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1. HOT RUNNER TECHNOLOGY Fig 4 7 Damage of a Power Module GUNTHER HOT RUNNER TECHNOLOGY Ch 1 error Load 24V fuse defective ENTER Fig 4 8 24V fuse defective 24V fuse defective On the power module LS device the 24V exit circle s fuse is defective Normally this knife edge protection fuse is located at the rear of the 24V power module 11 05 DPK DPT 33 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY 5 Serial Interface 5 1 General Information DPK DPT is equipped with one serial interface COMI see also chapter 3 5 11 Serial Interface This is a standardized RS232 interface An optional serial interface is as well available as an add on kit This second serial interface is used for connecting a DPK DPT to a molding machine With the interface it is possible to remote control and to display the information of the DPK DPT unit via the molding machine It enables easy quality control caused of a product data acquisition This time there are several types of serial interfaces 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 in the user manual of your machine For further infomation please contact GUNTHER HOT RUNNER SYSTEMS Because of several communication protocols for the different molding machines contact
2. Identifies thermocouple failures heat circuit disconnections and short circuits Corrects polarity errors at thermocouple connections independently by logical turning of the connections Turns off the power supply in case of a malfunction and signals the alarm via a potential free contact Parameters and programs are saved in an EEPROM and are therefore not lost in case of a power supply failure The DPK DPT is designed for easy use this makes installation and tool change simple Advantages for the user The DPK DPT 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 level prevents wrong operation All zones and the set and current values for each zone are displayed simultaneously The control parameters are adjustable according to the application The implemented diagnosis function tests the complete system including tools nozzles manifolds and the hot runner system for malfunction and is able to correct possible miswirings independently Circuits connected incorrectly are located before the start of an operation Low installation costs because of combined thermal and power connections The DPK DPT has numerous special functions for optimal system utilization Advantages for the user Power output surveillance is possible during an operation Decreasing
3. If errors occur which the system cannot debug independently the faulty zone will be switched off 11 05 DPK DPT 15 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY Evaluation Display Description Debugging wire Assignment mistake zone gt thermocouple Automatic debugging pol Polarity of thermocouples exchanged Automatic debugging no sig Thermocouple Shortcut Manual debugging break Thermocouple interrupted Manual debugging no load no load load interrupted Manual debugging OK no error 3 5 6 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 operator can change the language the PID parameter or calibrate the DPK DPT etc For further information refer to Chapter 3 6 Configuration Menu 3 5 7 Heater 5V 24V In this menu item the type of the low voltage load 5V 24V can be set for all zones 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 of 5V and 24V nozzles is not supported When using DPK units with software version 1 35 and higher a selection box is displayed for a short time after switch on and the user is able to adjust the current heater 5V 24V If the user does not take out any adjustments the box will fade out again after 4 seconds and the control
4. e Remove the top cover by removing the four screws on the side of the unit e Plug the interface into the 10 pin and 14 pin connectors on the front panel LR27 take caution of the right direction e Remove the cover panel at the rear of the DPK DPT 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 into 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 screws 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 DPT 38 11 05 DPK DPT User Manual Hot Runner System DPK DPT OUNIHER RUNNER TECHNOLOGY Interface and Master Slave Connections 2 RXD 1 1B 3 TXD 2 12 5 GND 3 2B 7 RTS 4 22 8 CTS 6 1A 7 8 2 DSUB 9 9 9 Y female female RS 232 Interface RS 485 Interface 1 RXD o 1 CTS 4 TXD 2 RTS 6 RXD 3 9 TXD 4 TXD 6 CTS 4 TXD passiv 7 RTS RXD passiv 8 RXD DSUB 9 psug o 9 TXD femalee female TTY Interface RS 422 Interface Fig 6 1 Interface
5. p RxD Displayplatine S i LR 27 Schnittstelien Modul DEFEKT DK ABSENKUNG TTY Schnittstelle Temperaturverst rker LR 26 T 160 m Conver ler 7 04 Load Conneclor Zone 13 Zone 14 Zone 18 Zone 12 Zone 15 Load Al Eu EM ES gt Eu E 4 Soen Moos Pofgn Vopu LAIG Terminal Board E EE QD 20VA Grafikdisplay Reglermodul LR 28 T160mA xs eee eee xa PE N L3 LZ LI Net Connecofr gez 22 0799 ee geor TOR Kenderung Datum 11 05 DPK DPT 55 User Manual Hot Runner Systems DPK 7 G U NIHER 7 7 Appendix G Position Schematic LGL ai 06514 CIGL ai 5 L ON D O e L 1 8 enm 63d SX ZZ 394 EZ 184 9x TZ EA 230799 uwa i l i DAVIDSMEYER amp PAUL GmbH U Positions plan 2 gt 5 56 11 05 u User Manual Hot Runner System DPK DPT 7 G U NIH ER 7 8 Appendix H Addresses G NTHER Heisskanaltechnik GmbH Industriegebiet Nord Sachsenberger Stra e 1 D 35066 Frankenberg Eder Deutschland Phone 49 64 51 50 08 0 Telefax 49 64 51 50
6. Weight Color 52 Data recovery after power fail data storage lifetime at least 10 years without battery LCD graphic display 40 x 71 mm seven segment LED display 8mm and LEDs Operating section Parallel display 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 468mm x 142mm x 345mm 13 0 kg 28 6 Ibs grey blue RAL 9018 RAL 5015 11 05 DPK DPT x amp User Manual Hot Runner System DPK DPT 7 G U NIH ER 11 05 DPK DPT 53 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY 7 5 Appendix E Service Form Addresses see Appendix H Addresses FAX To From Company Company Phone Phone FAX FAX City City Date Date Response partner O Please call back D Ask for customer service O Ask for repair Service form for control units from the Giinther Hot Runner Systems company Type of unit Serial number Program version Used connecting cable Voltage Net kind O Delta O Other 5 Zones 24V Zones 230V Zones If power units SV 24V are used are collective rails connected Description of previous history initial start up prior operation etc Problem description 54 11 05 DPK DPT User Manual Hot Runner System DPK DPT OUNIHER RUNNER TECHNOLOGY 7 6 Appendix F Schematic
7. 27 28 29 30 31 m 7 2 DUUM Connector 32 pin to the DPK DPT Transducer A7 A8 A9 A10 B7 B8 B9 BIO C7 C8 C9 CIO D4 D5 De Transducer D7 Ds Do Dio D7 D po Dio D7 DS po DS 9 Neutral Conductor A5 A5 A6 A6 B5 B5 B6 B6 C5 C5 Co Co A6 B6 C6 Fig 7 3 Load Connector 40 pin of the DPK15 DPTI5 44 11 05 DPK DPT User Manual Hot Runner System DPK DPT 7 G U NIH ER External Conductor AL A2 A4 B1 B2 B3 Ba Transducer A7 A9 a10 B7 B8 B9 10 C7 cs Transducer D7 Ds Do Dio pr ps Do pioj L LT T Neutral Conductor 5 A5 B5 B5 B6 B6 jeo Fig 7 4 Load Connector 40 pin of the DPK10 DPTIO External Conductor A2 Tranmsducer A7 A8 A9 AI0 7 NE Transducer D7 Ds L L 1 Neutral Conductor 5 A5 a6 a6 ao Fig 7 5 Load Connector 40 pin of the DPK5 DPT5 Hint In star circuit the return cables A5 A6 B5 B6 C5 and C6 are only connected to the neutral conductor In case of delta connection on
8. GUNTHER HOT RUNNER TECHNOLOGY User Manual _ Regulator DPK DPT 5 15 up Software Version P1 09f User Manual Hot Runner Systems DPK GUNTHER HOT RUNNER TECHNOLOGY Table of Contents Page 1 GENERAL 1 2 DISPLAY AND OPERATING CONTROLS 3 2 1 CONTROL PANEL 2 2 PARALLEL DISPLAY 4 3 OPERATING INSTRUCTIONS 5 3 1 TURNING ON 5 32 MULTI CHANNEL MODE 5 3 3 SINGLE CHANNEL MODE 6 3 4 OPERATING MODE 7 3 4 1 Changing Set Values 7 3 4 2 Switching Zones On and Off 8 3 4 3 Changing the Operating Mode Percentage Slave Temperature 9 3 4 4 Temperature Lowering Boost 10 3 5 MENU MODE 12 3 5 1 Set all Channels 14 3 5 2 Temperature Program 14 3 5 3 Temperature Lowering Boost 15 3 5 4 Power Monitor 14 3 5 5 Diagnosis 15 3 5 6 Configuration 15 3 5 7 Heater 5V 24V 16 3 5 8 Language 16 3 5 9 Start up Ramp 16 3 5 10 Temperature Window 16 3 5 11 Molding Machine Serial Interface 16 3 5 12 Turn on Time 17 3 5 13 Error History 17 3 5 14 Service 17 3 6 CONFIGURATION MENU 19 3 6 1 Softstart 19 3 6 2 Load Defaults 20 3 6 3 Calibration 21 3 6 4 PID Parameter 21 3 6 5 Thermocouple Assignment 20 3 6 6 Thermocouple Type 21 3 6 7 Switching C F 21 11 05 DPK DPT User Manual Hot Runner System DPK DPT OUNIHER HOI RUNNER TECHNOLOGY 3 6 8 User Password 3 6 9 Parameter 4 OTHER FU
9. Starting Ramp Lowering Boost Security Turn Off RUNNER TECHNOLOGY 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 pcs 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 moment protocols are available for Arburg Mannesmann Krauss Maffei and Engel Further protocols are planned 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 only DPK with automatic adjustment of the control parameters DPK uniform automatic parameters match by means of phase control mechanism DPT zero cross triac switch 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 Equal heating of each nozzle depending on the slowest one adjustable 0 255 0 255 F adjustable 0 255 0 255 F adjustable 0 500 0 500 11 05 DPK DPT 51 User Manual Hot Runner Systems DPK HOT RUNNER TECHNOLOGY GUNTHER Other Details Data Protection Display Keyboard Storage Temp Operating Temp Humidity Protection Type Dimensions
