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K Series User Manual with KTS Console

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1. i that may defer an Boost Time pne Et Button One condition Display Mode l tSi l F Time Secs Edit nput Signa Action Issue 9 6 User Manual for MTS Console 44 Setup page Console Parameters To select or modify Global parameters To select or modify Global parameters This contains a number of options for the system that you need to configure for the console to run correctly The Configure Controller box has a panel on the left which lists the various global parameters On the right is a second panel that has a brief description of the selected parameters In between these is a scroll bar that you can use to scroll up or down to the required parameter As you select any parameter then the buttons below the descriptive panel change to accommodate that parameter as follows 1 For parameters that need a quantitative input such as Timers then it offers an edit button alongside the current setting Touching Edit brings up a simple keypad where you make numeric entries 2 For parameters with a two way choice eg high low or enable disable then it offers two labelled button so tat you may select either choice 3 For parameters where there are three or more options eg language then it offers the multiple choice in the left hand System Options window Make you selection and then touch OK to return to the main selection of parameters 4 Finally touch OK at
2. 1 Select appropriate zones by simply touching them your choice is confirmed by the appearance of a blue border To select groups of zones you may either e repeatedly touch every zone in question until you have sufficient zones selected with their blue borders active or e touch the first and last zones within a range and then select Range from the side bar this increases your selection to include all the zones between the specified pair Unselecting is as simple as touching Cancel on the side bar or if there are only a couple of zones touching them a second time to de select them 2 Touch the Set command button on the upper right of the screen and enter your System password to display the temperature setting keypad 3 Check that this is a set point as opposed to a temperature raise or lower by selecting Set in the top Value box Ams Issue 9 6 Setting up the Operating Parameters 69 Setting Probe and Manifold temperatures Setting Probe and Manifold temperatures 1 Chose the operating mode for your zone or group of zones Auto or closed loop is the normally preferred mode However if you select Manual open loop or Slave notice how the prompt changes in the top window to accommodate your preferred mode Unless you need to be in either of these other modes touch Auto to return to the Set Temperature prompt 2 Enter the desired temperature or power setting o
3. 9 5 June 2007 Individual Setup information added to Setup and Config pages DH DH 9 6 Sept 2007 Configure IO board has new interface on Utils page DH IE Issue 9 6 User Manual for MTS Console 9 Contents Contents User Manual for MTS Console ccccccccceeescseeeeeeeeeaseeeeeeetesaaeeeeenenaaes 5 INEFOCDUCUION lt 4 duscaesiccdcsereaseedccecmessieceetarediestuannoedienctesgaameseseorreeee te 10 Setting up your Controller nesse e cor a e o e e aoi es 30 Setup page Console Parameters cccecccccceeeeeseseeeeeeenessaeeeeeneaes 43 Setting the Tool Parameters sssssssssnrrerrrrrrrrrnrrrrnrnrrnrrrenrreerrren 56 Setting up the Operating Parameters cccceeeeeeeeeee eee eeeeeeeeeee ee ees 68 RUNNING your controle isrtri oaren a AEEA aa RARAS 70 C stomising yo r controller scssi irere eisan e e ae ea ie 87 Maintaining your controller sssssssssssssrrrrssssrrrrerssnnnrersesnrrrerernrrnne 94 TROUDIESNOOUING as sree eie a A a edie 110 APPENDIX A ia a eE E T A A aa wae A anes bates 117 APPENDIX B oraina inae A A A ON A AEE NAE ANS 119 Glossary a aaa A Ae ee EE me eee reer er ar er repr ere ee 120 TNGEX E E E ties eit pie babed ehh Greet eabbeeedaicees due hicee his 121 Issue 9 6 User Manual for MTS Console 10 Introduction Specification Introduction Specification The following are general specifications The actual controller c
4. If the system detects any malfunctions in one or more of the control zones then it displays an error message on the main page in place of a temperature value If the system detects any abnormal condition it displays a warning message in the Main menu Fault and warning messages Any of the following messages may be displayed on the Fault Indication line Error Cause Action Message AMPS The controller is unable to supply the current requested Note This error message is most likely to be seen if the particular zone is set as a Spear type Isolate system supply check loom and heater wiring continuity Also check the heater resistance against other known good zones to see that it is not noticeably higher than average ERR Little or no temperature rise has been detected in that zone When the console starts to apply power it expects to see an equivalent heat rise at the thermocouple If the Thermocouple has been trapped and pinched elsewhere in the tool or cable then it cannot see the full heat rise that occurs at the tip If left uncorrected then there is a danger that the zone could overheat and damage the tip Instead the circuit maintains the output at whatever level it reached when the monitor circuit detected the fault and the error message was displayed Check thermocouple wiring it may be reversed Heater wiring may be faulty or element may be open circuit FUSE The fuse for that zo
5. Subnet mask Default gateway Use the following DNS server addresses Prefered DNS server 192 168 1 Altemate DNS server Issue 9 6 User Manual for MTS Console 108 Maintaining your controller Upgrading your controller Connect your PC to the MTS Console using the crossed Ethernet cable 8 Open the folder containing the ae i new Upgrade files Bupoadusng aee i Scan with AVG Free Right click on the files and select Pen f Send to gt upload with rcF TP pte ETC 9 etot device Cut Compressed zipped Folder Copy Desktop create shortcut Create Shortcut 2 Mail Recipient Delete My Documents Rename Lansicbnet By Winace Archiver J 3 Floppy A S gt Removable Disk F gt Removable Disk G 9 This opens rcFTP which needs EAE AE E e L configuration a O N e e G anaoa Click on new to open the Fiesty Profile Editor Peep ue Soria 10 In the Profile Editor FTP address Profile editor FTP address box type in the IP address of the 821581224 Loginname Password MTS Console noted at step 3 anonymous emen Click on anonymous to pensons complete Login name and Cet Password a In the lower Destination folder click on add Ce 11 In the Add folder box type in Add folder tmp If there is a dot before Add a destination folder the first open slash then delete it Click OK 12 Back in the Profile editor click on EMi
6. 1 Open the Setup page touch Config and if required enter your system password 2 Inthe Configure Controller box select Autostandby Timer and touch Edit 3 In the Keypad enter the required Standby time and touch Enter In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and return to the original setting Limits The maximum period for Auto Standby is 25 minutes Description This option is dependant on selecting Auto Standby as an Input Signal option Autostandby works together with the remote Input Signal so that if a cycling input is not detected within a pre configured period then the console assumes a Standby mode All zones that have any standby setting will respond to the condition by reducing their temperature to prevent unnecessary material degradation If the controller is running spear tip probes then Autostandby also switches the tips to Off Issue 9 6 User Manual for MTS Console 46 Setup page Console Parameters To select or modify Global parameters Boost Time seconds Setting 1 Open the Setup page touch Config and if required enter your system password 2 Inthe Configure Controller box select Boost Time and touch Edit 3 Inthe Keypad enter the required Boost time and touch Enter In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and return to the original setting Limi
7. Red 3 etc T C Open Mode Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the T C Open Mode column 2 Touch Set and if required enter your system Password 3 Inthe Select Zone or Option panel choose a recovery option or nominate a specific zone or select Cancel to leave it unchanged Description This column allows you to preselect the console response should it detect a failed thermocouple while the system is running To select the preferred response touch one or more zones then touch anywhere in the Auto T C column to bring up a Select Item list which has the following options nms Issue 9 6 Setting the Tool Parameters 57 Pre configured Set Up values Normal default setting If the zone s T C fails then the console does not instigate any action the zone power sets down to 0 and it shows a T C fatal alarm Auto Manual The console collects data over a period of time and after 10 minutes of steady running it has sufficient information about the power levels required to maintain the current set temperatures If the T C fails with this option selected then the console will run the particular zone in open circuit mode and use the average power levels that have been derived from historical performance Auto Slave In a similar way to auto manual the console has sufficient data and is able to match zone performance such that if a I C fai
8. 3 With this new tool tab active touch Save 4 Put the storage media into the USB socket and touch Backup 5 Wait until all the data has been saved to disk Export Utility Data 6 Keep the Memory Stick in the USB socket and select the Utility page 7 Touch the Export button and select the maximum and minimum temperatures for all zones and then touch Export to save the data to the USB Flash Memory Send us the resultant files 8 Take the Memory Stick to your computer and prepare an e mail with a brief description of your problem 9 Attach the Tool Settings and Export Data files to the e mail and send it to pms pmssystems com On receipt of your mail and attachment we can load your file into one of our own controllers and should be able to track down the problem Issue 9 6 User Manual for MTS Console 116 Troubleshooting CX Series Fuses CX Series Fuses There are supply fuses for three separate functions In the unlikely event of a fuse failure always isolate the incoming main supply before opening the rear cabinet door or removing any panels Replacement Fuses 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 correct fuse types are listed in the following tables Warning Power Supply Units PSUs The PSU is integrated into the main printed circuit board It has its own fuse which is located in a separa
9. PMS Sys tems User Manual for MTS Console with HRC X Controller PMS Systems Ltd Netherwood Road Rotherwas Hereford UK HR2 6JU Tel 44 0 1432 265768 e mail pms pmssystems com Fax 44 0 1432 263782 KEEP THIS SHEET SOMEWHERE SAFE Some areas of the controller software are password protected Every machine leaves our factory with two levels of password protection We recommend that you change these as soon as possible to establish your own security System Password LINUX User Password UNIX User Manual for MTS Console 5 Publications User Manual for MTS Console Copyright c PMS Systems Ltd 2001 This manual is intended for use with the MTS Console and HRC X Controller Serial No with which it was supplied Where fitted this controller is supplied with Alarm Key Switch Number This manual is written and prepared for Software Version 5 September 2007 Our policy is one of continuous improvement and we reserve the right to alter product specifications at any time without giving notice Issue 9 6 User Manual for MTS Console 6 User Manual for MTS Console Publications Issue 9 6 User Manual for MTS Console 7 Publications Publications Issue Date Changes Author Authorised 1 0 15 7 97 First formal Issue BNM AR 2 0
10. Touch Enter to confirm your request or Esc to defer the action Select Manual Working 5 Touch Manual 6 Set the required power Setting 7 Touch Enter to confirm your request or Esc to defer the action Select Slave Working 5 Touch Slave 6 Select the zone that you wish to Slave to 7 Touch Enter to confirm your request or Esc to defer the action Ams Issue 9 6 Running your controller 81 Checking Zone Settings Checking Zone Settings There is a Zoom facility that allows you inspect individual zones to see their individual configurations More importantly it is the only place where you can see what response speeds the controller has automatically selected for each zone Referring to How the Controller Works on page 19 that section describes how the control card initially ramps up the temperature to decide whether to use a fast medium or slow response curve for each zone Once the initial run has been done then the Zoom page shows the resultant speed selection Very occasionally on intermediate sized nozzles or manifolds the selection may not be the best match for optimum performance In which case you can check which Auto speed is associated the zones and on the Setup page chose to manually override the computer s choice and select a preferred response speed Touching any one zone on the main page causes the second button down to change from Mode to Zoom Touch Zoom and it reveal
11. material to flow manual request M C BOOST The zones are being temporarily raised to allow material to flow machine request The right hand Status window shows NORMAL if all the zones are at their set temperature and no faults have been detected If a fault is detected then it will change its display and colour as detailed below NORMAL Controller is running normally WARNING A zone s Temperature exceeds the warning limits ALARM This shows either a Fatal Error or a zone s temperature exceeds alarm limits Most zones will have preset first and second stage temperature alarm limits If any zone s temperature deviates past the first stage limit then a WARNING will be generated If any zone s temperature deviates further past the second stage limit then an ALARM will be generated There are also various conditions that are under constant supervision and if any of these arise then an ALARM which is known as a Fatal Error is shown in the same way Issue 9 6 User Manual for MTS Console 84 Running your controller Alarms Identifying Zone alarms To identify which zone is raising a Status alarm you need to switch to the main page to check zone information The EasyView page will also show zone and Alarm information however if the fault is not on a probe zone the EasyView page may not show the guilty sector Normal Zone This shows a healthy zone a state that is ident
12. other zones can be switched off to cool down This function allows you to configure this shutdown temperature to speed up or slow down the shutdown process Raising the shutdown Temperature means that zones do not have to cool down so much until subsequent stages are switched off which shortens the overall shutdown time Lowering the Shutdown Temperature has the opposite effect and lengthens the shutdown time Temperature Scale Setting 1 Open the Setup page touch Cancel then Config and if required enter your system password In the Configure Controller box select Temp Scale Select Deg C or Deg F as required In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and return to the original setting Description The temperature window allows you to select your preferred display temperature The system has an automatic selector which changes the display according to the mains supply frequency Where a 60 Hz supply is detected then the system displays temperatures in Fahrenheit and where a 50 Hz supply is detected the system displays in centigrade If this automatic display does not suit your own requirements then this Temperature Scale window may be used override the automatic display Finished Configuration Once you have completed all the necessary configuration boxes and want to save them as they have been set touch the OK button If you do not wish to acce
13. to reject it and return to the Setup page 5 Repeat the above steps to configure all the zones into their respective Shutdown Groups Limits There is a limit of 8 Shutdown Stages Description This column allows you to nominate the zone groups for staged shutdown Zones in Group 1 will be switched Off first followed by subsequent zones that you nominate for groups 2 3 4 etc the interval between shutdown stages is determined by the Shutdown Timer and the Shutdown Temperature in the Config panel Their interaction is shown in the following table nms Issue 9 6 Setting the Tool Parameters 67 Analog Sensor Type Shutdown Timer 0 mins Shutdown Temp with Set Temp at 260 200 Pre configured Set Up values Shutdown Pattern Each stage must cool down to 200 before it switches off and next stage starts cooling 5 mins 0 Each stage must cool down for 5 minutes before it switches off and next stage starts cooling 5 mins 200 Each stage will cool down for 5 minutes or until it cools down to 200 whichever occurs first and then it switches off and the next stage starts cooling 0 mins 260 The cooling sequence will cascade through the stages with no noticeable delay between them This combination should be avoided This option is only available if you have any Analog Flow Sensors fitted Setting 1 Open the Setup page select those zones that you
14. 59 Pre configured Set Up values Description Setting a Master zone for any group of s one Or Option zones is an option that must be left until Options all the zones have been initially configured Once you have allocated the Probes and Manifolds then you can select groups of dependent zones and use this option to set their master zone No master for this zone Manif 1 Manif 2 Usually you select a group of Probes in der to designate a common Manifold as or a Master Zone However on larger tools you may also select a group of smaller or sub manifold zones to designate a larger main distribution Manifold as their Master zone Both of these options are equally catered for using this option Warning and Alarm Levels Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in one of the four Alarm or Warning columns Touch Set and if required enter your system Password In the Keypad that appears touch type the required value for the particular value Note that Warning levels should be less than Alarm Levels 4 When finished each value touch Enter to accept the new entry or Esc to reject it and return to the Setup page 5 Repeat the above steps for the remaining High and Low settings Limits The maximum Warning or Alarm value that you can set for any of this group is 99 C or 178 F Descriptio
15. 7 11 97 Revised to incorporate software developments BNM AR 2 1 15 3 99 Revised to incorporate software developments DH AR 3 0 11 6 99 Manual Revision Includes recent minor software DH AR changes 3 1 12 8 99 Switching On Off and disconnecting console details DH AR added 3 2 19 8 99 Error messages updated DH AR 3 3 20 9 99 Changes to Chilled Water control and SPI devices DH AR added 3 4 05 01 00 Special Limits RTD amp Water are made pro active DH AR 3 5 06 09 00 Changes to troubleshooting section because surface DH AR mount control cards now have T C input fuses 3 6 21 09 00 Introduction of QwikFix Appendix DH AR 4 0 23 01 01 Introduction of EasyView Page to Touchscreen Console DH AR and separation of TS and TSi manuals 4 1 13 02 01 Graph page selection increased from six to twenty DH AR zones 4 2 21 01 02 Configure Controller Options changed for Boost DH AR Command and Display Option 4 3 11 02 02 Cable mis wiring disclaimer added DH AR 4 4 15 02 02 Extra instructions for using Setup page to make group DH AWR settings 5 0 March C and K manuals merged DH AWR 2002 Run controls moved to main page main page has 40 160 zone display options EasyView mini panel display controls changed Boost amp Standby controls moved from Global to autonomous zones New Master Only Startup mode introduced New remote option for Boost or Standby Utilities Mode sub page removed New Other Help in Troubleshooting Network facility
16. 98 Checking zone past performance graph 82 Checking Zone Settings 81 Coloured Headers 24 Configuring a printer 35 Configuring the test parameters 101 Console Startup 39 Controlled access though passwords 32 Controller Cards 17 Controller Power Supplies 13 Cool Time 101 Creating a new tool slot 42 Customising your controller 87 CX Series Fuses 116 Cycle Synch Input 29 Deleting a tool 91 Diagnose page 25 Display Group allocation 64 Display Mode 46 Drive bay access 16 Export Facility 96 Failure through mis wiring 13 Fault and warning messages 110 Good and Bad Rise 101 Graph page 24 Heat Time 101 Help Pages 26 How Boost is displayed in the Status Window 77 How the Controller Works 19 HRC Wiring Standards 117 Identifying Zone alarms 84 Individual Card Diagnostics 113 Input Signal 47 Interpreting the test results 103 Isolating the Controller 14 Keyboard 27 Keypad 27 Language 31 Limit Exceeded 37 Loading tool settings 90 Main Page Options 22 Maintaining your controller 94 Manual Boost 76 Master Only Startup Mode 74 Master Zone 58 Maximum Power Setting 61 Maximum Setpoint Setting 60 Minimum Setpoint Setting 60 Mode and Status Windows 20 Mode Input 28 Naming a new tool 89 Networking to your Controller 93 Normal Startup Mode 74 Numeric Input 27 Other problems with the Tool 115 Password active times 33 Password Override 34 P
17. User aborted test and the controller returns to Stop mode Ams Issue 9 6 Maintaining your controller 103 System diagnosis results System diagnosis results The Diagnostics page displays information about the testing progress by showing which zone is currently under test and whether it is in cooling or heating phase If any error is detected then a suitable error message is shown in the lower area The results are remembered and displayed in the lower box until a new test is initiated This means that when you open the Testing page you can see there are test results already on display these results have been stored from the last test that was run Test Results hard copies Some systems of diagnostic maintenance may require hard copies to be filed away If you need hard copies of test results then first ensure that a printer is connected and then touch the Print button at the bottom of the tool bar This prints out the contents of the lower information box directly to the printer Interpreting the test results Satisfactory Test If the diagnostic test finds no fault with any zone then the message Zone Test OK is displayed Unsatisfactory Test If the test detects any problems then it displays an error messages that is self explanatory Bellow is a complete list of the various messages along with further detail and possible causes User skipped Test You skipped the test for this zone by pressing Skip
18. access the many functions While most buttons do change between pages some are common such as Print and Help At the bottom of the every page there is a status line which indicates the current Working Mode and the Alarm Status of the controller Between the two is a Message bar which will be used to display other relative information such as e Display Group information e Password Prompts e Toolbank information Most of the functions can be operated by using your finger tip to touch particular areas of the screen However some functions for instance the key board and key pads and on line help have areas which may be difficult to select unless you use a suitable touch screen stylus Mode and Status Windows mae an yo The Mode window flashes whenever the system is in an abnormal state such as Stop Standby Startup Shutdown Boost or Testing Only Run Mode shows as continuous The Status window shows whether the system is a Normal healthy condition If not it shows a Warning or Alarm Status Ams Issue 9 6 Introduction 21 Screen Layout and Navigation The Main Page The main page shows a presentation of 20 Te zones at a time If you have more than 20 zones then you can use the PgUp and PgDn to scroll the display to other zones or the Display button to see more zones on the screen but with reduced information robe Prob A R a F 3 tA 2 NI a y5 Ae s Ee gt Al
