Milacron mfc hmanual

MFCHMFCHTEMPERATURE CONTROLLER
MILACRON MODEL
INSTRUCTION MANUAL • INSTALLATION • OPERATION • MAINTENANCE
PROCESS SUPPORT BUSINESS
4165 Halfacre Road Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
I.O.M. #032 8/00

INSTRUCTION MANUAL
MODEL ‘MFCH’
TEMPERATURE CONTROLLER
OPEN CIRCUIT MODEL
COVERING
INSTALLATION
OPERATION
MAINTENANCE
MFCHMFCHTEMPERATURE CONTROLLER
MILACRON MODEL
4165 Halfacre Road Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584

MILACRON ‘MFCH’ MOLD TEMPERATURE CONTROLLER
Page: 4
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
TABLE OF CONTENTS
1.0 SAFETY 7
1.1 Introduction 8
1.2 Safety precautions 9
1.2.1 Personal safety attitudes and actions 10
1.2.2 Work area 12
1.2.3 Setup and operations 13
1.2.4 Maintenance safety 15
1.2.5 Ventilation safety 20
1.2.6 Materials 20
1.3 Lifting and carrying 20
1.3.1 Lifting and carrying 20
1.3.2 Lifting and carrying by mechanical device 21
1.4 Occupational safety and health act
color coding system 22
1.5 OSHA lockout or tagout system 23
2.0 GENERAL 25
2.1 Safety 26
2.2 Efficiency 26
2.3 Component placement 27
3.0 INSTALLATION 29
3.1 General 30
3.2 To and from process connections 30
3.3 Water supply connection 31
3.4 Drain connection 31
3.5 Electrical connection 32
4.0 START UP SEQUENCE 35
4.1 General 36
4.2 System fill/operations procedure 36
4.3 Instrument operation 42
4.4 Shut down/disconnect sequence 53
5.0 TROUBLESHOOTING 55
5.1 Unit will not start (“power” light off) 56
5.2 Unit will not start (“power” light on) 56
5.3 Unit stops 57
5.4 Unit overheats 58
5.5 Unit underheats 59
5.6 Pressure relief valve leaks 60
6.0 MAINTENANCE 61
6.1 Pump seal replacement 62
6.2 Heating cylinder replacement 65
6.3 AVT modulating valve service 66
6.4 Probe calibration 69
6.5 Voltage changeover 71
6.6 Sensor probe service 73
6.7 Pressure switch service 74

Page: 5
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
‘MFCH’ MOLD TEMPERATURE CONTROLLER
6.8 MFCH instrument service 75
6.9 Flow meter service 77
7.0 MFCHCOMPONENTS 79
7.1 Mechanical system 80
7.2 Electrical system 82
8.0 RELATED DRAWINGS 85
8.1 MFCH physical 86
8.2 MFCH electrical 87
8.3 MFCH circuit schematic 88
8.4 MFCH regulator/bypass installation 89
8.5 MFCH dual zone dolly 90
8.6 MFCH stacking rack 91
9.0 APPENDIX 93
9.1 AS5 pump parts list - 1/2 hp to 1 hp 94
9.2 AS5 pump parts list - 1 1/2 hp to 3 hp 95
9.3 Parts list 96
9.4 Operation of mold purge 97
9.5 Dip switch setup 98
9.6 Advanced setup 99
9.7 SPI commands 101
9.8 Optional alarm operation 104

Page: 6
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
THIS PAGE INTENTIONALLY BLANK

Page: 7
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
1.0 SAFETY
1.1 INTRODUCTION
1.2 SAFETY PRECAUTIONS
1.2.1 PERSONAL SAFETY ATTITUDES AND ACTIONS
1.2.2 WORK AREA
1.2.3 SETUP AND OPERATIONS
1.2.4 MAINTENANCE SAFETY
1.2.5 VENTILATION SAFETY
1.2.6 MATERIALS
1.3 LIFTING AND CARRYING
1.3.1 LIFTING AND CARRYING
1.3.2 LIFTING AND CARRYING BY MECHANICAL DEVICES
1.4 OCCUPATIONAL SAFETY AND HEALTH ACT COLOR CODING SYSTEM
1.5 OSHA LOCKOUT OR TAGOUT SYSTEM

Page: 8
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
CAUTION
A CAUTION IS USED TO EMPHASIZE OPERATING
PROCEDURES, PRACTICES, ETC., WHICH IF NOT
STRICTLY OBSERVED, MAY RESULT IN MINOR
PERSONAL INJURY OR DAMAGE TO MACHINERY.
WARNING
A WARNING IS USED TO EMPHASIZE OPERATING
PROCEDURES., PRACTICES, ETC., WHICH, IF NOT
CORRECTLY FOLLOWED, MAY RESULT IN SERIOUS
PERSONAL INJURY OR DEATH.
DANGER
A DANGER IS USED TO EMPHASIZE OPERATING
PROCEDURES, PRACTICES, ETC., WHICH, IF NOT
CORRECTLY FOLLOWED, WILL RESULT IN SERIOUS
1.1 INTRODUCTION
A. This manual provides installation, operation and maintenance
information. The manual is prepared specifically for the operating
and service personnel responsible for the efficient operation of this
machine and should be available to them.
B. The contents of this manual and all engineering information
contained herein are the exclusive property of the Milacron
Marketing Company. It is furnished for customer use and
information only and is not an authorization or license to furnish
this information to others.
C. NOTES, CAUTIONS, WARNINGS, and DANGERS are used
throughout the manual to emphasize important and critical
information.
1. NOTE: a note is used to emphasize any operating
procedures, conditions, etc.

Page: 9
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
WARNING
IN ORDER TO CLEARLY SHOW DETAILS OF MACHINES,
SOME COVERS, SHIELDS, DOORS AND GUARDS HAVE
BEEN REMOVED OR SHOWN IN THE OPEN POSITION.
BE CERTAIN THAT ALL PROTECTIVE DEVICES ARE
PROPERLY INSTALLED BEFORE OPERATING THIS
EQUIPMENT. FAILURE TO HEED THIS WARNING MAY
RESULT IN SERIOUS PERSONAL INJURY AND/OR
DAMAGE TO YOUR MACHINE.
DANGER
OPERATING AND MAINTENANCE PERSONNEL MUST
READ AND UNDERSTAND THESE PRECAUTIONS
COMPLETELY BEFORE OPERATING, SETTING UP,
RUNNING, OR PERFORMING MAINTENANCE ON THE
MACHINE. FATAL INJURY MAY RESULT IF THE PREVIOUS
INSTRUCTIONS ARE NOT COMPLETELY FOLLOWED.
1.2 SAFETY PRECAUTIONS
A. The safety precautions for this Milacron machine have been
prepared to assist the operating and maintenance personnel in the
performance of good safety procedures.
B. These safety precautions are to be used as a guide to supplement
the following:
1. All other information pertaining to the machine.
2. Local, plant, and shop safety rules and codes.
3. Federal and state safety laws and regulations.
4. NOTE: emphasis will be placed on the latest edition of the
Occupational Safety and Health Standards, which is
available from the Department of Labor, Washington, D.C.
These standards (found in part 1910, title 29 of the code of
Federal Regulations) contain the current general industry
Occupational Safety and Health Regulations set forth by
federal legislation. Also applicable are standards from the
American National Standards Institute, such as
ANSI B151.1-1990.

Page: 10
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
WARNING
READ THE INSTALLATION SECTION OF THIS MANUAL,
AND BE CERTAIN THAT YOU UNDERSTAND IT BEFORE
ATTEMPTING TO MOVE OR INSTALL THIS MACHINE.
FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO HEED
THIS INSTRUCTION MAY RESULT IN SEVERE PERSONAL
INJURY OR DAMAGE TO YOUR MACHINE.
WARNING
DO NOT CLIMB ON THE MACHINE. CLIMBING ON
THE MACHINE CAN CAUSE A MACHINE
MALFUNCTION, AND MAY RESULT IN INJURY TO THE
CLIMBER. DO NOT STAND ON ANY PART OF THE
MACHINE. DO NOT REACH UNDER OR OVER COVERS
WHILE THE MACHINE IS OPERATING. FAILURE TO
HEED THIS WARNING MAY RESULT IN SEVERE
1.2.1 PERSONAL SAFETY ATTITUDES AND ACTIONS
A. Remember, in order to avoid accidents, you must think and act in a
safety-minded manner. Know and respect your machinery. Read
and practice the prescribed safety procedures. Make sure that
everyone who works for you, with you, or near you, fully
understands and follows these safety precautions and procedures
when operating the machine.
B. Always be mentally alert on the job, and stay in good physical
condition. A person who is not alert runs a greater risk of being
injured. Do not operate this machine while you are under the
influence of legal or illegal drugs or alcohol.
C. Avoid sudden movements, loud noises, etc., which can distract
others who are working near you. Be alert to conditions in your
working area and throughout the plant. Observe “No Smoking”,
“High Voltage”, and other warning signs.
D. Use tools for their intended use only. Check tools and equipment
frequently. Never use worn tools, frayed power cords, etc. You
should check to make sure that all electrical equipment is properly
grounded. Short cuts are not compatible with “safety mindedness”.

Page: 11
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
WARNING
WEAR THE PROPER CLOTHING FOR THE JOB AT ALL
TIMES, ALWAYS WEAR APPROVED EYE OR FACE
PROTECTION AND KEEP THEM (GLASSES, SHIELDS,
ETC.) CLEAN. WEARING SAFETY-TOE SHOES WITH
SKIDPROOF SOLES WILL HELP TO KEEP YOU FROM
SLIPPING AND FALLING. WEAR A SAFETY HAT. KEEP
YOUR PROTECTIVE EQUIPMENT IN GOOD
CONDITION AND BE SURE IT MEETS OR EXCEEDS ANY
REQUIRED OR RECOMMENDED STANDARDS. FAILURE
TO HEED THESE INSTRUCTIONS MAY RESULT IN
SERIOUS PERSON INJURY.
E. During machine operation, pay attention to the molding process.
Be alert for excessive vibration, unusual sounds, or other indications
of problems, and give them your immediate attention.
F. Be neat, and keep your work area clean. Place oily rags in a covered
metal container. Place trash and scrap in the proper waste
containers promptly; nails, broken glass, and chips are particularly
dangerous. Always use a broom and pan to pick up debris. Never
pick up debris with your bare hands as serious cuts may result.
Remove mails from lumber and containers that may be handled by
your or others.
G. Compressed air can be hazardous when it is used improperly. Never
use compressed air for cleaning the machine, work area,
workbench, tools, workpieces, measuring instruments, or clothes.
Make sure that air blasts from air-operated tools do not carry chips
or dirt toward you or others. Never blow air toward other people or
toward the machine, since the air itself may contain small chips.
I. Keep your machine in good operating condition at all times.
Inspect it regularly for parts that show wear or abuse. Replace worn
parts with authorized parts only. Report unusual sounds, smoke,
heat, damaged components, etc., to your supervisor.

