User Manual for MT Series Hot Runner Controller - Mold
Contents
1. plen T1 T2 e Z T C1 T C13 1 Ea T C 2 T C14 2 iom T C 3 T C15 3 4 7 OG 19 T C 4 T C16 4 Eiern T C 5 TIC17 5 4 ee T C 6 T C18 6 ORI T C 7 7 4 WOOF T C 8 8 TF e e e o e e e o PH FH T C 9 9 2 L ot OF ot OF OF OF OF OF T C 10 10 GND T C 11 11 T C 12 Type WZ 24 1RX J A E t Et E E E o d 44 mm 140 mm 130 mm ca 0 mm TempMaster MT User Manual Revision 2 1 Mold E Not Under documentation control if printed May be revised without notice Page 47 Feb 2013 Miaste T 3 L3 VI VI VI VI VI ande mm m m rr rrr rr rr wer e E NM en MU em ees N N ech sch eck sch x DN ND CO OON OD O1 P C QE Ow os a FR EES LO CO sl O3 OU JS GO M JM CCO J N S Max 230VAC 16A Type WZ 24 1RX EE N ke TempMaster p EECH Tool Connector MT xx 12 amp MT xx 18 Canadian Std M Cable 12 Zoo dro Tis 240 912 LEA 12 dE R12 1C 11 o H 230 911 E 112 9 23 R112. 196 7 LL T3 EE 189 ep SA A FB 179 5 166 4 D 4 e 3 AATE Tic lise e TN 15 e GND Power IC Connection ZONE PINS R 1 1 2 3 4 e M 230Vac 16A Connector WZ 24 2RX 35 mm 43 mm 140 mm 170 mm 56 mm 130 mm i os Revision 2 1 TempMaster MT User Manual Mold Masters Feb 2013 Page A6 Not Under documentation control if printed May be revised without notice Appendix A TempMaster Mit Tool Connector MT xx 12 amp MT xx 18 Europe pes ER
3. CHINA HONG KONG TAIWAN Mold Masters KunShan Co Ltd Zhao Tian Rd Lu Jia Town KunShan City Jiang Su Province People s Republic of China tel 86 512 86162882 fax 86 512 86162883 mmc sales moldmasters com UNITED KINGDOM Mold Masters UK Ltd Netherwood Road Rotherwas Ind Est Hereford HR2 6JU United Kingdom tel 44 1432 265768 fax 44 1432 263782 uk moldmasters com FRANCE Mold Masters France Zl la Marini re 2 Rue Bernard Palissy 91070 Bondoufle tel 33 1 82 05 00 80 fax 33 1 82 05 00 83 fr moldmasters com SINGAPORE MALAYSIA INDONESIA THAILAND Mold Masters Singapore PTE Ltd No 48 Toh Guan Road East 06 140 Enterprise Hub Singapore 608586 Republic of Singapore tel 65 6261 7793 fax 65 6261 8378 mmsinfo moldmasters com TempMlaster 7 Global Support SOUTH AMERICAN HEADQUARTERS BRAZIL Mold Masters do Brasil Ltda Rua Hum 1106 e 1126 Jd Manchester Nova Veneza Sumare Sao Paulo Brasil CEP 13178 440 tel 55 19 3922 4265 fax 55 19 3922 4266 vendas moldmasters com br U S A Mold Masters Injectioneering LLC 103 Peyerk Court Romeo MI 48065 USA tel 1 800 450 2270 USA only tel 1 586 752 6551 fax 1 586 752 6552 mmi ing moldmasters com KOREA Mold Masters Korea Ltd 708 Byucksan Digital Valley 5 Cha 60 73 Gasan dong Geumcheon gu Seoul 153 788 South Korea Tel 82 2 2082 4755 Fax 82 2 2082 4756 mmkr sales moldmasters com SPAIN
4. Run mode automatically to start heating the tool Switching off the whole Switching off individual controller modules When you switch the power off all zone Each module has it own power settings are memorised If you have set switch Use the button below the different zones to slightly different screen to turn the module off and on temperatures in order to get optimum performance then those settings are held and will be the same when you next switch on Switching off individual zones To switch off any single zone touch that zone to show the initial menu Touch to switch off that zone See that zone now displays OFF Repeat the same steps to switch back on again e Revision 2 1 TempMaster MT User Manual Mold Masters Feb 2013 Page 6 Not Under documentation control if printed May be revised without notice SCC oi i Temp aster The Controller Cabinet The power supply to the control cabinet is via a strain relief mounted cable gland plug wired in star or delta configuration Please check your specifications for details of which configuration has been configured Connections to the tool are by looms terminating type Contact 24pole connectors with 48pole housing or their equivalents There are normally two types of cables supplied a thermocouple connection and a power connection both using type H BE24BS as a preferred connector Typical wiring details are shown in Appendix A An alarm outpu
5. T10 T 220 910 10 SRI oe R10 T akt 9 _ Lg ND SL R 9 TC lt 200 9 8 s 0 08 20 R8 8 d 190 07 S TE Gam 80 96 6 e 07 18 lt are 05 Dag A i 160 04 s 4 8 3 150 93 _ KEN 9 2 1 149 Q2 2 e er Ia n 79 2 RB EL 3342883243 20000 0 30 M DA P OD OC daadadadadaoO Connection Hug 1 Connection Hug2 Fower TC Zone Hns Zone Hns Gel Fins Ke Ans R1 113 T1 1 13 RI3 143 T13 1 y13Q R2 214 T2 20140 RI4 214 T14 2 y14Q R3 315 T 3 3 15 R15 315 TC15 3 y150 R4 416 EA 40 166 R16 416 T16 At VIE R5 5417 T 5 5 176 RI7 51 17 TC17 5 y170 R6 6 18 T 6 6 18C R18 618 TC18 6 186 R7 719 T 7 7 y19C R9 7 19 TC19 7 y19C R8 8 20 TC 8 20 F20 820 T20 8 Y20 R9 9 21 T 9 O y21C R21 921 T21 99 y210 R10 10 22 TC10 10 y22 R22 10 22 1722 10 22 R11 11 28 T11 116 230 R23 11 23 T23 11 Y23 R12 12 24 T12 12 y24 R24 1224 T24 12 24 Ee LMT EE O Ir E 73 i ze SST briT gt Mold K mevision 2 TempMaster MT User Manual e Masters Feb 2013 Page Ag Not Under documentation control if printed May be revised without notice EZ Pomp Master 017 Index Alarm Extend 24 Alarm Messages 38 Alarm Output External 42 Auto Man 22 Boost whole cabinet 31 Boost Disable 23 Boost level setting 17 Boost Mode Individual zones 33 Controller Card Fuses 40 Current Display Screen 9 Default S
6. Touch X to return to main display and see that Zone 1 is now running in Manual Mode Manual Mode Power Level Touch the Manual zone to obtain the initial menu Touch AN to raise or v to lower the power setting and hence the temperature y TempMaster MT User Manual Revsin2 1 Mold 3 m Not Under documentation control if printed May be revised without notice Page 29 O Feb 2013 Masters TempMaster p Running your controller Slave Mode Slave mode is an alternative to Manual and can be selected if one zone has a faulty thermocouple The Slaved zone then mimics the same power output as the healthy zone and provided that they had been running at a similar power level previously then the slaved zone will hold a similar temperature From the Temperature Display Screen touch either zone to obtain the initial menu Touch x to obtain the Function Menu Touch Program and use up down keys to find Slave Touch Slave Touch Slave On Touch X twice to return to main display See that Zone 1 displays S2 to indicate it is slaved to Zone 2 To restore to Auto repeat the first five above steps and select Slave Off y Revision 2 1 TempMaster MT User Manual Mold 2 P Masters Feb 2013 Page 30 Not Under documentation control if printed May be revised without notice Running your controller TempMlaaster p Standby and Boost Mode There are two options for switching
7. or all may be changed to On in which case activating Manual Standby or Boost may generate an alarm output From the Temperature Display Screen touch either zone to obtain the initial menu Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu Touch AN or VV to find the page containing an Alarm option Touch any of the three options Alm tdn shown here to open the page and set it to On Touch X once to return to the Alarm Selection in order to Am tup select more Alarm options Dmm x x Touch X a second time to return to the main display Revision 2 1 TempMaster MT User Manual Feb 2013 Page 24 Not Under documentation control if printed May be revised without notice Setting up your controller TempMlaster 7 Language There are four language options available for the MT controller and selection is done as follows From the Temperature Display Screen touch either zone to obtain the initial menu Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu Touch AN or VV to find the page containing a Language option Touch Language to open the page and set it to the required language Touch X twice to return to the main display y TempMaster MT User Manual Revision21 Mold 3 ez Not Under documentation control if printed May be revised without notice Page 25 Feb 2013 Mast
