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1. t e J2 J3 Install jumpers J1 J2 J3 Do not connect Neutral Hue conductor Use black brown black conductor for 3 phases Green for GND Delta 4 wires System EUROPEAN SIAR 380v PHASE PHASE 220v PHASE NEUTRAL J4 Use 3 stand offs to install Interconnected Jumper J4 Do not install J1 J2 J3 Connect Neutral Bue conductor to Mp2 Use black brown black for 3 phasesand Green for GND WYE SIAR 5 wires System s Issue 1 3 Mold Masters Page 69 APPENDIX A MZ L Series Manual INSTRUC TION HOW TO CONVERT DELIA WYE FOR DOUBLE BREAKER SYSTEM AMERCAN DELIA 220V PHASE PHASE Install jumpers J1 J2 J3 Do not connect Neutral Bue conductor Use black brown black conductor for 3 phases Green for GND Delta 4 wires System BJROFEAN SIAR 380v PHASE PHASE 220v PHASE NEUTRAL Blue interconnection Blue from cable Tm lolo e ola o lo n el CAKARA t f t 1 Use 3 stand offs to install Interconnected Jumper J4 Do not install J1 J2 J3 Connect Neutral Bue conductor to Mp2 Use black brown blackfor 3 phases and Green for GND WE SIAR5 wires System s Install blue interconnectio
2. 2 Atthe Start prompt enter the number of the first zone in your target group and press ENT 3 Use 4 gt to select P Probe or M Manifold and press ENT 4 Atthe End prompt enter the number of the last zone in your target group and press ENT 5 Atthis step you have the opportunity to switch from Auto to Manual mode and back by repeatedly pressing ENT The chosen mode is shown by the prompt that changes between Temp and Power 6 While on your preferred mode enter the desired temperature or power decrease and press ENT 7 Atthis stage you can press ENT or CLR to confirm the command and return to the Set Zone s menu Page 38 Mold Masters Issue 1 3 MZ L Series Manual Running your controller Using Slave Mode to compensate for a failed thermocouple Issue 1 3 If a thermocouple fails while the controller is working then you may see different results A complete fail shows a T C error message against the actual zone and the actual temperature falls off to zero Sometimes it may be intermittent in which case it may show as uncontrolled temperature deviations for the concerned zone Your prime aim is to compensate for this condition and maintain production until the machine is free and the fault can be repaired Slave mode allows you to disregard the particular thermocouple and slave the faulty zone to work to another zone which is healthy This master zone then controls th
3. Boost setting boost temperature 28 Boost setting boost time 28 Boost Mode 36 Card LEDs 61 Checking your controller printing tool settings 46 Checking your controller recent temperature history 40 Controller Cabinet 17 Controller Cards 17 Dec Zones 38 Erased Values 20 Fan Fuses 62 Fault Messages 58 Fuses 62 How the Mold Master Controller Works 19 Inc Zones 36 Introduction 6 Master Zone Selection 27 Memory Check 20 Power Setting maximum limits 31 RAM Error 20 Restoring default Test Parameters 51 Safety Instructions 5 Self Diagnostic Tests 47 Self Diagnostic Tests interpreting results 54 Self Diagnostic Tests setting test parameters 50 Page 74 Mold Masters Self Diagnostic Tests viewing printing results 53 Sensor Type Selecting 24 Skipping Test Zones 52 Slave Mode compensating for a failed thermocouple 39 SM DM Caras 17 Standby Mode 36 Starting before switching on 7 Starting master zone for StartUp 35 Starting starting mode 32 Starting with Run 35 Stopping Wait Mode 35 Switching the whole system On and Off 8 Temperature Lowering 38 Temperature monitoring limits 30 Temperature Raising 36 Temperature display changing 22 Temperature Range Automatic 22 Test Zones selecting which are tested 52 Thermocouple compensting for a failed 39 Tool settings how to save 33 Tool settings verifying
4. TMMZ MAIN MENU MODE SETTINGS 1 Run 5 Set Zone s 2 Stop 6 Utilities 3 Standby 4 Boost Select li Press CLR for Main Screen STOP MODE There are 6 options available on the Main Menu which are described in the following pages Run Stop Standby and Boost Main Menu options 1 4 are immediate function options that put the controller into each particular working mode TMMZ MAIN MENU Change to Run Mode Enter Yes Clear No INFO Press CLR for Main Screen STOP TMMZ MAIN MENU Change to Standby Mode Enter Yes Clear No INFO Press CLR for Main Screen STOP TMMZ MAIN MENU Change to Stop Mode Enter Yes Clear No INFO Press CLR for Main Screen STOP TMMZ MAIN MENU Change to Boost Mode Enter Yes Clear No INFO Press CLR for Main Screen STOP Issue 1 3 Mold Masters The LCD Console MZ L Series Manual Set Zone s Menu The Set Zone s Menu is used to fix any one zone s temperature SET MENU 1 Set Zone 2 Set Zones 3 Inc Zones 4 Dec Zones Select Deg C STOP MODE It offers the following features e Set Zone is used to change any of the zones individually e Set Zones is used to set a group of zones to the same set point e Inc Zones is used to increase the temperature on a group of zones e Dec Zones is used to decrease the temperature on a group of zones This operation
5. 215 0032 tel 481 0 44 986 2101 fax 81 0 44 986 3145 email ookamoto mmkk co jp Singapore Mold Masters Singapore PTE Ltd 2 Corporation Road 3106 13 Corporation Place Singapore 618494 Republic of Singapore tel 65 6261 7793 fax 65 6261 8378 email agtan 9 moldmasters com sg also Malaysia Indonesia Thailand Mold Masters global support worldwide representatives Argentina Sollwert S R L La Pampa 2849 2 B C1428EAY Buenos Aires Argentina tel 54 11 4786 5978 fax 54 11 4786 5978 ext 35 email sollwert fibertel com ar Finland Oy Scalar Ltd Mestarintie 5 SF 12100 Oitti Finland tel 358 19 787 690 fax 358 19 787 6921 email timo makinen scalar fi India Unimark 201 Vikrant Industrial Estate Govandi Mumbai 400 088 India tel 491 22 2550 6712 fax 91 22 2550 6713 email unimark vsnl com Korea Kyung in System J 502 Kuro Distribution Business Center 636 62 Kuro Dong Kuro Ku Seoul Korea tel 82 0 2 2634 9453 4 fax 82 0 2 2634 9608 email kyungins 9 hanmir com Romania International Mold Trade Co SRL Str Constantin Aricescu Nr 21 Bl 20 Sc 2 Apt 20 Bucharest Sector 1 Romania tel fax 40 21 231 7843 email roman dial kappa ro Taiwan Credit amp Finder International Corp No 756 Chung Cheng Road Chung Ho City Taipei Hsien Taiwan ROC tel 886 2 22224993 fax 886 2 22224705 email cfic ms19 hinet net Australia
6. 5 for any other zones Issue 1 3 Mold Masters Page 25 Setting up your controller MZ L Series Manual Setting several Zones together If you have a number of channels that need common settings such as probes then it is easier to establish their settings as a group Global Set Start 1 P M End 37 Temp Press Enter for Manual Mode Deg C STOP MODE 1 At the Main menu select Set Zone s 5 gt Set Zones 2 2 At the Start prompt enter the number of the first zone in the group and press ENT 3 Use 4 gt to select P Probe M Manifold and press ENT 4 At the End prompt enter the number of the last zone in the group and press ENT 5 Next at the Temp prompt the system defaults to Auto working 6 If this is not your preferred mode then press ENT repeatedly to step though the Modes Manual Slave and back to Auto As you step through these modes then you see the prompt change to Power Slave and back to Temp Once you are in the preferred Mode then enter your required Temperature Power Setting or Slave Channel as appropriate and press ENT to establish your choice Page 26 Mold Masters Issue 1 3 MZ L Series Manual Setting up your controller Setting the Master Zone The Run command normally uses an auto selected Master Zone to regulate the heating of faster Probes During Run the main controller over
7. Comtec IPE 1084 South Road Edwardstown South Australia 5039 PO Box 338 Magill South Australia 5072 tel 61 0 8 8374 4633 fax 61 0 8 8299 0892 email bparrington comtecipe com France MAP BP 2001 F 91071 Bondoufle Cedex France tel 33 01 69 11 81 50 fax 33 01 60 86 69 33 email maud francigny 9 supratec fr Israel ASAF Industries Ltd 29 Habanai Street PO Box 5598 Holon 58154 Israel tel 972 3 5581290 fax 4972 3 5581293 email info amp asaf com Mexico Intec Plast S A de C V 185 Av Once Bod 8 Col San Juan Xalpa Iztapalapa 09850 M xico City D F tel 452 55 5612 2302 tel 452 55 5614 6371 fax 52 55 5612 2312 email intecplast att net mx Spain Tein Ingiener S L C Sep lveda 32 08015 Barcelona Spain tel 34 93 289 05 10 fax 34 93 289 05 11 email sandra romero tein moldmasters com Turkey MMG Consulting amp Engineering Yesil esme Sok No 30 3 Ciftehavuzlar 81060 Istanbul Turkey tel 90 216 357 0783 fax 90 216 385 0656 email mmgevrek superonline com Denmark H amp G Englmayer A S Skenkelsoevej 9 Postbox 35 DK 3650 Oelstykke Denmark tel 445 46 733847 fax 445 46 733859 email support englmayer dk also Norway Hong Kong Nicko International Ltd Rm 1203 Chevalier Commercial Centre 8 Wang Hoi Road Kowloon Bay Hong Kong tel 4852 2755 2783 fax 4852 2798 8656 email sales nicko com hk Italy Commerciale
8. Manual mode and back by repeatedly pressing ENT The chosen mode is shown by the prompt that changes between Temp and Power 6 While on your preferred mode enter the desired temperature or power increase and press ENT 7 Atthis stage you can press ENT or CLR to confirm your command and return to the Set Zone s menu Page 36 Mold Masters Issue 1 3 MZ L Series Manual Running your controller Not every zone will necessarily be affected Be careful if you have your controller set up with a mixture of zones i e some in Auto some as Manual At step 5 above the selection of Auto or Manual constrains your selection to only those channels that are of the same configuration For example Zones in Auto Before changing At 200 in Auto Zones in Manual At 50 in manual After choosing 20 Rises to 220 C C Rise Stays at 50 power applied After calling for 5 Stays at 200 C power increase Rises to 55 power applied The same principal applies to both Inc and Dec commands Issue 1 3 Mold Masters Page 37 Running your controller MZ L Series Manual Dec Zones This allows you to select a group of zones and uniformly decrease their set temperature by the same value Global Dec Start 1 P M End 37 Temp 5 Press ENTERr for Manual mode Deg C STOP MODE From the Main Menu select Set Zone s 5 gt Dec Zones 4
9. member of the proven family of Mold Masters Hot Runner Controllers is user friendly and retains the standard control facilities associated with other Mold Masters controllers How to use this manual The purpose of this manual is to give you a complete understanding of how best to use the controller and to assist where there are problems or faults The first part of this manual Introductory Tour contains a brief technical description of the system components and a portrayal of the Mold Masters operating philosophy that facilitates precision temperature control The following chapters then take you carefully through the stages of setting up and running a new control system After considering system maintenance the final sections look at trouble shooting to assist in the unlikely occurrence of a system fault Page 6 Mold Masters Issue 1 3 MZ L Series Manual Installation Installation Where to use this equipment WARNING 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 controllers 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