19. added to K Series Appendix New information added regarding the KM series case for Water Manifolds DH DH ARW PK 8 4 May 2005 Extra information about Allow ToolLoad option greying out Load button on ToolStore Page DH AWR 8 5 July 2005 Printer Utility allows connection to networked printers Extra instructions for upgrading via network connection DH SK 8 6 Aug 2005 Autostandby function replaces Spear Standby Function in Setup page configuration DH IE 8 7 Aug 2005 Shutdown Stages are introduced so that Staged Shutdown may switch off in a different order to Staged Startup DH IE 8 8 Sep 2005 More information about updating an MTS console without USB along with instructions for using a simple FTP program DH SK 8 9 Oct 2005 ToolStore increased to 5 banks of 20 slots 100 tools with extra selection controls DH IE 9 0 Oct 2005 Demo facility added for training or demonstration use DH SK 9 1 Sep 2006 Facility to Save All Tools added to ToolStore DH IE 9 2 Dec 2006 C Series option removed from Manual DH DH 9 3 Mar 2007 Auto Detect removed from Utilities page to Tool Page New Tool DH IE 9 4 Apr 2007 Pages changed to align with KTS manual where there are similar functions Appendix A Wiring standard includes Dual Supply option DH IE
20. and so is different to that held in the store The Utilities page The Utilities page contains Access to inspect and configure all the System Parameters such as Language and Passwords An Export facility that can export recent zone temperature data as a CSV Comma Separated Value file which can be displayed in a spreadsheet An Exit button that is the correct means of shutting down the console prior to switching off the main Isolator The Diagnose page This utility allows you to carry out a series of defined tests to check zone performance interaction heater wiring and thermocouple integrity This is a perfect tool for checking the condition of any mould tool after initial commissioning or any major maintenance System Setting Machine Name newraid Domain Name pmssystems com IP Address 217 10 148 148 Net Mask 255 255 255 224 Obtain Address Disable User Password 288008006 System Password HOO OOOE Password Timer 5 Minutes Hode RUN A Hessage TOUCH CONTROL Zone Probe 5 Start Current 250 C Test Stage Cooling 0 Zone Results Probe 5 Error Msg 0 Ri 2 Hode RUN A Hessage Status TOUCH CONTROL Issue 9 6 User Manual for MTS Console 26 Introduction Other pages accessible from the Navigation Screen The Set up page The Set up page is concerned mainly with setting up your system It displays all t
21. 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 In order to capture fleeting alarm conditions the relay is held on for about 15 seconds after the alarm condition is cleared The contacts are rated for 5A at 240V An optional input can be accepted through the same connector It may be used for Cycle Synch spear tips Inhibit Mode remote Boost or Standby or any other user definable function For exact details consult the specification for the particular model Pin Connection Input output 1 Auxiliary Input signal Dependent on Spec 2 Auxiliary Input Ground 3 Alarm 240v contact 1 Normally Open Contacts 4 Alarm 240v contact 2 1 5 Serial Port A male 9 way D panel connector can be provided for an RS 232 serial A port which is used to communicate with a remote computer for data collection The pin outs are as follows 2 Transmit 3 Receive 4 5 Ground 1 6 USB Port 6 A USB port is standard on all Touch Screen Consoles for connection 7 Handshake to a printer 8 9 nms Issue 9 6 APPENDIX B 119 APPENDIX B System Schematic HRC mTS Touch Screen Console COM2 LI Touch Controller Opto System Integrated COMI fe Industrial Isolator PC Motherboar Power ey USB s Q Q A Console E YA
22. command for Spear Tip nozzles When an external signal is used to trigger a Spear Tip nozzle then the Mode indicator on the status bar switches from RUN to BOOST and the Power indicator in each zone switches from Body power or current to Tip power What is seen on the touch screen depends on various factors as explained below Issue 9 6 User Manual for MTS Console 78 Running your controller Remote Boost The Mode Window Indicator The Mode indicator switches to BOOST and should only be used to confirm that an external Boost signal has been received It remains at BOOST for a period that is equal to that of the incoming remote signal PLUS one second it is no indication of the actual Tip boost period Individual Zone Power Indicators The power indicator on individual zones changes from Body to Tip display You may or may not see the Tip Pre Heat power level for a brief period This depends on the length of the Boost delay and the number of cards in the system If the controller has many cards the total scan time may exceed the Boost Delay period in which case the Pre heat power will not be seen so the Power Indicator shows the Boost Power only If the Boost Delay is set to 2 seconds or more the console has enough time to scan all the cards and you will initially see the Pre Heat power and then the Boost Power levels Once the Boost Period has expired then the zone power indicator returns to show main body power rega
23. control This is a method of control where power levels are set manually with no feedback of the zone temperature Another 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 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 that 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 Issue 9 6 Index 121 Index Alarm Time 45 Alarms 83 Alias 56 Allow ToolLoad 38 Analog Sensor Type 67 Autostandby Timer 45 Backing up tool settings 91 Baud Rate 39 Beacon and Sounder extension 84 Blanking Delay 37 Boost temperature 58 Boost Mode all configured zones 76 Boost Time 46 Boosting selected zones 76 Button One Mode 46 Changing Modes 80 Changing Temperatures 79 Checking Touch Screen Alignment
24. 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 both the on board and off board triacs using a number of self tuning algorithms e continuous monitoring of a reference voltage signal on the bus and adjusts the on board or off board triac output to compensate for fluctuations in the supply voltage the system can accommodate up to 30 swings in the supply Burst firing is normally used in systems operating at mains voltage and phase angle firing in low voltage systems The card requires no analogue calibration and is ready for use once set up from the display console Issue 9 6 User Manual for MTS Console 18 Introduction X Series Controller Cabinets Output Triacs The HRC X is built as either a 6 or 12 zone controller All the output triacs are mounted directly to a single main heatsink which ensures that each zone is capable of controlling a full 15 Amps Power Supply Units PSUs The main low voltage power supply unit in the HRX is located on the main output board It has two accessible input fuses to protect the supply In the event of a ruptured supply fuse then the controller should be turned OFF and isolated from the mains supply before they are replaced Replacement fuses should be of the same
25. for that I O _ Output 2 Temp Dist channel Note that once any option output 3 Boost has been selected it is not available Rae Hode EGS Display Group 1 Status for any other channel Inputs There are eight input options from which you may select any four These are Input Option Effect 1 Inactive This allows you to set the input as inactive and is available for any spare or unwanted channels 2 7 Run Standby Startup Stop The input sets the operating mode into any one of Boost or Shutdown the six running modes 8 Passkey This is reserved for future use with a physical pass swipe card or key Outputs There are eight output options from which you may select any four These are Output Option Effect Inactive This allows you to set the relay as inactive and is available for any spare or unwanted channels Inj ection Disable Enable The relay closes when all the zones are up to working temperature and the Status window shows Normal green on black Temp Dist Temperature The relay closes if any zone raises a Fatal Alarm Disturbance such as T C error or FUSE failed Boost The relay closes if the console goes into Boost Mode which may be initiated Manually or Automatically Hot Runner The relay closes if any Probe or Manifold zone sees a 2nd stage Alarm or a Fatal Error Cavity Alarm The relay closes if any Cavity RTD zone sees a 2nd stage Alarm or a Fatal Error Water Flow The relay clo
26. om Console Mains Keyb ard Mouse Data Cable USB Network Printer Cable Control Cabinet Opto Isolator Voltage Free alarm Contacts Heater Thermocouple Supply Outputs Inputs from to Tool Tool Issue 9 6 User Manual for MTS Console 120 Glossary Glossary Cabinet Loom LED Manifold Probe Prompt Tool Zone Burst fired Phase Angle fired Open Loop Closed Loop Cycle Synchronised On board triac Off board triac Unit containing control electronics Cables connecting control cabinet and tool Light Emitting Diode Warning Lights Background or runner heater Gate control heater Screen text asking the user for an 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 proportioned i e Off time to On time to obtain the required temperature Another 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
27. power limits Once this section has been completed then all the relevant settings may be saved to a slot in the Toolstore for easy recall Operating parameters Once a tool has been configured then you can enter the nominal operating parameters This includes such values as zone temperatures coolant temperatures and flow levels Issue 9 6 Setting up your controller 31 Setting up System Utilities Setting up System Utilities The Utilities screen gives you access to several user configurable parameters The only exception however is the first piece of information which shows the current Software version This is always shown as the version date and it is automatically reconfigured if ever the software is upgraded It is vital that you make a note of the Software version date should you ever need to contact your supplier with a technical query This helps to identify which version of the software you are currently using Generally the method for setting any parameter on this page is as follows e Open the page e Scroll up or down to find the required parameter e Touch the parameter setting on the right hand side e Touch Set at the top of the sidebar buttons If required enter your password into the keyboard If this is the first time you have set a parameter on this page then the system will ask you for your password to verify your authority If you alter subsequent parameters during this visit it will not ask for passwo
28. save x Give a name for the profile In the Save profile box give this configuration a name type MTS Console and click OK WS Conse Ams Issue 9 6 Maintaining your controller 109 13 14 15 16 On completion the MTS Console will 17 18 Upgrading your controller Finally check that the following Advanced settings are selected Auto select amp Close rcFTP after upload is complete Click on upload now to transfer the files to the MTS Console When the rcF TP window disappears then you have finished transferring the upgrade files On the MTS Console go to the Utilities page and touch Exit The MTS console will find the do_this_code program and the associated upgrade files The Micro Touch Screen console confirms this action by displaying the Installing Upgrade imi wmi Installing screen miiie upgrade then reboot with the new changes installed Check that the upgrade has been installed by going to the Utilities page and seeing that the Software date has changed to a newer date that that noted at stage 2 Disconnect the crossed Ethernet cable from both the Console and the PC and shut down the PC Issue 9 6 User Manual for MTS Console 110 Troubleshooting Fault and warning messages Troubleshooting The control system has several features which provide an early diagnosis of faults in the control system the tool heaters and thermocouple sensors
29. stage any typical temperature control card may be used for either a Probe zone or a Manifold Rack Address Alias Your must now allocate roles to the cards and to do this it helps to start with one type of zones such as the probes 1 Inthe Type column select the first and last cards within that group and then touch Range to include all those in between 2 With all the desired zones highlighted touch Set to bring up the Configure Box and touch Probe to configure those selected zones 3 You can also select the preferred header colour by touching any of the 16 preset colours available in the Panel Colour Picker if none is chosen then it defaults to the Type colour 4 This last step returns you to the main SetUp page where you will see that most of the Tool parameter boxes have been given pre configured values Some of those values may be correct for your immediate needs others may need to be tailored to your particular circumstances to match your tool mould Rack Address Alias Mode Run A Message Status E Complete setting up the zone types for all other zones before you set up the various parameters Issue 9 6 User Manual for MTS Console 54__ Setup page Console Parameters Pre configured Set Up values Pre configured Set Up values The diagram below shows the whole SetU
30. starts up in a preset homogenous or staged pattern Standby the system starts up such that any zones that have Standby temperatures configured will rise to those standby temperatures Zones that have no standby configured will rise to their normal operating temperature Run all zones will rise up to their normally designated operating temperature Machine Name Domain Name IP Address Net Mask and Obtain Address For any of these Networking parameters Setting 1 Touch Menu and open the Utils page 2 Scroll down to view Console Startup 3 Select the parameter by touching in the adjacent right hand box of one of the above parameters 4 Touch Set 5 If required type in your System password at the next prompt 6 Set the particular parameters either by Key pad or option select as required 7 Inthe parameter box touch OK to accept the new setting or Cancel to reject it and return to the original setting 8 Touch Back to return to the main page Description For details about configuring the networking parameters see the section Networking to your Controller on page 93 Issue 9 6 Setting up your controller 41 Setting up System Utilities Calibrate Touch Allows you to re calibrate how the screen response physically aligns with where you touch it For details about how to calibrate the touch screen refer to Checking Touch Screen Alignment on page 98 in the Maintenance section SPI Interface Set
31. that you cannot traverse any further in that particular direction Ams Issue 9 6 Running your controller 83 Alarms Alarms Whichever page may be active there is acommon Mode and Status window at the bottom of the page Mode I waiting Messages appear here Status Tag If your controller is switched on and running normally then the left hand Mode window will show RUN written as black text on white background and the opposite Status window will show NORMAL written in green text on black background If the controller is manually switched out of RUN mode then the Mode window will change Any of the following may be displayed according to what function has been selected and all apart from RUN will be seen flashing on and off to draw your attention to a possible abnormal condition The table below lists the different displays and their meaning RUN All control zones are working normally STOP The System has been shut down and the heaters are at room temperature STANDBY All zones with any Standby setting are reduced by that setting STARTUP The system has been started in a homogenous or staged heat rise It will switch to RUN when working temperature has been reached SHUTDOWN The system has been shut down in a homogenous or staged heat fall It will switch to STOP when room temperature has been reached BOOST All zones with any Boost setting are being temporarily raised to allow
32. the tip For such a type the displayed T C temperature could be noticeably different to the temperature of the plastic material at the tip In such a situation it helps if the operator can set some offset so that temperature on the main page reflects the working temperature at the tip rather than the actual T C temperature somewhere else within the probe The T C Offset Value allows you to achieve such temperature display compensation While using a set Temperature of say 250 C on the main page and then putting plus 20 degrees into the T C Offset column on the Setup page the zone will then control the temperature to 270 C However the main page will still show 250 C Also the offset is a constant value so that increasing the zone set temperature to 290 C on main page means that the zone is then controlled to 310 C at the T C point Using a minus T C offset has the same effect only working in the opposite direction i e with Set Temperature at 250 C and T C Offset at minus 30 C the actual controlled temperature at the T C is 220 C However the use of T C Offset is proportional This means that if you apply plus 20 offset to a zone whose set temp is normally 250 while the tool is at its ambient temperature of 21 then you will not see the display temperature immediately corrected by 20 to show 1 What happens is that the controller uses only a proportion of the offset while the tool is below its set temperature This graph
33. tool slot When setting up a new tool then your next step in the configuration sequence is to create a named tool slot OV Oo Nr tool 2 Davids Tool 2 3 4 5 6 7 lt p gt Hode RUN A Message Status NORMAL TOUCH CONTROL Touch Menu and open the Tool page Select a blank tool slot and touch Detect Enter your System password to gain access Type in a new name for the proposed tool and press Enter to continue If the tool is connected via a Network to any other cabinet the next step presents an option to select the local controller labelled Serial Port or a remote controller labelled hrcnetx If no network connected controllers are detected then it automatically passes this option and goes straight on to step 6 The console runs an automatic Card Detect routine to find out what type and how many cards are fitted in the selected controller Once it has gathered this information then the console opens the Setup page for you to start configuring the various Controller Parameters for this new tool If the system has any problem running the detect sequence it may report an Auto Detect Failed and ask if you want to repeat the Detect routine If the reason for failure is obvious such as a loose network cable or a mains glitch during the Detect routine then you may touch OK to re try card detection If the detection routine continues to fail then c
34. touch Export 3 The Export function defaults to exporting all Data for all zones If this is more than you require then use the zone selection and Temperature selection to modify the export file 4 Ifthe Max Temp and Min Temp options are enabled then the result sheet that is printed out shows the Maximum and Minimum temperatures that have been recorded for the particular zones rather than the current temperature at the time of printing 5 Ifthe Status option is enabled then any zones that are currently showing a Fatal Error such as Fuse will have that Error condition added to the print out 6 Touch Export gt Yes to export the spreadsheet file to the USB Flash Memory if plugged in or the tmp directory if not To extract the data via the network You can access the saved files on the tmp directory by using a PC which is connected to the console via the Ethernet socket using a crossed Ethernet cable Alternatively you may access the directory over a network provided the console is connected to the same network Either way you will first need to know the IP address of the console which you can read on the Utils page as in the above diagram Once you have prepared you r access to the console tmp directory you can export the required data by following steps 2 6 as detailed above Then continue as described below to view the saved data You can use either a standard browser such as Internet Explorer or a graphic FIP prog
35. type with the characteristics nms Issue 9 6 Introduction 19 How the Controller Works How the Controller Works PMS 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 the following self calibration routine Set Point ee ee rae ee tet eee nee Be fo _ 2 os Load f Test aa yee _ ad P4 a 2 Soft 3 Mr C Load Test Delay T T T T T 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 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 has built a mathematical model of the heater characteristics and so it can automatically select a Fast Medium or Slow response heating program that suits the tool This allows more efficient control of the zone
36. wish to configure and touch anywhere in the Sensor column 2 Touch Set and if required enter your system Password 3 Inthe Select Sensor panel choose a Sensor type that matches the selected zones or select Cancel to leave it unchanged Description If an Analogue input board is installed then you can use this column to choose from a Select Item list what type of input the analogue card is reading Most often it will be related to water flow rate but may include other parameters such as pressure positioning or any other measurable quantity The zone information on the main page will then be changed to reflect the analogue input such as L to read litres per minute on a Water Flow input Note however that the X Series has no option for using Analog cards Issue 9 6 User Manual for MTS Console 68 Setting up the Operating Parameters Pre configured Set Up values Setting up the Operating Parameters Once the Console and Tool parameters have been defined then you can set up the normal running temperatures for that tool To set your required zones you need to look at the main page to see all the various zones with their function colour coded to show probes manifolds and others Probe 2 3 Probe 4 Probe Pow 6 Pow 6 7 Probe 10 Pow o amm PgDn Pow YA Pow CA z Pow 8 RUN A Message Status NORHAL 2 OG Bee Oh hie Or To Select the appropriate zones
37. you can obtain a hard copy of any records or details you must connect a compatible printer via the printer port and then select an appropriate printer driver If the console has a USB port then it will be possible to connect to a local printer Alternatively without a USB port you must configure the Console to work to a Action networked printer 1 Touch Menu and open the Utils page Scroll down to show Printer m System Options Postscript Apollo 21000 Canon BJC 610 Any Epson Stylu Original Epson Epson Color 200 Auto Detect 7 Yes Postscript This driver supports any Postscript printer Touch the right hand box adjacent to Printer Touch Set In the panel that appears scroll down to find a suitable printer driver A brief description of the printers catered for by that selection is displayed in the adjacent window and touch that printer name a o 6 Ifthe console has a USB port then you can select Local or Network for your printer connection If there is no USB then you must opt fora Network printer Touch OK 8 If you have selected a Network printer you must supply the IP address for that printer While on the Utilities page select the Printer Address option and touch Set 9 Touch type in the IP address for the networked printer that you intend to use If you haven t got an IP address for a printer then consult your
38. 8 Sat 1 Probe 29 Sat 2 RUN A Hessage al a ki td TOUCH CONTROL Issue 9 6 Introduction 23 Screen Layout and Navigation Main Page Options Zone Grouping Display If you use a controller for a multi part tool it may be more convenient to show the display page with zones grouped as in the tool To show this option here are some typical screen shots from a two colour 16 16 zone tool This would normally show the first 20 zones all of colour 1 and some of colour 2 on the first page as shown below Scrolling down would show the rest of colour 2 on the second page Blue 2 Blue 3 Blue 4 Yellow 10 Yellow 11 Yellow 12 Pow Blue 8 Pow o Yellow 13 Pow 0 Yellow 6 Pow 0 Pow 0 Pow 0 Hode Run A Message Status E A Hessage Status E Page 1 both colours Page 2 rest of second colour By using the Zone Grouping feature that is described on page Error Bookmark not defined the new display would be as shown below Blue 1 Blue 2 Blue 3 Blue 4 Blue 5 ARPER Yellow 2 Yellow 3 Yellow 4 PCHRD CEN CEN PCH CCN POEN CCE CCEA Pow 03 Pow 0 Pow 0 Pow 0 Pow 0 Hode Pow 6 Pou 0 Pow 0 Po Blue 6 B
