Mold-Masters E-Multi EM1 User Manual Download Page 90

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9.21 Heater Replacement

WARNING

Contact with the barrel can cause severe burns. Exercise caution and wear

appropriate PPE when working on or around a hot barrel.

CAUTION

Do not overtighten thermocouple sockets. It is extremely difficult to remove

seized sockets.

CAUTION

1. Move the carriage to the fully back position.
2. Remove the front and rear guards. Remove the outer barrel cover and the

inner barrel cover.

1. Rear guard
2. Front guard

1. Inner barrel cover
2. Outer barrel cover

9-23

MAINTENANCE

E-Multi User Manual

Summary of Contents for E-Multi EM1

Page 1: ...version 5 User Manual Original Instructions...

Page 2: ......

Page 3: ...ety Hazards 3 13 3 9 E Multi Servo Carriage Safety Hazard 3 15 3 10 E Multi Radial Unit Hazards 3 16 3 11 Safety Symbols on the E Multi Injection Unit 3 18 3 12 Safety Guards 3 19 3 13 E Multi Weight...

Page 4: ...nections 7 6 7 6 1 Cooling Water Schematic 7 7 7 6 2 Corrosion Caused by Condensation 7 7 7 6 3 Cooling Water Quality 7 7 7 6 4 Coolant and Additives 7 8 7 7 Connection to a Diagnostic Computer Option...

Page 5: ...Maintenance 9 20 9 20 Barrel Head Removal and Replacement 9 22 9 21 Heater Replacement 9 23 9 22 Feed Assembly Removal and Replacement 9 27 9 22 1 Remove Feed Assembly 9 27 9 22 2 Install the Feed Blo...

Page 6: ...Spare Parts for the E Multi Radial 11 26 Section 12 Servo Carriage Option 12 1 12 1 Introduction 12 1 12 2 E Multi Servo Carriage Specifications 12 1 12 3 Material Handling 12 2 12 3 1 Preparation 12...

Page 7: ...izontal Position Adjustment 14 5 14 4 3 Front or Back Leg Position 14 5 14 4 4 Counter Weight Kit Optional 14 6 14 4 5 Assembly 14 7 14 5 Leveling Castors 14 8 14 6 Mold Installation 14 8 14 7 Mold Re...

Page 8: ...gure 7 11 Wireless network icon 7 10 Figure 8 1 E Multi main power switch 8 1 Figure 8 2 Button strip below controller display HMI 8 2 Figure 9 1 Comparison of clean and contaminated cooling lines 9 9...

Page 9: ...nt or back leg position 14 5 Figure 14 7 Heavy duty stand horizontal position adjustment 14 5 Figure 14 9 Heavy duty stand counter weight kit 14 6 Figure 14 10 E Multi stand leveling castors 14 8 Figu...

Page 10: ...1 Cooling System Water Limits 7 6 Table 7 2 Basic Water Quality Specification 7 7 Table 9 1 Preventive Maintenance Schedule 9 1 Table 9 2 Screw Torque Specifications 9 1 Table 9 3 Nozzle Tip and Locki...

Page 11: ...umentation This manual is part of the documentation package for your order and should be referenced along with the following documents included in the package The Bill of Materials BOM Together with t...

Page 12: ...sibility for documentation of products or systems if they are relocated or resold outside the intended country of destination as stated on the accompanying invoice and or waybill 1 7 Copyright 2020 Mo...

Page 13: ...ue bar Bar 14 5 psi in Inch 25 4 mm kg Kilogram 2 205 lb kPa Kilopascal 0 145 psi gal Gallon 3 785 l lb Pound 0 4536 kg lbf Pound force 4 448 N lbf in Pound force inch 0 113 Nm l Litre 0 264 gallon mi...

Page 14: ...4191 6077067 6079972 6095790 6099780 6113381 6135751 6162043 6162044 6176700 6196826 6203310 6230384 6270711 6274075 6286751 6302680 6318990 6323465 6348171 6350401 6394784 6398537 6405785 6440350 645...

Page 15: ...own KunShan City Jiang Su Province People s Republic of China tel 86 512 86162882 fax 86 512 86162883 china moldmasters com JAPAN Mold Masters K K 1 4 17 Kurikidai Asaoku Kawasaki Kanagawa Japan 215 0...

