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User Manual - Mold

1. ccccccccssccseeeeceeeeseeeeeeeeeseeeeeeeeeseeenees 10 11 PROOV ea E A eee ne eee E E E ee eee 10 11 MSA AUO a A E E ET E E A A EA E O E E 10 11 Injection Nozzle Replacement cccccccsccceccseeseeeceeceueceecsecceecaeeceeeceesaeesaeesaesaeesaeeseesags 10 11 Installing AGapter Plate ONO AW sc cekscdacceaaiaactsanatieceredavastcceuddscadenosenianedvasdeibedsasteiadelednasese 10 12 Preparing the AIU for Adapter Plate Removal and Installation ccccccccceeccvscceesenecenscenseens 10 12 Adapter Plate Removal and Installation ccccccccccceccseccuccnecceecseeceecseecuensesseessessuentessuensesseess 10 12 Nozzle Protrusion Adjustment cccccececeeceeeceeeceeceeecaeecsecceecaceceeecuesaeecseseuesaeeseessensages 10 13 BGI FER SIOR CCK aere E OERA 10 13 Adjusting Ber VOU SO esre nace ies E E EEE E EE EEEE T E 10 13 Belt Removal and Installation 2 0 0 0 ccc ccc cccceecseeeeeceeeeeeeeeceeeeeeseeseeeeeesueseeteeeeeseeteeeneeaeees 10 13 Progno WS Bae aean E E E 10 15 Purging Cooling Water from the System cccccccccecceeeeeeeeceeeceeeeeeeeseeeseeeseeeseeeeeeesseeeaes 10 16 Carriage Home Position Calibration cccccccccecccsseceeeseeeeeeceeeeseeeseeeceeeseueesueeeaeeaeeesaes 10 16 Injection Home Position Calibration ccccccceccceccceeeceeeeeeeeseeeeeeeeseeeseeeseeeseeeseeeeseeeaeeees 10 16 Torque Specifications iiinisicnevsinmnsesinaansdsueurnteneensenmnniniearessauied
2. P aS E Multi User Manual Current Live Status aa The live values displayed at this location are always displayed no mat Mold ter what screen you are on Mansers Mode Status An icon will be displayed at this location to indicate the current function being performed as well as the current machine mode See Runner Icon Description below for a description of the various icons that could be displayed A Screw revolution 0 rpm Operation Mode Select This button allows the user to select between Screw position three available operation modes 1 01 mim Manual Mode Machine will jog at full speed Inject pressure Set up Mode Machine will jog at set up speed Set up speed and ac cel decel ramps are configurable by user See Ramps Ready Standby Mode Machine will operate automatically when the molding machine provides the proper trigger and the EuroMap connec tions from the molding machine and robot are correct Help documentation Pressing this button will provide help documenta tion if available for the current screen being displayed Process Data Tools These buttons allows the user to view process data in various formats See PD Protocol and PD Cycle Time Data Screens for more information Display selected process data in a tabular format Display process data in a graphical format Display process data in a graphical format with SPC Display Cycle Time Data Analysis
3. ccc cccccccececcccccececececcccecececeneauacsteneuuaeaeereutavarsnsneneavanenentars 4 1 COMPONEN een E E ne ee ee ee eT 4 2 Section 5 Preparation cccccsecssceeseeseceeeeeeeceeeeeeeeeeseseees 5 1 UNPACKING ceraian artei ieceancasentanpavcnmasstsceosesandanesns 5 1 SMOE OMEGI es ee en E eee 5 1 Section 6 Installation cccccceceececcecceccacescencencenesceseensess 6 1 Attaching AlU to Mold MachiNG ssssisersresressrerner sererai pna EEEE ATERS 6 1 Controller Installation 0 0 ccccccccccececcccccccccceccccecececceaecceacacenecesueceateneaesueaeseeeaeseansneneass 6 1 E Multi User Manual AIUUMENXXLT A4 Rev 06 Mold Not under documentation control if printed May be revised withoutnotice itt Mate ile Electronic version is available atwww moldmasters co E Multi lt a Section 7 System Set Up ccccecceeeeeeceeeeeeeeeeeeeeeneeeeee 7 1 Connecting the Controller to the AlU 000 eccccccceeceeeeseeese cece eeseeeceeeeeeeeseeesaeeseeesaeeeaes 7 1 Connecting the Servo Cables and Routing them through the Cable Track ccccccccsesccseeseeees 1 Connecting and Routing Heater and I O Cables cece ccccceccceeeceeeaeecee esse eeseeeeeeeseeeeaes 7 2 Connecting Pneumatic and Cooling CONNECTIONS cccccceccceeeceeeceeeeaeeceeeeseeeseeeeeeeeeeeeaes 7 2 Connecting the Controller to the Molding M chine ccccccccececeeeeeeeeeeeeseeeseeeseeeseeeeaes 7 3 Connect
4. be recharged The opera tor can also check the oil lasters pressure from the control ler screen For E60 units the Inject Pressure should be 75 85 bar and for E490 units the pressure should be 25 35 bar Screw revolution oe ocrew position 000 er Recharging the system is done with an optional oil fill gt Inject pressure kit The kit allows the op har erator to charge an E Multi AIU to the recommended pressure Figure 22 Inject Pressure Oil Fill Kit What s in the box e Oil gun e Bag of parts e Fill tube with fittings Tee with fittings Pressure gauge e Flexible hose 2m with quick connects NOTE For continued warranty support use only synthetic gear oil 75W 90EP Mold Masters Part 104L1108I Assembly Instructions 1 Thread fill tube into port on oil fill gun and tighten Figure 23 Thread Fill Tube into Oil Fill Gun Port Pam AIUUMENXXLT A4 Rev 06 j _ Mold o11 20011 VMiasters E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 10 2 E Multi 2 Thread gauge into port on tee and tighten so gauge face is parallel to wrench flats on tee Figure 24 Thread Gauge into Port 3 Fill 500ml synthetic oil into oil gun Connect tee to quick disconnect port on injection housing 5 Connect flexible hose to tee and fill tube Figure 25 Connect Hose Op
5. ce ceeeeeeeeees 12 1 PTE OU GTON ea E E E E Gane aden E 12 1 SOY A E E E E AE E E E E A E eee ee 12 1 olandard Foal Sirera e E E E E E NT 12 1 FOU OOK COD ONC UIIS eisirean EEEE S SEES 12 2 E490 490XK Components cece cece eeceeeeeeeeeeeteeeeeceeeceeeceeegesseeteeecaetegeteeesgetseeteeeeeeeseeteaees 12 3 IZ AVDIO eea E ene oeeece tem ence eeee eee e scan coccmeereeceeceucen sate ueeseeusece a aceetensecee 12 4 LOVING LOUIS acter wore dor esa iste crf ce EE NEEE isto wee os cae nie nine onsets pa E A 12 4 PAG SIO e os osrtertona T E E eiguatosasO ued ote E E eansiosnteyeooec 12 5 PAIL OTITIS IV CUNO sere cate E E area matin E E E E 12 5 ACON AGUS LUMEN sosire E aen E EE EE EE E E NN EE a EERE 12 6 Horizontal Position AGjUStMeNT ccc eee ececeeceeeceeeceeeseeeeeeseeeseeeseeseeeseeeaeeeaeeseeeseeeaeeteeegs 12 8 MOIR OMO Aea oe eecu scence see eete sates sen E E senna seusee sonsaconeuee ueaeeutencasee 12 8 MOID tlc TON eee eee AE eee ee ee 12 8 DISAS SEDI eee ne ee eee eee S ee ee 12 8 ORGS SS DC CINGAU ONS seran en E E EEEE E R 12 8 E Multi User Manual AIUUMENXXLT A4 Rev06 Wiold Not under documentation controlif printed May berevisedwithoutnotice TO Maste Electronic version is available atwww moldmasters co Vil b rs E Multi A Appendix A Euromap 67 cccccceceeeeeeeeneeeeeeeeenseeeeeeeenee Ad Scope and Application saisontew en eueacin E curt ees tnaseeveyenssleneusereucat
6. CAUTION Q Avoid getting water on unpainted surfaces of the machine such as ball screws barrel feed screw belt tensioner etc If water is not removed unpainted surfaces will rust caus ing damage to the machine Do not run the system with the water cooling system turned off disconnected or purged Serious damage to the machine will result 1 Turn off water supply and return connections at the manifold 2 Disconnect return line from manifold and place in a bucket or other suitable container Disconnect supply line from manifold 4 Using low pressure lt 50psi compressed air blow into the supply line until no more water comes out of the return line 5 Repeat several times to ensure all water has been purged from the system 6 Check transparent cooling lines on machine to ensure no water remains Carriage Home Position Cali bration The first time the AIU is installed and any time it is transferred to a new machine with a different mold the carriage home position must be calibrated WARNING AN This procedure requires visual inspection of the machine while it is moving Wear eye protection NOTE For proper calibration ensure nozzle protru sion is set correctly Put the AIU into setup mode 2 Switch to the carriage setup screen need to insert proper picture graphic 3 Move the carriage forward until the nozzle is just touching the manifold inlet 4 Press the box to the right of
7. Slings 1x E60 Extension Bar 1 x E490 Extension Bar 1 x Extension Bar Mount ing Hardware Prior to Lifting Auxiliary Injection Unit CAUTION 1 Choose lift equipment that is rated for the pre D Never use the motor as an anchor point for scribed load lifting This will result in costly damage to the 2 Define the load path the path and orientation the unit item will move in while it is being lifted and the location and orientation where it will be set down Use recommended attachment points only Identify and avoid potential pinch points where an individual or a component of the lifting equip ment or load may be caught between two sur faces 5 Secure and balance the load in the chain or lifting device before it is lifted more than a few inches 6 Minimize swinging by bringing the hook over the load appropriately 7 Inch powered hoists slowly into engagements with loads Figure 28 Incorrect Use of Motor as Anchor E Multi User Manual AIUUMENXXLT A4 RevO6 Wiolg Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 4 0 3 E Multi Vertical Lift Connections E60 Shown E490 Similar Connect sling to motor end of Connect sling to motor end the support beam using one 5 8 of the support beam using a 16mm shackle in lifting hole 1 shackle in lifting hole Figure 29 Vertical Lift Connections b
8. Column color The table column of the parameter selected is displayed with this background color The colors to be selected are specified in the HMI configuration The number injections that should be used for determining the sample values minimum maximum difference By default the last 20 injections are used Number of shots b F pa AIUUMENXXLT A4 Rev 06 Mold E Multi User Manual 011 201 Wiasters Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 9 1 6 E Multi PD Cycle Time Analysis Screen Kuch Last HAIRY S 07 247 MPA Oi OA 1 92 768 0 114 Csele Interrunted Tourch here fer mare infeermiation a 0 00 Gin 8 06 ao gn a E wut re esr Purpose This screen supports optimization of the machine setup over the total period of a production cycle This pro vides an overview of selected movements which start at a particular time as well as an overview of their dura tion Description of the screen The screen shows the starting and running times of selected movements in the form of a bar graph and as nu merical values in an adjacent table The time window starts with a 0 at the start of a production cycle and ends with the last movement The time is displayed in seconds The buttons are used to show various values on the display Movements that are to be displayed are selected in th
9. 10 11 12 13 14 15 Lift the barrel into position in the support beam Slide the barrel into the barrel housing with the flat face facing up Install large nut onto end of barrel tighten to finger tight Install feed block into barrel housing Check gap between barrel housing and feed block it should be uniform for the entire contact surface Apply a light coat of synthetic grease to the four m8x45 screws install and finger tighten CAUTION Incorrect tightening of the screws may result in uneven clamping of the barrel and may cause damage to the machine Tighten screws in steps in a cross pattern ensur ing that the gap between the contact surfaces re mains constant as the screws are tightened Final torque to 29Nm in across pattern E490 units tighten barrel nut with large hook spanner E60 units tighten barrel lock nut Re install heater connector using four m5x16 screws torque to 9 5Nm in a cross pattern E60 units position feed screw nut so that the end of the nut and the end of the screw are flush 2mm Mate feed screw into feed screw drive E490 units install six m8x45 screws torque to 29Nm in a cross pattern E60 units tighten collet securing feed screw to feed screw drive Re install guards and check for interference with heater and thermocouple wires E Multi User Manual Not under documentation control if printed May be revised without notice Elect
10. 13 12 5 crane support Adjust the leveling mounts to align the E Multi unit vertically to the mold 15mm fine adjustment Release the crane support Push the lever forward towards the machine to mate the mold adapter plate to the mold Fasten the mold adapter plate to the mold per torque chart Readjust the leveling mounts if necessary i F p AIUUMENXXLT A4 Rev 06 j Mold o11 2011 Miasters E Multi AEE Height Adjustment Lifting Frame for Lifting AIUM1000301 Frame for AIUM1000300 Figure 43 Figure 44 Figure 45 Table 1 AIUM1000300 Nozzle Height mm 1037 5 1050 1062 5 1075 1087 5 1100 1112 5 1125 1137 5 1150 1162 5 1175 1187 5 1200 1212 5 1225 1237 5 1250 Table 2 AIUM1000301 Nozzle Height mm 1237 5 1250 1262 5 1275 1287 5 1300 1312 5 1325 1337 5 1350 1362 5 1375 1387 5 1400 1412 5 1425 1437 5 1450 1262 5 14425 M 1275 1475 o 127s GT 2 J poo ss o 2 no o o Eoo a Post Hole Position Post Hole Position Lifting Frame Hole Position Lifting Frame Hole Position G N N TI E 3 E Multi User Manual AIUUMENXXLT A4 RevO6 Wliolg Eam Not under documentation control if printed May be revised without notice 11 2011 Mast rs Electronic version is available at www moldmasters com 12 6 E Multi Lifting Lifting Frame for Frame for AIUM1000302 AIUM1000303 Figure 46
11. Disconnect power and encoder cables from both motors Disconnect oil pressure transducer cable Purge water from system see Purging Cooling Water from the System on page 10 16 Disconnect water cooling lines from the motor and injection housing Remove four screws holding cable track bracket to injection housing Fold cable track back into horizontal position away from injection housing Loosen four bolts securing the belt tensioner plate to the injection housing Using a hook spanner rotate the belt tension ec center to the fully loose position Remove belt from pulleys Remove 12 screws securing housings to linear guides Put a sling around the screw motor reducer Tilt the injection housing away from the support beam using a crane and the sling on the screw gearbox Slide the belt over the injection housing towards the motors until it clears the linear guide Lower the injection housing back onto the linear guide Remove the sling Slide the belt over the motors and off the machine Clean the pulleys and idler surface with solvent and a clean cloth Slide the new belt onto the motors towards the thrust housing as far as possible Put a sling around the screw motor reducer Tilt the injection housing away from the support beam using a crane and the sling on the screw gearbox Slide the belt over the injection housing towards E Multi User Manual Not under documentation control if printed Ma
12. EK_ E EL_ S lt amp lt amp lt amp amp lt amp amp gt amp amp lt X amp lt amp lt lt KK amp _ __K_ aeS i lt lt K KK amp q E amp 7 xx cyl l l l Ll LS S x _ gt H x c c _ x x x x ZTZ 7 zxH x _ _ _ _ ____ _ _ c lt c lt lt c _ lt _ lt c c lt _ gt c lt _ gt c lt z EI zE Not under documentation control if printed May be revised without notice 11 2011 Maste rs Electronic version is available at www moldmasters com 9 10 E Multi Material Data Kel hast HAYS 014 MP 01 06 79 2 168 0 114 Ce LE LARUE TRU here ia mpre niemiin Aiie mold daia EBI i d Fatini Commer Nano 640 Pe LEFELE MAG EST M 227950 Hn 0 66 PM arr Ss Material related settings such as temperature set points lowering temperature tolerance temperature etc can be saved and uploaded in the material data screen Description of the screen The upper section contains a table that can be used to show and or select all previously created material data records New material data records can be changed via the menu bar while existing records can be edited or deleted Screen Element Active material data Shows the name of the material data record that is currently loaded Drive Selection of a drive local compact flash or USB stick for saving and loading
13. May be revised without notice 611 201 WWasters Electronic version is available atwww moldmasters com A y Cm E Multi index A Adapter Plate 6 1 10 6 10 11 10 12 10 13 Barrel 4 2 7 2 10 3 10 4 10 5 10 6 10 7 10 11 10 12 10 15 Barrel purging 10 15 Barrel Removal and Installation 10 3 Belt Removal and Installation 10 13 Belt Tension 10 13 10 14 10 15 10 17 C Cable Track 7 1 Calibrate Carriage Home Position 7 3 Calibration 10 16 Carriage Home Position Calibration 10 16 Carriage Nozzle Screen 9 5 Cautions 3 2 Compact Stand 12 1 Assembly 12 5 E60 60X Components 12 2 E490 490X Components 12 3 Height Adjustment 12 6 Horizontal Position Adjustment 12 8 Sizes 12 4 Torque Specifications 12 8 Components 4 2 Connecting a Handheld HMI 7 3 Connecting a Robot 7 3 Controller 9 1 Calibration Screens 9 42 Carriage Nozzle Screen 9 5 9 25 Hold Screen 9 5 9 22 Info Log Screen 9 39 Injection Graphics Screen 9 5 9 28 Injection Screen 9 5 9 20 IO Monitor Detail Screen 9 37 IO Monitor Overview Screen 9 36 Machine Data 9 4 9 10 Machine Specification Screen 9 5 9 35 Material Data 9 4 9 11 Mold Data 9 3 9 9 Overview Screen 9 5 9 19 9 36 10 16 10 17 PD Cycle Time Analysis Screen 9 17 PD Protocol Screen 9 12 9 13 PD Protocol Screen Settings 9 13 Plasticize and Decompression Screen 9 5 9 23 Temperatures Screen 9 5 9 19 9 26 9 27 Time Settings Screen Max Act Times tab 9 34 Corrosion Protection 10 1 E Multi User Manual Not
14. The selection between the Binary Format later import for viewing possible and Text for import into Excel is made in the group Output mode format The group Output mode is used to select between Manual mode and Au _ tomatic mode Manual mode means that on activation of the Start Export aa button the current and complete measurement is output once into the Fite conan of specified file Any file with the same name is overwritten Automatic Mode means that at the start of the next measurement the data are written into the specified file in the format selected The export can either be explicitly terminated by the user or terminated if the end criterion is reached File Count The specification of an Interval gt 1 enables the selective omission of mea surement With binary measurements exactly one file will be created in the automatic mode for an order Output in the area Output file under Name These are then automatically given a consecutive number by the system e g MyExportFile000 bin MyExportFile001 bin After notification to the user any given measurement sequence with the same name is completely deleted prior to the start of the new measurement Eid Sine Garip mezd anual E gm Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 9 33 E Multi A Time Settings Screen Max Act Times tab Kellas HMIRYS OT 24i
15. and Off protects the console and keeps the switched load to a minimum to extend the life of the main isolator E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Switching On When the main power switch is turned to On the servo motors will not be enabled Once the computer completes its preamble the display will show the Overview page At this point the system is in Manual mode and is ready to have the heaters switched on to bring the barrel heaters to temperature Servos may be enabled by pressing the F10 button on the button strip located below the display Once the servos are enabled the LED at the top left of the button will turn on F4 F2 F3 F4 FS F6 F7 F8 FO F10 TE SETE eis The E Multi controller can be used in Manual Setup and Auto Ready mode Switching Off or Shutting Down Mold Masters recommends that you use the console to shut down the heating load and only use the main isolator to switch off the controller once it is a dormant controller 1 Shut down the heating Press the F8 button lo cated on the button strip located below the display The LED at the top left of the F8 button indicates heating status if the LED is lit heating is active otherwise heating is off 2 Shut down the controller Once heating has been turned off the sy
16. 76503 Baden Baden Germany Neumattring 1 76532 Baden Baden Germany tel 49 7221 50990 fax 49 7221 53093 europe moldmasters com INDIA Mold Masters Technologies Private Limited 247 Alagesan Road Shiv Building Saibaba Colony Coimbatore T N India 641 011 tel 91 422 423 4888 fax 91 422 423 4800 mmtplinfo moldmasters com U S A Mold Masters Injectioneering LLC 103 Peyerk Court Romeo MI 48065 USA tel 1 800 450 2270 USA only tel 1 586 752 6551 fax 1 586 752 6552 mmi ingq moldmasters com CZECH REPUBLIC Mold Masters Europa GmbH Hlavni 823 75654 Zubri Czech Republic tel 420 571 619 017 fax 420 571 619 018 cz moldmasters com MEXICO MM Hot Runner Injection Mexico S A de C V Av San Carlos No 4 Nave 2 Parque Industrial Lerma Lerma Estado de Mexico 52000 M xico tel 52 728 282 48 33 fax 52 728 282 47 77 mexico moldmasters com Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 2 1 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 86 512 86162882 fax 86 512 86162883 mmc sales moldmasters com JAPAN Mold Masters K K 1 4 17 Kurikidai Asaoku Kawasaki Kanagawa Japan 215 0032 tel 81 44 986 2101 fax 81 44 986 3145 info mmkk co jp FRANCE Mold Mast
17. E Multi User Manual AIUUMENXXLT A4 Rev0S Fey iid Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 10 9 E M ulti a Horizontal Lift Connections E490 Shown E60 Similar Connect one sling A to motor Connect one sling A to motor end of the support beam by feed end of the support beam by feed ing it through the lifting hole with ing it through the lifting hole with sling on either side of the motor sling on either side of the motor Connect other sling B to barrel end Connect other sling B to of the support beam using two barrel end of the support 5 8 16mm shackles beam using two 1 25 mm in the lifting holes shackles in lifting holes NOTE E60 units require blocks or shipping brackets when set down horizontally to prevent dam age to the linear actuator Figure 30 Horizontal Lift Connections E Multi User Manual AIUUMENXXLT A4 RevO6 Wiolg Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 1 0 1 0 E Multi Feed Assembly Removal and Replacement It is recommended that the barrel be purged before the assembly is changed See Purging the Barrel on page 10 15 If the barrel cannot be purged and the machine is oriented vertically it is recommended that a container be placed underneath the feed tube to feed
18. E60X Compact Stand Figure 39 E490 E490X Compact Stand Leveling Mounts Leveling pad fully extended Leveling pad fully retracted Figure 40 Leveling Pad Extended Figure 41 Leveling Pad Retracted E Multi User Manual AIUUMENXXLT A4 RevO6 FV ep iad Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 4 2 4 E Multi Assembly 1 Adjust compact stand to desired height using the coarse adjustments See Tables 1 4 on the next page for pin hole positions _ oe a a E ka taji Height Figure 42 Measuring Stand Height 2 Ensure stand horizontal adjustment is in the forward position push lever toward injection molding machine See Horizontal Position Adjustment on page 12 8 3 Assemble the mold adapter plate to the E Multi unit 4 Attach the crane support to the E Multi unit per Lifting the AIU on page 10 8 Using the crane lower the E Multi unit with the mold adapter plate onto the stand and hand tighten the stand to the unit with provided M12 bolts and washers CAUTION Make sure cables and tubing are not pinched during assembly 5 With the crane still attached move the unit with the stand to mate with the mold and fas ten the mold adapter plate to the mold refer to torque chart CAUTION Do not move the stand with the unit with out crane support E Multi User Manual Not under do
