER3 / ER4 installation - continued 16. Install the 8 screws (M16X50) and secure the vertical beam to the hori- zontal beam and hand tighten. 17. Install the 8 screws (M16X55) into the bottom of the horizontal beam and hand tighten.
  • Page 131 E-MULTI RADIAL OPTION 11-25 ER3 / ER4 installation - continued 23. Cut the cable ties which secures the small cable track to large cable track. 24. Install the small cable track to the barrel housing bracket with 2 flat head screws (M6x16).
  • Page 132 E-MULTI RADIAL OPTION 11-26 ER3 / ER4 installation - continued 29. Connect the pressure transducer cable to the pressure transducer on the injection housing. 30. Connect cooling lines to the manifold on the Injection housing. 31. Connect carriage motor cables to carriage motor. Make sure that the cables do not interfere with the cable track and do not bind against the support beam.
  • Page 133 E-MULTI RADIAL OPTION 11-27 ER3 / ER4 installation - continued 36. Turn on the controller and the barrel heats. 37. Rotate the clamping screw counterclockwise until the unit can be moved using the hand wheels. Check the color of the LED on the transducer con- nector, it should be red.

  • Page 134: Spare Parts For The E-Multi Radial

    After hold: Same as after injection, except that the nozzle moves back after E-Multi hold completes. 11.13 Spare Parts for the E-Multi Radial Contact your Mold-Masters representative if you need any spare parts for the E-Multi Radial system. E-Multi User Manual v4...

  • Page 135: Section 12 - Servo Carriage Option

    SERVO CARRIAGE OPTION 12-1 Section 12 - Servo Carriage Option 12.1 Introduction This section provides information that is special to the E-Multi Servo Carriage Option “EMSC” for E-Multi Auxiliary Injection Units. IMPORTANT Refer the full user manual for important safety, setup and operation informa- tion.

  • Page 136: Material Handling

    SERVO CARRIAGE OPTION 12-2 12.4 Material Handling 12.4.1 Preparation Refer to “Section 5 - Preparation” on page 5-1 for the preperation proce- dure. 12.4.2 Unpacking Refer to “5.2 Unpacking” on page 5-2 for the unpacking procedure. 12.4.3 Receiving inspection Refer to “5.3 Receiving Inspection” on page 5-2 for the receiving inspection procedure.

  • Page 137: Auto Purge

    “Table 11-3 Grease Lubrication Volume - Ball Screw Nut” on page 11-16 for lubrication specification. 7. Reinstall the support beam cover. 12.8 Spare Parts Contact your Mold-Masters representative if you need any spare parts for the E-Multi Servo Carriage system. E-Multi User Manual v4 © 2016 Milacron LLC. All Rights Reserved.

  • Page 139: Section 13 - Servo Cooling Option

    SERVO COOLING OPTION 13-1 Section 13 - Servo Cooling Option 13.1 Operation and specifications The cooling unit’s pump powers up with the controller and continuously circu- lates fluid through the motors. The E-Multi controller automatically switches the flow rate of coolant between high and low settings to maintain the motor temperatures in a safe range.

  • Page 140: Maintenance

    SERVO COOLING OPTION 13-2 13.2 Maintenance WARNING Disconnect the 4 pin pump connector from the cabinet when servicing or whenever the cooling circuit is opened to prevent accidental power-up of the pump with the controller. Make sure that the controller cabinet is powered off and unplugged from the power source.

  • Page 141: Servicing / Replacing The Heat Exchanger

    SERVO COOLING OPTION 13-3 13.2.2 Servicing / replacing the heat exchanger CAUTION Drain the reservoir before the disassembly of the cooling unit, see 13.2.3. CAUTION Cleaning the heat exchanger: Use a diluted solution of 5% acetic acid or any copper-safe aqueous acidic cleaning solution and flush the heat exchanger periodically depending on the mineral concentration in the cooling water.

  • Page 143: Section 14 - E-Multi Stands

    Your order documentation will indicate your stand type. If you require spare parts, or to find out more about other stand options, please contact your Mold-Masters representative. Table 14-1 E-Multi Stand Options E-Multi Model...

  • Page 144: Compact Stand

    E-MULTI STANDS 14-2 14.4 Compact Stand 14.4.1 Main Components 1. Top column with adapter bracket for EM1 / EM2 models 2. Top column with adapter bracket for EM3 models 3. Base column 4. Column hitch pin 5. Horizontal adjustment lever 6.

  • Page 145: Horizontal Position Adjustment

    E-MULTI STANDS 14-3 14.4.2 Horizontal Position Adjustment The compact stand lever is used to move the E-Multi adapter plate posi- tion toward or away from the mold, to aid installation and removal from the mold. The compact stand range of horizontal position adjustment is 50-75 mm (2 to 3 in.).

  • Page 146: Heavy Duty Stand

    E-MULTI STANDS 14-4 14.5 Heavy Duty Stand 14.5.1 Main Components 1. Adapter bracket for EM3 models 2. Adapter bracket for EM4 models 3. Linear rail & ball guides 4. Top/Bottom leveling plates 5. Top column 6. Clamping plates & screws 7.

