General - Günther Heisskanaltechnik
Contents
1. Fig 6 4 Wire Connection KRAUSS MAFFEI DW KAL P 20mA DSUB 9 Weidmiiller male plug 4 pol Fig 6 5 Wire Connection ENGEL Hint If an EPROM update is required at the same time of the interface installation disconnect the molding machine from the DPK before switching on At the order of an interface please note the type of the interface Technical Data Optional Interface Signal type RS232 level TTY level 20mA current loop optional RS485 level RS422 level Dataformat 2 x asynchronous full duplex Baudrate max 19200 Baud Cable length max 15m for RS232 max 300m for TTY cable cross section 0 4mm max 1000m for RS422 and RS485 Isolation 5kV Input Output 10 99 DPK 1 09 6 34 ZY GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 6 2 Initial Start Up 6 2 1 Testing Thermocouple Connections Install the device refering to chapter 6 1 Installation Disconnect the power connector Turn on the DPK The DPK now shows the software version e g P1 09 and begins to check the the hot runners Then the error message check load connector is displayed Change the parallel display to the set values by using the key Make sure to set all channels to the regulating mode Switch the parallel display to the exist values Now all connected channels must show a temperature value Otherwise the channels not working right have to be checked I2. Fig 3 3 Changing a Set Value The controller operation works independently from the entering of a value It is therefore not necessary to return to the scan mode Scan mode makes exact surveillance of critical regulation positions possible Value limits The temperatures are adjustable within a range from 0 to 500 C 0 to 932 F The percentage control mode is adjustable from 0 to 100 10 99 DPK 1 09 3 10 S GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 3 4 2 Switching Hot Runners On and Off If a hot runner is unused it is posible to switch it off CH Acta aS 2 G set 200 Heisskanaltechnik 24V OFF Temp Bild A Ch Exist Set Power 2 150 200 50 E at 40 3 0 300 100 4 100 100 0 Set 200 5 100 100 0 24V oO Temp Bild B Gi e CH Act 200 Ke 1 Set 200 SC 24V ON 4A Bild C Fig 3 4 Switching Hot Runners On and Off During the single channel mode move the mark to the ON OFF button by pressing the pa key Now the setting may be changed by pressing the or Y key Runners which are switched off will be displayed only in the multi channel mode and are not checked for faults anymore 10 99 DPK 1 09 3 11 S GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 3 4 3 Changing the Operating Mode Thermocouple Percentage In the event
3. D7 SS 7 4 Load Corner 40 pin of the DPK10 Channel 2 32 5 1 1 1 1 External Conductor A1 A2 a3 a4 Bi f f Transducer A7 A8 AD Alo B7 JJ Transducer D7 D8 Do Dio 7 JJ f Neutral Conductor _ As as a6 a6 Last TT Fig 7 5 Load Connector 40 pin of the DPK5 Hint In star circuit the return cables A5 A6 B5 B6 C5 und C6 only connected to the neutral conductor In the case of delta connection one does not mean an neutral conductor but another external conductor phase The connection position for special appliance revision S is different from the shown L D s B3 g N mm mm Changer NE Bo e D Nozzle Fig 7 6 Connection Example Controller Runner A7 of the DPK10 Hint The load plug is different from the DPK15 corresponding to the appliance Please take care of the corresponding table Fig 7 3 to 7 5 10 99 DPK 1 09 7 38 S GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 7 2 Appendix B Fuses Fuse Location for the DPK The up to 15 heating zones are fuse protected by super fast microfuses At the DPK 15 all of the load fuses are located on the back side of the controller Note that you have to switch off the controller before changing any fuse Hint Use only original fuses with the corresponding specifications One package of original reserve fuses has bee
4. GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 7 5 Appendix E Service Form Addresses see Apendix H Addresses FAX To From Company Company Phone Phone FAX FAX City City Date Date Response partner O Please call back O Ask for customer service O Ask for repair Service form for control units from the Giinther Hot Runner Sytems company Type of unit Serial number Program version Used connecting cable Voltage O Delta O Other SV Runners 24V Runners 230V Runners If power units 5V 24V are used are collective rails connected Description of previous history initial start up prior operation etc Problem description 10 99 DPK 1 09 7 45 S GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 7 6 Appendix F Schematic TxD RDO Displayplatine Grafikdisplay Senel Soch LR 27 Schnittstellen Modul DEFEKT OK ABSENKUNG RS 485 x d my Schnittstelle bi Fl D x3 Temperaturverst rker LR 26 pe Reglermodul LR 28 Converter A7 D4 Load Connec tor Zane 1 Zone 13 Zone 14 Zone 18 Zone 11 Zone 12 Zone 15 T 160 m Al xsfesefsselxs x eefee Load pa i BIS 2 BS o BIS 4 ga Bis 2 Eis a SH PORER VoDu LAs PofER Voou LAIG rofer Vonun LAS L 220 2804 PEN L3 LZ L Net Connecotr Terminal Board am Co EE Gp va ad ad aD ao MVA Er ee ree oe EE DAVIDSMEYER amp
5. PAUL emeh EE REENEN i ee 10 99 DPK 1 09 7 46 Ka G NTHER ot Runner Systems User Manual Hot Runner Systems DPK 7 7 Appendix G Position Schematic Ot plan FOO kel OO IN OG H iR15 2 _ sl OG kel OOPNOU Ot LR15 1 Mic BOO ER OO EN OU X2 GEI P SI PEG PETG Z1 Z3 F1 Z3 X4 PE8 oben F2 Z2 X5 PE9 mitte F3 Z1 X6 PE10 unten BES Deckel amp aez Hake 23 07 99 Jaepr Biait fv 1 7 47 os t onsplan P DAYIDSMEYER amp PAUL Gmb 10 99 DPK 1 09 User Manual Hot Runner Systems DPK ZY GUNTHER lot Runner Systems 7 8 Appendix H Addresses Headquarter GUNTHER Heisskanaltechnik GmbH Industriegebiet Nord Sachsenberger Stra e 1 D 35066 Frankenberg Eder Germany Phone Fax E mail Internet Germany G NTHER Heisskanaltechnik GmbH Mr Spork Sachsenberger Str 1 D 35066 Frankenberg GUNTHER Heisskanaltechnik GmbH Mr Stamm Sachsenberger Str 1 D 35066 Frankenberg WESCHU Mr Grajer Edisonstr 81 D 90431 Niirnberg Industrievertretungen Mr R mhild Thomas Mann Str 4 D 98597 Breitungen Verkaufsbiiro Nord Mr Ilmer Wolkenweher Weg 24 D 23843 Bad Oldesloe 10 99 DPK 1 09 49 64 51 50 08 0 49 64 51 50 08 50 info guenther heisskanal de hwww guenther hotrunner com Phone Fax E mail Phone 49 01 73 8 67 83 35 Fax 49 64 51 50 08 59 E mail spork guen
6. Warranty Condtions 1 Installation and implementation must be carried out by an electrician 2 Please refer to chapter 6 Installation and Inplementation of the DPK user manual prior to the installion of the device 3 Before connecting the device to the main power supply check the main voltage and the type of net star or delta 1 General The hot runner system DPK has been built and tested according to DIN 57411 part 1 and VDE 0411 part 1 Germany It has left the factory in perfect condition In order to keep your product fully operational and to guarantee safe operation please read this instruction manual carefully and follow all hints Before switching on it is important to check that the local voltage is identical to that allowed by the unit The plug may only be plugged into to an earthed socket Any disconnection of the earth cable e g an extension of the cable without earth connected can cause hazardous conditions to the unit Hint Disconnect mains before opening unit Refer to a qualified technician for servicing The DPK unit is an optimized hot runner control unit it is more efficient and reduces costs Advantages for the user e Available in 5 10 or 15 hot runner versions according to the user s requirements e The DPK automatically recognizes low voltage nozzles and 230V hot runner elements and sets its control parameters accordingly e Only one unit is required for mixed operation e PID controller with