19. Figure 47 Figure 48 mm Hole Position Position 1100 5 1112 5 4 1125 1137 5 1150 1162 5 1175 1187 5 mm Hole Position Position 1300 1312 5 1325 1337 5 1350 1362 5 1375 H 1387 5 G 1400 C H A G C 1200 1212 5 1225 1237 5 1250 1262 5 1275 1287 5 E 1300 D C 1412 5 1425 1437 5 1450 1462 5 1475 1487 5 K 1500 J J H E K J C F L 10 5 10 56 1125 o o 4 812 5 o 5 3 1825 o 1375 o 2 1837 5 o 150 o o 4 A 1350 11625 3 1625 o 175 2 o 1375 1875 o 1 887 5 120 3 o o 12125 o 2 o 125 o 12235 1 A o a5 o 12375 o 3 O 175 1250 2 50 12625 1 1462 5 O 1275 3 Do 175 12875 o 2 o 14875 1300 1 o0 b F ae E Multi User Manual AIUUMENXXLT A4 Rev 06 a Mold Not under documentation control if printed May be revised without notice 11 2011 Mast rs Electronic version is available at www moldmasters com 12 7 E Multi AE Horizontal Position Adjustment Lever Fully oan a Lever Fully Forward Figure 49 Horizontal Position Level Forward Mold Removal 1 Remove the bolts fastening the adapter plate to the mold Pull the lever fully back away from the machine Figure 50 Horizontal Position Level Back Torque Specifications Remove mold Mold Installation 1 Push the lever forward towards the machine to mate the mold adapter plate to the mold 2 If necessary adjust the
20. MA 0106 177 0 ey a i cy f i j rh i ate a fs wt VE ey e Ae tih p E Ribi This screen is used to set maximum times for the production process Description of the Elements TMaximum time settings can be made for the following areas e Injection e Plasticize e Carriage Nozzle Screen Elements Max inject time Specifies the maximum permitted injection time without delay time If this time is exceeded an alarm will be triggered and the cycle will be stopped Max plasticize time Specifies the maximum permitted plasticizing time without delay time If this time is exceeded an alarm will be triggered and the cycle will be stopped Decompression Max plasticize time Specifies the maximum permitted purging time without delay If this time is exceeded an alarm will be triggered and the cycle will be stopped F a E Multi User Manual AIUUMENXXLT A4 Rev 06 Ham Mold Not under documentation control if printed May be revised without notice 11 2011 Mas rs Electronic version is available at www moldmasters com 9 34 E Multi Controller E IVI gE iti Machine Specification Screen EPa HALREYS OT Z4 MMA 0T 0G 17A T6E0 129 LC EiT iisa a miin ihih ES O m The screen is divided into the areas of machine settings calibration settings configuration screens and KEBA screens service and maintenance screens The respective screens are
21. No of points Number of points in the linearization table After the auto calibration the values determined in the process voltage at position will be entered automatically into the fields All values can be subsequently changed by manual entry Calibration RPM Purpose This screen is used for the calibration of the screw s rpm per minute of the machine Description of the Screen The Table shows the values of the individual stages where they can also be changed manually The linear ization table is situation on the right half Linear Table Description of the Elements Description No of points Number of points in the linearization table 1 n After the auto calibration the values determined in the process rpm at velocity will be entered automatically into these fields All values can be subsequently changed by manual entry Calibration Injection Pressure Purpose This screen is used for the calibration of the injection pressure of the machine Description of the Screen The Table shows the values of the individual stages where they can also be changed manually The linear ization table is situation on the right half Linear Table Description of the Elements Field Description No of points Number of points in the linearization table 1 n After the auto calibration the values determined in the process voltage at position will be entered automatically into the fields All values can be subsequently changed
22. any plastic residue using soft brass tools only Remove nozzle tip with a 24 or 25mm 15 16 or 1 socket and clean plastic out of nozzle opening and inner cone Apply anti seize to the nozzle tip threads and re install nozzle tip Torque to 135Nm Clean mating surface of support beam with sol vent Wipe with a clean lint free cloth Clean mating surface of adapter plate with solvent Wipe with a clean lint free cloth Apply a light coat of oil to both contact surfaces Remove the barrel side shipping bracket Install adapter blocks and adapter plate X models only or adapter plate only all other models but leave screws loose Remove linear actuator manual access port cover using a 6mm hex driver Insert a 6mm hex driver into the linear actuator and turn to manually move the nozzle to the open ing of the adapter plate Measure the distance from the nozzle to the adapter plate bore at 12 3 6 and 9 oclock align so the distance is equal at all positions and tighten adapter plate bolts E F pa AIUUMENXXLT A4 Rev 06 Mold 011 201 Miasters E Multi 13 Manually move the linear actuator to move the nozzle fully forward and measure the protrusion from the adapter plate Verify that the protrusion is correct for the mold to being used If adjustment is necessary see Nozzle Protrusion Adjustment on page 10 73 14 Manually retract the nozzle past the adapter plate to allow installation onto the mol
23. bears on the thermocouples or allow the barrel to roll onto the thermocouples NOTE This procedure assumes the replacement bar rel is clean and the feed screw can be moved by hand This is required so that the screw can be reattached to the injection housing without having to move the housings Preparing the AIU for Barrel Removal and Installation 1 Purge the barrel as described in Purging the Bar rel on page 10 15 Move the carriage to the fully back position Move AIU to maximum shot volume housings completely separated 4 Remove feed tube and feed hopper Secure the machine as described in Lifting the AIU on page 10 8 b F p AIUUMENXXLT A4 Rev 06 Mold 611 201 Miasters 10 3 E M ulti a 10 11 12 13 14 15 Unbolt the AIU from the molding machine Separate the AIU from the molding machine by lift ing vertical mounting or moving sideways horizontal mounting Shut down and lock out controller Purge cooling water from the machine as de scribed in Section 10 Maintenance Purge Cool ing Water from the System Disconnect water connections from the AIU Disconnect pneumatic connection from the AIU Disconnect I O heater and motor connections from the AIU Lift the AlU as described in Section 10 Mainte nance Lifting the AIU and move to work surface If required change the AIU orientation to horizon tal Clean barrel and nozzle area remove an
24. control 1 Calibration Screens Kel las HMI RYS OT A44 MMA 0106 090 1Y Hegt Heating Zyre 3 outbol Telernee ERT 4 F otep in marz Eo a m a e a y _ E Lal dTa laleg Calibration Carriage This screen is used for the calibration of the carriage nozzle transducer of the machine Description of the screen The Table shows the values of the individual stages where they can also be changed manually The linear ization table is situation on the right half E Multi User Manual AIUUMENXXLT A4 RevO6 Wiolg eee ee SSS sss Pi i Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 9 42 E Multi Linear Table Description of the Elements Field Description No of points Number of points in the linearization table After the auto calibration the values determined in the process voltage at position will be entered automatically into the fields All values can be subsequently changed by manual entry Calibration Injection Purpose This screen is used for the calibration of the injection transducer of the machine Description of the Screen The Table shows the values of the individual stages where they can also be changed manually The linear ization table is situation on the right half Linear Table Description of the Elements Field Description S
25. default Find The Infolog entries are searched for the search term entered here and displayed with OK from to A specified time period can be entered in these input fields which restricts the Infolog entries displayed Confirm the entries b E Multi User Manual AIUUMENXXLT A4 RevO6 FV ep lad Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 9 AO E Multi Controller E iVi U ite Clears the text boxes Search from and to or the content of check boxes when the entry fields are empty By pressing this button all checkboxes are reset again Loads predefined basic settings Displays the corresponding help page Closes the dialog Changes are not adopted Logged events Text in the filter dialog Alarm 1 7 System _ I N Alarm Firmware message tarting stopping system cold start new start Module exchange Entry with new Serial no rev mod ule name PLC operation Starting stopping PLC starting stopping debug session Action in the online Starting stopping error of the KEM dialog system RO teachcontrol run time system Error protocol of Warning limits violation tolerance the PDP limits violation System message N Module exchange PLC action nfolog class co Teach action NO NO PDP error protocol tk 00 Text in the filter d
26. e eis Button Description Button Description F1Manual Setup Mode F2 Ready Auto Mode E Multi will not be controlled by the mold E Multi will be triggered by the molding ing machine in this mode This mode machine depending on the E Multi triggering is used for setup functions and jogging method selected motors See Appendix A Euromap 67 b F p E Multi User Manual AIUUMENXXLT A4 Rev 06 Mold Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 9 1 E Multi A Button Description Button Description F3 Carriage Move Retract The carriage can be retracted by placing the E Multi in Manual Setup mode and pressing this button F5 Screw Rotate The screw can be rotated by placing the E Multi in Manual Setup mode and pressing this button The screw will rotate until you press this button again to turn it off F7 Screw Advance The screw can be advanced by placing the E Multi in Manual Setup mode and pressing this button F9 Acknowledge Reset current alarms Any current alarms will be acknowledged and a reset will be attempted when this button is pressed Touch Screen Interface Status Display The carriage can be advanced by placing the E Multi in Manual Setup mode and pressing this button F6 Screw Retract The screw can be retracted by placing the E Mul
27. fully back position 3 Remove injection covers Take care not to drop spacers 4 With the drive power on use a 36mm open end wrench to loosen the screw collet Turn off the drive power but keep the heaters on Unscrew the collet and push the screw as far for ward as possible Turn the controller off Loosen idler pulley clamping screws using a 5mm hex key bit 9 Rotate the idler eccentric shaft to release the ten sion on the belt i F p AIUUMENXXLT A4 Rev 06 Mold o11 201 Miasters 10 13 E M ulti a 22 23 24 Remove belt from pulleys Disconnect the motor connectors from the motors Disconnect the transducer connector using a 5 5mm slotted screwdriver Remove four m6x16SHCS securing cable track bracket to the shaft cover on the injection housing Unfold cable track Position new belt as shown in Figure 33 New Belt Position Figure 33 New Belt Position If machine is oriented vertically skip to step 21 Remove linear guide safety screw Install belt change support block Install support block jacking screw Use jacking screw to lift support block until it is supporting injection housing Mark position of linear guide relative to the injec tion housing See Figure 34 Linear Guide Mark a L B Figure 34 Linear Guide Marking Loosen linear guide screws using a low profile hex key Unscrew screws with fingers Slide linear gu
28. further system infor the right mation OK Confirmation button for closing the dialog System Shows an overview of the configuration settings of the visualiza tion and the start up times of the loaded screens SysVars Shows an overview of the system variables the system is commu nicating with Update Refreshes the display Logfile Saves the overview of the communicating system variables in the file hmi log normally in the root directory of the system drive Spooler Opens the spooler dialog and shows all pending print jobs only under Vx Works Versions This dialog shows the system and application versions for the control and the visualization Network Opens the dialog for setting and displaying the network configuration This op tion is only available on the OF45x and on Handheld HMI Locks and releases the touch screen operation only for Handheld HMI and HMI Report Pressing this button on a local station opens a file selection dialog in which the status report can be saved on a drive with a specified name The drives and directories which are available can be specified in the HMI configura tion Pressing the status report button on a remote station will store the status report in the root directory of the system drive of the controller The status report contains the following information PMA stack up to 4 files Task analysis WVR file HMI event trace key presses Status report info file Boot log opti
29. good protection from moisture mild acids and alkaline conditions It should not con tain chlorinated solvents or silicone Mold Masters recommends LPS 2 Heavy Duty Lubricant or LPS 3 Premier Rust Inhibitor or equivalent see below Heavy Duty Lubricant Rust Inhibitor e g LPS 2 Heavy Duty Lubricant eg LPS 3 Premier Rust Inhibitor Nondrying oily film for Forms a transparent soft waxy long lasting lubrication film for protection and lubrication Loosens rusted and frozen parts Inhibits rust and corrosion protects Protects against corrosion on steel steel parts indoors for up to 2 years parts indoors for up to one year Inhibits exfoliation and filiform Displaces moisture corrosion of aluminum Excellent protection for Penetrates to displace moisture hand machine tools Does not contain chlori Does not contain chlorinated nated solvents or silicone solvents or silicones Nonconductive Non conductive Safe on most surfaces Safe on most surfaces Meets NSF requirements for Meets NSF requirements for H2 Registration 129027 H2 Registration category H2 aerosol 059849 bulk 129026 Aerosol 059848 Bulk Canadian Food Inspection Agency Canadian Food Inspection Agency Category n1 or equivalent Category n1 or equivalent E Multi User Manual AIUUMENXXLT A4 RevO6 Fes fii Not under documentation control if printed May be revised without notice 7 7 e Masters Electronic version is available at www moldmasters com 4
30. 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 mechani cal including photocopy recording or any information storage and retrieval system without permission in writing from the publisher All details standards and specifications may be altered in accordance with technical develop ment without prior notification May be manufactured under one or more of the following U S Patents 9118279 5135377 5142126 5148594 5206040 5217730 5223275 5227596 5227181 5235737 5238378 9238391 5268184 5269676 5282735 5284436 5299928 5312242 5326251 5334008 5334010 5346388 9366369 5366370 5387099 5405258 5421716 5427519 5429491 5437093 5441197 5443381 5460510 9474440 5494433 5496168 5507635 5507636 5536165 5591465 5599567 5614233 5641526 5644835 9652003 5658604 5695793 5700499 5704113 5705202 5707664 5720995 5792493 5795599 5820899 9843361 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 65757371 6625873 6638053 6648622 6655945 6675055 6688875 6701997 6739863 6752618 6755641 676
31. loading the data set Comment Comments about the current data set Name Designation of the component data record Date Creation date of the component data record i E Multi User Manual AIUUMENXXLT A4 Rev06 Wiolg Not under documentation control if printed May be revised without notice 611 201 VWasters Electronic version is available atwww moldmasters com 9 9 E Multi A Screen Element File size of the component data record Comments about the mold data set Load o Loads the Loads the settings of the selected component data record of the selected component data record eee Lends te stings ofthe selec component et eer _ the settings of the component data record that was newly created and or which is currently loaded Save as Saves the settings of the component data record that was newly created and or which is currently loaded under the name specified Deletes the selected component data record Renames the selected component data record Machine Data Kellas HERS OT A44 MPA OT BOT a Line 2d eee Actierints ar te Purpose Machine specific settings such as the number of heating zones drive type mold height adjustment maxi mum injection velocity may be loaded and saved in the Machine Data screen b E Multi User Manual AIUUMENXXLT A4 RevO6 FA ep iad _ gt Z _ a lt K XK _K z 2 __ _ __ _ gt amp amp amp
32. machines Depending on the configuration the controller is shipped with either a standard E67 cable a hybrid E67 to SPI adapter cable or a standard E67 cable and an SPI to E67 adapter plug In all cases the E67 CONTROLLER END of the cable connects directly to the IMM E67 connector on the control ler and the IMM END connects either directly to the molding machine or to the adapter plug which plugs into the molding machine Figure 18 Controller Cable Connections Connecting a Robot to the Con troller E Multi units are compatible with both E67 and SPI robots In all cases the controller is shipped with a robot jumper plug Ei wi tea i HALT Figure 19 Robot Jumper Plug Top Side If no robot is used connect the robot jumper plug to the ROBOT E67 connector on the controller If an E67 robot is to be used connect the robot s E67 cable to the ROBOT E67 connector on the controller If an SPI robot is to be used attach the supplied ROBOT SPI ADAPTER to the ROBOT E67 con nector on the controller and connect the robot s SPI cable into the ROBOT SPI ADAPTER E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Connecting a Handheld HMI optional E Multi units are available with optional handheld HMI units to allow control of the E multi when access to the co
33. of EUROMAP Not fixed by EUROMAP manufacturer dependent Supply from handling 0 V Reference potential device robot U ee ZC5 ZC6 ZC7 ZC8 ZC9 AIUVUMENXXLT A4 Rev 06 Mold o11 2011 Miasters E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com A iil E Multi AA Table 2 Plug on the injection molding machine Signals from the handling device robot to the injection molding machine Contact No Signal designation Description female A1 Emergency stop of The switch contact must be open when the handling device robot C1 handling device emergency stop is being actuated The switch contact opening robot Channel 1 causes emergency stop of the injection molding machine The switch contact must be operative if the handling device robot is switched off It is recommended that the switch contact is operative when the handling device robot is unselected A2 Emergency stop of The switch contact must be open when the handling device robot C2 handling device emergency stop is being actuated The switch contact opening robot Channel 2 causes emergency stop of the injection molding machine The switch contact must be operative if the handling device robot is switched off It is recommended that the switch contact is operative when the handling device robot is unselected gt GO Mold area free The swi
34. of the variable Un derneath it the variable name and the long text for the variable Force active are displayed E Multi User Manual AIUUMENXXLT A4 RevO6 FV ep lad _ Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 9 38 E Multi Controller ivi Ea ite Current value of the input output Note In case of a sensor failure this field will show A forced Actual value Info Log Screen value however will still be shown with a red border Set Value Value the input output is forced to Activates the forced setting of the value Ruel last HALAS 01 741 MP Tb 0 180114 Lae hemina Tourn rernm lz Time TATA Bodice FH Win tee Ph TAN bie FH 171 ce Pe TATA eae PH Tn Bae Pe TATA R08 Ph iin 64hie Pe TATA Ga Oe PH Tn Bee Pe TATA ERTA PH Inn tinia PH ATAI TENTS PH in 64s Pe APA Bees PH CPUID Counter Description Value systern e Malasia E e 0 Fil Operation Load VarGroup VG_MoldData Value Systeme TempZone 38 bMennQlashed te talaa Walaa syetern av Tarp Zone s8 ini atamaga 2 Oo valge ayslermey_TempZone 38 bone rr ue r falig valisa syaani ev TempZonefa bGomipToTemp rus gt falsa Wahoo prelama TempZone 37T baara true r false Value ayetini tv Terr fanaa intLestann Statue g 0 Value pysterm ey_Te
35. opened via the corresponding buttons i E Multi User Manual AIUUMENXXLT A4 Rev06 Wioli nnn ee TTC a P t pm Not under documentation control if printed May be revised without notice 611 201 MWlasters Electronic version is available at www moldmasters com 9 35 E Multi A IO Monitor Overview Screen KeP last HALAS 01 4 A Oi OA 619221680114 ld hirinwe THEA hese fee mnre CP 3560 x OMIT SA Bion oPaoco riim Pany Exitdode Eater Fanel_axi SLOTPCILO jam Panat SERCORIO sysiem Sercosring ORVEERCOSTO injection sv HIM _Seralnjeet Se SS OUOU UUILC ORVEERCOSE injection a PHA _SemoFinsi The IO monitor screen displays the status of the inputs and outputs of the hardware modules Description of the Elements The IO monitor screen is divided into two areas e Overview e Detail see chapter IO monitor detail Overview Screen The Overview screen is used for the selection of one or more hardware modules The modules are repre sented hierarchically in a tree structure as they are integrated in the system connections of CPU modules via bus couplers K Net K CAN SIO etc to the hardware modules The hardware modules required can be selected by clicking on the checkbox in the right column Selecting one structure element will mark all elements located below To de select a module click on it again Screen Elements Switches to the detail view of the selected module see O monit