  • Page 147: Horizontal Position Adjustment

    E-MULTI STANDS 14-5 14.5.2 Horizontal Position Adjustment The Heavy Duty Stand Linear Rail / Ball Guide assembly is used to move the E-Multi adapter plate position toward or away from the mold, to aid installa- tion and removal from the mold. - EM3 stand range of horizontal position adjustment is 0-125 mm (0-4.92 in.) - EM4 stand range of horizontal position adjustment is 0-30 mm (0-1.18 in.) 1.

  • Page 148: Counter Weight Kit (Option)

    E-MULTI STANDS 14-6 14.5.4 Counter Weight Kit (Option) Counter weight kits (for heavy duty stands) can be purchased to add further stability to the E-Multi machine-stand assembly or in cases where the stabi- lizing leg will not fit under the injection molding machine. The counter weight brackets are installed onto the lead leg of the base frame and the weights assembled onto the bracket posts.

  • Page 149: Assembly

    E-MULTI STANDS 14-7 14.5.5 Assembly 1. Assemble stand in the lowest position (the clamp plates can be loose). 1. Clamping Plates & Screws 2. Top and Base Column Assembly 3. Base Frame 2. Place the stabilizing leg under the base frame and install onto the clevis bracket with the clevis pin.

  • Page 150: Leveling Castors

    E-MULTI STANDS 14-8 14.6 Leveling Castors Once the E-Multi is in position at the machine, the leveling castor pads are extended equally until the stand is resting on the pads and the wheels are not touching the ground, rather than the castor wheels. With the wheels off the ground, the leveling pads can be used to provide additional height adjustment to align the adapter plate with the mold.

  • Page 151: Figure 14-11 E-Multi Stand-To-Mold Installation

    E-MULTI STANDS 14-9 Mold Installation - continued 8. Adjust the 3 leveling castors to raise the stand until the E-Multi center line is aligned to the mold center line. 9. Use the stand horizontal adjustment to slowly move the E-Multi adapter plate forward to contact the mold.
  • Page 152 E-MULTI STANDS 14-10 Mold Installation - continued 13. Heavy Duty Stand - If necessary, the top leveling plate may be adjusted in order to obtain fine leveling alignment. The SHCS should be loosened only enough to allow the plate to be raised and leveled by the set screws. After final leveling, the locking screws must be torqued as in “Screw Torque Specifications”...

  • Page 153: Mold Removal

    E-MULTI STANDS 14-11 14.8 Mold Removal 1. Remove the bolts fastening the adapter plate to the mold. 2. Move stand horizontal adjustment fully back: a) Compact Stand - pull lever away from the injection molding machine. b) Heavy Duty Stand - move the linear rail fully back on the ball guides and lock.

  • Page 155: Euromap 67

    E-MULTI STANDS Euromap 67 Scope and Application This EUROMAP 67 recommendation defines the connection between the injection molding machine and the handling device / robot. This is intended to provide interchangeability. In addition recommendations are given for signal voltage and current levels. Please note that the risk assessment for the movements of the handling de- vice / robot mostly require redundancy which is achieved by two channels on : ZA3, ZC3 and ZA4, ZC4 on the injection molding machine.
  • Page 156 E-MULTI STANDS Table A-1 Plug on the Injection Molding Machine Signals from the injection molding machine to the handling device / robot Contact Signal designation Description No. (male) Safety devices of The switch contact is closed when safety devices (e.g. safety machine guards, footboard safety, etc.) on the injection molding machine channel 1...
  • Page 157 E-MULTI STANDS Table A-1 Plug on the Injection Molding Machine Signals from the injection molding machine to the handling device / robot Contact Signal designation Description No. (male) Ejector back position HIGH signal when the ejector has been finally (e.g. after the number of its set cycles) retracted regardless of the moving platen position.
  • Page 158 E-MULTI STANDS Table A-2 Plug on the Injection Molding Machine Signals from the handling device / robot to the injection molding machine Contact Signal designation Description (female) Emergency stop of The switch contact must be open when the handling device / handling device / robot emergency stop is being actuated.
  • Page 159 E-MULTI STANDS Table A-2 Plug on the Injection Molding Machine Signals from the handling device / robot to the injection molding machine Contact Signal designation Description (female) Handling device LOW signal when the handling device / robot mode switch is / robot operation "Operation with injection molding machine".

  • Page 161: Water Quality

    E-MULTI STANDS Water Quality Table B-1 Detailed Water Quality Specification Constituents Units Closed Loop Tower Water pH Units 7.2 - 8.5 7.2 - 8.5 “M” Alkalinity < 500 “P” Alkalinity Total Hardness (as CaCO < 10 60 - 800 Calcium Hardness (as CaCO <...
  • Page 163 E-MULTI STANDS Index Verifying Injection Pressure Oil Circuit (Pre- load Pressure) 9-4 Vibrator Valve Check 10-1 Checking Lubrication of Linear Guides and Ball Screws 9-7 Warranty 1-1 Checking Oil Bath Level 9-7 E-Radial Specifications 11-1, 12-1 Fault and warning messages 10-2 Hazard areas 3-2 Heater Continuity Check 10-1 Injection Axis Referencing 9-19...
  • Page 164 Global Headquarters European Headquarters Asian Headquarters Mold-Masters (2007) Limited Mold-Masters Europa GmbH Mold-Masters (KunShan) Co, Ltd tel: +1 905 877 0185 tel: +49 7221 50990 tel: +86 512 86162882 fax: +1 905 873 2818 fax: +49 7221 53093 fax: +86 512-86162883 e: hotrunners-na@milacron.com...

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