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1. User manual control unit DP6 HOT RUNNER TECHNOLOGY 9 Appendix 9 1 Appendix A EG Konformitatserklarung For the following below listed products Gunther Hot Runner Controller DP6 We hereby confirm that above listed products comply to all important safety requirements that have been declared by the Council of Assimilation of legal regulations by the EC membership countries concerning electromagnetical conformity 89 336 EEC EMC electromagnetic compatibility 73 23 EEC Low voltage requirements To verify these products to electromagnetical conformity the following standards were referred to EN 50081 part 2 EN 50082 part 2 The above mentioned products also comply to DIN EN 61010 Teil 1 03 94 DAVIDSMEYER amp PAUL GmbH Elektronik Br sselerallee 12 D 41812 Erkelenz Erkelenz den 01 06 2012 J Marquardt Gesch ftsf hrer www guenther hotrunner com 212. ConF Pid1 6 Unit Hour SYS quit Meaning configuration menu The configuration menu is used to change the controllers parameters You have to enter the correct password before entering this menu area Consider that the digits of the password have to be entered starting right by pressing key A or B Each of the four digits must be entered by pressing the key M The standard password is 0099 PID parameters The item PID1 6 allows to change the PID regulation parameters for each zone manually temperature unit This menu item is used to choose the temperature unit C or F counter operating time The operating hours will be shown in this menu item system parameters After entering the menu item sys the system parameters of the DP6 can be changed The menu is protected by a password and enables the user to set and change all system parameters Changes to the system parameters should only be carried out by authorised and qualified personnel If the manual configuration of the system parameters is inadequate or faulty it is possible to load the standard default values as described in chapter 2 4 Loading default values exit menu By selecting quit the parameter menu is closed To return to the normal operating level press key A or B If for approx 10 seconds no key has been pressed the parameter menu will be quit automatically 14 www guenther hotrunner
3. Control Unit DP6 Hot Runner Controller for 6 zones GUNTHER T RUNNER TECHNOLOGY a ER UE OI Ze GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY GUNTHER Heisskanaltechnik GmbH Sachsenbergerstr 1 D 35066 Frankenberg Eder Tel 49 0 6451 5008 0 Fax 49 0 6451 5008 50 E mail info guenther heisskanal de Internet www guenther hotrunner com 26 09 2012 V1 4 Technical changes and errors excepted 2 www guenther hotrunner com GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY Contents 1 General notes 4 1 1 Safety information 5 2 Display and controls 6 2 1 Change operation mode 7 2 2 Temperature lowering 7 2 3 Temperature boost function 8 2 4 Loading factory defaults 9 2 5 Error messages 9 S Parameter settings 10 3 1 Parameter menu 11 3 2 Configuration menu 13 4 Further functions 15 4 1 Softstart 15 4 2 Ready for molding signal 15 4 3 Start up ramp 16 5 Connection of control circuits 17 6 Installation and start up 18 7 Table of faults and defects 19 8 Technical data 20 9 Appendix 21 9 1 Appendix A EG declaration of conformity 21 www guenther hotrunner com 3 GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY 1 General notes This control unit has been build according to DIN 57411 part 1 VDE 0411 Teill and the regulation and standards shown in the appended EG conformity declaration and has left the fact
4. com GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY 4 Further functions 4 1 Softstart The first heating of a hot runner system should be done as gently as possible When using 230V heaters a softstart is necessary in order to remove the moisture slowly from the heaters Therefore the output power increases in a so called ramp time from 0 to 40 during the first phase of the softstart The ramp time should guarantee that a temperature of 105 C is reached at its end During the following hold time the DP6 regulates the temperature to 105 independent to the selected set values During the hold time the nozzles are dried out adequately with a low thermical load This start up procedure occurs automatically when switching the controller on After the hold time the unit switches into normal operating condition The typical running time is 10 minutes Note The softstart function can be de activated in the parameter menu It will be reactivated again every time you power up the controller 4 2 Ready for molding signal At the end of the heating phase all zones reaches the temperature window of 5 C and are then in a steady state The complete hot runner readiness is achieved when all zones are adjusted for a certain time periode The DP6 activates the ready for molding relay after an adjustable delay time Especially for needle valve systems a ready for molding delay of f e 120 sec is recomm