36. phase supply is used this potential may be 415 volts or higher e High voltage and current cables are connected to the controller There is also a high voltage cable connection between the servo motor and controller Lock out electrical power before discon necting or connecting electrical cables e For all E Multi Controllers the main power switch is a rotary switch at the rear of the cabinet This switch is rated to safely disconnect the total load current during switch On and switch Off You can use a suitably sized padlock or similar device to lock the switch in the Off position to prevent operation during maintenance b Pam AIUUMENXXLT A4 Rev 06 Pia Mold o11 2011 Masters Cm E Multi Section 4 Overview Standard Features AIU Standard Features Controller Free standing control cabinet for 460 V 3 or The following are general features The actual control 400 V3 ler console supplied may have contractual variations e 10 meter cable length to allow flexible installa and differ in some specified options tion Supply voltage 400 V or 460 V 3 50 60 Hz e 15 inch touch screen HMI Delta no neutral The control cabinet can Process graphing be manufactured to accept a wide range of Process data monitoring supply voltages and sequence of phases Security user login profiles for administrator to e Voltage bandwidth stable within 20 supply operator voltage swing Language switchin
37. sida cveswecwsst seta vocdneniavencniesaeiensoendedieedatnushecevesuehstetsventensdesncotauii lt derst 9 36 IO Monitor Detail Screen scx csncwsnctvesenddasnbiiesened suiee bined eyecnsbababunaensinsamsiseed sequent ronthreaneyeateeteedecnseceet 9 37 MOLOI IOSD a teeta E steer se so gan tects ges ae merece 9 39 CaliDration SCOCNS ccccccccccseeeccsusccaceesususecasesnsusecsusesansessausesausessansessusenssessausessusensasessusensaass 9 42 Section 10 MainteENancCe cccccceccccccccccccceccnccucnnceceneeeanee 10 1 deann eee eee eee E eee 10 1 OENE Co f 6 ree een enn ere nee ee ee ee eer 10 1 GONOSION POGGIO Aa en nce ee cee en ee een eee ee eer 10 1 Protecting AIU Surfaces from Damage cccccsccceccceseceseceeeeeeeeceeecaescauesauecseeesaeeseeesaaes 10 2 LUDIC AUOT et i ees E et ee 10 2 CMECKING COM CVC ee A E E E E A 10 2 Recharging the High Pressure Oil CirCuit ccc ccccceccceeeceeeeeeeeseeeseeeseeeseeeseeeeseeeseeeseess 10 2 OCTET TINT EE E E E A EE E E E E 10 2 POSSI TC ONS aa a E E ET E E E EEEE E EET 10 2 Para o ISTUCS ara E E E NEN E ER A 10 3 Barrel Removal and Installation n0nnanannanannnnnnnanennnnnnnnnnnnnrennnrnrrnrnrrnrnrorrnrsrrnrsrrnrsrrnrnnne 10 3 Preparing the AIU for Barrel Removal and Installation cccccccccccccseeccseecseeeeecesnecsseetsnseeseeees 10 3 ROMIO TOG ITO a aE E EA E N AE E ER 10 4 Transferring Heaters and Thermocouples to New Barrel cccccccccsecccsee
38. the crossbars are all open route the servo small flat screwdriver into the small opening at the power cables on the side of the track closest to the end of the crossbar and prying the crossbar away machine and the servo feedback cables on the from the cable track Take care that none of the side furthest from the machine cable separators fall out Figure 9 E60 Cable Track 3 Close the crossbars by tapping with a rubber Figure 12 E60 Servo Cable Routing mallet Figure 10 Closing Crossbars Figure 13 E490 Servo Cable Routing F E Multi User Manual AIUUMENXXLT A4 Rev0S Pep iid oe ooo eeeeese a i _ Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 7 1 E iVi T ite Align Arrows System Set Up 6 Connect the servo cables to the motors See below for correct connector alignment Take care that the cables are connected to the correct mo tors Cables and motors are both clearly labeled Align arrows on Connector Halves i j F T f j Pa i r i l Led dy Figure 14 Connector Alignment 7 Once cables have been routed use wire ties to hold cables in place Figure 16 Barrel Heat Connector Connecting Pneumatic and Cooling connections 1 Install a 1 8NPT fitting Customer supplied into the vibrator needle valve Figure 15 Using Wire Ties to Hol
39. to have HIGH signal already when the mold open ing starts ZA6 Mold closed HIGH signal when the mold closing is completed Note The signal Enable mold closure is then no longer required see table 2 han dling device robot signals contact No A6 ZAT Mold open position HIGH signal when mold opening position is equal or more than re quired position Inadvertent alteration to mold opening stroke smaller than that required for the handling device robot to approach must be impossible The signal must remain HIGH as long as the mold is open and must not be interrupted by a change of operation mode or safety guard opening ZAA ZC4 N N ZA8 Optional Intermediate mold HIGH signal when mold opening reaches a set position smaller than opening position mold opening position see table 1 injection molding machine signals contact No ZA7 The signal remains HIGH to the end of mold open ing position Two sequences are possible with this signal a Mold opening stops on intermediate position and gives start sig nal to handling device robot Mold opening restarts with the signal Enable full mold opening see table 2 handling device robot signals contact No A7 b Mold opening does not stop on intermediate position however gives the signal to handling device robot At this sequence the signals Enable full mold opening see table 2 A7 and Mold area free table2 A3 C3 are not in use LOW signal when intermediate m
40. to space limita tions 13 Install other heaters as required Be careful not to twist heater cables when re installing 14 Put anti seize on thermocouple socket threads and re install the thermocouple sockets Finger tight plus 1 8th turn Do not overtighten 15 Re install thermocouples if removed There should be tension on the thermocouple cap when install ing If insufficient tension on the cap turn cap to provide sufficient tension i F p AIUUMENXXLT A4 Rev 06 Mold o11 2011 Miasters 10 5 E M ulti a 16 Feed new heater cable through strain relief on connector base 17 Re install connector base on support beam 18 Install new wire ties 19 Tighten lock nut on strain relief 20 Insert heater wires into terminals on connector insert and tighten 21 Re install connector insert 22 Test heater resistance using multi meter on con nector insert pins Feed Screw Cleaning and Re placement Preparing AIU for Feed Screw Removal 1 Purge the barrel see Purging the Barrel on page 10 15 2 Switch heaters on F8 a on controller 3 Enable servos F10 0 Move thrust housing to maximum shot size fully separated F6 l 5 Disable Servos F10 l Switch heaters off F8 a Move the machine to a work surface See Prepar ing the AIU for Adapter Plate Removal and Instal lation on page 10 12 WARNING Barrel will be hot wear appropriate PPE to protect from burns 8 Clean b
41. under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Drive Info Screen 9 5 Error Message 11 2 Euromap 67 9 5 A i F Fault and warning messages 11 1 Features 4 1 Feed Assembly 10 11 Installation 10 11 Removal 10 11 Feed Screw 4 2 10 4 10 6 10 15 Installation 10 6 Preparing AIU for Feed Screw Removal 10 6 Removal 10 6 G Guards 4 2 10 7 10 11 10 15 Handling and Lifting 3 2 Heater 7 2 10 4 10 5 11 1 11 2 Heater Continuity Check 11 1 Heater Replacement 10 5 High Pressure Oil Circuit 10 2 Hold Screen 9 5 Injection Graphics Screen 9 5 Injection Home Position Calibration 10 16 Injection Nozzle Replacement 10 11 Injection Screen 9 5 Installation 6 1 L Lifting the AIU 3 2 6 1 10 3 10 4 10 8 10 12 12 5 12 8 Horizontal Lift Connections 10 10 Lifting Kits 10 8 Prior to Lifting 10 8 Vertical Lift Connections 10 9 Lubricant 10 1 Lubrication 10 2 i F p AIUUMENXXLT A4 Rev 06 j Mold o11 2011 Miasters EMult M V Machine Specification Screen 9 5 Vibrator 4 2 11 1 Maintenance 10 1 10 4 10 17 Vibrator Valve Check 11 1 N W Nozzle Protrusion Adjustment 10 13 Warranty 1 1 O Oil level 5 1 10 2 Overview Screen 9 5 P Plasticize and Decompression Screen 9 5 Pneumatic and Cooling connections 7 2 Protecting AIU Surfaces 10 2 Purging Cooling Water 10 16 Purging the Barrel 10 15 Routing Heater and I O Cables 7 2 Running Icon Descrip
42. www moldmasters com 12 1 i Pam AIUUMENXXLT A4 Rev 06 Mold 01 221 Miasters E Multi AEE E60 60X Components AIUM1000277 Base AIUM1000278 Post AIUM1000279 Lifting Frame AIUM1000280 Lifting Frame AIUM1000281 Lever AIUM1000282 Link AIUM1000283 Bushing M12 Washer M12 Nylock Nut AIUM1000289 Hitch Pin w M12X30 Socket Head Cap M12X40 Socket Head Cap M12X150 Socket Head Cap AIUM1000284 Leveling Cas 3 or 4 oe Noa SS YS gt a ee nana oa A O N a O Figure 36 E60 E60X Stand Components k F a E Multi User Manual AIUUMENXXLT A4 Rev 06 Ham Mold Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 4929 E Multi E490 490X Components oS ae eS SY 10 M12X30 Socket Head Cap M12X40 Socket Head Cap M12X160 Socket Head Cap AIUM1000284 Leveling Cas AIUM1000294 Base AIUM1000295 Post AIUM1000296 Lifting Frame AIUM1000297 Lifting Frame AIUM1000325 Lever AIUM1000282 Link AIUM1000326 Bushing M12 Washer M12 Nylock Nut AIUM1000290 Hitch Pin w t Figure 37 E490 E490X Stand Components E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 12 3 i _ AIUUMENXXLT A4 Rev 06 Mold o11 2011 Miasters E Multi AE Sizes Available Figure 38 E60
43. 0 1 E Miults Protecting AIU Surfaces from Damage 1 Never leave or store the AIU on the factory floor Factory contaminates water spillage etc can damage the unit resulting in costly repairs 2 If possible the AIU should be stored as a complete unit Lubrication 1 Periodically lubricate linear guides using grease gun and high quality synthetic grease 2 Lubricate ball screws every 3 months Please reference installation drawing supplied with unit for locations NOTE For continued warranty support use only Mold Masters approved grease Part 104L1111I Checking Oil level WARNING This procedure requires guards to be removed Lock out tag out AIU before removing the guards 3 AIU should be in horizontal or vertical position 4 Oil level is checked using fill holes on either side of the housing 5 Remove plug from fill hole Oil level should be up to lower threads of fill hole 6 If necessary top up with synthetic gear oil 75W 90EP Mold Masters Part 104L11081 i NOTE For continued warranty support use only syn thetic gear oil 75W 90EP Mold Masters Part 104L1108l Maintenance Recharging the High Pressure Oil Circuit From time to time it may be necessary to recharge the oil in the injection housing Injection pressure is monitored by the controller using the pressure transducer If the pressure drops the controller will notify the operator that the system needs to
44. 06 Mold o11 2011 Miasters 10 11 E M ulti a Adapter Plate Removal and Installation Installing Adapter Plate onto AIU Q NOTE This procedure should be carried out on a work bench or table or machine maintenance stand Ensure it is capable of supporting the full machine load Preparing the AIU for Adapter Plate Re moval and Installation 1 Purge the barrel see Purging the Barrel on page 10 15 2 Retract the carriage so that the nozzle tip is on the AIU side of the adapter plate 3 Secure the machine as described in Lifting the AIU on page 10 8 Unbolt the AIU from the molding machine 5 Separate the AIU from the molding machine by lift ing vertical mounting or moving sideways hori zontal mounting 6 Purge cooling water from the machine as de scribed in Purging Cooling Water from the Sys tem on page 10 16 Disconnect water connections from the AIU Disconnect pneumatic connection from the AIU Disconnect I O heater and motor connections from the AIU Lift the AIU and move to work surface If required change the AIU orientation to horizon tal E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 10 12 1 10 11 12 Remove four m16 E60 or m20 E490 screws and remove adapter plate Figure 32 Screws on Adapter Plate Clean barrel and nozzle area Remove
45. 1557 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 71601071 7165965 7168941 7168943 7172409 7172411 7175419 7175420 7179081 7182591 7182893 7189071 7192268 7192270 7198740 7201335 7210917 7223092 7238019 724418 7252498 7255555 7258536 7270538 7303720 7306454 7306455 7314367 7320588 7320589 7320590 7326049 7344372 7347684 7364425 7364426 7370417 377768 7381050 7396226 7407379 7407380 7410353 7410354 7413432 7416402 7438551 7462030 7462031 7462314 7465165 7470122 7507081 7510392 7513771 7513772 7917214 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 78066871 7824163 7845936 7850442 7874833 7877163 7891969 7918660 7918663 7931455 7963762 D525592 RE38265 RE38396 RE38920 RE39935 RE40478 RE40952 RE41536E RE41648E Pending 2011
46. 21 E Multi A Hold Screen Kelas HA RYS 1 eT 1 J 4 i z I i d 1530 Jte 0 50 a mbit pitti TB bar 5 1000 38 78 0 50 o ere p Botew position 376 08 mm Li 500 38 78 0 50 T T eee a MEE r EN iret Pas PE 0 00 mim End 700 38 78 040 ae Min held preaeure kar Goong lime 500 Description of the screen Besides the input fields the pressure profiles red and the velocity profiles grey are shown in the form of curves The cooling time duration of cooling after hold pressure and the number of stages time intervals can be set here Besides entering the values directly into the fields the pressure and velocity values can also be adjusted with the arrow keys next to the profile curves For each click the profile curve is adjusted by 5 bar and or 5 A separate button is used to switch pressure and velocity to constant output Screen Elements Description Holding Pressure Stages The number of stages time intervals can be adjusted here maxi mum of 10 1 n Setting the Pressure and Velocity for the duration specified under To at hold pressure The input field for Velocity is available only with electric machines Depending on the number of stages additional input fields are shown here to adjust the stages 2 3 n These settings always ap ply for the time intervals between the end of the prior stage and the duration specified under To E Multi User Manual
47. AIUUMENXXLT A4 RevO6 Fes cll Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 9 22 E Multi Screen Elements End Setting the Pressure and Velocity between the prior stage and the final duration at hold pressure Spec inject pressure optional Displays the current specific injection pressure This field is only shown if a corresponding sensor is available Display of the current screw position Cooling Cooling Time The current cooling time actual value is shown in the left field grey The cooling time Setpoint can be entered into the right white field Plasticize and Decompression Screen Kellas HM RYS OT 24i MA 0106 09 0 1Y Markirni C EiT Slap Rackpre Charge T End too Sgm 0 63 Leu fet Purpose This screen is used to adjust the settings for plasticizing and decompressing Description of the screen The backpressure and screw feed speed for specific screw positions can be entered in the section Plasticize Ls me ee es Te and backpressure The values are shown in the form of curves to the right of the input fields They can be changed with the arrow keys In increments of 5 the back pressure is increased and or decreased with the red keys while the grey keys are used for the screw feed speed Additional input groups allow settings to be changed for Decompression before plasticiz
48. Comment Comments about the currently loaded material data set Name Designation of the material data record Date Creation date of the material data record Size File size of the material data record Comment Comments about the material data set i E Multi User Manual AIUUMENXXLT A4 Rev0O6 Wiolg Not under documentation control if printed May be revised without notice 611 201 WWlasters Electronic version is available atwww moldmasters com 9 1 4 E Multi A Screen Buttons Loads the settings of the selected material data record Save Saves the settings of the material data record that was newly created and or which is currently loaded Save as Saves the settings of the material data record that was newly created and or which is currently loaded under the name specified Removes the selected material data record Renames the selected material data record PD Protocol Screen Rue last HALAS 07a MP Oii 197 168 0 114 EEFT SSU PH Cath nie TOW hera i mame iiormatim E ADK es a Tampere Conygler mawa l STOPPED aLi interval 1st BS es a Shdt cunter A n ideal wala Minimu Weim Ceference RG err Te ep am g o wm We a o er Purpose The process data protocol PDP screen serves to show process data in tabular form The recorded values can be printed out during measurement or saved to a file Description of the screen The recorded system variables are shown in a table The
49. Description of the screen The individual heating zones are graphically depicted in the heating zones section The current temperature is shown in the middle of each heating zone The input fields for the temperature setpoint and the standby temperature are located underneath the heating zones Note The display depends on the number of heating zones See machine parameter screen Tab General Screen Elements Set Specifies the temperature set point value of the corresponding heat ing zone Depending on the selected operating mode of the barrel heater the specification is made in percentage of the maximum heating performance operating mode Setter or in degrees oper ating mode PID The operating mode of the barrel heater can be selected in the screen Temperatures Screen Standby Specifies the standby temperature of the corresponding heating zone in degrees The temperature is not lowered below this value If this function is activated the standby temperature is adopted as the new set point value Temperatures Soak time Specifies the waiting period until release of the screw movement measured as of the moment when the temperatures of all heating zones are within a specific tolerance Keep warm This function is used to hold the temperatures of the heating zones constantly above the lowering temperature This setting is only effec tive with the operating mode PID of the screw heater Optimize nozzle heating Pre selection
50. EE Ti User Manual Mold E Masters performance delivered E Miulti Table of Contents Section 1 Introduction cccecceceececcsccaccecencencenesneseenseas 1 1 waranty and LOCUS MANO ariel ceercepnrenanuisvadenanatesssn Seceetuuandeoe lt nctocaueiciesenecawseeciasiousbaeeseis 1 1 Release Details crete es cicwsatsstinsecetesacniein ci amaseataresedharhentaiawrehammstoacte dea Sacsaot basen etasentatnale heaadamseeeewecnbaannstetacesekaneeas 1 1 Trademarks and Patent c ccccccececceccccecccccccececceccececceacececueaeenecueauenecneaeeneaueaeeneeneaeeneanes 1 2 Section 2 Global Support cccseeeeeeeeeeeeeeeseeeeeeeeenees 2 1 SECUON S SAE Yaa ENA EEEN EAA 3 1 SYDOST woe cnt eseueseoreudmostesees 3 1 INMOGUCUON ieaccccraccccesvmensvevcecccasedicqadeus soddadeeccausvebansebndceedsunddpeeadsaendesudidaedeniauaneunseitedeseaGebedsase 3 1 GONElal Sally WANING senera eR E 3 1 Handling and Lifting PrecautionS 00nnannannannoannnnnnnonnnnnnnnnnnnnnrrnronrrnrrsrrnrnnnrnnernrrnrrnrrerene 3 2 Controller SAN eenerecerr nre EEE EE E r 3 2 General Cautions ccccccccccececcececcccececcacececcuceneceeneauaueauaceaeacenecesuentateneacsteatseeceaeeneansneaeass 3 2 Section 4 OvervieW cccccccceccecsecsccsccsccaceaceneeneeueeneeneseeeness 4 1 Standard Features AU oc cece cece cc ccccccceccececcccececccceceaccceaeaceneaeeneaeseeaeseeneatsneansutavseeaeanens 4 1 Standard Features Controller
51. MOLD MASTERS 2007 LIMITED ALL RIGHTS RESERVED k F pa E Multi User Manual AIUUMENXXLT A4 Rev06 Ay i Mold Not under documentation control if printed May be revised without notice 611 201 Wiasters Electronic version is available at www moldmasters com 4 ES E NMiults Section 2 Global Support Manufacturing Facilities GLOBAL HEADQUARTERS CANADA Mold Masters 2007 Limited 233 Armstrong Avenue Georgetown Ontario Canada L7G 4X5 tel 1 905 877 0185 fax 1 905 873 2818 info moldmasters com SOUTH AMERICAN HEADQUARTERS BRAZIL Mold Masters do Brasil Ltda Rua Hum 1106 e 1126 Jd Manchester Nova Veneza Sumare Sao Paulo Brasil CEP 13178 440 tel 55 19 3922 4265 fax 55 19 3922 4266 vendas moldmasters com br UNITED KINGDOM Mold Masters UK Ltd Netherwood Road Rotherwas Ind Est Hereford HR2 6JU United Kingdom tel 44 1432 265768 fax 44 1432 263782 uk moldmasters com Regional Offices AUSTRIA East and South East Europe Mold Masters Handelsges m b H Pyhrnstrasse 16 A 4553 Schlierbach Austria tel 43 7582 51877 fax 43 7582 51877 18 at moldmasters com KOREA Mold Masters Korea Ltd 708 Byucksan Digital Valley 5 Cha 60 73 Gasan dong Geumcheon gu Seoul 153 788 South Korea Tel 82 2 2082 4755 Fax 82 2 2082 4756 mmkr sales moldmasters com E Multi User Manual EUROPEAN HEADQUARTERS GERMANY SWITZERLAND Mold Masters Europa GmbH Postfach P O Box 19 01 45
52. Manual Australia Comtec I P E 1084 South Road Edwardstown South Australia 5039 PO Box 338 Magill South Australia 5072 tel 61 8 8374 4633 fax 61 8 8299 0892 bparrington comtecipe com Finland Oy Scalar Ltd Viertolantie 12 11120 Riihimaki Finland tel 358 19 783 191 fax 358 19 783 190 info scalar fi Portugal Gecim LDA Rua Fonte Dos Ingleses No 2 Engenho 2430 130 Marinha Grande Portugal tel 351 244 575600 fax 351 244 575601 gecim gecim pt Vietnam Lotus Chemical Technology 393 Dien Bien Phu St Ward 4 Dist 3 HoChiMinh City Vietnam tel 84 8 832 7605 fax 84 8 832 7730 dieuphuoc nguyen lotusfirma com Not under documentation control if printed May be revised without notice Electronic version is available atwww moldmasters com 2 2 Bulgaria Mold Trade OOD 62 Aleksandrovska St Ruse City Bulgaria tel 359 82 821 054 fax 359 82 821 054 contact mold trade com Israel ASAF INDUSTRIES Ltd 29 Habanai Street PO Box 5598 Holon 58154 Israel tel 972 3 5581290 fax 972 3 5581293 sales asaf com Romania International Mold Trade Co SRL Str Constantin Aricescu Nr 21 BI 20 Sc 2 Apt 20 Bucharest Sector 1 Romania tel 4021 230 60 51 fax 4 021 231 78 43 contact matritehightech ro b em E Multi Section 3 Safety Symbols The following symbols are used in this manual to highlight important information A WARNING Safety warning indicate
53. System Set Up Use to adjust system settings for the touch screen interface and to display system information Mold Data This data is specific to each mold used with the E Multi Mold settings can be saved and loaded again at any time through the HMI screen See Screen Functionality Descriptions for more informa tion b F p AIUUMENXXLT A4 Rev 06 j Ham Mold Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 9 3 E Multi A Element Description S Material Data can also be saved Any parameters related to a specific material can be stored and retrieved at any time See Screen Func tionality Descriptions for more information Machine Data can also be saved Any parameters configured for the general operation of the E Multi can be stored and retrieved at any time See Screen Functionality Descriptions for more information Note Be careful never to load the wrong mold material or machine data Unexpected operation may result Alarm Display This button will display the alarm screen The alarm screen displays a list of alarms triggered by the control system See Troubleshooting the Control System on page 11 1 Previous screen This button will take the user to the last screen that was displayed It is a quick way of navigating through the screens aa Running Icon Description These icons are displayed on the