10. The 15 fuses for all heating zones are placed on the left housing side The three 16 holders are mechanically different from the 10 holders The fuse number corresponds to the zone number Hint Please note that the DPK DPT can be delivered as 5 10 or 15 zone system The lettering of both upper 16 fuses has ambiguous meanings The controller DPK5 5 contains four 10A fuses for zones 1 4 and one 16A fuse for zone 5 The controller DPK10 DPTIO contains eight 10A fuses for zones 1 8 and two 16A fuses for zones 9 and 10 The controller DPK15 DPT15 contains 12 10A fuses for zones 1 12 and three 16A fuses for zones 13 14 and 15 Additionally to the heating zone fuses the DPK DPT 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 modules LR15 has a separate 160mA controller fuse 46 11 05 DPK DPT x amp User Manual Hot Runner System DPK DPT 7 G U NIH ER 11 05 DPK DPT 47 User Manual Hot Runner Systems DPK 7 G U NIHER 7 3 Appendix C Star Delta Operation Attention Disconnect the main s voltage and take care that there is no voltage at the DPK DPT before opening the device Please follow these safety instructions The unit DPK DPT is prepared for a standard connection of a 400V star net supply If a 240V delta net supply is necessary for
11. load difference Maximum permitted deviation of the zones s heating capacity among one another This parameter is not in use at the moment default 70 11 05 DPK DPT 23 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY min 0 max 100 7 temp windows 2 C Tolerance window for compensating overheating If the set temperature has been exceeded by more than the adjusted value the zone is switched off and the error message Zone xx Load Regulating deviation is displayed default 50 min 0 max 500 8 max 5V current in A Maximum current on which the 5V loads will be adjusted default 125 min 0 max 150 9 cooling ramp at C The ramp for regulated cooling of a zone begins with the set temperature plus the adjusted value default 40 min 0 max 100 10 heating ramp at C The ramp for regulated heating of a zone begins with the set temperature minus the adjustable value default 30 min 0 max 100 11 no load timeout sec Adjustable time for identifying a load interruption To release a load interruption error a zone with a power output of gt 98 has to be operated during the indicated time without the zone s set temperature having risen For manifolds loads gt 600W the double testing time is applied default 60 min 0 max 500 12 ext controller addr Address of a device connected externally e g Arburg molding machine default 1 min 0 m
12. temperature difference or current adjustable variables in Three additional LEDs are located beside each indicator to display the status of the zone If a zone is turned off appears in the accompanying display The percent control variable is displayed to zones which work in percentage control mode In addition the temperature state is one by one displayed for each zone If the green indicator shines behind the corresponding value this zone has reached the programmed temperature window ready for molding operation If the temperature exceeds the temperature window or lags behind it the red indicators will show Fig 2 2 Parallel Display DPK DPT Between the operating control and the parallel display the key and 4 LEDs are placed The key is used to display set value current value temperature difference or the display of current in The LEDs above the key show the selected display type 4 11 05 DPK DPT User Manual Hot Runner System DPK DPT 7 G U NIH ER 3 Operating Instructions 3 1 Turning On After the unit has been switched on the GUNTHER logo the program revision number and the serial number appear on the display When using a DPK unit the type of the low voltage load 5V or 24V is asked Moreover possibly important information are displayed Then the unit automatically performs a system check including the heating circuits and tests whether a low voltage or a 23
13. with which the zone is operated during the diagnosis default 40 min 0 max 100 20 diag cooling time sec Time used for cooling down the tools before the actual diagnosis starts To avoid incorrect measurements during the diagnosis by unintentional heating of neighbouring zones and to guarantee a regular cooling procedure the adjusted time is bided once again half after the checking of the single zones default 60 min 0 max 1200 21 low time visible from Softwarevers 1 33 21 molding machine check If this parameter is set to 1 a monitoring of the molding machine will be realized via the external lowering entrance In this case the actual lowering function is however annuled Realization of monitoring If the molding machine is active and in perfect condition it has to keep the contact for the external lowering closed It opens this contact if an error at the molding machine occurs Then the controller activates the lowering function after the time which has been adjusted in the menu item Temp lowering ext This kind of lowering provides that the controller is in ready for molding mode Now the lowering key serves for putting back the external lowering Within this setting the actual lowering function can not be used any more Standstill Monitoring default 0 min 0 max 1 22 boost for manifolds If this parameter is set to 1 the temperatures of the manifolds load gt 600W wil
14. 125A for 5V nozzles 100 is equivalent toca 25A for 24V nozzles 3 4 4 Temperature Lowering Boost Temperature Lowering If production stops for a longer period of time it is advisable to lower the set temperatures without turning the unit off By pressing key lowering temperature is activated In multi channel mode the display shows Lowering the adjusted lowering value at the left corner in single channel mode the following sign is displayed UL An external activation for lowering temperature is possible by connecting a closing contact at the rear side of the DPK DPT It is possible to connect a potential free contact to the unit with a cable which is available from G NTHER HOT RUNNER SYSTEMS especially to relay output of injection molding machines Temperature Boost For starting up the tools it is helpful to boost up the temperatures of all zones for a short time By pressing key C FT temperature boost is activated In multi channel mode the display shows T Boost the adjusted rising value at the left corner in single channel mode the following sign is displayed TC After a preadjusted time 120sec temperature boosting ends automatically It can also be ended by further activating of the key Normally the manifolds are excluded from temperature boost However they can be integrated in the boosting function if parameter 22 Menu gt Configuration gt Parameter g
15. Connections of the DPK DPT HES zcecececccoce e REECH gt DSUB 9 DSUB 25 Stecker Stecker Abb 6 2 Wire Connection Mannesmann Length 5 0m o jo pooooooocaona af DSUB 9 St 20mA Weidm ller male DSUB 255 DSUB 25 Bu plug 4 pol Abb 6 3 Wire Connection Engel Length 4 5 11 05 DPK DPT 39 User Manual Hot Runner Systems DPK HOT RUNNER TECHNOLOGY br 3 gn 20mA 2 DSUB 9 St DSUB 9 St malg Male 3 y i N E e e y 1 Nu AMP DIN 5 male Abb 6 4 Wire Connection Arburg Selogica Krauss Maffei MC4 Length 4 5m 0 2m DSUB 9 Stecker DSUB 9 Stecker Abb 6 5 Interface wire TYPE M S Wire 3 Length 3m DSUB 9 Stecker DSUB 9 Stecker DSUB 9 DSUB 9 DSUB 9 Stecker Abb 6 6 Interface wire TYPE M S Wire 5 Length 3m 40 11 05 DPK DPT d amp User Manual Hot Runner System DPK DPT G U NIH ER Hint If an EPROM update is required at the same time as the interface installation is active disconnect the molding machine from the DPK DPT before switching it 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 asynchron
16. GUNTHER HOT RUNNER SYSTEMS for availibility Please specify the type and manufacturer of your molding machine Please refer to the installation instructions for detailed information of installation The DPK DPT with an optional serial interface gets all data from the molding machine Any operation on the hot runner system is not necessary and for security reasons not possible Parameter and set temperature changes will be impossible if the DPK DPT 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 boost via keys C F and C FT is also not possible Hint If for example parameters should be changed the connection from the DPK DPT to the molding machine must be opened Disconnect the cable to the molding machine after switching off the DPK DPT or switch off the molding machine This causes no more data being sent to the DPK DPT Then the DPK DPT notes that no interface operation is current In this case the DPK DPT enables any user operations after a few seconds The DPK DPT then works as a stand alone unit The parameters and settings from the molding machine are stored in the DPK DPT This increases easy diagnosis to the hot runner system For the operation hints for the interface of the different molding machines please refer to your user manual The
17. Scheer warming In general an adjustment of 4 C is advisable This ensures that no deviations disturb the friction recognition see chapter 4 6 Friction Recognition and Monitoring default 0 min 0 max 10 29 stop after OK in min If 0 is set here this function will be deactivated By setting a time between 1 and 60 min this function is activated Then the power output of a zone is switched off automatically if it has been into regulating mode for longer than the adjusted time default 0 min 0 max 60 30 RS232 interface fixed Fixing of interface switching to RS232 default 0 26 11 05 DPK DPT User Manual Hot Runner System DPK DPT 7 G U NIH ER min 0 max 1 31 autom slave mode Switches the automatic leading function on 1 and off 0 If this function is switched on the hot runner system tries to establish a so called slaving zone for each zone in current and in ready for molding mode This slaving zones must show an at least similar behaviour set value actual value power output as the zone they are assigned to Having determined a slaving zone for a zone the controller switches into slave mode automatically if a thermocouple failure occurs at this zone Then the before determined slave zone is set as leading zone default 1 min 0 max 1 32 supress friction Suppression of regulating deviations caused by friction If 0 is set here this function will be deactiva