8. replace fuses When it comes to machine maintenance there is very little that you need to do to look after it Replacement parts We do not expect that you will need to repair any controller parts at board level other than fuses In the unlikely event of any board failure then we provide an excellent repair and exchange facility for all our customers Cleaning and Inspection Any excess dust that has entered into the cabinet may be removed with a light brush and vacuum cleaner External cables should be checked to see that there has no damage to the flexible conduit plugs or sockets If the flex has been squashed if there is visible damage or if there are any exposed conductors then for your own safety it must be replaced If the equipment is subject to vibration then we recommend that you use an insulated screwdriver to check that no terminals have become loose TempMaster MT User Manual Revision 2 1 de Mold Not Under documentation control if printed May be revised without notice Page 35 Feb 2013 Maste S TempMaster Ina Maintaining your controller Restoring factory settings and recalibration There are two main functions which are available for restoration and recalibration These are available via the Factory option which is password protected EE From the Temperature Display Screen touch either zone to obtain the initial menu E E EI Touch Ka to obtain the Function Menu Touch Progra
9. at 300 C temperature will lower to 200 C If your controller is set in Fahrenheit at 580 F temperature will lower to 400 F From the Temperature Display Screen touch either zone to obtain the initial menu Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu Touch AN or VV to find the page containing a Standby option Touch the Standby button to open the value setting option Standby Use AN and or Tel to set the desired Standby Temperature 101 H Note Hold your finger on or We to raise or lower value by large amounts Touch X twice to return to the main display y Revision 2 1 TempMaster MT User Manual Mold 2 P Masters Feb 2013 Page 18 Not Under documentation control if printed May be revised without notice Setting up your controller TempMlaster 7 Monitoring Temperature Limits Your controller card monitors the actual temperature of each zone and verifies that the zone is operating within specific limits Rather than fixed points of temperature the Ot and Ut Limits are set as deviation above or below the set point If these temperatures are exceeded the alarm relay on the MT card changes state to raise a disable injection interlock or alarm Warn and Alarm limits Although there is only one upper and one lower Alarm setting each gives a visual warning at half way point If an upper alarm is set to 10 deg then a Warning will show at 5 deg Th
10. greyed out then this function has been inhibited see page 23 From the Temperature Display Screen touch either zone to obtain the initial menu Touch X to obtain the Function Menu Touch Program to obtain the Program Menu Touch Boost to enter boost mode for the fixed 2 minute period The screen reverts to main display but you can see the boosted temperature and confirmation message tup flash alternately in the Actual Temperature window y TempMaster MT User Manual Revision21 Mjold I Not Under documentation control if printed May be revised without notice Page 33 O Feb 2013 Masters TempMaster p Running your controller Changing Set Temperature Auto or Manual Using the up and down buttons changes temperature setting for both Auto and Manual zones Increase Setting Touch on the zone to display the initial menu and touch to raise the temperature Touch X to revert to main Display Decrease Setting Touch on the zone to display the initial menu and touch NV to lower the temperature Touch X to revert to main Display dem Revision 2 1 TempMaster MT User Manual Mold p Masters Feb 2013 Page 34 Not Under documentation control if printed May be revised without notice Maintaining your controller TempMaster i Maintaining your controller Servicing and repairing your controller Always isolate your controller at source before you open the unit to inspect it or
11. keeping your finger on the up or down button will allow the setting to roll on it does not need repeated dabs to alter the setting by a larger amount e Turn the zone on or off by using the 67 button e Select more functions by touching the Ka button e Escape from Manual back into the default Auto mode by touching the 4 button e Leave this menu and return to two zone display by touching the X button TempMaster MT User Manual Revision 2 1 de Mold Not Under documentation control if printed May be revised without notice Page 9 O Feb 2013 Masters TempMaster Mit Navigation Fm Mold Masters Function Menu e 2607 7 cm Boost Pressing Ka on the initial menu brings you to the Function menu which has three function options and a further Program menu Manual puts the selected zone into manual operation Returning to Auto is achieved by touching in the previous options Standby decreases that zone temperature by a pre set amount Returning to Auto is achieved by touching in the previous options Boost raises that zone temperature by a pre set amount The temperatures remain at this raised level for two minutes then restores to Normal level Program Menus EN SS SS Alm lt Sch rz cac de m Program Menu Select Program from the function menu to reveal further set up options After you enter the p
12. paused In this condition all the zone temperatures can be reduced by the predetermined amount which helps to prevent degradation on certain materials To set the decrement refer to Setting Standby Level on page 18 Once standby mode is activated both zones would be reducing to standby temperature If the screen at step three shows the Manual Standby and Boost buttons greyed out then this function has been inhibited see page 23 From the Temperature Display Screen touch either zone to obtain the initial menu Touch X to obtain the Function Menu Touch Program to obtain the Program Menu Touch Standby to enter Standby mode and reduce zone temperatures The screen reverts to main display but you can see the standby temperature and confirmation message tdn flash alternately in the Actual Temperature window To come out of standby Touch the Standby Zone to obtain the initial menu Touch F to come out of Standby and revert to Auto Touch X to return to main display y Revision 2 1 TempMaster MT User Manual Mold 2 P Masters Feb 2013 Page 32 Not Under documentation control if printed May be revised without notice Running your controller TempMlaster 7 Boost Mode Individual zones This mode provides a means of temporarily boosting the zone temperature for a non user configurable period of 2 minutes If the screen at step three shows the Manual Standby and Boost buttons