Page: 12
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
WARNING
ACCIDENTS DUE TO CLOTHING OR OTHER ARTICLES
OF APPAREL BECOMING ENTANGLED IN MOVING
MACHINE ELEMENTS CAN CAUSE SEVERE INJURIES TO
YOU OR OTHERS. TO MINIMIZE THIS RISK, NEVER
WEAR NECKTIES, SCARVES, LOOSE HANGING
CLOTHING, OR JEWELRY, SUCH AS NECKLACES,
RINGS, OR WATCHES, AROUND MOVING
MACHINERY. WEAR A SHORT SLEEVE SHIRT OR ROLL
YOUR SLEEVES UP PAST YOUR ELBOW. AND KEEP YOUR
SHIRTTAILS TUCKED IN. RESTRAIN LONG HAIR WITH A
CAP OR HAIR NET. WEAR GLOVES ONLY WHEN THEY
ARE ESSENTIAL FOR HANDLING ROUGH, SHARP, OR
HOT PARTS, AND NEVER WHEN THE GLOVES CAN
BECOME ENTANGLED IN THE MACHINE.
WARNING
DO NOT LEAVE FOREIGN ARTICLES LIEING ON THE
MACHINE. THEY COULD CAUSE INJURY BY
DISTRACTING OR HITTING THE OPERATOR. THEY
COULD ALSO CAUSE MACHINE MALFUNCTION BY
SHORTING AND ELECTRICAL CIRCUIT OR BY JAMMING
THE MACHINE.
1.2.2 WORK AREA
A. Make sure your work area is free of hazardous obstructions and be
aware of protruding machine members while working around it.
Keep materials and equipment out of the aisles. Equipment should
always be returned to its proper storage place after use. Keep your
workbench neat and clean. Keep your tools and workpieces in
order.

Page: 13
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
WARNING
ALWAYS KEEP YOUR WORKING AREA CLEAN. DIRTY
WORK AREAS WITH HAZARDS SUCH AS OIL OR WATER
SPILLS MAY CAUSE SOMEONE TO FALL TO THE FLOOR
OR INTO THE MACHINE, RESULTING IN SERIOUS
PERSONAL INJURY. IF SPILLAGE OR LEAKAGE OCCURS,
IMMEDIATE ATTENTION IS RECOMMENDED. FAILURE
TO HEED THESE INSTRUCTIONS MAY RESULT IN
SERIOUS PERSONAL INJURY.
B. If work platforms are used around the machine, make sure that they
are sturdy and that they include antislip surfaces. Report worn or
broken flooring, stair treads, handrails or any other unsafe
conditions to your supervisor. When climbing, make sure ladders
and scaffolds are well built and in good condition. Never climb on
stock, machines, tote pans, boxes, piles of skids, etc.
C. Keep working space around electrical equipment clear of
obstructions and arranged neatly so that authorized personnel have
convenient access to all areas requiring their attention.
D. Avoid grinding operations near the machine. Abrasive dust can
cause inaccuracy, excessive wear, and possible part failures.
1.2.3 SETUP AND OPERATIONS
A. Become familiar with the machine before attempting any setup,
operation, or maintenance work. Respect the machine’s power and
capability. Memorize the location of all stop buttons before being
faced with an emergency. Learn what malfunctions each warning
light or alarm buzzer indicates. Know the controls and all external
moving parts of the machine. Read and understand all sections of
this manual and operate the machine only as set forth herein.
B. Only qualified personnel instructed in safety procedures and all
machine functions should be entrusted to operate this machine.
Never change the machine settings, or attempt to repair the
machine, unless you are trained and authorized to do so.

Page: 14
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
DANGER
DO NOT ATTEMPT TO PERFORM ANY SETUP,
OPERATION, OR MAINTENANCE WORK ON THE
MACHINE UNTIL YOU READ AND UNDERSTAND ALL
SECTIONS OF THIS MANUAL. FAILURE TO FOLLOW
THIS INSTRUCTION MAY RESULT IN FATAL INJURY.
DANGER
UNDER NO CIRCUMSTANCES ALLOW ANYONE TO
CLIMB THE STRUCTURE OF THE MACHINE. ALSO,
NEVER REACH IN UNDER THE GATE OR GUARD. NEVER
REACH OVER, UNDER, OR AROUND ANY MACHINE
GATES OR GUARDS WHILE THE MACHINE IS
OPERATING. FATAL INJURY MAY RESULT IF THESE
INSTRUCTIONS ARE NOT FOLLOWED COMPLETELY.
CAUTION
WHEN YOUR MACHINE FIRST ARRIVES AT YOUR PLANT
OR WHENEVER IT IS RELOCATED, CERTAIN SAFETY
PRECAUTIONS MUST BE OBSERVED. CONSULT THE
INSTALLATION SECTION OF THIS MANUAL FOR
PROPER METHODS AND PROCEDURES BEFORE
ATTEMPTING TO LIFT, MOVE, OR INSTALL THE
MACHINE. MAKE CERTAIN THAT YOUR LIFTING
EQUIPMENT IS RATED FOR SAFE LIFTING ABOVE THE
MACHINE WEIGHT. RESOLVE ANY QUESTIONS ABOUT
LIFTING, MOVING, OR INSTALLING THE MACHINE
BEFORE BEGINNING THESE PROCEDURES. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN
SERIOUS PERSONAL INJURY OR DEATH.

Page: 15
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
WARNING
SHUT OFF THE POWER TO THE MACHINE IF YOU
LEAVE THE OPERATING AREA. NEVER LEAVE THE
MACHINE RUNNING UNATTENDED. ALWAYS TURN
THE MAIN DISCONNECT SWITCH TO THE “OFF”
POSITION BEFORE ATTEMPTING TO CLEAN THE
MACHINE AT THE END OF THE WORKING DAY, OR IF
GUARDS OR COVERS ARE REMOVED TO EXPOSE
HAZARDOUS AREAS. DISREGARDING THESE
INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL
INJURY OR MACHINE DAMAGE.
WARNING
OPERATING AND MAINTENANCE PERSONNEL MUST
READ, UNDERSTAND, AND FULLY COMPLY WITH ALL
MACHINE-MOUNTED WARNING AND INSTRUCTION
PLATES. SUCH PLATES MUST NOT BE REMOVED,
PAINTED OVER, ALTERED, OR DEFACED. PLATES WHICH
BECOME UNREADABLE MUST BE REPLACED.
REPLACEMENTS ARE AVAILABLE FROM MILACRON.
DISREGARDING THESE INSTRUCTIONS MAY RESULT IN
SEVERE PERSONAL INJURY OR MACHINE DAMAGE.
C. Keep all electrical equipment in safe and proper working condition.
Defective equipment should be repaired or be permanently
disconnected. Thoroughly inspect any seldom-used electrical
equipment before use to assure it is safe and fit to be used.
D. For the protection of the operator and others nearby, it is
recommended that a vacuum device be used instead of compressed
air when cleaning any plastic shot spillage from the machine.
1.2.4 MAINTENANCE SAFETY
A. Before starting:

Page: 16
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
DANGER
BEFORE WORKING ON ANY ELECTRICAL CIRCUITS,
LOCK THE MAIN DISCONNECT SWITCH IN THE “OFF”
POSITION. DO NOT WORK ON THE MACHINE WITH
THE ELECTRICAL POWER ON. ANY MAINTENANCE
WORK THAT REQUIRES THE ELECTRICAL POWER TO BE
ON SHOULD BE PERFORMED ONLY BY A MILACRON
FIELD SERVICE REPRESENTATIVE. THE MACHINE’S
OWNER IS RESPONSIBLE FOR DETERMINING THAT ANY
OTHER PERSON PERFORMING WORK WITH THE
ELECTRICAL POWER ON IS TRAINED AND
TECHNICALLY QUALIFIED TO DO SO. FAILURE TO
HEED THIS WARNING MAY RESULT IN SEVERE
B. Never attempt to make repairs for which you are not properly
trained. Only qualified service and maintenance personnel should
perform maintenance or repair work on Milacron machines. Always
consult the manual before beginning any service or repair work. If
you have questions or are uncertain about the procedure, contact a
Milacron office for further information. Use only Milacron
replacement parts; others may impair the general safety and
operation of the machine. Warning or danger signs should be
placed conspicuously around the machine before performing
maintenance or service work.
C. When working on electrical equipment::
WARNING
BEFORE ATTEMPTING TO PERFORM MAINTENANCE
ON THIS MACHINE, READ, KNOW, UNDERSTAND AND
PRACTICE ALL OF THE SAFETY INSTRUCTIONS IN THIS
MANUAL. READ AND COMPLY WITH ALL MACHINE
MOUNTED WARNING PLATES. KNOW AND PRACTICE
ALL SAFETY RULES SET FORTH BY YOUR COMPANY.
FAILURE TO HEED THIS WARNING MAY RESULT IN
SEVERE PERSONAL INJURY.

Page: 17
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
D. Before removing or opening any electrical enclosure, cover, plate,
or door, make certain that the main disconnect switch is in the
open or OFF position. If any tool is required to remove a guard,
cover, bracket, or any basic part of the machine or controller, lock
the main disconnect switch in the OFF position using the locking
key provided with the machine. Tag the disconnect switch or post a
sign indicating that maintenance is being performed.
E. Control circuits connected with YELLOW wires are powered from a
source away from the machine. These circuits carry voltage even
when a machine’s main disconnect switch is OFF. Therefore, before
working on electrical circuits connected with yellow wires, locate
the circuit’s power source and lock it in the OFF position. (There
may not be any of these on your machine.)
F. Even with all electrical power disconnected, the control has some
residual voltage present for a time. Also internal components such
as capacitors will store high voltage for an indefinite period. For
these reasons, only qualified and trained electronic technicians who
know how to deal with these hazards should be permitted to
perform service work inside the control.
G. When removing electrical equipment, place numbered tags or
labels on any wires not already marked to identify them for proper
re-connection. If it is necessary to replace wiring, make certain it is
of the proper gauge so that is will have adequate current carrying
capacity. Close and securely fasten all guards, covers, shields, plates,
and doors before power is reapplied.
H. Working space around electrical equipment must be clear of
obstructions. Also, illumination should be adequate to allow for
proper operation and maintenance.
I. The nearest Milacron regional office must be notified before any
changes are made to the control software. Software changes must
be made by qualified personnel using approved methods and
supplied equipment. After the control is reprogrammed the
following must be checked immediately:
1. Any change to the programming must include all previous
safety-related devices, plus any new safety devices or safety
methods which are now indicated.
2. All safety-related devices must be inspected and tested to
ensure that they are working properly.
3. Safety guards, doors, shields, limit switches, etc., must be
interlock protected so that the machine will not operate if
they are not in position.
J. It is mandatory that all wiring diagrams, programming sheets,
programming tapes, and other documentation be updated when

