User Manual - Mold
Contents
1. 1 While on the Display page Turn the wheel to select the zone 2 Press the wheel then Turn it so that Lim is blinking 3 Press the wheel again to select the High Limit on the top row and Turn the wheel to set the required high Alarm limit and then Press to accept the new setting 4 The cursor automatically moves on to the Low Limit on the second row Turn the wheel to set the required low Alarm limit and then Press to accept it 5 After leaving the control wheel idle for a few seconds the display returns to its previous working mode and shows Auto Man or Off according to its original setting Bug TempMaster S6 12 Users Manual evision 1 4 Not Under documentation control if printed May be revised without notice Jul 2010 Page 19 Electronic version available at www moldmasters com TempMaster Setting up your controller Setting Zone Temperatures You can set the zone temperatures on a zone by zone basis as follows While on the Display page Turn the wheel once to select the zone 2 With the zone in Auto Press the wheel twice so that Auto is blinking and the Set temperature is selected 3 Turn the wheel to increase or decrease the Set Temperature then Press the wheel to accept the new setting Setting Manual Power Levels If you choose to run any zone in a Manual or Open loop mode then you need to switch it into Manual and then set its power output level as described here While on the2. Masters oju 2010 Page 29 T C Negative gt VG T C Negative 7 7 1 8 8 2 9 9 2 1 10 2 1 11 2 1 12 2 Pin i 1 T C Positive T C Positive 13 T C Negative T C Negative T C Positive T C Negative T C Positive T C Positive T C Negative T C Positive T C Negative 9 0 1 0 2 1 3 2 4 T C Positive T C Positive T C Negative T C Negative TempMaster S6 12 Users Manual Not Under documentation control if printed May be revised without notice Electronic version available at www moldmasters com Tempa index Index Alarm Limits Setting A 19 Boost Temperatures cccceceeereeeteeeneees 19 Boost Time 15 18 Changing the Tool Temperature 00 1 24 Controller Alamms 25 Controller Cabinet 13 Controller Cards neee 9 Erased Values cccccccseseeeeeeseeesenteeeeseees 12 Error MeSSQQe S cccesecceeeseeeeeseeeeeesceers 26 Front Panel Alarm LED 13 Front Panel LED 25 How the Mold Masters Controller Works 11 LEDS Front Panel 13 Manual Mode Working 24 Memory Check 12 Power Level Getting 24 RAM Emor 12 Response Speeds changing s essseeseeee 19 Running your Controller ssseseeseeeeeeeeeeeee 22 Safety Instructions sseeeeeeeeeeeeeeeeeneeeeeeeee 6 Screen intensity eeeeeseeseeeeeeeeseeeeeeeeeeee 18 TempMaster S6 12 Users Manual Not Under documentation control if printed May be revised without noti
3. Select the Mode page 2 Turn the wheel to select Bst Time 3 Press the wheel once more and Turn it to increase or decrease the Boost Time 4 lf you need to set another function while on this page then Turn the wheel to select that function Otherwise if there is no other function to change then leave the wheel untouched for a short time and it will return to the Display page Screen intensity To set the intensity of the characters on the screen and hence the legibility Select the Mode page Turn the wheel to select Display Press the wheel once more and Turn it to increase or decrease the screen character intensity 4 If you need to set another function while on this page then Turn the wheel to select that function Otherwise if there is no other function to change then leave the wheel untouched for a short time and it will return to the Display page D SH TempMaster S6 12 Users Manual i Revision 1 4 Mold Kee NI asters Not Under documentation control if printed May be revised without notice Jul 2010 Page 17 Electronic version available at www moldmasters com TempMaster Setting up your controller Configuring Zone settings Zone Speed settings The Speed parameter determines how fast the zone will respond to or anticipate changes in temperature While there are manual settings of Slow Medium or Fast the default setting is Auto This allows the zone to run the auto load sensor program descri
4. Display page Turn the wheel to select the zone 2 Press the wheel so that Auto blinks then Turn the wheel till the bottom line shows Man 3 Press the wheel so that Man blinks and the cursor shows alongside the Power setting 4 Turn the wheel to raise or lower the required power level then Press it to accept the new setting 5 After leaving the control wheel idle for a few seconds the display returns to its Manual working mode NOTE To return the zone to Auto working simply 1 Select the zone that is in Manual 2 Press the wheel to select the zone and turn it to select Auto 3 Press the wheel to engage Auto mode and the zone returns to its previously set temperature TempMaster S6 12 Users Manual Revision1 4 a _ Mold Not Under documentation control if printed May be revised without notice Page 20 Jul 2010 Masters Electronic version available at www moldmasters com g Running your Contest oe Pp viaster Running your Controller This section of the manual is divided into three main areas that are concerned with e the basic Starting and Stopping along with Boost and Pause controls e changing settings while the controller is running so that you can adjust temperatures to cope with varying operating conditions e recognising what alarms may be generated and what they mean and what to do about them What is included in this section Starting Stopping Pausing Standby how to put the heaters on