18. Value 0 manifold 2600W P Value 100 L Value 4 D Value 0 Temperature Unit C Temperature Window 10 C Lowering Value 50 C Rising Value 20 C Language English Interface DP Intern Heater 5V 24V DPK only 24V 20 11 05 DPK DPT x User Manual Hot Runner System DPK DPT 7 G UJ NI H IR HOT RUNNER TECHNOLOGY 3 6 3 Calibration The sophisticated and microcontroller supported temperature module of the DPK DPT is able to calibrate itself by using a calibration jack 4 RUNNER TECHNOLOGY Calibration Calibration Configuration Reading Data Reading Data Softstart Calibrating Offset Load Defaults Calibrating Gain Source missing Writing Data PID Parameter Wait Th couple Assignment Thermocouple Picture Picture C Deviation min Offset 0 max Offset 2 C avg Offset 1 50 min Gain 0 96 max Gain 17 avg Gain 06 Picture B Fig 3 12 Calibration The calibriation jack is available from GUNTHER HOT RUNNER SYSTEMS without it the error message of Picture C appears on the display 3 6 4 PID Parameter The operator can change the PID parameter using the menu item Pid Parameter So the operator is able to match the parameters to the controlled system It is possible to match the several parameters independently 3 6 5 Th couple Assignment Within this menu item the user
19. and increasing temperature for all control points by simply pressing a key Reading of the effective current at low voltage Several set value programs facilitate possible material or tool changes If desired a serial interface is available as connection to an injection molding machine 11 05 DPK DPT us User Manual Hot Runner System DPK DPT 7 G U NIHER The display and operating controls of the DPK DPT are separated into the operation control panel and the parallel display Great emphasis has been placed upon ease of use and a good layout n ontrol GUNTHER HOT RUNNER TECHNOLOGY Set Power 200 0 a 200 50 300 100 100 0 100 0 Fig 2 1 Control panel DPK Function Keys A Key C Fl lowering temperature in all zones B Key boosting temperature in all zones C Key MENU gt show menu D Key ENTER gt ENTER key to confirm inputs to quit program levels E H Keys changing amp adjusting set values and parameters cancel function 11 05 DPK DPT 3 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY For further details concerning keys and their functions see chapter 3 3 Operation 2 2 Parallel Display The parallel display consists of 15 three digit seven segment displays to exhibit set temperature present temperature
20. displayed in the right lower edge of the display 6 3 2 Changing a Power Module LR 31 The DPK DPT 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 message Because each LR31 1 driven by a separate phase zone 1 5 by L1 zone 6 10 by L2 and zone 11 15 by L3 the damaged module can be indentified easily For changing a power module you have to remove the cover of the case Mark the connecting lines of the module which is going to be exchanged to guarantee that the connections are not mixed up when installing the new module Afterwards the five load connections the neutral conductor the phase connection and the IIC Bus plug are detached from the power module After removing the corresponding screws at the heat sink rear of the housing the power module can be pulled out at the rear of the device Before installing the new power module it has to be coded corresponding to the zone assignment and its installing position by means of the jumper see below Coding a power module Now the power module can be put into the case from behind and can be arrested by means of the screws The connecting lines are linked like in the old module The cover is put on again and screwed up Now the controller can be taken into operation again Coding of a power module Depending on the module there are one two or three modules inside each DPK DPT
21. keys and Y By pressing key 4 or ENTER you will return to the menu If the key is used the displayed value will be stored as a new set value By using key the value will not be stored cancel function The menu structure is on the next page 12 11 05 DPK DPT User Manual Hot Runner System DPK DPT RUNNER TECHNOLOGY GUNTHER Menu structure of the DPK DPT Main Menu set all channels temp program temp lowering temp boost power monitor diagnosis configuration softstart load defaults heater 5V 24V calibration language pid parameter start up ramp th couple assignment temperature window thermocouple type molding machine switch C F turn on time user password error history parameters service Fig 3 7 Menu structure of the DPK DPT The menu item Heater 5V 24V is missing in units 11 05 DPK DPT 13 User Manual Hot Runner Systems DPK 7 G U N T H IR HOT RUNNER TECHNOLOGY 3 5 1 Set all Channels The menu Set all channels enables the operator to change the set temperature or to turn on or off all zones GUNTHER HOT RUNNER TECHNOLOGY Main Menu gt ESSUE Temp Programm Temp Lowering Temp C Temp Boost 100 Power Monitor Diagnosis ENTER Picture A Set all temp Fig 3 8 Set all Channels 3 5 2 Temperature Program A set value program is a
22. occurred faults It is possible to leaf through the list with keys and Y The following list shows the meanings of the different error shorthand expressions Error shorthand expression Description Hours Min Thermo plug Contact problems at thermo plug Hours Min Load plug Contact problems at load plug Hours Min calibration Calibration Hours Min Zxx Th pol Thermoelement error at zone xx Thermoelement Exchanged Hours Min Zxx Th break Thermoelement error at zone xx Thermoelement Failure Hours Min Zxx Th short Thermoelement error at zone xx Thermoelement Shortcut Hours Min Zxx Th over Thermoelement error at zone xx Overtemperature Hours Min Zxx Load break Zone xx Load Interrupted Hours Min Zxx Load short Load Shortcut Hours Min Zxx Load plaus 7 xx Plausibility Logical sequence of the loads 230V 24V 5V Hours Min Zxx Th over Zone xx Deviation from rule Hours Min Zxx 24V Fuse Zone xx 24V fuse defective 3 5 14 Service This menu item is used by the manufacturer of the DPK DPT for several settings It has its own password The user must not and needs not make any changes to this item 18 11 05 DPK DPT Eod amp User Manual Hot Runner System DPK DPT 7 G U NIH ER 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 operator can change the PID para
23. 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 have been changed it is advisable to change the program accordingly There are four set value programs available When the control unit is turned on the last one of the previous used programs will be reactivated automatically To reset all programs and parameters select the menu item Load Defaults see chapter 3 6 2 Load Defaults GUNTHER HOT RUNNER TECHNOLOGY Main Menu Set all channel emp Programm Temp Lowering Temp Program 2 power OFF 75 3 temp ON 100 Temp Boost 4 temp OFF 200 Power Monitor default Diagnosis Picture A e e Fig 3 9 Changing Temperature Program 14 11 05 DPK DPT md amp User Manual Hot Runner System DPK DPT 7 G U NIH ER 3 5 3 Temperature Lowering Boost By the two menus Temp Lowering and Temp Boost the operator can set a temperature increase or decrease By using key C F the temperature decreases to the value which has been adjusted in the menu Temp Lowering By using key C FT the temperature raises to the value which has been set in the menu Temp Boost 3 5 4 Power Monitor The menu Power Monitor shows the total power consumption and
24. refer to Appendix 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 Appendix A Parts and preassembled prewired thermocable systems will be supplied from G NTHER HOT RUNNER SYSTEMS company 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 G NTHER HOT RUNNER SYSTEMS company 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 zones is employed in DPKs not in DPTs the low voltage zones should be connected in a sequential arrangement of increasing voltages 36 11 05 DPK DPT SU e User Manual Hot Runner System DPK DPT U NTH ER beginning with zone 1 After all low voltage zones have been connected the 230V zones can be connected to the system For example in a 10 zone system zones 1 to 4 are low voltage types and zones 5 to 10 are operating at 230V The length of the power cable should not exceed 3 meters The following standard plug connections are available Low Voltage 20 pin for power components type DL 4 39 pin for power components type DL 6 and DL 8 40 pin for power components type TS 4 TS 12 40 pin for power components type LR 4 L