10. protects the controller and keeps the switched load to a minimum to extend the life of the main Isolator Switching On Provided the Start option has been set to Stop then switching the main power switch to On does not cause the zones to heat up Once the main menu is available you can select Run 3 from the main menu to start heating the tool Switching Off or Shutting Down We recommend that you use the controller to shut down the heating load and only use the main isolator to switch off the whole system once it is idle 1 Shut down the heating On the Main Menu select Stop 2 mode to reduce the heating to zero 2 Shut down the Controller Now use the Main Rotary Switch on the cabinet to isolate all the power from the whole system Page 8 Mold Masters Issue 1 3 MZ L Series Manual The LCD Console The LCD Console An Introductory Tour This part of the manual introduces you to the LCD console to show briefly what facilities are available and what information is available TEMP MASTER MULTIZONE TIVZ 24 Navigation The LCD Screen displays all the necessary pages and the keypad alongside provides you means of control Most of the pages operate in the same way for instance e to move between pages and for those pages where there is a choice between different functions enter the page or selection number at the Function prompt and press ENT e to leave a page and save the modificatio
11. 2 zone has an error NC Contact 2 NO Contact 3 B T rel oost ode relay closes when the MC Contact 3 Output 3 controller is put into Boost Mode NC Contact 3 NO Contact 4 MC Contact 4 Output 4 NC Contact 4 Mold Masters Issue 1 3 MZ L Series Manual Servicing and repairing your controller Servicing and repairing your controller WARNING Always isolate your controller at source before you open the unit to inspect it or replace fuses When it comes to machine maintenance there is very little that you need to do to look after it Replacement parts 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 Issue 1 3 Any excess dust that has entered into the cabinet may be removed with a light brush and vacuum cleaner Any internal cable forms that flex to accommodate opening doors should be checked to see that there is no fraying or damage to cable insulation External cable looms should be checked to see that there has been no damage to the flexible conduit plugs or sockets If the flex has been squashed if there is visible damage or if there are any exposed conductors then for your own safety it must be replaced If the equipment is subject to vibration then we recommend that you use an insulate
12. 32 Tool Store viewing 42 Tools changing a tool 44 Tools deleting a tool 44 Tools loading recalling a tool 44 Tools naming a tool 43 Tools saving a tool 43 Troubleshooting 58 Wait Mode Stopping 35 Warning Messages 58 Watchdog feature 20 Zone setting types 23 Zone Temperature setting in groups 26 Zone Temperature setting individually 25 Zone Temperature setting 25 Issue 1 3 trade marks and patents DURAe DURA FEMTO SHOTe DURA PICO SHOTe DURA CENTI SHOTe DURA DECI SHOTe DURA HECTO SHOT DURA MEGA SHOTe FLEX DURA HOT EDGEe INJECTIONEERINGe MASTERPROBE e MASTER SHOT MOLD MASTERSe MOLD MASTERS ACADEMYe MASTER SERIESe MOLD MASTERS SYSTEMe SCAN MASTERe STACK LINKe MERLINeare the registered trademarks of MOLD MASTERS LIMITED Information contained herein is to our best knowledge true and accurate but all recommendations or suggestions are made without guarantee Sincethe conditions of use are beyond our control Mold Mastersedisclaims any liability incurred in connection with the use of our products and information contained herein No person is authorized to make any statement or recommendation not contained herein and any such statement or recommendation so made shall not bind Mold Masterse Furthermore nothing contained herein shall be construed as a recommendation to use any product in conflict with existing patents covering any products or its use and no license implied or
13. Isola SPA Via G B Tiepolo 3 35010 Cadoneghe Padova Italy tel 39 0 49 706600 fax 39 0 49 8874231 email info 9 com isola it Portugal Gecim LDA Avenida Da Liberdade No 155 Bloco A 2 A D P 2430 Marinha Grande Portugal tel 4351 244 575600 fax 4351 244 575601 email gecim 9 gecim pt Sweden Forvema AB Box 34 Fritslavagen 42 S 511 21 Kinna Sweden tel 46 320 16611 fax 46 320 16065 email hakan boerjesson forvema se
14. K k KK KK KK A KK KK 41 Maintaining your Controller 45 More options 30A Mod controller and I O 55 Servicing and repairing your CON ON nn 57 Troubleshooting 58 Spare Pants NUMEN aD NINE gates ret Eke kb Da xeb G ken n 64 APPENDDS Ass 66 lec are be HHHH DDKD 73 16 c E 74 Issue 1 3 Mold Masters Page 3 Specification MZ L Series Manual Specification The following are general specifications The actual controller supplied may differ in specified options Supply Voltage Mains Voltage Output Control Method Earth Leakage Measurement Overload protection Thermocouple input Control range Temperature scale Card Diagnostics LED s Printer output connector Alarm Output T C Tool connector Heater Tool connector Keypad Display Case Details Page 4 380v 3 phase 50Hz with neutral others available 220 60Hz Delta Burst fired zero crossover and Phase Angle fired Open or closed loop Earth leakage measurement on individual cards set at 10mA Fast Blow Fuse Iron Constantan Fe Con type J Chromel Alumel type K 0 472 Centigrade Celsius 32 881 Fahrenheit Centigrade Celsius or Fahrenheit Scan T C Fault load output ground fault
15. This key enters the command selected on the screen E g to enter a value or select a menu option Clear Key If an entry is started the clear key erases the whole of the entry Pressing the clear key at the start of prompt returns the user to the previous screen Front Panel Status Indication There are three LED indicators to show the status of the controller e Green Controller is operating normally e Amber One or more zones are outside of the set limits e Red A fault has been detected such as thermocouple failed or system error and so the controller is in alarm Page 10 Mold Masters Issue 1 3 MZ L Series Manual The LCD Console The LCD Screen Press Enter for Main Menu STOP MODE The Home screen for the Console is the only screen that will show two boxes of data with a total display of 24 zones Displayed Data The display within each box shows Zone Set Act Power Zone Shows Shows Shows Power level Identifier Set temperature actual measured that is being supplied when in Auto temperature when to maintain the Set power level in Auto current temperature when in manual power in Using the arrow and Sn if slaved manual to Zone n and Error keys toggles messages when this display to ground they occur current Showing further Zones If more than twenty four zones have been configured to the controller then you can use the WV and A arrow
16. Value of 0 for Deg C 1 for Deg F C STOP MODE From the main menu 1 Select Utilities 6 gt Engineering 5 gt Temp Scale 7 2 Enter the system Password 3 Enter a value to indicate your preferred temperature range 0 for Degrees Centigrade 1 for Degrees Fahrenheit 4 Press ENT to confirm your choice Page 22 Mold Masters Issue 1 3 MZ L Series Manual Setting up your controller Setting the Zone types Issue 1 3 Each zone must be configured either as a probe or manifold and set to the correct speed Response Speed Our experience at Mold Masters is that the majority of probes show Satisfactory behaviour if you select Auto for response speed Some probes may require a faster response time and this may become apparent if the probe tends to run cooler than desired If this happens then a Fast response improves the situation Large masses such as manifolds may require slowing down by selecting Medium or Slow More recently a new generation of probes that are even faster have made their appearance and so we have added Ultra response times which are correspondingly faster in their response time To date very few controllers have required this ultra fast setting If your tool does need them you may select settings 4 which are all faster equivalents to the normal range Zone Type Start 1 End 3 Type Enter O for No Zone 1 for Probe 2 for Man
17. as thermocouple failed System Error or Temperature out of limits failed and so the controller is in alarm Deferring alarms Issue 1 3 Where a Temperature Limits Alarm output option has been fitted then you can disable it for a set period of time This allows the tool to reach its correct operating temperatures without raising a spurious out of limits alarm Mold Masters Page 29 Setting up your controller MZ L Series Manual Alarm Delay Power Delay 0 New 99 Enter a value of 99 for infinite delay 1 From the Main Menu select Utilities menu 6 gt Engineering 5 gt Alarm Delay 5 Enter the password 3 At the New prompt enter the required delay in minutes and press ENT Disabling alarms You can totally disable the Alarm Output by entering a value of 99 for the delay period 1 From the Main Menu select Utilities menu 6 gt Engineering 5 gt Alarm Delay 5 2 Enter the password 3 At the New prompt enter 99 and press ENT Monitoring temperature limits Your controller looks at the actual temperature of all the zones and verifies that the tool is operating within specific limits Rather than fixed points of temperature the Hi and Lo limits are set to degrees above and below the set point This provides an alarm window that moves with the set point Set Limits Power New Hi 10 New Lo Page 30 Mold Masters Issue 1 3 MZ L Series Manual Setting
18. changing test parameters is a complex matter that is beyond the scope of this operator s manual Therefore if you have any doubts or queries please call our service department for advice Setting your own test parameters Before considering your own test parameters please make yourself familiar with the meaning of the values especially Cooling and Heating Count These values are explained in the previous section Viewing the current parameters Test Values steps you through the six test parameters and invites you to insert your preferred option If at any stage you do not enter any value before pressing ENT then the default value is accepted and used 1 From the Main Menu select Utilities 6 gt Engineering 5 gt Test Values 3 Enter the System password 3 Atthe P Power prompt enter the percentage power that you wish to apply to the probe zones and press ENT 4 Atthe M Power prompt enter the percentage power that you wish to apply to the manifold zones and press ENT 5 Atthe Min Rise prompt enter the number of degrees that any other zone other than that under test is allowed to rise before a fail is recorded Any zones that experience a temperature rise above this minimum may have errant heater sensor wiring Press ENT if there is no reason to change the default 6 Atthe Max Rise prompt enter the degree rise centigrade that a zone is expected to reach taking the applied power into re