39. Introduced 5 1 July 2002 Password timer override introduced DH SK 5 2 Aug 2002 Zero Power note added DH AWR 6 0 Jan 2003 New Setup page and Setting up procedure DH SK 6 1 Jan 2003 Communication Speed added DH SK 6 2 Feb 2003 Export Data has Zone Min Max feature added DH SK 6 3 Mar 2003 Qwikfix repair no longer required Append D DH SK removed 6 4 April 2003 KTS Console Function explained DH SK 6 5 April 2003 TC Offset and Zone Grouping introduced DH AW 6 6 May 2003 Individual Zone Boost DH SK 6 7 Sept 2003 Extra Boost Information DH SK 6 8 Dec 2003 Input Network Screens Introduced DH SK 7 0 Feb 2004 Stage Startup introduced and Configure Controller DH SK changed substantially for new Systems Options 8 0 Jun 2004 Introduction of Standby Delay facility DH SK Introduction of Shut down timer Introduction of Spear Standby Zoom page and Calibrate Touch function added to Issue 9 6 User Manual for MTS Console 8 User Manual for MTS Console Publications MTS Introduction of T C Fail option in Setup page and changes to Master Zone Selection Introduction of extra Display Data page on MTS console and withdrawal of Set Actual and Power columns from Setup page SPI Interface control added to MTS Console 8 1 Mar 2005 Extra connection information added to IO cards in Appendix B DH ARW 8 2 8 3 Apr 2005 Apr 2005 New Appendix items AI8 Analog Input Card and WMOx Water Manifolds
40. L which is a water flow zone with flow in Litres per minute 4 Power Level this shows the percentage power that is being applied to the zone Note that in normal Burst Fire mode power is a function of time as opposed to current So a power rating of 50 means that full load current is being applied for 50 of the time and that the rest of the time it is running at zero power The actual time period for on and off is very brief and at 50 power it would be switched on and off for approximately 0 15 seconds at a time For a spear tip probe the displayed power is different again During the pre heat gate closed period the power displayed refers to the power in the main body of the nozzle still on a time function as above When a Boost signal is received it then indicates the power in the tip of the nozzle At a similar time the Status indicator at the bottom of the page switches from RUN to BOOST Although there may be some apparent discrepancy between the actual boost period and the displayed boost period in the Status window the Boost Display is explained in detail on page 77 If a zone is switched off then an Off Switch is shown below the Zone Name Issue 9 6 User Manual for MTS Console 22___ Introduction Screen Layout and Navigation Main Page Options If you want to see more than 20 zones at any one time then you can change the main page to show more zones with less information The sixth Function button has
41. N LEDs then you can see the SCAN LEDs flashing check the communication lead in a sequence as each card is briefly between the console and the controller checked for satisfactory cabinet communication If any card fails to If only one or two zones are displaying respond to the console then an N Z N Z then check the card for faults If error message is displayed for the you have recently changed any cards offending zone and put any older discrete component cards into a new controller that has surface mount cards then it is possible that the console s modern scan speed is too fast for the older control cards In such a condition check the console baud rate and try setting it to Low If this cures the problem and you later replace the older card for a newer surface mount version then remember to reset the Baud rate back to high for optimum working NONE The console has detected a control This Error message may be seen card that has no settings fleetingly during switch on it should disappear after the initial card scan If the message persists then you may need to re apply the correct card settings on the Setup page REV The card has detected an abnormal If the REV alarm persists then you input at the T C termination that should switch off the controller and indicates a shorted or Reversed investigate the offending zone thermocouple Alternatively you could slave the offending zone to a good zone until you have time to clear the fault R
42. Power Setting Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the Maximum Power column Touch Set and if required enter your system Password In the Keypad that appears touch type the Maximum Power value for the selected zones 4 When finished touch Enter to accept the new entry or Esc to reject it and return to the Setup page Limits The highest Maximum Power Setting that you can set is 100 power Description This column allows you to set the maximum power permitted for Manual Open Loop working for any zone or group of zones This parameter may be set to inhibit any changes up to excessively high probe temperatures that may cause material degradation or tool damage Issue 9 6 User Manual for MTS Console 62 Setting the Tool Parameters Pre configured Set Up values T C Offset Value Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the TC Offset column 2 Touch Set and if required enter your system Password 3 Inthe Keypad that appears touch type the Offset temp for the selected zones 4 When finished touch Enter to accept the new entry or Esc to reject it and return to the Setup page Limits The highest T C Offset temperature that you can set is 75 C or 135 F Description Some manufacturers make probes where the T C sensor is closer to the rear band heater than
43. Store page is greyed out while the system is in RUN mode Issue 9 6 Setting up your controller 39 Setting up System Utilities Baud Rate Communication Speed Setting 1 Touch Menu and open the Utils page Scroll down to view Baud Rate Select the parameter by touching in the adjacent right hand box Touch Set If required type in your System password at the next prompt Select Low or High as required Oy SE Ga In the Baud Rate box touch OK to accept the new setting or Cancel to reject it and return to the original setting 8 Touch Back to return to the main page Description Modern electronics enabled newer control cards to use a higher communication speed or baud rate to communicate with the console although they are capable of working at low speed as well Older cards however were only capable of communicating with the console at slow speed Normally new Touch Screen consoles are supplied with new Cabinets in which case there is no problem with communication between the two However if you are using a new console with an older cabinet there may be a mismatch between their communication speeds How to check the Communications To check that the console and cabinet are communicating observe the Scan LEDs on the control cards In a normal condition you can see the Scan LEDs flashing sequentially through the cards this shows that the console can talk to the control cards If no Sc
44. TD The RTD monitor cannot see an input Check the RTD and its wiring for a RTD is open circuit broken connection T C An open circuit thermocouple has For immediate recovery you can either been detected and no auto response slave that control zone to an adjacent has been selected in the T C Open zone or change to open loop control Error column of the Setup page Make a note of the above action so that when the controller is free you can check to see whether the input fuse on the control card has ruptured If the fuse is good then you may need to check the wiring for faults or even replace the thermocouple TRC If a triac fails it goes short circuit If the triac has failed return the and passes full load current In such a condition you have lost control of the load and cannot switch it off from the console The TRC alarm flags up the fault state which relies on operator intervention to manually shut the system down Note the triac monitor does not function in auto mode If the triac were to fail while the zone is run in auto then the only indication will be an abnormally high zone temperature because the triac is passing high uncontrolled current The TRC alarm is only seen if a triac fails on a zone that is running in closed loop manual condition controller for repair Issue 9 6 Troubleshooting 113 Individual Card Diagnostics Warning Abnormal Condition Message MAN The control zone
45. a certain configurable time See page 45 Maximum Setpoint Setting Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the Maximum Setpoint column Touch Set and if required enter your system Password In the Keypad that appears touch type the Maximum Setpoint value for the selected zones 4 When finished touch Enter to accept the new entry or Esc to reject it and return to the Setup page Limits The highest Maximum Setpoint temperature that you can set is 450 C or 850 F Description This column allows you to set the maximum setpoint value for any zone or group of zones This parameter may be set to inhibit any changes up to excessively high probe temperatures that may cause material degradation or tool damage If you try to raise the zone setpoint to any value which is above the Maximum Setting then the final setpoint depends on how the Limit Exceeded option see page 37 has been configured For instance if the current zone temperature is 350 and the Maximum setting is 400 if you try to set a new temperature of 450 then e with Limit Exceeded option set to Enabled the new set temperature would rise to 400 which is the highest allowable temperature setting e with the Limit Exceeded option set to Disabled the set temperature would not rise at all but will remain at 350 Minimum Setpoint Setting Setting 1 Open the Setup page select those zones that you
46. a dual function and while no zone is selected no blue highlight showing touching the Display button will cause the main page to cycle through 20 35 and 60 zone display s shown below 20 Zones each zone shows Zone name Set and Actual temperature and Power setting 35 Zones each zone shows Title and Actual 60 Zones each zone shows Actual Temperature After 60 zones the next touch on the Display button reveals a Data page which shows the setup data for all the console zones As well as Set and Actual temperature values it also shows the power used on each zone and if current coils are fitted the main and leakage current in each zone Probe 2 Probe 3 Probe 4 2 z 3 a G E Pow 8 Pow 8 Pow 0 Pow 0 Probe 7 Probe amp Probe 9 2 7 H pa G gt Pow 0 Pow 0 Pow 6 Pow o 22982 eE g E gE F al ol r my gt zog E F i 2 D rI ia Probe 12 Probe 13 Probe 14 Pow 8 Pow 8 Pow 8 Pow o Probe 16 Probe 17 Probe 18 Probe 19 Probe 20 a S a x Pow 8 Pow 8 Pow o Hode RUN A Message TOUCH Probe 2 Probe 3 Probe 4 CONTROL Probe 5 Probe 7 Probe amp Probe 9 Probe 16 Probe 12 Probe 13 Probe 14 Probe 15 Probe 17 Probe 18 Probe 19 Probe 22 Probe 23 Probe 24 Probe 27 Probe 2
47. a light tapping action removes loose dirt and dust Failure to do this reduces the flow of cooling air and may incur more expensive repairs if internal components subsequently overheat If filters do become clogged they need to be replaced and these can be obtained from your supplier quoting the serial number of the model 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 insulated screwdriver to check that no terminals have become loose Issue 9 6 User Manual for MTS Console 106 Maintaining your controller Upgrading your controller Upgrading your controller Why How In order to maintain our high quality our development engineers are making continual improvements to our control system We also listen to customers who will sometime suggest system changes that may be both useful and achievable Improvements which are gained from either of these routes will be offered to our custo
48. ached then the system automatically assumes a Run mode and confirms this by displaying a steady RUN sign in the Mode window NOTE Start up mode cannot run without a Master Zone selected If Start up is chosen with no Master Zone selected then the system automatically switches over to Run Mode Issue 9 6 Running your controller 75 Starting and Stopping and Pausing Shutdown This Shutdown mode is dependent on and is an opposite complement to the Startup mode With the Startup Mode set to Master Shutdown switches off the nominated manifold zones and all the probe zones have their Set temperatures adjusted to follow the manifold Actual temperature as it gradually reduces This allows the whole tool to cool in a homogeneous manner and so reduce thermal differences and stress On some tools however this may be an extremely slow process because the heat which is applied to the probes to keep them at the same temperature as the associated Master manifold conducts through to the manifold This can considerably extend the manifold s normal cooling time and consequently the whole shutdown process may take a long time Individual zones that have no Master Zone configured will simply switch off and cool down at their own rate Depending on tool design and zone location then the rate of cooling for masterless zones may or may not depend upon thermal conductivity from adjacent zones that are still being heated Note If Shu
49. ackup and Restore buttons at the top of the page can be used to make a complete backup or restoration of all the tools and their settings This is particularly useful for copying multiple tool settings from an old machine to a new one Davids Tool Delete The main window has four columns Hode RUN A Hessaze Status EN containing the following information Tool the allocated tool number Name a user configurable text field of xx characters that may be used to hold an identifying name for the tool The colour of the name is a key that shows the state of tool black shows a tool store that has been named using the Edit button but which holds no settings blue shows a tool that has been named it may or may not have stored settings and it is not in current use purple shows the tool that is currently in use and that has no changes to any settings that it may have in its store red shows a tool that is in current use but which has been changed from its stored settings during use Description a user configurable text field that may be used to hold an expanded description of the tool Connection this normally defaults to Local Serial which indicates that the tool settings are stored locally within the console memory However if the console is networked this may show the name of a remote console If so then it is not a local tool that may be used If that tool is loaded then the
50. ain page and it allows you to boost a single zone s temperature The Boost command is used as follows 1 Open the main page OF Pe QS Select the zone or zones that you wish to boost Touch Set to display the Keypad as seen here Touch Boost Touch Enter to boost the temperature of the selected zone or zones The Zone temperatures return to normal after the Boost time expires Issue 9 6 Running your controller 77 Remote Boost Remote Boost Remote boost tends to occur as one of two entirely different functions 1 For spear tip zones a cycling input is used to initiate the tip boost condition to open the probe gates The period and settings for this remote boost are configured on the setup page as a Spear Tip group and are not related to the normal Boost Time and Boost Value settings mentioned above 2 On machines using either the remote console input see appendix A or a 4 way I O card see Appendix B an operator has the ability to initiate a Manual boost by remote connection This remote boost uses the same settings as Manual boost and it operation falls under the same constraints as for Manual Boost as are mentioned above How Boost is displayed in the Status Window The Status bar at the bottom of the screen has a mode window which changes to display BOOST whenever a boost command has been initiated The period of time that the BOOST message is displayed may vary according to how the boost is ap
51. an LEDS light up then the communication has failed Check first that the data lead is correctly fitted and if all seems normal then change the Baud rate to Low as shown below You may observe an in between situation where some of the Scan LEDS light up while others do not This may happen if some of the cards in the older cabinet have at some time in the past been changed for newer ones In this case the few newer cards will communicate at the higher speed and light their Scan LEDs while the older original cards will remain unlit Console Startup Setting 1 Touch Menu and open the Utils page Scroll down to view Console Startup Select the parameter by touching in the adjacent right hand box Touch Set If required type in your System password at the next prompt Select Stop Startup Standby or Run as required In the Console Startup box touch OK to accept the new setting or Cancel to reject it and return to the original setting Oy Se G9 SB 8 Touch Back to return to the main page Description Issue 9 6 User Manual for MTS Console 40 Setting up your controller Setting up System Utilities This option allows you to select a particular Startup Mode for the console to adopt after initial switch on or console re booting It is not part of the ToolStore settings The Startup choices are Stop the system powers up with all the zones set to zero degrees Startup the system
52. at the unit is allowed to cool for before the controller applies the Heating Test Again you should not exceed 25 in this setting otherwise you may be waiting for a very long time between heating cycles Good and Bad Rise The Good Rise is concerned with the zone under test It is the temperature rise that the zone must achieve to be a Pass The Bad Rise is concerned with other adjacent zones The test monitors all other zones not being heated to see that they do not warm up by more than this preset temperature If any do warm up more than this Bad Rise then it detects Zone Interaction The default values for these two are 6 C for Good Rise and 2 C for Bad Rise Setting Test Parameters 1 For each parameter touch the relevant Edit button 2 Using the keypad enter the parameters for your test 3 When all four parameters are satisfactory touch OK to accept your settings or Cancel to reject them 4 If after setting up and testing the settings have proved to be unsuitable you can easily reset the factory settings by using the Reset button Reset Touching Reset restores the Heat times and Rises back to the original factory setting Issue 9 6 User Manual for MTS Console 102_ Maintaining your controller Running a Self Diagnosis test Running a Self Diagnosis test The diagnostic routine may be performed at any time that the controller is connected to the tool provided that it is not i
53. ation is to run the zone with the failed thermocouple sensor as a Slave to an adjacent and similar zone For details on how to do this refer to page 80 Changing a zone to slave working Rapid Temperature Fluctuations 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 heater We recommend that all earth connections be tested Not able to set a Higher Temperature This problem can occur if you try to set the temperature above the limits Check the current setting in the Limits column on the SetUp page and revise if necessary 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 Check the Power limits setting in the Limits column on the SetUp page and revise if necessary nms Issue 9 6 Troubleshooting 115 Other problems with the Tool Other problems with the Tool If you find that the Controller is not running correctly and cannot resolve the problem with either the manual or on line help then it may help us if we can see exactly how your system is configured To do this have a USB Memory stick available and follow the next steps Export the Tool Settings 1 Open the ToolStore page 2 Select an empty ToolStore slot and use the Edit button to give it a temporary name Temp for instance
54. ch type the Startup Stage Group number for the selected zones 4 When finished touch Enter to accept the new entry or Esc to reject it and return to the Setup page 5 Repeat the above steps to configure all the zones into their respective Startup Groups Limits There is a limit of 8 Startup Stages Description In order to use Staged Startup you need to configure different groups of zones into discrete stages There is no need to set the Startup Stages in any order although it may be a simpler task to start at the first group and then move on to subsequent groups Select the zones that you wish to nominate for any one stage in the Startup pattern and then touch anywhere in the Startup Stage column In the keypad that appears enter the stage number for that group Startup Group 1 will be the first to reach their operating temperature 2 the second group etc Continue with other groups of zones until all the zones have been configured Shutdown Stage allocating zones to This option is only available if you select Stage as a Startup Mode option in the global Config settings Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the Shutdown Stage column Touch Set and if required enter your system Password In the Keypad that appears touch type the Shutdown Stage Group number for the selected zones 4 When finished touch Enter to accept the new entry or Esc
55. console is in effect disconnected from the local controller and connected to a remote hot runner controller and will monitor and control that controller During this period the local controller is left running at its last set temperature without any local monitoring Issue 9 6 Customising your controller 89 Naming a new tool Naming a new tool It is essential that whenever you need to generate and create new tool settings then you must first create a named slot for the new tool If you configure all the new settings and then try to name and empty slot then all your new settings may be lost as you complete this sequence and you may have to start again To give a new name to a blank tool position 1 Open the ToolStore page and select an empty tool store 2 Touch New 3 At the keypad enter your System Password 4 Atthe Tool Name prompt enter the new name for tool position and press Enter 5 The next pop up window is the Connection option If you are using the console and controller as a single stand alone unit then the only available option is Local Serial If however you are programming a console that is connected to a number of different control cabinets over a network then you must select the appropriate cabinet address for the intended new tool 6 Use the Description section to add any relevant notes to the Tool Touch the Description column and then Set to bring up the keyboard to add the descriptive t
56. d required to Main Run Stop Change Set Alter temperatures Modes or modes Change Display options Go to Zoom or Graph page Zoom Set Alter temperatures or modes Graph View Keys Print Tools Export Exit shut down Load Save Backup New Create new tools console Restore Delete Utils Set Change Time Change any Utility Values Diagnose Start Test Configure Test Select zones to be tested Setup Set Config Change any values Issue 9 6 Setting up your controller 33 Setting up System Utilities Setting Password Security Every machine leaves our factory with two levels of password protection these are provided on a detachable page at the front of the Manual We recommend that you change these as soon as possible to establish your own security Edit System Password 1 SS 209 ISS 8 Touch Menu and open the Utils page Scroll down to view Edit System Password Touch the adjacent right hand box Touch Set The keyboard appears with the prompt PASSWORD and a scrolling message in the lower bar prompts you to enter the existing System password to establish your authority Once you have given the current System Password the next prompt changes to NEW SYSTEM PASSWORD where you can type in a new System Password and then Enter Re type in the new System Password for confirmation and touch Enter Touch Back twice to return to the Main Screen Edit Use
57. der to pass information both to and from the console You can set up your network connection within the Utilities page by touching the Network tab to see this screen What facilities Networking offers Provided your remote terminal has an X Win server you can easily communicate with the Console to return an emulation of the working program This means that you can monitor the Touch Screen Console and you also have the facility for remote control If you have network connections to multiple consoles then you can transfer files such as tool settings between the different machines Option System Setting Machine Name newraid Domain Name pmssystems com IP Address 217 10 148 148 Net Mask 255 255 255 224 Obtain Address Disable User Password SEMI IEE System Password SHIEH HEH Password Timer 5 Minutes Hode RUN A Message Status NORMAL How to make the connection In order to use this facility connect your console to an active network using a T base lead to the socket on the Touch Screen computer The next step is to allocate a unique name to the machine within your factory environment and set the domain name for your own system Obtaining an IP address depends on the size of your internal network For connection to a large network it may be sufficient to enable the Automatic IP facility On a smaller network you may need to disable the automatic facility and use the Edit butto
