Mold-Masters MILACRON E-Multi Manuals

Manuals and User Guides for Mold-Masters MILACRON E-Multi. We have 1 Mold-Masters MILACRON E-Multi manual available for free PDF download: User Manual

Mold-Masters MILACRON E-Multi User Manual (164 pages)

Brand: Mold-Masters | Category: Industrial Equipment | Size: 33 MB

Table of Contents
3
Section 1 - Introduction
11
Intended Use
11
Operator Training and Safety
11
Documentation
11
Warranty
11
Release Details
12
Table 1-1 Release Details
12
Trademarks and Patents
13
Section 2 - Global Support
15
Manufacturing Facilities
15
Regional Offices
15
International Representatives
16
Section 3 - Safety
17
Introduction
17
Safety Hazards
18
Figure 3-1 Injection Molding Machine Hazard Areas
18
Table 3-1 Safety Hazards
19
Safety Symbols Typical to Injection Molding Machines
21
Table 3-2 Typical Safety Symbols
21
E-Multi Safety Hazards
22
Figure 3-2 E-Multi Safety Hazards
22
Table 3-3 Safety Symbols Used on the E-Multi
23
Table 3-4 E-Multi Safety Hazard Details
24
Lockout Safety
25
Table 3-5 Energy Forms, Energy Sources, and General Lockout
26
Electrical Lockout
27
Safety Guards
28
Figure 3-3 Guards Layout. Em1 Shown
28
Handling
29
Lifting the E-Multi
29
Table 3-6 E-Multi Shipping Dimensions & Weight
29
Table 3-7 Auxiliary Injection Unit Lifting Kits
29
Figure 3-4 Do Not Use the Motor as a Lifting Point
30
Em1/Em2/Em3 Lift Connections
31
EM1/EM2/EM3 Vertical Lift Connections
31
Figure 3-5 Em1/Em2 Vertical Lifting Connections (Em3 Similar)
31
Table 3-8 Em1/Em2/Em3 Vertical Lift Connections
31
EM1/EM2/EM3 Horizontal Lift Connections
32
Figure 3-6 Em3 Horizontal Lift Connections. Em1 / Em2 Similar
32
Table 3-9 Em1/Em2/Em3 Horizontal Lift Connections
32
Em4 Vertical Lift Procedures
33
Lay the EM4 Horizontally on the Floor from the Shipping Crate
33
Lay the EM4 Horizontally on the Floor from a Horizontal Stand
34
Attach the Lifting Bar
34
Raise the EM4 to a Vertical Orientation with Two Lifting Machines
36
Raise the EM4 to a Vertical Orientation with One Lifting Machine
38
Raise and Install the E-Multi Onto the Injection Molding Machine
39
Em4 Horizontal Lift Connections
40
Figure 3-7 Em4 Horizontal Lift Connections
40
Table 3-10 Em4 Horizontal Lift Connections
40
Section 4 - Overview
41
E-Multi Models
41
Figure 4-1 E-Multi Models
41
E-Multi Components
42
Figure 4-2 E-Multi Components
42
Section 5 - Preparation
43
Shipping Contents
43
Figure 5-1 Oil Fill Kit (Optional)
43
Unpacking
44
Receiving Inspection
44
Section 6 - Installation
45
Attaching E-Multi to Mold / Machine
46
Controller Installation
47
Section 7 - System Set-Up
49
Connecting the Controller to the E-Multi
49
Routing and Connecting Servo Cables
49
Figure 7-1 Em3 Servo Cable Routing
49
Routing and Connecting Heater, I/O, IMM Cables
50
Figure 7-2 Cables Held with Wire Ties
50
Figure 7-3 Correct Connector Alignment
50
Figure 7-4 E-Multi Connection Locations
51
Connecting a Robot to the Controller
52
Connecting the Controller to the Molding Machine
52
Connecting a Hand-Held Hmi (Option)
52
Figure 7-5 Hand-Held Hmi and Connection
52
Figure 7-6 Robot Jumper Plug
52
Connecting Pneumatic Connections
53
Cooling Water Connections
54
Figure 7-7 Em3/Em4 Water Supply and Return Manifolds
54
Figure 7-8 Em3/Em4 Servo Motor Cooling Connections
54
Table 7-1 Cooling System Water Limits
54
Cooling Water Schematic Diagram
55
Corrosion Caused by Condensation
55
Cooling Water Quality
55
Figure 7-9 Water Cooling Schematic Diagram
55
Table 7-2 Basic Water Quality Specification
55
Coolant and Additives
56
Figure 7-10 Water Quality Specification Tag on E-Multi
56
Connecting Diagnostic Computer (Option)
57
Figure 7-11 Wireless Network Icon
58
Section 8 - Operation
59
Start up and Shut down
60
Switching on
61
Switching off (or Shutting Down)
61
Section 9 - Maintenance
63
Preventive Maintenance Schedule
63
Screw Torque Specifications
63
Table 9-1 Preventive Maintenance Schedule
63
Other Torque Specifications
64
Belt Tension Specifications
64
Table 9-2 Belt Tension Specifications
64
Table 9-3 E-Multi Lubrication
65
Verifying Injection Pressure Oil Circuit(Pre-Load Pressure)
66
Checking the Preload Oil Pressure
66
Assembling the Injection Pressure Oil Fill Kit
66
Charging the High Pressure Oil Circuit with the Oil Kit
67
Table 9-4 E-Multi Preload Pressures (1.34 Software)
68
Table 9-5 Grease Lubrication Mass - Injection Ball Screws
68
Checking Oil Bath Level
69
Checking Lubrication of Linear Guides and Injection Ball Screws
69
Purging Plastic from System
70
Purging Cooling Water from System
70
Moving the E-Multi to a Work Surface for Maintenance
71
Clean Servo Motor Cooling Lines
71
Indications of Cooling Line Contamination
71