19. in fact granted herein under the claims of any patents All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopy recording or any information storage and retrieval system without permission in writing from the publisher All details standards and specifications may be altered in accordance with technical development without prior notification May be manufactured under one or more of the following U S Patents 4609138 4705473 4740151 4747770 4771164 4777348 4786246 4793795 4795338 4818217 4820147 4836766 4837925 4865535 4891001 4911636 4917593 4917594 4919606 4921708 4923387 4932858 4938681 4941249 4945630 4979892 4981431 5000675 5002480 5007821 5015170 5022846 5028227 5030084 5046942 5049062 5061174 5094603 5106291 5118279 5118280 5122050 5125827 5135377 5142126 5148594 5206040 5217730 5223275 5227596 5227181 5235737 5238378 5238391 5268184 5269676 5282735 5284436 5299928 5312242 5326251 5334008 5334010 5346388 5366369 5366370 5387099 5405258 5421716 5427519 5429491 5437093 5441197 5443381 5460510 5474440 5494433 5496168 5507635 5507636 5536165 5591465 5599567 5614233 5641526 5644835 5652003 5658604 5695793 5700499 5704113 5705202 5707664 5720995 5792493 5795599 5820899 5843361 5849343 5853777 5935615 5935616 5935621 5942257 5952016 5980236 60
20. loads such as manifolds the control card will automatically switch over to burst fire control once the load has warmed up The card requires no analogue calibration and is ready for use once set up from the display console Output Triacs The controller card is fitted with four on board triacs that are capable of controlling heating loads of up to 15 Amps peak Power Supply Units MMPSU25 A separate power supply is provided for the cards data communications and an alarm output relay Page 18 Mold Masters Issue 1 3 MZ L Series Manual How the MZ Controller Works How the MZ 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 Whenever the controller is set to start the system goes into a self calibration routine This is illustrated in the following diagram and explained below Set Point Temperature Time 1 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 Power is slowly increased until the correct rate of rise is achieved 2 The controller now increases the zone temperature at a constant rate of rise until the temperature reaches about 110 C 230 F 3 At 110 C the controller performs a Load Test
21. on the zone heater to check its thermal characteristics The output power is reduced to zero for a test period and the temperature monitored for a response From all this information the controller builds a mathematical model of the heater characteristics so it can automatically select a Fast Medium or Slow response heating program that suits the tool This allows more efficient control of the zones 4 The controller continues to ramp up the temperature to the set point which should be achieved with minimum over shoot 5 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 Issue 1 3 Mold Masters Page 19 How the MZ Controller Works MZ L Series Manual Watchdog feature The Controller card CPU has a watchdog timer that has to be reset by the system every 3 milliseconds If for any reason the software fails to reset the timer the program is reset to the start position which initialises the controller and so protects the tool from over heating The card resumes control of the zone from the start position Safety Memory Check CAUTION Page 20 This controller uses RAM with a battery back up to store all your settings such as zones types temperatures limits and tool bank settings There is an extremely low small risk that an interruption may cause any of these settings to alter and if such an event should
22. up your controller 1 From the Main Menu select Utilities 6 gt Configure 3 gt Limits 6 2 At the New Hi prompt enter the degrees above set point upper limit and press ENT 3 At the New Lo prompt enter the degrees below set point lower limit and press ENT After both have been entered the controller returns to the main display and the limits are displayed at the bottom of the screen Maximum power limits If your controller is to be run in open loop mode then you can limit the maximum percentage power that is applied to any zone This option prevents damage by not overheating the tool when the machine is running in open loop mode Power Limit Power Maximum 85 Enter maximum allowed POWER Setting Deg C STOP MODE 1 From the Main Menu select Utilities menu 6 gt Configure 3 gt Power Limit 3 2 Atthe Maximum prompt enter your required maximum percentage power and press ENT Issue 1 3 Mold Masters Page 31 Setting up your controller MZ L Series Manual StartUp Mode This determines how your controller activates the system when the main Isolator is first switched on There are two options available e the controller applies voltage to the heaters and the zones rise up to their preset operating temperature e Stop the controller is idle and the zones are set to Zero temperature The operator then needs to select Run on the front p
23. 09616 6017209 6030198 6030202 6062841 6074191 6077067 6079972 6095790 6099780 6113381 6135751 6162043 6162044 6176700 6196826 6203310 6230384 6270 711 6274075 6286751 6302680 6318990 6323465 6348171 6350401 6394784 6398537 6405785 6440350 6454558 6447283 6488881 6561789 6575731 6625873 6638053 6648622 6655945 6675055 6688875 6701997 6739863 6752618 6755641 6761557 6769901 6776600 6780003 6789745 6830447 6835060 6840758 6852265 6860732 6869276 6884061 6887418 6890473 6893249 6921257 6921259 6936199 6945767 6945768 6955534 RE 38265 RE 38396 Pending The information contained herein is to our best knowledge true and accurate but all recommendations or suggestions are made without guarantee Since the conditions of use are beyond our control Mold Mastersedisclaims any liability incurred in connection with the information contained herein All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means without permission in writing from the publisher COPYRIGHT 2005 MOLD MASTERS LIMITED ALL RIGHTS RESERVED Copyright 2005 Mold Masters Limited Printed in CANADA November 10 2005 Mold Masters global support facilities Canada Mold Masters Limited 233 Armstrong Avenue Georgetown Ontario Canada L7G 4X5 tel 1 905 877 0185 fax 1 905 873 2818 email info moldmasters com Germany Mold Masters Europa GmbH Postfac
24. BRACKET Tool No 3 20MM CAP kOONAURSUNK ALL SET ZERO Select with Arrow keys Enter copies New Name to name STOP MODE To Name the Tool 1 From the Main Menu select Utilities 6 gt Tool Set menu 2 gt Name a Tool 1 2 Atthe Tool No prompt choose an empty row and press ENT 3 Enter a suitable and brief name for this tool setting You can use the arrow keys to select letters and symbols while numbers can be entered directly from the keypad 4 Once you have completed the Tool Store name move the flashing cursor to END and press ENT 5 Atthe next Tool No prompt press ENT to confirm the new name To Save the Tool 1 From the Main Menu select Utilities 6 gt Tool Set menu 2 gt Save Settings 2 2 Enter the tool number that corresponds to the tool that you have just named 3 Press ENT to confirm your choice or CLR to cancel it and return to the Tool Set menu Issue 1 3 Mold Masters Page 33 Running your controller MZ L Series Manual 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 using the graphical display of recent performance may help such decisions What is included in this section St
25. MIZ L User manual revision 1 3 www moldmasters com Mold series Masters performance delivered AMENDMENT RECORD Mold Masters Users Manual Issue Date Amendments Author Authorised 0 0B 24 04 01 First Issue DH SK 0 1B 11 09 01 Revised Issue TJ 1 0 20 09 01 Revised Issue DT JN 1 1 25 03 02 Revised Issue DT JN 1 2 01 12 02 Revised Issue DT JN 1 3 01 01 06 Added voltage requirement for DT JN external standby port Copyright 2001 Mold Masters Developments This manual is intended for use with the MZ L Series Controller Our policy is one of continuous improvement and we reserve the right to alter product specifications at any time without giving notice Page 2 Mold Masters Issue 1 3 MZ L Series Manual Contents Contents AMENDMENT RECORD EE 2 ois CTUM 3 SPE eee 4 Safety Instructions go c IS a NS s IS ad S 5 Welcome dioi tt intend doen cd leg sd cutn beg sd cd log Dd cn 6 ETE TOM NN 7 SCR And Off c E 8 Tig LCD Console L 9 The Controller Cabinet asssssssssssssssssssssass 17 How the MZ Controller Works r 19 Setting up your controller aa 21 Running your controller Jan oid Pan fond edes Jan Dold Jon KK KS 34 Customising your controller kk k k kk k
26. P 0D 0Q N I SU N E ALL SET ZERO Select with Arrow keys Enter copies New Name to name STOP MODE 1 From the Main Menu select Utilities 6 gt Tool Set 2 gt Name a Tool 1 2 Atthe Tool No prompt enter the number of a blank tool position and press ENT 3 To create the name use the arrow keys to select each letter in sequence and the ENT keys to put that letter or symbol into the new name You can enter numbers directly by using the keypad As characters are added then the new name is displayed at the bottom of the screen 4 When you have created an acceptable tool name move the cursor to the END and press the ENT key to put the new name into the tool position and return to the Tool Menu Saving tool Settings Tool settings can be saved at any time into a named tool position If the selected tool store already holds a tool setting then the act of saving into that slot causes the old settings to be overwritten and lost Therefore always make sure that you select the right Tool Store for new settings 1 From the Main Menu select Utilities 6 gt Tool Set 2 gt Save Settings 3 2 At the Tool No prompt enter the Tool number that indicates your chosen name position and press ENT 3 Confirm your decision by pressing ENT to confirm or CLR to exit without saving the new settings Issue 1 3 Mold Masters Page 43 Customising your controller MZ L Series Manu
27. Page 64 Mold Masters Issue 1 3 MZ L Series Manual Spare Parts List MZ 1O 30A MOD MZ INPUIT OUTPUT INTERFACE CARD 30A TWO ZONE MODULE MZLCD MZ MONO LCD INTERFACE Issue 1 3 Mold Masters Page 65 APPENDIX A MZ L Series Manual APPENDIX A MZ Wiring Standards Page 66 Mold Masters Issue 1 3 MZ L Series Manual APPENDIX A MZ 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 INFORMATION 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 Cable Marking Supply Description L1 black Phase 1 L2 black L3 brown N blue green yellow WARNING N B The delta supply cable does not have a blue neutral wire Cable colours may vary therefore wire up according to the Cable Markings 1 2 Loom Thermocouple cables RTD thermocouple cable colours and number may vary Refer to controller documentation for details Type J and K are supplied as below unless otherwise specified Type Positive Negative Positive Negative Positive Negative I Black white Red Bie white R