5. heating power of a similar nozzle and is set manually By simultaneously pressing the keys A and B you can change the operation mode of the selected zone from regulation over percentage to off Additionally the mode will change if you press the zone selection key for more than 2 seconds Note If the controller detects during normal operation a defective thermocouple the heater circuit turns off and an error message appears The DP6 controller switches over to percentage mode after confirming this message 2 2 Temperature lowering During any long term production pause it s advisable to lower the temperatures This prevents the material to get damaged In opposite to switching off the controller the production process can be restarted faster after the break Pressing the lowering key activates the lowering mode This is indicated by a green LED The set temperatures of all zones will be reduced by a adjustable value lowering value in C Fig 2 2 temperature lowering is activated The activated temperature reduction is indicated by a green glowing LED and the text red reduction Additionally the lowering temperature f e 50 C will be shown In order to achieve the most uniform cooling a ramp reduces the temperature within the first 2 minutes slowly The green light of the lowering key is blinking during this cooling ramp The temperature lowering value can be adjus
6. rEd or rEd A enables the user to set rEdA the lowering temperature or the lowering current temperature boost The menu item set value boost bOO0 is used to adjust the boost bOO _ temperature configuration menu The menu item configuration menu CONF enables the user to enter the ConF _ configuration menu This menu is protected by a password Please refer to chapter 3 2 Configuration menu 12 www guenther hotrunner com GUNTHER User manual contro unit DP6 HOT RUNNER TECHNOLOGY 3 2 Configuration menu entry point configuration menu ee ee A KP value Ki value KD value manual setting of the regulation parameters for zone 1 6 setting temperature unit CASE hourmeter settings SE m gt PAO PAO2_ PA50_ A i a parameter J 0010 RCE 0047 0047 ki PAOI PA5O It rmal a a Fig 3 1 flow chart of the configuration menu The system parameters of controller DP6 can be set in the configuration menu After entering the password 0099 the various items for frequently used parameters can be changed easily The item system allows changes to all parameters Therefore it is protected by an additional password Changes of system parameters must be carried out by authorised and qualified personnel www guenther hotrunner com 13 User manual control unit DP6 GUNTHER HOT RUNNER TECHNOLOGY Display
7. DP6 occurs mainly via the channel selector buttons and the A and B buttons Use the channel selection buttons to first select the control circuit zone and then modify the displayed set temperature The set temperature of the selected zone can be changed using the keys ands The set temperatures of several zones can be changed after selecting them To do this press the zone selector keys in quick succession A flashing parallel display indicates the selected zones The parallel display on the right side of the controller shows the current values for all six zones The M button is used to change the displayed value to the set temperature SET the current temperature ACTUAL the deviation DIFF and the output power in During normal operation the actual temperatures will be shown If there is a zone which has been turned off the display appears On the status display a green illuminated text OK indicates the ready for molding signal if the deviation is within 5 C 6 www guenther hotrunner com GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY 2 1 Change operation mode Normal operation mode for all zones is temperature regulation In a case of a defective thermocouple the mode can be changed temporarily to percentage with an adjustable output power in The setting for the unregulated output value in should correspond to the average
8. ended You can change the delay time for the OK signal using the parameter 57 in the system parameter menu The OK relay contact connector Wieland ST17 2BA on the controllers rear will turn on if the ready for molding signal is active This potential free relay contact 250 V 5 A can be connected with the molding machine to stop the cycle automatically in a case of unsuitable temperatures www guenther hotrunner com 15 GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY 4 3 Start up ramp A typical hot runner system contains some fast acting nozzles and single slow acting manifold plates To prevent material damages it s recommended to heat up all zones uniform to the slowest one The automatic start up ramp detects the slowest heater circuit manifold and tries to heat up this circuit as fast as possible All other zones will heat up only as fast as the detected manifold zone As a result all zones achieves their operating temperatures at one time start ramp 7 Aue Ve Manifold on zone 1 Fig 4 1 start up ramp detects the manifold on zone 1 During the start up ramp the text RP and the zone number of the detected manifold circuit will be displayed If the automatic manifold detection doesn t find the correct zone you can set the manifold zone also manually Therefore the parameter 42 is helpful Value of Function parameter 42 aa Start up ramp deactivated 1 6 manual ma
9. in C changed lowering value boo Sen bo KE KE boost value in C GA bee boost value configuration menu Enter a password Fig 3 1 flow chart for the parameter menu You will enter the parameter menu when you press the key M for more than 2 seconds Every following key stroke on M leads to the next menu item www guenther hotrunner com 11 GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY The function of each menu item will be activated using the keys A or B Then the display changes between no or Yes Once you entered a menu item the desired value can be changed using the A and B keys Parameter changes will be saved when you press the key M to leave the menu item The configuration menu is needed to change important system parameters like the PID regulation values Note The password for the configuration level is 0099 on default Display Meaning exit menu By selecting quit the parameter menu will be closed Press key A or B to quit return to the normal operating level If for approximately 10 seconds no key has been pressed the parameter menu closes automatically softstart The softstart function for 230V nozzles is selected by entering the menu SoFt SOFT Here you can enable or disable the softstart function temperature lowering rEd The menu item set value lowering