Page: 18
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
changes are made to the control program, or to any electrical or
electronic circuit hardware. All personnel who come into contact
with the machine must be immediately alerted to any and all
changes made.
K. It is the responsibility of the owner/user to add any additional
protective components that become necessary from modifications
or changes to the machine or its components or operational
characteristics.
L. Inspect and test all safety devices regularly to assure that they
function properly. Replace all malfunctioning components before
operating the machine again. All safety-related guards, shields, etc.,
must be in place before and during machine operation.
DANGER
WHEN PREPARING TO WORK ON THE MACHINE,
BEFORE REMOVING OR OPENING ANY ELECTRICAL OR
MECHANICAL GUARD OR COVER, MAKE CERTAIN
THAT THE MAIN DISCONNECT SWITCH IS LOCKED IN
THE “OFF” POSITION AND TAGGED TO INDICATE
THAT MAINTENANCE IS BEING PERFORMED. FAILURE
TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
SEVERE OR FATAL PERSONAL INJURY.
WARNING
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
STANDARDS REQUIRE THAT SIGNALS ENTERING INTO
OR LEAVING FROM THIS UNIT, CONNECTING TO AN
EXTERNAL SOURCE OVER 30 VOLTS, AND NOT
DISCONNECTED WHEN THE MAIN DISCONNECT
SWITCH IS TURNED OFF, BE IDENTIFIED BY USING
CONDUCTORS WITH YELLOW INSULATION (OR WITH
YELLOW SLEEVING OR MARKING ON SUCH WIRES IF
MULTI-CONDUCTOR CABLES OR OTHER SPECIAL
WIRING METHODS ARE USED). FAILURE TO FOLLOW
THIS INSTRUCTION MAY RESULT IN SEVERE PERSONAL
INJURY.

Page: 19
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
DANGER
WHENEVER WORK IS TO BE PERFORMED AWAY FROM
THE MAIN DISCONNECT SWITCH, PLACE THE
DISCONNECT SWITCH IN THE OFF POSITION AND
TAG IT WITH LABEL STATING “OUT OF SERVICE, DO
NOT START! MAINTENANCE BEING PERFORMED”.
ADDITIONAL PRECAUTIONS, SUCH AS LOCKS ON THE
CIRCUIT BREAKERS OR BREAKER BOXES, OTHER SIGNS
OR WARNINGS ARE ALSO REQUIRED TO ENSURE THAT
THE EQUIPMENT WILL NOT BE ENERGIZED BY OTHER
PERSONNEL WHILE MAINTENANCE IS BEING
PERFORMED. FAILURE TO ADHERE TO THESE
INSTRUCTIONS MAY RESULT IN FATAL INJURY.
DANGER
ALWAYS MAKE CERTAIN THAT ANY COMPONENT IS
SAFELY POSITIONED BEFORE WORKING ON IT -
FOR EXAMPLE, ON A STURDY WORKBENCH.
NEVER WORK ON A COMPONENT WHILE IT IS
HANGING FROM A CRANE OR ANY OTHER LIFTING
MECHANISM. FAILURE TO HEED THIS WARNING
MAY RESULT IN FATAL INJURY.
WARNING
ORANGE IDENTIFYING MARKINGS ON COVERS, AND
GUARDS, ETC., INDICATE THAT THEY ARE TO BE
REMOUNTED IMMEDIATELY AFTER ADJUSTMENTS
HAVE BEEN MADE TO THE COMPONENTS UNDER
THEM. BE SURE ALL GUARDS, COVERS, PLATES, AND
DOORS ARE CLOSED AND SECURELY FASTENED
BEFORE POWER IS APPLIED. FAILURE TO HEED THIS
WARNING MAY RESULT IN SERIOUS PERSONAL INJURY.
M. Working on components which can fall:
N. Before reconnecting power:

Page: 20
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
O. Forcing and hammering parts:
1. Never hammer parts together or force them to make them
work. When striking a workpiece or fixture for adjustment,
use a babbit or soft hammer and wear protective eyewear.
1.2.5 VENTILATION SAFETY
A. Fumes, dust, and gases may be produced in a plastics processing
environment. Adequate ventilation must be supplied. It is
recommended that the construction, installing, inspection, and
maintenance of exhaust systems conform to the requirements of
ANSIZ9.2, “Design and Operation of Local Exhaust Systems”, and
also to any recommendations from the material supplier.
1.2.6 MATERIALS
A. Various materials may be used with this machine. Before using,
mixing, or diluting materials in the machine, contact the
manufacturer or authorized supplier of the material to determine
whether or not the material is suitable for the intended application,
and request a Material Safety Data Sheet (MSDS) from the material
manufacturer.
1.3 LIFTING AND CARRYING
A. Improper lifting or carrying can result in serious injury; especially
back injury. This section contains some suggestions that can serve
to help you avoid such injury.
B. Evaluate the load first for weight and size. Inspect the load for nails
and other protrusions which might cause injuries. Decide whether it
can be moved by one person, several, or whether a device like a
fork-lift or crane will be required. Get the necessary help before
proceeding.
1.3.1 LIFTING AND CARRYING
A. Make sure that your footing is secure. Crouch as close to the object
as practical. Get a good grip on the object. Lift slowly by
straightening your legs. Keep your back relatively straight. Your leg
muscles, not your back, should do the work. Keep the load close to
your body as you come up. Raise the load to the carrying position
before you begin walking. If it is necessary to change your direction
while carrying the load, turn your body with changes of foot
positions.
B. To set the load on a bench or table, place it on the edge and let
thetable provide part of the support. Then push the load forward
using your arms and , if necessary, part of the body.

Page: 21
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
WARNING
REGULARLY INSPECT SLINGS, CHAINS, HOISTS AND
OTHER LIFTING DEVICES. FOR FREQUENCY OF
INSPECTIONS, REFER TO THE WILLIAMS-STEIGER
OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA)
1910.179 AND ANY INSTRUCTIONS APPLICABLE TO
THE EQUIPMENT. REPAIR OR DISCARD UNSAFE
EQUIPMENT PROMPTLY. FAILURE TO HEED THIS
WARNING MAY RESULT IN SERIOUS PERSONAL INJURY.
C. If you must lift the load higher than your waist, first lift it waist high
(as just described), then rest it on a support while you change your
grip. Now bend your knees again to give added leg muscle power
for the final lift.
D. When carrying an object, be sure you can see clearly over the load.
Do not try to change the loads position or adjust it, while you are
in motion. If the load interferes with normal walking, get help.
E. Put the load down on the floor surface from a waist high carrying
position by bending your knees. Keeping your back straight and the
load close to your body, lower the object with your arm and leg
muscles.
1.3.2 LIFTING AND CARRYING BY MECHANICAL DEVICE
A. For loads that are too heavy for safety standards, or that exceed
your own physical strength limitations, use a power hoist or other
mechanical carrying device. Bulky or hard to handle objects should
also be lifted or carried with such devices rather than by hand. This
can help you avoid injury. Use hook-up methods recommended by
your safety department, and know the signals for safely directing a
crane operator.
B. There are many other safety suggestions that could be made. If
there is a question regarding safety, ask your company safety
engineer or call your Milacron representative.

Page: 22
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
1.4 OCCUPATIONAL SAFETY AND HEALTH ACT COLOR
CODING SYSTEM
A. The Occupational Safety and Health Act (OSHA) designated a color
coding system for the marking of various areas on machines. This
coding is also part of an ANSI standard. The system is designed to
point out the various areas of the machine which are shielded or
guarded, the potential pinch points, and other areas of potential
hazard. Since operator safety, with maximum machine productivity
is of upmost concern, everyone who works around the machine
should read and understand this color coding system:
1. “Stop buttons or electrical switches used for the emergency
stopping of the machine shall be RED”.
2. “ORANGE shall be used as the basic color for designating
dangerous parts of machines, or energized equipment
which may cut, crush, shock, or otherwise injure personnel,
to emphasize such hazards when enclosure doors are open,
or when gear, belt, or other guards around moving
equipment are open or removed, exposing unguarded
hazards.”
WARNING
CRANES, HOISTS, SLINGS, EYEBOLTS, ETC. HAVE
SAFETY-RATED CAPACITIES WHICH SHOULD NEVER BE
EXCEEDED. BE SURE THAT EQUIPMENT IS ADEQUATE
FOR THE LOAD AND APPLICATION. REFER TO
STANDARDS AND APPLICABLE INSTRUCTIONS FOR
ANY LIFTING EQUIPMENT YOU USE. (FOR EXAMPLE,
USAS STANDARD B18.15, PUBLISHED BY THE
AMERICAN SOCIETY OR MECHANICAL ENGINEERS,
UNITED ENGINEERING CENTER, NEW YORK,
CONTAINS INFORMATION CONCERNING SAFE
LIFTING LOADS FOR DIFFERENT SIZE EYEBOLTS, FOR
VARIOUS ANGLES OR LIFT, AND FOR VARYING
APPLICATIONS.) FAILURE TO HEED THIS WARNING
MAY RESULT IN INJURY.
DANGER
NEVER PLACE ANY PART OF YOUR BODY UNDER A
SUSPENDED LOAD OR MOVE A SUSPENDED LOAD
OVER ANY OTHER PERSON. BE CERTAIN THAT YOU
HAVE A SAFE SPOT TO DEPOSIT A SUSPENDED LOAD
BEFORE LIFTING IT. FATAL INJURY MAY RESULT IF
THESE INSTRUCTIONS ARE NOT COMPLETELY
FOLLOWED.

Page: 23
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
Note: the color orange should never be exposed when all
safety guards and covers are properly in place.
3. “YELLOW shall be the basic color for designating caution
and for marking physical hazards such as: striking against,
stumbling, falling, tripping, and ‘caught in between’. Solid
yellow and black stripes, yellow and black checkers (or
yellow with a suitable contrasting background) should be
used interchangeable, using the combination which will
attract the most attention in the particular environment.
4. “Colors shall meet the tests specified in Section 3, Color
Definitions, of ANSIZ53.1-1967. Safety Color Code for
marking Physical Hazards.”
5. When surfaces of the machine have been color code
for safety precautions, these colors should not be changed.
1.5 OSHA LOCKOUT OR TAGOUT SYSTEM
A. Effective January 8, 1990, an OSHA regulation requires a “positive,
lockable” means to remove all energy sources from equipment prior
to service or maintenance. For further information on this
regulation, “Typical Minimal Lockout or Tagout System Procedures”
published in the Federal Register, Volume 54, Number 169, Page
36691, dated Friday, September 1, 1989.

Page: 24
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584

Page: 25
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
2.0 GENERAL
2.1 SAFETY
2.2 EFFICIENCY
2.3 COMPONENT PLACEMENT

Page: 26
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
2.1 SAFETY
A. It is important to become thoroughly familiar with this manual and
the operating characteristics of the equipment.
B. Several important references are made to safety considerations in
this manual. It is the owner’s responsibility to assure proper
operator training, installation, operation, and maintenance of the
water temperature controller.
2.2 EFFICIENCY
A. Long term efficiency of operation is largely determined by proper
maintenance of the mechanical parts of the unit and the water
quality. MILACRON recommends filtering where required to
prevent solids from plugging critical parts (pumps, heaters, seals for
example). MILACRON highly recommends the services of a team
of competent water treatment specialists be obtained and their
recommendations followed. MILACRON accepts no responsibility
for inefficient operation, damage caused by foreign materials, or
failure to use adequate water treatment.
This warning label is attached
to the lift off panel.