28. There is a limited amount of memory available to store test results If this message is seen too many errors have occurred to store them all Mold Masters Issue 1 3 MZ L Series Manual More options 30A Mod controller card and I O card More options 30A Mod controller card and I O card 30A Mod controller card This special controller card is able to boost the output current to 30A ideal for high power application Each 30A controller card contains two zones and takes up two slots in cabinet I O interface card This Input Output card offers four separate digital inputs plus one analogue input and four outputs Its main function is to facilitate remote operation and so the 4 digital Inputs and Outputs have been nominally programmed by the manufacturer to provide the functions listed below other functions may be available on request The fifth T C input however is user configurable within the Easy Set Up page where you can set its individual Warning and Alarm levels Setting up I O card address An 8 way DIP switches on the card need to be set to the correct address for the console to read the card This is normally the next count or number following the number of zones that are currently installed in the controller For instance If a MZ contains 13 of QMOD caras the current zone count is 13x4 52 zones These zones are counted starting at zero so the last control zone is number 51 not 52 Following this exa
29. U euroboard size with two DIN connectors and are mounted in a single rack which may take up to a maximum of 6 cards Each card has three main components e thermocouple amplifiers e CPU e multi voltage output triacs Thermocouple Amplifiers The thermocouple amplifiers have preset responses for both J and K type thermocouples The selection of Sensor type on the Utilities Menu sets a flag that is read by the control card this in turn sets the differential amplifier to match the selected thermocouple type Issue 1 3 Mold Masters Page 17 The Controller Cabinet MZ L Series Manual Central Processor Unit CPU The CPU provides the following facilities e closed and open loop control of the zones e communicates settings and thermocouple readings over the data link to the display micro processor e checks for alarm conditions including blown output fuse s incorrect thermocouple wiring Zone over temperature condition heater not responding to controller output and generates alarm information for the display screen and alarm relay if fitted e controls the output power to the on board triacs using a number of self tuning algorithms e controls a row of diagnostic LED s mounted on the edge of the controller cards These LED s can be seen through the window in the faceplate of the controller e monitors the thermocouple every 20 milliseconds Phase angle firing is normally used for power control However on heavier
30. actual settings if you have changed them since loading the tool In every case the printout is sent directly to your connected printer If however no printer is detected then the controller reverts to normal working after approximately 10 seconds Current status This option prints out your control settings as they are currently set 1 From the Main Menu select Utilities 6 gt Print Reports 4 gt Current Status 1 Current tool This choice prints out the settings for the tool that is currently selected They may be different to the Current status if any settings have been modified since the tool was loaded 1 From the Main Menu select Utilities 6 gt Print Reports 4 gt Current Tool 2 Database Tool This final choice prints out the tool settings for any other tool that you have stored in your tool bank that you are not currently using 1 From the Main Menu select Utilities 6 gt Print Reports 4 gt Database Tool 3 2 At the Tool No prompt enter the number of the tool which you want to print out and press ENT Page 46 Mold Masters Issue 1 3 MZ L Series Manual Maintaining your Controller Self Diagnostic Tests What is tested during a self diagnosis check The Mold Masters Controller has a diagnostic testing tool that allows you to check that every zone is functioning correctly The routine may be used e asan acceptance check e to see that a new tool is wired up
31. al Recalling tool settings Once settings have been saved to the controller then they may be instantly recalled as follows 1 From the Main Menu select Utilities 6 gt Tool Set 2 gt Load Settings 4 2 Atthe Tool No prompt enter the number of the tool that you wish to load to your controller and press ENT 3 Confirm your decision by pressing ENT to confirm or CLR to exit without loading the new settings NOTE f you select a tool that has no settings in its memory then you are prompted to press CLR to exit the menu To change to another tool that has settings start again at step 1 Changing tool settings To permanently change a tool s settings this procedure saves CAUTION new settings to a tool position and over writes any that are already there Once you have done this then previous settings in the nominated position cannot be recovered 1 Adjust the settings using appropriate menus and tools 2 From the Main Menu select Utilities 6 gt Tool Set 2 gt Save Settings 3 3 Atthe Tool No Prompt enter a number which corresponds to the tool which you want to change and press ENT 4 Confirm your decision by pressing ENT to confirm or CLR to exit without saving the new settings Deleting a tool Once you have deleted a tool there is no way to recover its previous CAUTION settings Take care that you are deleting the correct tool To remove a tool and all its settings from any posit
32. and fuse fault RS 232 serial DB9 male connector Double pole change over volt free contacts 5A max burden Contact H BE24BS Male Contact H BE24SS Female 4x4 matrix tactile switch 16 x 40 characters 128 x 240 pixels LCD CFL Back Light Heavy duty metal cabinet Mold Masters Issue 1 3 MZ L Series Manual Safety Instructions Safety Instructions WARNING 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 WARNING CAUTION Issue 1 3 Within this manual safety instructions are marked as follows 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 A CAUTION warning identifies where there may be a hazardous situation which if not avoided may result in damage to property Caution warnings present no personal danger but may cause the equipment to fail or lose its memory Mold Masters Page 5 Welcome MZ L Series Manual Welcome Mold Masters welcomes you to their MZ range of temperature controllers for hot runner injection moulding tools This particular
33. anel to start heating the tool To select either of these modes 1 From the Main Menu select Utilities 6 gt Engineering 5 gt StartUp Mode 8 2 Enter the password 3 Atthe Mode prompt enter 0 for Run or 1 for Stop and press ENT How to verify your tool settings One screen enables you to check how the controller is currently set up The area on the left displays shared settings such as Boost and Temp Scale The table on the right shows individual settings channel modes on or off board triac type of sensor and power display Power Show Settings Boost 15 Deg Time 5 Maximum 85 Alarm 99 Min STDBY 5 sec Scale AUTO C Startup Run Master None Press Clear to exit 1 From the Main Menu select Utilities 6 gt Configure 3 gt Show Settings 7 Look through the displayed current settings to see everything is set as required Page 32 Mold Masters Issue 1 3 MZ L Series Manual Setting up your controller How to save your tool settings Once you have configured the controller to operate as you require it is good practice to save the settings to avoid having to repeat all these steps There is a memory bank that can store and recall up to 10 different combinations of power zone and alarm settings This page only describes how to save your immediate settings however all the tool store features are fully explained in the Customising chapter Name Tool END
34. arting Stopping Pausing Boost how to apply a short increase Raising and lowering set temperatures Using Slave Mode to compensate for a failed thermocouple Looking at temperature history for the last 5 or 60 minutes Page 34 Mold Masters Issue 1 3 MZ L Series Manual Running your controller Starting Stopping and Pausing How Run works The Mold Masters controller is preset to self select one of the manifold zones to be a Master Zone During Start up power is applied to all zones but the target temperature for the faster Probes is set to follow the actual temperature of the master manifold The manifold has a slower heat rise time than the probes and the result is a uniform temperature rise across the whole tool However if a homogenous rise is not required there is the option to de select the Master Zone in the Engineering menu Doing this would mean that all the zones reach their set operating temperature in their own time in which case the Probes would be quicker to reach their normal operating temperature De selecting a Master Zone controlled Start up 1 From the Main Menu select Utilities 6 gt Engineering menu 5 gt Master Zone 9 2 Enter the Password 3 the Manifold prompt enter 0 press ENT to return to the Engineering Menu Run Mode 1 From the Main Menu select Run 1 and press ENT to confirm Stop Mode 1 From the Main Menu select Stop 2 and press ENT
35. bleshooting FUSE The fuse for that zone has Replace the fuse with one of failed the same rating and type i e High Rupture Current load Please Note A fuse can only N TE NA l gt trol fail due to a fault external to kai i is he obo du the controller Identify and d y Riad i 9 rectify the fault before module Hea replacing the fuse GND The system has detected an Check your heater wiring for earth fault a low impedance path to earth HELP There is a system failure Please contact Mold Masters LINE No mains supply Check supply wiring for synchronisation pulses being presence of all three phases received LOAD No load on that zone Only Isolate the system supply and occurs when in manual check the connections closed loop mode where the between the controller and current is pre set The current the tool heaters Also check sensing circuit has not the heater for continuity detected a current flow therefore the zone is flagged as not having a load N Z The controller card in this Check card for faults rack position is not responding NONE A Zone type appears not to There is a communications be selected for the card problem Try a replacement controller card T C An open circuit thermocouple Either slave that control zone has been detected to an adjacent zone or change to open loop control Later check to see whether the input fuse on the control card has r