54. able atwww moldmasters com A 1 E Mult A Components E60 Shown E490 similar 1 Support beam The backbone of machine All components connect to the support beam 2 Injection housing Provides injection pressure for machine 3 Injection motor Provides power to injection housing 4 Barrel housing Provides material to barrel for injection 5 Screw motor Provides power for the feed screw 6 Barrel Feed Screw Used for conveying molten plastic into the mold Heaters Used to maintain proper barrel temperature to keep plastic at proper consistency for injection 8 Feed block Where plastic pellets are fed into the barrel 9 Drive belt Connects the two ball screws so they drive together 11 10 Mounting holes Used for attaching the AIU to the adapter plate 11 Linear actuator Used to engage the nozzle tip with the manifold inlet 12 Vibrator Used to help plastic pellets feed properly into the feed block 13 Pressure transducer Gives pressure feedback to controller pressure inside injection housing 14 Oil fill bleed manifold Used for filling and pressurizing in jection housing with oil 15 Electrical connections Figure 3 E Multi Components Guards Removed for Clarity E E Multi User Manual AIUUMENXXLT A4 Revo Wliold Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 4 2 E Mu
55. arrel and nozzle area remove any plastic residue 9 Remove nozzle tip clean plastic out of nozzle Opening Removal E490 Units 1 Remove six m8x35 screws securing splined ring to feed drive 2 Push the screw towards the barrel until the m10x25 screws securing the splined ring retainer is accessible 3 Remove bolt retainer and splined ring 4 Push the feed screw towards the barrel as far as possible 5 Pull feed screw out through nozzle end of barrel E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 10 6 E60 Units 1 Unscrew collet securing feed screw to feed drive 2 Remove retaining nut from screw Nut is left hand thread 3 Push the feed screw towards the barrel as far as possible 4 Pull feed screw out through nozzle end of barrel Cleaning Use a brass bristled brush to clean plastic from the feed screw Installation E490 Units 1 Insert feed screw into barrel 2 Push feed screw until end protrudes past barrel end far enough for splined ring to be installed 3 Install splined ring retainer and m10x25 bolt Torque to 29Nm Push feed screw into feed drive hub 5 Install six m8x35 screws torque to 29Nm ina cross pattern NOTE It may be necessary to use a hex key inserted between the hook spanner notches and bolt heads to hold the screw from turning while torquing the bolt
56. at there has been no damage to the flexible conduit plugs or sockets If the flex has been squashed if there is visible damage or if there are any exposed conductors then for your own safety the loom must be replaced Upgrading In order to maintain our high standards of quality our development engineers at Mold Masters are making continual improvements to our control system We also listen to customers who will sometime suggest sys tem changes that may be both useful and achievable Improvements which are gained from either of these routes will be offered to our customers and should you decide that they would be beneficial to your own control system will be quite straightforward to imple ment yourself There is usually no need to send your control system back to the Mold Masters factory for such upgrades Instead they will on request be sent to you in the form of one Compact Flash Card that can be read by your controller The following instructions will guide you through the upgrade procedure Mold Masters recommends that you always wait until your controller is free before implementing any up grade This ensures that in the event of a mishap such as an error or a power interruption at a crucial point that normal production will not be adversely af fected 1 Turn off power to E Multi 2 Check that you have the upgrade Compact Flash Card 3 Open the front door of the E Multi Cabinet 4 Useapen to press th
57. atetseence A i LC SCIOTO aioe cuacacuserteancg psrtes EE tone ntanedesaraagn E E E N E A i PIUG and SOCKET OUIOT scsitescccecdoscncts netic aaueedccnudiasadenteneaduicandusgetneteuaneenedaabalewhoseedarctadeex eral A i Table 1 Plug on the injection molding machine ccc eccc cece eee e seca seca eeaeeeeeeseeeseeeeeeeeess A ii Table 2 Plug on the injection molding machine cece ccceecceeeseeeeeeeeeeseeeeeeeeeeseeeaeeeaees A iv b E Multi User Manual AIUUMENXXLT A4 Rev0S Wiold a t _ Not under documentation control if printed May be revised without notice 611 201 VWasters Electronic version is available at www moldmasters com yiii E Multi Section 1 Introduction We would like to take this opportunity to thank you for purchasing a Mold Masters E Multi Auxiliary Injection Unit AIU The purpose of this manual is to assist users in the integration operation and maintenance of an E Multi AIU This manual is designed to cover most system configurations For additional information please contact your representative or a Mold Masters office Warranty and Documentation Please check with your order documentation for warranty details Documentation will include one or all of the following e Parts list containing all system components Together with the general assembly drawing the parts list should be referenced when ordering spare parts e General assembly drawing Important Please do not return any parts to Mo
58. ation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 4 4 2 E Multi Error Message Cause _ ____ Acton _ _ O Z O O Alternatively you could slave the offending zone to a good zone until you have time to clear the fault An open circuit thermocouple has For immediate recovery you can been detected either slave that control zone to an adjacent zone or change to open loop control Later check to see whether the input fuse on the con trol card has ruptured or if the fuse is good replace the thermocouple Triac fault This can only occur Check the current output on the when in manual mode and auto channel If the triac has failed re matic mode where the current is turn to Mold Masters for repair pre set manually If for instance the triac output current is higher than the set point the controller attempts to reduce output to the level re quired If it fails the triac may have failed and it is flagged as faulty Warning Message Abnormal Condition e The control zone is in manual mode The zone is slaved to another control zone where represents the number of that zone i e S 2 means the zone is slaved to Zone 2 The same power is being sent to both zones In the Display page the set point displayed on the selected zone is the same as that on the slave zone TEST Displayed when the zone is in diagnostic test mode WARN If during the test
59. aved Trend If this field is activated the tolerance band for the curve is trans ferred from the trend curve This field is only available if trend curves for the curve are available File Start Export Load vene Starts the export of the current curve Load Measurement Opens a saved measurement and shows the variable values in the diagram File b E Multi User Manual AIUUMENXXLT A4 RevO6 Fes fii a a ee eeeeeeeeeeeeeeeaeaeaeaeSeaeaeaeaeaeaeaeaeaeaeas aoaoaeaeaeaeaeaeaeeeeeeeeeeeeeeeeeeeeeeeeeeee i i Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 9 30 E Multi se br nisi Jal Deeply mode Spat FosiborTine NF Maurier of henas 5 Proposal Start postion 160 60 nin do Set proposal 1 04 rane Slop postan 0 00 nimi 0 00 nam interred Postion 0 100 aer lt lt Sal proposal 0 000 sec Duration a asa ger an Set proposal 6 000 ser intereal 0 008 sec noo get Field Description Display mode Selection of the display type for the diagram Time Displays the measurement as y t graph injection and hold pressure Position Displays the measurements as y x graph inject only Split Position Time Displays the measurements in two diagrams as y x graph injecting up to reaching of the change over point then as y t graph hold pressure The display may be changed while a measurement is runnin
60. be selected and transferred to Selected the selected parameters list Parameters Lists Tolerance Settable tolerance from which a deviation of Reference Cycle the current cycle from the reference value is displayed by the color of the bar turning to red Sort Start time The movement is sorted according to start time to better follow the sequence of move ments visually k F pa E Multi User Manual AIUUMENXXLT A4 Rev 06 Hm Mold Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 9 18 E Multi Overview Screen Kel las HMI RYS 01a MMA 01 06 177 0 a EiT Tigger Mold at Clomzed Pos mnono 00 a HS Stari delar count o Total Auto Clos 1 Achrsl inject preggure Screw position Aches Shot Vol Pariage Preig T Acin Goati Forrit Temparalure ingui Zone 1 Te Aai Robot Teaeraterd Ingut Zone 7 Temperature input Zone J stately a iat i ae ma AuioRoody fe rad ad Mold Clear vi iW Mold Open m mi Mold iose M w W Screen Components Description Model and Serial Number Model and serial numbers for the E Multi Use these numbers to ref erence your system when talking to Mold Masters support personnel Live Temperature Zone Values This section displays the actual and setpoint values for the heating zones These values may be changed on the Temperatures Scr
61. block con nection to catch the remaining feedstock from the feed tube Figure 31 Container under Feed Tube to Feed Block Connection If the machine is oriented horizontally it is recom mended that as much feedstock as possible be re moved using a vacuum cleaner to prevent feedstock from spilling onto the machine Removal 1 Purge cooling water from AIU see Purging Cool ing Water from the System on page 10 16 2 Remove guards from the system see Guards Removal and Installation on page 10 7 3 Disconnect any connections to the feed system For horizontal installations remove feed hopper from feed block then go to step 8 5 Disconnect and remove feed hopper from feed tube 6 Loosen two m8x25 screws attaching feed tube to feed block 7 Remove the two screws and lift the feed tube away from the feed block 8 Remove the vibrator from the feed block and tem porarily tie out of the way 9 If feedstock was not purged from the unit use a vacuum cleaner to remove feedstock from feed block and barrel 10 Place a clean absorbent cloth underneath the cooling connections to the feed block and discon nect the cooling lines 11 Remove four m8x45 screws from the feed block E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 12 Remove the feed block from the system 13 Check the feed block and ba
62. by manual entry a F p E Multi User Manual AIUUMENXXLT A4 Rev 06 i Mold Not under documentation control if printed May be revised without notice 611 201 Wiasters Electronic version is available at www moldmasters com 9 43 E Multi Section 10 Maintenance Cleaning Off Line Storage WARNING Store in cool dry place not direct sunlight Do not use lacquer thinner to clean the ma e Store safely so the unit will not be ac chine cidently moved or damaged 1 Periodically wipe exposed parts of the machine e Use light oil to coat surface of with a clean oil free cloth beam that mates with mold 2 If necessary the machine can be cleaned with a damp cloth moistened with soap and water or dusted with compressed air Make sure to wipe machine with a dry cloth after washing to prevent rust Clean the barrel and heaters with non lubricated compressed air only Do not remove lubrication from the ball screws or linear guides Corrosion Protection 1 Purge any plastic from the unit before storing Parts of the AIU will oxidize rust especially in environments with any moisture or salt in the air Before the unit is placed in storage it should be thoroughly cleaned and non painted surfaces sprayed with a protective coating Do not wrap the unit in plastic wrap as this may trap condensation The unit can be further protected by vacuum sealing in a polyethylene bag with a silicate absorbent The coating should offer
63. cseecceeceseeceseesseesseeees 10 4 oA TODA E raa E E E E A E 10 5 Heater INEDIACCING Mirssscsctasvecsacescianneragaasteiaceaneieaiechsventaxicaeedasiatianasanantedesandspteradaneatnedessenniaas 10 5 E Multi User Manual AIUUMENXXLT A4 Rev0S Wiolgd Electronic version is available atwww moldmasters com E Multi A Feed Screw Cleaning and Replacementt cccccecccsccceeeceseceeeceeeecaeeseeeseeessseseeeeaeeesaees 10 6 Preparing AIU for Feed Screw REMOVAL ccccsccccseccseccceeccsuscsseessueessuesseuesseeessecsseesseessueesaeeeas 10 6 PV OVEN aaa ne sees wre tse sees ee A sect ets ees sg aloe setae EEA E E NE EE 10 6 AI et EIEEE AAE ceca nee nyse AO O ONE asin AIEE eae NOE A 10 6 M O a E E E E EE E EEEE E E E O EE 10 6 0g 0 Fs 0 e ne nn S S 10 7 IS QV ON ceria peti nese sts PO we pada teen sitet E EE 10 7 Guards Removal and Installation c ccccccccccccccseccsucccsneccseetseeseucssecsseeesseessuesseeeseessteesseessnes 10 7 EUNANA IU aa E A A 10 8 Av UD diirelalam ector Unt LENING KIS sorisa er means cere Rett nnnet ete oan irs earner eee Renee eer een meres 10 8 Prior to Lifung Auxiliary Injection UNI sncedasncsuseravsce sawsee ca vewedenctensncoyabi scaryetanawedeceeieencaredaevessatenen 10 8 verica LIK CONNECCION S esseer EEE E E SE EEE 10 9 Horizontal Lift CONNMCCTtIONS c cccccccccseccceccseccseecsusessucesueccsueesseesseesaeeeseessuessesessuseseeessnessqaes 10 10 Feed Assembly Removal and Replacemen
64. ct the carriage so the nozzle tip is on the AIU side of the adapter plate 9 Reinstall AIU as described in Attaching AIU to Mold Machine on page 6 17 E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Belt Tension Check Belt tension should be checked every six months A correctly tensioned belt has a deflection of 1 5 to 3mm 1 16 to 1 8 If a belt tension meter is available the correct tension for E60 models is 216 241Hz and for E490 models is 150 168Hz Adjusting Belt Tension E60 Models 1 Using a 5mm hex key loosen but do not remove the five m6 bolts on the eccentric shaft retaining plate 2 Rotate the eccentric shaft using a 55mm hook spanner until correct belt tension is achieved 3 Tighten the five m6 screws and torque to 9 5Nm 84in Ib E490 Models 1 Loosen but do not remove the four m12 bolts se curing the eccentric shaft cover plate 2 Rotate the eccentric shaft using a 7Omm hook spanner until correct belt tension is achieved 3 Tighten the four m12 screws torque to 25Nm 18 5lb ft in a cross pattern Belt Removal and Installation A WARNING Lock out tag out machine before performing maintenance CAUTION Do not rotate ball screws with belt removed otherwise realignment will be necessary E60 Models 1 Purge plastic from machine 2 Move injection housing to the
65. cumentation control if printed May be revised without notice Electronic version is available at www moldmasters com Torque M12 bolts to specified torque refer to torque chart For the E490 E490X model tilt the E Multi unit using the crane until the unit is leveled then torque the M12 bolts to specification Adjust the 3 leveling mounts so that they are com pressed 15mm available fine adjustment Release the crane support Alternate Method 1 Adjust compact stand to desired height using the coarse adjustments See tables 1 4 on next page for pin hole positions Ensure horizontal adjustment is in the back position push lever away from injection molding machine See Horizontal Position Adjustment on page 12 8 Assemble the mold adapter plate to the E Multi unit Attach the crane support to the E Multi unit per Lifting the AIU on page 10 8 Using the crane lower the E Multi unit with the mold adapter plate onto the stand and fasten with provided M12 bolts and washers per torque chart CAUTION Make sure cables and tubing are not pinched during assembly For the E490 E490X model tilt the E Multi unit using the crane until the unit is leveled then torque the M12 bolts to specification With the crane still attached position the stand adjacent to the machine so that the mold adapter plate is within 50mm of the mold CAUTION Do not move the stand with the unit without 9 10 11 12
66. d 15 Replace linear actuator manual access port cover and tighten 16 AIU is ready to be installed onto molding machine Nozzle Protrusion Adjustment NOTE Nozzle protrusion adjustment must be per formed when the manifold inlet depth changes for example when moving the AIU to another molding machine or when a different nozzle is installed The nozzle protrusion is set from the factory for a 6mm protrusion past the adapter plate 1 Retract the carriage so that the nozzle tip is on the AIU side of the adapter plate 2 Remove the AIU from the molding machine as described in Preparing the AIU for Adapter Plate Removal and Installation on page 10 12 3 Manually move the nozzle fully forward See Installing Adapter Plate onto AIU on page 10 12 steps 10 amp 11 Clean residue from the manifold inlet 5 Measure the distance from the manifold surface not the locating ring surface to the opening of the manifold inlet 6 Measure the distance from the tip of the nozzle to the surface of the adapter plate This distance should be 1mm more than the manifold inlet to manifold surface distance 7 To adjust the protrusion loosen the jam screw on the carriage link using a 5mm hex key The adjuster screw can then be turned to move the nozzle to achieve the correct protrusion The adjuster screw head size is 32mm 1 1 2 Once the protrusion is correct tighten the jam screw to 16Nm 138in lbs 8 Manually retra
67. d Cables in Place 2 Install two 1 4NPT fittings customer supplied into Connecting and Routing Heater the cooling connector bulkheads and I O Cables 3 Connect a clean dry non lubricated air supply not l exceeding 120 psi to the vibrator needle valve 1 Uncoil the heater and I O cables and make sure they are not kinked or twisted Check the cables 4 Open the air supply slowly check for leaks and for nicks or other damage from shipping correct if necessary 2 Connect the MOLD END of the heater cable to 5 Connect water supply to left bulkhead connector the connector on the AIU and return to right bulkhead connector 3 Connect the MOLD END of the I O cable to the connector on the AIU 4 Route the cables towards the motor end of the Supply Return AIU taking care not to interfere with any mov ing parts or obstructing the air connection The cables may be tied to the motor end shipping bracket as required 5 Connect the CONTROLLER END of the cables to the BARREL HEAT CONNECTOR and AUX INJ UNIT connectors on the controller Figure 17 Water Supply Connections k E Multi User Manual AIUUMENXXLT A4 RevO6 Wiolg Not under documentation control if printed May be revised without notice 11 2011 Maste mo Electronic version is available at www moldmasters com 7 2 Se E Multi Connecting the Controller to the Molding Machine E Multi units are compatible with both E67 and SPI in jection
68. d zoom function A cursor can be faded in and moved via touch screen or with the ar row keys The values at the current cursor position are shown in the value display The zoom function can be used to change the time sector displayed in the window in stages The button Total view switches back to the view of the total cycle Screen Buttons Total view Clears the zoom function and switches back to the display of the total production cycle View Selection of comparative values in the bar and value display Can only be selected in the comparison display The selected view is also used for the comparison bar in the bar graph Elements Description S Last cycle Comparative values of last cycle Reference cycle Values of the previously stored reference cycle Limit values Set limit values Set reference The last complete cycle is stored as a reference for future compari son Compare Times Selection of the display mode for the value display Times Display of start end and duration of movement Comparison Display of the current movement duration of the com parison value last cycle reference value or limit value selected in the display and the difference between both The limit values can be set in the screen User permission gt 10 is required for setting the values Cursor on off Fading in of a cursor for selecting the displayed values Opens a cycle time setup window Elements Description S Movements amp Movements can
69. e Compact Flash eject but ton 5 Remove the existing Compact Flash Card Insert the Compact Flash Card with the label to the front 7 Power up the E Multi 8 Confirm version number displayed on the Over view Screen matches the document that came with the upgraded Compact Flash b AIUUMENXXLT A4 Rev 06 Mold z o11 201 Masters 10 17 E Multi Section 11 Troubleshooting If the vibrator is working reconnect the air line to Thermocouple Electrical Check 4 The controller system has functionality to monitor ther mocouple performance 1 A working thermocouple will show a realistic temperature based on the environment it is in Defective thermocouples will read 100 C on the controller 2 Ifa thermocouple shows as defective change the thermocouple 3 If the new thermocouple shows 100 C there is probably a wiring problem check the wiring and connections Heater Continuity Check This procedure requires access to the heater connec tor Power down the machine before disconnecting heater cable 1 Testing of the heaters is done with a multimeter set to measure resistance 2 The heaters are wired to the connector in pairs starting with pin 1 and 17 3 Checking the resistance across the pins should show around 48 ohms for a 1000w heater and 96 ohms for a 500w heater 4 A reading of 0 ohms indicates a shorted heater and a reading of infinity indicates an open heater Transducer Out
70. e and Decompression after plasticize i E Multi User Manual AIUUMENXXLT A4 Rev06 Wiolgd nnn eT TTC k t pm Not under documentation control if printed May be revised without notice 611 201 MWlasters Electronic version is available at www moldmasters com 9 23 E Multi A Screen Elements Plasticizing and backpressure SSOSC SC S S Ss S S Stages The number of stages path sections maximum of 5 Setting the Back pressure and RPM between the end position of the previous stage in case of stage 1 the end position of the previous part movement and the position specified under to at dosing 5 End Setting the Back pressure and RPM between the previous stage and the end position specified under until at dosing Inject Pressure Injection pressure display Delay Once the end position has been reached and the waiting time speci fied under Delay Time has passed plasticizing starts Screw speed Displays the current screw feed speed Screw position Displays the current screw position Decompression before Plasticize These settings apply only for semi and fully automatic mode The settings made under Decompressing after Plasticize apply to manual mode Mode Mode of decompression before plasticizing with the following selec tion options No no decompressing Time decompression for a specified time duration Position decompression until a specified screw positio