Page: 27
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
2.3 COMPONENT PLACEMENT
A. The MILACRON ‘MFCH’ temperature controller with instrument is
designed to circulate temperature stabilized water through the
process system to result in process temperature control.
B. Please note that the ability of the equipment to achieve this
objective is significantly affected by the method of installation.
C. If the operator has any questions, contact the MILACRON Sales or
Service Department at 513-536-2584.
A
B
C D FE
G
H I
J
F
K
MN N
L
W
V
U
O
R
Q
P
S
T
A From process pressure
gauge
B To process pressure
gauge
C Heater
D Heater/Pump discharge
cylinder
E To process/high temp
sensor
F Electrical cabinet
G Hinged electrical cabinet
panel door
H Microprocessor
controller
I Operator display (not
visible)
J Power cord
K Swivel caster
L Electric pump motor
M Pump seal flush
N Unit drain
O Pump casing
P Flow indicator sensor
Q Water supply connection
R Pressure switch/from
process gauge
connection
S From process
connection
T Pressure relief valve
U AVT modulating cooling
valve
V Drain connection
W To process connection

Page: 28
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584

Page: 29
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
3.0 INSTALLATION
3.1 GENERAL
3.2 TO AND FROM PROCESS CONNECTIONS
3.3 WATER SUPPLY CONNECTION
3.4 DRAIN CONNECTION
3.5 ELECTRICAL CONNECTION

Page: 30
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
3.1 GENERAL
A. All process piping materials (such as hose, rigid piping, valves or
filters) used in process water piping circuitry must be rated for
350°F minimum temperature and 200 PSI minimum pressure.
B. All such materials must have the equivalent or larger diameter of
the particular process connection that length of process piping is
connected to.
3.2 TO AND FROM PROCESS CONNECTIONS
A. Connect the unit’s TO PROCESS port to the ‘water in’ port on the
process manifold.
B. Connect the unit’s FROM PROCESS port to the ‘water out’ port on
the process manifold.
C. Process water piping circuitry should be designed to avoid an
excessive use of elbows and/or lengths of pipe or hose. If hose is
the material of choice, avoid tight twists or curls and excessive
lengths.
D. Valves and filters may be installed in the process water piping
circuitry to facilitate service and maintenance, provided that such
devices maintain the full inside diameter of the process connection.
If installed, all such devices must be open and clean during unit
operation.
To process connection:
connect to “water in” on process manifold
From process connection:
connect to “water out” on process manifold
Drain connection:
connect to one of the following:
• plant’s open drain
• tower water system return
• chilled water system return
Water supply connection:
connect to one of the following:
• plant’s city water source
• well water source
• tower water supply
• chilled water supply

Page: 31
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
3.3 WATER SUPPLY CONNECTION
A. Connect the unit’s WATER SUPPLY
port to the plant’s city water supply,
well water supply, tower water system
supply or chilled water system supply.
B. Water supply pressure requirements
vary with operating temperatures.
Figure 3.2A tabulates the required
operating water supply pressures for
various operating process
temperatures. The required water
supply pressure retains process water
in a liquid state at temperatures above
180°F. Failure to maintain the
required water supply pressure will
eventually induce premature
maintenance in susceptible areas
such as the shaft seal and heating
cylinder.
C. The factory recommend minimum
operating water supply pressure
requirement is identified on the
unit’s data pate (figure 3.2B).
D. Static water supply pressure can be
determined at the unit’s location by
reading the unit’s 0-160 PSI
pressure gauges when the unit’s
motor pump is OFF (figure 3.2C).
E. If water supply pressure as read on
the unit’s pressure gauges exceeds
75 PSI, a pressure reducing valve
must be installed in the water
supply line (refer to section 7.4 of
this manual for installation
information). The factory
recommended ‘regulated pressure
out’ is 55 PSI (figure 3.2D).
3.4 DRAIN CONNECTION:
A. Connect the unit’s DRAIN port to
one of the following determined by
the choice of water supply source:
1. Plant’s open drain for well
or city water supply.
OPERATING WATER
TEMP SUPPLY
PSI
180°F 20 psi
190°F 25 psi
200°F 30 psi
210°F 35 psi
220°F 40 psi
230°F 45 psi
240°F 50 psi
250°F 55 psi
Figure 3.2A
Typical Data Plate Figure 3.2B
Static pressure indication Figure 3.2C
Typical pressure reducing valve Figure 3.2D

Page: 32
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
2. Tower water system return for tower system water supply.
3. Chilled water system return for chilled water system supply.
B. The factory recommends the water supply and drain line pressure
differential be a minimum of 10 psi to ensure proper cooling.
C. For most applications, the drain
line should not be valved. However,
for installations with a pressurized
drain system, it may be necessary
to install a valve in the drain line. In
such cases, the installed valve must
be fully opened after installation
and the valve handle removed. This
prevents operating the unit with a
closed drain valve. The valve
handle can be reattached to the
valve body when it is necessary to
close the valve (figure 3.3A).
D. CAUTION: the unit must never be operated with a closed drain line
valve. A closed drain line valve prevents adequate system cooling
and will lead to unit overheating. Overheating of the unit may lead
to unit damage and/or serious personal injury.
3.5 ELECTRICAL CONNECTION
A. NEMA 1 MODELS (no “J” in model number suffix)
1. Electrical power supply requirements for Nema 1 units (see
figure 3.5A) are identified
on the equipment data
plate. Verify that available
voltage supply is the same
as the unit’s voltage
requirements. WARNING:
DO NOT CONNECT THE
UNIT TO A VOLTAGE
SUPPLY SOURCE NOT
EQUAL TO THE UNIT’S
VOLTAGE REQUIREMENTS
AS SPECIFIED ON THE
UNIT’S DATA PLATE. Use
of incorrect voltage will
void the unit’s warranty and cause a significant
hazard that may result in serious personal injury and/or unit
damage.
2. A four conductor cable, 10 foot in length, has been
provided for connection to a fused disconnecting means.
Figure 3.5A
Nema 1 electrical
construction style
Typical drain valve installation Figure 3.3A

Page: 33
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
3. The owner supplied fused disconnecting means shall be
sized and installed according to the unit’s power supply
requirements and local electrical codes.
B. NEMA 12 MODELS (“J” in model number suffix)
1. NEMA 12 units (figure
3.5B) are constructed with
a dust tight electrical
enclosure and branch
circuit fusing. Electrical
power supply requirements
are identified on the
equipment data plate.
Verify that available voltage
supply is the same as the
unit’s voltage requirements.
WARNING: DO NOT
CONNECT THE UNIT TO
A VOLTAGE SUPPLY
SOURCE NOT EQUAL TO
THE UNIT’S VOLTAGE
REQUIREMENTS AS SPECIFIED ON THE UNIT’S DATA
PLATE. Use of incorrect voltage will void the unit’s warranty
and cause a significant hazard that may result in damage to
the unit or serious personal injury.
2. Appropriate conduit and fittings should be selected which
will maintain the integrity of the cabinet.
3. Supply a power conductor sized according to the unit’s
power supply requirements. Connect the power conductor
to the unit’s power supply entry terminal block.
C. CONTROL CIRCUIT WIRING
1. The unit’s supplied control
circuit is 110 volt, 1 phase,
60 cycle. The control circuit
is supplied by the factory
installed transformer. A
control circuit fuse is
provided (figure 3.5C).
D. GENERAL
1. Make certain all ground
connections to the unit are
properly affixed.
2. Make certain the power conductor, disconnecting means,
and fusing are properly sized according to the unit’s power
supply requirements.
Control circuit transformer fuse
Figure 3.5BNema 12 electrical
construction style
Figure 3.5C

Page: 34
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
3. Make certain all electrical connections are tightly affixed.
Any loose wiring connections must be tighten before
engaging the power supply.
4. Make certain no moisture or standing water is present
inside the electrical cabinet.
Motor Contactor
Transformer
Sensor Probe
Connector
Instrument
Connector
Power Entry
Transformer Fuse
Overload RelayOverload ResetHeater
Contactor
Pressure
Switch

Page: 35
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
4.0 OPERATIONS
4.1 GENERAL
4.2 MACHINE START UP/OPERATIONS PROCEDURE
4.3 INSTRUMENT OPERATION
4.4 SHUT DOWN/DISCONNECT PROCEDURE

Page: 36
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
4.1 GENERAL
A. Failure to follow the factory required operation procedures may
adversely affect the unit’s ability to adequately control process
temperature and may create a hazardous operating condition
which may result in unit damage or serious operator injury.
B. The Operations segment of this manual is outlined below:
4.2 Machine start-up/operations procedure - follow this
segment to start the unit after the initial installation or to
restart the unit after reinstallation to the same or different
process. This section includes information on system fill,
electric motor phasing (pump rotation) and process flow
adjustments.
4.3 Instrument - follow this segment to start up and operate
the instrument. This section includes information on
automatic and manual venting, setpoint selection and
adjustment, and feature explanations.
4.4 Shut down procedure - follow this segment to shut down
the unit. This segment includes information on system cool
down, shut down, electrical power supply precautions, and
disconnection from system.
4.2 MACHINE START UP/OPERATIONS PROCEDURE
A. SYSTEM FILL
1. Engage the water supply source by opening the water
supply valve (customer installed) at the unit’s location. If a
valve is not installed, engage the water supply source at the
plant’s water supply central control point.
2. Once the water supply
source is open, the unit
will fill automatically. Allow
a few moments for the the
unit to completely fill. The
operator can determine
the unit is properly filled
when the TO PROCESS
pressure gauge and the
FROM PROCESS pressure
gauge stabilize at equal or
closely similar pressure
(figure 4.2A).
3. The operator must check for any water leakage in the unit’s
mechanical system, the process and throughout the plant’s
water supply system. If a water leak is observed, the
Unit pressure gauges
indicating total system fill
Figure 4.2A

