User Manual
Contents
1. MICROPROCESSOR BASED TEMPERATURE CONTROLLER DUAL DIGITAL DISPLAY INDICATIING DUAL TYPE THERMOCOUPLE SENSOR LKMHEATLOCK HLDC 15 amp HLDC 10 USER MANUAL HOT RUNNER TEMPERATURE CONTROLLER LKMHEATLOCK CO LTD HEAD OFFICE ADDRESS ADRESS IN CHINA 2 F Cheung Kong Electronic Qiao Li Lnd Area Chang Ping Building 4 Hing Yip Steet DongGuan Guangdong China Kwun Tong HongKong TEL 852 2341 2321 TEL 86 0769 333 0020 FAX 852 2343 0990 FAX 86 0769 393 9020 E MAIL Ikmheatlock lkm com hk CAUTION A A Never insert or remove a controller from a mainframe with the AC power on Hazardous potentials exist on components inside the mainframe and controller Always disconnect AC power to the mainframe when servicing Because these temperature controls or associated equipment may not always fail safe an approved temperature and or pressure safety control should be used for safe operation GENERAL DESCRIPTION The Series zone temperature controller is a PID controlled instrument specifically designed for runnerless hot runner plastic injection molding applications The controller is self adjusting and capable of maintaining a very high degree of temperature accuracy over a wide rage of operating conditions Simplified controls and the use of status indicators allow the operator to make adjustments easily The status display also provides visual indication of normal or abnormal operating conditions existing in both the cont2. Pressing the DISPLAY key will toggle between them 1 Manual Control Output percent display followed by P modifiable by user 2 Measured Heater Current display followed by A AUTO MODE To select Auto Mode press the MODE key until the manual LED turns off This mode allows the operator to adjust the Setpoint temperature value by pressing the UP DOWN arrow keys There are three different parameters that can be viewed on the lower display while in Auto Mode Pressing the DISPLAY key will toggle between them 1 Setpoint value modifiable by user 2 Output Percent display followed by P 3 Measured Heater Current display followed by A FUNCTIONS The controller provides the following functions SENSOR SAMPLING A OPTIONAL thermocouple is sampled using a 16 bit dual slope integrating A D converter Input voltages corresponding to temperatures from 32 to 999 F O to 537 are processed with a resolution of 1 F C CLOSED LOOP CONTROL A PID control algorithm is used to adjust the amount of power delivered to the load The Proportional Band and Derivative parameters are individually and directly adjustable The Integral parameter tracks the Derivative parameter by a fixed ratio OPEN LOOP CONTROL In open loop MANUAL CONTROL operator is able to set the output percentage ADJCOMPSTEP HEATER BAKE OUT Graduated phase angle activation of the TRIAC is provided for drying
3. 13 RATE 7 DEVIATION ALARMS 33 F 20 C INTRODUCTION Thank you for choosing this Control Congratulation on your purchase Used properly this precision instrument will provide you with many years of trouble free and productive service The Series zone controllers offer many advanced features designed to increase productivity and ensure fast accurate and repeatable mold temperature control 1 vV Compatible with all G units and all existing Hot Runner Controls for easy retrofit replacement G Is Registered Trademark Of The DME CO Simultaneous display of both process setpoint temperature and process temperature percent power output or Heater current Autotuning independently adjusts zone control characteristics Built in diagnostics alert operator to fault conditions AdjCompStep circuitry provides for safe heater warm up through gradual phase angle fired voltage control Soft Start 1 1 V 1 1 PRODUCT DESCRIPTION The Zone is a microcontroller based Hot Runner family control module that provides temperature control and operator interface function It controls one temperature zone by sensing a J or K thermocouple see jumper table The Zone operator input is via a 4 button keypad The controller has two displays comprised of seven segment LED s The upper display is a three character display and the lower display is a four character display Additionally the unit has 3 discrete LED indicat
4. MODE Key again when in manual mode returns the control to automatic mode AdjCompStep BAKE OUT SOFT START Gradually applying power to the heaters extends the life of the heaters and the mold Phase angle firing is used to implement the AdjCompStep feature The AdjCompStep will last for 5 minutes or until the temperature reaches 221 AdjCompStep is a self terminating feature but the operator may also terminate it by pressing the MODE key AUTOTUNE The tune operation will follow AdjCompStep The tuner looks for stability in the process temperature before it proceeds If system stability cannot be achieved within a fixed time period then the tune process will terminate The operator has the ability to terminate Autotuner execution by pressing the MODE key while the Autotuner is active During autotuning the display alternately flashes A tu and the process value NORMAL CONTROL MODE AUTO The control algorithm used for Normal control MODE is PID The rate and proportional band parameters appear in the menu system The reset parameter is always set to a value equal to five times the rate The Controller has a fixed cycle time of 100 ms 10 2 BUMPLESS TRANSFER The Controller employs an intelligent bumpless transfer When the process is within five degrees of setpoint the controller periodically records the output percent necessary to maintain setpoint When an operator initiated transition to Manual Control occurs the recor