7. After the unit has been switched on the G nther logo the program revision number and the serial Number will be shown on the display Then the unit automatically performs a system check which includes the heating circuits whether a low voltage or a 230 volt load is connected After the system check the DPK detects the load if it is a low voltage or 230 V The Display will show a table of all loads If faults are detected on the system or the loads nozzles distributor or cables the fault is displayed and the loads are switched off At the same time the parallel display shows TST Test and then the detected voltage of the load If a load turned of in reasen of a fault or if it is not connected the parallel Display will be shown 3 2 Multi Channel Mode After the adjusting of the loads has been performed the controller is in the multi channel mode In this mode every five channels are display for a short time interval G GUNTHER Heisskanaltechnik Ch Exist Set Power 1 200 200 0 2 150 200 50 3 0 300 100 4 100 100 0 5 100 100 0 Fig 3 1 Multi Channel Mode The set value and the current value in degrees celsius or degrees fahrenheit is displayed in this mode The control value is also displayed in per cent for 230V nozzles or in ampere A for 24V or SV nozzles 230V loads pass through a so called softstart if the set temperature is higher than 105 C 2219F If
8. L1 ul 400 V Star L2 L3 240 V Delta BEER mess Fig 7 9 Star Delta Switch Over UI U2 U3 200V 250V Close the cover Attention The voltages U1 U2 und U3 must be within a range of 200V 250V If the unit is powered with other voltages the warranty expires and in some cases the unit can be damaged When using a Delta net supply the cable is not compatible for the different versions That means that the DPK 5 should only be used with a cable intended for a five hot runner unit The use of a cable designed for a 10 or 15 hot runner unit will lead to operations errors 10 99 DPK 1 09 7 41 ZY GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 7 4 Appendix D Technical Data Connection Specifications Terminal Voltages 200 250 V AC per phase 50 to 60Hz typ star connection Load Connection Load Type Thermocouple Error Output OK Output Lowering Input 10 99 DPK 1 09 Star Connection 3 phase supply with neutral 200 250 V between phase and neutral Delta Connection 3 phase supply without neutral 200 250 V between two phases 10A per channel fuse 10A super fast FF 10A 1 runner per phase 16A see max current of phase phase load 5 channels per phase max 25A Maximum Power DPK 5 phase L1 channel 1 4 je2 3 KW 10A channel 5 3 6 KW 16A max overall load CE 3 6 KW 16A ll ll DPK 10 phase
9. actual values The control parameters are adjustable according to the application The implemented diagnostic tests the complete system including tools nozzles distributors and the hot runner system for malfunction Incorrectly connected circuits are located before start of operation Low installation cost due to combined thermal and power connections The DPK has numerous special functions for optimal system utilization Advantages for the user Power output surveillance is possible during operation Decrease and increase temperature for all control points by simply pressing a key Reading of the effective current at low voltage Several set value programs simplify material or tool change If desired a serial interface is available as connection to the injection molding machines 10 99 DPK 1 09 1 5 User Manual Hot Runner Systems DPK A GUNTHER lot Runner Systems The display and operating controls of the DPK are located on the operation control panel and the parallel display Great emphasis has been placed upon ease of use and a good layout Set Z GUNTHER Heisskanaltechnik Power 200 200 300 100 100 0 50 100 0 0 D a Tel M H een A B E C D Fig 2 1 control panel DPK Function Keys A Key C FL gt lowering temperature all zones B Key C FT gt raising temperature all zones C Key MENU gt show menu E H Keys NGS gt changing amp adj
10. free relay contact OK for 230V max 1A is switched on A corresponding plug with 2 5m cable can be ordered from the GUNTHER HOT RUNNER SYSTEMS company 10 99 DPK 1 09 6 31 ZY GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems Input Lowering Abs By using potential free external contact the DPK can be set to lowering Hint Attention Never connect any voltage to this input Serial Interface One serial interface RS232 is included in every DPK For a connection to a molding machine a second serial interface is required Depending on the molding machine and its protocol a RS232 RS 485 RS422 or TTY current loop interface is required You can get this interface as an add on kit or from the manufacturer installed when ordering a new DPK For further information please contact Giinther Hot Runner Systems 6 1 3 Additional Interface The add on kit includes e 1 interface module e 1 preassembled flatcable e 5 m interface cable 2 x 0 5 mm shielded assembled for connection to the molding machine Arburg Engel or Krauss Maffei please note the type at your order e 2 pcs spacer bolts including nut Installation Hint Attention Disconnect main power before opening system e Remove the top cover by removing the four screws on the side of the unit e Plug the interface into the 10 pin an 14 pin conectors on the front panel LR27 take caution of the right direction e Remover the cover pane
11. only valid for 15 minutes or up to the moment where the DPK is turned off For further changes to the configuration you need to enter it again A GUNTHER Heisskanaltechnik configuration softstart gt calibration language pid parameter switch C F Fig 3 11 Configuration 3 6 1 Softstart When 230V nozzles are used it is necessary to employ the softstart start up procedure to dry out the moisture that has collected in the heating elements In order to do this in the first phase of the softstart the set time value of the menu softstart is increased from 0 to 50 The ramp time should be selected in such a manner that the DPK reaches the temperature of 105 C at the end of the ramp If the temperature is less than 105 C at the end of the ramp the DPK will increase the temperature to 105 C After the DPK has reached the 105 C the second time controlled phase of the softstart the holdtime begins The ramp and the hold time is adjustable by the menu softstart and could be changed in 2 seconds steps The holdtime is used to adequately dry out the nozzle with a low thermic load This start up operation will begin automatically if it s been activated in the softstart menu after the control unit or runner is switched on and also after a program change The softstart start up procedure is activated individually and automatically for each zone when the actual temperature of a 230V nozzle remains belo