Page 16: ...k y Ata ehir Istanbul Turkey tel 90 216 577 32 44 fax 90 216 577 32 45 turkey moldmasters com Mold Masters International Representatives ARGENTINA Sollwert S R L tel 54 11 4786 5978 e sollwert fiberte...

Page 17: ...ct its personnel in the safe operation of equipment including the use of all the safety devices Provide its personnel with all necessary protective clothing including such items as a face shield and h...

Page 18: ...g machine hazard areas Top view with guards removed Front view with guards removed 2 10 5 3 Top View with Guards Removed 2 5 9 1 4 7 6 9 8 Front View with Guards Removed 1 Mold area 2 Clamping mechani...

Page 19: ...of the plasticizing and or injection unit including nozzle Movements of parts of the power operated nozzle shutoff and their drives Over pressurization in the nozzle Thermal Hazards Burns and or scal...

Page 20: ...ping action caused by hose assembly failure Possible release of fluid under pressure that can cause injury Thermal hazards associated with hot fluid Area Inside the Guards and Outside the Mold Area Se...

Page 21: ...protective equipment such as face shields and use heat resistant gloves when working around the feed inlet purging the machine or cleaning the gates of the mold Remove purged material from the machine...

Page 22: ...ot surfaces which could result in burns Keep flammable liquids or dust away from the hot surfaces as they could ignite Follow good housekeeping procedures and keep floors clean to prevent slips trips...

Page 23: ...Accumulator Sudden release of high pressure gas or oil can cause death or serious injury Discharge all gas and hydraulic pressure before disconnecting or disassembling accumulator Warning Hot Surface...

Page 24: ...onnected to the thermocouple connectors and vice versa For mixed power and thermocouple connections ensure that the power and thermocouple connections have not been wired incorrectly Communications In...

Page 25: ...ce to avoid potential risk of electrical shock Often power sources are inadvertently turned on or valves are opened mistakenly before maintenance work is completed resulting in serious injuries and fa...

Page 26: ...de energized and appropriately locked out This can include gravity compressed air hydraulics steam and other pressurized or hazardous liquids and gases see table below 6 When the work is completed pr...

Page 27: ...ckout attachments and tag valves Bleed off excess air If pressure cannot be relieved block any possible movement of machinery Kinetic Energy Energy of a moving object or materials Moving object may be...

Page 28: ...case of hydraulic needle valve systems drain the oil from the lines and cylinders and dispose it in an environmentally responsible manner 3 The electrical components are to be dismantled separating t...

Page 29: ...ing hazard molten material 4 Entanglement hazard belt drive 5 Hot surface hazard 6 Mandatory lift points 3 8 E Multi Injection Unit Safety Hazards Figure 3 2 E Multi safety hazards 3 13 SAFETY E Multi...

Page 30: ...ys keep guards in place Molten Material Splashing Hazard High pressure molten plastic may spray from the nozzle Always use personal protective equipment PPE High temperature molten plastic may spray f...

Page 31: ...eaters could ignite flammable liquids or dust Ergonomic Hazards Lift Hazard Attempting to lift or support the unit during installation could result in injury Combination Hazards Failure Disorder of Co...

Page 32: ...tanglement hazard 3 Hot surface hazard 4 Splashing hazard molten material 5 Pinch point 6 Grounding 7 Electric shock hazard 8 Body crush hazard Figure 3 3 E Multi Radial safety hazard locations 3 16 E...

Page 33: ...dial carriage assembly and the slot in the vertical beam during carriage movement Keep fingers and hands away from this area Shearing Hazard A shearing hazard exists between the barrel barrel cover no...

Page 34: ...osed hot surfaces will cause serious burn injury Wear adequate personal protective equipment PPE when working near these areas Warning Entanglement Hazard Belt Drive A person could become entangled in...

Page 35: ...the machine with guards removed CAUTION When installing the machine guards front and rear covers and the barrel covers check that they do not pinch water lines air lines or thermocouple wires when the...

Page 36: ...hipping Dimensions and Weight Model Length mm in Width mm in Height mm in Weight kg lb EM1 EM2 1520 60 740 29 840 33 300 660 EM3 2080 82 840 33 910 36 500 1100 EM4 3302 130 914 36 991 39 1300 2860 ER1...

Page 37: ...ngs 3 14 1 Prior to Lifting the E Multi Injection Unit 1 Choose lift equipment that is rated for the prescribed load See equipment tag 2 Define the load path the path and orientation the item will mov...