71. e setup screen The bar can be arranged after the initial run The processes are sorted in ascending order according to their start time Bar graph Two horizontal bars are displayed for each movement Upper bar in blue color Comparative value option The last cycle 1 a previously stored reference cycle or 2 entered limit values Lower bar in green or red color Current last movement Green bar Movement within limit values Red bar Movement has exceeded limit values As soon as a movement starts the bar of the current cycle grows on the time axis until the movement stops If a movement exceeds a set limit or tolerance value of the compared reference curve the bar turns red No other action is triggered however Above the current bar a second value with the selected comparative value is displayed The total cycle time is displayed as an additional bar at the bottom of the screen The time axis is scaled so that it shows the total cycle time It can also be scaled with the zoom function b z i F e E Multi User Manual AIUUMENXXLT A4 Rev 06 Mold Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 9 17 E Multi A Screen Elements Display of values The times are shown in the form of a table next to the bar graph A time or difference display can be selected See Screen Buttons below view and compare times Cursor an
72. ederinnniattasrpadvwemaunbinidiadyenteaniuendita 10 17 Preventive Maintenance SCNHEUIe cccccccccccescceeeceeeeceeecececeeeseuecseesegeeseeesaeeseeesaeesees 10 17 E Multi User Manual AIUUMENXXLT A4 Rev0S Wiold Not under documentation control if printed May be revised without notice 7 7 7 eaa Masters Electronic version is available at www moldmasters com yi E Multi Servicing and Repairing your COntroller cccccecccecccsecceeeeeeeeeeeeseceseeecsueeeueeseeeseeeseeesaess 10 17 Replacement parts c cccccccseccecneecsueceecsuccuessuecensuecensusssensuecensessuecsussnecsuseuensetsueseessusseesenenes 10 17 ceang ano INS PECON serer aee E EE E cioeea sare 10 17 CO IGN e E E E AAE EE O E AE E 10 17 Section 11 Troubleshooting cccceceeeeeeeeeeeneeneeeeeees 11 1 Thermocouple Electrical CHeCK cccccccscceeeceeeseeteeeteeeeeeesseteestseceueeeeeseeeeaeeeeetseeneeeaeeeaess 11 1 Heater CONUNUNY CCC Kes cesencacencsercnssmesecrateeetecsanenstonnocdencsenstaendasndderevancsnnsenseanitedssehanseedeeens 11 1 Iransd cer Output Cie CK csser isinira E EU 11 1 Vibrator Valve CNC CNG sosser sete nn een NE T AEE EAE AEE EEEREN 11 1 Troubleshooting the Control System ccccccc cece eeccececeeeeeeeeeeeeeeeeseeeseeessueeseeeseeeseeeseeeaes 11 1 Fault IO Warning TOS CaO CS sar sites acdsee eee ane spats sec seas aataa catsup estes EEEE ANE 11 1 Section 12 Compact Stand Option
73. een Sequence Start Trigger This window displays the current start trigger settings The settings may be changed on the Euromap 67 screen Trigger This is the Euromap I O signal from the molding machine that starts the E Multi process Start Delay Time When the Euromap signal is detected this time de lay is added before the E Multi process starts Set to zero to disable i Pa E Multi User Manual AIUUMENXXLT A4 Rev06 FF A Not under documentation control if printed May be revised without notice 611 201 MWlasters Electronic version is available at www moldmasters com 9 19 E Multi A Screen Components Live Data This is a live display of some production variables Actual Injection Pressure This is the pressure currently produced by the injection process Screw Position This is current size of the shot Actual Shot Volume Carriage Position Actual Contact Force This is the force generated by the nozzle car riage Euromap This is a quick overview of the live status of the Euromap wiring see Euromap 67 Appendix A Red signal is logical false Green signal is logical true Grey signal is not used Injection Screen Be et RS 1 a ek Purpose This screen is used to adjust the settings for the screw movement during injection and the switchover point Description of the screen Besides the input fields the pressure profiles red and the velocity profiles grey are shown in the form of curves Beside
74. eiy wet I O00 ere sxe Achyal inject pegoun IT bar Screw position 1 01 mm o IY Toeeance epee Ratcure ariaa Roteure attwati Trend curry Attia Delete tart LA ee Injeed velo hy sal 0 00 mms Actual eget pretiu JA bar ib E Multi User Manual AIUUMENXXLT A4 RevO6 Wliolg een SSS sss sss zj p t _ Not under documentation control if printed May be revised without notice 611 201 Wasters Electronic version is available atwww moldmasters com 9 32 E Multi Trend Properties Tab Ref curve activated Specifies whether the curve is to also be adopted as reference curve The Actualize button adopts the actual shot as reference curve You can specify here whether the trend curves are saved and displayed for the curves Deletes the last saved trend curve Thane Dims eur Acton Mo arton i F Pon Fai Abtoiute Tolerance 0 00 wm Mojem Tl 8050 nee e jr ingeri eei ay ial 160 mr Arte bebctl ones bare af ba 1 oe Delete all Deletes all saved trend curves Tolerance Properties Tab Element Description S Error action Specifies which action to execute if the curve is not completely within the toler ance range of the monitoring tube Absolute tolerance The tolerance range of the monitoring tube can be specified here maximum deviation for X Y and T Export Settings This dialog is accessed by choosing the Set up then Export button
75. er and the belt slowly rotate the pulleys counterclockwise helping the belt onto the pulleys and idler Rotate back and forth as required until belt is correctly seated Tension the belt by turning the eccentric shaft us ing a hook spanner See Belt Tension Check on page 10 13 Tighten the eccentric shaft clamping screws with a 5mm hex key bit Torque to 9 5Nm 84in lb using a cross pattern Move the pulleys back and forth to check for proper movement of belt Reinstall screw into drive shaft and tighten collet by hand If screw cannot be moved rotate pulleys by hand to move injection housing to the screw Turn on the controller Enable the drive power Tighten the collet using a 36mm open end wrench Reinstall injection covers The gap between the injection cover and the injection housing should be the same all the way around the housing Pam AIUUMENXXLT A4 Rev 06 i Moid 011 201 Masters E Multi E490 Models il 2 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Move housings to maximum separation Disconnect screw see Feed Screw Cleaning and Replacement on page 10 6 Move screw fully into barrel Remove AIU from molding machine If required move the AIU into the horizontal posi tion Move the AIU onto a clean level work surface Remove the carriage guards Guards Removal and Installation on page 10 7
76. erating Instructions Power up controller and engage emergency stop Open bleed nipple by turning counterclockwise 3 Pump gun until no more air bubbles emerge from bleed tube Close bleed screw 5 Pump gun until pressure gauge reads 0 9 0 3bar for E490 units or 2 7 O0 3bar for E60 units 6 Putarag under the manifold to catch oil when disconnecting fill kit 7 Disconnect tee from injection housing using quick connect 8 Put caps on both quick connects WARNING Do not run machine with fill kit attached Damage to the machine and serious injury to the operator may result E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 9 Check the injection housing oil levels This will prevent pressure build up in the case resulting from any small internal leakage that may have occurred Remove the fill ports check the oil level and drain or top up as necessary Re install the drain ports CAUTION Q Ensure you do not open the high pressure oil plug High Pressure Oil Plug Oil Fill Port Figure 26 Oil Fill Port Not to be Confused with High Pressure Oll Plug Barrel Removal and Installation WARNING Contact with the barrel can cause severe burns Exercise caution when working on or around a hot barrel CAUTION cf Thermocouple connections on the barrel are easily damaged Do not position the barrel so it
77. ers France ZI la Marini re 2 Rue Bernard Palissy 91070 Bondoufle tel 33 1 82 05 00 80 fax 33 1 82 05 00 83 fr moldmasters com POLAND Mold Masters Europa GmbH Skr Pocztowa 59 00 908 Warszawa Poland tel 48 0 66 91 80 888 fax 48 0 66 91 80 208 pl moldmasters com i E Multi AE Regional Offices Con t SINGAPORE MALAYSIA INDONESIA THAILAND Mold Masters Singapore PTE Ltd No 48 Toh Guan Road East 06 140 Enterprise Hub Singapore 608586 Republic of Singapore tel 65 6261 7793 fax 65 6261 8378 mmsinfo moldmasters com SPAIN Mold Masters Espana Serennia Business Center Buenos Aires 37 29 08902 Hospitalet de Llobregat Barcelona Spain tel 34 93 802 36 01 fax 34 93 802 49 08 es moldmasters com International Representatives Argentina Sollwert S R L La Pampa 2849 2f B C1428EAY Buenos Aires Argentinia tel 54 11 4786 5978 fax 54 11 4786 5978 Ext 35 sollwert fibertel com ar Denmark Norway Sweden Englmayer A S Skenkelsoevej 9 Postbox 35 DK 3650 Oelstykke Denmark tel 45 46 733847 fax 45 46 733859 support englmayer dk Italy Commerciale Isola SPA Via G B Tiepolo 3 35010 Cadoneghe Padova Italy tel 39 49 706600 fax 39 49 8874231 info com isola it Turkey MMG Consulting amp Engineering Yesil esme Sok No 30 3 iftehavuzlar 81060 Istanbul Turkey tel 90 216 357 0783 fax 90 216 385 0656 mmgevrek superonline com E Multi User
78. for optimizing all heating zones The optimization itself is only started once this option has been selected and the heaters have been switched on Carriage Heating Mode Temp 1 Temp x Set tolerances Specifies the operating mode of the corresponding heating zone with the following setting options Tol high Tol low Specifies the tolerance within which the actual temperature of the heating zones must be specification in degree If this tolerance is exceeded an alarm will be triggered Only when all zones are within the tolerance is movement of the screw possible b a F p E Multi User Manual AIUUMENXXLT A4 Rev 06 Mold Not under documentation control if printed May be revised without notice 011 201 Masters Electronic version is available at www moldmasters com 9 27 E Multi A Injection Graphics Screen Kel las HM RYS OT 24i MA 01 06 17A 0 ey L BEHET seni inlorral 6 020 ser Duration 9 980 gee baa 1800 The Injection Graphics screen is used for measurement and display of preset system variables Description of the screen The recorded variables are shown as curves in a diagram Measuring interval and measurement length only for display type Time are shown above the diagram The names and the current actual values of the variables are shown below the diagram The following functions are possible e Definition of reference curves e Display of the last trend curve e Monitoring us
79. g Duration Specifies the duration for the measurement This field can only be modified when the measurement is stopped Attention This also effects a deleting of all trends references and measure ment curves This option is only active in the display modes Time and Split Interval Displays the time period between two measurements This is automatically calculated by the system This field is only available in the display mode Time Set proposal The application suggests values for the Measuring interval and Interval based on the set ramps and profiles These values can be adopted using this button The new measurement interval is adopted in the process The Interval value shows the minimum measuring interval This option is only active in the display modes Time and Split i E Multi User Manual AIUUMENXXLT A4 Rev06 Wiolgd Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 9 31 E Multi A Parameter Settings This dialog is accessed by clicking on the legend element of the desired curve e g Inject Velocity set Shown below Inject velocity set O 00 cms This dialog contains the three tabs Curve properties Trend Properties and Tolerance properties Soweton TA a Granit igri 1 00 mm ps D 0 00 min Curva Lina Cota Aiteal curve sibie x aon re __ injeetvalo
80. g English German Chinese e Supply earth leakage trip 10 mA per individual Metric imperial unit switching zone ground fault monitoring for tool protection Servo axes control for injection and screw e Overload protection miniature circuit breaker rotation e Mains voltage output pattern burst fired with e DC motor control for carriage movement zero voltage crossover and phase angle fired e Linear bearing for guiding injection housing and e Temperature control method closed loop auto barrel housing or open loop manual with Mold Masters soft e Water cooled barrel housing ware s Closed loop injection speed amp pressure control e Control range 160 400 Centigrade Celsius 10 injection speed profiles 100 mm s maxi e Temperature Scale Centigrade Celsius or mum injection velocity Fahrenheit 10 hold pressure profiles e Printer output connector USB printer port e Closed loop screw speed e Alarm output closing contact relay 5 Amp max 5 back pressure profiles e Screw ring check e Standard Euromap 67 and SPI interfaces for IMM and robot e Single ready button to set unit to standby e Selectable triggering signal e 220 V barrel heaters J type thermocouple feedback Keep barrel warm feature Figure 1 E Multi AIU Figure 2 E Multi Controller E Multi User Manual AIUUMENXXLT A4 Rev0O6 Wiolg 2 Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is avail
81. g vane SinwoLseuieas 9 9 VATA ACD ct sees crt ate E E E E oat acai Panam E E E A T E E 9 10 MAI Al T een EE ent te snp aero E E A EEEE E TE EEEE 9 11 POFO 801610 Bc 212 e aa E E E ONETAN EENE EEEN EE ON E EA 9 12 PD Protocol Screen Seti GS ccccccccsecccseccsseccsusecsuecsusessueeseessusesauessusssenessuseseuensusssauetsnsesaneeas 9 13 PD Cycle Time Analysis SCICON essrraoerisersrpeineri irti EE EErEE EE EAER EEE eria iei 9 17 E Multi User Manual AIUUMENXXLT A4 Rev0S Bap ied Not under documentation control if printed May be revised without notice 7 7 co Viasters Electronic version is available atwww moldmasters com E Multi O 2 0 E1 AS E 22 PEA nee E OO ee nee E Ona cn E eT ne wn On er ee A ee 9 19 WG CHONM SCI CCI bist care canst certs berate cen anscaamuatcsien E E E A E 9 20 HOWE SCV OC PEA E EET A A ses peieag oriow ete A 9 22 Plasticize ANA Decompression Screen ccccccvccceecceecsescceessnessuenseeceecsessuensuenseeeseesessaeenseeeneees 9 23 Carriage Nozzle Scre n cccccccsecccssecseeecsuessescssusesesensusessnetsesessuseasnessueesenesssesauseaseessusssaesans 9 25 POPE AUC S S61 CC a E E EE E E E A EN EE 9 26 E TORG So TEO a a e E E A ee eek nes ee eee 9 28 Time Settings Screen Max Act Times t D ccccccccscccsececsescneccsesensuecsesensuscseneessessuessesesaneeas 9 34 MACHINE SDCCITICAUON SCIECN pic scscserssiie aie icewereainncebevccnsndvuaynoansnuainen NE 9 35 IO Monitor Overview Screen
82. he screen Used to select display language and units of measure as well as settings for the local date and time System information is displayed but not changed on this screen Other functions of the setup screen can be invoked via the setup menu buttons Screen Element Used to select a system language from those available Date and time The system time and the current date of the controller can be set here These are centrally managed and saved on the controller Unit Allows the user to select a unit of measure for displaying information on the controller Imperial Relative Absolute etc i E Multi User Manual AIUUMENXXLT A4 Rev06 Wiolgd Not under documentation control if printed May be revised without notice 611 201 Wiasters Electronic version is available atwww moldmasters com 9 7 E iVi Ui ite E Multi Controller Shows the name of the user that is logged in and the access level of the user 1 16 HMI Version Shows the current version of the Kemro view standard runtime system format Vxx yy Shows the IP address of the HMI computer Host IP Shows the IP address of the controller Opens the login dialog and or the user administration Display Set brightness and contrast of the Handheld HMI display only on Handheld HMI and HMI System Restart HMI This button is used to ac Restarts the HMI cess additional menu but Details tons which are described on This menu entry can be used to display the dialog box for
83. ialog Note Infolog class Description System information Information of the PLC runtime sys tem at start up System warning Error when reading a config entry SV not found etc System error Errors which affect the control e g FU could not be started etc Critical system Warning Error i Critical error Error which has a critical effect on NO ik i oO error Fatal system error Total crash Text in the filter dialog nfolog class Change in value Operator actions Changes in value via user input File operation 15 File operations Loading saving files e g recipes etc Mode 16 Switching operat Changing operating mode ing mode Change of user 20 Action of the user User login logout administration administration actions the system insufficient memory etc Fatal error Application _ K b a F p E Multi User Manual AIUUMENXXLT A4 Rev 06 d Mold Not under documentation control if printed May be revised without notice 611 201 MWlasters Electronic version is available at www moldmasters com 9 41 E Multi A Text in the filter dialog Infolog class Description Example SSS 21 HMI application Application specific Entry from the HMI application action in the visual izatio Application PLC 1 Application specific 1st entry from IEC application action in control 0 Application PLC 2 24 Application specific 2nd entry from IEC application action in
84. ide out from under injection hous ing For E60X models slide the guide towards the E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 10 14 25 26 2T 28 29 30 3i 32 33 34 35 36 37 38 39 40 41 42 43 44 barrel for E60 models slide the guide towards the motors Move belt over injection housing and all the way to the barrel housing Remove old belt Move linear guide back into place using marks from step 21 Reinstall screws Tighten screws with hex key and hex key extender If machine is in horizontal orientation remove jacking screw support block and reinstall safety Screw Remove the old belt from the machine Reinstall the cable track bracket to the injection housing shaft cover using four m6x16 SHCS Torque to 16Nm in a cross pattern Reinstall transducer cable connector using a 5 omm slotted screwdriver Reconnect motor connectors See Connecting the Servo Cables and Routing them through the Cable Track on page 7 1 Position belt so it is completely around the oppo site side pulley on the idler pulley and on top of the connector side pulley The belt will not reach all the way around the connector side idler and the part that does not seat must be towards the beam Taking care that the pulleys don t change position relative to one anoth
85. ief description of the various HMI screen buttons For greater detail see the Screen Functional ity Description of each screen in the following pages Overview Screen This screen is the main screen for the system and displays data that gives a good overview of the operation of the E Multi Drive Info Screen This screen displays status and temperature values for the Injection and Plasticize servo motors Injection Screen This screen is used to adjust the settings for the screw movement during injection and the switchover point Hold Screen Holding pressure settings may be adjusted on this screen Plasticize and Decompression Screen This screen is used to adjust the settings for plasticizing and decom pressing Injection Graphics Screen The Injection Graphics screen is used for measurement and display of preset system variables Machine Specification Screen This screen serves as a central access point for all configuration screens as well as service and maintenance screens Euromap 67 This screen allows the user to monitor the hard wired I O that is between the molding machine E Multi and the robot See also Appendix A Eu romap 67 on page A i E Multi User Manual AIUUMENXXLT A4 Rev06 Wiolgd Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 9 5 E Multi A P
86. ing a Robot to the Controller cece cccceeeceeeeseeese cece eeseeeceeeeeeeseeesaeeseesseesaes 7 3 Connecting a Handheld HMI Optional cccccecccseccseeeeeeeseeeceeeseeeceeeeeeeseeeseeeseesaeeeaes 7 3 Calibrate Carriage Home Position ccccccccccccceccceeceeeceeeeseeeseeeseeeseeesseeesueeseeesaeeseeseeesaes 7 3 Section 8 Start Up Shut DOWN 0 ccceceeeeeee eee eeeeee ee 8 1 MOOC UO aan eee tonne ee nnnenne eer ere eee eee ee ee ee eee ere 8 1 Controller Start Up and Shut OW ican santa sasacaxsanssancatcnntencsaceanaeteuninedeerneadaiantadsedegeaaniens 8 1 SWC O OD ea e E E E A E E AEA E EA E E A AT EE E 8 1 Section 9 E Multi Controller ccccccccceeccnccseceeceneeees 9 1 MV OAUC UO ereere E E EE EEA EE EAEE A 9 1 Cabinet Mounted Control Buttons cccccccceeccceeeeceeeceeeeseaeeseeesseeeseeesaeessaeeseeessessseeeess 9 1 Touch Screen IUCN CS sosiete teann EE aN Ea ideien 9 2 TE om B 6 2 EEA ne RT nN N AE IA TEE A 9 2 VSOP TENON E I a a a E E EE E OOE A I EO 9 3 Running ICON Description 0 0 1c secs secs eecseecseecseecsueesueesuessuessuessuessessenssseessuessuessesseessesauesseessnesseetaes 9 4 SCIECH Navigation BURON Baf oises cosczcencesoacesatsivntddincentetusellevauivddivubdardeasaceenenvesauedovtddomnedecenntl 9 5 Pn F OTC UO AN Veee E E AEE E NEE E E AE TEE EAEE AA AE 9 6 SLEE E o EN A E E A A A E E A EN 9 7 MOG O a tps ess cca ces ecg beta cee E E vena enheiedaea
87. ing of the selected carriage movement mode Before plasticizing the carriage retracts to its end limit or for a speci fied time depending on the selected carriage movement mode After injection the carriage retracts to its end limit or for a specified time depending on the selected carriage movement mode i E Multi User Manual AIUUMENXXLT A4 Rev06 Wiolgd Not under documentation control if printed May be revised without notice 611 201 VWasters Electronic version is available atwww moldmasters com 9 25 E M ulti A Carriage Backward Optional Rel set pos Bwd Used to scale the carriage movement After jogging the carriage to the fully backward position set the Rel set pos Bwd to zero mm Carriage Contact Force Relative position of the nozzle to mold inlet The nozzle contact force per unit compression of spring The contact force that the nozzle applies to the mold inlet It is an indicator to acknowledge the nozzle contact force has reached the set point Temperatures Screen Kopke HMRS 01 24 MM 01 08 194 680 Te Biandby 100 100 100 b E Multi User Manual AIUUMENXXLT A4 RevO6 Fea ici p eee llll _ T _ 2 _S_ amp eaeaaaaa p t _ Not under documentation control if printed May be revised without notice 11 201 MWlas r Electronic version is available atwww moldmasters com 9 26 E Multi The temperature settings for the heater can be entered in this screen