13. rise Check thermocouple wiring it may be has been detected in that reversed Heater wiring may be faulty zone When the console starts or element may be open circuit to apply power it expects to see an equivalent heat rise at the thermocouple If the Thermocouple has been trapped and pinched elsewhere in the tool or cable then it cannot see the full heat rise that occurs at the tip If left uncorrected then there is a danger that the zone could overheat and damage the tip Instead the circuit maintains the output at whatever level it reached when the monitor circuit detected the fault The output fuse for that zone Replace the fuse with one of the same has failed Please Note A fuse rating and type i e High Rupture can only fail due to a fault Current load fuse The blown fuse is external to the controller located either on the control card Identify and rectify the fault before replacing the fuse Note The fuse detection circuit requires a continuous low level current through a high impedance bleed resistor to maintain the alarm condition As a result the load circuit is still connected to the mains voltage supply and it is not safe to attempt to repair or replace the fuse without first isolating the circuit If the fuse in question is mounted on a control card then it is safe to unplug the board in order to isolate the circuit and replace the fuse on the card The system has detected an Check your heater
14. to standby or boost mode 1 You can set each zone individually by using the module touch screens 2 Alternatively you can switch all zones together by using the cabinet Boost Normal Standby selector shown below Standby whole cabinet Switch the Boost Normal Standby selector towards the right and select Standby All zones are set down by the standby amount and remain at that lower temperature until the switch is restored to the centre off position Boost whole cabinet Switch the Boost Normal Standby selector towards the left and select Boost All zones are raised by the boost amount for a set period of two minutes even though the switch may be left in Boost position No Standby or Boost option Note that if the Factory setting has been set to Manual Disable then the Standby Boost rocker switch will have no D effect on controller temperature If you suspect it may have the Function Menu If the three buttons have been greyed TUE out as in this view then Standby and Boost are not available been set then touch any zone and then touch Ka to obtain Standby Boost individual zones These are described on the following pages TempMaster MT User Manual Revision 2 1 Fm Mold Not Under documentation control if printed May be revised without notice Page 31 O Feb 2013 Masters TempMaster p Running your controller Standby mode Individual zones This mode is available for times when the mould tool is
15. wiring for a low earth fault impedance path to earth Revision 2 1 TempMaster MT User Manual Mold Masters O Feb 2013 Page 38 Not Under documentation control if printed May be revised without notice Troubleshooting No mains supply synchronisation pulses being received The three phase supply is used in a cross over detection circuit to generate timing pulses for accurate phase control and firing the triac If the phase detection fails on one or two phases then there is no pulse to use to measure phase angle and the LINE error message is generated Meanwhile all circuits on the healthy phases will continue to work normally The card has detected an abnormal input at the T C termination that indicates a shorted or Reversed thermocouple An open circuit thermocouple has been detected and no auto response has been selected in the T C Open Error column of the Setup page Other possible fault Conditions Rapid Temperature Fluctuations TempMaster mv i There is a phase detection circuit on each K Series card and a common phase detection circuit on all other controller types Although a fault in such circuits may cause the LINE error message such fault is very rarely seen The most common error is either the absence of one phase or if a plug has been re wired incorrectly a swapped phase and neutral If a LINE error message occurs then switch off and isolate the controller then check supply
16. 1 905 877 0185 fax 1 905 873 2818 info moldmasters com INDIA Mold Masters Technologies Private Limited 247 Alagesan Road Shiv Building Saibaba Colony Coimbatore T N India 641 011 tel 91 422 423 4888 fax 91 422 423 4800 mmiplinfo moldmasters com Regional Offices AUSTRIA East and South East Europe Mold Masters Handelsges m b H Pyhrnstrasse 16 A 4553 Schlierbach Austria tel 43 7582 51877 fax 43 7582 51877 18 at moldmasters com MEXICO MM Hot Runner Injection Mexico S A de C V Av San Carlos No 4 Nave 2 Parque Industrial Lerma Lerma Estado de M xico 52000 M xico tel 52 728 282 48 33 fax 52 728 282 47 77 mexico moldmasters com Revision 2 1 Feb 2013 EUROPEAN HEADQUARTERS GERMANY SWITZERLAND Mold Masters Europa GmbH Postfach P O Box 19 01 45 76503 Baden Baden Germany Neumattring 1 76532 Baden Baden Germany tel 49 7221 50990 fax 49 7221 53093 europe moldmasters com JAPAN Mold Masters K K 1 4 17 Kurikidai Asaoku Kawasaki Kanagawa Japan 215 0032 tel 81 44 986 2101 fax 81 44 986 3145 info mmkk co jp CZECH REPUBLIC Mold Masters Europa GmbH Hlavni 823 75654 Zubri Czech Republic tel 420 571 619 017 fax 420 571 619 018 cz moldmasters com POLAND Mold Masters Europa GmbH Skr Pocztowa 59 00 908 Warszawa Poland tel 48 0 66 91 80 888 fax 48 0 66 91 80 208 pl moldmasters com Page 50 ASIAN HEADQUARTERS
17. 1 244 575601 gecim gecim pt BULGARIA Mold Trade OOD 62 Aleksandrovska St Ruse City Bulgaria Tel 359 82 821 054 Fax 359 82 821 054 contact mold trade com IRELAND Bray Engineering Services Mr Liam Shortt Unit F3 Network Enterprise Business Park Kilcoole Co Wicklow Ireland Tel 353 1 201 5088 Fax 353 1 201 5099 info BrayEngineeringServices com RUMANIA International Mold Trade Co SRL Str Constantin Aricescu Nr 21 BI 20 Sc 2 Apt 20 Bucharest Sector 1 Romania Tel 4 021 230 60 51 Fax 4 021 231 78 43 contact matritehightech ro www moldmasters com Version February 20 2013 Updates are available at http www moldmasters de marketing download locations Mold Masters Worldwi e Locations pdf DENMARK NORWAY SWEDEN Englmayer A S Skenkelsoevej 9 Postbox 35 DK 3650 Oelstykke Denmark Tel 45 46 733847 Fax 45 46 733859 support englmayer dk ISRAEL ASAF INDUSTRIES Ltd 29 Habanai Street PO Box 5598 Holon 58154 Israel Tel 972 3 5581290 Fax 972 3 5581293 sales asaf com TURKEY MMG Consulting amp Engineering Yesil Gesme Sok No 30 3 Ciftehavuzlar 81060 Istanbul Turkey Tel 90 216 357 0783 Fax 90 216 385 0656 turkey moldmasters com gt TempMaster MT User Manual Revision21 Mjold e Not Under documentation control if printed May be revised without notice Page 51 Feb 2013 Masters
18. Alarms for Manual Standby or Boost operation Language Setting the Required Temperatures gt TempMaster MT User Manual Revision 2 1 de Mold Not Under documentation control if printed May be revised without notice Page 11 Feb 2013 Masters TempMaster p Setting up your controller Setting Zone Numbering For MT Controllers that have two or more modules there an option that allows you to number the higher zones in a logical sequence The result for an MT 06 06 for example would appear as seen here To set this numbering style proceed as follows From the Temperature Display Screen touch either zone to obtain the initial menu Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu Touch AN or VV to find the page containing a Zone option Touch Zone to open the zone numbering option Use AN and or V to set the desired zone number Touch X twice to return to the main display y Revision 2 1 TempMaster MT User Manual Mold P Masters Feb 2013 Page 12 Not Under documentation control if printed May be revised without notice Setting up your controller TempMlaster 7 Setting the Temperature Scale The MT Controller can show temperature in Fahrenheit or Centigrade Changes in this parameter apply to both zones of the controller card From the Temperature Display Screen touch either zone to obtain the initial menu