Page: 37
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
operator must disengage the water supply system, relieve
all pressure, and repair the leak. The operator must verify
the leak is repaired by refilling the system as outlined in this
procedure.
4. During system fill, air is trapped at various places in the
water system. Air is purged automatically via the AVT valve
during initial pump start-up (outlined below). All air must
be purged before the unit is engaged for process
temperature control. Entrained air in the system will
adversely affect the unit’s ability to control process
temperature. The operator can determine all entrained air is
purged when no pressure spikes are evident via the unit’s
pressure gauges.
5. Adequate water fill and
pressure must be supplied
to the unit for efficient and
safe operation. To ensure
sufficient water fill, an
electrical panel mounted
pressure switch (figure
4.2B) is supplied with the
unit. A capillary line feeds
the pressure switch. If the
water supply pressure is
not adequate to close the
switch, the unit can not be
operated. This safety
system prevents the unit from operating when inadequate
water fill and pressure are supplied to the unit. If the unit is
operated without adequate water fill and pressure, the unit
may be susceptible to overheating and could result in unit
damage and/or serious injury to operating personnel.
B. ELECTRIC MOTOR PHASING (PUMP ROTATION)
1. The instrument has electronic circuitry to determine if the
MFCH unit is phased
correctly.
2. Identify the PHASE
indicating light on the
MFCH display panel.
(figure 4.2C). If the light is
‘flashing red’, the MFCH
unit is incorrectly phased.
To correct, continue with
step 3. If the light is ‘solid
green’, the unit is correctly
phased.
Panel mounted pressure
switch
Figure 4.2B
Phase light Figure 4.2C

Page: 38
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
3. If the unit is phased incorrectly, the operator must:
a. Disengage the electrical power supply to the unit at
the unit’s disconnect switch. Follow proper lockout
procedures before proceeding.
b. Once the electrical power supply is disengaged,
reverse any two power leads of the power cord at
the disconnect terminals.
c. Note: reversing any two power leads of the power
cord will correctly phase the power supply. The
operator must reverse the power leads at the
disconnect switch
only and not at
the power entry
terminals on the
unit’s electrical
panel (figure
4.2D). The unit’s
internal electrical
system wiring is
phased correctly at
the factory and
must not be altered
in the field.
4. To visually verify pump
rotation via the unit’s pressure gauges, toggle between the
START and STOP push buttons and observe the unit’s
pressure gauges. Once the electric motor is engaged, the
TO PROCESS pressure will
indicate 25-40 PSI more
than the FROM PROCESS
indicated pressure (figure
4.2D). In this state, the
electric motor is turning
the pump in the correct
clockwise rotation. If this
state is not evident
(pressure gauges indicate
same or similar pressure)
when the electric motor is
engaged, the unit is
incorrectly phased and the
phase should be corrected
as outlined in step 3.
5. An alternate method of determining pump rotation is to
visually inspecting the rotation of the pump motor shaft
and is outlined below.
Correct rotation as indicated
by pressure gauges
Figure 4.2D
Do not reverse power leads
at the unit’s power entry to
correct phase.
Figure 4.2D

Page: 39
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
a. Supply electrical power to the unit by engaging the
unit’s disconnect switch. Once the correct voltage
is supplied to the unit, the POWER light on the
unit’s control panel will illuminate.
b. Open hinged electrical cabinet panel cover. The
panel cover is secured by a support strap. Note
that the electrical power is engaged at this point
and caution must be observed while the
electrical supply is engaged and the cabinet
panel is open.
c. Locate the electric motor (figure 4.2E). The electric
motor can be identified when the electrical panel
cover is open. The operator must identify the
motor shaft inside
the electric motor
housing. The
motor shaft can be
seen through the
vent slots in the
motor housing or
by removing the
shaft cover (figure
4.2F).
d. Toggle the unit’s
START and STOP
push buttons. This
will quickly cycle
the electrical motor
“on” and then
“off”.
e. Observe the motor
shaft. When the
unit’s START switch
is pressed, the
motor shaft will
rotate. When the
unit’s STOP switch
is pressed, the
motor shaft will slowly “coast” to a stop. As the
motor shaft slows to a stop, the operator can
identify the rotation of the motor shaft. Correct
rotation (correct phase) is “clockwise”, when
viewed from the rear of the motor. Incorrect
rotation is “counter-clockwise” (incorrect phase)
when viewed from the rear of the motor. If the
shaft does not rotate when the START switch is
pressed, the operator must identify the cause as
outlined in this manual’s troubleshooting and repair
section.
Remove shaft cover to view
the motor shaft
Figure 4.2F
Electric motor Figure 4.2E

Page: 40
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
f. If the motor shaft is determined to be phased
correctly, continue with the start up procedure at
step C. If the motor shaft is determined to be
phased incorrectly (shaft turns in a counter-
clockwise direction), correct by following the
procedure outlined in step 3.
C. PROCESS FLOW ADJUSTMENTS
1. The operator must determine and set proper water flow
rate for the most efficient and trouble free operation.
a. Water flow rate through the process is determined
by the pressure loss in the process loop. Generally,
higher flow rates result turbulent flow achieving
maximum temperature control and lower
maintenance.
b. If the flow rate exceeds the motor HP capacity, the
electric motor will draw excessive amps. This is a
result of the process loop’s ability to flow water at a
greater rate than can be provided by the MFCH
pump. This will eventually result in tripping the
thermal motor overload relay (overload relays
open) and the unit will shut down and illuminate
the PUMP O/L indicating light on the display.
2. If a motor overload
(excessive flow) situation is
encountered and the motor
overload circuit has tripped
(opened), the operator
must manually reset the
overload relay before
operations can continue.
This is done by opening
the electrical panel cover,
identifying the reset lever
on the overload relay
(figure 4.2H), and pushing
the reset lever “in” until
the overloads are reset
(evidenced by a “clicking”
sound as the overloads
reset).
3. The MFCH instrument
displays the process flow
rate in the FLOW display
window (figure 4.2I). To
adjust the process flow
rate, continue with step 4.
Motor overload relays and
reset lever
Figure 4.2H
Flow display window Figure 4.2I

Page: 41
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
4. To set the process flow rate via the flow meter:
a. Determine the pump’s maximum flow rate. This is
indicated by the last two digits listed in the model
number of the unit. The model number is stamped
onto the unit’s data plate. For example, if the
model of the unit is “MFCH-1035”, “35” indicates
the pump’s maximum flow rate (35 GPM). The
indicated flow rate should not be exceeded during
operations. If it is, a possible overload condition
may develop. Refer to section 9.2 for additional
information on the unit’s model number.
b. Start the unit and observe the indicated flow rate
(see section 4.3 of this manual for instrument
operation instructions). If the indicated flow is
higher than the maximum flow rate for the unit, a
throttling valve must be installed in the “from
process” water line. The throttling valve can be a
gate valve or a ball valve.
c. With the throttling valve installed, fully close the
valve and then engage the pump motor. Slowly
open the throttling valve and monitor the indicated
flow rate until the flow rate is below the pump’s
maximum flow rate. At this point, the process flow
is now correctly adjusted. The valve should remain
in the position during operations.
6. An alternative method to set the process flow rate is to
measure the pump motor amperage and adjust the process
flow rate via the motor amperage:
a. Open electrical cabinet panel door. The panel cover
is hinged and held open by a support cable. Note
that the electrical power is engaged at this point
and caution must be observed while the cabinet
panel is open.
b. Identify the motor starter block. This block consists
of the motor starter contactor and the overload
relay.
c. Place an amp meter on a single power lead
emanating from the overload relay.
d. Locate the motor name plate on the pump motor
housing (figure 4.2J). The full load amp rating for
the motor is listed on the name plate.
e. Engage the electrical power supply and start the
electrical pump motor by pressing the START key
on the display.

Page: 42
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
f. The amp meter will
display the motor
amps. Compare
the actual motor
amps as displayed
on the amp meter
to the full load
amp rating as listed
on the motor name
plate.
g. If the amp draw is
excessive (higher
than the listed name plate amp rating), a throttling
valve must be installed in the “from process” circuit
line. The throttling valve can be a gate valve or a
ball valve.
h. With the throttling valve installed, fully close the
valve and then engage the pump motor. Slowly
open the throttling valve and monitor the motor
amps as displayed on the amp meter until the
actual motor amps equals the listed full load amp
rating of the motor. The process flow is now
correctly adjusted. The valve should remain in the
position during operations.
3.3 INSTRUMENT OPERATION
A. INSTRUMENT START-UP
1. When the correct electrical power and adequate water
supply pressure are supplied to the unit, it is possible to
start the unit for temperature control duty.
2. When the electrical power supply is engaged to the unit,
the MFCH instrument (figure 4.3A) will momentarily
illuminate all indicating lights and digits on the display
head. After a short delay, the MFCH instrument will display
the controller software version number. At this time, the
operator can verify that all lights and digits are functioning
properly. If the operator determines an indicating light or
digit does not illuminate, the instrument must be removed
and sent to the factory for repair.
3. With electrical power supplied to the unit, the POWER light
will illuminate. The display will remain dark with exception
of the PROBE, VALVE and PHASE lights (which will be ‘solid
green’ if those conditions are ‘ok’). This is the normal
“stop” state of the MFCH instrument. If the operator
determines the PROBE, VALVE and PHASE lights are
‘flashing red’, the operator must determine the reason and
correct:
Motor name plate Figure 4.2J

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MILACRON
4165 Halfacre Road
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Phone: 513-536-2584
a. Probe error: a possible cause of a probe error is
the probe service connection is wet. Locate the 2
pin (white plug) service connection, open and dry
with compressed air. If this action does not remove
the error indication, inspect the probe wiring,
which could be incorrect or damaged. Probe
connections are at the instrument panel. Correct
wiring is (from top to bottom) ‘white’ - ‘black’ -
‘white’ - ‘black’ - ‘red’ - ‘red’. If probe connections
are correct, the probe may be faulty and should be
replaced.
b. Valve error: a valve error indicates the instrument
cannot verify valve position. Refer to section 6.3 for
AVT valve service.
c. Phase error: follow the procedure outlined in
section 4.2. paragraph B ‘Electric Motor Phasing’ to
clear a phase error. If a phase error can not be
cleared even though the pump motor is rotating
correctly, the three phase monitor is defective and
should be replaced. Disconnect the unit until a
replacement is obtained.
4. After a ‘flashing red’ fault indication is diagnosed and
repaired, the ‘flashing red’ indication will turn ‘solid red’.
The operator can clear a ‘solid red’ fault indication by
pressing the START key.
Figure 4.3A
MFCH INSTRUMENT DISPLAY

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MILACRON
4165 Halfacre Road
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Phone: 513-536-2584
5. When the START key is pressed, The MFCH instrument will
immediately check the status of the water supply pressure
switch (WATER PRESS light), the motor overload switch
(PUMP OL light) and the high temperature safety switch (HI
TEMP light) for acceptable operating conditions. If these
systems are found to be ‘ok’, the lights will be ‘solid green’
and the unit will begin process temperature control
operation. If a system is not found to be ‘ok’, the light will
‘flash red’ and the MFCH instrument will prevent process
temperature control operation.
6. Conditions that will prevent the unit from starting process
temperature control operations are:
a. Water supply pressure inadequate (pressure
switch is open). The WATER PRESS indicator light is
‘flashing red’. The unit is prevented from operating
without adequate water supply pressure by an
electrical panel mounted pressure switch. Sufficient
water supply pressure must be present to close the
switch and consent the safety circuit.
b. Motor overload switch opened. The PUMP O/L
indicator light is ‘flashing red’. The electric motor is
protected from overload conditions (excessive flow)
by a set of thermal overload relays which open
(trip) with excessive amperage and prevent electric
power from reaching the electric motor. If the
overload relay is open, the overload relay must be
reset before operations can continue. An excessive
flow condition must be corrected immediately.
c. High temperature limit switch open. The HI
TEMP indicator light is ‘flashing red’. The unit is
prevented from operations with temperatures
exceeding 256°F by the high temperature limit
switch. This switch is installed in the “to process”
temperature sensor. If this switch is open (due to a
high temperature condition), the control circuit is
not consented and the unit cannot be started. If a
high temperature condition exists, the unit must
first cool down (reduce water temperature) before
the high temperature limit switch will automatically
reset to allow operation.
B. INSTRUMENT OPERATION
1. The operator must verify the PROBE, VALVE, AND PHASE
lights are ‘solid green’. If these lights are ‘flashing red’, the
operator must determine why and correct.
2. Process temperature control operation is started by pressing
the START push button.