12. that a thermocouple fails to function or for any other reason the percentage control mode can be carried out to continue the control operation manually The current will then be displayed in percent Mark the menu item power or temp in single channel mode by pressing the ES key choose between thermocouple or percentage by pressing the or Y key cH at 200 Z G NTHER 200 Heisskanaltechnik 24V ON Temp Bild A Ch Exist Set Power 1 200 200 0 2 150 200 50 Gin Act 200 3 0 300 100 4 100 100 0 Sel 200 5 100 100 0 24v on EZ Bild B e Sa Percentage 1 Ges 24V ON Bild C Fig 3 5 Changing the Operating Mode For low voltage nozzles it will be 100 approximately 125A for SV nozzles 100 approximately 25A for 24V nozzles 10 99 DPK 1 09 3 12 D GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 3 4 4 Temperature Lowering Rising If production stops for a longer period of time it is advisable to lower the set temperatures without turning the unit off By pressing the key C Fl lowering temperature is activated The display shows in the multi channel mode at the left corner t lowering in the single channel mode the following sign TC An external activation of the temperature lowering is possible by connecting a closing contact at the rear
13. the softstart is active all 230V loads are clamped to 105 C This clamping ends if all loads have reached this temperature see chapter 3 6 1 Softstart Hint At the apperance of any failure the multi channel mode will be interupted and the failure will be visualized on the display If several errors occur then the channel whose error was recognized first is displayed This is also valid if the display is switched from the menu mode to the multi channel mode after the apperance of any failure 10 99 DPK 1 09 3 8 D GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 3 3 Single Channel Mode To change from the multi channel mode to the single channel mark a channel with the keys marked or Y By pressing the keys or Enter the channel is entered in single channel mode The single channel mode is now shown on the display In this mode all data rated value actual value load caracter current power consumption of each channel will be shown Z G NTHER Heisskanaltechnik CH Act 200 1 Set 200 24V ON 4A Fig 3 2 Single channel Mode At first in the single channel mode the channel number is marked By pressing the key 4 the display mode returns to the multi channel mode Towards a cycle of 2 seconds the mark switched off now it is possible by pressing the key 4 to turn the display mode to the scan mode The fo
14. variable parameters fast heating of 5V and 24V low voltage nozzles careful heating of 230V hot runner elements e Control operation is possible at all times even in the event of thermocouple failure e Existing power units from the 160 series can continue to be used as the DPK control unit is compatible with all existing GUNTHER power units e Because of the module construction system upgrades are possible The DPK is reliable and safe due to continuous checking and monitoring functions Advantages for the user e Continuous self monitoring function e Protects low voltage nozzles from current overload e Identifies thermocouple failures heat circuit disconnections and short circuits e Turns off the power supply in case of a malfunction and signals the alarm via a potential free contact e Parameters and programs are saved in an EPROM and are therefore not lost in the case of a power supply failure 10 99 DPK 1 09 1 4 ZY GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems The DPK is designed for easy use this makes installation and tool change simple Advantages for the user The DPK is especially designed for simple and easy operation The multi function keypad has an easy to use layout and because of its dust and water proof key pad it withstands tough environments The simple operator entry levels prevents wrong operation All hot runners are simultaneously displayed and for each hot runner the set and
15. 05 E mail m_demicheli gunther france com Phone 44 14 74 87 97 74 Fax 44 14 74 87 30 63 E mail info gunther co uk Phone 358 93 44 55 44 Fax 358 93 43 40 52 0 E mail jukka traderingman fi Phone 1 84 72 15 78 74 Fax 1 84 72 15 78 05 E mail info ghrsi com Phone 886 2 22 9903 16 Fax 886 2 22 99 05 35 E mail industra ms29 hinet net Phone 972 39023902 Fax 972 3 90 23 90 3 E mail supadlitd netvision net il Phone 420 I 84 72 39 66 Fax 42 0 I 84 72 39 66 E mail guenther trysky sochor Qiol cz Phone 48 22 62 25 228 Fax 48 226297774 E mail guenther pro onet pl Phone 43 I 86 94 764 Fax 43 1 86 94 76 47 E mail guenther kabsi at Phone 36 12 39 05 17 Fax 36 12 39 05 17 E mail baslertrade mail datanet hu 7 49 User Manual Hot Runner Systems DPK D GUNTHER Hot Runner Systems Worldwide Grupo Zoica Eduardo Campos Madrigal S A de V C Sadi Carnot No 77 Col San Rafael MEX D F 06470 Delg Cuauhtemco Center Plast Mr Gonzalez Palacio C Sant Gabriel 17 Lo 3 E 08950 Esplugues de Liob Technisches B ro Backer Mr B cker Pieter Lieftinckweg 20 NL 1505 HX Zaandam Battenfeld Hong Kong Ltd Mr Pechtl 2F1 No 18 Dai Fat Street Tai Po Industrial Estate Hong Kong N T Tai Po Millutensil SRL Mrs J
16. 5 29 ZY GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 6 Installation and Start Up 6 1 Installation 6 1 1 Location The absolute dimensions of the DPK are specified in appendix D Pay attention to guarantee a sufficient air circulation behind the DPK regulator unit heat sinks Ensure sufficient air circulation at the bottom of the DPK is supplied by an installed fan The system must be set up on a stable and level area The DPK must be preserved from physical shock and vibration For the maximum operating temperature please refer to appendix D Please take care of the other operating conditions listed in apendix D Protect the DPK from dust and dirt When the device is assembled for example in a service cabinet a cable inlet of 120 x 90 mm should be provided 6 1 2 Electrical Connections The following electrical connections are required for installation DPK Three phase CEE 32A plug Phasedistribution DPK 5 Ll Fuse 25A L2 L3 not connected DPK 10 ER Fuse 25A DPK 15 L1 L2 L3 Fue25A Hint Please check mains voltage star delta prior to installation Star is the standard configuration of the delivered unit Delta is possible if the voltage between two phases is not higher than 200 250V Please refer to apendix C Thermocouple Cables The thermocouple cable requires a 32 pin 2 x 16 pins socket with a suitable housing The cable assignment is listed in apendix A Parts and preassembled pre
17. GUNTHER Heisskanaltechnik GmbH DPK User Manual Software Version P 1 09 and higher SOLL SET 1 IST EXIST 2 3 4 5 GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems Table of Contents Page 2 DISPLAY AND OPERATING CONTROLS 2 6 2 2 PARALLEL DISPLAY 2 7 3 OPERATING INSTRUCTIONS 3 8 B 1 TURNI B 2 MULTI CHANNEL MODE 3 k LE CHANNEL MODE 9 B 4 OPERATING MODE 10 d OTHER F TIONS 4 2 4 1 READY TO START MOLDI 4 2 4 2 TERROR MESSAGES 4 23 d START RAMP 4 27 5 SERIAL INTERFACE 5 28 5 1 GENERAL INFORMATION 5 28 5 2 TROUBLE SHOOTING 5 29 10 99 DPK 1 09 2 S GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems Table of Contents Page 6 1 INSTALLATION 6 30 6 2 INITIAL START gt Ge e H gi APPENDIX 7 37 6 TALLI EW SOFTWARE EPROM 6 36 JL APPENDIX CONNECTIONS TO THE DPK 7 37 2 APPENDIX B FUSES 7 39 3 APPENDIX C STAR DELTA OPPERATION 7 41 NDIX D TECHNICAL DATA NDIX E SERVICE FORM 7 45 NDIX F SCHEMATIC 7 46 NDIX G POSITION SCHEMATIC NDIX H ADDRESSES 7 48 APPENDIX I EG DECLARATION OF CONFORMITY 7 1 Ge IS jer jor W e gt gt gt I gt Ve e e IS elle s ls le e Is Ta re A da I D Le 10 99 DPK 1 09 ZY GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems
18. Heisskanaltechnik configuration softstart load default calibration languae pid parameter D gt switch c f switch c f temperature in fahrenheit ENTER Bild A Fig 3 13 Switching C F 3 6 6 Temperature Window The width of the windows for the value of the existing temperature can be changed in the menu item temperature window Is the value of the temperature at the nozzle within this window this will cause the lightning of the O K indicator in the parallel display If all temperatures are in within the window the ready to mold output will be set 10 99 DPK 1 09 3 22 S GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 4 Other Functions 4 1 Ready to Start Molding As soon as the adjusted runners have reached the preset temperatures the OK LED is switched on and in the bottom line of the display appears the text ready for molding Additionally a potential free relay contact is switch on This relay contact is located on the rear side of the system and is marked with OK The OK LED and the relay output will be switched off in case of e a fault e lowering 4 2 Error Messages In the event of a fault the display will show the fault and the protection system will shut down the power With this fault the relay contact is switched By pressing the ENTER key the faulty channel will be switched off and the other channels will be sw
19. K we hereby confirm that above listed products comply to all important safety requirements that have been declared by the Council of Assimilation of Legal Regulations by the EC membership countries concerning electromagnetical conformity 89 336 EWG EMV 73 23 EWG Low Voltage Requirements To verify these products to electromagnetical conformity the following standards were referred to EN 50081 Part 2 EN 50082 Part 2 The above mentioned products also comply to DIN EN 61010 Teil 1 03 94 This declaration applies to all above listed products with the folowing production index Production Index D and E The production index is the number behind the serial number on the identification label of the product The identification label is located on the right side of the product DAVIDSMEYER amp PAUL GmbH Elektronik Humboldtstr 2 4 D 50181 Bedburg Bedburg 01 08 1999 J Marquardt Managing Director Expressions recommended by EM V Rechtsvorschriften und ihre Anwendung in der Praxis Franzis Verlag 1993 0 99 DPK 1 09 7 1
20. L1 channel 1 4 je2 3 KW 10A channel 9 3 6KW 16A phase L2 channel 5 8 je2 3 KW 10A channel 10 3 6KW 16A max overall load CE 7 2 KW 2x 16A DPK 15 phase L1 channel 1 4 je2 3 KW 10A channel 13 3 6KW 16A phase L2 channel 5 8 je2 3 KW 10A channel 14 3 6KW 16A phase L3 channel 9 12 je2 3 KW 10A channel 14 3 6KW 16A max overall load CE 10 8 KW 3x16A see also apendix A 5V 120A per channel using our power units 24V 25A per channel using our power units ohmic and inductive ohmic loads are allowed thermoelectric couple Typ L FeCuN1 electronic compensation potential free contact normaly open max 230V 1A unfused potential free contact normaly open max 230V 1A unfused connect a potential free contact normaly open 7 42 User Manual Hot Runner Systems DPK D GUNTHER ot Runner Systems Net Cable Sockets Fuses Ser Interface Regulator Load Matching Output Control Range Set Range Softstart Starting Ramp Lowering Boost Security Turn Off 10 99 DPK 1 09 32A CEE plug standard Load connector 40 pin Amphenol Thermocouple connector 32 pin Amphenol Triac unit Microfuse FF 10A 5 x 20mm type Schurter SA super fast for Triacs 4 pes per module LR15 Microfuse FF 16A 6 3 x 32mm type Schurter SA 1 pcs per module separated on the back side of the device RS232 TTY RS422 RS485 At the
21. R15 The phase control in the DPK is realized with the thyristor module LR 15 Depending on the model there are 1 3 modules inside of each DPK Every module is driven by its own phase Channel 1 5 by L1 channel 6 10 by L2 and channel 11 15 by L3 On the LR 15 there are two jumpers for the channel setting They have to be set like the figure shows The DPK checks the thyristors of each power module at every adjustment In case of an error the corresponding phase of the module is displayed with an error massage The damaged module can be easy locted by measuring the phase Attention Attention Disconnect the mains voltage and take care that there is no voltage at the DPK before opening the device Please following these safety instructions 5 Runner 10 Runner ez 15 Runner Fig 7 8 Jumper Settings for the Power Module LR 15 10 99 DPK 1 09 7 40 D GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 7 3 Appendix C Star Delta Opperation Attention Disconnect the mains voltage and take care that there is no voltage at the DPK before opening the device Please following these safety instructions The unit DPK is prepared for a standard connection of a 400V star net supply In case a 240V delta net supply is necessary for example USA this can be adapted by using four screwbridges Disassemble the unit cover Connect bridges as shown in the diagrams below
22. clear statement about a load disconnection could be given For all channels the set value in ampere can be displayed To check the heater current a clamp ampmeter with true RMS measurement should be used For low voltage nozzles a range of 0 150A is required High voltage nozzles requires a range of 0 10A If there are problems with the installation of the DPK please contact our service department for help Please use the service form in appendix E and send it to the next service department 6 3 Installing new EPROM updates Hint Attention Disconnect the mains voltage and take care that there is no voltage at the DPK before opening the device Please follow the safety instructions To install a software update disconnect the power and thermocouple connections from the DPK Disconnect also the serial interface to a molding machine Now remove the top cover of the DPK and get the EPROM out of the module LR28 When installing the new EPROM take care of the right direction and fit in socket of the circuit After that get the EPROM out of the module LR27 When installing the new EPROM take also care of the right direction and fit in socket of the circuit Following this step close the cover of the DPK Attention Do never exchage the EPROMs After turning on the DPK again the DPK performs an update and an adjustment Now the DPK should work normally The actual software version is displayed in the right lower edge of the display wh
23. en the DPK is turned on 10 99 DPK 1 09 6 36 S GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 7 Appendix 7 1 Appendix Connections to the DPK Last Load OK Thermo C F5 F9 F13 2 g Ei FIO F14 Def Abs Cr FIS KEN R So anon non Fig 7 1 Connections on the Rear Side of the DPK Ser Serial Interface OK Ready to Start Molding Def Fault Abs Lowering external Channel 1 21 3 4 5 fo 7 8 9 10 i 12 13 14 Metal red_ 1 2 3 4 5 6 7 8 17 18 19 20 21 22 Constantan biue 9 10 11 12 13 14 15 16 25 26 27 28 29 30 Fig 7 2 Thermocouple Connector 32 pin to the DPK Channel 1 2 33 4 5s flo fT 7 8 fo fo i 12 13 J 14 J 5 Transducer A7 A8 a9 A10 B7 B8 B9 B10 C7 C8 C9 C10 D4 D5 D6 Transducer D7 D8 D9 D10 D7 D8 D9 D10 D7 D8 Ds D10 D7 Ds D9 Neutral Conductor As A5 A6 A6 B5 BS B6 B6 C5 C5 Co Co A6 B6 Co Fig 7 3 Load Connector 40 pin of the DPK15 10 99 DPK 1 09 7 37 S GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems Channel ___ 23 415 Le 2 External Conductor Al A2 A3 Ad BI B2 D8 Transducer DT Da Do bio