25. the current separated for each phase at the moment GUNTHER HOT RUNNER TECHNOLOGY Main Menu Power Monitor Set all channel EN 1560 W L2 5 6 1232W Temp Lowering L3 8 2 1804 W Temp Boost gt Power Monitor Monitor Total Power 4596 W Diagnosis Picture A e e Fig 3 10 Power Monitor 3 5 5 Diagnosis Within the menu item Diagnosis a check of zone assignment and wiring can be carried out For that purpose all channels are first cooled down after the start of the diagnosis Afterwards all channels are heated up separately and the reaction of the thermocouples will be established This way possible miswirings at the thermocouples can be located and repaired if necessary During the diagnosis each zone to be tested its kind of heater as well as the established reaction of the corresponding thermocouple are displayed in a line At the end of the line a short evaluation text is announced see below If assignment mistakes zone thermocouple are recognized within the diagnosis the user will be asked if these mistakes should be repaired automatically at the end of the diagnosis If the user answers with Yes a logical re connection of the circuits will be carried out and the hot runner system can be operated without any hardware modification Otherwise the user has to repair the assignment mistakes by changes within the hardware
26. to monitor the molding process and to localize possibly plugged nozzles It uses the physical effect of the friction warming Scheer warming to localize defective nozzles If plastic is pushed through a nozzle with high pressure Scheer warming develops Because of the friction energy resulting from this procedure the temperature of the nozzle increases for a short time If this effect is missed at a nozzle when injecting the plastic it can be supposed that a problem blockage exists here 11 05 DPK DPT 29 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY The function can be activated in the Parameter Menu Menu gt Configuration 99 gt Parameter gt 28 friction temperature by setting of a friction temperature If 0 is set here the function will be deactivated The temperature which is to be set here can lie between 1 C and 10 C The adjusted temperature value is a threshold over that the current temperature has to increase in ready for molding mode in order to recognize friction In general an adjustment of 4 C is advisable This guarantees that no deviations disturb the friction recognition If friction recognition is activated all nozzle channels zones with a load lt 600W will be checked on friction cyclically in 0 5 second intervals Within this procedure the friction cycle time between the phases of injection will be established While recognizing friction the text frictio
27. tool will be ready for duty Additionally the message ready for molding is shown on the display Appropriate to the default values the temperature window s value is set to 10 C 3 5 11 Molding Machine Serial Interface A transmission protocol for the DPK DPT s COM2 interface can be adjusted in the menu item Molding machine The COM2 interface is an optional extension of the control element and can be installed directly when buying the controller or subsequently Via this interface a communication between controller and molding machine is possible so that the controller can be operated by the molding machine 11 05 DPK DPT 17 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY At the moment there are transmission protocols available for Arburg Engel and Krauss Maffei interfaces see Chapter 5 Serial Interface 3 5 12 Turn on Time The hours of operation are displayed in the menu item Turn on Time They describe the time in which the DPK DPT has been switched on from its first operation on and will be displayed in hours and minutes 3 5 13 Error History Within this menu item it is possible to see the last occurred and receipted mistakes related to the hours of operation The meter reading of the hours of operation from the moment of the occurred error on is followed by the error report The occurred fault will be distributed as a shorthand expression The list contents the 64 last
28. 08 50 E mail info guenther heisskanal de Internet www guenther hotrunner com 11 05 DPK DPT 57 User Manual Hot Runner Systems DPK 7 G U T H R HOT RUNNER TECHNOLOGY 7 9 Appendix I EG Declaration of Conformity For the following below listed products G nther Hot Runner Controller DPK5 15 DPT5 15 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 73 23EWG 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 DAVIDSMEYER amp PAUL GmbH Elektronik Humboldtstr 2 4 D 50181 Bedburg Bedburg 01 06 2004 J Marquardt Managing Director Expressions recommended by EMV Rechtsvorschriften und ihre Anwendung in der Praxis Franzis Verlag 1993 58 11 05 DPK
29. 0V load is connected The display will show the table load recognition which is divided into the tested channel s number the kind of load and its potential power At the same time the respective field of the parallel display shows Test and then the detected voltage of the load If a load turns off due to a fault or if it is not connected the parallel display will show During initial start up and or after resetting the controller to its factory settings the unit starts an question after switch on in that the language for the menu can be set by keys and Y If this question is not operated within five seconds English will be adjusted as current language automatically 3 2 Multi Channel Mode After the adjusting of the loads the controller is in multi channel mode In this mode always five zones are displayed for a short time interval GUNTHER HOT RUNNER TECHNOLOGY Zone Exist Set Power 1 200 200 096 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 centigrade or degrees fahrenheit are displayed in this mode The control value is displayed in percent for 230V nozzles DPK DPT or in ampere A for 24V or 5V nozzles DPK Hint At the appearance of any failure the multi channel mode will be interrupted and the failure will be visualized on the display
30. DPK5 DPT5 gt 1 power module in the lower installing shaft DPK 10 10 2 power modules in the lower and middle installing shaft DPK 15 DPT 15 gt power modules in the lower middle and upper installing shaft On the LR 31 there are two jumpers for the zone setting The figure shows how they have to be set gt Jo 11 15 Zone 6 10 Zone 1 5 Zone ur Mo o gt r gt Bi 11 05 43 User Manual Hot Runner Systems DPK Fig 6 7 Jumper Settings for the Power Module LR31 7 Appendix 7 1 Appendix A Connections to the DPK DPT 1 Netz Last Load Thermo LA 2776 o M e ER MM 2020 70 Abs 220 40 60 20 210 130 50 280 x0 120 40 20 wo no 30 0 100 20 Ser Fre 70 79010 F je FI F2 F FA 96 F5 F6 H F6 FIO F11 F12 8688 w Fig 7 1 Connections on the Rear Side of the DPK DPT Do Soenonno e Ser Serial Interface Ready to Start Molding Def Fault Abs Lowering external Zen un um ES Metal 3 413 6 7 L8 17 is 29 2 22 23 Constantan blue 9 10 11 12 13 14 15 16 25 26
31. If several errors occur the zone whose error was recognized 11 05 DPK DPT 5 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY first will be displayed This is also valid if the display is switched from menu mode to multi channel mode after the appearance of any failure 3 3 Single Channel Mode To change from multi channel to single channel mode mark a zone with keys or By pressing key gt or Enter this zone is entered in single channel mode In this mode all data set value actual value load character current or power consumption of the displayed zone is shown GUNTHER HOT RUNNER TECHNOLOGY ZONE Act 200 1 ss 200 24v 4A Fig 3 2 Single Channel Mode In single channel mode the zone number is marked at first By pressing key lt the display mode returns to multi channel mode After two seconds the mark fades out and then it is possible to turn the display mode to the scan mode by pressing key lt The following sign indicates the scan mode C D 2 2 In this mode the zones with set and current values will be shown the display one by one Zones which are switched off will be skipped The scan mode can be cancelled by pressing any key and restarted by pressing key after two seconds when the marking of the zone number faded out again Hint If a fault occurs the sca
32. NCTIONS 4 1 READY TO START MOLDING OPERATION 4 0 AUTOMATIC SLAVE MODE 4 3 AUTOMATIC RECOGNITION OF LOAD ADAPTERS 4 4 TEMPERATURE LOWERING BOOSTING WITH TEMPERATURE PROGRAM 4 5 STANDSTILL MONITORING 4 6 FRICTION RECOGNITION AND MONITORING 4 7 FAULT REPORT 5 SERIAL INTERFACE 5 1 GENERAL INFORMATION 5 20 TROUBLE SHOOTING 6 INSTALLATION START UP AND MAINTENANCE 6 1 INSTALLATION 6 1 1 Location 6 1 2 Electrical Connections 6 1 3 Additional Interface 6 2 START UP 6 2 1 Initial Start Up 6 2 2 Additional Information 6 3 MAINTENANCE 6 3 1 EPROM Update 6 3 2 Changing a Power Module LR31 7 APPENDIX 7 1 APPENDIX CONNECTIONS TO THE DPK DPT 7 2 APPENDIX FUSES 7 3 APPENDIX STAR DELTA OPERATION 7 4 APPENDIX D TECHNICAL DATA 7 5 APPENDIX E SERVICE FORM 7 6 APPENDIX F SCHEMATIC 7 7 APPENDIX POSITION SCHEMATIC 7 8 APPENDIX H ADDRESSES 7 9 APPENDIX I EG DECLARATION OF CONFORMITY 11 05 DPK DPT 22 22 28 28 28 27 28 28 28 29 33 33 34 35 35 35 35 37 41 41 41 41 41 42 43 43 45 47 49 53 55 57 56 62 ZGUNIHER User Manual Hot Runner System DPK DPT HOT RUNNER TECHNOLOGY Warranty Conditions Installation and implementation must be carried out by an electrician Please refer to chapter 6 Installatio
33. R 12 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 5 zones AG 5 16 pin connector socket with cable for max 8 zones AG 8 32 pin connector socket with cable for max 15 zones AG 16 When ordering a power cable the following information is required Number of low voltage zones Number of 230V zones Type of low voltage connections such as 20 pin 39 pin or for DLA for DL8 or DL12 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 DPT and the power unit the load connector of the DPK DPT is mechanically coded The power cables should be equipped with the same encoder system as the DPK DPT This applies only in units using a star net supply see Appendix C You can also order cables for connecting several low power units to a DPK DPT e g connection for 2 x DL8 or 3 x DL4 etc Signal Inputs and Outputs of the DPK DPT 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 normally open contact for 230V max 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 G NTHER HOT RUNNE