36. correctly e asamaintenance aid to check that a working tool is functioning correctly This routine allows the controller to step through all the zones heating one at a time and checking that appropriate heat rises are detected The following describes the tests and shows what is deemed as a pass It also describes some errors that may result in Failures or Warnings 1 Once a test has been initiated the display returns to a main screen and messages are displayed to keep you informed about progress 2 Initially the whole tool is cooled so that it can start from a stable environment and then starts to run sequentially through each zone 3 The main screen displays a message COOLING STAGE and the first zone displays TEST in the Act column During the cooling all zones are checked to see that none experience a significant temperature rise 4 After a period of time the main screen displays a message POWER TEST and the Set column for the zone under test shows a quantity of percentage power that is applied to the zone under test While this is happening it monitors every other zone to see that only the zone under test experiences a temperature rise If no temperature rise is detected for the zone under test it increases the applied power and looks once more for a heat rise It continues this cycle of raised power and monitoring until it reaches the count number of times stipulated in the Test D
37. d screwdriver to check that no terminals have become loose Mold Masters Page 57 Troubleshooting MZ L Series Manual Troubleshooting The control system has several features which provide an early diagnosis of faults in the control system the tool heaters and thermocouple sensors If the system detects any malfunctions in one or more of the control zones then it displays an error message in the Main Screen instead of a temperature value If the system detects any abnormal condition it displays a warning message in the Main Screen Fault and warning messages Error Indication line Any of the following messages may be displayed on the Fault Cause Action Message AMPS The controller is unable to Isolate system supply check supply the current requested loom and heater wiring Occurs only in manual mode continuity when a current level has been pre set AUTO The controller has detected a Check from the tool back to T C failure and Automatically the controller for a switched this zone to manual disconnected Thermocouple It is using recorded settings to maintain the zone temperature Note this will only be seen if you have Auto Manual Mode Enable ERR No temperature rise has been Check thermocouple wiring it detected in that zone may be reversed Heater wiring may be faulty or element may be open circuit Page 58 Mold Masters Issue 1 3 MZ L Series Manual Trou
38. do not exceed the following limits Temperature to 35 C Relative Humidity 9096 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 Issue 1 3 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 1 905 877 0185 1 800 450 2270 Fax 1 905 873 2818 Mold Masters Page 7 Switching On and Off MZ L Series Manual Switching On and Off The main Power Switch is a rotary Switch at the back of the cabinet This Switch is sufficiently rated to disconnect the total load current during switch On and switch Off You can use a suitably sized padlock or similar device to lock the switch in the Off position to prevent operation during maintenance Although the main switch has the capacity to switch the whole system Off we recommend that you only do this in an emergency situation Your console and cabinet use computer technology and you should normally switch the system off in stages as detailed below A sequenced method for switching On and Off
39. e temperature for the faulty slaved zone Single Zone Zone 1 P M Slave 22 P Press ENTER for Auto Mode 1 From Main Menu select Set Menu 5 gt Set Zone 1 2 At the Zone prompt enter the number of the zone which has the failed thermocouple 3 Use 4 gt to select P probe or M Manifold and press ENT 4 Press the ENT button sufficient times until you get the Slave Prompt 5 Enter the number of another healthy zone that is currently working to the same set temperature as that which you require for the faulty zone and press ENT Note Conditions for slaving zones You must select a healthy zone to slave on to For instance if Zone 3 is already slaved to Zone 6 and you now wish to slave Zone 2 then you might not select Zone 3 as a master zone You must choose any other healthy zone and this includes Zone 6 which is currently selected as a master zone for Zone 3 6 The Actual column for the slaved zone now shows S n where n is the number of the zone that you have slaved to Mold Masters Page 39 Running your controller MZ L Series Manual Any subsequent changes for instance temperature changes that are made to the master zone affect the slaved zone also Check zone performance graph Your controller can record and display the temperature history for any zone over a period of time In this model there is the option to view a historical graph for the last 5 m
40. ed K Gren white NA NA vele med x 1 3 Loom Power cables The power cables have no specific colour except the ground wire which is green yellow The rest is numbered Issue 1 3 Mold Masters Page 67 APPENDIX A MZ L Series Manual 1 4 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 5A at 220V Input Output Auxiliary Input signal Standby Port require Auxiliary Input Gnd external 12VDC Pin Connection ________ Input Output 220v contact 1 Alarm Port Alarm 220v contact 2 u 9r 1 5 Serial Port A male 9 way D panel connector is provided for an RS 232 serial port This has a dual purpose it can output to a serial printer or communicate with a remote computer for data collection The pin outs are as follows Pin Connection KEN PE KUER Configuration for the serial printer Data length 8 bit Baud rate 9 600 Parity none Protocol DTR Sig Polarity mark Mold Masters Issue 1 3 MZ L Series Manual APPENDIX A INSTRUC TION HOW TO CONVERT DELIAWYE FOR SNGLE BREAKER SYSIEM AMERICAN DELIA 220V
41. efaults 5 Provided that the zone under test rises by an appropriate degree that zone is deemed to have passed the test The message OK is displayed and the controller moves on to the next zone 6 If however the controller fails to detects an appropriate heat rise in the zone under test then it may have detected one of two possible errors Issue 1 3 Mold Masters Page 47 Maintaining your Controller MZ L Series Manual a if another zone exceeds the Max Rise rather than the one under test it indicates that there is a crossover somewhere between a probe and its thermocouple In this case the test sequence displays a FAIL message in the status line for the zone under test Note if there is a crossover then you should expect to see a second FAIL message to show with which other zone the wiring is crossed b ifthe zone under test exceeds the Max rise but a significant heat rise is also detected in other zones such that they exceed the Min Rise then the controller displays a WARN message These other zones are physically close to the zone under test but not necessarily numerically adjacent This fault is usually caused by excessive thermal conduction which impedes accurate temperature sensing and so results in imperfect temperature control At the end of the Tool Test the system stores and displays all the results The particular incidences described above are displayed in further detail For instance t
42. ell need this chapter of the manual This initial set up is detailed here in easy to follow steps that help you to become familiar with your new equipment What is covered in this section How the system automatically selects temperature range Setting your preferred temperature display Configuring the controller to your tool Setting zone types Matching sensor types Setting the required temperatures Selecting the Master Zone Setting boost values Setting alarms and limits Checking your initial settings Saving your initial settings Issue 1 3 Mold Masters Page 21 Setting up your controller MZ L Series Manual Automatic temperature range selection The MZ has an automatic function that establishes the temperature scales It works by detecting the supply frequency and sets the temperature scale to centigrade on 50 Hz supplies and Fahrenheit for 60 Hz supplies This automatic setting means that the temperature is displayed in degrees Fahrenheit in America and degrees Centigrade in most European countries There are however some countries that have different parameters for instance Brazil uses Centigrade but has 60 Hz supplies Should this situation arise you can change the system temperature scale to a preferred range Setting the temperature display Where the automatic detection shows the temperature as Centigrade rather than Fahrenheit or vice versa then you can easily change it Temp Scale Scale Enter a
43. ered as satisfactory Any heat rise below this figure is counted as a fail If any other zone exceeds this setting then there must be cross wiring between heaters and thermocouples Please note that the last two default values for minimum Rise and Maximum Rise are stored as Centigrade temperatures and displayed as numbers only If your system is using the Fahrenheit scale either through automatic detection of supply frequency or set as a preferred scale you should change these two figures to obtain a correct test Minimum Rise should be changed from 2 C to 4 F and Maximum rise changed from 6 C to 11 F respectively These figures test correctly for a system displaying in Fahrenheit 2 Press CLR to exit from this menu Mold Masters Page 49 Maintaining your Controller MZ L Series Manual Why you may need to change your test parameters Normally there is no reason to alter the test parameters in your self diagnostic routine There are however two conditions that may require extra attention If your system is displaying temperatures in Fahrenheit rather than centigrade then as previously explained it is necessary to alter the Minimum Rise and Maximum Rise to compensate for temperature scale see the previous Caution notice for details b If you are failing to get a satisfactory test because you have an unusually large heating mass such as a heated platen then you may need to compensate for this However
44. h 19 01 45 76503 Baden Baden Germany Neumattring 1 76532 Baden Baden Germany tel 49 0 7221 5099 0 fax 49 0 7221 53093 email info 9 moldmasters de China Mold Masters Kun Shan Co Ltd Zhao Tian Rd Lu Jia Town Kun Shan City Jiang Su Province People s Republic of China tel 86 512 86162882 fax 0512 86162883 email MMC Sales moldmasters com regional offices United Kingdom Mold Masters UK Limited Unit 28 The Gateway Birmingham Airport Birmingham B26 30D United Kingdom tel 44 0 121 781 7800 fax 44 0 121 782 4604 email bdavison moldmasters co uk Canada Mold Masters Technology Center 41 Todd Road Georgetown Ontario Canada L7G 4R8 tel 1 905 877 0185 fax 1 905 873 2818 email info moldmasters com Brazil Mold Masters do Brasil Ltda Rua Hum 1106 e 1126 Jd Manchester Nova Veneza Sumar Sao Paulo Brasil CEP 13178 440 tel 55 19 3922 4265 fax 55 19 3922 4266 email moldmasters moldmasters com br Austria Mold Masters Handelsges m b H Kirchenplatz 6 A 4552 Wartberg an der Krems Austria tel 43 0 7587 7297 0 fax 43 0 7587 7297 77 email office moldmasters at also Switzerland U S A Mold Masters Injectioneering LLC 2751 New Cut Road Spartanburg South Carolina 29303 USA tel 1 800 450 2270 fax 1 905 873 2818 email info amp moldmasters com Japan Mold Masters K K 1 4 17 Kurikidai Asaoku Kawasaki Kanagawa Japan