5. a _ Mold Not Under documentation control if printed May be revised without notice Page 26 Jul 2010 Masters Electronic version available at www moldmasters com g APPENDIX A TempMaster APPENDIX A HRC Wiring Standards The following standards only apply to TempMaster S6 controllers wired to HASCO standard Other specifications may have been stated when the controller was ordered Please refer to the supplied specification details 1 CONNECTION INFORMATION 1 1 Mains supply cable termination Please take extreme care when connecting the controller to the mains supply especially if it is a three phase supply Incorrect connection may appear to work but can result in damage to the controller The controller is normally supplied with the mains supply cable suitably terminated into an appropriate plug However if the unit is requested without any mains plug then the conductors will be labelled as shown below Cable Marking 3 phase star supply L1 Phase 1 L2 Phase 2 L3 Phase 3 N Neutral Earth Symbol Earth Cable colours may vary therefore wire up according to the Cable Markings 1 2 Loom Thermocouple cables Thermocouple cable colours and number may vary Refer to controller documentation for details Type Positive Negative 1 3 Loom Power cables The colour of the power cables are as follows Supply Live supply Neutral return TempMaster S6 12 Users Manual gt Pa de Revis
6. controllers are designed to perform in closed and open loop configurations However we consider that the normal operating mode is closed loop Whenever the controller is set to start the system goes into a self calibration routine This is illustrated in the following diagram and explained below Set Point Temperature Load Test Delay T T T T T T T Time e The zone controller slowly ramps up the heater power and simultaneously looks for a positive temperature change at the thermocouple input The controller verifies the actual rate of rise against a predetermined value Power is slowly increased until the correct rate of rise is achieved e The controller now increases the zone temperature at a constant rate of rise until the temperature reaches about 110 230F e At110 the controller performs a Load Test on the zone heater to check its thermal characteristics The output power is reduced to zero for a test period and the temperature monitored for a response From all this information the controller has built mathematical model of the heater characteristics and so it can automatically select a Fast Medium or Slow response heating program that suits the tool This allows more efficient control of the zones e The controller continues to ramp up the temperature to the set point which should be achieved with minimum over shoot e Having built a virtual model to map the tool and heater characteristics the controller
7. equivalent Turn amp Press control wheel 4 x 40 characters LCD Screen one for S6 and two for S12 Metal case 32w x 14h x 37d cm TempMaster S6 12 Users Manual Not Under documentation control if printed May be revised without notice Electronic version available at www moldmasters com TempMaster Introduction Safety Instructions DO NOT enter the cabinet without first ISOLATING the supplies here are unguarded terminals inside the cabinet which may have a dangerous potential across them Where a three phase supply is used then this potential may be at 415 volts or higher Safety Notices an explanation Within this manual safety instructions are marked as follows A WARNING symbol and message shown here identifies where there may be a hazardous situation which if not avoided may result in death or injury to personnel Most warnings pertain to electrical aspects and you must comply with them to minimise any personal danger A CAUTION warning identifies where there may be a hazardous situation which if not avoided may result in damage to property Caution warnings present no personal danger but may cause the equipment to fail or lose its memory TempMaster S6 12 Users Manual a Revision1 4 Mold Not Under documentation control if printed May be revised without notice Page 6 Jul 2010 Masters Electronic version available at www moldmasters com g TempMaster Introduction Where to use thi