88. ing to the filter settings The filters for alarms system errors and application are predefined By selecting filter off all entries can again be displayed Independent filters can be defined via menu item Filter and the en tries searched for text or time of occurrence Also settings for the display of events can be made display of long text log file on and chronological display of events The entire Info log can be written to any file that is selected via the file selection dialog Opens a sub menu for the selection of the following views Compact Only the connection designations and the status icons are displayed Normal The assigned system variable is displayed besides the connection designations and the status icons List Shows the connections in tabular form Opens a printer dialog and prints out the Info log All currently dis played messages will be printed Displays the corresponding help page for the selected line help for the Info log class _ Alarm 1 hr Gvriem Message infesmation Vatue Change Alanm 2 PCE Change Warnita File Operamcan Alarm 2 kr PLO Action Emor Mode Change Aarm d Teach Acton Critical Error Veer Change 7 aims 7 Por cor Protocot Fatal ero e Hal application Alarm 6 Application PLOT alarm F Application PLCJ Fini Screen Elements Check boxes Alarm System The corresponding Infolog class is displayed by selecting a check box All Infolog classes are selected by
89. ing tolerance band The change over point the point at which the system changes from injection to hold pressure is shown as a vertical line The area between the maximum latest and minimum earliest change over point is shown as a white bar at the upper edge of the diagram In a properly set up process this bar should be very narrow The mean value of all change over points to present is shown as a black line within the white bar The display of the measured values curves occurs selectively in the following modes e Time y t graph e Position y x graph e Split mixed form both diagram types Ww E Multi User Manual AIUUMENXXLT A4 RevO6 FV ep lad Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 9 28 E Multi Mode Description S Time mode In this display mode the x axis of the diagram corresponds to the duration of the injection process injection and hold pressure Position mode In this mode the diagram is displayed position dependently The position values are shown on the x axis the end value 0 mm is always located at the right edge The measured values are recorded from the start of the injection process until reaching the change over point Split mode In this mode two diagrams are displayed The left diagram contains the position dependent y x graph of the injection phase The measurement in this graph ends
90. ion where the system changes to hold pressure This criterion is acti vated by selecting the adjacent check box Inject time Specifies the duration measured from the start of the injection process until the point when the system changes to hold pressure This criterion is activated by selecting the adjacent check box Inject pressure Specifies the injection pressure at which the optional system changes to hold pressure This criterion is activated by selecting the adjacent check box This field is only shown if a sensor is available for injection pressure Cut off activation Screw position at which the switch over point position op detection is activated This function avoids the er tional roneous actuation of the switch over point detec tion at the start of the injection This setting is only available when the injection pressure box is checked Intrusion Intrusion is used to pre charge the manifold by plasticizing running the screw before injection When enabled plasticizing will run for the Intrusion time before beginning injection Optionally the user may also enable the Cutoff pressure which will stop plasticizing if the Intrusion Cut off Pressure is reached before intrusion times out e E Multi User Manual AIUUMENXXLT A4 Rev 06 A Mold Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 9
91. ise caution when working around the barrel and wear heat resistant gloves if necessary Do not operate the equipment with uncon fined long hair loose clothing or jewelry including name badges neckties etc These may get caught by the moving belt mechanism and can cause serious injury or death Never disable or bypass a safety device It is highly recommended that all operators wear appropriate personal protective equip ment when working with injection molding machines Check frequently for possible oil or water leaks If necessary stop the machine and make repairs When performing maintenance work always ensure molding machine lock out tag out of all sources of power Unplug and lock out the controller before performing any maintenance work The AIU is designed to be run with the guards in place Do not run the machine with guards removed If guard removal is required for maintenance replace guards once maintenance has been performed Do not modify guards i F p AIUUMENXXLT A4 Rev 06 Mold o11 2011 Miasters E Mult eee General Cautions Please note the following general cautions Q e The AIU must be connected to a water cooling system for proper performance Maintain water temperature above the dew point to prevent condensation from forming on the machine e Don t climb or stand on machine when performing maintenance e Use only specified lifting points when in stalling or moving the machine e Al
92. l 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 2 Clean end of barrel plastic residue on barrel will make it difficult to remove the heaters Remove wire ties if required Remove thermocouples from their mountings Remove thermocouple sockets from barrel oP oh a Remove one m6x12 screw securing grounding strap to barrel Loosen clamp screws on heaters 8 Slide heaters off barrel one ata time Heater and Thermocouple Installation 1 Install heaters in reverse order of removal Bar rel will have alignment markings that show correct heater locations Tighten clamping screws on heaters 0 2 Apply anti seize compound to thermocouple sock ets and install Tighten to finger tight plus 1 8 turn more NOTE Take care that heater cables are not twisted when installing heaters CAUTION Do not overtighten thermocouple sockets It is extremely difficult to remove seized sockets 3 Install thermocouples into sockets Thermocou ples should be tight in sockets if thermocouples are not tight move nut on thermocouple housing so that thermocouple is tight when attached to socket 4 Reconnect ground strap using one m6x12 screw torque to 16Nm 5 Install new wire ties if required b F pa AIUUMENXXLT A4 Rev 06 Mold o11 20011 Masters E Multi Installing the Barrel 1 2
93. ld Masters without pre authorization and a return authorization number supplied by Mold Masters Limited Release Details Release Date AIUUMENXXLT US Letter format Nov 2011 06 AIUUMENXXA4 A4 format Nov 2011 a 6o E Multi User Manual AIUUMENXXLT A4 Rev06 Wiolgd Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 4 1 E M ulti a Trademarks and Patents ACCU VALVE DURA FLEX DURA FLEX SERIES FUSION SERIES HOT EDGE INJECTIONEERING MAS TERPROBE MASTER SHOT MOLD MASTERS MELT DISK MOLD MASTERS ACADEMY MASTER SE RIES MASTERSOLUTION MASTERSPEED MERLIN MOLD MASTERS SYSTEM 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 sugges tions 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 recom mendation so made shall not bind Mold Masters Furthermore nothing contained herein shall be construed as a recommendation to use any product in conflict with existing patents covering any products or its use and no license implied or in fact
94. leveling mounts to align the E Multi unit vertically to the mold 15mm fine adjustment 3 Fasten the mold adapter plate to the mold per torque chart Disassembly 1 Remove the bolts fastening the adapter plate to 5 Remove bolts fastening the stand to the E Multi the mold unit Pull the lever fully back away from the machine Attach the crane support to the E Multi unit per Lifting the AIU on page 10 8 With the crane roll the assembly away from the machine E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 12 8 With the crane lift the E Multi unit up and away from the stand b AIUUMENXXLT A4 Revo6 Wiole i _ 01 21 Masters E Miults Appendix A 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 device robot mostly require re dundancy which is achieved by two channels on Table 1 ZA3 ZC3 and ZA4 ZC4 on the injection molding machine EUROMAP 12 shall therefore only be applied for replacement purposes on existing equipment Description The signals in both the injection molding machine and the handli
95. lfunctions it dis plays an error message on the Alarm screen If the system detects any abnormal condition it displays a warning message on the Alarm screen See the chart on the next page Fault and warning messages Any of the messages on the following pages may be displayed on the Fault Indication line i F p AIUUMENXXLT A4 Rev 06 Mold o11 2011 Miasters E Multi A Error Message Cause Action S AUTO The controller has detected a T C Check from the tool back to the failure and Automatically switched controller for a disconnected Ther this zone to manual It is using mocouple recorded settings to maintain the zone temperature pe Note this will only be seen if you have selected Auto Manual Mode En able ERR No temperature rise has been de Check thermocouple wiring it may tected in that Zone be reversed Heater wiring may be faulty or element may be open circuit FUSE The fuse for that zone has failed Replace the fuse with one of the Please Note A fuse can only fail same rating and type i e High due to a fault external to the con Rupture Current load fuse The troller Identify and rectify the fault blown fuse is located either on the before replacing the fuse control card or on the off board triac module lf fitted GND The system has detected an earth Check your heater wiring for a low fault impedance path to earth Note this can only be detected by controllers fitted wi
96. ling device robot is in position to enable of core pullers 2 to the movement of the core pullers 2 to position 1 It is recommended position 1 Enable that the signal remains HIGH at least until Core pullers 2 in position movement for han 1 signal is given by injection molding machine see table 1 injection dling device robot molding machine signals contact No ZB7 The signal shall remain to approach freely at least until position 2 has been left see table 1 injection molding machine signals contact No ZB8 Optional Enable movement of HIGH signal when the handling device robot is in position to enable core pullers 2 to po the movement of the core pullers 2 to position 2 It is recommended sition 2 Enable core that the signal remains HIGH at least until Core pullers 2 in position pullers 2 to remove 2 signal is given by injection molding machine see table 1 injection the molding molding machine signals contact No ZB8 The signal shall remain at least until position 1 has been left see table 1 injection molding machine signals contact No ZB7 ee Not fixed by EJROMAP manufacturer dependent a Reserved for future use by EJROMAP Optional Reserved for future use by EUROMAP Not fixed by EUROMAP manufacturer dependent Supply from injection OV Reference potential molding machine i C5 C6 C7 C8 C9 E Multi User Manual AIUUMENXXLT A4 Rev0O6 Wiolg Not under documentation control if printed
97. log for the filter settings Selection of the modules to be displayed DI DO etc Note Temperature inputs and or outputs are taken into account ac count with the filters Al and or AO View Opens a sub menu for the selection of the following views Compact Only the connection designations and the status icons are displayed Normal The assigned system variable is displayed besides the connection designations and the status icons List Shows the connections in tabular form Prints the current view Unforce all This button can be used to cancel all forced IO states The states of the inputs or outputs are displayed with the following icons Digital input output DI DO state off Digital input output DI DO state on 2500 Analog output Al AO with example value 2 5 V Temperature inputs TI are displayed the same as analog inputs Input or output forced By selecting an input or output a corresponding input dialog DI carnage limit ret appears for modifying the respective values or states Ree Information ee ae ey By opening the input dialog the long name of the related sys Di limit switch reference tem variable is stored in the clipboard This can be inserted into nee i the text field of the parameter selection in the settings dialog of dai the software oscilloscope and the screens of the process data NE E package via the insert key of the virtual keyboard Force state The header of dialog shows the short name
98. lti Section 5 Preparation Unpacking 1 S Crate should be moved using a forklift or pallet truck If using a crane then crate must be slung from underneath Never lift from the top of the crate Remove accessory boxes manual and anything other than the AIU Remove plastic wrap as necessary Remove the four 3 8 lag screws from the ends of the shipping brackets using a 9 16 or 14mm socket The AIU ships with lifting hardware installed Use a two leg chain bridle to remove the AIU from the crate hipment Contents E Multi AIU Documentation package user manual mechani cal and electrical drawings Lifting kit Horizontal and Vertical Feed Block Vertical Feed Tube Oil fill kit option for maintenance for any E Multi unit Part EMULTIFILLKITO1 Receiving Inspection 1 2 Check that the AIU has not been damaged in transit Check all wires and cables Ensure they are not kinked or damaged and are still connected prop erly Check for oil leaks on the machine If oil is visible find the source of the leak and correct Check oil level as described in Checking Oil level on page 10 2 E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available atwww moldmasters com Figure 5 Oil Fill Kit Figure 6 E Multi Wiring and Connectors P AIUUMENXXLT A4 Rev 06 l _ Mold 01 21 Masters E Miults Secti
99. mpZonef3 bionet bug fiye Valu ayetan ev TempZone 26 bGotLipToTemp tue falne Wahae system TempZone 36 barnn lashed tre r falee Value Sitter tv_ Temptonesa6 integer State O Wahoe eaten ey Tempione 36 bone hue r fare Valid ayata tv_ Ten 2onea6 borima rus gt falte Valao ralan ov TempZone 3 49 bGotipToTemp true gt falee ADMIN ADMIN ADIMIN ADMIN ADMIH A MIH ADMIH ADMIH ADMIN ATIMINI ADMIH ADMIN ADMIN ADMIN ADMIN System events alarms user changes system errors etc are recorded or logged in the Info log In this way a complete machine history for example can be realized The Info log screen only displays information Alarms cannot be confirmed here Description of the Elements All system events are shown in the table A status line underneath the table shows the entire text of the se lected entry Using the menu bar the entire info log can be saved or printed out The list can be limited to specific system events using the aid of a filter This makes it easier to find entries E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 9 39 i Par AIUUMENXXLT A4 Rev 06 l Mold o1 201 Masters E iVi Ui ite E Multi Controller Allows a filter to be selected Pressing the button restricts the display accord
100. n Position Time Specifies the screw position and or the duration of the decompres sion The display is dependent on the mode selected Velocity Specifies of the velocity for the linear screw movement This field can only be edited when Time or Position mode has been selected Decompression after Plasticize Mode Mode of decompression after plasticizing with the following options No no decompressing Time decompression for a specified time duration Position decompression until a specified screw position Position time Specification of the screw position relative distance to position Plasticizing end and or duration of decompression The display is dependent on the mode selected Pressure Specifies of the pressure for the linear screw movement This field can only be edited when Time or Position mode has been selected Vibration Unit The vibrator is attached to the feed hopper or feed tube Vibration can be used to help the flow of material into the feed block Use Vibration Unit Checking this box will enable the vibration unit Unchecking the box will disable the vibration unit Vibration On Time Specifies the amount of time the vibration is on within the off on cycle Vibration Off Time Specifies the amount of time the vibration is off within the off on cycle T __ E Multi User Manual AIUUMENXXLT A4 Rev 06 er Mold _ Not under documentation control if printed Ma
101. ng device robot are given by contacts e g contacts of relays or switches semiconductors etc The contact making is either potential free or related to a reference potential supplied to a contact of the plug mounted on the injection molding machine or the handling device robot see Tables 1 and 2 All signals which are not optional shall be supported by all injection molding machines and handling devices robots Plug and socket outlet Figure 51 Plug on Handling Device Left Plug on Injection Molding Machine Right The connection between the injection molding machine and the handling device robot is achieved by the plugsspecified below For the injection molding machine and the handling device robot the plug contacts should be capable of taking a minimum of 250 V and 10 A See Figure 51 Plug on Handling Device Left Plug on Injection Molding Machine Right on page A i arrangement of pins and sockets viewed from the mating side opposite the wiring side b _ E Multi User Manual AIUUMENXXLT A4 Rev 06 Mold Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com A i E Multi a eT Table 1 Plug on the injection molding machine Signals from the injection molding machine to the handling device robot Contact No Signal designation Description male ZA Emergency stop of The switch contact mu
102. nstallation CAUTION The AIU controller should be in stalled in a clean dry environment where the ambient conditions do not exceed the following limits Temperature 0 to 35 C Relative Humidity 90 non condensing e It should be located in such a way that the main disconnect is easily ac cessible in case of emergency e The AIU 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 sup ply requirements If the local supply is outside the specified range please contact Mold Masters for advice e The cable used to connect the AIU controller to the disconnect should be suf ficient for the maximum load of the AIU Install a strain relief into the supply cable hole on the connector side of the controller Remove disconnect terminal cover Figure 7 Controller Supply Cable Hole i p E Multi User Manual AIUUMENXXLT A4 Rev 06 _ MViold o11 201 Miasters Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 6 1 E M ulti a 3 Feed supply cable through strain relief and route wires to disconnect and ground See Figure 8 Controller Power Connection Points Disconnect screws using a 5mm hex driver 4 Replace disconnect terminal cover Ground L1 L2 L3 Figure 8 Cont
103. ntroller is inconvenient The handheld HMI connects to the HANDHELD HMI connector on the controller HOw h Figure 20 Handheld HMI left and Controller Connection right Calibrate Carriage Home Posi tion The first time the AIU is installed and any time it is transferred to a new machine with a different mold the carriage home position must be calibrated See Car riage Home Position Calibration on page 10 16 F AIUUMENXXLT A4 Rev 06 i o11 2011 Miasters E Miulti Section 8 Start Up Shut Down Introduction Before the AIU can be used the controller will need to be set up Please see Touch Screen Interface on page 9 2 for details on setting parameters such as e Heating e Control e Injection speeds e Trigger signals etc Controller Start Up and Shut Down For all E Multi Controllers the main power switch is a rotary switch at the rear of the cabinet This switch is rated to safely disconnect the total load current during switch On and switch Off You can use a Suitably sized padlock or similar device to lock the switch in the Off position to prevent op eration during maintenance Figure 21 Main Power Switch Although the main switch has the capacity to switch the whole system Off it is recommended that this is only done in an emergency The controller uses computer technology and should be switched off in stages A sequenced method for switching On
104. number of process values is arbitrary The table can be scrolled horizontally and vertically The color scheme of the individual columns can be selected in PDP setup The lower part of the screen shows the reference value minimum maximum and the difference between the two values as well as the mean value for each process value The number of cycles injections that are taken into account can be adjusted the default is 20 injections E E Multi User Manual AIUUMENXXLT A4 RevO6 Wiola Not under documentation control if printed May be revised without notice 11 2011 Wilias rs Electronic version is available atwww moldmasters com 9 1 2 E Multi Screen Buttons Start stop Starts stops the measurement of process data The button is displayed alter natively depending on the current status of the measurement Opens the settings dialog of the PDP protocol See PD Protocol Screen Set tings Take as reference The values of the current measurement are set as reference values Further measurements can be compared with these values Details off This option is used to show and or hide the status line at the upper edge of the screen Delete Deletes the displayed list Keep list clear list Stops or starts the display of new values The protocol log continues to run in the background A renewed actuation of the button contin ues the display on the position of the current measurement PD Protocol Screen Settings aina
105. old opening position is not in use b E Multi User Manual AIUUMENXXLT A4 RevO6 FV ep lad Not under documentation control if printed May be revised without notice 611 201 Wiasters Electronic version is available atwww moldmasters com A ii Appendix A Euromap 67 Signal designation Supply from handling Contact No male ZA9 ZB2 ZB3 ZB4 Optional Optional UJ UJ UJ N O S Optional Optional device robot Enable operation with handling device robot Automatic Ejector back position Ejector forward posi tion Core pullers 1 in po sition 1 Core pullers 1 free for handling device robot to ap proach Core pullers 1 in po sition 2 Core pullers 1 in position to re move molding Core pullers 2 in po sition 1 Core pullers 2 free for handling device robot to ap proach Core pullers 2 in position to remove molding E Miults Description 24 V DC Reference potential HIGH signal when the injection molding machine is able to be oper ated with handling device robot This signal shall not be used to start the handling device robot If the signal turns LOW during the opera tion mode of the handling device robot operation with injection molding machine it is recommended that the handling device robot continues its automatic cycle until the end position HIGH signal when the ejector has been finally e g after the number of its set cycles retrac