45. he two zones which displayed FAIL because of crossover both show a full message Heater TC Common with Zone NN The second incident which detected thermal conduction and showed WARN displays the full message T C Interaction with zone NN and points to those zones where excess heat was detected There is not room to fully describe all the potential faults and we trust that you should never see any of them on your own controller However there is a complete list of error messages on page 54 that explains their meaning and which helps to identify probable causes Page 48 Mold Masters Issue 1 3 MZ L Series Manual Maintaining your Controller Using and Viewing current parameters CAUTION Issue 1 3 To see what current values are in the test routine 1 From the main Menu select Utilities 6 gt Engineering 5 gt Test Defaults 4 The screen displays Probe Power how much power is applied to the probe zones Manifold Power how much power is applied to the manifold zones Minimum Rise this is a first stage level which only the zone under test should pass If any other zones heat up by more than this it means that there is excessive thermal conduction from one zone to another which may cause poor temperature control This value may be varied to take thermal mass and probe proximity into account Maximum Rise this is a second stage level which the zone under test must exceed to be consid
46. ifold Select Utilities menu 6 gt Configure 3 gt Zone Type 1 At the Password prompt enter the password At the Start prompt enter the zone number for the first zone in your target group and press ENT 4 At the End prompt enter the zone number for the last zone in your target group and press ENT 5 At the Type prompt enter the type of zone and press ENT At the Speed prompt enter the desired response speed and press ENT 7 Repeat steps 1 to 6 for the other Zone types manifold and cycle synchronised Mold Masters Page 23 Setting up your controller MZ L Series Manual Matching sensor types There are two different types of probe sensors J type and K type with different characteristics Control cards use differential amplifiers with dual settings in order to respond correctly to either type Your choice of thermocouple type at this screen sets a flag that is read by the control card However the sensor type is normally configured to a J Type before leaving the factory and should only need to be altered in rare circumstances Sensor Type Start 1 End 40 Type Enter 0 for J T C 1 for Type K T C Select Utilities menu 6 gt Configure 3 gt Sensor Type 2 Enter the password 3 At the Start prompt enter the number of the first zone in your target group and press ENT 4 Atthe End prompt enter the number of the last zo
47. il 20mm Glass Fuse Antisurge 100mA Fans Every Cabinet has auxiliary fans to ensure adequate cooling 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 its supply fuse which is located on the main termination rail 1 1 4 Glass Fuse Antisurge slow blow Page 62 Mold Masters Issue 1 3 MZ L Series Manual Troubleshooting Controller Cards The current surface mount controller card has protection fuses for both the T C input and for the heating load output Older cards which are identified by having the main CPU mounted in a socket only have output fuses If the Fuse LED indicator shows that the output fuse has ruptured then the card may be easily removed and the fuse changed If the T C LED indicator shows an open circuit T C circuit then this may indicate that the input fuse has ruptured Input Fuse Type Surface mount quick blow Code 62MAQBSM Fuse Rating 63mA QMOD Output Fuse Type HRC High Speed BUSS 1 1 4 Fast blow 30A MOD Output Fuse Type Rating 32A Issue 1 3 Mold Masters Page 63 Spare Parts List MZ L Series Manual Spare Parts List QMOD MMPSU25 QUAD SWITCHING CARD FOR MZ 25 W PSU PACK POWER SUPPLY LCPUPT02 MZ MONO LCD ASSEMBLY MCABLE 12 MPLUG 12 12 ZONE CABLE ASSEMBLY T E T E 12 ZONE PLUG ASSEMBLY
48. inutes or the last 60 minutes 1 From the Main menu select Utilities Menu 6 gt Graph 1 2 Atthe Zone prompt enter which zone you want to view and press ENT 3 Use 4 gt to select P Probe or M Manifold and press ENT The temperature time graph now displays how that chosen zone has behaved over the last 5 minutes and the legend at the bottom shows further options At this point you may e Press ENT to toggle the time viewed between 5 minutes and 60 minutes e Use the A and V keys to toggle between X1 and X2 temperature scale e Use the lt and gt keys to move the viewed temperature window up and down the scale e Press CLR to exit the viewed graph and return to the Zone prompt At this stage you can select another zone to view or press CLR or ENT to return to the Main Menu Page 40 Mold Masters Issue 1 3 MZ L Series Manual Customising your controller Customising your controller Your controller has a dedicated Tool Bank which enables you adapt it quickly to different circumstances It has ten available positions that can be individually named saved and recalled whenever the tool or job changes Our convention is that new tool settings must have a name If you try to save a tool setting to an empty position that you have not yet named then the machine does not accept your request To amend this situation you must go back and name the tool position then load it with yo
49. ion 1 From the Main Menu select Utilities 6 gt Tool Set menu 2 gt Delete a Tool 2 2 Atthe Tool No prompt enter the number of the tool that you wish to delete and press ENT 3 Confirm your decision by pressing ENT to confirm or CLR to exit without saving the new settings Page 44 Mold Masters Issue 1 3 MZ L Series Manual Maintaining your Controller Maintaining your Controller Maintaining your controller considers how you look after your machine It includes electrical functional testing that may be carried out as either preventative or fault finding maintenance It also considers the physical aspects of maintenance and lists those routines that can extend the useable lifetime of your machine What is included in this section Printing tool settings for the records Running a self diagnostic test check that all is functioning correctly Viewing and printing test results saving diagnostic test results Servicing and repairing your controller Issue 1 3 Mold Masters Page 45 Maintaining your Controller MZ L Series Manual Printing tool settings If you want a hard copy of any tool settings then your controller can do this for you The print facility enables you to print the complete tool settings for any tool that may be inthe tool bank but not in current use e in current use but changed e the stored settings for the tool that you are currently using which may be different to the
50. is fully described on page 25 in the Setting Up Chapter Utilities The Utilities option allows you to set up many of the variables in your controller according to different tool requirements Utilities 1 Graph 2 Tool Set 3 Configure 4 Print Reports 5 Engineering Select Deg C STOP MODE Mold Masters Issue 1 3 MZ L Series Manual The LCD Console Graph The Graph option allows you to select any zone in order to display its recent temperature performance over the last 5 or 30 minutes Graph Zone Zone 1 P M Use Arrow Keys to Select Type P Probe Body M Manifold Deg C STOP MODE Tool Set The Tool Set option gives access to a store for up to 10 different tool settings which you can use at any time Tool Menu END BRACKET 1 Name a Too 20MM CAP 2 Delete a Tool 3 Save Settings 4 Load Settings Select FPUOONOUARWNE ALL SET ZERO STOP MODE Configure The Configure option allows you to set up many of the variables in your controller according to different tool requirements Configure 1 Zone Type 2 Sensor Type 3 Power Limit 4 Boost Value 5 Boost Time 6 Set Limits 7 Show Settings Select Deg C STOP MODE Issue 1 3 Mold Masters Page 15 The LCD Console MZ L Series Manual Print Reports The Print Report option allows you to print out both current and stored tool settings to a connected prin
51. is probably due to an error in the supply wiring No Card Present No card was detected in the rack at the slot identified with the displayed zone Cooling Test Failed All zone temperatures had to be stable or falling before the heating test begins If any zones continued to rise with power set to zero within the cooling period this error is raised Heating Test Failed Temperature did not rise by the set number of degrees within the heating period This may be caused by an open circuit heater a pinched shorted or dislodged thermocouple or the zone was set to on board triac when the cabinet was wired for off board triacs Check for Reversed T C Temperature appeared to be decreasing when power was applied Below 0 or Reversed T C May be caused by a reversed thermocouple Also in the unlikely event that the test was carried out at an ambient temperature below 0 C the controller would not work with the resulting negative temperature readings Failed to React Correctly Unexpected results This message is followed by further error messages T C Interaction with zone A different zone s to the one being tested had an unacceptable rise in temperature greater than Minimum Rise set in Test Values Indicates faulty T C positioning or close zone proximity Heater TC Common with zone Cross wiring fault between displayed zones Could be either Heater or thermocouple wiring at fault Message Overflow
52. mple the I O card should be counted as number 52 You must now set the DIP switches on the I O card to its counted value for the console to see the card and C read its information The diagram the right shows the I O card with the li Fl DIP switches at the left edge Looking at the card in the same orientation moving a switch element to the DIP Switches right R sets that switch to 0 while moving the switch to the eft L sets the switch to 1 1 In setting the switch to address 52 which in binary Micro count is 00110100 the first switch from the bottom 8 is number 8 and is the highest element in the binary number or most significant bit In this IPS example setting the number 52 00110100 the switches shouldbe RRLLRLRR LEDs Issue 1 3 Mold Masters Page 55 More options 30A Mod controller card and I O card MZ L Series Manual I O Connections Description Nominal Function Input 1 20 Input 1 Go to RUN Mode Input 1 Input 2 Input 2 Go to STANDBY Mode Input 2 Input 3 Input 3 Go to STARTUP mode Input 3 Input 4 Input 4 Go to STOP Mode Input 4 Inputs Input 5 Thermocouple Input Input 5 ape Injection Enable Disable rel njection Enable Disable relay closes once MC Contact 1 Output 1 up to temperature NC Contact 1 NO Contact 2 rel j ontroller Zone Alarm relay closes when a MC Contact 2 Output