19. High Speed If the module shows a FUSE alarm then the card may be easily removed and the fuse changed Only use Ceramic Body Fuses on Control Cards NEVER use glass bodied fuses 114 Ceramic FF Fast blow fuse I nput Fuse Type Surface mount quick blow If the module shows a T C alarm then this may indicate that the input fuse has ruptured The card may be easily removed and the fuse changed Part Code 62MAQBSM Fuse Rating 62mA Output Fuse Revision 2 1 TempMaster MT User Manual Mold e EIA M M M MM A A LLL UU pe Masters Feb 2013 Page 40 Not Under documentation control if printed May be revised without notice Appendix A TempMaster IM Lr Appendix A MT Wiring Standards MT WIRING STANDARDS The following standards only apply to controllers wired to Mold Masters standard Other specifications may have been stated when the controller was ordered Please refer to the supplied specification details 1 CONNECTION NFORMATI ON 1 1 Three Phase Designation Please take extreme care when connecting the controller to the three phase supply Incorrect connection may appear to work but can result in damage to the controller The controller is supplied according to your requirements in either a star or delta supply For European Star 380V For 2 4 zones controller cabinet Use 4 conductors Cable Marking Supply Description Earth Symbol Earth
20. MT User Manual evision Mold e Not Under documentation control if printed May be revised without notice Page 15 Feb 2013 Masters TempMaster p Setting up your controller Setting the Ramp feature Normally the controller starts to heat a zone and then it pauses at around 120 C for 2 minutes in order to dry out any damp that may be present see page 8 for full description If you prefer not to wait for this dwell period then you can use the Ramp feature to skip the delay period and attain molding temperature quicker The default setting is normally Ramp On which follows the normal delay period From the Temperature Display Screen touch either zone to obtain the initial menu Touch X to obtain the Function Menu Touch Program to obtain the Program Menu Touch AN or VV to find the page containing the Ramp option x Touch Ramp and set it to Off Touch X twice to return to the main display y Revision 2 1 TempMaster MT User Manual Mold 2 P Masters Feb 2013 Page 16 Not Under documentation control if printed May be revised without notice Setting up your controller TempMlaster 7 Setting Boost Value Before you can use the Boost function you must first configure the Boost value The Boost settings made here are only for Boost Temperature and are individually set for each zone The Boost period is set at 2 minutes and is not configurable When boost is activated the controll
21. Mold Masters Espana Serennia Business Center Buenos Aires 37 29 08902 Hospitalet de Llobregat Barcelona Spain tel 34 93 802 36 01 fax 34 93 802 49 08 es moldmasters com TempMaster MT User Manual Not Under documentation control if printed May be revised without notice Global Support TempMaster DL International Representatives ARGENTINA Sollwert S R L La Pampa 2849 2 B C1428EAY Buenos Aires Argentinia Tel 54 11 4786 5978 Fax 454 11 4786 5978 Ext 35 sollwert fiberTel com ar FINLAND Oy Scalar Ltd Viertolantie 12 11120 Riihimaki Finland Tel 358 10 387 2955 Fax 358 10 387 2950 info scalar fi ITALY Commerciale Isola SPA Via G B Tiepolo 3 35010 Cadoneghe Padova ltaly Tel 39 49 706600 Fax 39 49 8874231 info com isola it VIETNAM Lotus Chemical Technology 393 Dien Bien Phu St Ward 4 Dist 3 HoChiMinh City Vietnam Tel 84 8 832 7605 Fax 84 8 832 7730 dieuphuoc nguyen lotusfirma com AUSTRALIA Comtec I P E 1084 South Road Edwardstown South Australia 5039 PO Box 338 Magill South Australia 5072 Tel 61 8 8374 4633 Fax 61 8 8299 0892 bparrington comtecipe com GREECE lonian Chemicals S A 21 PenTelis Ave 15235 Vrilissia Athens Greece Tel 30 210 6836918 9 Fax 30 210 6828881 m pavlou ionianchemicals gr PORTUGAL Gecim LDA Rua Fonte Dos Ingleses No 2 Engenho 2430 130 Marinha Grande Portugal Tel 351 244 575600 Fax 35
22. SC 2 gt gt ZONE PINS R 1 3 8 m 06 05 R2 4 9 T1 1 6 KAS C2 2Q 7 8 3 rE Maximum 60 el 230Vac 16A s Connector NE 0 o WZ 10 1FX GND yal t 93 mm ca 0 mm 03 mm dem Revision 2 1 TempMaster MT User Manual Mold p Masters Feb 2013 Page 44 Not Under documentation control if printed May be revised without notice Appendix A TempMaster TUI Tool Connector MT xx 04 sp FU R4 R3 Ve 13 E 5 R2 due H lle 63 113 mm 138 mm Kee 90 ei TempMaster MT User Manual Power TC Connection ZONE PINS R 1 9 10 R 2 11 12 R 3 13 14 R 4 15 16 TC 1 1 2 IC 2 3 4 TC 3 5 6 TC 4 7 8 Maximum 230Vac 16A ET BE E EE 56 mm 103 mm Revision 2 1 fe Mold Not Under documentation control if printed May be revised without notice Page 45 Feb 2013 Masters TempMaster p7 CHE ECH Tool connector MT xx 06 Wi ollo AES S 240 612 b L 23 e11 Gi Fb K5 I Ee 219 69 pm Sn C pm
23. Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu Touch AN or VV to find the page containing a C F option Touch C F to open the Temperature Scale option Select either C or F to suit the local operating preference Touch X twice to return to the main display The Main Display is now in Centigrade y TempMaster MT User Manual Revision21 Mold 3 ez Not Under documentation control if printed May be revised without notice Page 13 Feb 2013 Masters TempMaster p Setting up your controller Matching Sensor Types There are two different types of probe sensors J type and K type with different characteristics The sensor type is normally configured to a J type before leaving the factory and should only need to be altered in rare circumstances Changes in this parameter apply to both zones of the controller card From the Temperature Display Screen touch either zone to obtain the initial menu Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu Touch AN or VV to find the page containing the T C option Touch T C to open the sensor type option Select either J or K to suit the tool in use Touch X twice to return to the main display System is set to running appropriate thermocouple type y Revision 2 1 TempMaster MT User Manual Mold P Masters Feb 2013 Page 14 Not Under documen
24. User Manual for MT Series of Hot Runner Controller m 08 SEH ae SR KE MUSIC Masters performance delivered KEEP THIS SHEET SOMEWHERE SAFE MT Controllers come with a fixed password which is entered via the two arrow keys The Password is Tt up down up up down TempMaster MT User Manual TempMaster Mit TempMaster MT User Manual Amendment Record on Oct 2010 Approval Issue 1 3 Mar 2011 New functions for Inhibit Manual DH DT Alarm Extensions T C Auto Man option Start Ramp option and Language Option Mar 2011 Software Revisions DH DT isi DH 1 42 Jan 2012 Auxiliary Alarm connector details DH changed Mar 2012 Zone rating corrected to 15A May 2012 Revised Star Delta configuration DH DH 2 0 July 2012 Added Zone number ground fault DH DT option and more languages DH Feb 2013 Leak Detect Alarm added DH Copyright 2010 Mold Masters Developments This manual is intended for use with software Version 1 7 for the MT Series Controller Our policy is one of continuous improvement and we reserve the right to alter product specifications at any time without giving notice TempMaster MT User Manual Revision 2 1 d Mold Not Under documentation control if printed May be revised without notice Page 1 Feb 2013 Masters TempMaster p E Contents TempMaster MT User Manual 3 IC IVC CC 2 MO 3 precio EEE A A 9 Setting up your controller rrrrrrnrrrrn