58. different zones into groups Before you embark on this particular exercise it will make grouping easier if you first read all of the following a Before you start grouping zones then all the zones by default are in Groupl Before you allocate the zones into groups then it is worth noting how many zones you are starting with and plan which zones will go into which groups For example a tool with 140 zones say 128 probes and 12 manifolds may need to be set up as four groups each with 32 zones and 3 manifolds As you start to group the zones into these groups you should start by assembling group 2 then 3 then 4 All the zones that are left after step three will automatically remain in group 1 As you assemble each group of zones then the remaining zones will automatically re number themselves This means that you appear to put zones 1 35 in Group 2 then zones 1 35 in group 3 and finally zones 1 35 into group 4 Although you appear to be selecting the same group each time it is in fact a different group of renumbered zones and you can confirm this by checking the rack addresses Following these steps and working on the given example then on completion the main page would show the following Issue 9 6 Setting the Tool Parameters 65 Pre configured Set Up values Group Probes Manifolds 1 1 32 1 3 2 33 65 4 6 3 66 98 7 9 4 99 128 10 12 When you have completed the zone g
59. e 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 detect enough heat rise in the zone under test then it may have detected one of three possible errors e if another zone exceeds the Bad Rise rather than the one under test it indicates that there is a cross over 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 e if the zone under test is seen to fall in temperature rather than rise then this is a sign that the T C polarity is reversed e if the zone under test substantial exceeds the Good rise but a significant heat rise is also detected in other zones such that they exceed the Bad Rise then the controller displays a WARN message These other zones are physically close to the zone under test but not necessarily in numerically sequence This fault is usually caused by excessive thermal conduction which impedes accurate temperature sensing and so results in imperfect temperature control Issue 9 6 User Manual for MTS Console 100 Maintaining your controller Self Diagnostic Tests At the end of the Tool Test the system stores and displays all the results The particular incide
60. e existing set point Mode Input The operating mode of any zone can also be set from the keypad The three buttons are Auto this is the default mode for the controller i e closed loop where the controller output is determined as a set temperature and which rely on feedback from the thermal sensor In this mode inputs are as shown in the prompt entered in degrees temperature Manual this is an optional mode i e open loop where the controller output is fixed at a set power level which is determined by you the operator In this mode input shall be a percentage power level Slave this is a fallback mode which can be successfully used if a thermal sensor has failed Rather than switching to manual you have the option to slave the faulty zone to a working one The temperature on the faulty zone then mimics the good zone that is working in auto or closed loop Provided the Value box is at Set the prompt asks for the identity of a target zone which should be operating at a similar temperature Note you cannot nominate another zone that is already slaved to another Slaving Guidelines Although Slaving seems a straightforward technique there are several points that you should bear in mind when using this option 1 You can only slave like zones for like zones You cannot slave a probe zone to a manifold zone the system will not permit such a selection 2 You cannot nominate another zone that is already slaved to a
61. e supply requirements If the local supply is outside the specified range please contact PMS Systems Ltd for advice Tel 44 0 1432 265768 Fax 44 0 1432 263782 Issue 9 6 User Manual for MTS Console 14 Introduction Isolating the Controller Isolating the Controller The main Power Switch is sufficiently rated to disconnect the total load current during switch On and switch Off To prevent its operation during maintenance you can use a suitably sized padlock or similar device to lock the switch in the Off position 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 uses computer technology and you should normally switch the system off in stages as detailed below A sequenced method for switching On and Off protects the console and keeps the switched load to a minimum to extend the life of the main Isolator 02 C F or 0 Power is NOT Switched Off The heat of a nozzle is proportional to the applied current Setting any zone to zero degrees temperature or 0 power means that only the current is reduced to zero However the current control is not a breaking contact switch but a semi conductor device known as a Triac This means that at zero current there may still be some voltage at the nozzles On a single phase or 3 phase star supply with a neutral the triac is on the live side of the supply t
62. en the upper function buttons provide Stop or Start and Mode selection When you want to alter the temperature or operating mode of any zone or inspect a zone on the graph page then your first step is to select that particular zone Doing so automatically change the top three function buttons over to Set Zoom and Range in readiness for your next command Note that it possible to open the main page expecting to find the Start Stop buttons but find the Set Zoom buttons active with apparently no zone selected In such a case you will have a warning that reads ZONE selection active in the lower message bar and that by scrolling further down the pages you find a selected zone at the end of the list that is keeping the Set button active Touch Cancel to deselect all zones and the Start Stop buttons will reappear on the screen Issue 9 6 User Manual for MTS Console 72 Running your controller Starting and Stopping and Pausing Run Run command switches all the heaters on so that they independently rise up to their set temperature To switch all the heaters on and prepare the tool for moulding 1 Open the main page 2 Touch Run 3 At the confirmation prompt touch OK to confirm your request or Cancel to defer the action Notice that the Run button now reads Stop Stop To switch all the heaters off so that the tool can cool down 1 Open the main page 2 Touch Stop 3 At the confi
63. etting Allow ToolLoad see page 38 Saving tool settings Tool settings can be saved at any time back into memory But there may be two variations to saving changes Over writing the last settings with new saved settings If you have changed tool settings and know that they are satisfactory then you can save them back into the same tool store 1 Open ToolStore 2 See that the current tool is displayed in red which indicates that settings have been changed 3 Touch Save to overwrite the old ToolStore settings Saving modified settings without losing existing ones If you have changed some tool settings and want to keep them but at the same time you wish to retain the old unmodified settings then it becomes necessary to create a new store to save them into The following method allows you to do this without losing either the old or the new settings 1 Open the ToolStore page Select a spare blank tool tab Touch Save At the keypad enter your System password Ol de tS At the Save to Tool name prompt confirm your decision by pressing OK to confirm or Cancel to exit without saving the new settings Issue 9 6 Customising your controller 91 Deleting a tool Deleting a tool Once you have deleted a tool there is no way to recover its previous settings Take care that you are deleting the correct tool To remove a tool and all its settings from any position 1 Caution 2 3 4 O
64. etting option for Rack Position on the Touchscreen Console Description This indicates where on the rack the particular card or zone is located This reading does not refer to a physical position but is determined by a miniature logic switch on the back plane board Alias Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the Alias column Touch Set and if required enter your system Password In the Keyboard at the Alias Name prompt touch type the new name back space deletes characters 4 When finished touch Enter to accept the new entry or Esc to reject it and return to the Setup page Description If no Alias is given then the system shows zone types on the main page with their inherent type name i e Probe 1 2 3 etc or Manifold 1 2 etc However setting up Alias enables it to show the zones with a more meaningful name On a two colour machine for instance it may be more useful to name one bank as Red 1 2 3 etc and the second bank as Blue 1 2 3 etc To use the Alias function select all the zones within a named group and touch the Alias column Touch Edit to display the keyboard and key in a new name you can remove any existing name by touching the Back Space key Alias is an auto numbering function so if you number the first zone in a group Red 1 subsequent zones in the same selected group bear the following numbers i e Red 2
65. ext Renaming an existing tool If you need to edit the name of an existing tool this can simply be done It does not matter whether that tool is in current use or not 1 Open the ToolStore page Touch the relevant tool tab Touch in the Name column against the relevant tool then touch Set At the keyboard enter the System password Si et At the name prompt edit the existing name and then touch the enter button Issue 9 6 User Manual for MTS Console 90 Customising your controller Loading tool settings Loading tool settings Once a tool setting has been saved into memory then it may be recalled at any time However you should remember that the operating mode for the controller cabinet remains unchanged by loading another tool So if your controller is in Run mode and another tool setting with different temperatures is selected and loaded then the tool will immediately change to run at the new incoming temperature settings To use the Load tool function 1 Open the ToolStore page 2 Select the tab for the desired tool 3 Touch Load 4 At the Load and USE Tool name prompt confirm your decision by pressing load Tool to confirm or Cancel to exit without saving the new settings NOTE If the Allow ToolLoad option has been set to Disable then if the system is in RUN mode the Load button is greyed out because swapping Tools on the fly is not permitted For information about s
66. fication to confirm which type is fitted to the probes Select RTD for temperature monitoring circuits on WT cards Display Group allocation Setting 1 Limits Open the Setup page select those zones that you wish to configure and touch anywhere in the Display Group column Touch Set and if required enter your system Password In the Keypad that appears touch type the Display Group number for the selected zones Note that Display Group defaults to Group 1 start by allocating to the second third fourth groups etc by typing 2 on the first setting then 3 4 etc for repeat settings all remaining zones are then left as Group 1 When finished touch Enter to accept the new entry or Esc to reject it and return to the Setup page There is a limit of 6 Display Groups Setting Zones to No Display If you set any zones to Display Group 0 then those zones will function but not be seen on the Display page The more common use for this function is to hide the IO3 board which has 4 I O circuits and a T C circuit none of which would normally need to be seen but which must remain functional to work It is possible that other applications may also require such an invisible function and if this option is used then only the Setup Page displays all of the detected cards within the associated controller Description As mentioned earlier in the manual the Display Group function allows you to configure
67. guring Master Zones is similar to the Master Follow option but rather than just the two stages it allows you to nominate up to eight stage groups that will heat up in successive stages When Staged Startup is selected then the shutdown automatically follows a Staged Shutdown Note however that there is a separate allocation for shutdown groups so a shutdown pattern need not be the same as the startup sequence Selecting Staged Startup also enables the Shutdown Timer and Shutdown Temperature options If both options are set to a preferred value then stage switching will occur at whichever parameter is reached first time or temperature see page 66 for more detailed information about the interaction between Shutdown Time and Shutdown Temperature A more complete description of these modes is detailed in the Startup section on page 74 Issue 9 6 Setup page Console Parameters 49 To select or modify Global parameters Standby Delay This option is dependant on selecting Standby as an Input Signal option Setting 1 Open the Setup page touch Cancel then Config and if required enter your system password In the Configure Controller box select Standby Delay and touch Edit In the Keypad enter the required Delay time and touch Enter In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and return to the original setting Limits The Standby De
68. he password When you stop making changes and the timer renders the password inactive you must re enter the System password to make further changes Issue 9 6 User Manual for MTS Console 34 Setting up your controller Setting up System Utilities If while the System password is active you visit a lower level page that only requires User Level 1 password level eg Display main or none at all eg Graph then the System password will expire after 20 seconds but on doing so it becomes a User Level 1 password which would allow you to continue setting lower level parameters Setting your password timer A OY Oe oo aS Touch Menu and open the Utils page Scroll down to view Password Timer Touch the right hand box adjacent to Password Timer Touch Set If required type in your System password at the next prompt In the following keypad touch type your required password active time in minutes and then Enter Touch Back twice to return to the main page Password Override To override the User and System Password control set the Password Timer to 99 This setting negates the need to enter a Password at any of the usual checkpoints such as Load Tool or Temperature Change Under this condition the only function that still needs a Password input is the Change Password action Issue 9 6 Setting up your controller 35 Setting up System Utilities Configuring a printer Before
69. he resulting negative temperature readings Failed to React Correctly Unexpected results This message is followed by further error messages T C Interaction with zone NN 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 NN Cross wiring fault between displayed zones Could be either Heater or thermocouple wiring at fault Message Overflow 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 Issue 9 6 Maintaining your controller 105 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 Everywhere suffers some degree of contamination and so you need to inspect the fan filters at regular intervals according to your own environment The filters are removable and
70. he tool setting information on a single scrollable screen that may be printed out to provide maintenance and installation records The Help Pages The touch console has a full help section that offers help on all aspects of the console the controller and all its functions The general Help menu can be reached from the Help menu button on the main page Other pages have help buttons that link into the relevant sections Rack Type Address Alias TOUCH CONTROL Bao Forud Main Menu About Running About Diagnose About Utils About Toolstore About Setup Troubleshooting About the Controller Help Index TOUCH CONTROL Issue 9 6 Introduction 27 The User Interface The User Interface There are many places within the setting up and operating procedures where the system needs your input It may require either alphabetic entry for Passwords or tool names or numeric entry for temperature settings or various limits Whenever such an input is needed then the controller will bring up either the Keyboard or the Keypad as an interface for your input The Keyboard It is a standard QWERTY layout with touch activated keys Touching the keys enters the particular character into the display line the back space button deletes them starting from the last entry To use the Shift key you may e Touch it once which initialises the next letter and then returns to l
71. his keeps residual voltage to a low value However on a 3 phase delta wired supply there will be phase voltage on the nozzle while the controller s main isolator is On even when the heating is set to zero degrees 0 or Off ALWAYS isolate the controller before you open up a controller to examine any wiring or change fuses Remember that with respect to the mains supply 0 power is NOT Off Issue 9 6 Introduction 15 Switching On and Off Switching On and Off Switching On Switching ON the Main Isolator for the controller may or may not start to heat up the zones it depends on how the Console Startup option is configured see page 48 If Console startup is set to Stop then the tool remains at zero power and at room temperature If it set to any of the other three options Startup Standby or Run the controller applies power to the zones so that they heat up Switching Off or Shutting Down We recommend that you use the console to shut down the heating load and only use the main isolator to switch off a dormant controller 1 Shut down the heating On the main page select the Stop mode and reduce the heating to zero 2 Shut down the Console On the Utils page touch the Exit button and this will shut down the Console Computer 3 Shut down the Controller Finally use the main power switch to isolate all the power to the whole system Issue 9 6 User Manual for MTS Console 16 Introduct
72. ies 7 At the Internet Properties box check that the computer has an IP address If Obtain an IP Address Automatically is selected then click on Use the following address and type in an IP address that has the same first three groups 192 168 1 and a different last number to that used by the MTS Console in step 3 Set the Subnet Mask number to 255 255 255 0 Click OK and accept the new TCP and Local Area properties A LAN or High Speed internet Suas 06 amp onf Local Area Connection 3 Properties PIK General Authentication Connect using E Realtek RTL8139 Family PCI Fast amp This connection uses the following items a client for Microsoft Networks M E Fie and Printer Sharing for Microsoft Networks A JE QoS Packet Scheduler Intemet Protocol TCP IP Install Description Transmission Control Protocol Intemet Protocol The default wide area network protocol that provides communication across diverse interconnected networks Show icon in notification area when connected Notify me when this connection has limited or no connectivity General You can get IP settings assigned automatically your network supports this capabilty Otherwise you need to ask your network administrator for the appropriate IP settings Obtain an IP address automatically Use the following IP address IP address 2 wa 0 8 255 255 255 0 SBOE SE
73. iew Blanking Delay Select the parameter by touching in the adjacent right hand box Touch Set If required type in your System password at the next prompt In the following keypad touch type your required delay time in minutes and then Enter Touch Back to return to the main page The maximum period for Blanking Delay is 98 minutes Overiding You can override the Blanking Delay so that it remains permanently visible by setting this time to 99 minutes Description In order to optimise screen life the screen saver blanks the monitor screen after it has been idle for a preset time You can set this preset time so that the screen stays visible for more or less time by using the Screen Blanking Delay option Issue 9 6 User Manual for MTS Console 38 Setting up your controller Setting up System Utilities Allow ToolLoad Setting 1 Touch Menu and open the Utils page Scroll down to view Allow Toolload Select the parameter by touching in the adjacent right hand box Touch Set If required type in your System password at the next prompt Select Disable or Enable as required ON OT ee In the Allow Toolload box touch OK to accept the new setting or Cancel to reject it and return to the original setting 8 Touch Back to return to the main page Description This option determines whether tools may be changed while the system is in Run mode Select Enabled if you
74. ified by the second temperature window showing Green text on black background Warning Zone This shows a zone with a first stage warning the actual temperature window has changed to black text on yellow background This indicates that the temperature of this zone has deviated from the set temperature by a preset level see zone limits for exact details Alarm Zone Here the set temperature display is seen as white numbers on a red background Since it is displaying the actual temperature then it must be a second stage temperature alarm in which a zone temperature has now deviated from the set point by an even larger margin The Status Warning may also be derived from zone with a Fatal Error as shown here in which case the actual temperature is replaced by an abbreviated Error message for a full list of al the possible Error messages and their meanings consult the Trouble shooting table on page 110 Beacon and Sounder extension If your controller is fitted with a Beacon and Sounder it acts in a supervisory capacity only Any incidence of a 2nd stage temperature alarm or fatal error alarm such as Fuse or T C is extended to the beacon sounder module Curing the alarm condition will extinguish the beacon sounder A key switch is also provided to mute the sounder at any time Note however that no reminder is given to show that the sounder is muted when the system is healthy Re occurrence of subsequent alarm conditions will ca
75. in page 2 Touch Mode to activate the a a Mode menu aa 99 oad ea 3 Touch Standby 4 At the confirmation prompt i 2 Probe 3 touch OK to confirm your ize 250 request or Cancel to defer the Eo action The controller is now placed into the Standby mode Issue 9 6 User Manual for MTS Console 74 Running your controller Starting and Stopping and Pausing Start up Start up mode applies heat to the zones in a predetermined pattern rather than switching on all the zones at once Normal Startup Mode With Master Only Startup disabled then the tool will achieve a homogenous rise for all zones that have a declared Master zone In this mode the controller modifies the Set Temperature of any probes or sub manifolds that have a Master zone to follow the Master zone s Actual temperature As the Master zone s temperature rises then so will its sub zones rise at the same rate rather than rush away at their own speed All other zones that have no declared Master zone remain set at zero When any Master zone reaches its Set Temperature all the zones in the tool are then switched over to Run Zones which have previously been held at zero are then allowed to reach their normal working temperature Master Only Startup Mode In certain moulds such as Manner Gate Valve tools you must start up in two stages to protect the gating valves and seals from stress caused by the