24. f the display only show maximum temperatures between 20 C and 40 C then the blue and red cables of the thermocoples are expected to be exchanged 6 2 2 Testing Heater Disconnections Switch off unused channels Set all channels to 0 C or 0 at disconnected load connector Connect the load connector After turning the device off and on there should be no load circuit interupted messages If there is any fault the corresponding channel will be displayed For further testing the damaged channel should be switched off 6 2 3 Testing Thermocouple and Load Crosswiring Set all channels to regulating mode and set a temperature value of 0 C Switch off unused channels to get no error messages from them Now no error messages should be displayed Set the parallel display to the existing values Set the first channel to 100 C and watch at the parallel display The temperature of the corresponding channel should increase now If the temperature of another channel increases faster there is an error in the connection Set the channel to 0 C again Now test the next channel 10 99 DPK 1 09 6 35 S GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 6 2 4 Additional Information Hint When working with the 230V loads switch off the DPK and disconnect it from the power source Opposite of other regulating units for 230V the DPK checks the loads at the power up precedure by using a current measurement So a
25. he nozzle because it reaches the set value much earlier then the other nozzles The starting mechanism ensures an even set value based heat on all of the different nozzles The individual nozzle will be decoupled from the leading mechanism if the slowest channel reached the temperature window The starting ramp is indicated in the multi channel mode by a short text wich gives an information about the slowest channel and that the starting ramp is activated in the bottom line on the display and in the single channel mode by the following symbol The number behind the sign is the number of the slowest channel 10 99 DPK 1 09 4 27 GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 5 Serial Interface 5 1 General Information The DPK is equipped with one serial interface COMI see also chapter 3 5 4 Serial Interface This is a standardized RS232 interface An optional serial interface COM2 is available An add on kit is also available This second serial interface is used for a connection to a molding machine With the interface COM2 it is possible to remote control and display the information of the DPK unit via the molding machine It enables easy quality control caused of a product data aqusition This time there a serveral types of serial interface available Depending on the molding machine a RS232 a RS485 or a TTY interface is deliverable Which interface is needed for your molding machine is described i
26. itched on During the hot runner test all channels without a fault switched on and so it is not a mistake it is only a warning that the faulty channel is switched off A channel which evoked a warning is switched in the off temperature mode when no load is detected and switched in the off percentage mode when no thermocouple is detected The following faults are possible Z G U NTH ER Thermocouple Failure Helsskenaltechalk The thermocouple of the shown channel was not found Please check the thermocouple and its wires Ch 1 error thermocouple break floating or not connected ENTER Fig 4 1 Thermocouple Failure 10 99 DPK 1 09 4 23 User Manual Hot Runner Systems DPK S GUNTHER lot Runner Systems 2 GUNTHER Heisskanaltechnik Ch 1 error thermocouple exchange ENTER Fig 4 2 Thermocouple Exchange Z GUNTHER Heisskanaltechnik Ch 1 error Thermocouple shortcut ENTER Fig 4 3 Thermocouple Shortcut A GUNTHER Heisskanaltechnik Ch 1 error thermocouple over temperature ENTER Fig 4 4 Over Temperature 10 99 DPK 1 09 Thermocouple Exchange The thermocouple of the shown channel is not connected right The and connections are exchanged Please change the direction of the connections Thermocouple Shortcut There is a short circuit at the thermocouple or its connections at the shown channel Plea
27. l at the rear side of the DPK e Pull the pole connector with its flat cable through the opening of the unit and connect the D SUB 9 pin connector by using the spacer bolts and nuts from the outside of the unit e Plug the flat cable onto the interface module take caution of the direction Attention Check the polarity Pin 1 of the PCD must correspond to pin 1 of the socket e Check the right jumper settings e Close the top cover and fix it by using the srews e Install the cable to the molding machine connect it on both sides and fix the screws of the connectors e Setup the right protocol type in the DPK 10 99 DPK 1 09 6 32 User Manual Hot Runner Systems DPK D GUNTHER ot Runner Systems 2 RXD 1 1B 3 TXD 2 1Z 5 GND 3 2B 7 RTS 4 2Z 8 CTS 6 1A 7 1Y 8 2A DSUB 9 psuB9 I 2Y female female RS 232 Interface RS 485 Interface 1 RXD 1 CTS 4 TXD 2 RTS 6 RXD 3 RXD 9 TXD 4 TXD 6 CTS TXD passive 7 RTS RXD passive 8 RXD DSUB 9 psup9 TXD female female TTY Interface RS 422 Interface Fig 6 1 Interface Connections of the DPK OMSK LI din e e e e en 1 Nm AMP DIN 5 male 20mA 2 DSUB 9 male Fig 6 3 Wire Connection ARBURG 10 99 DPK 1 09 6 33 User Manual Hot Runner Systems DPK S GUNTHER lot Runner Systems DSUB 9 DSUB 25 Stecker Stecker
28. l be changed after a time of 10 seconds and the display will show the single or multi channel mode If a menu item is confirmed the value may be changed by pressing the and Y keys By pressing the oder ENTER key you will return to the menu If the ENTER key is used the displayed value will be stored as a new set value By using the 4 key the value will not be stored cancel function The menu structure is on the next page 10 99 DPK 1 09 3 14 User Manual Hot Runner Systems DPK S GUNTHER ot Runner Systems Menustructure of the DPK set all channels temp program temp lowering temp boost molding machine power monitor turn on time configuration heater 5V 24V language service Fig 3 7 Menu structure of the DPK 10 99 DPK 1 09 softstart load defaults calibration pid parameter switch C F temperature window 3 15 A GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 3 5 1 Set All Channels The menu set all channels enables the operator to change the temperature the controller output or to turn on or off all channel Z GUNTHER Heisskanaltechnik main menu set all temperature temp program set all channel temp lowering temp 100 SC temp boost molding machine power monitor ENTER Bild A Fig 3 8 Set All Channel 3 5 2 Temperature Program A set value program i
29. llowing sign indicates the scan mode ZD In this mode the zones with set and actual values will be displayed in the display one by one Runners wich are switched of will be skipped The unit A C F for each zone number will be displayed at the same time The scan mode ca be cancelled by pressing any key and restarted by pressing the 4 key after 2 seconds when the mark of the channel nummber swiched off again Hint If a fault occurs the scan mode will be terminated and channel number causing a fault will be shown on the display If several faults occur at the same time the zone where the first fault occured is displayed 10 99 DPK 1 09 3 9 S GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 3 4 Operating Mode 3 4 1 Changing Set Values During the single channel mode move the mark to the set value by pressing the key The desired set value is entered by pressing the key and Y The key function is dynamic i e the longer the key is pressed the quicker the set point value changes CH Act 200 S E G an Set 200 G Heisskanaltechnik 24V ON Temp Bild A Ch Exist Set Power 1 200 200 0 2 150 200 50 EN 1 Act 200 3 0 300 100 4 100 100 0 set Rui 5 100 100 0 24V ON Temp Bild B e O CH Act 200 1 Set 250 S 24V ON 4A Bild C