8. is working normally while the other four show alarm conditions if an error is detected Reading down from the top these are Colour Meaning RED Hi Level Alarm the current temperature is above the high temperature alarm level GREEN Normal the channels is within the temperature limits for that normally lit zone BLUE Low Level Alarm the current temperature is below the low temperature alarm level RED T C the system has detected an open circuit on the thermocouple input RED FUSE the system has detected that the output fuse has ruptured AMBER LOAD the system is supplying some regulated load current normally flashes Panel Error Messages Each zone has the ability to raise an individual error message which indicates that the controller has detected a fault If an alarm condition is detected then an Error Message is displayed in the third row of the affected zone A full list of Error Messages along with the interpretation and a suggested action to investigate appears in the following Troubleshooting section TempMaster S6 12 Users Manual Revision1 4 H _ Mold Not Under documentation control if printed May be revised without notice Page 24 Jul 2010 Masters Electronic version available at www moldmasters com g Troubleshooting a Troubleshooting Error Messages The control system has several features which provide an early diagnosis of faults in the control system t
9. Turn amp Press wheel The S12 has two screens with one Turn amp Press wheel as you scroll laterally through the zones then the control will move across from one page to the other As you Turn and Press the wheel the screen confirms your selected function by highlighting the last character of the required function with a blinking square As you turn the wheel it has an automatic accelerate action which helps when setting temperatures If you turn the wheel quickly the settings will alter by a large quantity but as you turn the wheel more slowly the increments are smaller which makes for fine adjustment If at any time you stop making changes and leave the wheel idle for about 10 seconds then the controller will default back to its previous idle state with no changes made TempMaster S6 12 Users Manual Revision1 4 _ Mold Not Under documentation control if printed May be revised without notice Page 12 Jul 2010 Masters Electronic version available at www moldmasters com g WER Cm eee TrempMaster The Screen Interface Di Mold Masters The Controller has three main pages that may be seen during normal Running and during Setting Up these are named Display Setup and Mode This identity is shown at the bottom left of the page on the S12 it is shown only on the left hand screen To select the different pages push the wheel so that the page name is blinking and then turn the wheel to show t
10. User Manual for HRS6 12 Series of Hot Runner Mold Masters UK Ltd Tel 44 0 1432 265768 Mold ZE Ss Netherwood Rd Rotherwas Email office moldasters co uk D i Hereford UK HR2 6JU Fax 44 0 1432 263782 lasters TempMaster S6 12 Users Manual Revision1 4 B Mold Page 2 ouz Masters Not Under documentation control if printed May be revised without notice Electronic version available at www moldmasters com TempMaster 56 12 Users Manual Nian TempMaster S6 12 Users Manual Amendment Record Issue Date Amendments Author Authorised 1 0 Dec 2005 Initial Provisional Issue DH SK 1 1 Feb 2006 First Issue DH SK 1 2 July 2007 S12 Variant Added DH SK 1 3 Dec 2007 Replacement Fuse Information DH DH Added 1 4 Jul2010 Reformatted for Mold Masters DH DH Copyright c Mold Masters UK Ltd 2006 This manual is intended for use with the TempMaster S6 12 Series controller GerialNo with which H was supplied Our policy is one of continuous improvement and we reserve the right to alter product specifications at any time without giving notice DE TempMaster S6 12 Users Manual evision 1 4 gt m Mold eee Maste e Not Under documentation control if printed May be revised without notice Jul 2010 Page 3 Electronic version available at www moldmasters com eee Conteris Contents TempMasier 36 12 Users Manual lt 0cictcnidnue dca nnndmeinananudiinn 3 Eeer 4 EE ee
11. as soon as convenient ee Revision ia TempMaster S6 12 Users Manual Mold im if d May b d with e Not Under documentation control if printed revi ithout notice Masters Jul 2010 Page 25 SECH Electronic SE Gelee Temp Master Troubleshooting Servicing and repairing your controller Always isolate your controller at source before you YQ A replace fuses or open the unit for inspection Only use Ceramic Body Fuses NEVER use glass Lg bodied fuses 7 When it comes to machine maintenance there is very little that you need to do to look after it Replacement parts Mold Masters does not expect that you will need to repair any controller parts at board level other than fuses In the unlikely event of any board failure then we provide an excellent repair and exchange facility for all our customers Regular Inspection The front grill and the fan s should be checked periodically to see that no airway is clogged and that the fan is free to rotate Failure to do this can allow lint and dust to collect and reduce the flow of cooling air This in turn may incur more expensive repairs if internal components subsequently overheat External cable looms should be checked to see that there has been no damage to the flexible conduit plugs or sockets If the flex has been squashed if there is visible damage or if there are any exposed conductors then for your own safety it must be replaced TempMaster S6 12 Users Manual Revision1 4