76. ion The Touch Screen Family The Touch Screen Family There are several variations of our leading Touch Screen Consoles and while they share the same user interface there are one or two operating differences of which you need to be aware Differing Storage media The TS KTS and MTS consoles use different media for backing up and restoring tool settings The TS variety uses a standard 31 2 floppy disk and the KTS uses compact flash CF cards via a PCMCIA adapter while the MTS can use a USB Flash Memory stick for exporting and upgrading Differing drive bay access Different Consoles also have different locations for their drive bays some of which are immediately apparent and some a little less so KTS drive bay is accessed TSA drive bay is open and through an opening door at the visible at the left hand side top of the case and immediately viewed from the front behind the handle SMART CARD via roma Adapter 3 Floppy disk Bay hs MTS Uses USB Flash Memory Stick into USB Socket on the underside of the console Micro Touch Screen Installing upgrade nms Issue 9 6 Introduction 17 X Series Controller Cabinets X Series Controller Cabinets 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 ter
77. 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 main 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 Individual Card Diagnostics If a fault on a control card is suspected check the LED card status lamps 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 LOAD LED indicates a supply to the heater FUSE LED lit when the load fuse fails To remove a SM card from its slot pull the red handles forwards and gently pull the card out There is no need to switch off the main supply However if operational requirements allow the cabinet may be isolated The shrouded terminals on the euroback board are live unless the power supply is switched to OFF Warning Issue 9 6 User Manual for MTS Console 114 _ Troubleshooting Specific Faults Specific Faults Failed Thermo Couple Either an alarm or a diagnostic test may show that a thermocouple has failed The simplest way to temporarily overcome the situ
78. lay defaults to 0 which means that there is normally no delay in responding to a Standby request If a delay is required then you can configure the delay period from 0 to 99 minutes in 1 minute steps Description This function allows you to delay the controller from going to Standby when it is selected via the remote input it is only configurable if you set the Input Signal option to Standby This delay is used to hold the mould at its normal working temperature for a short period after receiving a go to Standby input from the moulding tool If the Standby request exceeds the Standby Delay timer then the controller will reduce the appropriate zone temperatures to their Standby level If however the Standby request is removed before the Delay timer times out then it resets its time count and the zone temperatures will have been maintained at their normal working point Note Selecting Standby Delay does not effect any manual switching into Standby that may be selected on the touch screen console Shutdown Timer This option is dependant on selecting Stage as a Startup Mode option Setting 1 Open the Setup page touch Cancel then Config and if required enter your system password In the Configure Controller box select Shutdown Timer and touch Edit In the Keypad enter the required Delay time and touch Enter In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and ret
79. lias Manif 1 Manif 2 2 Select the parameter To select any one value you may touch the associated column at any point in the column including the header This highlights the parameters against the selected zones Warn Warn Alarm Alarm High Low igh Low Touching in another column deselects the first parameter and accepts the second selection ail RUN A Message Status NORMAL TOUCH CONTROL 3 Set the Value The next step is to program in the Standby value by touching Set on the Function bar If this is your first visit to the Setup procedure then you are first asked for a password to establish your authority Subsequent visits from the same screen do not require repeated authorisation RUN A Hessage After entering the password either a ASE EEL EE keypad or a related SetUp box appears on the screen where you can input new preferred values Issue 9 6 User Manual for MTS Console 56 Setting the Tool Parameters Pre configured Set Up values Setting the Tool Parameters There are numerous parameters that are associated with each card type and most of them are automatically configured after zone detecting and allocating These values may be accepted or reconfigured to your own preferred values and an explanation of each parameter is given in the following pages Rack Position Setting There is no S
80. llowed by Probes then Manifolds then Specials e Mixed mode groups the probe and manifold zones as they are positioned within the card rack so that manifolds may appear out of sequence order but grouped with their corresponding probe zones nms Issue 9 6 Setup page Console Parameters 47 To select or modify Global parameters Input Signal Setting 1 Open the Setup page touch Cancel and if required enter your system password In the Configure Controller System Options select Input Signal Select Standby Auto Standby or Boost as required In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and return to the original setting Description Your console may have a remote input normally open pair that can be closed to switch the operation mode of the controller The available options are STANDBY this switches the controller into Standby mode while the remote line is closed and returns to its previous state when the signal is removed If this option is selected then you can also use the Standby Delay option to defer the Standby condition for a preset time AUTO STANDBY rather than switch to an immediate Standby condition this option enables the Autostandby Timer It is used where you need to monitor a cycling condition which while running will reset the timer each cycle to keep the temperature at normal If the cycling stops eg the mould stops o
81. local IT department Touch Enter 10 While on the Utilities page select the appropriate Paper Size 11 Touch Set to see the Paper size selection panel 12 Select A4 or Letter to accommodate your preferred paper size 13 Touch OK to accept the chosen Paper size or Cancel to leave the page without making any change 14 Touch Back twice to return to the main page Should you have any difficulties then contact your supplier for further help OPERATION NOTE if need to cancel a print queue then touch the Clear Print Queue button on this page It cancels any print requests that are in the current queue Issue 9 6 User Manual for MTS Console 36 Setting up your controller Setting up System Utilities Configuring a Quad Input Output card If the detect sequence finds an IO card during the initial stages then the Quad O button on the Utilities screen becomes active touching this button opens the setup screen for the card where its default I O options may be seen as Inputs 1 4 Run Standby Startup Boost Outputs 1 4 Injection Disable Temperature Disturbance Boost Inactive You can configure the Input Output options on this screen To Configure the Input Output options 1 Goto the Utilities page and select the Quad I0 Configuration Quad O tab er 2 Select the desired Input or Output and ii Input 3 Startup touch Set Input 4 Stop 3 Select your preference
82. lue 7 Blue 8 Blue _9 Blue 10 Yellow 7 E EE ee ee M a ED 230 Pow Pow 8 Pow 8 Pow o Pow 6 om Pow 8 Po Pow 6 Blue 11 Blue 42 Blue 13 Blue 14 Blue 15 Yellow 12 Yellow 14 Ee Ee ee ee ae 250 250 PCEN CEN CEN PCH PCH P1sP 2y POR iE 250 Pow 6 Pou 0 Pow 0 Pou 02 Pow 0 Pow 0 Po Pow 0 Po Blue 16 Print ide 250 Pow 0 aia Mede RUN A Hessage Status RUN A Hessage Group 1 First Colour Group 2 Second Colour Note that this display option cannot be switched between Grouped and Ungrouped on the main page Once it has been configured on the Setup Page then it remains as the preferred display option However the Display button on the main page still functions in its own right and so the number of zones and the amount of displayed information still alters to accommodate more zones on each touch of the button Issue 9 6 User Manual for MTS Console 24 Introduction Screen Layout and Navigation Main Page Options Coloured Headers Where required you can change the preset zone header colours A facility within the Setup Configuration allows you to pick from any of 16 different preset colours that you can use for any zone type Main Page Other functions Once you select any zone within the main page the buttons at the side change to offer more functions a Set Touch Set to bring up the keyboard ready to set the working tempera
83. lure is detected it will automatically switch the failed zone into Slave mode and automatically select the most appropriate zone to master the failed zone The main problem with Auto Manual and AutoSlave is that the console needs to collect a reasonable amount of performance data upon which it can make a manual or slave match this is normally achieved after 10 minutes of running at a steady temperature If the T C failure occurs before sufficient run data has been collated then the zone will default to 0 power and show a T C fatal alarm There is a fourth alternative which you may select and this does not need to pre collect any performance data but does rely on your prior knowledge about zone performance Nominated Zone Slaving in this option if you have previous knowledge of zone behaviour then you may nominate any zone to master a failed zone Using this option may mean that you select one zone at a time and nominate a master zone for each in turn For instance you could slave Zone 1 to Zone 2 Zone 2 to Zone 3 Zone 3 to 4 etc If the system sees a multiple T C failure then it will cascade the slave pattern In the above pattern if Zone 1 T C fails then it will slave to Zone 2 If Zone 2 subsequently fails then Zones 1 and 2 will both slave to Zone 3 Standby temperature Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the Standby column Touch Set and if required ente
84. mers and should you decide that they would be useful to your own control system it will be quite straightforward for you to implement the upgrade yourself There is usually no need to return your control system for such upgrades They can on request be sent to you in the form of a USB Memory Stick which can be read by your controller If you have access to the Internet they may be downloaded from our site at pms pmssystems com These following instructions will guide you through the upgrade procedure We recommend that you always wait until your controller is free before implementing any upgrade This ensures that in the event of a mishap such as an error or a power interruption at a crucial point and then normal production will not be adversely affected If the machine cannot easily be released then ensure that the whole system is operating satisfactorily and disconnect the data cable that connects the touch screen console to the controller the controller will continue to maintain operating temperatures without the console although you will lose your monitoring for a while Procedure for an MTS Console with USB connection 1 Download the available upgrade from the PMS website and transfer the complete file onto a USB Flash memory stick 2 Release the controller from any production working 3 Plug the Flash Memory into the MTS USB socket 4 Reboot the console and let the Upgrade self install 5 With the upgrade completed
85. minating in Harting type Han A or E female connectors or their equivalents There are normally two types of looms supplied a thermocouple loom using type HA and a heater supply loom using type HE and typical connector and wiring details are show in Appendix A An alarm output option is available for extending the alarm or perhaps inhibiting the injection process A USB printer port may be provided for producing hard copies of certain screens Again please check with the system specification for details Controller Cards There are two boards mounted inside the HRCX cabinet The larger main output control board with the triacs heatsinks and current measure coils controls the output power and hence the zone temperatures Then there is a smaller input board which accepts the thermocouple inputs and uses its single CPU to control the main output sections The two cards together have four main components e thermocouple amplifier e CPU e multi voltage output triac e current measuring coils that read zone output current Thermocouple Amplifiers All our cards are provided with one of two possible thermocouple amplifiers One is designed to handle type J thermocouple inputs and the other type K inputs 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
86. mperatures Changing Temperatures If any conditions change such that you need to change any settings whilst your mould is running then there are many features on the main page that enable you to fine tune your controller TOUCH CONTROL To change the working temperature 1 Open the main page 2 Select the desired zones this automatically changes the function keys from Global to Zone 3 Touch Set to display the keyboard 4 Enter the password to display the keypad and either Configure a new set temperature 5 Touch Set 6 Enter the new Temperature 7 Touch Enter to confirm your request or Esc to defer the action Raise the overall temperature 5 Touch Plus 6 Enter the amount you wish to raise it by 7 Touch Enter to confirm your request or Esc to defer the action Lower the overall temperature 5 Touch Minus 6 Enter the amount you wish to lower it by 7 Touch Enter to confirm your request or Esc to defer the action Issue 9 6 User Manual for MTS Console 80 _ Running your controller Changing Modes Changing Modes Mode RUN A Message To change the Working Mode 1 Open the main page 2 Select the desired zones this automatically changes the function keys from Global to Zone 3 Touch Set to display the keyboard 4 Enter the password to display the keypad and either Select Auto Mode 5 Touch Auto 6 Set the required Temperature 7
87. n These four columns set the first and second stage Warning and Alarm levels that monitor the zone temperatures These generate visual warnings should the Actual temperatures deviate too far from the nominal Set temperature If no other values are chosen these parameters are automatically set to 5 C for Warning and 25 C for Alarm levels However all these may be reset to a preferred value by touching in the relevant column and then setting new levels on the keypad If any temperatures deviate by an amount that exceeds the first stage limits constitutes a warning This displays a Warning message in the lower Status box and the offending zone has its Actual Temperature window changed to Black text against yellow background If any temperature then deviates further and exceeds the second stage limits it raises the situation to Alarm This occurrence displays an Alarm message in the lower Status box changes the Actual temperature window to show White text against a Red background and actuates an Alarm relay that may be used to set of a Beacon Siren of other remote device These Warning and Alarm limits are a common feature on all zones whether they control or monitor Issue 9 6 User Manual for MTS Console 60 Setting the Tool Parameters Pre configured Set Up values Using an Alarm Delay can accommodate fleeting alarms that become a nuisance this holds off the outgoing alarm until the limits have been exceeded for
88. n use for production We have designed this testing page so that you can easily define and conduct self diagnosis tests to check zone interaction heater wiring and thermocouple integrity Config Probe 5 Error Msg 0 R I gt Hode RUN A Message Status TOTOHE CONTROL The Information panel at the top right of the screen gives constant feedback about the current zone under test showing whether it is at the cooling or heating stage so that you can observe the test in progress To select zones for testing The normal settings for Tool testing are such that a test will check all zones at the default test settings If you want to select a specific group of zones for testing or change the default test values then touch Config to display the Configure ToolTest panel Touch First zone to display a full list of available zones within the current tool touch the First zone that you wish to include in the Tool Test Touch Last zone to display a list of zones starting with the First zone that you selected in the previous step To run the self diagnosis Start the test on the selected zones by touching Start on the side bar To pass over or skip zones To pass by or skip any zones touch the Skip button while on an unwanted zone The test report shows User Skipped test and moves on to the next zone To stop the test prematurely and miss out the remaining zones touch the Cancel button The test report shows
89. nces described above are displayed in further detail For instance the two zones which displayed FAIL because of crossover both show a full message Heater TC Common with Zone NN The second fail example would show Below 0 or Reversed T C and the third 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 the 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 110 that explains their meaning and which helps to identify probable causes If no problems are detected the last message reads Zones nn to NN tested OR 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 1 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 2 Ifyou 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 changing test parameters is a comple
90. nd allows you to temporarily raise the temperatures of selected zones for a set period see page 45 to read about Boost Time The value entered here allows you to individually set that temperature increase on a zone by zone basis Any zones are left at zero will not respond to a Boost request but stay at their normal operating temperature If the associated zone is a Spear zone then the Boost is applied to the Tip and not the Body Please note that during a boost command the Boost Time is the main determining factor If on a slow responding manifold you set a high boost temperature while the boost time is set short then the zone is unlikely to reach your set Boost temperature before the Boost Time limit expires Finally the Status window will display a Boost indicator for as long as the external Boost signal is applied even if the Boost Timer for normal or spear nozzles has expired and the current has returned to its normal level Master Zone Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the Master Zone column Touch Set and if required enter your system Password In the Select Zone or Option panel you can either a nominate that there is no master zone b select a Master zone from one of the existing Manifolds zones or c touch Cancel to leave this screen and return without making any changes Issue 9 6 Setting the Tool Parameters
91. ne has failed Please Note A fuse can only fail due to a fault external to the controller Identify and rectify the fault before replacing the fuse Note The fuse detection circuit requires a continuous low level current through a high impedance bleed resistor to maintain the alarm condition As a result the load circuit is still connected to the mains voltage supply and it is not safe to attempt to repair or replace the fuse without first isolating the circuit If the fuse in question is mounted on a control card then it is safe to unplug the board in order to isolate the circuit and replace the fuse on the card Replace the fuse with one of the same rating and type i e High Rupture Current load fuse The blown fuse is located either on the control card or on the off board triac module If fitted GND The system has detected an earth fault Note this can only be detected by controllers fitted with EM Cards or MD240 diagnostics Check your heater wiring for a low impedance path to earth Issue 9 6 Troubleshooting 111 Fault and warning messages HELP There is a system failure and the Please make a note of the serial console does not know how to numbers for both the controller and respond console Also note the console This alarm may occur if an older software date on the Utilities page model console is connected to a later Contact your supplier with this
92. nother If for example zone 2 is currently slaved to zone 3 you cannot slave zone 1 to zone 2 The leading zone must already be a healthy zone 3 You cannot nominate a zone that creates a loop If for example zone 2 is slaved to zone 3 then you cannot slave zone 3 back to zone 2 4 When selecting a lead zone to slave to you should find a similar zone type that is currently operating at the same temperature and at the same power level If you nominate a lead zone that is working at the same temperature but outputting a noticeably different power level then the slaved zone may not regulate efficiently Ams Issue 9 6 Hode Aube Introduction 29 The User Interface Cycle Synch Input Some controllers may be associated with Cycle Snych spears that have Body and Tip heaters Where you need to set up the tip values this keyboard Pre Heat 0 0 net Tine 0 0 will be displayed The display at the top prompts you Bst Pou 0 0 my tine for one specific parameter and after each is entered it automatically moves on to the next until all four parameters have been entered If you enter any value incorrectly touching Esc steps you back through the entries so that you may correct the error Alternatively you can call up the keypad again and touch Enter to step past the good entries without changing them until you return to the bad entry to correct it Full i
93. ns to enter your preferred IP address and Sub net mask details Networking configuration depends a lot your system and should only be carried out by competent IT staff Should you need further information please contact PMS Systems Ltd Issue 9 6 User Manual for MTS Console 94 Maintaining your controller What is included in this section Maintaining your controller Maintaining your controller is all about keeping it in order checking records and settings and running self diagnostic checks There are no user serviceable parts inside the Touch Screen controller and in the unlikely event of equipment failure you should return the unit for attention What is included in this section Printing out various pages and tables for your records Exporting performance data Checking Touch Screen alignment Running a self diagnostic test check that all is functioning correctly Viewing and printing test results saving diagnostic test results Upgrading your controller Servicing and Repairing your controller Issue 9 6 Maintaining your controller 95 Print Out Facility Most of the pages on your controller contain a Print button on the side screen Print Out Facility This prints tabular data that relates to the particular screen MAIN page TOOL page prints out the Zone Name Actual and Set Temperatures and Power level for ALL zones regardless of how the main page display is currently set Select any
94. nside the cabinet which may have a dangerous potential across them Where a three phase supply is used then this potential may be at 415 volts or higher Safety Notices an explanation 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 Warning 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 aution Caution warnings present no personal danger but may cause the equipment to fail or lose its memory Issue 9 6 User Manual for MTS Console 12 Introduction Welcome Welcome PMS welcomes you to their HRC range of temperature controllers for hot runner injection moulding tools This particular member of the proven family of Hot Runner Controllers is user friendly and retains the standard control facilities associated with other PMS controllers About the controller The display console and controller cabinet together are designed for use in the plastic injection moulding industry as temperature controllers for third party hot runner systems as commonly used in mould tools They must not be used in residential commercial or light industrial environments Fu