30. moment protocols are availible for Arburg Mannesmann Krauss Maffei and Engel Further protocols are planed e g SPI EURO MAP17 CAN BUS please call us PID adjustable from the front parameters are programmable and can be locked automatic recognition of 230V and low voltage loads with automatic adjustment of the control parameters uniform automatic parameter match by means of phase control mechanism 0 to 500 C 0 to 932 F 0 to 100 3 phases 1 adjustable ramp on 50 of the set value 2 heat up to 105 C 3 adjustable hold time on 105 C Equal heating of each nozzle depending on the slowest nozzle adjustable 0 255 C 0 255 F adjustable 0 255 C 0 255 F adjustable 0 500 C 0 500 F 7 43 User Manual Hot Runner Systems DPK S GUNTHER lot Runner Systems Other Details Data Protection Display Keyboard Storage Temp Operating Temp Humidity Protection Type Dimensions Weight Color 10 99 DPK 1 09 Data recovery after power fail data storage lifetime at least 10 years without battery Operating section Parallel display LCD graphic display 40 x 71 mm seven segment LED display 8mm and LEDs Front panel with integrated mechanical keys and key foil 0 to 70 C 0 to 35 C Storage 30 80 not condensing Operation 40 70 not condensing IP 20 W H D 468mm x 142mm x 345mm 13 0 Kg 28 6 lbs grey blue RAL 9018 RAL 5015 7 44 S
31. n enclosed with the DPK 1 Netz 0 Last Load F5 F9 F13 Fl F2 F FA VG 0000 peu fi6s0e 1 EM F7 F8 spre ede 3 013 S 4 a 4 O FI E2 ARATA OOOGG 198935 FFIOA 5x 20mm A0000 9 Schurter SA VED 10 9090 10 FFI6A 6 3 x 32mm a SchurterSA E Fig 7 7 Position of the Load Fuses of the DPK The figure shows a part of the DPK s back plate The 15 fuses for all heating zones are placed on the left housing side The three 16A fuse holders are mechanically different from the 10A holders The fuse number correspond to the zone number Hint Please note that the DPK can be delivered as 5 10 or 15 channel system The lettering of both upper 16A fuses have ambiguous meanings The controller DPK5 contains four 10A fuses for the zones 1 4 and one 16A fuse for the zone 5 The controller DPK10 contains eight 10A fuses for the zones 1 8 and two 16A fuse for the zones 9 and 10 The controller DPK15 contains 12 10A fuses for the zones 1 12 and three 16A fuse for the zones 13 14 and 15 Additionally to the heating zone fuses the DPK contains up to four internal controller fuses The main controller fuse for the major electronics is placed on the main board LR28 and has a nominal value of 160mA T Each of the power moduls LR15 is has a separate 160mA controller fuse 10 99 DPK 1 09 7 39 ZY GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems Power Module L
32. n the user manul of your machine For further information please contact Giinther Hot Runner Systems Caused of several communication protocols for the different molding machines contact Giinther Hot Runner Systems for availability Please specify the type and manufacturer of your molding machine Please refer the installation instructions for detailed information of installation The DPK with an optional serial interface gets all data from the molding machine Operation on the hot runner system is not necessary and for security reasons not possible Parmeter and set temperature changes are impossible if the DPK is connected to a molding machine This means especially the set values the change all channels function the temperature programs and the setting for temperature lowering and boost A temperature lowering or rising is also not possible Hint If for example Parameters should be changed the connection from the DPK to the molding machine must be opened Disconnect the cable to the molding machine after switching off the DPK or switch off the molding machine This causes no more data to be sent to the DPK Then the DPK notes that no interface operation is current In this case the DPK enables any user opperations after a few seconds The DPK then works as a stand alone unit The parameters and setting from the molding machine are stored in the DPK This increases easy diagnostics to the hot runner system For the opperation hints fo
33. ning 5 24v load follows 230v load check wiring ENTER Fig 4 8 Plausibility Error Z GUNTHER Heisskanaltechnik error triac short circuit on line x ENTER Fig 4 9 Damage of a Power Module 10 99 DPK 1 09 Plausibility Error The arrangement of the loads referring to the channel number is not the normal order The low voltage nozzles should be connected to the low channel numbers 230V nozzles should be to the higher channels after them The parallel display shows the types of nozzles after the adjustment If this order is chosen intentionally the opperation can go on after confirming this warning Damage of a Power Module Befoer the adjustment a damaged triac was found on one of the power modules Every off the max three power modules is driven by one phase So the damaged module can be found easy by disconntion the modules one by one Please change the damaged module by an electrcian or contact Ginther Hot Runner Systems Please disconnect the line voltage before oppening the case Pay attention to the safety instructions 4 26 ZY GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 4 3 Starting Ramp In hot runner systems you will often find loads with different thermic time constants If the time constants differ widely then a fast nozzle reaches its set value earlier than the slow manifold This physically based heat up delay can generate plastic defects in t
34. peration are displayed in the menu turn on time Every time when the DPK is switched on this time is incremented 3 5 7 Configuration By choosing the menu item configuration the configuration menu will be entered You need a password to enter this menu In the configuration menu the operater can change the language the PID parameter or calibrate the DPK etc For further information refer to Chapter 3 6 Configurationmenu 3 5 8 Heater 5V 24V In this menu item the type of the low voltage load 5V 24V for all channels can be set This means the DPK is able to work in a mixed mode with 230V and 5V nozzles or in a mixed mode with 230V and 24V nozzles A mixed mode for 5V and 24V nozzles is not supported 3 5 9 Language In this menu item you are able to change the language for the display and the menu The DPK supports three languages german english and french 3 5 10 Service This menu item is used by the manufacturer of the DPK for several setting This menu has ist own password The user must not and need not make any changes to this menu 10 99 DPK 1 09 3 18 D GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 3 6 Configuration Menu By scrolling through the main menu the configuration menu can be entered A password is needed to enter this menu In the configuration menu the operater can change the PID parameter or calibrate the DPK etc The password for the configuratin menu is 0099 The entered password is
35. r the interface of the different molding machines please refer your use manual The following interface paramters are set if a protocol type is changed Interface Type TTY 20mA 4800 Bit s 8E1 TTY 20mA 4800 Bit s 7E1 Krauss Maffei V24 RS232 9600 Bit s 7E2 TTY 20mA 4800 Bit s 8NI 10 99 DPK 1 09 5 28 D GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 5 2 Trouble Shooting Hint For faults that are not associated with the interface connection the DPK should be disconnected from the molding machine There are several red and green LEDs inside the DPK You can watch them after opening the case The LEDs for the connection to the molding machine are located on the display circuit front panel The two other LEDs on the module LR 28 are for the internal communication between the operator display panel and the regulator module By flickering the LEDs indicate that a data flow is current green RXD_ Input DPK Flickering indicates The DPK gets data from the molding machine red TXD Output DPK Flickering indicates The DPK sends data Hint If the DPK detects any failure the loads will be disconnected from the power line This error state is displayed on the DPK If the channel which caused this error is switched off the error state is confirmed After that the other channels are switched on again Your can get further information in chapter 4 2 Error Messages and 6 2 Initial Start Up 10 99 DPK 1 09