25. ce to return to the main display y Revision 2 1 TempMaster MT User Manual Mold 2 P Masters Feb 2013 Page 20 Not Under documentation control if printed May be revised without notice Setting up your controller TempMlaster 7 Setting Mold Leak Detection By monitoring average power it may be deduced that any zone ET that start to require a higher power level to maintain some temperature may have a fault condition The most common fault HERE to exhibit this behaviour is that of plastic melt leaking away from the nozzle This in turn requires more power to heat the extra gt ET plastic which is possibly leaking somewhere into the mould or runner system Leak Detection in the MT is means of setting a known power level above which the unit triggers an output alarm and gives visual signal if extra power is measured In this case the alarm is the common outgoing alarm condition and the visual signal is seen when the power level in the zone window displays red rather than normal yellow as seen alongside From the Temperature Display Screen touch either zone to obtain the initial menu Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu Touch AN or VV to find the page containing a Leak option Touch Leak to open the page then touch AN and VV to set the Leak Detection power level Touch X twice to return to the main display y Revision 2 1 T
26. e same holds true for the under temp alarm level From the Temperature Display Screen touch either zone to obtain the initial menu Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu Touch Ot to open the value setting option Use L and or L to set the desired Over Temperature Limit Note Hold your finger on Jor LIto raise or lower value by large amounts Touch X to return then Ut to open the Under Temperature Limit Use L and or L to set the desired Over Temperature Limit Touch X twice to return to the main display y Revision 2 1 TempMaster MT User Manual evision Mold e Not Under documentation control if printed May be revised without notice Page 19 Feb 2013 Masters TempMaster p Setting up your controller Setting Ground Fault Detection The default setting is On where the card will start to decrease power if it detects more than 20mA leakage current If it detects an earth leakage of 40 mA or more then it reduces output to zero If the option is set to Off then the zone will continue to deliver normal power From the Temperature Display Screen touch either zone to obtain the initial menu Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu Touch AN or VV to find the page containing an Ground selection Touch Gnd to open the page and set it to On or Off as required Touch X twi
27. empMaster MT User Manual evision Mold I Not Under documentation control if printed May be revised without notice Page 21 Feb 2013 Masters TempMaster au Setting up your controller Setting response to Thermocouple failure Choose a response for any zone that detects a failed thermocouple Normal Auto Man OFF No action corrective taken the zone power sets down to 0 and it shows a T C fatal alarm Auto Manual Auto Man ON The zone has sufficient data after 10 minutes steady running to switch to Manual mode at a power level that should hold the previous temperature From the Temperature Display Screen touch either zone to obtain the initial menu Touch Eas to obtain the Function Menu Touch Program to obtain the Program Menu Touch AN or VV to find the page containing an Auto Man option Alm Man Off Touch Auto man to open the page and set it to On m Touch X twice to return to the main display gt de Revision 2 1 TempMaster MT User Manual Mold E e En M M M ue A AA LLL QLL ou SS Me c st Masters Feb 2013 Page 22 Not Under documentation control if printed May be revised without notice Setting up your controller FempMiaster 7 I nhibiting users from switching to Manual Standby or Boost It is possible to stop a user from selecting Manual Control or Standby or Bo
28. er will raise the zone temperature Please note that on a slow responding manifold if you set a high boost temperature the zone may not reach the set boost temperature before the boost time limit expires The default or factory Boost setting is 75 C or 135 F If your controller is set in Centigrade at 200 C temperature will raise to 275 C If your controller is set in Fahrenheit at 400 F temperature will boost up to 535 F From the Temperature Display Screen touch either zone to obtain the initial menu Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu 1 Touch AN or VV to find the page containing a Boost option HD Touch Boost to open the value setting option ES x Use AN and or Tel to set the desired boost Temperature Touch X twice to return to the main display y TempMaster MT User Manual Revision21 Mold 3 f Not Under documentation control if printed May be revised without notice Page 17 Feb 2013 Masters TempMaster a Setting up your controller Setting Standby Value Before you activate Standby function you must first configure the amount The Standby settings made here are only for Standby Temperature and are individually set for each zone When standby is activated those zones with any standby value configured will reduce their temperature The default or factory Standby setting is 100 C or 180 F If your controller is set in Centigrade
29. ers TempMaster p Setting up your controller Setting the Required Zone Temperatures Once all the user options have been set then you should set the normal operating temperatures From the main display touch whichever zone whose temperature you wish to set Use AN and or V to adjust the set temperature Note you do not need to touch just once for each degree change keeping your finger or stylus on the button will allow the temperature to run up or down until it reaches the desired set point Touch X to return to the main display Repeat for other zones Mold Iz Revision 2 1 TempMaster MT User Manual e BIA M M M e MH X Me A LLL PR aUo M ep Masters Feb 2013 Page 26 Not Under documentation control if printed May be revised without notice Running your controller TempMlaster 7 Running your controller Running your controller is concerned with everyday use of the controller for normal production use This is considered as selecting an appropriate run mode for the machine according to whether the tool is working or waiting It may also be necessary to make changes to the heater temperatures and to use the graphical display of recent performance which may help such decisions What is included in this section Run Mode Off Mode Standby Mode Manual Mode open loop control Slave Mode Standby Mode Boost Mode how to apply a short increase Changing Set Temperatu