12. bed on page 10 during its first start and so determine which of the three manual settings best suits the load You can override this automatic selection by selecting one of three preferred speeds on a zone by zone basis as described here 1 Select the Setup page 2 Turn the wheel to select Spd on the required zone 3 Press the wheel twice to make the word AUTO on the top row blink then Turn it to change the zone speed from Auto to select the manual speed setting to either FAST MEDI Medium or SLOW then Press the wheel to select that speed 4 If you need to set another function Standby or Boost temperature while on this page then Press the wheel again to select that function Otherwise if there is no other function to change then leave the wheel untouched for a short time and it will return to the Display page Setting the zone Boost and Standby Temperatures The Boost and Standby temperatures may be set on a zone by zone basis Both are set as temperatures above or below the set temperature as opposed to a specific temperature values These values can be set as described below Select the Setup page 2 Turn the wheel to select Spd on the required zone 3 Press the wheel once to make the word Spd on the bottom row blink then Turn it to select either Bst or Stby and Press the wheel once more to make the appropriate setting blink 4 While Stby blinks Turn the wheel to set the required Standby temperatu
13. can maintain the temperature at an accurate point with virtually no deviation TempMaster S6 12 Users Manual Revision1 4 H _ Mold Not Under documentation control if printed May be revised without notice Page 10 Jul 2010 Masters Electronic version available at www moldmasters com g Introduction TempMaster Watchdog feature The Controller card CPU has a watchdog timer that has to be reset by the system every 3 milli seconds If for any reason the software fails to reset the timer the zone power is set to zero to protect the tool against over heating The controlling card resets to the auto tune start position and power is increased in progressive steps until correct temperature control is re established Safety Memory Check E Mold Masters This controller uses flash memory to store all your settings such as temperatures limits and alarms There is an extremely low small risk that an interruption may cause any of these settings to alter and if such an event should occur then there must be no risk to the equipment To ensure that this cannot happen there is a safety memory check facility This checks to see that no value has been changed since the last time that the controller was used If this facility detects that any setting is different then it protects your system by automatically erasing every single stored setting within its memory If such a rare occurrence happens to your controller then you will be met by the fo
14. ce Electronic version available at www moldmasters com Servicing and Repairing ecceeeeeeee 27 Setting intial controller parameters 17 Setting Manual Power Levels sssassse1ee1 21 Setting up your controller c ceeeeeees 16 Setting Zone Temperaiures 21 SpPecificatiOn scceeiee ces cdhheeeestiwctsedennaieree 5 Standby Temperatures sssessreeerereeeereeee 19 Starting Stopping and other options 23 Switching On and On 8 RL 17 Temperature Gcale ennenen 17 Temperature Scale C or F ccscsceeeeeees 15 The control wheel interface ss essssnasseeeee 13 The TempMaster Controller ccceeeeee 9 The Screen Interface 14 Thermocouple J OF KK eeeeeeesceeeseeeeteeeeeeees 15 Troubleshootng 26 Watchdog Feature s eseeeeieeeeeeeereeeeeeeeene 12 WelcOMe cieri e enne 7 Zone Temperature Alamms 19 Zones switching off unwanted zones 24 Revision1 4 evisiont Mold Page 30 Jul 2010 Masters
15. d zone then Press to select that zone 2 Press to select the percentage power function 3 Turn the wheel to raise or lower the required percentage power level and Press to set it Turning any individual zone off Di Mold Masters Any single zone can be individually switched off while leaving the other working zones unaffected When a zone is turned off its previous Auto or Manual levels are retained in memory so that when you later switch it back on it will revert to its known setting 1 Turn the wheel to highlight the required zone then Press to select that zone 2 Turn the wheel again to select the OFF function and Press to select that function To switch the zone on again use the control wheel to select the zone and then turn again to select Auto or Man It will revert to the selected mode at the temperature or power level that was used prior to being switched off D TempMaster S6 12 Users Manual Revision 1 4 Not Under documentation control if printed May be revised without notice Jul 2010 Page 23 Electronic version available at www moldmasters com TempMaster Running your Controller Controller Alarms There are two sources of alarms that may alert you to any problems within the mould tool or the controller These may occur as alarm LEDs or screen error messages and are detailed below Front Panel LEDs Below each zone panel are six back lit symbols Two should be normally lit if the zone