36. re Window 5 C Lowering Value 50 C Rising Value 50 C Language German Interface Arburg Heater 5V 24V 24V 10 99 DPK 1 09 3 20 D GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 3 6 3 Calibration The sophisticated and microcontroller seconded temperature module of the DPK could calibrate its self by using a calibrationjack Heisskanaltechnik calibration calibration configuration reading data reading data softstart calibrating offset load defaults calibrating gain source missing gt writing data language wait pid parameter l switch C F Bild A Bild C deviation min offset 0 oO max offset 2 avg offset 1 min gain 0 max gan 17 avg gain 06 Bild B Fig 3 12 Calibration The calibriation jack is available from GUNTHER HOT RUNNER SYSTEMS without the jack the error message of Fig C will be shown on the display 3 6 4 PID Parameter The operater can change the PID parameter using the menu item pid parameter So the operator is able to match the parameter to the controlled system It is possible to match the paramters independently 10 99 DPK 1 09 3 21 User Manual Hot Runner Systems DPK GUNTHER lot Runner Systems 3 6 5 Switching C F By choosing the menu item switch C F it is possible to choose between degrees celsius or fahrenheit Z GUNTHER
37. s a preprogrammed series of set values and their corresponding operating methods which a user can change and enter into the system They can be entered and activated solely by the menu temp program If the tools or the molding compounds are changed it is advisable to also change the program accordingly There are 4 set values programs available When the control unit is turned on the last one of the previously used programs will be automatically reactivated To reset all programs and all parameters select the menu item default 4 GUNTHER Heisskanaltechnik main menu temp program set all channel PO SEA emp program ag I e 2 power OFF 75 temp lowering 3 temp ON 100 temp boost i 4 temp OFF 200 molding machine default power monitor Bild A Fig 3 9 Changing Temperature Program 10 99 DPK 1 09 3 16 D GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 3 5 3 Temperature Lowering Rising By the two menus temp lowering and temp boost the operator could set the increase or decrease temperature By using the C F key the temperature drops about the value which adjusted in the menu temp lowering By using the C FT key the temperature rises about the value which adjusted in the menu temp boost 3 5 4 Serial Interface The DPK is generally delivered with one serial interface COMI This interface is a standard RS 232 in
38. se check the thermocouple and its wires Over Temperature The thermocouple of the shown channel detects a temperature above 500 C Please check this thermocouple and its wires You should also check the thermocouples for neighboring nozzles 4 24 S GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems Z GUNTHER Check Thermo connector Heisskanaltechnik The connector of the thermocouple at the shown channel is missing or is not fixed Please check the connections Ch 1 error thermocouple check thermo connector ENTER Fig 4 5 Check Thermo connector 4 GUNTHER Load Interrupted Heisskanaltechnik The wires to the power module or to the nozzle of the shown channel are interrupted Please check the load fuses and the wires Ch 1 error load iow powerhealer In normal operation the load interruption is only or not connected detected at a percetage value of 100 This error ENTER message can occup at the adjustage In this case the power of the nozzle could be to small for this application Fig 4 6 Load Interrupted E G U NTH E R Load Connector Failure The load connector is lost or not fixed Please Heisskanaltechnik check th econnector Ch 1 Error check load connector ENTER Fig 4 7 Load Connector Failure 10 99 DPK 1 09 4 25 User Manual Hot Runner Systems DPK A GUNTHER lot Runner Systems Z GUNTHER Heisskanaltechnik war
39. side of the DPK It is possible to connect a potential free contact to the unit with a cable which is available from GUNTHER HOT RUNNER SYSTEMS specially for relay output of injection molding machines Additionally it is possible to increase the temperature for all runners at the same time By pressing the key C F T the temperature rise is activated The display shows in the multi channel mode at the left corner t boost in the single channel mode the following sign TC The temperature lowering mode is cancelled by pressing the key C F once more Now the old set values are valid The lowering value may be adjusted by the menu temp lowering in C F 0 255 The rise temperature mode is cancelled by pressing the key C FT The rising value may be adjusted by the menu temp boost If the lowering or rising is cancelled the old set values are restored 10 99 DPK 1 09 3 13 S GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 3 5 Menu Mode By pressing the menu key the menu mode is activated The main menu will be shown on the display 4 GUNTHER Heisskanaltechnik main menu gt temp program temp lowering temp Boost softstart powermonitor Fig 3 6 Main Menu Use the und Y keys to select and the A or ENTER key to confirm a menu item If the operater does not makes modifications in the main or in a other menu the display mode wil
40. terface The serial interface COMI is only to connect a DPK to a personal computer or to comunicate with other DPK An optional serial interface COM2 for injection molding machines is available An add on Kit for delivered units is also available With the interface COM2 it is possible to remote control and display the information of the DPK unit via the injection moulding machine The interface enables easy quality control because of the possible production data acquisition Because each injection moulding machine producer has ist own communication protocol use the menu item molding machine to select the protocol of the molding machine You can see which interface is needed by reading the user manual of the molding machine or contact G nther Hot Runner Systems for further information In the menu are the items Arburg Engel und Kraus Maffei see Chapter 5 Interface 3 5 5 Power Monitor The menu power monitor will show the total power consumption and the current separated for each line at the moment Z GUNTHER Heisskanaltechnik main menue power monitor set all channel L1 71 A 1560 W temp program L2 5 6 A 1232 W temp lowering L3 82 A 1804 W temp boost S moulding machine total power 4596 W Bild A E Fig 3 10 Power Monitor 10 99 DPK 1 09 3 17 S GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 3 5 6 Turn On Time The hours of o