34. R SYSTEMS company Output Ready to Start Molding OK As soon as the adjusted zones have reached the preset temperatures the output Ready to start molding operation is switched on In addition a potential free relay contact for 230 max 1A is switched on A corresponding plug with 2 5m cable can be ordered from G NTHER HOT RUNNER SYSTEMS company Input Lowering Abs 11 05 DPK DPT 37 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY By using a potential free external contact the DPK DPT can be set to lowering Attention Never connect any voltage to this input Serial Interface One serial interface RS232 is included in each DPK DPT For a connection to a molding machine a second serial interface is required Depending on the molding machine and its protocol a RS232 RS485 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 DPT For further information please contact GUNTHER HOT RUNNER SYSTEMS 6 1 3 Additional Interface The add on kit includes e interface module e 1 preassembled flatcable e 5m interface cable 2 x 0 5mm shielded assembled for a 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 Attention Disconnect main power before opening system
35. The temperatures are adjustable within a range from 0 to 500 C 0 to 932 F As a default the excess temperature disconnection is set to 500 C If a less safety shutdown is carried out in the parameter menu the set value attitude of this value is also limited The percentage control mode is adjustable from 096 to 100 11 05 DPK DPT 7 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY 3 4 2 Switching Zones On and Off If a zone is unused it is possible to switch it off CH Act gre 56 Set 200 GUNTHER HOT RUNNER TECHNOLOGY 24V LEES OFF Temp Picture A CH Exist Set Power 2 150 200 50 E At 40 3 0 300 100 4 100 100 0 Sel 200 i 5 100 100 096 24V Temp Picture B e CH Act 200 G 1 Set 200 SC 24V ON 4A Picture C Fig 3 4 Switching Zones On and Off In single channel mode move the mark to the ON OFF button by pressing key E Now the setting can be changed by pressing key or Y Hint Zones which are switched off will only be displayed in multi channel mode and are not checked on faults anymore 8 11 05 DPK DPT x User Manual Hot Runner System DPK DPT 7 G UJ NI H IR HOT RUNNER TECHNOLOGY 3 4 3 Changing the Operating Mode Percentage Slave Temperature In the case that a thermocouple fails to function or for any other reason it is possible to con
36. ax 20 13 passwort customer Password allowing the user to carry out changes in the configuration menu default 99 min 0 max 9999 14 passwort Additional password for locking single functions concerning set value changes If 0 is set here this password function is deactivated For the first activation of this function the controller has to be restarted default 0 min 0 max 9999 15 display averaging 24 11 05 DPK DPT OUNIHER User Manual Hot Runner System DPK DPT HOI RUNNER TECHNOLOGY The set value is displayed as median value which has been determined from the single set temperatures of the several zones Within this parameter the user is able to adjust how many set temperatures should be considered for establishing the median value being displayed default 10 min 0 max 20 16 test 5V after 230V Switching on off the plausibility function The plausibilty test checks if low voltage loads follow 230V loads default 1 min 0 max 1 17 diag max temp C Temperature difference to which a zone has to be heated up during the diagnosis Only if this difference temperature has been reached during the diagnosis within the adjusted time the zone is accepted as OK default 30 min 0 max 200 18 diag heating time sec Time in which the zone has to reach the difference temperature during the diagnosis default 240 min 0 max 1200 19 diag output in Power output
37. e does not mean a neutral conductor but another external conductor phase The connection position for special appliance revision S is different from the one shown L I B3 Nozzle 8 Changer e B9 DI Fig 7 6 Connection Example Controller Runner 7 of the DPK10 DPTIO Hint The load plug is different from the DPK15 DPT15 corresponding to the appliance Please take care of the corresponding table Fig 7 3 to 7 5 11 05 DPK DPT 45 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY 7 2 Appendix B Fuses Fuse Location for the DPK DPT The up to 15 heating zones are fuse protected by super fast microfuses On the DPK15 DPT15 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 been enclosed with the DPK DPT 1 Netz 0 Last Load F5 F9 F13 Fl F2 WE TTE 0000 10202 2 PT 15222 3 4oQoO 4 oo 4 S690 4 AR ne 42920 8o0QoQ 8 EFIOA 5 x 20mm 9 OoOo Schurter SA 7s 10 9 090710 FF16A 6 3 x 32mm Schurter SA 9 Fig 7 7 Position of the Load Fuses of the DPK DPT The figure shows a part of the DPK DPT s back plate
38. em DPK DPT GUNTHER HOT RUNNER TECHNOLOGY GUNTHER HOT RUNNER TECHNOLOGY Ch 1 error Thermocouple Shortcut ENTER Fig 4 2 Thermocouple Shortcut GUNTHER HOT RUNNER TECHNOLOGY Ch 1 error Thermocouple Over temperature ENTER CIFL CIFT Fig 4 3 Over Temperature GUNTHER HOT RUNNER TECHNOLOGY Ch 1 error Thermocouple Check thermo connector Thermocouple Shortcut At the shown zone there is a short circuit at the thermocouple or its connections Please check the thermocouple and its wires Over Temperature The thermocouple of the shown zone detects a temperature above 500 C Please check the thermocouple and its wires You should also check the thermocouples of neighbouring nozzles Check Thermo connector The connector of the thermocouple at the shown zone is missing or not fixed Please check the connections 11 05 DPK DPT 31 User Manual Hot Runner Systems DPK GUNTHER HOT RUNNER TECHNOLOGY Fig 4 4 Check Thermo connector GUNTHER HOT RUNNER TECHNOLOGY Ch 1 error Load Low power heater or not connected ENTER Fig 4 5 Load Interrupted GUNTHER HOT RUNNER TECHNOLOGY Warning 5 24V load follows 230V load check wiring ENTER Fig 4 6 Plausibility Error GUNTHER HOT RUNNER TECHNOLOGY Er
39. example USA this can be adapted by using four screwbridges Disassemble the unit cover Connect bridges as shown in the diagrams below L1 lt lt 400 V N Star NA L1 7 zov Eum n vm Delta W ue 48448420124 EN Kl Fig 7 8 Star Delta Switch Over Ul U2 U3 200V 250V Close the cover Attention The voltages U1 U2 and U3 must be within a range of 200V 250V If the unit is powered with other voltages the warranty will expire and in some cases the unit can be damaged When using a delta net supply the cable is not compatible with the different versions That means that the DPK5 5 should only be used with a cable intended for a five zone unit The use of a cable designed for a 10 or 15 zone unit will lead to operation errors 48 11 05 DPK DPT x amp User Manual Hot Runner System DPK DPT 7 G U NIH ER 11 05 DPK DPT 49 User Manual Hot Runner Systems DPK GUNTHER HOT RUNNER TECHNOLOGY 7 4 Appendix D Technical Data Connection Specifications Terminal Voltages 200 250V AC per phase 50 to 60Hz typ star connection Load Connection Load Type Thermocouple Error Output OK Output Lowering Input 50 Star Connection 3 phase supply with neutral 200 250V between phase and neutral 3 phase supply without neutral 200 250V between two phases 10A per zone fuse 10A s
40. following interface parameters will be set if a protocol type changes Interface Type TTY 20mA 4800 Bit s SEI TTY 20mA 4800 Bit s TEI Krauss Maffei V24 RS232 9600 Bit s 7E2 TTY 20mA 4800 Bit s 8N1 34 11 05 DPK DPT User Manual Hot Runner System DPK DPT 7 G U NIH ER 5 2 Trouble Shooting Hint If faults which are not associated with the interface connection occured the DPK DPT should be disconnected from the molding machine There are several red and green LEDs inside the DPK You can watch them after opening the device The LEDs for the connection to the molding machine are located on the display circuit front panel The two other LEDs on the module LR28 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 DPT Flickering indicates The DPK DPT gets data from the molding machine red TXD Output DPK DPT Flickering indicates The DPK sends data Hint If the DPK DPT detects any failure the loads will be disconnected from the power line This error state is displayed on the DPK DPT If the zone which has caused this error is switched off the error state will be confirmed After that the other zones are switched on again You can get further information in chapter 4 7 Fault Report and 6 2 1 Initial Start Up 11 05 DPK DPT 35 GUNTHER Use
41. ftstart has been activated in the menu and if the actual temperature of a 230V nozzle remains below 80 and the set value is over 100 C In single channel mode the softstart is indicated by the following signs ramp time hold time In multi channel mode it is indicated by the text softstart and the time left After the whole time the unit will be switched to normal operating mode To prevent overheating of the molding material in the 5V 24V nozzles only important for DPKs the 5V 24V nozzles are also limited to 105 11 05 DPK DPT 19 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY during softstart The temperature lowering function is taken into consideration during softstarts so that the DPK DPT 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 DPT loads up the parameters and values to the factory settings Attention All individually entered settings of the DPK DPT values and parameters will be deleted The following table shows the default settings Set all Channels 150 C all set temperatures Temperature Programs 1 power OFF 25 2 temp ON 20 C 3 temp ON 150 C 4 temp ON 200 C Softstart ON over all time 10min hold time 5min ramp time 5min PID Parameter nozzle lt 600W for all zones P Value 100 I Value 9 D