16. for your general use Once the unit has been switched on select the page title and push the wheel so that Display blinks Turn the wheel till you see Mode and Press it to engage that page Bst Time 1864 Temperature Scale To set the temperature scale to either Centigrade or Fahrenheit Select the Mode page Turn the wheel to select Scale Deg Press the wheel once more and Turn it to select C Centigrade or F Fahrenheit 4 If you need to set another function while on this page then Turn the wheel to select that function Otherwise if there is no other function to change then leave the wheel untouched for a short time and it will return to the Display page T C Sensor To set the T C Sensor type to either J Type or K Type Select the Mode page Turn the wheel to select T C Type Press the wheel once more and Turn it to select J U Type or K K Type Fon If you need to set another function while on this page then Turn the wheel to select that function Otherwise if there is no other function to change then leave the wheel untouched for a short time and it will return to the Display page TempMaster S6 12 Users Manual Revision1 4 a _ Mold Not Under documentation control if printed May be revised without notice Page 16 Jul 2010 Masters Electronic version available at www moldmasters com g Setting up your controller TrempMaster Boost Time To set the overall Boost Time in seconds
17. ge 5 The TempMaster Console jiscisiciscetsscsanicetenusecapes cenusedsncintpisass denciateianetendalenumnenameake 12 Setting up Re Tee EE 15 Running your Controller ANNE ENEE 21 TESS SIRO GING E 25 APPENDIX E 27 CONNEC HONG eege EE 29 EDERT 29 MNS score eect ee ee ee ee eee ee eee 30 TempMaster S6 12 Users Manual SE gt evision1 4 Mold Masters Jul 2010 Not Under documentation control if printed May be revised without notice Electronic version available at www moldmasters com Page 4 Te E aSr Introduction Specification The following are general specifications The actual controller console supplied may have contractual variations and differ in some specified options E Mold Masters Supply Voltage Supply Voltage Tolerance Supply Protection Overload Protection Mains Voltage Output Output Current Control range Temperature scale Control Method Thermocouple input Front panel LED Indicators T C amp Heater Tool connector Input Device Display Case Revision 1 4 Jul 2010 Page 5 415v 3 phase 50 60Hz with neutral 20 supply voltage swing Miniature Circuit Breaker High Speed Semiconductor Fuse Links Burst fired zero crossover amp phase fired soft start 15 A max 0 472 Centigrade Celsius Centigrade Celsius or Fahrenheit Open or closed loop with HR software Type J or Type K Normal running high and low temperature Alarm Harting type Han A or
18. he three different pages Their function is as follows Display Shows the current running conditions for the zones The four rows from the top of the page show Set Actual Power Set the Temperature to which the zone has been set Actual the Temperature which is being currently read on that zone Power the Power level currently being used to maintain that temperature Display the name of the selected page However the bottom row may also be used to select further parameters for each zone which includes the auto temperature the manual power level the zone alarm limits and the zone on Off switch Setup Shows the current operational settings for the zones The four rows from the top of the page show Speed The speed that has been selected for the zone It may be left as its optimal AUTO setting or changed to Fast Medium or Slow if required see page 18 for more details Standby The temperature by which the zone is reduced when a Standby condition is selected Boost The Temperature by which the zone is temporarily raised when a Boost condition is selected NOTE that during a Boost mode it is the Boost Time that takes precedence over Boost Temperature If the Boost temperature has not been reached by the time a Boost period expires then the zone reverts to its normal set temperature rather than staying in Boost in order to reach the configured Boost temperature Setup the name of the
19. he tool heaters and thermocouple sensors If the system detects any malfunctions in one or more of the control zones then it may display any of four error messages in the Display page Error Message Cause Action ERR No temperature rise has Check thermocouple wiring it been detected in that may be reversed Heater wiring zone may be faulty or element may be open circuit FUSE The fuse for that zone has Replace the fuse with one of the failed same rating and type i e Fast Acting Fuse 16A Please Note A fuse can 250VAC 6 3 x 32mm Ceramic only fail due to a fault Remove the cover to access the external to the controller fuses which are located on the Identify and rectify the main PCB inside the unit fault before replacing the fuse OVER The particular Zone There could be an interaction temperature is exceeding between the zones or the wrong the limits thermocouple may be connected to the zone input Check the thermocouple wiring REV The card has detected an If the REV alarm persists then abnormal input at the T C you should switch off the termination that indicates controller and investigate the a shorted or Reversed offending zone thermocouple Alternatively you could slave the offending zone to a good zone until you have time to clear the fault T C An open circuit Check the thermocouple wiring thermocouple has been for a loose connection If OK detected then replace the thermocouple