Page 38: ...ions Table 3 11 EM1 EM2 EM3 Vertical Lift Connections EM1 EM2 EM3 Connect sling to motor end of the support beam using one 16 mm 5 8 in shackle in lifting hole Connect sling to motor end of the suppor...

Page 39: ...using two 16 mm 5 8 in shackles in the lifting holes NOTE EM1 EM2 units require blocks or shipping brackets when set down horizontally to prevent damage to the linear actuator Connect one sling A to...

Page 40: ...the slings are on either side of the motor 3 Connect slings to the barrel end of the support beam using two 25 mm 1 in shackles in the lifting holes 4 Ensure that the slings are securely attached to...

Page 41: ...Purge cooling water from the system See Purge Cooling Water from System on page 9 8 9 Disconnect water pneumatic I O heater and motor connections 10 Remove the E Multi injection unit from the stand 11...

Page 42: ...ps 5 Attach and tighten the two M16 screws to the holes in the lifting bar Torque to 101 Nm 75 ft lbs 6 Check that the hitch pins are secure 7 Attach the slings to the shackles on the lifting bar The...

Page 43: ...ect slings to the barrel end of the support beam using two 25 mm 1 in shackles in the lifting holes 3 Attach the barrel end slings to the other lifting machine 4 At the same rate slowly lift the E Mul...

Page 44: ...Multi injection unit on a surface that will not mar the adapter plate wood cardboard etc 9 Carefully remove the lower slings and shackles Do not remove the E Multi injection unit from the upper lifti...

Page 45: ...Multi injection unit to a vertical position Use this procedure if only one lifting machine is available 1 Remove any slings from the lower adapter plate position 2 Attach the slings from the lifting...

Page 46: ...to ensure proper nozzle contact 3 Raise the E Multi injection unit off the floor using the lifting machine 4 Clean the adapter plate mating surfaces 5 Lift the E Multi injection unit into place above...

Page 47: ...support beam by feeding it through the lifting hole with sling on either side of the motor Connect other sling B to barrel end of the support beam using two 25 mm 1 in shackles in lifting holes A B Fi...

Page 49: ...er 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 10 Mounting Holes Used for attaching the E Mult...

Page 50: ...on page 3 20 for weight dimensions and safe lifting instructions 5 1 Shipping Contents E Multi Crate E Multi injection unit Oil fill kit optional Lifting hardware Horizontal and vertical feed blocks...

Page 51: ...injection unit ships with lifting hardware installed Use a two leg chain bridle to remove the E Multi injection unit from the crate See E Multi Weight Specifications on page 3 20 5 3 Inspection 1 Che...

Page 52: ...ut in the controller and mold machine before installation of the E Multi injection unit into the system WARNING LIFT POINTS When doing any work on the machine that requires moving and lifting the mach...

Page 53: ...orrect torque See Screw Torque Specifications on page 9 1 IMPORTANT Please refer to the installation drawing supplied with unit for complete information on services and connections 1 Clean the molding...

Page 54: ...m DO NOT enter the cabinet without first ISOLATING the supplies OR having a qualified person selecting the BYPASS SWITCH to ON to gain live access to the controller There are unguarded terminals insid...

Page 55: ...uld be installed in a clean dry environment where the ambient conditions do not exceed the following limits Temperature 0 to 45 C Relative Humidity 90 non condensing 6 4 E Multi User Manual INSTALLATI...

Page 56: ...re not routed through the cable track All cables should be routed so they do not interfere with the mold or molding machine operation 7 1 1 Route and Connect Servo Cables WARNING Make sure that the ca...

Page 57: ...he MOLD END of the heater cable to the connector on the E Multi injection unit 3 Connect the MOLD END of the I O cable to the connector on the E Multi injection unit 4 Route the cables towards the mot...

Page 58: ...couple connection 4 Zone connections for hot runner control option 5 Remote HMI connection 6 EM1 2 3 barrel heater and thermocouple connection 7 Injection molding machine E67 connection 8 E67 connecti...

Page 59: ...e cable always connects to the injection molding machine E67 connection on the controller If used with an E67 injection molding machine the cable plugs into the injection molding machine s E67 connect...

Page 60: ...ll drastically shorten the life of the pneumatic vibrator Damage to the vibrator as a result of using air pressure over 4 13 bar 60 PSI is not covered under warranty CAUTION 1 Install a 1 8NPT fitting...