30. ettings 36 Display Screens 9 Factory 23 Factory Settings 36 Fan Fuses 40 Fuses 40 Gnd 20 Ground Fault Detection 20 How the MT Controller Works 8 Initial Menu 9 Language 25 M Dis 23 Maintenance 35 Manual Mode 29 Mold Leak Detection 21 Off Mode 28 PID 15 Plugs Configuration 48 Power Output Screen 9 Program Menu 10 Ramp 16 Run Mode 28 Running your controller 27 Safety Instructions 4 Screen Navigation 9 Sensor Type Selecting 14 Set Temperature changing 34 Setting up you controller 11 Slave a zone 30 Specific faults 39 Specifications 3 Standby whole cabinet 31 Standby Disable 23 Standby level setting 18 Standby mode Individual zones 32 Standby Boost Switch 31 Star Delta changing 43 Switching the whole system On and Off 6 Temperature alarms setting 19 Temperature Display Screen 9 Temperature Scale changing 13 The Controller Cabinet 7 Three Phase Designation 41 TMXL MT Compatibility 3 Troubleshooting 38 Wiring Standards Delta Star 41 Zone Numbering Setting 12 Zone Temperature setting 26 gt Revision 2 1 Ke TempMaster MT User Manual Vision Mold gt Not Under documentation control if printed May be revised without notice Page 49 Feb 2013 Masters Global Support Manufacturing Facilities GLOBAL HEADQUARTERS CANADA Mold Masters Limited 233 Armstrong Avenue Georgetown Ontario Canada L7G 4X5 tel
31. g a TMXL card into an MT case would render the output circuit unprotected since there would be no output fuse Conversely it is safe to put an MT Cards into a TMXL case since this would overprotect by having series output fuses on the card and under the case lid gt TempMaster MT User Manual Revision 2 1 d Mold Not Under documentation control if printed May be revised without notice Page 3 Feb 2013 Maste S TempMaster 7 EES Safety Instructions DO NOT enter the cabinet without first ISOLATING the supplies there are unguarded terminals inside the cabinet which may have a dangerous potential across them Where a three phase supply is used then this potential may be at 380 volts or higher Safety Notices an explanation A WARNING symbol and message shown here identifies where there may be a hazardous situation which if not avoided may result in death or injury to personnel Most warnings pertain to electrical aspects and you must comply with them to minimise any personal danger E Revision 2 1 TempMaster MT User Manual Mold Masters Feb 2013 Page 4 Not Under documentation control if printed May be revised without notice Introduction TempMaster DL Installation Where to use this equipment Mold Masters Hot Runner temperature controllers are designed for use in the plastic injection moulding industry as temperature controllers for hot runner systems as commonly used in mould tools The contr
32. green yellow For 5 zones or higher controller cabinet Use 5 conductors Change jumper settings by joining all MP1 MP2 and MP3 to the blue N conductor at the terminal blocks Cable Marking Supply Description N Mp1 Mp2 Neutral blue Mp3 Earth Symbol Earth green yellow For American Delta 240V TempMaster MT User Manual Revision 2 1 de Mold Not Under documentation control if printed May be revised without notice Page 41 O Feb 2013 Masters TempMaster v Appendix A For 2 4zones controller cabinet Use 4 conductors Cable Marking Supply Description Earth Symbol Earth green yellow For 5 zones or higher controller cabinet Use 4 conductors Change jumper settings by joining R MP3 S MP1 and T MP2 at the terminal blocks Do not link all MP1 MP2 and MP3 together Cable Marking Supply Description N B The delta supply cable does not have a neutral wire Cable colours may vary therefore wire up according to the Cable Markings 1 2 Alarm Output A cabinet connector provides an alarm output from an internal set of relay contacts Using an external power source the cabinet can initiate a number of warning devices whenever any zone goes into an alarm state This is commonly used for beacons audible alarms or informing the moulding machine The contacts are rated for 0 5A at 220V An input can be accepted through the same connector It may be used for Remote Standby Mode For exact detail
33. m to obtain the Program Menu Touch AN or V to find the page containing a Factory option Factory mek 1 Enter the password and then touch v to access the next screen The Factory screen gives two options which are Factory Defaults restore the unit to default settings eee D CAL enter a calibration check routine Gem Mie M Dis enable e disable user options x These are described below Jl 0 Default settings These are the settings which would have been applicable when the unit left the factory and was first received They are Zone Temperature 260 C or 500 F Standby level 100 C or 180 F Boost level 75 C or 1359F Over temperature range 10 C or 18 F Under temperature range Extended Alarms for Manual Standby and Boost gt Revision 2 1 TempMaster MT User Manual Mold Masters O Feb 2013 Page 36 Not Under documentation control if printed May be revised without notice Maintaining your controller TempMlaster 7 Calibration Routine Before starting Temperature calibration you need a a Thermocouple simulator capable of providing accurate set points of 20 C and 400 C b a suitable connector plug so that you can connect your simulator to the appropriate zones without any heater zones being connected If in doubt consult the loom wiring diagram to check for heater and t c pin connections Calibration sequence 1 Connect the simulator to the normal T C inp
34. ments allow the cabinet may be isolated The shrouded terminals on the euroback board are live unless the power supply is switched to OFF gt TempMaster MT User Manual Revision 21 Mold e Not Under documentation control if printed May be revised without notice Page 39 Feb 2013 Masters TempMaster Ia Troubleshooting Overload protection There is an MCB which offers general overcurrent protect and there are fuses for various subcircuits Of the two rear panel mounted fuses one protects the cooling fans and the second protects the internal back plane distribution which feeds the individual cards If you find that any fuse has ruptured then please make sure that you replace the faulty fuse for a new one with identical characteristics All the fuse types are listed in the attached tables Fans If any fan has stopped working then first inspect the unit to see if there are any blockages or objects fouling the impellors Once you are certain that the fan is free to rotate then proceed to check the panel mounted fuse at the rear of the unit Class 114 Glass Fuse Antisurge Controller Cards Each module card has separate protection fuses for its on board power supply the T C input and for the heating load output On board Power supply The module power supply has a mains voltage glass fuse located alongside the power supply circuit 20mm Glass slo blo fuse MT Card Fuse Location Output Fuse Type HRC
35. nrrrrnnnrrrnnnerrnnnennannenrannennansennansnnnnssnnnnnee 11 Running your controller 20 Maintaining your Gopntroller 35 HOME OI MEME Tm TT 38 PAO OCHO Pi qq 41 Do c m 49 Mold Revision 2 1 TempMaster MT User Manual Masters Feb 2013 Page 2 Not Under documentation control if printed May be revised without notice introduction TempMaster Mt Introduction Specifications The following are general specifications The actual controller supplied may differ in specified options available 220 60Hz Delta 15A super quick acting FF fuse on both legs Centigrade Celsius or Fahrenheit 0 472 C or 32 882 F TMXL MT Compatibility The MT Series Controller has been designed to give some interchangability with its predecessor the TMXL2 It is built to the same size and fits into an apparently identical cabinet However there is one major physical change which is the main zone fuses These have been moved from under the cabinet lid on the TMXL2 to on the card for the MT This means that you can pull out individual cards to safely access and change any ruptured output fuse In the TMXL2 output fuses were located under the cover which meant shutting the system down to gain safe access to replace a ruptured fuse DO NOT put TMXL cards into an MT case Although cards appear interchangeable puttin