Adapter Plate Removal and Installation
72
Cleaning Recommendations
72
Injection Nozzle Replacement
75
Nozzle Protrusion Adjustment- Toggle Link Models
75
Nozzle Protrusion Introduction
75
Figure 9-1 Protrusion Adjustment Parts. Em1 Shown, Other Models
76
Nozzle Protrusion Adjustment Procedure - Manual Protrusion Adjustment
77
Nozzle Protrusion Adjustment - Automatic Adjustment
79
Carriage Home Position Calibration
79
Manual Calibration
79
Automatic Calibration
80
Figure 9-2 Automatic Calibration
80
Injection Axis Referencing
81
Cleaning the Bolt-Type Shut off Nozzle's Bolt
82
Barrel Head Removal & Replacement
84
Heater Replacement
85
Feed Assembly Removal and Replacement
88
Feed Assembly Removal
88
Install the Feed Block
90
Feed Screw Cleaning and Replacement
91
Preparing for Feed Screw Removal
91
Feed Screw Removal
92
All Units
93
Cleaning
94
Install the Feed Screw
94
Barrel Removal and Installation
96
Removing the Barrel
96
Transferring Heaters and Thermocouples to a New Barrel
98
Installing the Barrel
99
Belt Tension Adjustment
101
Belt Removal and Installation
102
Servicing and Repairing Your Controller
104
Section 10 - Troubleshooting
105
Thermocouple Electrical Check
105
Heater Continuity Check
105
Transducer Output Check
105
Vibrator Valve Check
105
Servo Motor Temperature Check
106
Troubleshooting the Control System
106
Fault and Warning Messages
106
Figure 10-1 Alarms Screen with Motor Temperature Alarm
106
Section 11 - E-Multi Radial Option
107
Introduction
107
E-Multi Radial Specifications
107
Table 11-1 E-Multi Radial Specifications
107
Figure 11-1 Main Components of the E-Multi Radial
108
E-Multi Radial Safety Hazards
109
Figure 11-2 E-Multi Radial Safety Hazard Locations
109
Table 11-2 E-Multi Radial Safety Hazards Details
110
Unpacking
111
Figure 11-3 Sling Positions of the E-Multi Radial Vertical Beam
111
Receiving Inspection
112
Figure 11-4 Forward Sling Attachment
112
Figure 11-5 Rear Sling Attachment
112
Figure 11-6 Oil Fill Kit (Optional)
112
E-Multi Radial Installation (Em1 and Em2 Models)
113
Figure 11-7 Tilting the E-Multi Radial from the Horizontal to Verti
115
Installation Onto Injection Molding Machine
117
Manual Position Adjustment
118
Figure 11-8 Gap between the Rotating Plate and Lockring
118
Calibrate Home Position
121
Auto Purge
121
E-Multi Radial Maintenance
122
Lubrication of the E-Multi Radial Carriage Ball Screw and Linear Guides
122
Table 11-3 Grease Lubrication Volume - Ball Screw Nut
122
Service of the E-Multi Radial Carriage Assembly and Servo Motor
125
Er3 / Er4 Installation
126
Spare Parts for the E-Multi Radial
134
Section 12 - Servo Carriage Option
135
Introduction
135
E-Multi Servo Carriage Specifications
135
E-Multi Servo Carriage Safety Hazards
135
Table 12-1 E-Multi Servo Carriage Specifications
135
Table 12-2 E-Multi Servo Carriage Safety Hazard Details
135
Material Handling
136
Preparation
136
Unpacking
136
Receiving Inspection
136
Installation
136
Calibrate Home Position
136
Auto Purge
137
Maintenance
137
Checking the Lubrication of the Ball Screw
137
Spare Parts
137
Section 13 - Servo Cooling Option
139
Operation and Specifications
139
Closed Loop Specification
139
External Loop Specification
139
Materials in Contact with Coolant
139
Table 13-1 Materials in Contact with Coolant
139
Maintenance
140
Draining the Coolant
140
Figure 13-1 Bottom Side of the Cooling Unit Showing the Drain Plug
140
Servicing / Replacing the Heat Exchanger
141
Cleaning the Heat Exchanger
141
Troubleshooting
141
Table 13-2 Troubleshooting
141
Section 14 - E-Multi Stands
143
Introduction
143
Stand Safety
143
Stand Options
143
Figure 14-1 Compact Stand
143
Figure 14-2 Heavy Duty Stand
143
Table 14-1 E-Multi Stand Options
143
Compact Stand
144
Main Components
144
Figure 14-3 Compact Stand Main Components
144
Horizontal Position Adjustment
145
Assembly
145
Figure 14-4 Compact Stand Horizontal Position Adjustment
145
Figure 14-5 Compact Stand Assembly
145
Heavy Duty Stand
146
Main Components
146
Figure 14-6 Heavy Duty Stand Main Components
146
Horizontal Position Adjustment
147
Front or Back Leg Position
147
Figure 14-8 Heavy Duty Stand - Front or Back Leg Position
147
Figure 14-7 Heavy Duty Stand Horizontal Position Adjustment
147
Counter Weight Kit (Option)
148
Figure 14-9 Heavy Duty Stand Counter Weight Kit
148
Assembly
149
Leveling Castors
150
Mold Installation
150
Figure 14-10 E-Multi Stand Leveling Castors
150
Figure 14-11 E-Multi Stand-To-Mold Installation
151
Mold Removal
153
Disassembly
153
Euromap 67
155
Table A-1 Plug on the Injection Molding Machine
155
Water Quality
161
Table B-1 Detailed Water Quality Specification
161

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