Page 61: ...folds Figure 7 8 EM3 EM4 Servo motor cooling connections Both inlet and outlet are 1 4NPT connections If the 3 8NPT ports are used then the 1 4NPT ports must be plugged Contact your local service repr...

Page 62: ...ing Water Quality CAUTION Use clean water Contaminated water will clog the servo motor cooling channels It may result in decreased cooling performance and necessitate replacement of the servo motors C...

Page 63: ...rrosion will not occur Figure 7 10 Water quality specification tag on E Multi 7 6 4 Coolant and Additives CAUTION Damage caused by corrosion or condensation is not covered under warranty CAUTION If th...

Page 64: ...o the Ethernet port on the diagnostic computer Note that the diagnostic computer may differ from the one shown 3 Connect the diagnostic computer power supply and connect to mains power Use the include...

Page 65: ...r The wired connection must be used to connect to the controller Mold Masters does not support alternate network configurations Connection problems when using alternate configurations are not covered...

Page 66: ...ergency The controller uses computer technology and should be switched off in stages A sequenced method for switching on and off protects the console and keeps the switched load to a minimum to extend...

Page 67: ...MI The E Multi controller can be used in Manual Setup and Auto Ready mode 8 4 Switch Off Shutdown Mold Masters recommends that you use the console to shutdown the heating load and only use the main cu...

Page 68: ...ut E Multi Radial Option only Check every 3 months add grease if necessary Belt Tension Check every 6 12 months adjust if necessary 9 1 Preventive Maintenance Schedule 9 2 Screw Torque Specifications...

Page 69: ...lb ft Feed Block EM1 M8 23 17 EM2 M8 28 20 5 EM3 M10 50 37 EM4 M12 65 48 9 4 Belt Tension Specifications Table 9 5 Belt Tension Specifications Description Model Hz Belt Tension EM1 EM2 216 241 EM3 150...

Page 70: ...hium grease Kl ber Lubrication ISOFLEX NBU 15 Shell Gadus S2 Loctite 30530 Barium based thickening agent Kl ber Lubrication Staburags NBU 8EP Lithium based thickening agent Kl ber Lubrication Kl berpl...

Page 71: ...mm 1 0 in further This will decompress the screw and make sure the pressure value is showing idle pressure 4 Check the pressure reading on the controller If the pressure is below the lower limit the h...

Page 72: ...ut and the pressure will drop significantly If this happens open the bleed screw about turn and examine the oil that comes out NOTE The oil should be clear without bubbles and not foamy 6 Close the bl...

Page 73: ...22 2 180 31 612 56 43 806 623 25 1 688 24 480 43 33 624 482 EM3 100 200 22 4 135 59 969 81 57 1 178 830 2 0 1 4 29 21 2 16 2 11 25 3 202 46 440 63 44 912 643 28 2 553 37 022 50 35 727 513 32 1 954 28...

Page 74: ...reads of the fill hole 4 Fill with synthetic gear oil as indicated in Table 9 6 on page 9 3 as required NOTE For continued warranty support use only approved synthetic gear oil as specified in Table 9...

Page 75: ...screw position as almost at 0 8 Press and release the F5 button to start screw rotation Once no more material runs out of the nozzle press and release F5 again 9 Disable servo motors 10 Turn off barre...

Page 76: ...high servo motor temperature at or above the warning or alarm levels default 75 C and 80 C 167 F and 176 F respectively may also indicate that cooling lines are contaminated A B C A New 3 8 water tube...

Page 77: ...Adapter plates are specific for each E Multi injection unit and mold pair Adapter plates may not be as shown 1 Purge the system of plastic and cooling water 2 Place the E Multi injection unit in hori...

Page 78: ...the screws loose If required install adapter blocks with the adapter plate 8 Remove the linear actuator manual access port cover to expose the jam screw and adjusting screw 9 Loosen the jam screw on...

Page 79: ...usion Adjustment Toggle Link Models on page 9 13 When protrusion is correct tighten the clamping screw to the proper torque See Table 9 2 Screw Torque Specifications on page 9 1 3 2 1 1 Nozzle tip 2 A...

Page 80: ...ion 9 16 Nozzle Protrusion Adjustment Toggle Link Models 9 16 1 Introduction WARNING This procedure must be done with the barrel at operating temperature Wear appropriate personal protective equipment...