36. ollers must not be used in residential commercial or light industrial environments Furthermore they must not be used in an explosive atmosphere or where there Is a possibility of such an atmosphere developing They should be installed in a clean dry environment where the ambient conditions do not exceed the following limits Ambient temperature 10 50 C Relative Humidity up to 95 non condensing When in use this equipment does not emit audible noise in excess of 10dBA Controller Tool Connections The various connections to the system using the cables supplied with the equipment are specified in Appendix A Controller Power Supplies The control cabinet can be manufactured to accept a wide range of supplies and sequence of phases Refer to the serial plate in the controller cabinet for confirmation of the supply requirements If the local supply is outside the specified range please contact our Service department for advice Tel 44 1432 265768 Fax 44 1432 263782 gt TempMaster MT User Manual Revision 2 1 de Mold Not Under documentation control if printed May be revised without notice Page 5 Feb 2013 Maste S TempMaster p7 TEE Switching On and Off The main power switch is a rotary switch found at the front of the Controller It is sufficiently rated to disconnect the total load current during switch On and switch Off Switching On When the controller is switched on all zones go into
37. ost function To do this open the Factory setting page and tick the M Dis Manual Disabled box as shown below From the Temperature Display Screen touch either zone to obtain the initial menu Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu Touch or VV to find the page containing a Factory option r Factory 4 doko 1 Enter the password and then touch v to access the next screen Factory gt Defaults CMS 27 13 Check the M Dis box OCal Touch v to return to the main display To check this setting touch KA and Program to see these User function buttons greyed out and no longer function To reset return to the Factory box and uncheck M Dis Note Selecting this option will inhibit the front panel rocker switch so that Standby or Boost selection there will also be ineffective TempMaster MT User Manual Revision 2 1 Fn Page 23 oreb203 Masters Not Under documentation control if printed May be revised without notice TempMaster a Setting up your controller Extending Alarms for Manual Standby or Boost operation Y Mold gt Masters There are a currently three conditions which may be selected to generate external alarm conditions These options are available to give an outgoing closing signal if the controller is set to Manual Alm Man Standby Alm tdn or Boost Alm Tup Their default condition is Off but any
38. re FT Noli Page 27 oreb203 Masters Not Under documentation control if printed May be revised without notice TempMaster Mit Running your controller Run Mode Controller here shows one zone turned Off Touch that zone and then touch to Start Touch X to return to main screen and see Zone 1 now in Auto Run mode Repeat these steps for the other zone if needed Off Mode Single Zone Each card controls two zones at a time which can be turned off individually Touch either zone and then touch to Stop Touch X to return to main screen and see Zone 1 now in Off mode Repeat these steps for the other zone if needed Off Mode Single Module Turn the module off by touching the button on the front of the individual card y Revision 2 1 TempMaster MT User Manual Mold 2 P Masters Feb 2013 Page 28 Not Under documentation control if printed May be revised without notice Running your controller TempMlaster 7 Manual Mode Manual mode open loop working can be simply selected as an alternative to running in Auto closed loop If the screen at step three shows the Manual Standby and Boost buttons greyed out then this function has been inhibited see page 23 From the Temperature Display Screen touch either zone to obtain the initial menu Touch X to obtain the Function Menu Touch Manual to enter manual mode and go to open loop working
39. rogram menu then AN and V buttons cycle you through the various options seen in the above diagram A more complete description of these various parameters is explained further on in the Setting up and Running sections of this User Manual Revision 2 1 TempMaster MT User Manual Feb 2013 Page 10 Not Under documentation control if printed May be revised without notice Setting up your controller TempMaster Mt Setting up your controller New MT series controllers leave the factory with their default settings which are as shown in this table 260 C or 500 F Standby level 100 C or 180 F Boost level 75 C or 135 F Over temperature range 10 C or 18 F Under temperature range Ramp Extended Alarms for Manual Standby and Boost If you are reconfiguring your controller to a new tool or environment then this chapter of the manual shows how to alter those default settings to your preferred values and afterwards to save them Should anything seem wrong with your new settings then it is possible to restore the default settings at any time see Restore Default on page 36 What is covered in this section Setting your preferred Temperature Scale Matching Sensor Types J or K Changing zone PID Characteristics Setting the Ramp Feature Setting Boost Level Setting Standby Level Monitoring Temperature Limits Setting response to Thermocouple failure Inhibiting users from switching to Manual Standby or Boost Extending
40. s consult the specification for the particular model HAN4A Pin Connection Input output 1 Auxiliary Input signal Ht D otandby Port Auxiliary Input Ground Alarm 240v contact 2 Alarm Contacts Revision 2 1 TempMaster MT User Manual Mold Masters O Feb 2013 Page 42 Not Under documentation control if printed May be revised without notice Appendix A TempMaster INE Voltage Selection Star or Delta three way strap installed Star Supply Option to tie three lines to neutral two way straps not required OD GO D pj two way straps installed Delta Supolv Option to tie three lines to phases pply YP LEE 04 three way strap not required TempMaster MT User Manual Revision2 1 Mjold EH m Not Under documentation control if printed May be revised without notice Page 43 O Feb 2013 Masters TempMaster CHE ECH Tool Connector MT 2 2 0 Power IC Connection 2 z
41. t option is available for extending the alarm or perhaps inhibiting the injection process Controller Modules The controller is dual zone modular unit that provides real time temperature control Each card has three main components e thermocouple input circuits e CPU e multi voltage output triacs Thermocouple Inputs The thermocouple inputs have preset responses for both J and K type thermocouples The selection of sensor type can be done in Program Menu this in turn sets the CPU linearization to match the selected thermocouple type Central Processor Unit CPU The CPU provides the following facilities e closed and open loop control of the zones e processes thermocouple and current readings to show on display e checks for alarm conditions including excess current incorrect thermocouple wiring zone over temperature condition low impedance between heater and ground and generates alarm information for the display screen and alarm relay e controls the output power to the on board triac using a number of self tuning algorithms The card requires no analogue calibration and is ready for use once set up from the display console Output Triacs The controller card has a pair of board triacs that are capable of controlling heating loads of up to 16 Amps peak gt TempMaster MT User Manual Revision 2 1 d Mold Not Under documentation control if printed May be revised without notice Page 7 Feb 2013 Mas