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MILACRON
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Phone: 513-536-2584
a. When the START push button is pressed, the MFCH
instrument will immediately display the previously
selected setpoint temperature in the SETUP display
window, as indicated by the TEMP light. The
selected setpoint temperature is displayed
continuously unless the operator selects FLOW,
NETWORK or MACHINE setup displays. After 10
seconds of inactivity in the FLOW, NETWORK or
MACHINE setup parameters, the setup display will
automatically revert to the TEMP display.
b. When the START push button is pressed, the MFCH
instrument will immediately display the TO
PROCESS temperature as read by the TO PROCESS
temperature sensor. The TO PROCESS temperature
sensor is mounted at the top of the
heater/discharge tank. All MFCH controller
functions are based on this temperature. The
operator can select between the TO or FROM
process temperature for display in the
TEMPERATURE window. The display reverts to the
TO process temperature after 10 seconds of
inactivity if the FROM process parameter is
selected. Process temperatures can be programmed
to display in Fahrenheit or Celsius as indicated by
the °F or the °C lights (refer to section E paragraph
6 for more information).
3. If the indicated TO PROCESS temperature is less than 100°F,
the MFCH instrument will automatically open the AVT
modulating cooling valve for 30 seconds. This automatic
system vent cycle will purge entrained air from the system
(MFCH unit, hoses/piping circuitry and tooling) to the drain
and is effective in most process situations. Venting is
indicated by a flashing COOL light on the MFCH display.
Note that the CAPACITY % display will read “100”. If the
automatic vent cycle does not result in the venting of all
entrained air to the drain (evidenced by a “rattling” sound
in the unit and fluctuating pressure gauges), the operator
must manually action a forced vent. Forced venting
(manual system venting) is done by depressing and holding
the START or STOP push button for more than 5 seconds.
Release the START or STOP push button to conclude the
forced vent.
4. If the TO PROCESS temperature exceeds 100°F, the MFCH
instrument will bypass the automatic system vent cycle and
step immediately to process temperature control operation.
5. The operating SETPOINT temperature is selected by using
the SELECT push button to index to the TEMP indicating
light. Depress the UP arrow push button or DOWN arrow

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MILACRON
4165 Halfacre Road
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Phone: 513-536-2584
push button until the preferred setpoint temperature is
indicated in the SETUP display window. Setpoint
temperatures can be adjusted anytime during the process
temperature control cycle. Once adjusted, the MFCH
instrument will affect action to bring the system in line with
the adjusted setpoint temperature. Note: the operator may
directly adjust the setpoint without using the SELECT key
when the TO process light is on.
6. The TEMP DEV (temperature deviation) light will remain off
unit the setpoint temperature is achieved and maintained.
7. Press the STOP key to halt unit operations.
C. INSTRUMENT CONTROLS
(FIGURE 4.3B)
1. START PUSH
BUTTON: this switch
starts unit operations
by engaging electrical
supply to the pump,
heater and AVT
modulating cooling
valve. Depress and
hold the START push
button to initiate a
forced vent of the unit
by opening the AVT
modulating cooling
valve to quickly cool
the unit on demand.
2. STOP PUSH BUTTON: this switch stops unit
operations by disengaging electrical supply to the pump,
heater and AVT modulating cooling valve. Depress and
hold the STOP push button to initiate a forced vent of the
unit by opening the AVT modulating cooling valve to
quickly cool the unit on demand.
3. SELECT PUSH BUTTON: use this push button to select the
programmable parameters. Parameters will appear in the
TEMPERATURE window and the value will appear in the
SETUP window.
4. UP ARROW: depress and hold this push button to increase
the selected parameter. If this push button is pressed
momentarily the value is incremented by one unit. If the
push button is held down for more than one second, the
value will increase slowly at first and then faster after about
two seconds.
Figure 4.3B

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MILACRON
4165 Halfacre Road
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Phone: 513-536-2584
5. DOWN ARROW: depress and hold this push button to
decrease the selected parameter. If this push button is
pressed momentarily the value is incremented by one unit.
If the push button is held down for more than one second,
the value will increase slowly at first and then faster after
about two seconds.
D. TEMPERATURE DISPLAY (figure 4.3C)
1. TO: illuminates when the “to process” water
temperature is displayed. TO is the default setting of the
TEMPERATURE display window.
2. FROM: illuminates when the “from process” water
temperature is selected. Note: The instrument will revert
back to the TO temperature display after 10 seconds if the
FROM process temperature was selected and displayed and
the instrument was left in that state.
a. Use the SELECT key to index to the FROM
indication light. The “from process” temperature
will be displayed in the TEMPERATURE window.
3. °C: illuminates when the °C (Celsius) temperature display
parameter is selected.
4. °F: illuminates when the °F (Fahrenheit) temperature display
parameter is selected. °F is the default setting of the
instrument.
E. SETUP DISPLAY (figure 3.3D)
1. TEMP: illuminates when SETPOINT temperature is
displayed. TEMP is the default display setting of the SETUP
display window.
Figure 4.3C
Figure 3.3D

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MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
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Phone: 513-536-2584
2. The setpoint temperature can be adjusted by:
a. Use the SELECT key to index to the “SP” display in
the TEMPERATURE window (the TEMP light is
illuminated). The setpoint temperature value is
displayed in the SETUP window. Use the UP arrow
or DOWN arrow keys to select the setpoint
temperature value.
b. When the MFCH instrument is in the default state
(TO process temperature display), the operator may
adjust the setpoint temperature with the UP or
DOWN arrow keys without using the select key. If
the MFCH instrument is in any other state (i.e. the
NETWORK parameter state) the operator must use
the SELECT key to index to the TEMP indication to
adjust the setpoint.
3. The HI and LOW temperature alarm values are
programmed by:
a. Use the SELECT key to index to the “HI” display in
illuminated). The high temperature alarm value is
and DOWN arrow keys to select the value (1-30
units selectable).
b. Use the SELECT key to index to the “LO” display in
illuminated). The low temperature alarm value is
or DOWN arrow keys to select the value (1-30 units
selectable).
4. FLOW: illuminates when the flow parameter is selected.
The flow parameter is an alarm trigger. Once the flow
setting is programmed, an alarm signal is generated if the
flow decreases to the programmed value. 30 seconds of
flow stability must be maintained before the instrument will
arm the flow alarm. The flow setting is programmed by:
a. Use the SELECT key to index to the “LoF” display in
the TEMPERATURE window (the FLOW light is
illuminated). The low flow value is displayed in the
SETUP window. Use the UP arrow or DOWN arrow
keys to select the value (0-999 units selectable).
5. NETWORK: illuminates when the communications
parameters are selected. Communications parameters
available are “communications address”, “baud rate” and
“protocol”. The communications parameters are
programmed by:

MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
a. Communication address: the communications
address is the number assigned to the unit in a
network. Use the SELECT key to index to the “Adr”
display in the TEMPERATURE window (the
NETWORK light is illuminated). The communication
address value is displayed in the SETUP window.
Use the UP arrow or DOWN arrow keys to select
the value (1-99 units selectable).
b. Baud rate: the baud rate is the data transfer rate of
between the unit and the host computer. Use the
SELECT key to index to the “rAt” display in the
TEMPERATURE window (the NETWORK light is
illuminated). The baud rate value is displayed in the
SETUP window. Use the UP arrow or DOWN arrow
keys to select the value (1200-2400-4800-9600
units selectable).
c. Protocol: the protocol is the data format for
communication between the unit and the host
computer. Use the SELECT key to index to the
“Pro” display in the TEMPERATURE window (the
NETWORK light is illuminated). The protocol value
is displayed in the SETUP window. Use the UP
arrow or DOWN arrow keys to select the value (SPI
or CAC selectable). “SPI” is the standard Society of
Plastics Industry, Inc. protocol. “CAC” is the
CAMAC protocol used on older CMI machines.
6. MACHINE: illuminates when the machine parameters are
selected. Machine parameters available are: “Fahrenheit
temperature display with GPM (gallons per minute) flow
display”, or “Celsius temperature display with LPM (liters
per minute) flow display”.
a. Use the SELECT key to index to the “Unt” display in
the TEMPERATURE window (the MACHINE light is
illuminated). The machine value is displayed in the
SETUP window. Use the UP arrow and DOWN
arrow keys to select the value (“F” or “C” are
selectable). “F” indicates Fahrenheit temperature
display with GPM flow display. “C” indicates Celsius
temperature display with LPM flow display.
Page: 49

Page: 50
MILACRON
4165 Halfacre Road
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Phone: 513-536-2584
F. FLOW DISPLAY (figure 4.3D)
1. The FLOW display shows information concerning the pump
generated flow. The flow measuring mechanism is installed
in the cooling cylinder.
a. PUMP ON: this light illuminates when the pump is
operating.
b. LPM - Liters per minute: this light illuminates
when the “C” machine parameter is selected (see
paragraph 6.a above).
c. GPM - Gallons per minute: this light illuminates
when the “F” machine parameter is selected.
G. CAPACITY % DISPLAY (figure 4.3F)
1. The CAPACITY % display shows information
concerning the “in use” heating and cooling capacity of
the unit. HEAT and COOL indicating lights determine which
capacity percent is displayed.
a. HEAT: when this light is illuminated, the unit is in
the heating mode (heater on). The number
displayed in the CAPACITY % window is percent of
“on-time” use of the heater.
b. COOL: when this light is illuminated, the unit is in
the cooling mode (heater off) and the AVT valve is
opening. The number displayed in the CAPACITY %
window is “how much” the AVT valve is open.
Figure 4.3F
Figure 4.3E