Page 81: ...usion without these blocks CAUTION It is also necessary to check the manifold inlet sometimes also called the sprue bushing or backplate depth to verify that it is within the allowable limits of the E...

Page 82: ...be screwed far enough back to not touch the mold when moving the carriage forward 4 Use the F4 button to move the carriage forward until the clevis link touches the stop pin as shown below On EM1 mode...

Page 83: ...d the stop pin The clevis link should be within 0 3 16 in of the stop pin On EM1 models the clevis link should be visible in the 10mm window but not completely covering it This is the reference positi...

Page 84: ...nozzle is just touching the manifold inlet This is the reference position as described in 9 16 on page 9 13 4 Choose Set 5 Press the F4 button on the controller to increase nozzle contact force Conti...

Page 85: ...ion graphic will show the nozzle tip in the green region If the nozzle is not adjusted correctly the carriage will move to a preset position and tell the operator to adjust the nozzle using the manual...

Page 86: ...tup mode with heats on and up to operating temperature carriage referenced and carriage retracted from the mold 2 Navigate to the screw settings page 3 In the lower left hand area tap the Reference bu...

Page 87: ...urrounding the shut off nozzle bolt will accumulate plastic material The material must be regularly cleaned out or the bolt may not function properly or it may seize In a vertical orientation any exce...

Page 88: ...pin Compressed air can be used to blow the plastic from the bolt NOTE If the bolt is seized completely a heat gun may be used to help soften the residual plastic 4 If necessary replace the heater band...

Page 89: ...barrel head should be easily removed in the hot condition It is not necessary to remove the nozzle tip from the barrel head to remove the barrel head 3 Perform maintenance to the barrel screw or check...

Page 90: ...n thermocouple sockets It is extremely difficult to remove seized sockets CAUTION 1 Move the carriage to the fully back position 2 Remove the front and rear guards Remove the outer barrel cover and th...

Page 91: ...m the connector base 7 Unscrew the heater wires from the insert 8 Loosen the lock nut on the strain relief 9 Pull the heater cable out of the connector base 10 Remove the connector base 11 Loosen the...

Page 92: ...on heaters NOTE Take care that heater cables are not twisted when installing heaters 18 For socket type thermocouples a Apply anti seize compound to thermocouple sockets and install b Tighten to fing...

Page 93: ...the lock nut on the strain relief 26 Insert the heater wires into the terminals on the connector insert and tighten 27 Reinstall the connector insert 28 Test heater resistance using a multimeter on t...

Page 94: ...rizontally it is recommended that pellets be removed using a vacuum cleaner to prevent pellets from spilling onto the machine 9 22 1 Remove Feed Assembly 1 Purge cooling water from E Multi injection u...

Page 95: ...lets are not purged from the unit use a vacuum cleaner to remove pellets from feed block and barrel 8 Disconnect the cooling lines 9 Remove the feed block from the system 10 Check the feed block and b...

Page 96: ...ten 3 In a cross pattern torque the screws in steps ensuring that the gap for the entire contact surface remains uniform as the screws are tightened See Table 9 2 for torque specifications Gap to be u...

Page 97: ...o can result in serious injury 1 Move the machine to a work surface See Move the E Multi Injection Unit for Maintenance on page 9 9 2 Remove front and rear guards 1 2 1 Rear guard 2 Front guard 3 Clea...

Page 98: ...the collet securing the feed screw to the feed drive shaft 1 2 1 Feed screw 2 Collet right hand thread b Push the feed screw the collet and the retaining nut out of the feed drive shaft toward the bar...

Page 99: ...t the screw retaining bushing and the screw collar 1 2 3 4 1 Screw collar 2 Feed screw 3 Screw retaining bushing 4 Retaining bushing bolt All Units 2 Push the feed screw towards the barrel as far as p...

Page 100: ...the correct step 2 for your system The remaining steps are the same for all units EM1 EM2 Units 2 Secure the feed screw to the drive shaft a Apply anti seize compound to screw threads and screw nut ou...

Page 101: ...the feed screw into the barrel Once the end protrudes past the barrel end far enough to install the screw collar install the splined ring b Install the screw collar retaining bushing and bolt Torque...

Page 102: ...ew Torque Specifications on page 9 1 for torque specifications All Units 3 Reinstall the front and rear guards Ensure the gap between the guards and the injection housing is the same all around the ho...