95. nstruction on setting up these zone types are given on page 52 Issue 9 6 User Manual for MTS Console 30 Setting up your controller The User Interface Setting up your controller New Touch Screen consoles and controllers are provisionally configured at the factory and you may not need this section for a new system However you should always check through any new controller to see that its settings are correct for the tool with which is about to be used Also if you a reconfiguring your Touch Screen console to a new tool or environment then you may well need this chapter of the manual There are three distinct areas involved in setting up a controller According to your needs you may need a combination of any of the following Utilities Parameters The Utilities page contains a number of global parameters that determine how the console functions Some are concerned with the overall operating environment such as passwords time and date settings and printer connections While others such as Display options and ToolLoad options directly affect the console and tool operation Tool parameters Tool parameters are configured on the Setup page must be configured to suit the particular tool this includes delegating zones to act as probes or manifolds setting temperature monitoring cooling and coolant flow monitoring Operation limits also come under tool variables for instance warning and alarm levels and maximum
96. nt about 1 2 seconds so that it can scan the screen several times and take a good average reading A quick dab at the screen may give rise to reading errors which does not lead to satisfactory calibration During the process the cross hair target will be set to five different positions to cover the whole of the screen area How to Calibrate the screen 1 Open the Utils page and scroll to the bottom of the list to find the Calibrate Touch function Touch Recalibrate and then Set If required enter the System password and continue In the next option touch Enable to reveal the calibration screen TOUCH CONTROL The screen shows a cross hair target with an instruction that reads To calibrate screen please poke the cross hairs Using your stylus touch the centre point of the cross hairs OO coy O When you come away from touching the screen the cross hair target will move to another position 9 Repeat steps 6 and 7 until all five locations have been tested after which the screen will return back to the Utilities page Issue 9 6 Maintaining your controller 99 Self Diagnostic Tests Self Diagnostic Tests What is tested during a self diagnosis check The Controller has a diagnostic testing tool which allows you to check that every zone is functioning correctly The routine may be used e as an acceptance check e to see that a new tool is wired up correctly e asa maintenance aid to check that a wo
97. nue to work and isolate the controller then check normally supply wiring for presence of all three phases LINK This will occur if the console is Check that the network link is good switched to a remote controller with and or the remote controller is still a network link but it cannot establish switched on and available any communication with the remote unit The console can display the appropriate zones for the particular tool but it cannot relay any temperature information It shows a LINK fatal error in place of the actual temperature LOAD No load on that zone Only occurs Isolate the system supply and check when in manual closed loop mode the connections between the controller where the current is pre set The and the tool heaters Also check the current sensing circuit has not heater for continuity detected a current flow therefore the zone is flagged as not having a load OVER The RTD zone has detected a Check that a different RTD has not temperature in excess of 99 C This is an abnormal alarm because RTD circuits can only read from 0 99 deg so a fault must be suspected and investigated Meanwhile no control zones are affected been fitted Issue 9 6 User Manual for MTS Console 112 _ Troubleshooting Fault and warning messages N Z All the control cards are interrogated If every zone shows N Z and no cards in sequence on a working controller show or flash their SCA
98. oducts there is an Ultra option Triac Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the Triac column 2 Touch Set and if required enter your system Password 3 Inthe Configure Card Triac panel choose either On Board or Off Board Triacs for the selected zones 4 Touch OK to accept the new speed setting or Cancel to leave it unchanged Description This column allows you to select the triac to match the load and different cards have different needs K series Controllers with 1 2 3 or 6MOD cards use only On Board triacs and does not show this column X Series with 6 or 12 zone cards use only On Board triacs and does not show this column Setting any zone type to Spear automatically sets the Triac selection to Both Sensor Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the Sensor column 2 Touch Set and if required enter your system Password 3 Inthe Select Item panel choose either J Type or K Type Sensor for the selected zones or select Cancel to leave it unchanged Description All control and monitoring cards need to be correctly matched to the tool temperature sensor Issue 9 6 User Manual for MTS Console 64 Setting the Tool Parameters Pre configured Set Up values Select J Type or K type as suitable for Closed loop Control if in doubt check with the tool speci
99. onsole supplied may have contractual variations and differ in some specified options Supply Voltage 415 Volts 3 phase 50 60 Hz with neutral Other available include 240 380 400 and 480 volts in Star or Delta configuration Voltage Bandwidth Stable within 20 supply voltage swing Supply earth leakage trip 300mA note this is for tool protection Overload protection Miniature Circuit Breaker Mains Voltage output pattern Burst fired with zero voltage crossover Low Voltage output pattern Typically 24 volts AC User configurable between burst fired or phase angle Low voltage transformer 1 2 kW with optional upgrade to 2 kW Output overload protection High speed semiconductor fuse links Temperature control method Closed loop Auto or open loop Manual with HR Software Control range 0 472 Centigrade Celsius 32 881 Fahrenheit Temperature Scale Centigrade Celsius or Fahrenheit Printer Output Connector USB Port Data Communications RS 232 serial DB9 male connector Alarm Output Closing Contact Relay 5 Amp max T C Tool Connector Harting type Han A or equivalent Heater Tool Connector Harting type Han E or equivalent Issue 9 6 Introduction 11 Safety Instructions Safety I nstructions Warning DO NOT enter the cabinet without first ISOLATING the supplies there are unguarded terminals i
100. ontact PMS Systems Ltd for advice After all the parameters have been correctly set up then you may return to this Toolstore page later and add any appropriate Tool Notes Issue 9 6 Setup page Console Parameters 43 Creating a new tool slot Setup page Console Parameters Many Console parameters may be thought of as global because they affect either a how the console behaves for all tools eg temperature scale is Centigrade or Fahrenheit or b how all the zones behave within a single tool setting eg Boost time is set as one period of time for all zones that have any Boost temperature set There are two ways in which you may reach the Configure Controller options that lie behind the Config button Automatically This occurs whenever you create a new tool setting See the previous page for a full description Once the Console has completed the Card Detect routine for a new tool then it automatically switches you to the Configure Controller menu in the Setup page in order to configure the Console Parameters Manually In order to view or change a Global parameter 1 Check that no zones are currently selected and that the Set button is greyed out while the Config button is active 2 Ifany zones are currently selected then touch Cancel this makes the Config button active Configure Tool Autostdby Timer ii Options Alarm Time Delay in seconds
101. ool settings If there is any information stored in the selected tool bank slot then this process over writes new information into that memory slot Caution There is an option within this sequence to restore either all of the stored tools or just one selected tool To Restore a single Tool To restore a saved tool setting from a USB memory stick back into the tool bank 1 2 3 4 6 Open the ToolStore page Insert the memory stick with the data into the USB socket Select the tool tab where you intend to restore the incoming tool data Touch Restore on the opening page and enter the password if required to the on screen keyboard The tool setting data is read back into the tool bank slot and over writes any information that is in that memory slot Remove the memory stick To Restore a Tool bank page To restore a saved tool setting from a USB memory stick back into the tool bank hi 2 9 Open the ToolStore page Insert the memory stick with the data into the USB socket Select and empty ToolBank page touch Restore and enter the password if required to the on screen keyboard The tool setting data is read back into the tool bank slots and over writes all of the previous tool bank data Remove the memory stick Issue 9 6 Customising your controller 93 Networking to your Controller Networking to your Controller Touch Screen consoles can communicate over an Ethernet network in or
102. oolStore page 25 Training and Demonstration Mode 86 Triac 63 Troubleshooting 110 Upgrading your controller 106 User Password 33 Using On Screen Help 85 Using the tool store page 88 Utilities page 25 Warning and Alarm Levels 59 Watchdog feature 19 Welcome 12 X Series Controller Cabinets 17 Zone Grouping Display 23 Zone Status Information 21 Zone Type Options 52 Zoom Page 24 Issue 9 6
103. orded temperature data The Console appears to be working and it gives a real trace when Graph page is selected While in this mode you can train users how to set and modify temperatures alarms and other parameters and see the changes on the screen Selecting Demo Mode 1 Select the Tool Page 2 Select and load any tool Options Serial Port Select the method of 3 Select the required tool make a note ME correction for console default is of the current Connection value serial 4 Touch Connection and then Set 5 Inthe Select Item option touch ction Demo Mode 6 Accept the warning that this option will disable the Console While in Demo Mode you can select and load other tools By making sure that the next tool is connected to Demo Mode you can see the same pre recorded temperature data applied to your new tool De selecting Demo Mode Taking the console out of Demo mode is a simple reverse of the Selection routine 1 Select the tool page 2 Select the current tool being used 3 Touch Connection and Set 4 In the Select Item option select the original setting that was noted at Step 3 while selecting Demo Mode above 5 Restore the console and controller back to production if required nms Issue 9 6 Customising your controller 87 What is included in this section Customising your controller Your controller has a dedicated Tool Bank which enables
104. ower case such as in Names e Touch it twice which causes it to LOCK ON TO UPPER CASE e Touch it once more to reset all letters to continuous lower case When you have finished typing then touch either e Enter to enter your typed text or e Esc to leave the keyboard without saving or entering text The Keypad The Controller automatically displays the keypad whenever it needs a numeric input The keypad may be seen with differing variations according to the required input Numeric Input The Numeric keypad is offered whenever the system needs figures only It has the numerical touch pads that allow you to input numbers and a display line at the top to show your input There are also three function buttons Delete removes the last numbers typed in Enter inputs the displayed figures into the controller Esc closes the keypad and does not enter any input to the controller Issue 9 6 User Manual for MTS Console 28 Introduction Value Input The User Interface Temperature Value Input Two further rows of buttons are the Value and Mode buttons This version of the keypad is displayed wherever the controller may require more information such as controlling zones on the main page The three buttons on the Value row are Set enters the value to be a set point Add adds the value that you enter to the existing set point Subtract subtracts the value that you enter from th
105. ower Mode 47 Pre configured Set Up values 54 Print Out Facility 95 Rack Position 56 Remote Boost 77 Restoring tool settings 92 Run 72 Running a Self Diagnosis test 102 Running your controller 70 Safety Instructions 11 Saving everything to a Tool Bank 69 Saving tool settings 90 Screen Layout and Navigation 20 Select Slave Working 80 Self Diagnostic Tests 99 Sensor 63 Servicing and repairing your controller 105 Set up the Zones 52 Setting Password Security 33 Setting Probe and Manifold temperatures 69 Setting the Tool Parameters 56 Setting up the Operating Parameters 68 Setting up your controller 30 Setting Zones to No Display 64 Set up page 26 Shutdown 75 Shutdown Stage allocating zones to 66 Shutdown Temperature 50 Shutdown Timer 49 Slaving Guidelines 28 Specification 10 Issue 9 6 User Manual for MTS Console 122 Index Speed 63 SPI Interface 41 Staged Group Startup 74 Standby temperature 57 Standby Delay 49 Standby Mode 73 Starting and Stopping and Pausing 71 Start up 74 Startup Mode 48 Startup Stage allocating zones to 66 Stop 72 Stopping individual zones 72 Storage media 16 Switching On and Off 15 System diagnosis results 103 System Password 33 System Time and Date 31 System Utilities 31 T C Offset Value 62 T C Open Mode 56 Temperature Scale 50 Temperature Value Input 28 To select zones for testing 102 T
106. p chart and the differing values that are given to both Probe and manifold zones following type configuration Different zones types are pre configured to set values as seen in the table below Parameter Probe and Manifold Cards Other Monitoring eF T ge E Synchro Spear Rack Position slot address slot address slot address Alias blank blank blank Standby amp Boost 0 C or 0 F blank 0 C or 0 F Master Zone blank blank blank Warn Hi amp Lo 50C or 99 F blank 50C or 99 F Alarm Hi amp Lo 25 C or 45 F 25 C or 45 F 25 C or 45 F Max Temp Setting 350 C or 662 F 350 C or 662 F 350 C or 662 F Max Power Setting 80 blank 80 T C Offset Value 0 C or 0 F blank 0 C or 00 F Speed Auto blank Auto Triac On Board blank Both Sensor J Type blank J Type Display Group 1 blank 1 Startup Stage off off off Shutdown Stage off off off Analog Input blank 20 lit min Flow blank If these preset figures are not suitable for the tool in question then you can simply change them to your preferred values by following the next pages Issue 9 6 Setup page Console Parameters 55 Pre configured Set Up values Using the SetUp page to set up the parameters Setting each parameter follows a similar pattern that is explained below 1 Select the zones In order to set up any tool parameters you first need to select the zones Rack Type Address A
107. p page Console Parameters To select or modify Global parameters Selecting Percent will allow you to display the percentage power level that is being applied to the Tips during the Boost part of the mould cycle During the non boost period the zone displays the percentage power that is being applied to the body only Selecting Amps allows see the pre heat and boost current in the Tips During the non boost period the zone display returns again to the percentage power that is being applied to the body only Startup Mode Setting 1 Open the Setup page touch Cancel then Config and if required enter your system password In the Configure Controller System Options select Second Startup Select Master Follow Master Only or Stage as required In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and return to the original setting Description This option allows you to switch between three different starting modes which are MASTER FOLLOW a default option that ties the faster acting nozzles set temperature to slower manifold s actual temperature This results in a homogenous rise with all zone temperatures coming up together MASTER ONLY heats only the nominated Master zones first it does not STAGE apply any power to the subordinate nozzles until the Master zones have reached their set temperature see page 58 for information about confi
108. pen the ToolStore page Select the unwanted tool tab Touch Delete At the Delete Tool name prompt touch delete Tool to confirm your decision or Cancel to exit without deleting Backing up tool settings There is an option within this sequence to back up either the one selected tool or a complete tool bank 20 tools This latter option is designed to help restore a batch of tool settings when setting up a new or replacement MTS console Whichever option is chosen the MTS console uses a USB connected Memory Stick for backing up and restoring tool settings To save backup one selected tool setting ale 2 9 4 Open the ToolStore page Insert a memory stick into the USB socket Select the tool that you wish to backup Touch Backup and enter a user password if required to the on screen keyboard When the backup has been completed remove the memory stick from the USB socket and write the tool name onto the label To save backup all the tool bank 1 2 9 Open the ToolStore page Insert a memory stick into the USB socket Select the required tool bank page touch Backup on the opening page and enter a user password if required to the on screen keyboard When the backup has been completed remove the memory stick from the USB socket and write the tool name onto the label Issue 9 6 User Manual for MTS Console 92 Customising your controller Restoring tool settings Restoring t
109. pening and closing then a short time later the Autostandby Timer will time out and set the temperature down to its Standby level BOOST this switches the controller into boost mode NOTE 1 The remote input is only effective when the system is in RUN mode 2 This function defaults to BOOST when the controller has Spear zones 3 Only those zones that have Boost or Standby temperatures configured in their SetUp will respond to the remote input signal Power Mode Setting 1 Open the Setup page touch Cancel then Config and if required enter your system password 2 Inthe Configure Controller System Options select Power Mode 3 Select Percent or Amperes as required In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and return to the original setting Description on controllers with normal probes If you have control cards with current measuring coils fitted to your system then this option enables the main page to show either Current or Percentage Power in the zone boxes on the main page If there are no current measuring coils then the option should be set to Percent otherwise the Power Current display will show Zero on controllers with Spear Probes If your tool is using Spear and Tip Probes then this option decides whether you will see amps or percentage power while a boost signal is received Issue 9 6 User Manual for MTS Console 48 Setu
110. plied and what system it applies to Mode BOOST Status RS Manual Boost command for simple single element nozzles If a Boost condition is manually initiated for all or individual zones then the message bar shows BOOST in black letters on a yellow background The BOOST message persists for the same Boost Time period that has been preset in the Configure Controller Setup When that preset time expires the nozzle returns to normal running temperature and the Status Bar returns to showing RUN Remote Boost command for simple single element nozzles If a boost Command is received from an external source via the I O board then the message bar shows M C BOOST as black letters on a white background The time that the message displays for is dependant on the external signal If the external signal is brief for example it lasts 1 second and the Boost Time is set to something longer perhaps 3 seconds then the nozzles are boosted for 3 seconds after which they return to normal level The M C BOOST signal is also displayed for 3 seconds after which it returns to RUN If the Boost Time is set to 3 seconds and the external signal lasts for 4 seconds then the nozzles are still boosted for 3 seconds and then return to their nominal value However the M C BOOST message in the Status bar is displayed for the longer 4 seconds while the external signal is present even though no boost current is being applied for the last second Remote Boost
111. pt the changes made touch Cancel The configure menu disappears and the system reverts back to any previous selections that may have been made Issue 9 6 Setup page Console Parameters 51 SetUp Page cards that may be detected The SetUp page displays a grid array that you can reveal by using the scroll bars at the right and bottom of the screen Cards that are initially detected by the New Tool process are shown in the left hand column while the rest of the grid remains blank The following is a list and description of the cards that may be detected by your console Card and Description gt 6 zone card at 5 Amp rating for Probes Issue 9 6 User Manual for MTS Console 52__ Setup page Console Parameters Using the SetUp page to set up the Zones Using the SetUp page to set up the Zones How to select zones single or multiple Before you start to set up the various zones it helps to pause and see how this page works To set up a tool you need to select the various groups of zones and then configure the various parameters Select the zones by touching the white boxes in the Type column Touch the boxes that are next to the particular cards that you intend to configure Touching el i Mode RUN A Message Status one box selects that channel which then turns to blue with white text Touching the box again deselects the zone Touching more s
112. r target slave zone according to the mode that you chose in the previous step To correct a setting during this step Delete undoes your last entered figure 3 Touch Enter to confirm your settings or Esc to return to the main page without accepting the new choice and values Saving everything to a Tool Bank Once you have configured all the initial settings transfer all the settings into the tool bank slot which you named in Stage 1 so that they may be re used at any time tool 2 Davids Tool TOUCA Can OL Saving your tool configuration Select the Tool store tab to display the tool store window 2 If your new tool is not selected then touch it now to open that memory slot 3 Touch Save to save all your new configurations settings into this new slot Issue 9 6 User Manual for MTS Console 70 Running your controller Setting Probe and Manifold temperatures Running your controller This section of the manual is divided into four main areas that are concerned with e the basic Starting and Stopping along with Boost and Pause controls e changing settings while the controller is running This allows you to make changes while the controller is running so that you can adjust temperatures and change any parameters to cope with varying operating conditions e inspecting historical graphs that can display how any zone has behaved over the last 5 or 30 minutes or even the la
113. r MTS Console 76 Running your controller Manual Boost Manual Boost There are two methods of applying manual boost which are described below However the use of zone temperature Boost is dependant on the following There are two quantities that determine boost the boost temperature described on page 58 and it s time described on page 46 It is this period of time that takes precedence within a boost command Once the boost period expires then the extra heating power is removed regardless of whether the zones actually reached the temperature that may be called for by the zone SetUp parameter Boost only raises the temperatures of zones that have a boost value configured see Console parameters on page 58 for Spear tip nozzles only the Tip temperatures are raised see page Error Bookmark not defined Boost mode is only available while the system is in Run mode Boost Mode all configured zones Boost Mode provides a means of temporarily raising zone temperatures the feature may be used on its own or as a means to recover from Standby Mode 1 2 3 4 Open the main page Touch Mode to activate the Mode menu Touch Boost At the confirmation prompt touch OK to confirm your request or Cancel to defer the action Boosting selected zones If you need to boost just some of the configured zones in order to clear one or more zones then you have a Single Zone Boost facility This is available from the m