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c. DEAD BAND: when this light is illuminated, the
unit is not in the HEAT or COOL mode.
H. PROCESS DISPLAY (figure 4.3G)
1. The process display is an alarm
indication for TEMPERATURE
DEVIATION and FLOW.
a. TEMP DEV: this light
will be ‘solid green’
when the process
temperature is within the programmed
setting. The light will be ‘solid yellow’ if
the process temperature deviates outside the
programmed setting. If the temperature remains
out of band for 90 seconds or more, the light will
‘flash red’ and activate the alarm.
b. FLOW: this light will be ‘solid green’ when the
process flow is within the programmed setting. The
light will ‘flash red’ if the flow deviates beyond the
programmed setting. The light will be ‘solid red’ if
the flow once had deviated but is now within the
programmed settings.
I. MACHINE STATUS (figure 3.3H)
1. Machine status lights indicate the operating
status of several machine components. For each
component: a ‘solid green’ light indicates an acceptable run
condition; a ‘flashing red’ light indicates that the
component is currently in an unacceptable run condition; a
‘solid red’ light indicates the component had once been in
an unacceptable run condition but is now in an acceptable
run condition. A ‘solid red’ light can be cleared to a ‘solid
green’ light by pressing the START key.
a. PROBE: indicates the status of the “to process” and
“from process” sensor probes.
b. WATER PRESS: indicates the status of the water
supply pressure switch.
c. HI TEMP: indicates the status of the high
temperature limit switch.
Figure 4.3G
Figure 3.3H

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d. PUMP OL: indicates the status of the pump motor
overload relay. See section 4.2 paragraph C.2 for
more information on the motor overload relay.
e. VALVE: indicate the status of the AVT modulating
cooling valve.
f. PHASE: indicates the status of the electrical phasing
of the unit. See section 4.2 paragraph B for more
information.
J. COMMUNICATION DISPLAY (figure 4.3I)
1. The communications display indicates the
kind of exchange between the host
computer and the unit. A single light is
used:
a. GREEN FLASH: indicates the unit is
sending information to the host
computer.
b. YELLOW FLASH: indicates the host computer is
sending information to the unit.
K. ALARM DISPLAY (figure 4.3J)
1. ALARM: when this light illuminates ‘solid
red’, an unacceptable condition has
developed. A 115 volt alarm output is
provided for external (factory or customer
installed) alarm beacon or buzzer. An alarm
signal can be silenced by pressing the
START key.
4.4 SHUT DOWN/DISCONNECT SEQUENCE
A. PRECAUTIONS/WARNINGS
1. The operator must precisely follow all shut down
procedures outlined in this manual. If the operator fails to
do so, an unsafe condition can develop resulting in damage
to the unit or injury and/or death to operating personnel.
2. When disconnecting the unit from the process system, the
operator must determine the unit’s process temperature is
at ambient or below 85°F and all system pressure is relieved
and the unit’s pressure gauges read “0”. Injury or death to
operating personnel and damage to the unit could result if
a hot and pressurized unit is disconnected from the system.
Figure 4.3I
Figure 4.3J

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MILACRON
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Phone: 513-536-2584
B. UNIT SHUT DOWN (without system disconnect)
1. Adjust the setpoint temperature to 32°F. The MFCH
instrument will disengage the heater contactor (if engaged)
and fully open the AVT valve. Allow the unit to operate in
this condition until process temperature as indicated on the
TEMPERATURE display is at the ambient water supply
temperature or below 85°F.
2. Stop unit operations by pressing the unit’s STOP key. This
action disengages the unit’s electric pump motor.
3. Disengage the water supply
to the unit by closing the
unit’s water supply valve (if
installed) or by turning off
the water supply source at
the central control point.
Determine if any residual
pressure is evident in the
system by checking the
unit’s pressure gauges.
Relieve all system pressure
if evident by opening the
pressure relief valve (figure
4.4A).
4. Disengage the electrical supply to the unit by switching
“off” the fused disconnect. Determine the POWER light on
the MFCH display is OFF.
C. UNIT SHUT DOWN (with system disconnect)
1. Adjust the setpoint temperature to 32°F. The MFCH
instrument will disengage the heater contactor (if engaged)
and fully open the AVT valve. Allow the unit to operate in
this condition until process temperature as indicated on the
TEMPERATURE display is at the ambient water supply
temperature or below 85°F.
2. Stop unit operations by pressing the STOP key. This action
disengages the unit’s electric pump motor.
3. Disengage the water supply to the unit by closing the unit’s
water supply valve (if installed) or by turning off the water
supply source at it’s central control point. Determine if any
residual pressure is evident in the system by checking the
unit’s pressure gauges. Relieve all system pressure by the
pressure relief valve.
4. Disengage the electrical supply to the unit by switching
“off” the fused disconnect. Determine the POWER light on
Pressure relief valve Figure 4.4A

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MILACRON
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Phone: 513-536-2584
the MFCH display is “OFF”. Disconnect and remove the
unit’s power cord from the fused disconnecting device.
5. Before disconnecting and removing the process circuitry, be
certain all system pressure is vented and the pressure
gauges read “0”. When the process circuitry is
disconnected and removed from the unit, a small amount
of water will be discharged from the unit. Please note that
this water should not be warm or pressurized if all shut
down and disconnecting procedures were followed.
Remaining process water can be discharged by removing
the pump casing drain plug.

Page: 55
MILACRON
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Phone: 513-536-2584
5.0 TROUBLESHOOTING
5.1 UNIT WILL NOT START (POWER LIGHT IS NOT ILLUMINATED)
5.2 UNIT WILL NOT START (POWER LIGHT IS ILLUMINATED)
5.3 UNIT STOPS
5.4 UNIT OVERHEATS
5.5 UNIT UNDERHEATS
5.6 PRESSURE RELIEF VALVE LEAKS

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MILACRON
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5.1 UNIT WILL NOT START (POWER LIGHT IS NOT ILLUMINATED)
A. Power supply to the MFCH unit is OFF. The operator should
determine the POWER light on the MFCH display is “off”. If so, the
operator should check for the follow conditions:
1. One or more fuses at the main disconnect device are open
(blown). Determine continuity at each fuse. If continuity is
not determined, replace the fuse. Then determine cause of
blown fuse.
2. Control circuit transformer fuse is open (blown). Determine
continuity at the control circuit transformer fuse. If
continuity is not determine, replace the fuse.
5.2 UNIT WILL NOT START (POWER LIGHT IS ILLUMINATED)
A. Power supply to the MFCH unit is ON. The operator can
determine that electrical power supply to the MFCH unit is “on” by
an illuminated POWER light on the MFCH display. Even with the
main power supply on, the MFCH unit is prevented from operating
by one of the following conditions:
1. “WATER PRESS” light ‘flashing red’ - water supply
pressure inadequate (pressure switch is open). The unit is
prevented from operation without adequate water supply
pressure by an electrical panel mounted pressure switch.
Sufficient water supply pressure must be present to close
the switch and consent the circuit to the electric motor
starter.
2. “PUMP O/L” light ‘flashing red’ - motor overload switch
opened. The electric motor is protected from overload
conditions (excessive flow) by a set of thermal overload
relays. These relays will open (trip) and prevent electric
power from reaching the electric motor. If the overload
relay is open, the overload relay must be reset before
operation can continue. An excessive flow condition must
be isolated and corrected immediately.
3. “HI TEMP’ light ‘flashing red’ - high temperature limit
switch open. The unit is prevented from operations at
temperatures exceeding 256°F by a “high temperature limit
switch”. This switch is installed in the “to process”
temperature sensor. If this switch is open (due to a high
temperature condition), the control circuit is not consented
and the unit cannot be started. If a high temperature
condition exists, the unit must first “cool down” (reduce
water temperature) before the “high temperature limit
switch” will automatically reset to allow operation.

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5.3 UNIT STOPS
A. The operator should determine the main power supply to the
MFCH unit is ON by an illuminated POWER light on the MFCH
display. With the main power supply “on”, the MFCH unit will be
prevented from operations by the following conditions:
1. “WATER PRESS” light ‘flashing red’ - water supply
pressure inadequate (pressure switch is open). The unit is
prevented from operation without adequate water supply
pressure by an electrical panel mounted pressure switch.
Sufficient water supply pressure must be present to close
the switch and consent the circuit to the electric motor
starter.
2. “PUMP O/L” Light ‘flashing red’ - motor overload switch
opened. The electric motor is protected from overload
conditions (excessive flow) by a set of thermal overload
relays. These relays will open (trip) and prevent electric
power from reaching the electric motor. If the overload
relay is open, the overload relay must be reset before
operation can continue. An excessive flow condition must
be isolated and corrected immediately.
3. “HI TEMP” light ‘flashing red’ - high temperature limit
switch open. The unit is prevented from operations at
temperatures exceeding 256°F by a “high temperature limit
switch”. This switch is installed in the “to process”
temperature sensor. If this switch is open (due to a high
temperature condition), the control circuit is not consented
and the unit cannot be started. If a high temperature
condition exists, the unit must first “cool down” (reduce
water temperature) before the “high temperature limit
switch” will automatically reset to allow operation.
B. The operator should check the POWER light on the MFCH display.
If the POWER light is off, main electrical power to the MFCH unit is
not supplied. The operator should check the following conditions:
1. One or more fuses at the main disconnect device are open
(blown). Determine continuity at each fuse. If continuity is
not determined, replace the fuse. Then determine cause of
blown fuse
2. Control circuit transformer fuse is open (blown). Determine
continuity at the control circuit transformer fuse. If
continuity is not determine, replace the fuse.

Page: 58
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5.4 UNIT OVERHEATS
A. Unit “overheating” is evidenced by “to process” temperatures
consistently above the selected setpoint temperature. Overheating
is also evidenced by a “to process” temperature that continues to
escalate above the SETPOINT temperature with no apparent
cooling action, even though the “cool” light is on. Extreme
overheating is evidenced by “to process” temperatures over 256°F.
The operator should check for the following conditions:
1. Inadequate water supply pressure. The MFCH unit must
be supplied with the proper water supply pressure to
provide cooling when required. Operations with improper
water supply pressure will prevent adequate cooling when
needed, leading to an overheat condition. The operator
must check the plant’s water supply pressure at the unit.
Static water supply pressure can be determined at the unit’s
location by reading the unit’s 0-160 PSI pressure gauges
when the unit’s pump motor is OFF.
2. AVT valve defective. The MFCH instrument opens and
closes the AVT cooling valve in incremental steps between
0 to 100% as prescribed by the current process load. A
continual discharge stream of process water to drain is
present under most operating conditions (except at full
heat-up). This allows the MFCH unit to maintain virtual
straight-line control of process water temperature. If the
AVT valve becomes clogged with process water debris or
scaled with mineral deposits, its operation is hindered or
fully prevented and adequate process water discharge to
drain is prevented. The operator must remove the AVT
valve and remove any loose debris. Massive debris or scale
deposits may necessitate replacement of the AVT valve. The
procedure for servicing the AVT valve is outlined in Section
5.3 of this manual.
3. Drain line obstruction. The operator must determine if the
drain line is obstructed by the following conditions. Section
3.4 outlines the parameters of correct drain line installation.
a. Closed drain line valve. An installed but partially
or fully closed valve in the drain line prevents full
discharge to drain and contributes to an
overheating condition. The operator should
determine the drain line is open.
b. High drain back pressure. Pressurized plant drain
lines will prevent flow to drain if the differential
between the water supply pressure and the drain
line pressure is inadequate. The factory recommend
minimum differential is 20 psi. If the differential is
less than the factory recommendation, plant service