53. n between Mp3s Page 70 Mold Masters Issue 1 3 MZ L Series Manual APPENDIX A Thermocouples and Power Output Configuration NS 212 121 210 29 18 77 16 25 14 123 12 Z 2 l 1 hol l 7 le T s J Bb 2 1 Thermocouples Male 2455 Power Output Female H BE24BS Issue 1 3 Mold Masters Page 71 MZ L Series Manual PLUGS CONFIGURATION MOLD END 12 ZONES 3 4 8 5 78 9 132 Thermocouples Page 72 Mold Masters Issue 1 3 MZ L Series Manual Glossary Glossary Cabinet Loom LCD LED Manifold Probe Prompt Tool Zone Burst fired Phase Angle fired Closed Loop Open Loop Cycle Synchronised On board triac Off board triac Issue 1 3 Unit containing control electronics Cables connecting control cabinet and tool Liquid Crystal Display Light Emitting Diode Warning Lights Background or runner heater Gate control heater Screen text asking the user for input Temperature controlled mould for injection moulding of thermoplastic components Control zone may be probe or manifold heater Also known as time proportioned where a half wave mains waveform is used i e the power is turned on when the waveform is at zero volts and the triac remains on until the next zero volt point is reached At the next zero point the triac is re triggered to start the next half cycle The half waveforms are time p
54. ne in your target group and press ENT 5 Enter 0 for Type J 1 for Type K and press ENT Page 24 Mold Masters Issue 1 3 MZ L Series Manual Setting up your controller Setting the required temperatures When you first set up your controller you must consider e which channels will be Probe Manifold e whether they will operate in Closed Loop Auto Mode Open Loop Manual Mode or Slaved to other channels e what will be your required operating temperature or power settings Setting one Zone at a time Probes and Manifolds Your can set up one channel at a time by using the Set Zone command from the Main Menu Single Zone Zone 1 P M Temp 280 Press ENTER for Manual Mode 1 At the Main menu select Set Menu 5 gt Set Zone 1 2 the Zone prompt enter the zone number that you are configuring and press ENT 3 Use lt gt to select P Probe or M Manifold and press ENT 4 Next at the Temp prompt the system defaults to Auto mode 5 If AUTO is not your preferred mode then press ENT repeatedly to step though Manual and Slave and back to Auto As you step through these modes then you see the prompt change to Power Slave and back to Temp Once you are in your preferred Mode enter the required Temperature Power Setting or Slave Channel as appropriate and press ENT to establish your choice 6 Repeat Steps 1
55. ns press ENT e to leave a page without saving the modifications press CLR Status Line At the bottom of the display is a status line which indicates any operational mode of the controller such as Run Standby or Boost Password Protection System Password is 2 A A Certain pages or screens generally those which are related to configuring zones setting limits and zone operating modes are protected by a password To prevent unauthorised changes initial entry requires a system password for access Once the password has been supplied then all protected menus are available for the next 30 seconds Also this timer will reset when you enter such a screen and not restart until you leave it This means that you can swiftly move from one protected screen to another within one session Once you have left any protected screen and 30 seconds have elapsed then the protection becomes active once more Issue 1 3 Mold Masters Page 9 The LCD Console MZ L Series Manual Keypad The standard keypad has 16 keys including 10 numeric keys 0 9 4 arrow keys up down left and right an enter key marked ENT and a cancel or clear key marked CLR Number Keys These enter a value or menu option always followed by the enter key Arrow Keys These are used for display and tool store options The left arrow is used to correct entry errors It erases the last digit up to the start of the field Enter Key
56. o set the temperature above the limits Check the current setting in the Limits menu and revise it if necessary Issue 1 3 Mold Masters Page 61 Troubleshooting MZ L Series Manual Not able to set a Higher Power level This problem occurs if you try to exceed the percentage power level limit that has been previously set Select Utilities 6 gt Configure 3 gt Show Settings 7 to see the current limits and revise if necessary 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 Fuses There are supply fuses for four separate functions and a side panel mounted MCB for the whole unit In the unlikely event of a fuse failure always isolate the incoming main supply before opening the cabinet door or removing any panels Replacement Fuses WARNING 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 Power Supply Units MMPSU25 The PSU is mounted on top of the upper chassis plate and is behind the termination rail It is supplied by its own fuse that is located on the same termination ra
57. occur there must be no risk to the equipment If a zone had previously been set to say 260 deg should become corrupted to perhaps 520 deg then the controller must not attempt to establish the incorrect temperature upon the next start up command To ensure this cannot happen there is a safety memory check facility This checks to see that no value has been changed since the last time the controller was used If this facility detects any setting is different then it protects your system by automatically erasing every single stored setting within its memory If such a rare occurrence happens to your controller you will be met by the following screen when you switch it on CAUTION SYSTEM RAM ERROR Stored Values HAVE been ERASED Press Clear to exit B If you see this screen you will need to go through all the various screens and input all appropriate settings This basic task is described in the Setting Up section of this manual The task is easier if you have all the correct settings written down in a safe place Mold Masters recommends that a hard copy of all the controller and tool settings be saved in a safe place Mold Masters Issue 1 3 MZ L Series Manual Setting up your controller Setting up your controller New MZ series controllers are correctly configured at the factory and you should not need this section for a new system However if you reconfigure your controller to a new tool or environment you may w
58. on Interpreting Test Results Viewing previous test results The controller always saves the last and most recent test results Provided you have not carried out another tool test your last test results are still in memory to view 1 From the Main Menu select Utilities 6 gt Engineering 5 gt View Results 2 Printing Results 1 Ensure that you have a suitable printer connected to your controller 2 From the Main Menu select Utilities 6 gt Print Reports 4 gt Test Results 4 and press ENT Note If the system does not detect a printer connection then it automatically aborts the print command after approximately 10 seconds and returns to the last menu Issue 1 3 Mold Masters Page 53 Maintaining your Controller MZ L Series Manual Interpreting the test results Page 54 These are some of the errors that you may receive after running a system test Each is listed along with its probable causes User skipped Test You skipped the test for this zone by pressing ENT while it was being tested User Aborted Test You aborted out of the test by pressing CLR at this point Open Circuit T C Thermocouple detected as being open circuit Check thermocouple wiring for displayed zone Blown Fuse Check card fuse This message is also displayed if the zone was set to use an off board triac that was not installed N B Off board triacs have their own fuse No Mains Sync Pulse This
59. parately as described below Boost Temperature Boost Value Increase 15 Enter Temp to BOOST the Settings by Deg C STOP MODE 1 From the Main Menu Select Utilities 6 gt Configure 3 gt Boost Value 4 Enter the System password At the Increase prompt enter the degree rise required and press ENT Boost Time Boost Time Max Time 45 Enter Time Limit for the BOOST 1 From the Main Menu Select Utilities 6 gt Configure 3 gt Boost Time 5 2 Enter the System password 3 At the Max Time prompt enter the Boost Time calculated in seconds and press ENT Page 28 Mold Masters Issue 1 3 MZ L Series Manual Setting up your controller Standby Delay Standby Delay rower Delay 99 New 0 Enter a value to delay the start of standby mode Deg C STOP MODE The time in seconds to activate the standby feature reduce 50 below the set temperature 1 From the Main Menu Select Utilities 6 gt Engineering 5 gt Standby Delay 6 Enter the System password 3 At the New prompt enter the required delay in seconds and press ENT Console Alarms Your Mold Masters Controller has three LEDs on the front panel to advise you about the condition of the tool and controller Green Normal the controller is working normally Amber Warning One or more zones are outside their limits Red Alarm A fault has been detected such
60. r an example where you wish to test say zones 20 25 out of a total of 40 zones Skipping early zones with the ENT button Run the tool test for all the zones and force it to ignore the first 19 zones by pressing ENT while it is looking at each of the early unwanted zones Skipping late zones with the CLR button As part of the same test monitor the test through zones 20 25 and then press the CLR button to abort the rest of the test What is displayed after using the ENT and CLR buttons The final test results show messages for all the zones It displays e the error message user skipped test against those zones which you forced it to bypass with the ENT button e test result messages for zones 20 25 the message and user aborted test is displayed for all the remaining zones after pressing the CLR button Page 52 Mold Masters Issue 1 3 MZ L Series Manual Maintaining your Controller Viewing and printing test results Viewing test results At the end of a self diagnosis if the display does not automatically switch to display the results then select Utilities 6 gt Engineering 5 gt View Results 2 This display is a table that lists satisfactory zones and also any errors that are detected by the test Zones that perform normally display no message at all while those that produce a fault condition display one or more error messages Allowable error messages are listed in the secti
61. rides all the Probes normal Set temperatures and substitutes them with the Manifold Actual temperature By doing this the faster responding probes are held back to follow the slower rising manifold temperature The results of this programming mean that the whole tool warms up in a homogenous manner By selecting this Master Zone screen you can over ride the controller s automatic selection of manifold zone to some other zone that you may consider more appropriate You may also use this screen to completely de select any Master Zone so that all the zones can warm up in their own time without any probes being held back to follow a slower manifold MZ uses manifold1 1M as the default master zone Master Zone Manifold 1 Enter a Manifold Zone which will become the Master or 0 for None 1 From the Main Menu select Utilities 6 gt Engineering 5 gt Master Zone 9 Enter the System Password At the Master Zone prompt enter the zone number for your preferred manifold or 4 Enter a 0 zero if you wish to de select any master zone and enable faster probe warm up times 5 Press ENT to put your selection into memory and return to the Engineering Menu Issue 1 3 Mold Masters Page 27 Setting up your controller MZ L Series Manual Setting Boost Values Before you can use Main Menu gt Boost 4 you must first configure the amount and period of boost heat These two parameters are configured se