5. Segment LEDs 3 digit upper Red and 4 digit lower Red 14 2 mmy 0 4 9 15 mm 0 36 Blue LED Red LED Green LED ORG LED Triac 15 A at 120 240 Vac 4 Momentary Switches 16A Power Switch 115 to 240 V 50 60 Hz Nominal All specifications are subject to change without notice ERROR CODE DSIPLAY ERROR CODE Er 01 Er 02 Display Flash Display Flash Display Flash Er 03 Display Flash DESCRIPTION Loop Break Down Output Short Open Thermocouple Reverse Thermocouple Open Heater Manual End
6. ded output percentage is used 8 FUNCTIONS CONTINUED CURRENT MONITOR OUTPUT FAILURE DETECTION The Current Monitor processor continually monitors heater current readings to insure that they correlate with output activity If the output device signal HEAT is off and a current flow is detected then the processor will post a triac short error the Lower Display will toggle flash Er 02 error message the Alarm LED will light all other indicators are set off and all control processing will terminate If the output device is on but no current flow is detected then the processor will post a bad heater error the Lower Display will toggle flash Er 03 error message the Alarm LED will light all other indicators are set off and all control processing will terminate If either of these error conditions is detected the OPTIONAL Power Interrupt Relay provided by the hardware will open to interrupt power between the TRIAC and the heater There is no automatic recovery from either of these problems Once detected and posted power to the unit must be cycled for control processing to resume SENSOR ERROR DETECTION When a sensor error is detected the upper display will toggle between TC and the cause of the thermocouple error r tc if the thermocouple is reversed o tc if the thermocouple is open The alarm LED will light and the output will turn off NORMAL OPERATING MODE The following summarizes key functionality wi
7. for three seconds Exit the menu by holding down the DISPLAY key for three seconds 1 PID Parameter Menu 2 Par Parameter Menu gt To select next item in menu use the DISPLAY key The PID menu contains three items 1 Pb Proportional Band 2 rAte Tacking integral 3 A tun Autotune Operation On OFF gt To adjust parameters use the up or down keys gt To select next item in menu use the MODE key PROPORTIONAL BANDWIDTH This item is accessible within the Menu This PID control parameter is adjustable from 0 1 to 999 F 537 C RATE This item is accessible within the Menu This PID control parameter is adjustable from 0 0 to 999 AUTOTUNE On ENABLE Tunes every time power is applied OFF DISABLE Uses currently stored PID values The Par menu contains two items 1 LPb t Loop Break Time This item is accessible within the Menu This parameter is adjustable OFF or from 10 to 999 seconds 2 HT SU Heater Save Temperature This item is accessible within the Menu This parameter is adjustable OFF or from 1 to 999 F 537 C heater limited temperature 5 Modes of Operation Manual Mode To switch to Manual Mode from Auto Mode press the Mode key until the Manual LED illuminates This mode allows the operator to adjust the Manual Output Percentage 0 to 10096 by pressing the UP DOWN arrow keys There are two different parameters that can be viewed on the lower display while in MANUAL mode
8. heaters on startup LOOP BREAK PROTECTION Software will monitor the response of the system to changes in the output for the purpose of detecting a control loop break Display will read Er 01 TEMPERATURE INDICATION Actual process temperature is indicated on the Process Display upper display Units For C for this display are determined by a jumper see page 2 displayed on the lower display HEAT ON INDICATION A single Blue LED is lit whenever the output is on For additional output state information the operator will also be given the ability to directly monitor the heater output percentage form the front panel s lower display see page 4 CURRENT MONITORING The Controller is capable of monitoring and displaying the average current being delivered to the load The display is in 0 1 ampere increments 7 FUNCTIONS CONTINUED MANUAL CONTROL MODE AUTO MANUAL has easy accessibility from the front panel Pressing the MODE Key until the LED adjacent to MANUAL legend is illuminated will cause manual control to begin Manual Control is also activated at zero percent when input error conditions arise and under these circumstances is activated automatically regardless of the MODE key Enable state The initial control percent established when manual control is activated is dependent upon the cause of activation When entered normally because of operator actions a bumpless transfer is attempted Pressing the