42. is able to see and change the assignment of the thermocouples to the zones This way it is possible to combine zones and thermocouples in any order To avoid open regulating circuits each thermocouple can only be assigned to one zone With the cursor keys the thermocouple assignment can be adjusted With keys and Y a zone can be selected To change the thermocouple of this chosen zone the number of the corresponding thermocouple has to be selected with key By pressing key 4 the selection of the thermocouple s number will be abolished and the line for the zone will be selected again Now another zone of which the thermocouple assignment has to be changed can be chosen Then the entered values can be accepted by pressing key ENTER With keys MENU or the menu item can be left again without accepting the changed setting 11 05 DPK DPT 21 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY 3 6 6 Thermocouple Type Besides the type L thermocouples the hot runner system also supports type J and K thermocouples In the menu item Thermocouple Type the thermocouple s type can be adjusted for each zone as well as for all zones To adjust the thermocouple s type one zone or even all zones are selected with keys Pn Then the type can be set with keys or Y When confirming the changes with key ENTER the new setting will be accepted With ke
43. itched on with key C F or via the external lowering entrance Temp Boost with Temperature Program 4 To boost up temperature a temperature program for prescribing the set values can be used too The adjustment of the set values for boost is carried out like those for lowering with the exception that now temperature program 4 is used This function is also activated in the Parameter Menu Menu gt Configuration gt Parameter gt 24 program 4 for boost The boosting function is switched with key C FT 4 5 Standstill Monitoring With the standstill S monitoring function the molding machine s impeccable function can be supervised The molding machine s control is carried out via the DPK DPT s external lowering entrance However this causes that the actual lowering function cannot be used any more If the molding machine works regularly it keeps a potential free contact which is connected to the controller s lowering entrance closed If a fault occurs at the molding machine it will open the contact After the time of delay which has been set in the menu item Temp lowering ext the controller then activates the lowering function For this kind of lowering it is necessary that the controller is in ready for molding mode In this case key C F is used to put back the external lowering 4 6 Friction Recognition and Monitoring Depending on the condition of the tools this function is able
44. l be risen too when switching on the boosting function default 0 min 0 11 05 DPK DPT 25 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY max 1 23 program 3 for lower If this function is activated 1 temperature program 3 will be loaded and the controller will work with the values set there when lowering is carried out default 0 min 0 max 1 24 program 4 for boost If this function is activated 1 temperature program 4 will be loaded and the controller will work with the values set there when boosting is carried out default 0 min 0 max 1 25 ext input for boost By activating this function the external lowering entrance is converted into an external boosting entrance If then the contact for the external lowering is closed the boosting function will start default 0 min 0 max 1 26 operating hours The current operating hours can be seen here default min 0 max 27 operating minutes The current operating minutes can be seen here default min 0 max 28 friction temperature This parameter is used for switching on and adjusting friction monitoring If 0 is set here this function will be deactivated For switching on monitoring a temperature between 1 C and 10 C has to be adjusted The adjusted temperature value is a threshold over that the current temperature has to increase for recognizing friction
45. ler starts the adjustment with the last adjusted kind of heater This automatic search of the heater can be switched on and off in the parameter menu Menu Configuration gt Parameter 33 5V 24V startup check DPT units miss this menu item because they are connected to 230V nozzles only 3 5 8 Language In the menu item Language you are able to change the language for the display and the menu The DPK DPT supports the following languages English German French Portuguese Italian Dutch Danish 16 11 05 DPT User Manual Hot Runner System DPK DPT d G U 3 5 9 Start up Ramp In hot runner systems you will often find loads with different thermic time constants If the time constants differ widely a fast nozzle will reach its set value earlier than the slow manifold This physically based heat up delay can generate plastic defects in the nozzle because it reaches the set value much earlier than the other nozzles For this reason the starting mechanism Start up Ramp is connected This guarantees a regular warming of the different nozzles related to the set value The ramp function can be switched on and off in the menu item Start up Ramp Additionally it is possible to choose a zone for leading the ramp or the adjustment auto Within the adjustment auto the DPK DPT establishes the slowest zone in a 90 seconds lasting testing phase independently and determines it as leading
46. meter or calibrate the DPK DPT etc The password for the configuration menu is 0099 The entered password is only valid for 15 minutes or up to the moment when the DPK DPT is turned off For further changes to the configuration you need to enter it again GUNTHER HOT RUNNER TECHNOLOGY Configuration Softstart p Calibration PID Parameter Th couple Assignment Thermocouple Type Fig 3 11 Configuration 3 6 1 Softstart When 230V nozzles are connected to the system it is necessary to employ the softstart start up procedure to dry out the moisture that has collected in the cold heating elements The softstart is divided into two time controlled phases During the first phase the value of the menu softstart does increase from 0 to 50 The ramp time should be selected in such a manner that the DPK DPT reaches the temperature of 105 C at the end of the ramp If the temperature at the end of the ramp is less than 105 C the DPK DPT will raise it to 105 C independently After the DPK DPT has reached the 105 C the second time controlled phase of the softstart begins Within this phase the temperature of the zones is hold to 105 as long as the hold time is set in the menu item so that the nozzles dry out adequately with a low thermic load Ramp time and hold time add up to the whole time which can be adjusted in the menu in two minute steps This start up operation begins automatically if the so
47. n Start up and Maintenance of the user manual prior to the installation of the device Before connecting the device to the main s power supply check the main s voltage and the type of net star or delta 1 General The hot runner system DPK DPT 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 totally operational and to guarantee safe operation please read this instruction manual carefully and follow all hints Before switching on it is important to check if the local voltage is identical to that allowed by the unit The plug may only be plugged into 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 the unit Refer to a qualified technician for servicing ATTENTION This is a user manual for DPK units as well as for DPT ones User of the DPT have to consider that these devices are only to use with 230V nozzles If the device is used to temperate low voltage nozzles 5 or 24V anyway this may cause defects and will lead to the loss of guarantee Therefore consider that all remarks about low voltage nozzles are only of importance for DPK user but not for DPT user because these devices are only to use with 230V nozzles Never connect to low voltage nozzle
48. n mode will be terminated and the channel as well as its fault will be displayed If several faults occur simultaneously the first identified one will be shown 6 11 05 DPK DPT d amp User Manual Hot Runner System DPK DPT 7 G U NIH ER 3 4 Operating Mode 3 4 1 Changing Set Values For changing the set value of a zone it has to be switched into single channel mode see picture A Then the set value can be marked by pressing key P and the desired set value can be adjusted by pressing keys and The key function is dynamic i e the longer the key is pressed the quicker the set point value changes CH Act 200 Set 200 24V ON Temp GUNTHER HOT RUNNER TECHNOLOGY Picture A Ch Exist Set Power 1 200 200 096 2 150 200 50 E act 2007 3 0 300 100 4 100 100 0 se id 5 100 100 0 24V Temp Picture B at 200 1 sa 250 24V 4A Picture C Fig 3 3 Changing a Set Value Indeed the controller operation works independently from the entering of a value It is therefore not necessary to return to the scan mode The scan mode makes exact surveillance of critical regulation positions possible For faster adjusting of all set values to the same value the command Set all channels see Chapter 3 5 1 Set all channels may be used Value limits