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MILACRON
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personnel should take measures to reduce drain line
pressure.
4. MFCH instrument defective. The MFCH instrument is
designed and manufactured exclusively for MILACRON.
The MFCH instrument is life-tested and found to be field
reliable. However, in the case where the instrument is
determined to be defective, the operator must remove the
assembly according to instructions outlined in section 6.8
and return the assembly to the factory. The MFCH
instrument is not a field serviceable component.
5.5 UNIT UNDERHEATS
A. Unit “underheating” is evidence by operations with “to process”
temperatures consistently below the selected setpoint temperature.
1. Process water leakage. When the MFCH instrument
engages the heater to elevate process temperature, the
input of heat into the process can be offset by:
a. Defective AVT valve. If the AVT valve is defective, it
may pass a larger than required stream to drain,
thus providing unwanted cooling. A defective AVT
valve should be repaired immediately.
2. Heater element failure. A failed heater element will not
input adequate heat into the process to elevate the process
water temperature. The operator must check amps at the
heater contactor with the contactor energized. Zero amps
at the contactor indicate a failed heater or burnt wire
connections. The operator should remove the failed heater
and replace with a new heater according to the procedure
outlined in section 6.2.
3. The process may experience heat loss by:
a. Unit capacity too low. This occurs when the
process requires more heat than the MFCH unit’s
heater is capable of producing. The only option in
such cases is to install a MFCH unit with an
adequate heater KW rating for the load.
4. MFCH instrument defective. The MFCH instrument is
designed and manufactured exclusively for MILACRON.
The MFCH instrument is life-tested and found to be field
reliable. However, in the case where the instrument is
determined to be defective, the operator must remove the
assembly according to instructions outlined in section 6.8
and return the assembly to the factory. The MFCH
instrument is not a field serviceable component.

Page: 60
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
5.6 PRESSURE RELIEF VALVE LEAKS
A. The MFCH unit has a 150 psi pressure relief valve mounted in the
cooling cylinder. If the valve is found to be leaking, the operator
should check the following:
1. Water supply pressure exceeds 75 psi. The MFCH unit is
designed to operate with water supply NOT exceeding 55
psi. See section 3.3 paragraph B for specific water supply
pressure requirements at corresponding setpoint
temperatures. If the plant water supply pressure exceeds 75
psi, it is possible that the pressure relief valve may leak.
Static water supply pressure can be determined at the unit’s
location by reading the unit’s 0-160 PSI pressure gauges
when the unit’s motor pump is OFF. If the water supply
pressure at the unit’s location exceeds 75 PSI, a pressure
reducing valve must be installed in the water supply line.
The factory recommended ‘regulated pressure out’ is 55
PSI. Refer to section 8.4 for regulator installation drawing.
2. Back flow prevention device in water supply line. If a back flow
prevention device (check valve, pressure regulator, closed valve) is
installed in the water supply line, increased pressures from thermal
expansion are unable to move into the water supply line. This will
increase the unit’s internal pressure causing the pressure relief valve
to leak. Refer to section 8.4 for regulator installation drawing.
3. Valve contamination. The pressure relief valve may become
contaminated with water debris causing the valve not to close
properly. If this is the case, flushing the valve for a moment will
cleanse the seat and allow it to work properly. If flushing the valve
does not remedy the leaking, the valve must be replaced.
4. Extreme internal system pressure. If the internal pressure in the
MFCH unit is elevated, the pressure relief valve will leak as a safety
measure to dissipate excessive pressure. If this is the case, the
operator must determine why the system internal pressure is
excessive and correct the condition.

Page: 61
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
6.0 SERVICE/MAINTENANCE
6.1 PUMP SEAL REPLACEMENT
6.2 HEATING CYLINDER REPLACEMENT
6.3 AVT COOLING VALVE SERVICE
6.4 PROBE CALIBRATION
6.5 VOLTAGE CHANGEOVER
6.6 SENSOR PROBE SERVICE
6.7 PRESSURE SWITCH SERVICE
6.8 MFCH INSTRUMENT SERVICE
6.9 FLOW METER SERVICE

Page: 62
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
6.1 PUMP SEAL REPLACEMENT
A. The MFCH unit pump
seal is a carbon/niresist
shaft seal assembly
including a stationary
member, rotating
member and tension
spring (figure 6.1A).
B. The life cycle of the
pump seal is
determined by hours of
use, operating
temperature and water
quality. Poor water quality is the primary reason for
premature pump seal failure.
D. The operator should follow this procedure to replace the pump
seal:
1. Disengage process operations according to the procedure
outlined in section 4.4.
The operator must be
certain all system pressure
is relieved and the unit’s
pressure gauges read “0”.
2. Disengage main power
supply. The operator must
verify the POWER light on
the MFCH display head is
“off”.
3. Remove the lift-off access
panel and set aside (Figure
6.1B).
4. Open the electrical cabinet
panel door. The support
strap can be disconnected
and the MFCH instrument
assembly unplugged from
the umbilical to allow the
panel door to fully open
(figure 6.1C).
Stationary member
Rotating Member Tension Spring
Figure 6.1A
Remove lift-off access panel Figure 6.1B
Electrical cabinet panel cover
fully opened
Figure 6.1C

Page: 63
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
5. Drain machine. The
machine can be drained by
removing the pump casing
drain plug.
6. Remove the three motor
wire leads from the motor
wiring terminals. The
operator should “map” the
wire terminal locations to
ensure correct rewiring.
The power cord should be
removed from the motor
housing (figure 6.1D).
7. Locate and remove the 4
pump casing bolts. These
bolts secure the motor and
motor adapter to the pump
casing (figure 6.1E).
8. Separate the motor and
motor adapter from the
pump casing to expose the
pump impeller (figure
6.1F). Remove the motor
and motor adapter from
the MFCH unit and place
on a workbench to
continue the procedure.
9. Locate and remove the
dust cap from motor end
to expose slotted motor
shaft. The motor shaft is
free to rotate, but must be
secured to remove the
impeller. To secure the
motor shaft, insert a flat
bladed screw driver in slot
to hold the shaft stationary
(figure 6.1G).
10. Locate and remove impeller
locking screw (figure 6.1H).
Using a socket and ratchet,
the impeller retaining screw
can be removed. Once the
retaining screw is removed,
the impeller can be
“unthreaded” from the
motor shaft to expose the
pump seal assembly.
Motor leads Figure 6.1D
Pump casing bolts Figure 6.1E
Impeller Figure 6.1F
Motor shaft Figure 6.1G

Page: 64
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
11. Remove all seal parts
(figure 6.1I). Note seal
component arrangement
to facilitate reassembly.
12. Clean the motor shaft and
lubricate with a mild soap
solution. Note: oil must
never be used as a
lubricant since it will
damage the rubber parts
of the seal assembly.
13. Install new stationary seal
member in pump casing
cavity (figure 6.1J). The
operator must be certain
the stationary seal member
is fully squared and seated
in cavity.
14. Slide the rotating member
onto the lubricated pump
shaft (figure 6.1K). The
not to damage or tear the
rubber bellows assembly.
15. Place the spring onto the
rotating member.
16. Align the tension spring
and rotating member
before reinstalling the
impeller (figure 6.1L). The
the spring and rotating
member are aligned before
the impeller is fully
tightened and the impeller
retaining screw is
reinstalled.
17. Clean the pump casing,
cavities, impeller and O-
ring before reassembly.
18. Mate the motor and motor
adapter to the pump
casing. Reinstall the 4
pump casing bolts.
Removing impeller locking
screw with ratchet
Figure 6.1H
Seal components Figure 6.1I
Stationary member Figure 6.1J
Rotating member Figure 6.1K

Page: 65
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
19. Reconnect the motor power
cord and leads.
20. Reconnect the MFCH
instrument and resecure the
panel door support strap.
E. When the pump seal replacement
procedure is complete, the operator
may restart the MFCH unit according
to section 4. In many cases, a new
pump seal will experience a small
amount of leakage for a short time. This is normal, and is no cause
for alarm. After operating the unit for a few moments, the new seal
will take seat and the leak will stop.
6.2 HEATING CYLINDER REPLACEMENT
A. The MFCH unit’s heater is a flange
mounted assembly (figure 6.2A).
The heater assembly is inserted into
a cast tank and secured by 4 bolts.
B. The operator can determine if the
heater requires replacement when
the heater draws “0” amps or
when a continuity check of each
heater element is negative.
C. Generally, heaters fail due to low water flow, low water pressure, air
in the system, or defective heating elements.
D. The operator should follow this procedure to replace the heater:
1. Disengage process operations according to the procedure
outlined in section 4.4. The operator must be certain all
system pressure is relieved and the unit’s pressure gauges
read “0”.
2. Disengage main power supply. The operator must verify the
POWER light on the MFCH
display is “off”.
3. Remove the lift-off access
panel and set aside
4. Drain machine. The
machine can be drained by
removing the pump casing
drain plug.
5. Remove heater’s junction
box cover to located wiring
Heater Figure 6.2A
Heater junction wires Figure 6.2B
Aligning impeller and spring Figure 6.1L

Page: 66
MILACRON
4165 Halfacre Road
Batavia, Ohio 45103
www.milacron.com
Phone: 513-536-2584
connections. The operator should “map” the wiring
connections to ensure correct reinstallation (figure 6.2B).
6. Disconnect the three power leads from the heater
terminals. Remove the power cord from the junction box.
7. Remove the 4 heater
mounting bolts (figure
6.2C).
8. Remove heater (figure
6.2D).
9. Before the new heater is
installed, the mating
surface of the cast tank
should be cleaned. Once
cleaned, place the new
heater gasket onto the tank
mating surface. Coat the
mating surface with a high
temperature gasket sealant.
10. Set new heater into tank.
Aligning the bolt pattern of
the heater and tank
flanges.
11. Replace the 4 heater
mounting bolts. Alternate
to the opposite bolt while
tightening.
12. Reconnect the power cable to the heater terminals. Be
certain to tighten the power cord junction box connector.
Replace the junction box cover.
D. When the heater replacement procedure is complete, the operator
may restart the MFCH unit according to the procedure outlined in
section 4.
6.3 AVT COOLING VALVE SERVICE
A. The MFCH unit’s AVT cooling valve
is a two component assembly,
consisting of the motor/gearbox
and valve assembly, mated with a
machined aluminum coupling. The
AVT valve assembly is housed by a
aluminum cover plate (figure 6.3A).
The cover plate is secured by two
set screws and can be removed.
Heater mounting bolt Figure 6.2C
Remove heater Figure 6.2D
AVT valve aluminum cover
plate installed
Figure 6.3A

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