9. ne A tu and Process Value The Autotune process can terminate itself for two reasons Self termination occurs because the process has either completed or an error has been detected When the process has completed the Autotune Active Indicator A tu is removed and the display reverts to a steady display of the process Value When the process self terminates due to an error condition the Autotune Active Indicator will toggle with a mnemonic indicating the specific error condition that has occurred The Autotune process can also be terminated by pressing the MODE key while the Autotune process is active The unit will go directly to Normal Control Mode the Autotune Active Indicator A tu is removed and the display reverts to a steady display of the Process Value 10 Specifications Operating Temperature Shipping Temperature Humidity sensor Type Jumper Selectable sensor Range Sampling Rate Noise Rejection Temperature Accuracy Repeatability Displays Upper Display Height Lower Display Height Output Status Indication Alarm Status Indication Manual Mode Indicator Soft Start Mode Indicator Control Output Device Type optional 30 A Operator Activation Interface Power Requirements 32 to 131 F O to 55 40 to 158 F 40 to 70 TO to 9596 Non Condensing J or K Thermocouple 32 to 999 F O to 537 C 10 Hz 100 ms Common Mode gt 100 series Mode gt 70 dB 0 3 of span 0 1 of span 7
10. ors to indicate system status The Controller consists of two electronics boards Microcontroller and Display a triac heat sink assembly and a front panel assembly It is physically and electrically compatible with the existing other brands mainframe system The Zone is intended for use in an industrial environment by both technical and nontechnical personnel With this in mind the Controller hardware and software are designed for straightforward use with a high level of fault tolerance 3 Panel Descriptions Hotrunner Controller PROC TEMP 120 240VAC 50 60 HZ 15AMP 3600W MAX CE O HLDC 15 Process Temperature Display 3 Digit Alarm Indicator Red LED Light Heat On Indicator Blue LED Light Manual Mode Green LED Light Soft Start Orange LED Flash Setpoint Percent Output or Heater Current Display 4 Digit Up Arrow Increases temperature setpoint in normal mode or increases values in menu mode Hold for fast step progression Auto Manual Mode Green LED On Indicates Manual Mode Display Setpoint Percent Output or Heater Current When held for 3 seconds it displays menu PID Down Arrow Decreases temperature setpoint in normal mode or decreases values in menu mode Hold for fast step progression Power Switch MUST BE OFF TO REMOVE OR INSTALL UNIT 4 ENTERING AND CHANGING PARAMETER VALUES The Parameter menu contains two items Enter the menu by holding down the DISPLAY key
11. roller and or load INSTALLATION Set jumper configuration to desired operation see jumper table To install the controller in a mainframe release the locking device on the lower edge of the unit by pulling the plunger gently away from the panel Align the upper and lower edges of the controller printed circuit board with the respective card guides on the mainframe and slide the unit all the way into the mainframe until the rear connector is completely engaged Lock the controller into the frame by depressing the plunger on the locking device Safety Warning In addition to presenting a potential fire hazard high voltage and high temperature can damage equipment and cause severe injury or death When installing or using this instrument follow all instructions carefully and use approved safety controls high limit etc Only suitably trained personnel should perform electrical wiring of connections Do not locate this instrument electrical where it may be subjected to excessive shock vibration dirt moisture oil or other liquids Safe operating temperature rang is 32 to 1317F 0 to 55 C 1 JUMPER SELECTIONS MAIN BOARD DISPLAY BOARD a WHEN INSTALLED CLOSE OPEN JP1 SOFT START ALWAYS AUTO SOFT START JP2 K THERMOCOUPLE J THERMOCOUPLE JP3 DEGREES CELSIUS DEGREES FAHRENHEIT JP4 NOT USED NOT USED JPS NOT USED NOT USED STANDARD FACTORY DEFAULTS SETPOINT 392 F 200 C AUTOTUNE DIS PROPORTIONAL BAND
12. thin Normal Operating MODE Pressed briefly this key indexes to the next available amp lower display item Pressed for an extended time three seconds menu system entry will occur UPARROW This key will increment the current value of the item presented is one that can be incremented A setpoint value is an example of a lower display item which can be incremented The measured Heater Current value is an example of a lower display item which cannot be incremented 9 FUNCTIONS CONTINUED DOWN ARROW This key will decrement the current value of the item presented on the lower display when the item presented is one that can be decremented E This key will terminate AUTOTUNE or Soft Start or will change the AUTO MANUAL mode selection NORMAL OPERATING MODE DISPLAY FUNCTIONS In the absence of any special circumstances or error conditions the upper display 3 character display of the Controller is dedicated to the presentation of the Process Value when the unit is in Normal Operating MODE The Process Value is displayed in accordance with the temperature scale established by the Units jumper In the absence of any error conditions the lower display 4 character display of the Controller is used to present a variety of items The operator can index through the available items with brief presses of the DISPLAY key AUTOTUNE ACTIVE INDICATOR Whenever the Autotune Process is active the upper display will toggle between Autotu
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