106. on 6 Installation WARNING e Lock out tag out controller before installation e Put molding machine into mold change mode e Ensure mounting hardware is capable of supporting the expected load Torque mount ing hardware to correct torques See Torque Specifications on page 10 17 e Ensure all lifting devices are rated for the load e Use correct lifting points See Lifting the AIU on page 10 8 CAUTION NOTE Please reference installation drawing supplied with unit for complete informa tion on services and connections Q Clean the molding machine and mold where the AIU will be mounted Any plastic residue on the manifold inlet must be removed to ensure proper nozzle contact Install adapter plate onto AIU See Installing Adapter Plate onto AIU on page 10 12 Verify that AIU carriage is retracted to prevent bending the carriage link a For vertical installations lift the AIU into place above the manifold inlet and install screws Torque in a crosswise pattern b For horizontal installations move the AIU into place beside the manifold inlet and install screws Verify stand is at the correct height and install screws Torque in a crosswise pattern _ N e E Multi is designed to be used only with molds capable of accepting auxiliary injection units e Ensure E Multi placement will not interfere with injection molding machine movement Attaching AIU to Mold Machine Controller I
107. onal Network status System catalog KNet status Info log KNet error Current PCB configuration Performance log Screens Used to switch to other application screens The screen options are specified in the HMI configuration Switch to a screen by selecting it in the dialog and pressing the confirmation button E Multi User Manual AIUUMENXXLT A4 RevO6 Wiolg so Not under documentation control if printed May be revised without notice 11 2011 MVMaste ers Electronic version is available at www moldmasters com 9 8 zi E Multi Mold Data tl RueP hast MLAS 01 741 MPM TO 018114 rit le interno ThA hee fee ere eaman z Le SE Acie mold deta ETid sopini Nano iin PM ra NMA ET PM 822950 wn eag PM iring Mold specific settings e g all process data such as movement settings profiles temperature set points can be stored and uploaded again as material data records in the component data screen Description of the screen The upper section contains a table that can be used to show and or select all previously created mold data records A mold data record contains the settings for profiles temperatures mold height etc New mold data records can be changed via the menu bar while existing records can be edited or deleted Screen Element Description Active mold data Currently loaded component data record Drive Selection of a drive local compact flash or USB stick for saving and
108. or detail Shows additional information on the selected modules k E Multi User Manual AIUUMENXXLT A4 RevO6 FV ep fill Not under documentation control if printed May be revised without notice 611 201 VWasters Electronic version is available at www moldmasters com 9 36 E Multi Controller E iVi Ea ite Select Statistics Starts or stops the selected CPUs CPUs may also be restarted Reset Start Stop All available CPUs are displayed here below each other The state of the CPU is displayed as follows p CPU is running a CPU is stopped Start stop The selected CPU is started or stopped according to its state The selected CPU is restarted IO Monitor Detail Screen Kells HMI RYS Oe MWA 0106 172 0 Ts 8 L EiT aeni B Maleti a me m a m mn j ua CL elele Ires For purposes of debugging error analysis the input output values can be forced in this screen Description of the Elements For each selected hardware module the current values of the inputs and outputs are displayed Screen Buttons Shows the selection of modules Filter on off The filter for the display can be switched on or off with this button b F p E Multi User Manual AIUUMENXXLT A4 Rev06 F ba Mold Not under documentation control if printed May be revised without notice 611 201 Wiasters Electronic version is available at www moldmasters com 9 37 E Multi A Screen Elements Opens the dia
109. or for HIGH signal when the handling device robot enables the movement ward for ejector forward The signal must remain HIGH at least until Ejec tor forward signal is given by the injection molding machine see table 1 injection molding machine signals contact No ZB4 Enable movement HIGH signal when the handling device robot is in position to enable of core pullers 1 to the movement of the core pullers 1 to position 1 It is recommended position 1 Enable that the signal remains HIGH at least until Core pullers 1 in position movement for han 1 signal is given by injection molding machine see table 1 injection dling device robot molding machine signals contact No ZB5 The signal shall remain to approach freely at least until position 2 has been left see table 1 injection molding machine signals contact No ZB6 Optional Enable movement of HIGH signal when the handling device robot is in position to enable core pullers 1 to po the movement of the core pullers 1 to position 2 It is recommended sition 2 Enable core that the signal remains HIGH at least until Core pullers 1 in position pullers 1 to remove 2 signal is given by injection molding machine see table 1 injection the molding molding machine signals contact No ZB6 The signal shall remain at least until position 1 has been left see table 1 injection molding machine signals contact No ZB5 Optional Enable movement HIGH signal when the hand
110. oved to remove the E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com Outer Barrel Cover cover The injection covers are held in place by four screws each two on the sides one on the feed block side and one on the beam side Each linear actuator guard is held in place by four screws E490 E490 units have three sets of guards as well injection covers beam cover and barrel covers The injection covers are held in place by three screws two on the sides and one on the feed block side The barrel cov ers are the same as on the E60 units and the beam cover is held onto the beam with six screws In both cases when installing the barrel covers check that the covers do not pinch the heater or thermocou ple wires and that the covers will not crush or shear the heater or thermocouple wires when the unit moves i F p AIUUMENXXLT A4 Rev 06 Mold 611 201 Miasters 10 7 E M ulti a Lifting the AIU WARNING When doing any work on the machine that requires lifting the machine 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 costly damage to the machine and severe injury or death Auxiliary Injection Unit Lifting Kits Recommended Option 2 x 5 8 16mm Bow Shackles 2 x 1 Bow Shackles 2 x 48 Slings 2 x 72
111. printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 9 14 E Multi Availanie Parameter Selected Parameter Variables Cam g Com Ejector Heating reife ie Mog Prosucton ually Leendatined Par aereetar Add Parameter Selection List of the system parameters selected for the protocol gt lt lt lt Moves the parameters in the direction specified User defined Opens the dialog for the creation of a user defined group of system variables Parameter Direct entry of a system variable via the keyboard If the keyboard is displayed a variable designation from the clipboard can be inserted with the appropri ate button a variable designation can be copied from the O monitor to the clipboard for example Inserts the selected system variable to the list of selected parameters i E Multi User Manual AIUUMENXXLT A4 Rev06 Wiolgd Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 9 1 5 E Multi A Selected Parameter _ feo o Column color Y r Randin Aip Number of shots 20 x va Settings Properties Tab A background color can be assigned to the individual columns of the protocol table on this page Selected Parameter List of the system parameters selected for the protocol
112. procedure a temperature interaction is found between zones this message is displayed FAIL The zone under test has failed The zone has passed testing b E Multi User Manual AIUUMENXXLT A4 Rev06 Wiolg 2 Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 11 3 E NMiults Section 12 Compact Stand Option Introduction The E Multi Compact Stand supports E Multi units while in the horizontal feed orientation Safety CAUTION E Multi compact stands are intended for sup port of E Multi units only Do not use these stands for transportation of the E Multi unit When assembled with the E Multi unit these stands are TOP heavy Do not leave stand unattended when assem bled with the E Multi unit Standard Features Provides support for E Multi units in horizontal feed orientation Height range from 1100mm to 1500mm 50mm of allowable lateral movement to provide clearance for mold removal Leveling feet provide stable anti vibration place ment once set in place and allow for an extra 15mm height adjustment Casters within leveling feet provide easy trans portation of the stand only stand is not for use for transportation of the E Multi unit Figure 35 Compact Stand E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at
113. put Check Transducer function is checked automati cally every cycle If the transducer is defective an alarm will be shown on the controller Vibrator Valve Check 1 The vibrator runs on every cycle when the feed screw Is turning If the vibrator is not moving check the air pressure to the vibrator by closing the air needle valve and disconnecting the air line from the supply side of the valve 2 Open the needle valve slowly and check for air pressure on the supply line If there is no pres sure check the pneumatic connection to the ma chine If there is pressure close the valve recon nect the air line to the valve and open the valve 3 Next check the mechanical function by discon necting the air supply tube from the solenoid valve on the support beam and applying compressed air to the tube If the vibrator is working properly it should start to vibrate when compressed air is applied E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com the valve and disconnect the valve cable Apply 24VDC to pin 1 and OVDC to pin 2 The valve should open and the vibrator should start to vibrate If the valve does not move replace the valve with a known good one Troubleshooting the Control System The control system has several features which pro vide an early diagnosis of faults in the control system If the system detects any ma
114. rint Functionality Relies HALAS 01 741 MP Oii 1 1660114 __Efo Taine mi To open the print dialog touch the black colored box on the top left of the cur rent screen containing the name of the i ii i screen Create and Time Jar Bathinges eer lanun HMi Vorsion Verw Standard 158a Device tP 104015150 Hers flrs ey ee When you click on the Setup button the set up screen on the right will open The printer settings are described below Screen Element Use Printer Print to Fil MIME Type Selection of a MIME type for the out put file Directory Target directory for the output file Filename File name of the output file E Multi User Manual AIUUMENXXLT A4 Revo Wliold Not under documentation control if printed May be revised without notice 611 201 VWasters Electronic version is available at www moldmasters com 9 6 l E Multi Screen Functionality Descriptions System Set Up q Rue iast HALAS 01a MM Te 0 10114 anin nemuwa Tourn ieni fee more infesrmator CE Language English 7 Lani Cate ard Time Jari 17 2011 0210 PM r _ impesiat _ ansotute w Relate per Arian 16 Hmi virsioni ViewStandard 1 58a Daniek 10 3015168 Hostif TET eiia versions The setup screen is used to adjust the display of system information Description of t
115. roller Power Connection Points E Multi User Manual AIUUMENXXLT A4 Rev06 Wiold Not under documentation control if printed May be revised without notice 611 201 VWasters Electronic version is available atwww moldmasters com 6 2 ee ee E Multi Section 7 System Set Up Connecting the Controller to For 490 models the AIU 4 Open the crossbars by inserting a small flat head screw driver into one side of the slot in the cross There are six cables that connect the controller to the bar and prying down and then the other To close AIU There are two servo power cables two servo the crossbar fold it down and put the tab into one encoder cables one heater cable and one I O cable side of the slot and then tap closed with a rubber The motor power and encoder cables need to be routed through the cable track before being connected to the motors The heater and I O cables can be con nected directly and all the cables should be routed so they do not interfere with the mold or molding machine operation mallet Connecting the Servo Cables and Rout ing them through the Cable Track 1 Uncoil the servo cables and make sure they are not kinked or twisted Check the cables for nicks or other damage from shipping NOTE For the next steps the method to open the cable track crossbars is differ a ent for E60 and E490 models Figure 11 E490 Cable Track For E60 models 2 Open the cable track crossbars by inserting a 5 Once
116. rom barrel housing F6 Run feed motor until no more material flows from nozzle F5 f Bring injection housing close to barrel housing F7 Run feed motor again until no more material flows from nozzle Disable servos F10 KJ Switch barrel heaters off F8 l i F p AIUUMENXXLT A4 Rev 06 Mold o11 2011 Miasters E M ulti a Purging Cooling Water from the System NOTE If AIU will be moved frequently a purging tool can be made to allow fast clean and safe purg ing of cooling water from the AIU The tool consists of two lengths of hose a short one with a valve and airline quick connect and a longer one with a heavy weight at one end to prevent the hose from moving when air pressure is applied both with quick connects to connect to the AIU To purge the system the hoses are connected to the AIU and the weighted end of the hose placed into a bucket With the air valve off the other hose is connected to the AIU and to a compressed air supply By slowly opening the valve the air purges the water out WARNING AN Burn Hazard Do not disconnect water cooling fittings on the machine without first purging the system If water contacts a hot barrel steam or hot water may be released from the machine This procedure requires compressed air Do not direct compressed air at body parts do not look into compressed air stream and do not look into or at fitting when blowing compressed air into it
117. ronic version is available at www moldmasters com Heater Replacement The heaters are labeled 1 6 or 7 for E490 models with heater 1 next to the barrel housing and heater 6 or 7 at the nozzle end WARNING Use caution The barrel will be extremely hot for some time after shut down Once guards are removed wear heat resis tance gloves or wait a number of hours until the barrel has cooled down NOTE If there is plastic residue on the nozzle tip it must be cleaned off to allow heater removal To avoid mixing up heaters and thermocouples number them prior to removal Move carriage to fully back position 2 Cut the wire ties to free heater wires Remove the heater connector insert from connec tor base Unscrew heater wires from insert Loosen lock nut on strain relief Pull heater cable out of connector base Remove connector base Loosen heater clamping screw s oe ot Ss ot ae If required remove thermocouples and thermo couple retaining sockets 10 Slide heater off end of barrel If the failed heater is not at the end remove heaters before failed heater as well 11 Using old heater as a template cut new heater s wire to same length Cut braided shield back from wire 5cm 2 Strip insulation off heater wires to 10mm Install ferrules using ferrule crimper 12 Install new heater with heater cable pointing to housing end of barrel The exception is heater 1 which has to be facing tip end due
118. rrel mating surfaces and clean if necessary remove any remaining feedstock from barrel Installation 1 Install feed block into barrel housing 2 Check gap between barrel housing and feed block it should be uniform for the entire contact surface 3 Apply alight coat of synthetic grease to the four m8x45 screws install and finger tighten CAUTION Incorrect tightening of the screws may result in uneven clamping of the barrel and may cause damage to the machine 4 Tighten screws in steps in a cross pattern ensur ing that the gap between the contact surfaces remains constant as the screws are tightened Final torque to 29Nm in a cross pattern 5 Connect the water cooling lines Re install the vibrator and torque bolt to 9 5Nm For vertical installations re install feed tube using two m8x25 screws torque to 29Nm 8 Re install feed hopper 9 Reconnect feed connections 10 Reconnect water cooling hoses 11 Slowly open water cooling valves check for leaks 12 Replace guards CAUTION Do not re use purged feed stock Damage to the AIU from contaminated feed stock is not covered under warranty Injection Nozzle Replacement Because of the possibility of variation between nozzles it is recommended that any time a nozzle is changed the adapter plate be realigned Chang ing the nozzle is described in the section Installing Adapter Plate onto AIU on page 10 12 i F p AIUUMENXXLT A4 Rev
119. s E60 Units 1 Insert feed screw into barrel 2 Install collet onto screw end 3 Install retaining nut onto screw end so that the end of the screw is protruding 1 3mm from the surface of the nut 4 Tighten collet securing feed screw to drive i F pa AIUUMENXXLT A4 Rev 06 Fie Mold 01 211 Masters Maintenance Safety Guards Guards Layout E60 shown E490 similar Connector Side Injection Cover N Connector Side Linear Actuator Guard E Multi Opposite Side Linear Actuator Guard Opposite Side Injection Cover U lt H i n O Inner Barrel Cover Figure 27 E60 Safety Guards Guards Removal and installation h WARNING Guards should not be removed unless main tenance is required and should be replaced after maintenance work is complete Do not run the machine with guards removed NOTE Linear actuator guards on E60 models are an integral part of the support structure when the machine is placed horizontally on a work surface These guards should only be re moved when the AIU is in the vertical position or attached to the molding machine or mainte nance stand E60 E60 units have three sets of guards injection covers linear actuator guards and barrel covers The inner barrel cover is held onto the barrel housing with two screws and the outer barrel cover is held onto the beam with five screws The outer barrel cover screws only need to be loosened not rem
120. s PELET Kind of measure Stat Delay A Tima menur Ui interral Shot Cycte maasure Humber of records Prope _ toile dolaat bt printe Una Decimalgeparator z J Description of the screen The setup button in the PD Protocol screen opens the settings dialog There are three tabs Measure Param eter Parameter Selection and Properties The various setting options are described in detail below Settings Measure Parameter Tab The measurement and output of the protocol can be adjusted in this section Input Field Description o Time measure When this measurement type is selected the measurement is made at the time intervals set in nterval Cycle measure When this measurement type is selected the measurement is made after each number of shots number of machine cycles predefined in nterval i E Multi User Manual AIUUMENXXLT A4 Rev06 Wiolgd Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 9 1 3 E Multi A Input Field Description Start delay Delay between the activation of the start button and the actual start of mea surement For time measurement the specification is made in seconds and for cycle measurement according to the number of injections Interval Specifies measurement interval For time measurements the specification is made in seconds minimum and for c
121. s a potentially haz ardous situation which if not avoided could result in serious injury or death CAUTION Caution indicates that damage to equipment is possible if instruction is not followed IMPORTANT Important indicates useful additional infor mation or is used as a reminder of important information Introduction Any instructional material provided by Mold Masters for the operation and maintenance of the E Multi Auxiliary Injection Unit AIU does not in any way absolve the employer from fulfilling the following obligations and Mold Masters disclaims liability for injury to personnel using equipment supplied It is the responsibility of the employer to e Ensure the original and continuing competence of personnel caring for setting up inspecting and maintain ing injection molding equipment e Establish and follow a program of periodic and regular inspections of injection mold ing equipment to ensure they are in safe operating condition and proper adjustment e Ensure that no modifications repairs or rebuild of portions are made to the equip ment that reduce the level of safety existing at time of manufacture or remanufacture E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com General Safety Warnings The equipment supplied is subjected to high injection pressures and high tempera tures Exerc
122. s entering the values directly into the fields the pressure and velocity values can also be adjusted with the arrow keys next to the profile curves For each click the profile curve is adjusted by 5 bar and or 5 A separate button is used to switch pressure and velocity to constant output F pa E Multi User Manual AIUUMENXXLT A4 Rev 06 Ham Mold Not under documentation control if printed May be revised without notice 611 201 VWasters Electronic version is available at www moldmasters com 9 20 E Multi Screen Elements Number of adjustable stages maximum of 10 1 n Setting the pressure field Pressure and quantity field Velocity be tween the end position of the previous stage in the case of stage 1 screw position Back end position and the position specified under and during injection Setting the pressure field Pressure and quantity field Velocity between the end position of the previous stage and the end position during injection Spec inject pressure optional Displays the current specific injection pressure This field is only shown if a corresponding sensor is available Switchover point The change over point at which the system changes from injection to hold pressure can be adjusted in this section When selecting more than one criterion the system changes over to hold pressure as soon as one condition is met Elements Description o Screw position Specifies the screw posit
123. set rel startposition text at top right corner of the screen Injection Home Position Cali bration There are only two instances when the injection home position needs to be calibrated If the machine pro gram is updated or the injection motor is removed The procedure for calibrating the injection home posi tion is as follows 1 Ensure the barrel is up to temperature Switch the controller into service mode E Switch to the Drive Info screen by pressing the Overview Screen button and then pressing the Drive Info button D 4 Press the Start Reference button Stat Reference 5 Press F7 Li button below HMI screen The text field next to the Start Reference button changes from Not Referenced to Referenced 6 Check the position on the top right of the screen it should be 1 0 7 The injection drive is now calibrated b _ E Multi User Manual AIUUMENXXLT A4 Rev 06 Ham Mold o11 2011 Miasters Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 10 16 E Multi Torque Specifications Nominal Treaa Size Preventive Maintenance Sched ule Preventive Main Frequency tenance Belt Tension Every 6 12 months 2 Check oil level in Only if oil seems to thrust housing be leaking 3 Grease linear Every 6 months guides 4 Lubricate ball Every 6 months screws 4 points Servicing and Repairing yo