114. r Password 1 Ol Gee Or 8 Touch Menu and open the Utilities screen Scroll down to view Edit User Password Touch the adjacent right hand box Touch Set The keyboard appears with the prompt PASSWORD Touch type your existing System password to establish your authority If you have just set a new System Password at previous screen then this step will not apply In the keyboard that appears when the prompt reads NEW USER PASSWORD touch type your new User Password and then Enter Re type in the new User Password for confirmation and touch Enter Touch Back twice to return to the main page About password active times There is a password timer function in used to limit System or User access time Once you have entered a User level 1 password then it remains active until the password timer expires in which case you must re submit the password to make further changes If however you make more changes within the configured time out period it resets the timer This allows you to continue setting up parameters beyond the timer period and not until your last use does it eventually time out to render the password inactive When you have entered a System Level 2 then it remains active on that particular page where it was given or for any other page where any password System or User is required As with the User password the password timer does not start to time out until you stop making any changes that require t
115. r your system Password In the Keypad that appears touch type the Standby value ie the amount by which you want to reduce the running temperature 4 When finished touch Enter to accept the new entry or Esc to reject it and return to the Setup page Limits The maximum Standby value that you can set is 250 C or 450 F Description A Standby command allows you to temporarily reduce the temperatures of selected zones until a Run command restores the zones to their normal operating temperature The value entered here allows you to individually set that temperature depression on a zone by zone basis Any zones are left at zero will not respond Issue 9 6 User Manual for MTS Console 58 Setting the Tool Parameters Pre configured Set Up values to a standby request but stay at their normal operating temperature The Add and Subtract buttons allow you to trim the temperature Boost temperature Setting 1 Limits Open the Setup page select those zones that you wish to configure and touch anywhere in the Boost column Touch Set and if required enter your system Password In the Keypad that appears touch type the Boost value ie the amount by which you want to increase the running temperature When finished touch Enter to accept the new entry or Esc to reject it and return to the Setup page The maximum Boost value that you can set is 250 C or 450 F Description A Boost comma
116. ram such as CuteFTP Type in the console IP address to your browser or Issue 9 6 Maintaining your controller 97 Export Facility FTP agent and then you can navigate to the tmp directory and access the CSV data file Once the data file has been unzipped it can then be read by any spreadsheet program so that you can examine how the various zones have performed over the last 24 hours that the console has been working This 24 hours may represent a continuous period over the last day or if the console has not been in continuous use it is collated into chunks of time over a number of days or even weeks If the latter then the data identifies the time and date for each chunk of information Issue 9 6 User Manual for MTS Console 98 Maintaining your controller Checking Touch Screen Alignment Checking Touch Screen Alignment If at any time you should find that there appears to be a misalignment between where you touch the screen and what part responds then there is a re alignment facility that can be found on the Utilities page This runs a brief target and touch calibration routine which can realign touch to response While running the calibration function you should use a suitable stylus to make a small point contact are with the screen rather than use your finger which would have a large contact area and lead to possible errors To maintain accuracy you should touch and hold the stylus in position for a short mome
117. rd a second time However if your subsequent settings come much later then the password timer may expire and you will need to enter your password again All the following parameters are found within the Utilities page although not necessarily in the following order Software Version This shows which version of the software is installed it is not user configurable If you need to contact PMS Systems Ltd regarding any technical issues then it is often helpful to have the software date to hand Setting the System Time and Date We recommend that you set the correct time and date so that any hard copies of Tool Test or Export Data will be correctly marked up when printed out To adjust the Time touch Set and if asked enter your Password In the keyboard that appears set the current time and then Enter You can set the Date similarly Language You may select a preferred language for the screen and online help This option offers a drop down selection for different screen language options select any language and then touch OK NOTE after selecting a different language the console will temporarily shut down as it restarts in the new selected language If the system is in RUN mode then the Control cards will maintain the working temperatures during this brief change over Issue 9 6 User Manual for MTS Console 32__ Setting up your controller Setting up System Utilities Controlled access though password
118. rdless of the condition of the external Boost signal The following graph shows examples of how the Boost Display may vary Start of End of End of End of External External Internal External Boost Signal Boost Signal latch Boost Signal Y less than 4 secs Y 4 secs more than 4 secs lt lt lt External Boost Signal goes high short circuit to call for Boost and may vary in length If Delay Time Boost Time is jess than 4 secs Example 1 then intemal latch holds BOOST indication on the Probe A7 TipTemperatue Status Bar until end of 4 second latch has a short delay lt gt lt lt lt Tip Temperature Power Level Pow 28 lt lt lt Body Tip Tip boost level Tip pre heat Body i lt lt lt Power level seen in Zone Window Power ETS wafat lt lt lt Runn Mode displayed in Status Window If Delay Time Boost Time is more than 4 secs Example 2 then BOOST indication on the Status Bar stays until end of the Dealy Boost Time Body Tip Tip boost level Body If external signal is longer than Delay Boost time and longer than 4 seconds then it holds the Boost indication Example 3 on the Status Bar until External signal expires Body Tip Tip boost level Tip pre heat Body nms Issue 9 6 Running your controller 79 Changing Te
119. reinstate the controller back to production running Procedure for an MTS Console without USB connection Equipment Required 1 A suitable PC with an Ethernet port 2 Acrossed Ethernet cable suitable for PC to PC connection 3 The upgrade files from PMS Systems Ltd These will comprise of two or more files one of which will be named do_this_ code and the subsequent files will contain the upgrade program which the do_this_code program will install 4 A File transfer program rcFTP_setup exe supplied by PMS Systems Ltd Issue 9 6 Maintaining your controller 107 Procedure At the MTS Console Make sure that the MTS console is switched on and open the Utilities page Upgrading your controller Make a note of the current software date for later reference Check the Console IP Address If there is no current address or if the current address is unsuitable ie the same as your PC then touch Set enter the System password provide a suitable IP Address for instance 192 168 1 222 Install the supplied rcF IP transfer program and reboot the PC 2 3 and touch Enter At your PC 4 5 Check that the PC has a unique IP address one is different to the MTS Console Do this by opening Network Connection within the Control Panel then right click on the LAN icon and select Properties 6 At the next properties box select the General tab Select Internet Protocol TCP IP and click on Propert
120. rking tool is functioning correctly This routine allows the controller to step through all the zones heating one at a time and checking that proper 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 you can choose to stay on the testing page or return to the main page These give you a different perspective on the test in progress and you can switch between them 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 On the Testing page the Testing Rack Position box displays information about which zone is under test and that it is in Cooling phase During the cooling all zones are checked to see that none experience a significant temperature rise 4 After a period of time it enters the Heating phase and 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 Heat Time stipulated in the Tool Test Parameters 5 Provided that the zone under test exceeds the Good Ris
121. rmal expansion Configuring the tool to enable Master Only Startup ensures that only those zones that are set as Master usually one or more manifold zones are initially switched on all other zones are set to Zero Once the Master Zones reach their set working temperature then the remaining zones are switched on for the complete tool to reach working temperature Staged Group Startup To This option is similar to the Master Only startup detailed above but it offers more stages in the startup pattern for complex stack moulds In Stage Startup each nominated group of zones is switched on in sequence which allows the first group of zones to be energised and allowed to reach their nominal operating temperature before subsequent groups are heated up Allocating zones into discrete startup stages is detailed in the Setting up procedures on page 66 Enabling Staged Startup is switched within the Configure Controller options which may be accessed via the Setup Page and Configure option and is detailed on page 44 use Startup Made 1 On the Display page touch Startup if it is immediately available otherwise touch Mode and then Startup in the Mode menu 2 At the confirmation prompt touch OK to confirm your request or Cancel to defer the action 3 The system initiates the pre configured Start up pattern while the top button changes to Shutdown The Mode window shows STARTUP as a flashing sign 4 When normal temperatures are re
122. rmation prompt OK to confirm your request or Cancel to defer the action Notice that the Stop button now reads Run Selecting Stop does not remove voltage from the heaters it switches off by setting all the target temperatures to Zero Do NOT try to change fuses or Warning disconnect units while in this mode Stopping individual zones To switch individual zones to off 1 Open the main page 2 Touch the zone or zones that you wish to switch off 3 Touch Set 4 At the following keyboard enter the User password to confirm your authority At the keypad touch Off and OK to confirm the action On return to the main page the stopped zones display the Off symbol no 7 Toreset the zone s repeat these steps and touch On the temperature setting will be restored from memory WARNING Selecting Off does not remove voltage from the heaters it switches off by setting the target temperatures or current flow to Zero Do NOT try to change fuses or disconnect units while in this mode rms Issue 9 6 Running your controller 73 Starting and Stopping and Pausing Standby Mode This mode is available for times when the mould tool needs to be paused Under this command any zones that have some Standby temperature configured are reduced in temperature to prevent degradation on certain materials while standing in the tool Read about setting up Standby temperature on page 57 1 Open the ma
123. rouping exercise you can verify the finished results by returning to the main page and scrolling through the different pages As each group is separately shown the message in the lower status bar tells you which group is currently displayed in the window Proper use of the Zone Alias naming feature reinforces this facility If for instance each zone is dedicated to a different colour or material then use the Alias feature to name the zones so Material Probe Manifold Manifold colour Alias Alias 1 Blue Blue 1 32 1 32 Blue 33 35 1 3 2 Yellow Yellow 1 32 33 65 Yellow 33 35 4 6 3 Red Red 1 32 66 98 Red 33 35 7 9 4 Green Green 1 32 99 128 Green 33 35 10 12 Zone Display Grouping has no effect on the operation of the controller It exists only to facilitate the operator control interface in situations where a tool might have distinct groups of zones that are more easily monitored as separate groups Issue 9 6 User Manual for MTS Console 66 Setting the Tool Parameters Pre configured Set Up values Startup Stage allocating zones to This option is only available if you select Stage as a Startup Mode option in the global Config settings Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the Startup Stage column Touch Set and if required enter your system Password In the Keypad that appears tou
124. rthermore they must not be used in an explosive atmosphere or where there is a possibility of such an atmosphere developing About the manual The following table describes the various user sections Section Description Introduction The first part of this manual contains a brief technical description of the console and the cabinet followed by Safety Instructions and Installation notes The Introduction pages introduce the various interface screens that are found within the Console and then describe the operating philosophy that facilitates precision temperature control Setting up your controller This section describes how to set up the controller from basic steps as if it were to be used in a new environment Normally all new controllers are supplied with all the Set up details ready configured to your needs However it would be necessary to consult these pages should you ever need to reconfigure a controller to a new tool or environment Running your This section is for operators it describes how to Start Stop and Pause the heating load It deals with making temperature changes and controller describes how to interrogate the controller about past performance The final pages of this section describe the various alarms that may be displayed on the controller Customising This section describes how to use the ToolStore to save permanent changes to tool settings These may be required either to u
125. s 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 normally supplied according to your requirements in either a star or delta supply although some models may have a dual supply options which accepts either Star or Delta 3 phase supply Cable Marking Supply Description Li Phase 1 L2 Phase 2 L3 Phase 3 N Neutral Earth Symbol Earth N B The delta supply cable does not have a neutral wire Cable colours may vary therefore wire up according to the Cable Markings Issue 9 6 User Manual for MTS Console 118 APPENDIX A 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 J Black White K Green White 1 3 Loom Power cables The colour of the power cables depends on whether the controller is supplied for star three phase supply or delta three phase supply Three phase Live supply Neutral type return star brown blue delta brown yellow 1 4 Alarm Output Auxiliary Input An option cabinet connector provides an alarm output from an internal set of relay contacts Using an external power source the
126. s 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 Watchdog feature The controller card CPU has a watchdog timer that must be reset by the system every 3 milliseconds If for any reason the software fails to reset the timer the zone power is set to zero to protect the tool against over heating The controlling card resets to the auto tune procedure and power is increased in progressive steps until correct temperature control is re established Issue 9 6 User Manual for MTS Console 20 Introduction Screen Layout and Navigation Screen Layout and Navigation The main page has a Menu button at the bottom of the side buttons that activates the navigation screen jy From this screen you can access the D a 7 Toolstore Diagnose Utilities other screens which are Toolstore to select other tool amp D J Setup Help Back options Diagnose for self diagnostic testing i Hode RuN Display Group 1 Status EMAA Utilities to set up essential global parameters Setup to configure specific tool parameters Help to access the online manual Back to return to the Main page On the right hand edge of each page are the various buttons which
127. s When you first use your Touchscreen controller you find as you go through some pages that some functions are protected by password access Wherever a password is required then a prompt in the message window at the bottom of the screen indicates whether the particular function requires a User or a System password Three levels of control If the User Password option is set to Enabled then there are three levels of control 1 Open Level includes various functions that need no password such as Start and Stop 2 User is a Level 1 password which gives low level access to e switch the tool on and off e alter temperatures e select different tools 3 System is a Level 2 password which gives high level access to e all user level functions e set the user password e re configure the settings for a new tool e store and load new tool settings to from the disc Two Levels of Control If the User Password option is set to Disabled then all those functions that would normally need a User Level 1 Password become Open Level and no longer require any Password to access Only those higher functions that require a System Level 2 password retain their Password protection Password Application Table Here is a detailed list of what level of password is required for various functions on the different pages Page Screen No Password required to Level 1 User password required to Level 2 System passwor
128. s the zoom page Probe 1 st BE Power 10 Zone Settings Speed Setting Auto Offset Value 9 Maximum Temp 350 C Maximum Power 808 Master Zone No Master Hode RUN A Message Status The top of the page shows the zone name or alias in its appropriate colour background along with live temperature information which is relayed from the main page The lower half shows the current setup configuration which can be scrolled to see all the information Meanwhile the ZoneUp and ZoneDn buttons allow you to browse other zones without having to return to the main page and reselect If the selected zone is a spear type then the extra Tip information is shown at the upper right hand side of the screen as seen here Spear 1 pore Pre Heat Sga f Boost Pow st DE ly Tine Pauer 128 Boost Time Zone Settings Speed Setting Auto Offset Value Oo Maximum Temp zoe Maximum Power 808 Master Zone No Master Hode RUN Display Group 1 TOUCH CONTROL Issue 9 6 User Manual for MTS Console 82 Running your controller Checking zone past performance graph Checking zone past performance graph Your controller can record and display the temperature history for any zone over a period of time It has the option to view the historical graph for the last 5 to 30 minutes depending on the selected range Inspecting the last 5 to 30 minu
129. se the your T controller on different moulding tools or to save and recall other controller settings Maintaining Maintaining your controller is mostly concerned with keeping it in order your checking records and settings and running self diagnostic checks controller As there are no user serviceable parts inside the Touch Screen controller then electro mechanical maintenance comprises mainly of keeping the unit clean and changing air filters Trouble This final section lists the various Error messages that may be displayed shooting along with possible causes and actions It also has guidance for some possible faults and details about fuses and replacing them Issue 9 6 Introduction 13 Where to use this equipment Where to use this equipment The display console and controller cabinet together are designed for use in the plastic injection moulding industry as temperature controllers for third party hot runner systems as commonly used in mould tools They 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 The HRC cabinet and Touch Screen console should be installed in a clean dry environment where the ambient conditions do not exceed the following limits e Temperature 0 to 35 C e Relative Humidity 90 non condensing When in use this equipment does no
130. ses if any Water Flow zone sees a 2nd stage Alarm or a Fatal Error Stopped The relay closes to confirm that the console has been stopped by one or more external sources nms Issue 9 6 Setting up your controller 37 Setting up System Utilities Other Utilities Parameters There are a number of controller parameters that are also setup within this page Limit Exceeded Setting 1 Touch Menu and open the Utils page 2 Scroll down to view Limit Exceeded 3 Select the parameter by touching in the adjacent right hand box 4 Touch Set 5 If required type in your System password at the next prompt 6 Select Disable or Enable as required 7 Inthe Limit Exceeded box touch OK to accept the new setting or Cancel to reject it and return to the original setting 8 Touch Back to return to the main page Description This option sets the response of the console when an operator tries to set a zone temperature that exceeds the preset limit DISABLED means that an attempt to set the temperature above the limit is non effective and the set temperature remains unaltered after touching the Enter button ENABLED means that if an operator attempts to raise a current temperature from 350 to 450 when the reset limit is 400 then the set temperature will rise to the 400 degree limit value and no more Blanking Delay Setting 1 J Limits a Touch Menu and open the Utils page Scroll down to v
131. shows how a proportion of the offset is used while the tool is below its set temperature Note that the need for T C offset is not exclusive to such probes as first mentioned this facility could have other uses for different production situations Corrected Offset at low temperature Pa Positive Offset Set O Temperature amp i S pee Offset Ambient Zero Issue 9 6 Setting the Tool Parameters 63 Pre configured Set Up values Speed Setting 1 Open the Setup page select those zones that you wish to configure and touch anywhere in the Speed column 2 Touch Set and if required enter your system Password 3 Inthe Configure Card Speed panel choose a preferred control speed for the selected zones 4 Touch OK to accept the new speed setting or Cancel to leave it unchanged Description The Speed parameter determines how fast the zone will respond to or anticipate changes in temperature While there are manual settings of Slow Medium or Fast the default setting is auto This allows the zone to run an auto load sensor program during its first start and determine which of the three manual settings best suits the load After a first run the Zoom page will show the setting as either manual Slow Med or Fast or Auto setting A Slow A Med or A Fast However there are some miniature probes on the market that may require a very fast speed setting and for these pr
132. st 24 hours With such information being so easily available it makes problem solving easier to pinpoint e recognising what alarms may be generated and what they mean and what to do about them What is included in this section Starting Stopping Pausing how to put the heaters on hold for a short time Looking at Startup and Shutdown methods Boost how to apply a brief raise in temperature Using the main page to control and monitor temperatures Using Slave Mode to compensate for a failed thermocouple Looking at temperature history for the last 5 or 60 minutes Alarms what alarms may be seen on the controller nms Issue 9 6 Running your controller 71 Starting and Stopping and Pausing Starting and Stopping and Pausing Other than simple power on Run or Power off Stop your controller offers more options to Start Stop and Pause your moulding tool heaters Touching Mode reveals these extra functions which are all described in the following pages You can use the main page to control both the global operating of the system such as Run and Stop as well as the individual zone operations such as temperature and mode changes In order to accommodate this range of functions the top most function buttons have different functions that change according to need Probe 2 Probe 4 Probe zz Ka 250 Pow on TOUCH CONTROL While no zone is selected with its borders highlighted in blue th