42. tation control if printed May be revised without notice Setting up your controller TempMlaster 7 Changing zone PI D Characteristics On initial start up each module CPU reads the zone heater characteristic and determines an appropriate PID curve for that zone Occasionally the zone may not pick an optimum setting or even if correct you may wish to override that setting and change the zone response time In this situation you may select and alter the PID setting for any zone Generally speaking a small nozzle works best on a Fast setting while a larger manifold uses Med ium and a really large heating platen may require Slow If you are having problems matching a zone then consult your local dealer for service advice Also note that once the controller has run and the PID curve has been selected then the screen will show which speed was automatically selected by making that ring blue In the example below PID has selected Fast and shows a blue ring there From the Temperature Display Screen touch either zone to obtain the initial menu Touch Ka to obtain the Function Menu Touch Program to obtain the Program Menu Touch AN or NV to find the page containing the PID option PID euo 1 Touch PID and select an alternative timing Um Med Touch X twice to return to the main display System is set to running appropriate thermocouple type y Revision 2 1 TempMaster
43. ters TempMaster Ou I ntroduction How the MT Controller Works Mold Masters controllers are designed to perform in closed and open loop configurations However we consider that the normal operating mode is closed loop This is illustrated in the following diagram and explained below mS SetPoint v E s Oo Q E 9 e _ rt 1 gt E rE 120 C mpm rE ETI ROAR SENSE A A Time The zone controller slowly ramps up the heater power and simultaneously looks for a positive temperature change at the thermocouple input The controller verifies the actual rate of rise against a predetermined value in program parameter r1 Power is slowly increased until the correct rate of rise is achieved At ramp temperature rE the dwell time rt is activated 2minutes this permits any residual moisture in the heating elements to be eliminated After all zones reached to ramp temperature they will start heating up together again The controller continues to ramp up the temperature to the set point with the speed set in program parameter r2 which should be achieved with minimum over shoot Having built a virtual model to map the tool and heater characteristics the controller can maintain the temperature at an accurate point with virtually no deviation Setting the Ramp feature On Off Normally the controller starts to heat a zone and then it pauses at around 120 C for 2 minutes in order to dr
44. uts for both zones on the module being calibrated Touch Cal and v to start the calibration routine The screen asks for a 20 C source set you T C simulator to 20 C The screen timer counts down as it sets the low range setting The screen asks for 400 C source set your T C simulator to 400 C The screen timer counts down as it sets the high range setting Qu QU QE d Sr P The screen informs you that the calibration has completed 8 Remove the T C Simulator and temporary connector M Dis Option It is possible to stop a user from Factory selecting Manual Control or Standby or Defaults D Boost function To do so check the OCal M Dis Manual Disabled box on this screen Che TempMaster MT User Manual Revision 2 1 Fn Mold Not Under documentation control if printed May be revised without notice Page 37 Feb 2013 Masters TempMaster Na Troubleshooting Troubleshooting Individual Card Diagnostics The control system has several features which provide a diagnosis of faults in the control system the tool heaters and thermocouple sensors If a zone temperature is seen to deviate from the actual setting beyond the alarm limits then the display will change to White text in Red box and generate a remote alarm The following is a list of alarm conditions that may be detected and which will also activate the output contacts Error Cause Message Little or no temperature
45. wiring for presence of all three phases If the REV alarm persists then you Should switch off the controller and investigate the offending zone Alternatively you could slave the offending zone to a good zone until you have time to clear the fault For immediate recovery you can either slave that control zone to an adjacent zone or change to open loop control Make a note of the above action so that when the controller is free you can check to see whether the input fuse on the control card has ruptured If the fuse is good then you may need to check the wiring for faults or even replace the thermocouple The most likely cause of temperature fluctuations is extraneous voltages being picked up by the thermocouple cable i e common mode This may be due to poor earthing of the tool or a faulty shielded thermocouple wire or alternatively a faulty heater We recommend that all earth connections be tested Ground fault detection The Ground fault detection detects any fault caused by earth leakage current Earth faults can be caused if a tool has been idle for some time and damp has got into one heater It may be possible to identify the heater and repair the faulty zone by using the adjacent heaters to heat it up and dry it out so curing the original problem Module Removal To remove a control module from its slot unscrew four corner screws first There is no need to switch off the main supply However if operational require
46. y out any damp that may be present see page 8 for full description If you prefer not to wait for this dwell period then you can use the Ramp feature to skip the delay period and attain molding temperature quicker i n Revision 2 1 TempMaster MT User Manual Mold Masters Feb 2013 Page g Not Under documentation control if printed May be revised without notice E Temp Master D Navigation This part of the manual introduces you to the controller card to show what facilities are available and what information is available Main Display Screens Once the controller card is turned on it always shows temperature display for the two zones along with set Temperature current applied power and percentage power with those various elements shown here On each module there will be Zone 1 and Zone 2 There is no way for you to configure multiple modules to read successive zones ie Zone 1 Zone 2 Zone 3 Zone 4 etc Zone ID Actual Temperature and scale Current Mode the example here has Zone 1 in Auto Zone 2 in Manual Current reading Percentage Power Applied Initial Menu Press anywhere in Zone 1 area or Zone 2 area to get an initial menu for either zone note that the initial menu will always appear at the bottom half of the screen In this menu the buttons are as follows e Set the auto temperature or manual power level up or down by using the AN and V buttons Note
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