49. n recognition is displayed in the status line of the display If the controller has recognized friction it shows the friction cycle and the detected zones in the status line If friction has been recognized at all nozzle channels cyclically the OK exit is set The OK exit is cancelled if friction has not been recognized at all nozzles Then it has to be assumed that nozzles without friction are plugged 4 7 Fault Report In the event of a fault the display will show the fault and the protection system will shut down the power With this fault a relay contact is closed This relay contact is located on the rear side of the system and is marked with DEF By pressing key ENTER all zones except the faulty one will be switched on The DEF relay contact will be opened as well During the DPK DPT adjusting all zones no errors only warnings will be displayed because faulty zones do not start after the adjustment A zone which evoked a warning is switched into the off temperature mode when no load is detected and switched into the off percentage mode when no thermocouple is detected The following faults are possible G U N H 2 Thermocouple Failure HOT RUNNER TECHNOLOGY The thermocouple of the shown zone Please check the thermocouple and it Ch 1 error Thermocouple Break floating or not connected ENTER Fig 4 1 Thermocouple Failure 30 11 05 DPK DPT User Manual Hot Runner Syst
50. one 13 DPK DPT controller 10 15 Adaption of a 10 zone tool to a 15 zone Rewiring of Zone 9 to Zone 13 DPK DPT controller Rewiring of Zone 10 to Zone 14 The different load adapters are available from G NTHER Hot Runner Systems Company The load adapter s automatic recognition can be switched off in the parameter menu Menu gt Configuration gt Parameter gt 34 load adapter recog 28 11 05 DPK DPT 29 User Manual Hot Runner System DPK DPT G U NIH ER 4 4 Temperature Lowering Boosting with Temperature Program Temp Lowering with Temperature Program 3 Apart from setting a fixed value for the lowering temperature it is also possible to use temperature program 3 for lowering This way an individual temperature for lowering can be assigned to each zone For adjusting the lowering temperatures temperature program 3 has to be activated in the menu item Temperature Programs Afterwards any set values can be set for all zones These adjusted set values will later be loaded as new set values for lowering when the lowering function has been activated After adjusting the set values an other temperature program in which the normal settings for the tools are carried out is activated In addition the function for lowering with temperature program 3 has to be activated in the Parameter Menu Menu gt Configuration gt Parameter gt 23 program 3 for lower Lowering can be sw
51. ous full duplex Baudrate max 19 200 Baud Cable length max 15m for RS232 max 300m for cable cross section 0 4mm max 1 000m for RS422 and RS485 Isolation 5kV Input Output 11 05 DPK DPT 41 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY 6 2 Start Up 6 2 1 Initial Start Up e Install the device refering to Chapter 6 1 Installation e Turn on the DPK DPT Now it shows the software version e g P1 30 and begins to check the zones Afterwards possible errors as e g Load Interrupted or Thermocouple Failure are displayed e After confirming the faults the defective zones are switched off Repair possibly occurred faults and switch on the controller again e If no fault has occurred or all displayed errors have been repaired the diagnosis function should be started see chapter 3 5 6 Diagnosis By means of this function the assignment of zone and thermoelement can be tested 6 2 2 Additional Information Hint When working with the 230V loads switch off the DPK DPT and disconnect it from the power source Opposite of much other regulating units for 230V the DPK DPT checks the loads at the power up procedure by using a current measurement Because of that a clear statement about a load disconnection can be given For all zones the set value in ampere can be displayed To check the heater current a clamp amperemeter with true RMS measurement should be
52. r Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY 6 Installation Start Up and Maintenance 6 1 Installation 6 1 1 Location The absolute dimensions of the DPK DPT are specified in Appendix D Pay attention to guarantee a sufficient air circulation behind the DPK DPT regulator unit heat sinks Ensure that a sufficient air circulation is supplied at the bottom of the DPK DPT by an installed fan The system must be set up on a stable and level area The DPK DPT has to 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 Appendix D Protect the DPK DPT 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 11 Fuse 25 12 L3 not connected DPK 10 EES Fuse 25A DPK 15 LL L2 L3 Fue25A DPT Three phase CEE 32A plug Phasedistribution DPT 5 L1 Fuse 25 12 L3 not connected DPT 10 EES Fuse 25A DPT 15 Ll L2 L3 Fue25A 2 Hint Before starting installation please check the main s voltage star delta Star is the standard configuration of the delivered unit Delta will be possible if the voltage between two phases does not exceed 200 250V Please
53. ror triac short circuit on line x ENTER 32 Load Interrupted The wires to the power module or to the nozzle of the shown zone are interrupted Please check the load fuses and the wires In normal operation mode the load interruption is only detected at a percentage value of 100 This error message can occur at the adjustage In this case the power of the nozzle could be too small for this application Plausibility Error The arrangement of the loads referring to the zone number is not in normal order At first the low voltage nozzles should be connected to the low zone numbers and then the 230V nozzles should be connected to the higher zones The parallel display shows the types of nozzles after the adjustment If this order is chosen intentionally the operation can go on after confirming this warning When using a DPT unit the order of the loads referring to the zone number is not important because there are only 230V loads and no low voltage nozzles Damage of a Power Module A damaged triac was detected on one of the power modules Each phase of the power drives its own power module So the damaged module can be determined Please let the damaged module be changed by an electrician or contact GUNTHER Hot Runner Systems Please disconnect the line voltage before opening the device Pay attention to the safety instructions 11 05 DPK DPT User Manual Hot Runner System DPK DPT GUNTHER
54. s but only to 230V nozzles The DPK DPT unit is an optimized hot runner control unit it is very efficient and reduces costs Advantages for the user Available in 5 10 or 15 zone 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 For DPT units this step is not important because they only work with 230V nozzles e Only one DPK unit is required for mixed operation DPTs do not work in a mixed mode e PID controller with variable parameters fast heating of 5V and 24V low voltage nozzles DPK careful heating of 230V zones DPK and DPT e An automatic slave mode is able to switch zones with faulty thermocouples into slave mode automatically A manual slave mode can be activated for each zone e Control operation is possible at all times even in the event of thermocouple failure 11 05 DPK DPT 1 User Manual Hot Runner Systems DPK GUNTHER HOT RUNNER TECHNOLOGY As the DPK DPT control unit is compatible with all existing GUNTHER power units existing power units from the 160 series can still be used Because of the module construction system upgrades are possible The DPK DPT is reliable and safe due to continuous checking and monitoring functions Advantages for the user Continuous self monitoring function The DPK protects low voltage nozzles from current overload
55. t 22 boost for manifolds is set to 1 M Besides an external activation of the boosting function can be carried out For that purpose the external lowering function has to be deactivated because both functions are operated via the entrance Abs at the DPK DPT s rear For deactivating the external lowering function and or for activating the external boosting function the value for the parameter 25 Menu gt Configuration gt Parameter gt 25 ext input for boost has to be set to 1 in parameter menu 10 11 05 DPK DPT 2 User Manual Hot Runner System DPK DPT 7 G U NIH ER Hint All settings can be carried out via the menu options Temp Lowering and Temp Boost 11 05 DPK DPT 11 User Manual Hot Runner Systems DPK 7 G U N u HER 3 5 Menu Mode By pressing key the menu mode is activated The main menu will be shown on the display GUNTHER HOT RUNNER TECHNOLOGY Main Menu Temp Program Temp Lowering Temp Boost Power Monitor Diagnosis Fig 3 6 Main Menu Use keys and Y to select and key gt or ENTER to confirm a menu item If the operator does not make modifications in the main or in another menu the display mode will be switched off after a time of 10 seconds and the display will show single or multi channel mode If a menu item is confirmed the value may be changed by pressing
56. ted For activating this function a value between 1 and 3 has to be adjusted This value is a factor for smoothing down the measured temperature value The larger the value is chosen the slower the regulating becomes default 0 min 0 max 3 33 5V 24V startup check When switching the controller on this parameter activates 1 or deactivates 0 the questioning of the low voltage nozzles 5V 24V in DPK devices default 1 min 0 max 1 34 load adapter recog Activates 1 or deactivates 0 the automatic recognition of load adapters default 1 min 0 max 1 Attention By loading the default values all parameters are set to their default values again 11 05 DPK DPT 27 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY 4 Other Functions 4 1 Ready to Start Molding Operation As soon as a zone has reached the temperature window the corresponding zone s green OK LED switches on in parallel display If all adjusted zones have reached their preset temperatures a potential free relay contact will be switched on additionally This relay contact is located on the rear side of the system and is marked with OK In addition the text ready for molding appears on the display The OK LED and the relay output will be switched off in case of gt a fault gt lowering gt apreset temperature outside the temperature window 4 2 Automatic Slave Mode The automatic sla