124. side bar while the E Multi is operating They are displayed above the operation mode icon These icons give the user valuable information on the current status of the E Multi Haren OO ee O O l Screw is injecting Screw is rotating Plasticizing vi screw revolution Screw position 1 01 M Inject p ressure 5 Screw is moving backward Tih Screw is moving forward a Peer Nozzle is moving forward Nozzle is moving backward E Multi User Manual AIUUMENXXLT A4 Rev 06 Mold gt lt _ _ gt gt _ gt _ gt _ gt _ i E amp E amp EzE_ E amp _ EEEEKE lt c lt __ _ _ lt lt lt E lt L lt _ __ _ c lt gt EL_K i gt gt KK KK amp amp _x xx amp amp xx amp amp amp amp amp amp amp q V V V gt 2 2ETYE _2_E C 7 7 7_xKx K KXKx Z Z XxX ZIZX XH mxmn m T nmj 0 gt 5 gt xx x KC _ _ _ n auCyuanaanan amp x __E_x _x_x _E _ _ x _ _XxEXE 7 Not under documentation control if printed May be revised without notice 11 2011 Maste rs Electronic version is available at www moldmasters com 9 4 E Multi Screen Navigation Button Bar At the bottom of each screen is a group of buttons that allows the user to navigate through the various HMI screens Below is a br
125. st be open when the injection molding machine ZC1 machine emergency stop device is being actuated Opening the switch contact channel 1 causes emergency stop of the handling device robot ZA2 Emergency stop of The switch contact must be open when the injection molding machine machine emergency stop device is being actuated Opening the switch contact channel 2 causes emergency stop of the handling device robot ZA3 ZC3 Safety devices of The switch contact is closed when safety devices e g safety guards machine footboard safety etc on the injection molding machine are operative channel 1 so that dangerous movements of the device robot are possible The signalis active in operation mode The signal must be the result of limit switch contact series of mold area safety devices according to EN 201 Safety devices of The switch contact is closed when safety devices e g safety guards machine footboard safety etc on the injection molding machine are opera channel 2 tive so that dangerous movements of the handling device robot are possible The signal is active in any operation mode The signal must be the result of limit switch contact series of mold area safety devices according to EN 201 ZAS Reject HIGH signal when the molding is a reject HIGH signal when the mold is open and must remain HIGH at least until Enable mold clo sure Optional see table 2 handling device robot signals contact No A6 It is recommended
126. stem may be turned off using the rotary disconnect on the back of the controller i F p AIUUMENXXLT A4 Rev 06 Mold 01 221 Miasters E Miults Section 9 E Multi Controller Introduction This part of the manual describes the Touch Screen Interface or Human Machine Interface HMI and shows what functions and information are available The console housing contains all components necessary to generate displays and information for the control cabinet and includes a USB port Ethernet connections are also provided From the various screens software on the screen allows you to e Set individual nozzle temperatures Set high and low tem perature limits for closed loop zone control e Configure and calibrate nozzle position and contact force e Create mold specific setups recipes These can be stored and called up when molds are changed e Configure the injection sequence and monitor it e Configure the hold sequence and monitor it e Configure the plasticize sequence and monitor it e Use the oscilloscope functionality to monitor operation e Control the password protection on all settings e Print out any displays or data listings e Connect and monitor Euromap connection between the E Multi molding machine and robot Cabinet Mounted Control Buttons The cabinet mounted buttons control frequently used functions to help prevent excess wear on the touch screen F3 Fa F5 Fe F7 F8 F9 F10 imi eis
127. tch contact is closed when the handling device robot is C3 outside the mold area and does not interfere with mold opening and closing movements The switch contact must be opened when the handling device robot leaves its start position If the switch contact is open neither opening nor closing of the mold may occur However the injection molding machine may ignore this signal when mold opening is carried out after e g an intermediate stop see table 1 injection olding machine signals contact No ZA8 if the optional sequence is selected on the injection molding machine The signal must have the described effect even when the handling device robot is switched off It is recommended to close the switch contact when the handling device robot is unselected Reserved for future use by EUROMAP A5 a Not fixed by EUROMAP manufacturer dependent Ki KBR A6 Enable mold closure HIGH signal when the handling device robot is retracted enough for start of mold closure The signal must remain HIGH at least until Mold closed see table 1 injection molding machine signals contact No ZA6 is available If the signal is LOW as a result of a fault mold closing must be interrupted The signal Enable mold closure must not be a logical or with either other signals e g Close safety guard or a push button in any operation mode The signal must be HIGH if the handling device robot is switched off It is recommended to have HIGH signal when
128. ted regardless of the moving platen position The signal is the acknowledgement for the Enable ejector retraction signal see table 2 handling device robot signals contact No B3 when the ejector sequence is selected It is recommended to have HIGH signal when the ejector sequence is not in use HIGH signal when the ejector has been advanced The signal is the acknowledgement signal for the Enable ejector advance see table 2 handling device robot signals contact No B4 It is recommended to have HIGH signal when the ejector sequence is not in use HIGH signal when the core pullers 1 are in position 1 see table 2 handling device robot signals contact No B5 It is recommended to have LOW signal when the core puller sequence is not in use HIGH signal when the core pullers 1 are in position 2 see table 2 handling device robot signals contact No B6 It is recommended to have LOW signal when the core puller sequence is not in use HIGH signal when the core pullers 2 are in position 1 see table 2 handling device robot signals contact No B7 It is recommended to have LOW signal when the core puller sequence is not in use HIGH signal when the core pullers 2 are in position 2 see table 2 handling device robot signals contact No B8 It is rec ommended to have LOW signal when the core puller sequence is not In use Reserved for future use of EUROWAP SSS J Reserved for future use of EUROMAP J Reserved for future use
129. th EM Cards or MD240 diagnostics HELP There is a system failure Please contact Mold Masters Sys tems HIGH The water flow sensor has detected Check that the coolant water sys a high flow rate tem is not blocked or leaking LOW The water flow sensor has detected a low flow rate LINE No mains supply synchronisation Check supply wiring for presence of pulses being received all three phases LOAD No load on that zone Only oc Isolate the system supply and curs when in manual closed loop check the connections between mode where the current is pre set the controller and the tool heaters The current sensing circuit has not Also check the heater for continuity detected a current flow therefore the zone is flagged as not having a load OVER The RTD zone has detected a tem Check the wiring to see that there is perature in excess of 99 C no fault Check that a different RTD has not been fitted N Z The controller card in this rack posi Check card for faults tion is not responding NONE A Zone type appears not to be There is a communications prob selected for the card lem Try a replacement controller card REV The card has detected an abnormal If the REV alarm persists then you input at the T C termination that should switch off the controller and indicates a shorted or Reversed investigate the offending zone thermocouple b E Multi User Manual AIUUMENXXLT A4 RevO6 FV ep lad Not under document
130. the handling device robot is unselected gt N Enable full mold HIGH signal when the handling device robot has taken the part and Optional opening allows to continue mold opening The signal must remain HIGH until Mold open signal is given by the injection molding machine see table 1 injection molding machine signals contact No ZA7 A8 E Reserved for future use by EUROMAP 9 Supply from injection 24V DC 2A Reference potential molding machine T b E Multi User Manual AIUUMENXXLT A4 RevO6 FV ep lad Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com A iv Appendix A Euromap 67 E iV CI ite Contact No Signal designation Description female Handling device LOW signal when the handling device robot mode switch is Opera robot operation tion with injection molding machine HIGH signal when the handling mode operation with device robot mode switch is No operation with injection molding handling device machine HIGH signal when the handling device robot is switched robot off Enable ejector back HIGH signal when the handling device robot enables the movement for ejector back The signal must remain HIGH at least until Ejector back signal is given by injection molding machine see table 1 injec tion molding machine signals contact No ZB3 UJ Q JJ K ee N O O1 NO Enable eject
131. ti in Manual Setup mode and pressing this button F8 Nozzle Heaters The nozzle heaters can be turned off on at any time with this button Note If the heater temperature is outside the preset limits the E Multi will not operate and an error will be displayed F10 Enable Servo Motors The injection and screw servo axis motor control is enabled by pressing this button The LED on the top left corner of this button will light up when the drives are enabled No mo tion will occur if this button is not lit up The status display is located at the top of the screen and is always shown The status display has 5 boxes of information oO very i Buy 112610 7 15 PM Mozzle Heating Application error 191 in zone 4 E Pee eee EEE Varning error status messages 11 2610 7 15 PM The current date and time The current user b AIUUMENXXLT A4 Rev 06 MWiolg 11 201 Waste ie E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 9 2 E Multi System Button Bar On the right hand edge of each screen is the system button bar The bar displays basic system information and controls basic functionality To operate functions simply touch the button using either your fingers or a blunt pointer Element Description gt oS Screw revolution rom Screw position in Inject pressure 42398 psi
132. tion 9 4 Rust Inhibitor 10 1 S Safety 3 1 3 2 Screen Navigation Button Bar 9 5 Servicing and Repairing your Controller 10 17 Servo Cables 7 1 Set Up 7 1 Start Up and Shut Down 8 1 Status Display 9 2 Switching Off 8 1 Switching On 8 1 System Button Bar 9 3 T Temperatures Screen 9 5 Torque Specifications 10 17 Touch Screen Interface 9 2 Transducer Output Check 11 1 Troubleshooting 11 1 U Unpacking 5 1 E E Multi User Manual AIUUMENXXLT A4 Rev 06 i Ce Viold Not under documentation control if printed May be revised without notice 11 2011 Maste Electronic version is available at www moldmasters com www moldmasters com A Mold Masters and the Mold Masters logo are registered trademarks of IS0 9001 CERTIFIED Mold Masters 2007 Limited 2011 AIUUMENXXLT A4 Rev 06 performance delivered
133. tion on the displayed curves The measurement values at this position are displayed in the legend Pressing the Cancel button exits the dialog Maximize Enlarges or shrinks the displayed graph display hide legend Tol band Activates or deactivates the display of the tolerance bands for all curves Trend Display hide the trend display The previous curves are displayed simultaneously with the current curves in a slightly lighter color than the current curve The number of curves to be displayed can be set in the settings dialog and is limited to 10 curves Reference Activates or deactivates the display of the reference curve for all curves Tolerance band Transfer Enables the transfer of curves into a monitoring range inside which the curve is to move The reference curve or the available trend curve can be referenced for every variable here as source A selection dialog is displayed in which a selection can be made whether the refer ence curve or the trend curves are used as source for the tolerance band If the trend curve or reference curve are not available the corresponding selection box is deactivated The selection box is also deactivated if no matching Tolerance proper ties were entered Element Display of the available curves Ref If this field is activated the tolerance band for the curve is trans ferred from the reference curve This field is only available if a refer ence curve for the curve is s
134. ur Controller WARNING Always isolate your controller at source before you open the unit to inspect it or replace fuses When it comes to machine maintenance there is very little that you need to do to look after it Replacement parts Mold Masters does not expect that you will need to repair any controller parts at board level other than fuses In the unlikely event of any board failure then we provide an excellent repair and exchange facility for all our customers Cleaning and Inspection Every environment suffers some degree of contamina tion necessitating the need to inspect the fan filters at regular intervals The filters are removable and a light tapping action removes loose dirt and dust Failure to do this reduces the flow of cooling air and may incur more expensive repairs if internal components E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com subsequently overheat If filters do become clogged they need to be replaced Replacement filters can be obtained from Mold Masters Please quote the model type and year of manufacture Any excess dust that has entered into the cabinet may be removed with a light brush and vacuum cleaner If the equipment is subject to vibration we recommend you use an insulated screwdriver to check that no terminals have become loose External cable looms should be checked to see th
135. ways replace pinched or damaged ther mocouples e Always operate the system using correctly installed J type thermocouples Handling and Lifting Precau tions When lifting the AlU follow the procedures out lined in Lifting the AIU on page 10 8 e Choose lift equipment that is rated for the prescribed load e Use recommended attachment points only See Lifting the AIU on page 10 8 e Define the load path the path and orienta tion the item will move in while it is being lifted and the location and orientation where it will be set down e Identify and avoid potential pinch points where an individual or a component of the lifting equipment or load may be caught between two surfaces e Secure and balance the load in the chain or lifting device before it is lifted more than a few inches e Minimize swinging by bringing the hook over the load appropriately e Inch powered hoists slowly into engage ments with loads E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available atwww moldmasters com 39 Controller Safety Most controller warnings pertain to electrical hazards It is crucial to comply with these warn ings to minimise any personal danger e DO NOT enter the cabinet without first ISO LATING the supplies there are unguard ed terminals inside the cabinet which may have a dangerous potential across them e Where a three
136. when the change over point has been reached and is then continued on the right time dependent y t graph for the hold pressure phase Menu Button Activate Deactivate Activates deactivates the measurement The button label changes with the current status of the measurement Configuration Opens the General Configuration dialog See Set up Configuration Dialog table for further details Set all ref curves This is used to select all displayed curves as reference curves Pressing the button again cancels the selection of reference curves Export Opens the Export Settings dialog for the export of measurements See Export Set tings table for further details Load original setup If data from a file was loaded and displayed via the import function this function can be returned to for the currently running measurement ZOOM XXx Enlarges the displayed area by the corresponding factor User defined An arbitrary area can be selected and then displayed magnified here Auto scale The x y scales are automatically adapted to the optimum scaling i E Multi User Manual AIUUMENXXLT A4 Rev06 Wiolg Not under documentation control if printed May be revised without notice 11 2011 Masters Electronic version is available atwww moldmasters com 9 29 E Multi A Actual value Shows the actual value cursor Shown by a red cross per curve that can be shifted using the position buttons Left Right to any posi
137. y be revised without notice 11 2011 Masters Electronic version is available at www moldmasters com 9 24 E Multi Carriage Nozzle Screen Kel les HMR S OT AAi MA OT OG 1 eT ey hii Tit I Pe A Mei GET z _ a ee eg BEE Carriage Pos KAN Contact fore Got Contactforce reached 4 Maks sura Barral and baki aro at tamperatune 2 Face und in Set Up mode ue 3 ove the carriage freards the hol nunver intel wnt the nogzie touches the inked ate Tha maie iaut Gaadicn be the carnage Slut of hirii egiii Cheik the it Camaya fend Retan nce bow Mote The Carrioge Pow should ka seentin a Esi Curaga Jorn Reine oneck bia ja ahh ime in ad Lip meda 5 The norte louch force can be set 0 lo 10 KHL 6 Fornoemal operation M wet the injerton uni to Manual or Auwiolready mode Loi delale Ee Pipes Te The carriage mode backward group allows selection of a carriage retract option The pressure and quantity for specific carriage paths levels are specified in the groups carriage forward and carriage backward Next to the input fields the pressure profiles red and the velocity profiles grey are shown in the form of curves on machines with position sensors for the carriage Description Deactivate carriage retract If this is selected the carriage doesn t move from the injection position After plasticizing the carriage retracts to its end limit or for a speci fied time depend
138. y be revised without notice Electronic version is available at www moldmasters com 29 30 31 32 33 34 35 36 37 38 39 the barrel housing until it clears the linear guide Lower the injection housing back onto the linear guide Remove the sling Re install twelve screws securing the housings to the linear guides tighten in a cross pattern and torque to 29Nm Slide the belt onto the pulleys Engage belt with pulleys so that there is little or no slack across the top Using a hook spanner rotate the belt tensioner eccenter until the belt deflection is correct see Belt Tension Check on page 10 13 Tighten the four screws securing the belt tensioner plate to the injection housing torque to 33Nm Move cable track back to operating position Install four screws securing cable track bracket to injection housing Reconnect water cooling lines to injection housing and motor Reconnect oil pressure transducer cable Reconnect motor power and encoder cables Purging the Barrel oS amp lf 9 10 10 15 WARNING Material purged from machine will be extremely hot Ensure protective guards are in place around the nozzle to pre vent molten plastic from splashing Set the controller to manual operation Switch barrel heaters on F8 Move carriage back away from mold F3 3 Enable servos F10 l Once barrel has reached injection temperature separate injection housing f
139. y plastic residue Removing the Barrel 16 17 18 19 20 21 22 23 24 25 NOTE If the screw is to be separated from the barrel follow instructions to remove screw first See Feed Screw Cleaning and Replacement on page 10 6 Remove guards E490 units remove six m8x25 screws securing the feed screw to the feed drive shaft E60 units unscrew the collet holding feed screw to feed drive shaft Remove four m8x35 screws from the feed block If the feed block will also be changed place a clean absorbent cloth under the water cooling connections on the feed block and disconnect the water lines remove bolt securing the vibrator Remove the feed block and tie back out of the way Remove the large nut securing the barrel to the barrel housing Remove wire ties as required to remove heater and thermocouple cables from support beam Remove four m5x12 screws securing heater con nector to support beam Remove barrel by pulling away from barrel housing until barrel clears barrel housing Barrel may now be lifted up and away from the support beam CAUTION Barrel assembly on E490 units may weigh up to 30kg E Multi User Manual Not under documentation control if printed May be revised without notice Electronic version is available at www moldmasters com 10 4 Transferring Heaters and Thermocou ples to New Barrel if required Heater and Thermocouple Removal 1 Number al
140. ycle measurements according to the number of shots Number of records Number of measurement points e g events 10 means that exactly 10 values per variable are recorded to file check box If activated the protocol is simultaneously saved to a file This parameter can also be modified at runtime of the measurement to file input field File name of the protocol file to printer If activated the protocol is simultaneously saved to a printer A printer dialog opens Error action The selection of an action which is executed when an error occurs This field can only be modified if output to file is activated ISO Imperial Specification of the unit system for the protocol The system wide selected unit system is not affected by this setting This field can only be modified if output to file is activated Absolute Relative Specification of the number representation for the protocol The system wide selected number representation is not affected by this setting This field can only be modified if output to file is activated Decimal separator The selection of the decimal separator that is used for the output is made here Default The default separator of the system is used Period A period is used as separator Comma A comma is used as separator This field can only be modified if output to file is activated k F pa E Multi User Manual AIUUMENXXLT A4 Rev06 ALF s Hm Mold Not under documentation control if

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