133. t emit audible noise in excess of 10dbA Controller Tool Connections If the main power switch for the controller has a red handle on a yellow plate then the controller should be connected to an independent supply that stays live when the main moulding tool is switched off If the controller has a black handle on a silver grey background then you should connect it to a sub circuit of the main tool so that the controller is isolated when the main tool is switched off The various connections between the controller cabinet and your system using the cables supplied with the equipment are shown in the looms or cable data sheet and Appendix A Equipment failure through mis wiring Before you energise the system pay special attention to how the supply to your controller is wired and how it is connected to the mould Lack of attention to detail causes errors such as incorrect wiring of mains supply phases into the controller crossing heater supply feeds with thermocouple detection although this error can be eliminated by the adoption of PMS Standard connections In such cases wiring errors have caused equipment failure PMS Systems Ltd cannot be responsible for damage caused to the controller by customer wiring and or connection errors Controller Power Supplies The control cabinet can be manufactured to accept a wide range of supplies and sequence of phases Refer to the serial plate in the controller cabinet for confirmation of th
134. tdown is chosen with no Master Zone selected then the system automatically switches over to Stop Mode With the Startup Mode set to Staged Shutdown consecutively switches off the zone groups in timed intervals and in the order as nominated by Shutdown Stage configuration The Shutdown Timer within the Configure Controller section sets the time delay for between each group being switched off and therefore determines how long it takes for the complete tool to cool down Note If the Shutdown timer is set to Zero then the system will still attempt to carry out a Staged shutdown but will use a fixed temperature of 100 C as a shutdown trigger level rather than a fixed time period Accordingly the first group is switched off and once it has cooled down to 100 C then the second group is switched off and so on until all groups are switched off However in some tools the thermal conduction between heated and cooling groups could considerably extend the time that it takes for any group to cool down to the set level As a result the Shutdown process would again be very slow To select Shutdown Mode proceed as follows 1 Open the main page 2 Touch Mode to activate the Mode menu 3 Touch Shutdown 4 At the confirmation prompt touch OK to confirm your request or Cancel to defer the action Once the Master manifold reaches zero or room temperature then the system automatically assumes a Stop mode Issue 9 6 User Manual fo
135. te holder on the front edge of the PCB Class 20mm Glass Fuse Antisurge Rating 315mA Fans The CX Series Controller has a single fan to assist cooling The fan has a supply fuse of the following characteristics Class 20mm Glass Fuse Antisurge Rating 315mA If the fan has stopped working then first inspect the unit to see if there are any blockages or objects fouling the impellers Once you are certain that the fan is free to rotate then proceed to check its supply fuse The fan fuse is located in an in line fuse connector inside the main case Controller Cards The current controller card has protection fuses for both the T C input and for the heating load output 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 Output Fuse Type HRC High Speed Card type Six Zone Three Zone Two Zone One Zone Fuse Rating 5A 15A 20A 30A Input Fuse Type Surface mount quick blow Code PMS part 62MAQBSM Fuse Rating 62mA nms Issue 9 6 APPENDIX A 117 APPENDIX A HRC Wiring Standards The following standards only apply to controllers wired to PMS standard Other specifications may have been stated when the controller was ordered Please refer to the supplied specification detail
136. tes To view a temperature trace history select one or more zones and then touch Graph The graph page then displays a live trace of current temperature against a 30 minute time trace If more than one zone was selected then up to six may be seen at any one time anda ee ees colour key at the bottom of the page to shows which trace represents which zone To see other zone traces then simply touch ZoneUp or ZoneDown to alter the zones currently on display There is also a means to magnify the scale however once this magnification is selected the screen freezes its traces at that point in time No further live updating occurs but scales can be expanded to see closer detail on the historic trace Magnifying Views After touching View the graph trace is static and no longer updates in real time However you now have ZoomX and ZoomX which zoom the time scale from 30 minutes down to 5 minutes full scale Similarly you have the two buttons marked ZoomY and ZoomY which zoom the temperature scale from 250 degrees down to 7 5 degrees full scale While using the Zoom feature small arrows appear on the scale graticules If while zooming in the trace moves out of the window you can drag the appropriate scale to move the graph into the main viewing area Also r o age dg gg ee when you reach the end of either scale oe n aes the small arrows will disappear to Hoge RuN A Hessace show
137. the bottom of the panel to accept your parameter values alternatively touch Cancel to leave this screen without changing any existing settings For an overview of all these parameters and how they are currently set touch the View button Configure Tool Option Current Setting Alarm Time Secs Al Boost Time 0 Secs Display Mode Sorted Input Signal Standby Master Only Disable Power Mode Amperes Startup Mode Master Standby Delay Mins f Action rine o Issue 9 6 Setup page Console Parameters 45 To select or modify Global parameters Alarm Time seconds Setting 1 Open the Setup page touch Config and if required enter your system password 2 Inthe Configure Controller box select Alarm Time and touch Edit 3 Inthe Keypad enter the required Alarm time and touch Enter In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and return to the original setting Limits The maximum setting for Alarm Time is 999 seconds Description Use this to configure a brief delay between an alarm condition being detected and an external alarm being sent This allows you to prevent fleeting deviations causing nuisance alarms or to compensate for slow reacting systems Autostandby Timer minutes This option is dependant on selecting AutoStandby as an Input Signal option Setting
138. ting 1 O SRG sk Touch Menu and open the Utils page Scroll down to view SPI Interface Select the parameter by touching in the adjacent right hand box Touch Set If required type in your System password at the next prompt At the numeric keypad enter an address between 1 and 224 your IT department should be able to provide the appropriate address number for the command machine Touch ENT to accept the new address or ESC to leave without making any changes The parameter now shows the SPI Address and lt Active gt provided it sees the remote machine is connected and running Alternatively it shows the SPI Address and lt Inactive gt if the console does not detect any SPI messages for a period of 30 seconds Description You can configure the MTS console to communicate through the serial port to a remote machine using SPI protocol Once the SPI Interface parameter has been set to an appropriate address the console announces itself to the remote machine as a Self tuning General Purpose Temperature Control The remote operator is then able to send commands such as adjust zone temperature s and the MTS console will respond accordingly To Disable the SPI Interface Repeat the above procedure but use the address 0 zero The parameter now shows SPI not running to confirm your new setting Issue 9 6 User Manual for MTS Console 42 Setting up your controller Creating a new tool slot Creating a new
139. tool and print out the tool details similar to the SETUP printout without having to load the tool DIAGNOSE page prints out the results of a tool test once it has finished UTILS page SETUP page GRAPH Page prints out all the current Utility settings for the tool currently loaded prints out the whole SetUp page with all the current settings for the current tool prints out an image of the graph trace while not in any Close up View mode Issue 9 6 User Manual for MTS Console 96 Maintaining your controller Export Facility Export Facility You can extract the last 24 hours of zone performance data as a zipped spreadsheet This data is written in a CSV comma separated value form and then compressed into a zip file before exporting If the Console has a USB connection then Export will write the zipped CSV file onto a memory stick which is plugged into the USB socket If there is no USB connection then it will write the same file into its tmp directory System Setting Machine Name newraid Domain Name pmssystems com IP Address 217 10 148 148 Net Mask 255 255 255 224 Obtain Address Disable User Password HEHEHHE System Password HHHH Password Timer 5 Minutes Mode RUN A Message Status M TOUCH CONTROL To extract the data using USB port and Memory Stick 1 Insert a USB Flash Memory Stick into the USB port 2 Select the Utils page and
140. ts The maximum period for Boost Time is 9999 seconds Description This option allows you to set how many seconds the zone temperature is boosted for whenever Boost Mode is selected To set the boost time period touch the Edit button to show the keypad and key in your required setting Button One Mode Setting 1 Open the Setup page touch Config and if required enter your system password In the Configure Controller Options select Button One Mode Select Run or Startup as required In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and return to the original setting Description You can use Button One Mode to set the preferred starting option It offers a choice between RUN and STARTUP on the first or top button on the main page Whichever starting mode is selected here other modes can still be accessed via the MODE button Display Mode Setting 1 Open the Setup page touch Config and if required enter your system password In the Configure Controller System Options select Display Mode Select Sorted or Mixed as required In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and return to the original setting Description This option allows you to choose how the main page and set up page group the zones e Sorted mode separates all the zone types into a pre determined order which is Spear zones first fo
141. ture or mode b Zoom Page Touch Zoom for this page which shows live data for the Actual Set and Power levels for the selected zone in the upper half Speed Setting Offset Value a table with the zone data from the maximum Temp 5C jaximum Power 80x setup page in the lower half Master Zone No Haster Hode RUN A Message TOUCH CONTROL c The Graph page Touch Graph to see a page with graphs showing temperature against time for up to six zones at a time 20 15 10 Probe 1 RUN A Message TOUCH CONTROL Ams Issue 9 6 Introduction 25 Other pages accessible from the Navigation Screen Other pages accessible from the Navigation Screen The ToolStore page ToolStore is a tool bank in which you can store up to 100 tool configurations It also enables you to backup tool settings to storage media and restore them to the controller whenever they are needed again The status of the displayed tool configuration is colour coded to indicate Black The store has a name but holds no data Blue There are settings saved in this tool bank Purple A tool that is currently being used with saved data Description tool 1 tool 2 Davids Tool A test descrip kill fred test p word test out instr hella Red This indicates a tool that is currently being used but whose data has been modified
142. ubsequent boxes adds them to the initial selection Any configuration that is subsequently selected is applied to all the highlighted zones Touching non adjacent boxes and then the Range button on the right hand side extends your selection to include all the zones in between the first two zones selected Zone Type Options Probe Manifold or Not Used The different control cards 1MOD 2 MOD 3MOD and 6MOD can be used for a variety on heater zones however these fall into two main types which may be either Probes or Nozzles and Manifolds of different sizes The Configure Card slot allows you to set the zones to either Probe or Manifold so that the control card can match its load A third option is Not Used which is available to switch off any excess zones that are not connected to a load This may occur where 3 6MOD cards give 18 zones but only 16 are required for a particular tool in such case the last two spare zones can be configured as not used Once a type has been selected then the Setup page is populated with pre configured parameters These values may easily be modified to suit your own circumstances rms Issue 9 6 Setup page Console Parameters 53 Using the SetUp page to set up the Zones How to set the Zone Types As seen earlier the Setup Grid displays various Icons in the first column to show what cards have been detected However none of the cards know their function At this
143. urn to the original setting Limits The maximum period for Shutdown Timer is 99 minutes Description This sets a delay period that is used to hold on successive groups during a Staged Shutdown It sets in minutes the time that successive zone groups must wait before each switches off Setting this option to zero makes the timer in effective so that Staged shutdown is reliable solely on temperature Issue 9 6 User Manual for MTS Console 50 Setup page Console Parameters To select or modify Global parameters Shutdown Temperature This option is dependant on selecting Stage as a Startup Mode option Setting 1 Open the Setup page touch Cancel then Config and if required enter your system password In the Configure Controller box select Shutdown Temp and touch Edit In the Keypad enter the required temperature and touch Enter In the Configure Controller box touch OK to accept the new setting or Cancel to reject it and return to the original setting Limits The Shutdown Temperature setting defaults to 0 which represents an extremely long shutdown interval The highest shutdown temperature permitted is 260 C or 500 F and if this set value is equal to or higher than the normal temperature then it has no effect and the shutdown interval becomes dependant on the Shutdown timer Description During a Staged shutdown each stage must cool down to a preset value before
144. use the beacon to light but not create an accompanying audible alarm nms Issue 9 6 Running your controller 85 Using On Screen Help Using On Screen Help The micro touch console has a limited on screen help section that is text based only The Menu has a Help button that takes you into a help section with information on the following topics e Start Stop amp other universal run modes e Individual zone Boost amp Stop modes Back Formira Contents Exit e Temperature adjustments e Closed Open loop or Slaving About Running About Diagnose e Main page display options About Utils About Toolstore e Graphical Temperature History a g N e Graph Zoom operation Help Index e Lower Status Bar amp Alarms e Card indicators amp alarms TOUCH CONTROL Issue 9 6 User Manual for MTS Console 86 Running your controller Training and Demonstration Mode Training and Demonstration Mode Your controller has a Demo Mode that can be used for training or demonstration purposes While this mode is engaged the controller will not communicate with the associated Controller Cabinet therefore we recommend that you ensure that the system is idle before using the Demo Mode Facility About Demo Mode While in Demo Mode the console behaves as normal and all the usual facilities are available The main difference is that Demo mode feeds every zone within the selected tool with a stream of pre rec
145. version cabinet If the early version information to hand console does not recognise an alarm that has been generated by a later generation control card then it cannot display an appropriate alarm message The console software has a routine to check incoming messages and it flags up a HELP message if such a condition arises HIGH The water flow sensor has detected These are both monitoring conditions a high flow rate only and neither will cause any LOW The water flow sensor has detected snutdown Ob Pelee action However you should check that the coolant a low flow rate water system is not blocked or leaking to ensure that no overheating occurs LINE No mains supply synchronisation There is a phase detection circuit on pulses being received The three each K Series card and a common phase supply is used in a cross over phase detection circuit on all other detection circuit to generate timing controller types Although a fault in pulses for accurate phase control and such circuits may cause the LINE error firing the triac If the phase message such fault is very rarely detection fails on one or two phases seen The most common error is then there is no pulse to use to either the absence of one phase or if measure phase angle and the LINE a plug has been re wired incorrectly a error message is generated swapped phase and neutral If a LINE Meanwhile all circuits on the healthy error message occurs then switch off phases will conti
146. while it was being tested User Aborted Test You aborted out of the test by pressing Cancel 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 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 Issue 9 6 User Manual for MTS Console 104 Maintaining your controller System diagnosis results 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 OC the controller would not work with t
147. wish to be able to switch on the fly In Run mode or Disabled if you wish to prevent such changes and force the operator to shut down to swap tools How you use this option will depend on local circumstances and the following may be helpful If your ToolStore contains variations of the same basic tool each with the same number of zones and all configured similarly except that there may be temperature variations between the different tools If so then you may well want to swap tools on the fly as this gives you the ability to make preset temperature changes to suit special conditions Alternatively a console may have a collection of very different tools within the ToolStore because it may be physically moved from one controller to another and used on different presses With different zone counts and operating conditions then it is more likely that you may want to bar operators from switching tools on the fly in Run mode Finally a console may be configured to several controllers via a local network in which each controller may have similar or dissimilar tools and settings In this situation the ToolStore Load button is the only way in which the console may be switched to communicate with different controllers Consequently an operator may need to select different tools while the current tool remains in Run mode and so the console would have Allow ToolLoad set to Enable NOTE If ToolLoad is disabled then the Load button on the Tool
148. wish to configure and touch anywhere in the Minimum Setpoint column Touch Set and if required enter your system Password In the Keypad that appears touch type the Minimum Setpoint value for the selected zones 4 When finished touch Enter to accept the new entry or Esc to reject it and return to the Setup page Limits The lowest Minimum Setpoint temperature that you can set is 0 C or O F Description This column allows you to set the minimum setpoint value for any zone or group of zones This parameter may be set to inhibit any changes up to excessively low probe temperatures that may cause moulding problems If you try to set a new low temperature which is below the Minimum Setting then the final temperature depends on how the Limit Exceeded option see page Issue 9 6 Setting the Tool Parameters 61 Pre configured Set Up values 37 has been configured For instance if the current zone temperature is 250 and the Minimum setting is 200 if you try to set a new temperature of 150 then e with Limit Exceeded option set to Enabled the new set temperature would lower to 200 which is the lowest allowable temperature setting e with the Limit Exceeded option set to Disabled the set temperature would not alter at all but will remain at 250 NOTE If on any zone the Maximum and Minimum Setpoints are set to the same value then the operator cannot make any setpoint changes to that particular zone Maximum
149. x matter that is beyond the scope of this operator s manual Therefore if you have any doubts or queries please call the PMS service department for advice Issue 9 6 Maintaining your controller 101 Configuring the test parameters Configuring the test parameters Normally there is no reason to alter the test parameters in your self diagnostic routine These have been preset at the factory to give correct testing However if you are failing to get a satisfactory test possibly because you have an unusually large thermal mass such as a heated platen then there is a provision for you to adjust the Tool Test parameters This menu becomes available if you touch the Config button on the testing page and enter the system password Heat Time For the zone under test the temperature must rise by at least the temperature shown in the Good Rise box during the specified Heat Time for the zone to pass the test Increasing the Heat Time lengthens the period for the test and changing the Heat Time should be limited to small changes an increase of 1 doubles the overall test time The maximum setting for Heat Time is 25 if you find that this seems to be insufficient heating time for your particular tool then please contact your supplier for further advice It may happen if a controller is connected to a tool that has a higher thermal mass that the one that the system was originally set up for Cool Time This is the time th
150. y 77 5 32 HE 3 4 3 5 a Z ME g AE 2 o r 2 Sil a w MI 25 2 Ze HE H Sle o G 9 N PB F By z s Kai pa Fa Ss H e 2 x g 2 x 5 g 2 x F gt F pa R 3 v S Hode RUN A Hessage The control buttons at the side can change according to your immediate needs e While the page is idle no zones selected you can use the top two buttons to select the operating mode of the controller e You can use the Display button to alter the number of zones seen on the main page e Ifyou touch any zone in readiness to change values then the control buttons change to Set Zoom Graph and Cancel e Ifyou touch the Menu button then a Menu list appears from which you can select other pages or an On Line help facility Zone Status Information Probe 6 ij At maximum resolution each zone displays a full control panel that carries four pieces of information 1 Zone Header this carries the name or alias name of the zone against a colour coded background 2 Actual temperature which changes colour to show status Green on Black Healthy Black on Yellow Warning 1st stage temperature deviation White on Red Alarm 2nd stage deviation or Fault message 3 Temperature scale C Celsius or F Fahrenheit and Set Temperature The only other value that may be seen here is
151. you adapt it quickly to different circumstances It has twenty available positions that can be individually configured named saved and recalled whenever the tool or job changes 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 a tool position Networking to your Controller Issue 9 6 User Manual for MTS Console 88 Customising your controller Using the tool store page Using the tool store page Tool Page information Opening the Tool page allows you to see tool 4 what different tool settings are saved ee away for immediate use an The initial window shows the first twenty ms T tool slots alongside the PgUp and Pem cest ont reir fA ARER PgDn buttons There are 5 different zj pals gt pages or banks of tools giving a total Redel RUN A Hessaxe Ea capacity of 100 ToolSlots To use any one tool first find the appropriate page by using PgUp and PgDn Once you have opened the required page touch and select any one tool the tool is highlighted with a blue background and the buttons on the left side change to allow you to use the selected tool The B

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