20. hold for a short time Boost how to apply a brief raise in temperature Changing the Zone Temperature Turning any individual zone off About Controller Alarms D SH TempMaster S6 12 Users Manual i Revision 1 4 Mold ees NI asters Not Under documentation control if printed May be revised without notice Jul 2010 Page 21 Electronic version available at www moldmasters com TempMaster Running your Controller Starting Stopping and other options Other than simple power on Run or power off Stop your controller offers more options including Pause or Standby and Boost These modes are all available from the main Display page as described in the following paragraphs RUN The S6 12 controller automatically defaults to Run from switch on To switch to Run if not already in that mode Select the Mode page Turn the wheel to select Mode and Press Turn the wheel to select RUN and Press Leave the wheel idle and it will shortly default back to the main Display page STANDBY To switch to Standby FON gt 1 Select the Mode page 2 Turn the wheel to select Mode and Press 3 Turn the wheel to select Stdby and Press 4 Leave the wheel idle and it will shortly default back to the main Display page Note the system remains in Standby until you reselect another mode BOOST To select a temporary Boost mode 1 Select the Mode page 2 Turn the wheel to select Mode and Press 3 Turn
21. ide range of supplies and sequence of phases Refer to the serial plate in the controller cabinet for confirmation of the supply requirements If the local supply is outside the specified range please contact Mold Masters UK for advice Tel 0 44 1432 265768 Fax 0 44 1432 263782 TempMaster S6 12 Users Manual gt D d Revision 1 4 Mold Kee Masters Not Under documentation control if printed May be revised without notice Jul 2010 Page 7 Electronic version available at www moldmasters com TompMaster Introduction Switching On and Off For the S6 12 models the main Power Switch is an MCB at the rear of the cabinet The breaker is sufficiently rated to disconnect the total load current and is used for switching On and Off 0 C F or 0 Power is NOT Switched Off The heat of a nozzle is proportional to the applied current Setting any zone to zero degrees temperature or 0 power means that only the current is reduced to zero However the current control is not a breaking contact switch but a semi conductor device known as a Triac This means that at zero current there may still be some voltage at the nozzles On a 3 phase star supply with a neutral the triac is on the live side of the supply this keeps residual voltage to a low value However you should ALWAYS isolate the controller before you open up a controller to examine any wiring or change fuses Remember that with res
22. ion 1 4 Mold EE Maste S Not Under documentation control if printed May be revised without notice Jul 2010 Page 27 Electronic version available at www moldmasters com TempMaster APPENDIX A 2 S 6 LOOM TOOL END CONNECTIONS HASCO Standard Wiring Tool Connector Harting Han 24E 1 off female insert 09 33 024 2701 1 off housing 09 30 024 0301 Connections Zone Pin Connection Pin_ Connection T C Positive T C Neg ative 6 Return 18 T C Negative 8 Return 20 T C Negative 9 Supply 21 T C Positive 2 o for TempMaster S6 12 Users Manual Revision1 4 EH Mold 7 Not Under documentation control if printed May be revised without notice Page 28 Jul 2010 Masters Electronic version available at www moldmasters com TempMaster P 3 S 12 LOOM TOOL END CONNECTIONS Power Connector Harting Han 24E 1 off female insert 09 33 024 2701 1 off housing 09 30 024 0301 Connections 1 Supply Return 7 8 Supply Return 9 Thermocouple Harting Han 24E 1 off male insert 09 33 024 2601 1 off housing 09 30 024 0301 Connections 7 Supply 19 Return 9 Supply 2 Supply 10 10 Supply Supply 11 11 Supply Supply 12 12 Supply Return 24 Return Connection Zone Pin Connection 2 T C Positive T C Negative T C Positive T C Positive T C Negative T C Positive T C Negative gt PS e Revision 1 4 Mold
23. its Thermocouple Amplifiers The Thermocouple amplifier used in the S 6 12 controller can be configured for use with either J or K type thermocouples You can set this option on the Mode page Central Processor Unit CPU The CPU provides the following facilities e closed and open loop control of the zones e communicates settings and thermocouple readings over the data link to the display micro processor e checks for alarm conditions including blown fuse incorrect thermocouple wiring zone over temperature condition heater not responding to controller output and generates alarm information for the display page e controls the output power to the triacs using a number of self tuning algorithms e monitors the thermocouple every 20 milliseconds Input and Output Supplies The power supply to the cabinet is via a cable at the rear of the panel that is fitted with a 3 phase 32A plug Connections to the tool are made through one or two cables which carry the heater supplies and thermocouple connections Tool to Controller terminations are made through a Harting type Han E connectors and the wiring details are shown in Appendix A gt A TempMaster S6 12 Users Manual i Revision 1 4 Mold Masters Not Under documentation control if printed May be revised without notice Jul 2010 Page 9 Electronic version available at www moldmasters com TempMaster Introduction How the Mold Masters Controller Works Mold Masters