41. ther heisskanal de Phone 49 01 729 41 12 26 Fax 49 64 51 50 08 59 E mail stamm guenther heisskanal de Phone 49 911 96 12 300 Fax 49 911 96 12 30 50 E mail thomas grajer weschu de Phone 49 36 84 88 68 0 Fax 49 36 84 88 68 22 E mail roemhild TV gmx de Phone 49 45 31 80 07 39 Fax 49 45 31 80 07 63 E mail w h ilmer t online de 7 48 User Manual Hot Runner Systems DPK ZY GUNTHER ot Runner Systems Worldwide G NTHER France S A Mr Demicheli 6 rue Jules Verne F 95320 Saint Leu La Foret GUNTHER U K Mr Heendeniya 52 Lambardes New Ash Green GB Longfield Kent DA3 8HU Trader Ingman Oy Mr Ingman Str msintie 23 A 1 FIN 00930 Helsinki GUNTHER Hot Runner Systems Inc Mr Vander Noot 725 Hastings Lane USA Buffalo Grove Illinois 60089 Industrade Corporation Room No 202 No 5 Wu Chuan Road Hsin Chuang Taipei Hsien Taiwan R O C Su Pad Ltd Mr Sadeh 2 Hamelacha Street New Industrial Zone IL Rosh Ha Ayn 48091 Dipl Ing Petr Sochor Ve Vilkach 1849 CZ 347 01 Tachov GUNTHER S C Mr Olszowski ul Poznanska 14 m 33 PL 00 680 Warszawa Dipl Ing H G nther Ges m b H Mr Feik Speichmiihlgasse 1 A 2380 Perchtoldsdorf Basler Trade KFT Mr Zastrow Postbox 25 H 1581 Budapest 10 99 DPK 1 09 Phone Fax E mail Phone 33 I 39 32 03 04 Fax 33 1 39 32 03
42. ust Oselieri Corso Buenos Aires 92 1 20124 Milano Brale Ltda Mr Holdschmidt Rua Joao de Barro 52 BR 83326 470 Pinhais PR DUMIS Mlaka d o o Mr Urana Oretnekova pot 9 SL 4000 Kranj HH Plastkombi aps Mr Hansen stergade 24 D DK 3200 Helsinge DELPLACE Ltd Marc Delplace B Sc Eng 6061 Thimens Boulevard CAN St Laurent QC H4S 1V8 Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail 10 99 DPK 1 09 52 55 66 47 32 52 55 46 40 14 zoica df1 telmex net mx 34 93 47 3771 3 34 93 49 90 43 8 centerplast airtel net 31 75 68 18 00 0 31 75 68 18 00 1 t b backer wxs nl 852 26 66 91 40 852 26 65 25 26 bathk hk super net 39 02 29 40 43 90 39 02 20 46 677 millut tin it 55 41 66 82 59 5 55 41 66 82 59 5 brale brale com br 386 42 74 10 00 386 42 74 10 01 dumis siol net 45 48 79 98 88 45 48 79 80 16 mail hh plastkombi dk 1 51 44 85 77 80 1 51 44 85 11 28 marc delplace qc aibn com Davidsmeyer amp Paul GmbH Elektronik 7 9 Apendix I EG Declaration of Conformity For the following below listed products Giinther Hot Runner Controller DP
43. usting set values and parameters cancel function gt ENTER KEY to confirm inputs D Key ENTER to quit program levels 10 99 DPK 1 09 2 6 D GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems 2 2 Parallel Display The parallel display is a 15 fold 3 digit seven segment display for set temperature actual temperature temperature difference or actual adjustable variables in Du Three additional LEDs are located beside each indicator to display the status of the zone If a channel is turned off appears in the accompanying display The percent control variable is displayed to channels which work in the setting mode SOLL SET IST EXIST DIFF A Fig 2 2 parallel display DPK Between the operating controls and parallel display the key and 4 LED s are placed The key is used to display the set value actual value temperature difference or the display of current in The LEDs above the key shows the selected display type The temperature state in addition is one by one displayed for every channel If the green indicator shines behind the corresponding value this channel has reached the programed temperature window ready for molding There is an over and under indicator also which is a red indicator for both conditions 10 99 DPK 1 09 2 7 S GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 3 Operating Instructions 3 1 Turning On
44. w 100 C because the set value is programmed over 100 C The softstart is indicated in the single channel mode by the following sign aa ramp time hold time In the multi channel mode by the text softstart and the countdown in the left corner After the end of the holdtime the unit will switch from softstart to normal operating mode To prevent overheating of the molding material in the 5V nozzles during combined operations employing both 5V and 230V nozzles the 5V nozzles are limited to temperatures not exceeding 10 99 DPK 1 09 3 19 ZY GUNTHER User Manual Hot Runner Systems DPK lot Runner Systems 105 C during softstart The temperature lowering is taken into consideration during softstarts so that the DPK unit can begin to operate immediately with an instant temperature lowering 3 6 2 Load Defaults By selecting the menu item load defaults and affirming the questions with yes twice the DPK loads up the parameters and values to the factory settings Attention All individual entered settings of the DPK values and parameters will be deleted The following table shows the default settings Set All Channels 100 C all set temperatures Temperature Programs 1 power ON 50 2 power OFF 75 3 temp ON 100 C 4 temp OFF 200 C Softstart ON over all time 10min hold time 5min ramp time 5min PID Parameter P Value 60 for all channels I Value 60 D Value 30 Temperature Unit C Temperatu
45. wired thermocable systems will be supplied from Giither Hot Runner Systems Power Cables The power cable requires a 40 pin connector plug with a suitable housing Because of the large number of possible arrangements and the required special crimping tools preassembled power cables manufactured by the GUNTHER HOT RUNNER SYSTEMS should be used In order to maintain a standard and for compatibility reasons the following procedures should be followed If a combination of low voltage and 230V runners is employed the low voltage runners should be connected in a sequential arrangement of increasing voltages beginning with runner 1 After all low voltage runners have been connected the 230V runners should then be connected to the system For example in a 10 runner system runners 1 to 4 are low voltage types and runners 5 to 10 are operated at 230V The length of the power cable should not exceed 3 meters 10 99 DPK 1 09 6 30 D GUNTHER User Manual Hot Runner Systems DPK ot Runner Systems The following standard plug connections are avalible Low Voltage e 20 pin for power components type DL 4 e 39 pin for power components type DL 6 and DL 8 e 40 pin for power components type LS 4 LS 12 e 40 pin for power components type LR 4 LR 12 e For the 160 T12 respectively DL 12 one 20 pin and one 39 pin plug must be used 230V e 10 pin connector socket with cable for max 5 runners AG 5 e 16 pin connector socket with cable for ma
46. x 8 runners AG 8 e 32 pin connector socket with cable for max 15 runners AG 16 When ordering a power cable the following informations is required e Number of low voltage runners e Number of 230V runners e Type of low voltage connection such as 20 pin 39 pin or for DL4 for DL8 or DL12 e Type of 230V connections 10 pin 16 pin or 32 pin or AG 5 AG 8 AG 16 Hint To prevent connection errors between the temperature controller DPK and the power unit the load connector of the DPK is mechanically coded The power cables should be equipped with the same encoder system as the DPK This applies only for units using a star net supply see apendix C You can also order cables for connecting several low power units to a DPK e g connection for 2 x DL8 or 3 x DL4 etc Signal Inputs and Outputs of the DPK Output Fault Def If a thermocouple or heating circuit failure is detected it will be reported here The output Defect fault is a potential free normaly open contact for 230V max 1A or a protected extra low potential as specified by VDE VDE union of german electrical engineering The contact must be fused externally A corresponding plug with 2 5m cable can be ordered from the GUNTHER HOT RUNNER SYSTEMS company Output Ready to Start Molding OK As soon as the adjusted runners have reached the preset temperatures the output Ready to start molding operation is switched on Additionally a potential
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