Page 103: ...required so that the screw can be reattached to the injection housing without having to move the housings If the screw is to be separated from the barrel follow instructions to remove the screw first...

Page 104: ...the barrel to the barrel housing 6 Remove the ground wire screw and wire ties required to remove the heater and the thermocouple cables from the support beam 1 3 2 1 Connector screw 2 Heater wires 3...

Page 105: ...Barrel See Heater Replacement on page 9 23 8 Disconnect the barrel housing thermocouple Barrel housing thermocouple 9 Slide the barrel out of the barrel housing 9 38 E Multi User Manual MAINTENANCE 2...

Page 106: ...ith the flat face facing up 2 Install the large barrel nuts onto the end of the barrel and tighten finger tight 3 Install the feed block onto the barrel housing See Install the Feed Block on page 9 29...

Page 107: ...g and Replacement on page 9 30 7 Reinstall the front and rear guards Make sure the gap between the guards and the injection housing is the same all around the housing Also make sure there is no interf...

Page 108: ...ieved See Belt Tension Specifications on page 9 2 4 In a cross pattern tighten the eccentric shaft locking plate screws and torque See Screw Torque Specifications on page 9 1 5 Check belt tension agai...

Page 109: ...ossible into the barrel 7 Turn the controller off 8 Purge the water lines See Purge Cooling Water from System on page 9 8 9 Remove the screws securing the eccentric shaft locking plate 10 Rotate the e...

Page 110: ...ble track 17 Position the new belt as shown below 18 Mark the position of the linear guide relative to the injection housing See Figure 9 5 Figure 9 5 Linear guide position 19 Loosen the linear guide...

Page 111: ...nect Servo Cables on page 7 1 28 Install the belt over the idler and the toothed pulleys Take care that the pulleys do not change orientation relative to one another 29 Slide the belt onto the pulleys...

Page 112: ...how output similar to those in the same area If the output is significantly different replace the thermocouple If the new thermocouple shows 100 C 148 F there is probably a wiring problem Check the wi...

Page 113: ...tube If the vibrator is working properly it should start to vibrate when compressed air is applied 2 If the vibrator is working reconnect the air line to the valve and disconnect the valve cable Apply...

Page 114: ...controller automatically disables the motors when the alarm temperature is reached The motor temperature can be monitored in real time on the E Multi controller For more information about motor tempe...

Page 115: ......

Page 116: ...than the mold The E Multi Radial has a servo controlled carriage axis which allows the system to be operated in sprue break mode or in continuous nozzle contact mode In sprue break mode the nozzle ret...

Page 117: ...5 1 3 4 1 Vertical beam assembly with E Multi 2 Horizontal beam assembly 3 X axis brake 4 Clamping bolts 5 Adapter plate 11 3 E Multi Radial Components 11 2 E Multi User Manual E MULTI RADIAL OPTION...

Page 118: ...slings to the unit as shown in Figure 11 2 Figure 11 3 and Figure 11 4 Use the slings provided in the crate Note the approximate point of the center of gravity 4 Raise the lifting machine just enough...

Page 119: ...he E Multi injection unit and the E Multi Radial have not been damaged in transit 2 Check all wires and cables Ensure they are not kinked or damaged and are still connected properly 3 Check for oil le...

Page 120: ...Radial has a high center of gravity which can shift during installation Read all instructions prior to starting the installation procedure The center of gravity will move forward as the vertical beam...

Page 121: ...er cable track bracket and remove the two M10 shipping screws Remove screws from both sides Remove two M10 shipping screws 3 Slowly start raising the lifting machine causing the upper vertical beam to...

Page 122: ...sides 2 both sides 3 both sides 4 both sides 5 beneath center b Torque to half the recommended torque setting following the same order as shown See Screw Torque Specifications on page 9 1 2 3 1 1 Lif...

Page 123: ...water and air lines 7 Release the orange X Axis brake and slide the unit back until it is balanced and stable 8 Remove the lifting slings Attach the appropriate lifting devices to the hole at the top...

Page 124: ...oller connection procedure See Controller Installation on page 6 3 and System Setup on page 7 1 Note that the E Multi Radial has an additional set of cables for the carriage axis servo motor and the c...

Page 125: ...tic is likely Contact an E Multi representative for recommended design guidelines for the spherical nozzle tip inlet geometry The clamping bolts are special hex flange bolts yellow zinc in color and d...