57. tinue the control operation manually in slave mode or in percentage control mode For that purpose the menu item Power Temp or Slaving are marked with key gt and can then be chosen by pressing key or Y CH Is 200 Set 200 GUNTHER HOT RUNNER TECHNOLOGY 24V gem ON Temp Picture A Ch Exist Set Power 1 200 200 096 2 ous u v 4 200 bi 4 100 100 0 2005 5 100 100 0 24v Picture B e e s Percentage 1 UE 24V Picture C Fig 3 5 Changing the Operating Mode Temperature control mode In this mode temperature control is accomplished by means of a fuzzy PID controller which evaluates the signal of the thermocouples and adapts the corresponding power at the exit Slave mode This mode of operation can be used for zones in which an error or defect at the thermocouple has occured Here the faulty zone is attached to a freely selectable zone and operated with the same power output as the leading zone Please note that the leading zone and the attached zone exhibit a similar behaviour Percentage control mode This mode allows to adjust a fixed power output between 0 and 100 for the selected zone 11 05 DPK DPT 9 GUNTHER User Manual Hot Runner Systems DPK DPT HOT RUNNER TECHNOLOGY For low voltage nozzles only valid for DPK not for DPT it will be 100 is equivalent to ca
58. tor of the system is able to adjust a password that must then be entered by the user to carry out changes to the set points or to the operating mode Standardly this function is deactivated i e the code is set on zero 3 6 9 Parameter The menu item Parameter is only to be used by authorized personnel Parameter changes can influence the function of the controller Please take consultation with the G NTHER Hot Runner Systems Company if changes at the system s parameters seem to be necessary This applies especially to the parameters marked grey in the following short description Short description of the adjustable parameters Menu gt Configuration gt Parameter 1 max temperature C Maximum permitted temperature If a zone exceeds the adjusted temperature value the controller will switch off the power output and display the error Zone xx Thermocouple Overtemperature default 500 min 0 max 500 2 controller address Specifies the controller s device address default 3 min 0 max 20 3 diff temp rampe Shows the temperature difference which has to be identified on at least one manual or automatic established manifold for activating the ramp function default 20 min 0 max 500 4 lowering percent in Lowering value for percentage control mode default 20 min 0 max 100 5 boost percent in Boosting value for percentage control mode default 10 min 0 max 50 6
59. uper fast FF 10A 1 zone per phase 16A see max current of phase phase load 5 zones per phase max 25A Delta Connection Maximum Power DPK DPT 5 phase L1 zone 1 4 2 3 KW 10A per zone zone 5 3 6 KW 16A max overall load CE 3 6 KW 16 DPK DPT 10 phase L1 zone 1 4 2 3 KW 10A per zone zone 9 3 6 KW 16A phase L2 zone 5 8 2 3 KW 10 per zone zone 10 3 6 KW 16 max overall load CE 7 2 KW 2 16 DPK 15 phase L1 zone 1 4 23KW 10A per zone zone 13 3 6 KW 16A phase L2 zone 5 8 2 3 KW 10 per zone zone 14 3 6 KW 16 phase L3 zone9 12 23KW 10A per zone zone 15 3 6 KW 16 max overall load CE 10 8 KW 3x16A Low voltage loads 5V 120A per zone using our power units 24V 25A per zone using our power units ohmic and inductive ohmic loads are allowed thermoelectric couple Type L Fe CuNi electronic compensation thermoelectric couple Type J Fe CuNi electronic compensation thermoelectric couple Type NiCr Ni electronic compensation potential free contact normally open max 230V 1A unfused potential free contact normally open max 230V 1A unfused connect a potential free contact normally open 11 05 DPK DPT User Manual Hot Runner System DPK DPT OUNIHER Net Cable Sockets Fuses Ser Interface Regulator Load Matching Output Control Range Set Range Softstart
60. used For low voltage nozzles only connected to DPKs a range of 0 150A is required High voltage nozzles connected to DPKs as well as to DPTs require a range of 0 10A If there are problems with the installation of the DPK DPT 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 Maintenance Attention Disconnect the main voltage and take care that there is no voltage at the DPK DPT before opening the device Please follow the safety instructions 6 3 1 EPROM Update To install a software update disconnect the power and thermocouple connections from the DPK DPT Disconnect the serial interface and the molding machine as well Now remove the top cover of the DPK DPT 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 care of the right direction and fit in socket of the circuit again 42 11 05 DPK DPT 2 User Manual Hot Runner System DPK DPT G U NT H R HOT RUNNER TECHNOLOGY Following this steps close the cover of the DPK DPT Attention Do never exchange the EPROMs After turning on the DPK DPT again it performs an update and an adjustment Now the DPK DPT should work as usual When the DPK DPT is turned on the current software version is
61. ve mode makes it possible that zones with defective thermocouples can go on running anyway For that purpose the hot runner system in the current and in ready for molding mode tries to establish a so called slaving zone for each zone This slaving zone must show a similar behaviour with respect to power output and set value If the controller has determined a slaving zone for a zone a defective thermocouple at this zone does not lead to its switch off inevitably Instead of switching off the faulty zone is switched into slave mode automatically and receives the before determined slave zone as leading zone This way the controller can go on running nearly without any interruption After loading the default values the automatic slave mode is activated In the parameter menu it can be disabled or activated again Menu gt Configuration gt Parameter gt 31 autom slave mode 4 3 Automatic Recognition of Load Adapters After the adjustment this function checks if a load adapter is connected to the unit s load exit Load adapters serve to the adaption of for example 5 zone tools to 10 or 15 zone controllers They ensure that the manifolds are wired to the controller s 16A exits There are three different adapters in use Load Adapter Function Wiring 5 gt 10 Adaption of a 5 zone tool to a 10 zone Rewiring of Zone 5 to Zone 9 DPK DPT controller 5 15 Adaption of a 5 zone tool to a 15 zone Rewiring of Zone 5 to Z
62. y MENU or after repeated pressing of key 4 the menu item can be left without accepting the new adjustment If type K thermocouples have been adjusted an infobox is displayed when switching the controller on next This infobox shows a list of all zones with type K thermocouples Furthermore the type K thermocouples are displayed at the left corner in single channel mode In this mode the load s indication switches with the thermo type s indication Type J and L thermocouples are not announced separately because they show a similar behaviour When loading the default settings all thermocouples will be resetted to type L Note However the use of type K thermocouples is only supported by hot runner systems with production index D or higher The controller s production index is noted down on its type plate letter behind the serial number 3 6 7 Switching C F By choosing the menu item Switch it 1 possible to change between degrees centigrade and degrees fahrenheit GUNTHER HOT RUNNER TECHNOLOGY Configuration Switch C F Load Defaults Calibration Temperature In PID Parameter Kerri Th couple Assignment Fahrenheit Thermocouple Type gt ETORO ENTER Picture A e Fig 3 13 Switching C F 22 11 05 DPK DPT User Manual Hot Runner System DPK DPT d G U NIH ER 3 6 8 User Password In the menu item User Password the crea
63. zone Furthermore a lowering value can be adjusted for all zones except the leading zone Around this value the set values of all zones are lowered until the leading zone has reached its set value If the ramp function is switched on and the softstart is ended it will be activated with each set value leap gt 50 Then the leading zone is heated to its set value According to their percentage of the set value the other nozzles are driven up slowly to their set values so that their heating procedure is braked essentially The end of the starting ramp is achieved as soon as the leading zone has reached its temperature window Just now the individual nozzles will be decoupled from the leading mechanism and heated to their set value In multi channel mode the starting ramp is indicated by the text Ramp and by displaying the leading zone In single channel mode the following symbol is displayed The number behind the sign indicates the slowest zone manifold 3 5 10 Temperature Window Within this menu item a tolerance for the existing temperature can be specified This implies that if the actual temperature of a zone reaches a value which lies within the set value the tolerance this zone will be declared as ready to start molding This is shown by flashing of the corresponding zone s green OK indicator in the parallel display If all zones are within their tolerance sector around the set value the DPKs DPTs OK exit will be set and the
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