10. isplay load defaults appears after choosing to load the dEF default values for approx 5 sec 2 5 Error messages During it s operation the controller DP6 runs some diagnostic functions including a check of the thermocouples Any fault or defect will be indicated by a short report The heater circuit will always be disconnected in case of a fault or defect Note System faults can be confirmed by pressing key M The following error messages may appear during operation Display Meaning Thermocouple failure No A thermocouple is disconnected or interrupted on one wire Sens Please check the thermocouple s wiring Polarity error at thermocouple connection Pol Polarity error at the thermocouple s connection of control circuit 1 The tH 1 thermocouple seems to be connected with wrong polarity Please check the wiring of your thermocouple Note When confirming the fault report thermocouple failure or polarity error with key menu the DP6 switches into percentage control mode automatically If the problem has been solved before confirming with key menu the controller remains in temperature regulation mode Thermocouple short circuit Err A short circuit has occurred in control circuit 1 This fault can be detected tH 1 after a period of min 90 sec Please check the wiring of your www guenther hotrunner com 9 GUNTHER User manual co
11. ket Installation e Plug in the 24 pin load connector with the connected regulation zones e Plug in 16A CEE mains plug for power supply e Turn on the main switch e Set the desired set temperatures for all zones e During initial start up you should activate each zone one after the other So you can find possible mix up of thermocouples or heater loads e After switching on the control unit please wait for a few minutes until all zones are heated up evenly 18 www guenther hotrunner com GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY 7 Table of faults and defects During operation the DP6 checks continuously the regulation circuits on faults or defects A corresponding error message will be shown if an error appears Message Fault Defect Possible cause Countermeasure Fault report Thermocouple of Thermocouple is not Check connection plug no sensor 3 zone 3 defect connected or and cable of thermocouple interrupted Fault report Polarity error at Polarity error atthe Correct the polarity Pol TH 1 thermocouple of thermocouple zone 1 C Fault report 100 output defective fuse or Check the 16A fuse of no load 2 power but no disconnected heater zone 2 or temperature or short circuit on the check the thermocouple increasement on thermocouple zone 2 Significant Thermocouple Check the earth wire of fluctuation of defect or load circuit the load circuit temperature not earthed Tem
12. nifold presetting zone number 1 6 automatic manifold detection default 16 www guenther hotrunner com GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY 5 Connection of control circuits one 2 zone 3 zone 4 zone5 zone heaters Zone 1 zone 2 2 Fig 5 1 connector on the DP6 rear On the controllers rear you will find the 24 pin HAN24 connector for the heater circuits and the thermocouples Each 230 V load circuit and it s thermocouple will be connected using these solid 20A contacts Please refer to fig 5 2 for informations about the assignment for heaters and thermocouples zone 1 2 3 4 5 6 load 1 phase 1 3 5 7 9 1 load 2 neutra 2 4 6 8 10 12 Thermocouple 13 15 17 19 21 23 Thermocouple 14 16 18 20 22 24 Fig 5 2 Assignment load and thermocouple connection www guenther hotrunner com 17 GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY 6 Installation and start up heaters load main switch OK contact thermocouples fuses F1 F6 Fig 6 1 rear of the DP6 controller Ensure that the controller DP6 has a stable position where no heat can occur The electrical connection will be done using the 5 pin CEE plug in 16 A version The used CEE socket must be fused with a 16 A circuit breaker It s not allowed to operate the controller on a 32 A CEE soc
13. nowledge and experience GUNTHER assumes no liability for damages caused by Not following the manual Improper use Use of untrained personnel Unauthorized conversions and technical changes Use of unauthorized spare parts 4 www guenther hotrunner com GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY 1 1 Safety information The control unit DP6 is designed for temperature regulation of six hot runner circuits As an application is the control of all 230 V hot runner zones provided With an output power of up to 3500 W very different 230 V loads can be operated via the integrated pulse control group On the rear the illuminated main switch the combined load and thermocouple plug and the six load fuses are positionized The plugs contact assignment is shown in chapter 5 Connection of control circuits For the protection of each circuit the six load fuses F1 F6 are located below the load connector Use exclusively only fuse elements type 6 3 x 32mm 16A SA super fast acting Attention The maximum current for the heater circuits should not exceed 16 A Use only original fuse type Schurter 16A SA 6 3x32mm www guenther hotrunner com 5 GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY 2 Display and controls set temperature exist temperature parallel display lowering 50 C Fig 2 1 controls of the DP6 The simple operation of the controller