Page 126: ...ct rotation position required for final nozzle concentricity Plunger 4 Loosen the X Axis brake Use the handles to position the E Multi Radial to the correct X Axis position Tighten the X Axis brake 5...

Page 127: ...e cleaned again 12 Perform a carriage calibration following the procedure Calibrate the Carriage Home Position on page 9 17 13 Loosen the X Axis brake 14 With the controller in Manual mode move the un...

Page 128: ...ets the mold touch position to the 0 0 mm in the setup profile screen The carriage then moves to 10 mm 0 4 in position At this position the E Multi is ready to be switched to Auto mode NOTE You may se...

Page 129: ...into the lubrication access hole There is a shearing hazard if the carriage moves and serious injury can occur The E Multi Radial carriage assembly requires periodic maintenance of the ball screw nut...

Page 130: ...11 10 1 2 EM3 and EM4 Models 1 Move the carriage to the fully up position 2 Remove the access cover 3 Bring the carriage down approximately 50 mm 2 in to access the grease nipple for the spring pack a...

Page 131: ...le 11 2 for lubrication specification Carriage ball screw nut lubrication position Carriage down 130 mm from fully up position 6 Lubricate the four linear guides on the lower assembly Lower assembly l...

Page 132: ...se contact your Mold Masters representative for instructions Removal of any of the carriage assembly including the servo motor any of the servo motor components the gear box or any of the mounting scr...

Page 133: ...ten the clamping screw so much that the unit locks as this will prevent proper alignment of the nozzle to the inlet CAUTION 1 Remove adapter plate from shipping crate 2 Place the adapter plate on the...

Page 134: ...r plate Insert and hand tighten the 4 bolts M20X90 in the accessible holes 5 Unclamp the horizontal beam assembly with the clamping screw Rotate the screw counterclockwise until the end of the head is...

Page 135: ...position x axis is parallel to tiebars Torque the other two bolts to 339 Nm 250 ft lbs 8 Use front hand crank and move the x axis so that the vertical beam mounting flange is above the turret 9 Lock...

Page 136: ...g bar with a choker configuration 13 Lift the vertical beam with two lifting devices If a crane and forklift are used the crane should lift the lifting bar end 14 Change the beam orientation so that t...

Page 137: ...izontal beam and hand tighten 18 Torque the lower four bolts M16X50 into the vertical beam to 122 Nm 90 ft lbs in a cross pattern and repeat for the upper four bolts into the vertical beam 19 Torque t...

Page 138: ...th 2 flat head screws M6X16 Torque the screws to 10 Nm 7 4 ft lbs 25 Cut the cable ties which secures the small cable track to large cable track 26 Install the small cable track to the barrel housing...

Page 139: ...ransducer on the injection housing 32 Connect cooling lines to the manifold on the injection housing 33 Connect carriage motor cables to carriage motor Make sure that the cables do not interfere with...

Page 140: ...emperature use the hand wheels on the lower base to position the E Multi nozzle as close as possible to the manifold inlet 41 Press the F1 button It puts the controller in setup mode The F1 LED should...

Page 141: ...in the nozzle with the system clamped 55 Calibrate the carriage from the screw settings page Verify that the barrel does not deflect when the nozzle makes contact 56 Navigate to the carriage setup pa...

Page 142: ...mode the nozzle retracts automatically from the sprue bushing The nozzle retracts and extends with each injection cycle as required for parting line injection applications 12 2 E Multi Servo Carriage...

Page 143: ...old Set up the controller before you use the E Multi Servo Carriage Set up the controller before you use the E Multi Radial 1 Make sure that the E Multi is in Setup mode and the servo motors are turne...

Page 144: ...the Ball Screw The E Multi Servo Carriage assembly requires periodic maintenance of the ball screw nut 1 Move the carriage back to the rear hardstop 2 Remove the support beam cover Unscrew 4x button h...

Page 145: ......

Page 146: ...r drives when the motor temperature reaches 85 C 185 F 13 1 1 Closed Loop Specification Pump high flow rate 3 6 LPM 1 gal min Pump low flow rate 1 6 LPM 0 42 gal min Pump pressure bypass opens at 4 1...

Page 147: ...ke sure that the E Multi injection unit is flushed and completely purged of water Disconnect the pump before you empty the reservoir Failure to do so will damage the pump if it runs dry CAUTION 1 Blow...