62. roportioned i e Off time to On time to obtain the required temperature An alternative method of supplying power The power is turned on at a calculated point within the mains waveform and turned off as the waveform crosses the zero volt point This is done continuously for every half waveform The technique is normally used for low voltage power control The normal control method where a controller receives temperature information from the zone and compares actual temperature with the required temperature or set point The controller adjusts the power level according to the difference between these two values An alternative method of control where power levels are set manually with no feedback of the zone temperature Also referred to as Thermal Gate Control The probe tip heater is synchronised with a signal from the moulding machine This activates the boost mode where the probe tip heaters are given an increase in power to melt the gate and allow injection A control card mounted device which controls the amount of energy supplied to the zone by regulating the phase angle of the AC voltage or burst firing the supply voltage This is similar to the above but a much higher rated device for the control of zones where the power requirement is high or two outputs per zone are required e g cycle synchronised or other dual voltage Mold Masters Page 73 MZ L Series Manual Index Alarms deferring 29 Alarms disabling 30
63. s on the keypad to scroll down or up to display them To access Main Menu To gain control access Press ENT to reveal the Main Menu Issue 1 3 Mold Masters The LCD Console MZ L Series Manual MZ Operation Block Diagram Se Run 0 o Y Y Y Y Zone m m 0 Y Y Y Y Utilities Set Set Inc Dec Stop 2 gt 6 gt Menu Zone Zones Zones Zones Standby 3 gt Graph Boost 4 lt 0 Y Y Y Y e w o fa y y y y Name Delete Save Load a Tool a Tool Settings Settings a gt un Y Y Y Y Y X Y 0 e 9 le 5 8 m Y Y Y Y Y Y Y Zone Sensor Power Boost Boost Set Show Type Type Limit Value Time Limits Settings Print 0 Y Y Y Reports a 8 fa Y Y Y 0 Y Current Current Database Test Status Tool Tool Results Engin gt gt Y Y Y eering D B 0 D D 0 0 Y Test View Test Test Alarm Standby Temp Startup Master Tool Results Values Defaults Delay Delay Scale Mode Zone Page 12 Mold Masters Issue 1 3 MZ L Series Manual The LCD Console Main Menu options
64. spect Any zones that fail to reach this maximum value may Page 50 Mold Masters Issue 1 3 MZ L Series Manual Maintaining your Controller have faulty heaters or errant wiring Press ENT if there is no reason to change the default Pressing ENT continues to step through the six settings Pressing CLR accepts the new values and returns you to the main Engineering Menu Resetting the Test Parameters In order to restore the test parameters back to their original factory setting select Utilities 6 gt Engineering 5 gt Test Defaults 4 The default test values are then automatically restored Issue 1 3 Mold Masters Page 51 Maintaining your Controller MZ L Series Manual Performing a system diagnosis The diagnostic routine may be performed at any time the controller is connected to the tool provided that it is not in use for production 1 From the Main Menu select Utilities 6 gt Engineering 5 gt Test Tool 1 The system then runs through a comprehensive test routine which is described earlier See What is tested during a self diagnosis check Skipping Zones during testing If your controller has more than a few zones and you wish just to test say two or three suspect zones there is no way of configuring the self diagnostic routine to look at specific zones and ignore the others However the ENT and CLR buttons can be used in different ways to skip past early and late zones Conside
65. ter Printing 1 Current Status 2 Current Tool 3 Database Tool 4 Test Results Select Deg C STOP MODE Engineering The Engineering section falls into two main areas as seen below Engineering 1 Test Tool 2 View Results 3 Test Values 4 Test Defaults 5 Alarm Delay 6 Standby Delay 7 Temp Scale 8 Startup Mode 9 Master Zone Select Deg C STOP MODE e the first four options allow you to set up and run diagnostic health check routines on your system e the last five options a few extra facilities that are needed during preliminary setting up for different tools Mold Masters Issue 1 3 MZ L Series Manual The Controller Cabinet The Controller Cabinet The power supply to the control cabinet is via a bulkhead mounted 3 pole plug wired in star or delta configuration Please check your specification for details of which configuration has been supplied Connections to the tool are by looms terminating in Contact H BE24 connectors Wiring details are shown in Appendix A An alarm input and output connector is available for extending the alarm or perhaps inhibiting the injection process A serial printer port is provided for producing hard copies of certain screens Again please check with the system specification for details Controller Cards The main controller cards are four zone modular cards that provide real time temperature control These are all standard 6
66. the LED window and the front panel of the controller From top to bottom they are SCAN The LED flashes during normal operation to indicate data bus activity TC LED is lit when the thermocouple is open circuit FUSE LED is lit when fuse fails GND LED is lit if any heater has 10mA or more leaking to chassis ground LOAD 1 4 LED indicates a supply to the particular zone Note there is One Load LED for each zone on the card To remove a card from its slot pull the black handles forward and gently pull the card out There is no need to switch off the main supply However if operational requirements allow the cabinet WARNING may be isolated The shrouded terminals on the euroback board are live unless the power supply is switched to OFF Specific Faults Rapid Temperature Fluctuations e 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 e Another cause of temperature fluctuations is by the control cards detecting varying mains supply frequency and consequently changing temperature scales The problem can be overcome by forcing the system to a particular temperature scale in the Engineering menu Not able to set a Higher Temperature This problem can occur if you try t
67. to confirm Standby Mode This mode is available for times when the mould tool is paused In this condition all the probe temperatures are reduced by 50 C This helps to prevent degradation on certain materials Meanwhile the manifold is maintained at its normal operating temperature to allow a fast restart 1 From the Main Menu select Standby 3 and press ENT to confirm Issue 1 3 Mold Masters Page 35 Running your controller MZ L Series Manual Boost Mode Boost Mode provides a means of temporarily boosting the Probe or Probe Tip temperature To determine how much rise and for how long it is applied refer to the Setting Boost Values on page 28 1 From the Main Menu select Boost 4 and press ENT to confirm To Raise and Lower Operating Temperatures If you need to increase or decrease the set temperature for one or more zones then two commands within the Set Zone s menu are available for you to use Inc Zones This allows you to select a group of zones and uniformly increase their set temperature by the same value 1 From the Main Menu select Set menu 5 gt Inc Zones 3 2 Atthe Start prompt enter the number of the first zone in your target group and press ENT 3 Use 4 gt to select P Probe or M Manifold and press ENT 4 Atthe End prompt enter the number of the last zone in your target group and press ENT 5 Atthis step you have the opportunity to switch from Auto to
68. uptured or if the fuse is good replace the thermocouple REV Thermocouple is reversed Check the polarity of T C Issue 1 3 Mold Masters Page 59 Troubleshooting MZ L Series Manual TRC Triac fault This can only occur when in manual mode and closed loop where the current is pre set manually If Check the current output on the channel If the triac has failed return to Mold Masters for repair for instance the triac output current is higher than the set point the controller attempts to reduce output to the level required If it fails the triac may have failed and it is flagged up as faulty Abnormal Condition Warning Message MAN The control zone is in manual mode S The zone is slaved to another control zone where represents the number of that zone i e S 2 means the zone is slaved to Zone 2 The same power is being sent to both zones In the Display page the set point displayed on the selected zone is the same as that on the slave zone TEST Displayed when the zone is in diagnostic test mode WARN If during the test procedure a temperature interaction is found between zones this message is displayed FAIL The zone under test has failed Page 60 Mold Masters Issue 1 3 MZ L Series Manual Troubleshooting Individual Card Diagnostics If a fault on a controller card is suspected check the LED card status lamps what can be viewed through
69. ur new settings What is included in this section Inspecting the tool store looking at what has been saved Naming a tool creating a new tool position Saving tool settings putting settings into a new tool position Recalling tool settings reusing past tool settings that have been saved Changing tool settings altering existing tool settings Deleting a tool how to clear tool position Issue 1 3 Mold Masters Page 41 Customising your controller MZ L Series Manual What is in the tool store You can see what tools are available and which are in use by selecting from the Main Menu Utilities 6 gt Tool Set 2 The display then shows you Tool Menu END BRACKET 1 Name a Tool 20MM CAP 2 Delete a Tool 3 Save Settings 4 Load Settings Select kOONAURSUNK ALL SET ZERO STOP MODE Tool number of the tool position One of the positions is marked with an asterisk which indicates which tool settings are currently loaded into the system Name The name that you have given to each tool position Set Any tool position that has settings saved in it shows a Y in this position Blank positions that have been named but contain no information have no indication in this column Page 42 Mold Masters Issue 1 3 MZ L Series Manual Customising your controller Naming a tool To give a name to a particular tool position Name Tool END BRACKET Tool No 3 20MM CA

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