14. ntrol unit DP6 HOT RUNNER TECHNOLOGY thermocouple Over temperature The temperature of control circuit 1 crosses the security mark The max allowed temperature can be set as system parameter and is set to 500 C as standard t Hi Ch1 Err Ambient temperature above limit Temp The unit detected an ambient temperature of above 70 C 3 Parameter settings The controller s operation depends on the setting of the parameters For easy access the most important parameters are displayed in a menu The parameter menu is divided into a user menu and a configuration menu to which the access is restricted by a password In the user menu only non critical system parameters can be changed Caution The access to configuration data is protected by a password The configuration should only be changed by authorised and qualified personnel Inexpert configuration may cause damage of the hot runner system The person who sets the unit into operation is responsible for the correct configuration of the controller 10 www guenther hotrunner com User manual control unit DP6 GUNTHER HOT RUNNER TECHNOLOGY 3 1 Parameter menu normal operation exit point to normal operation softstart ON OFF setting lowering value setting boost value configuration So DH am SOF SOFt LA yes softstart ON softstart OFF Ech nO a EI Ed e EP Ed Le y lowering value
15. ory in perfect condition In order to maintain this standard and to guarantee safe operation please read this user manual carefully and follow the instructions Ensure that your local supply voltage corresponds to the unit s nominal voltage before switching on For safe operation the unit must be plugged into an earthed socket Any disconnection of the earthed conductor e g by using an extension flex without earthed conductor may cause severe danger Attention Pull mains plug Always disconnect the unit from mains before working on electrical connectors This control unit contains hazardous voltage Any repair and service work must be carried out by qualified and authorised personell only The components inside the unit are maintenance free for our customers They are exclusively serviced by G nther Hot Runner Systems To operate the control unit a fuse protected 16 A CEE socket must be used Please note that the DP6 uses 2 phases with a maximum current of 16 A This device is used in the commercial sector The operator of the device is therefore subject to the legal obligations for workplace safety In addition to the safety instructions in this manual be valid for the range of the device safety accident prevention and environmental protection regulations are observed All statements and information in this manual has been complied in accordance with applicable standards and regulations the prior art as well as our many years of k
16. perature load circuits Check assignment of doesn t increase swapped heater circuit to the thermocouple Note The earth wire of all tool elements like heaters and thermocouples must be in a good condition Lack of earthing or insufficiently earthed heating elements may cause severe errors in temperature reading Note During initial start up the zone s assignment must be checked For that purpose the user should heat up the control circuits one by one and monitor the temperature rise www guenther hotrunner com 19 User manual control unit DP6 GUNTHER HOT RUNNER TECHNOLOGY 8 Technical data Nominal Voltage Mains plug Nominal capacity Standby capacity Load connection Temperature sensor Fuses Regulation Storage temperature Operating temperature Protection type Dimensions Colour Weight 20 2 phasig 2 x 230VAC 5 10 L1 L2 N PE CEE 16A Stecker 5 polig 2 Phasen belegt Lange 3 m 7000 W 2x16A ca 10 VA 6 x heater circuit 230V 16A zones 1 6 Harting series HAN24 contacts 1 12 6 x thermocouple Typ L FeCu Ni Harting series HAN24 contacts 13 24 16A FF Schurter Typ SA super fast acting for triacs zone 1 6 Fuzzy PID regulator with puls group control 0 bis 500 C 0 932 F 25 bis 80 C 0 bis 45 C IP 20 B H T 259mm x 95mm x 290mm grau und blau RAL 9018 und RAL 5015 3 8 kg www guenther hotrunner com GUNTHER
17. ted using the main menu item red The factory default value is 50 C www guenther hotrunner com 7 GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY 2 3 Temperature boost function For starting a tool it can be helpful to raise all temperatures for a short period After pressing the boost key the set temperatures of all zones increases to the adjustable boost value f e 25 C boost value in C BOOST button Fig 2 3 activated BOOST function The activated temperature boost is indicated by a green glowing LED and the text boo boost Additionally the boost temperature value f e 25 C will be shown In order to achieve the most uniform heating a ramp increases the temperature within the first 2 minutes slowly The green light of the boost key is blinking during this heating ramp The temperature boost value can be adjusted using the main menu item boo The factory default value is 25 C 8 www guenther hotrunner com GUNTHER User manual control unit DP6 HOT RUNNER TECHNOLOGY 2 4 Loading factory defaults The system parameters of the DP6 can be set in the parameter menu item Sys In case of an error in the parameter configuration the unit offers the possibility to load the standard factory default values again For that purpose press keys A and B and M simultaneously during the controllers power on situation display meaning LOAd The d
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