Page 148: ...w the hose fittings from the ports of the heat exchangers 8 Unscrew and remove the heat exchanger coil from the reservoir plug NOTE Installation is the reverse of disassembly 13 2 3 Troubleshooting Ta...

Page 149: ......

Page 150: ...rious injury as well as damage to the machine 14 1 Introduction E Multi stands are designed to support the E Multi injection machines when used in a horizontal feed orientation 14 2 Stand Options E Mu...

Page 151: ...EM1 EM2 models 2 Top column with adapter bracket for EM3 models 3 Base column 4 Column hitch pin 5 Horizontal adjustment lever 6 Base frame 7 Leveling castors Figure 14 3 Compact stand main component...

Page 152: ...away from the mold Push the lever forward towards the machine to move the adapter plate toward the mold Figure 14 4 Compact stand horizontal position adjustment 14 3 3 Assembly The compact stand is s...

Page 153: ...guides 4 Top Bottom leveling plates 5 Top column 6 Clamping plates and screws 7 Base column 8 Base frame 9 Stabilizing leg adjusting screw and rod nut 10 Stabilizing leg clevis and cotter pin 11 Stabi...

Page 154: ...th the floor to prevent the assembly tipping The stand can be placed with the lead leg of the base frame under the front or the rear of the E Multi injection unit The most stable configuration is with...

Page 155: ...ility to the E Multi injection unit stand assembly or in cases where the stabilizing leg will not fit under the injection molding machine The counter weight brackets are installed onto the lead leg of...

Page 156: ...in Secure the clevis pin with the cotter pin 2 1 3 1 Clevis pin 2 Clevis bracket 3 Cotter pin 3 Install the stabilizing leg adjusting screw into the screw nut in the end of the stabilizing leg Adjust...

Page 157: ...UTION Do not move the stand with the unit installed without crane support CAUTION 1 Roll the assembled empty stand close to the injection molding machine i e within 3 m 9 84 ft 2 Install adapter plate...

Page 158: ...zle and mold inlet are properly aligned 11 Move the stand as far towards the injection molding machine possible This will ensure the largest possible clearance when moving the injection unit away from...

Page 159: ...eavy Duty Stand Slowly lower the stabilizing leg until it makes light contact with the floor then tighten the adjusting screw by a 1 2 turn more Do not overtighten this screw or it will raise the leve...

Page 160: ...the injection molding machine Heavy duty stand move the linear rail fully back on the ball guides and lock 3 Attach the lifting devices and crane to the E Multi injection unit and stand assembly and...

Page 161: ......

Page 162: ...lding machine and the handling device robot is achieved by the plugs specified below For the injection molding machine and the handling device robot the plug contacts should be capable of taking a min...

Page 163: ...old opening position See table 1 injection molding machine signals contact No ZA7 The signal remains HIGH to the end of mold opening position Two sequences are possible with this signal a Mold opening...

Page 164: ...ignal when the core pullers 1 are in position 2 See contact No B6 It is recommended to have LOW signal when the core puller sequence is not in use ZB7 Optional Core pullers 2 in position 1 Core puller...

Page 165: ...ning 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 contact No ZA8 if the optional s...

Page 166: ...e movement of core pullers 1 to position 2 Enable core pullers 1 to remove the molding HIGH signal when the handling device robot is in position to enable the movement of the core pullers 1 to positio...

Page 167: ...1 Manganese as Mn ppm 0 05 0 05 Total Iron as Fe ppm 0 5 0 1 Anions Free Chlorine as Cl2 ppm 0 1 0 Chloride as Cl ppm 400 400 Sulfate as SO2 ppm 300 300 Silica as SiO2 ppm 150 150 Microbiological Act...

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Page 169: ...to a Work Surface for Maintenance 9 9 P Purging Cooling Water from System 9 8 Purging Plastic from System 9 8 R Release Details Document 1 1 S Safety Hazard Areas 3 2 Lockout 3 10 Safety symbols Gene...

Page 170: ...tel 1 248 544 5710 e usa moldmasters com MEXICO tel 52 442 713 5661 sales e mexico moldmasters com UNITED KINGDOM tel 44 1432 265768 e uk moldmasters com POLAND tel 48 669 180 888 sales e poland mold...

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Mold-Masters E-Multi EM1, User Manual

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