24. ll rise in temperature when Boost mode is selected When the timer expires all the zones drop back to their normal set temperature TempMaster S6 12 Users Manual a Revision1 4 Mold Not Under documentation control if printed May be revised without notice Page 14 Jul 2010 Masters Electronic version available at www moldmasters com g Setting up your controller ee oP Master Setting up your controller New TempMaster controllers are not normally configured at the factory You should always check through any new controller to see that its settings are correct for the tool with which it is about to be used If you are checking a new controller or reconfiguring an older controller to use it with a different tool or environment then you may need to refer to this chapter of the manual What is covered in this section E Mold Masters Setting the Controller parameters including Boost Time Temperature scale Thermocouple Type and Screen Intensity Setting the Tool Parameters including Zone Speed Settings Boost and standby Temperatures Zone Alarm Limits Zone Temperatures D TempMaster S6 12 Users Manual Revision 1 4 Not Under documentation control if printed May be revised without notice Jul 2010 Page 15 Electronic version available at www moldmasters com TempMaster Setting up your controller Setting initial controller parameters First you should check the MODE page to see that these settings are correct
25. llowing message when you switch on CAUTION SYSTEM RAM ERROR Stored values HAVE been ERASED If you read this then you need reset all appropriate settings This basic task is described in the next chapter of this manual The task is easier if you have all the correct settings written down in a safe place Mold Masters recommends that a hard copy of all the controller and tool settings is saved in a safe place D TempMaster S6 12 Users Manual Revision 1 4 Not Under documentation control if printed May be revised without notice Jul 2010 Page 11 Electronic version available at www moldmasters com TempMaster The TempMaster Console The TempMaster Console Screen 40 x 4 LCD Screens display all the necessary information which is divided into four rows to normally show Set temperature Actual temperature Power level Speed Setting and in the bottom left the page Name TempWMiaster S6 Front panel Status Indication There are 6 LED indicators below each channel to show its status From the top there are Red The temperature is above the upper limit Green The controller is operating normally Blue The temperature zone is below the lower limit Red T C There is no detected Thermocouple input Red fuse The output fuse has ruptured Amber load The system is delivering output load current The Turn amp Press control wheel interface All the control and setup functions are accessed through the
26. pect to the mains supply O power is NOT Off TempMaster S6 12 Users Manual Revision1 4 a _ Mold Not Under documentation control if printed May be revised without notice Page 8 Jul 2010 Masters Electronic version available at www moldmasters com Introduction TempMaster The TempMaster S6 amp 12 Controller The S6 amp S12 is a two part case with the display and control functions on the front while the input and output cables and the main switch are mounted on the rear panel Both the output load fuses and the input thermocouple fuse are mounted on the main circuit board s If you need to check or replace a fuse then you should isolate the controller from any electrical supply before you open the case Controller Cards There are three boards mounted inside the cabinet Two boards are fixed to the front facia one to house the main LCD display unit and the second is an interface for all the LED display alarms The third board controls the zone temperatures and it has four main components e thermocouple amplifiers e CPU e multi voltage output triacs e power supply The S12 has a similar construction but uses two LCD displays and two LED interface boards The two main control boards differ in that only one board has the common power supply while the other has all the thermocouple inputs and amplifiers Both main boards have six output control circuits and each board has its own CPU to control those six circu
27. re reduction then Press to accept the new setting 5 To follow on and set the Boost temperature Press the wheel to make Spd blink then Turn the wheel to select Bst and Press once more 6 With Bst blinking and the temperature selected Turn the wheel to raise or lower the required boost temperature Note in a Boost mode condition it is the Boost Time that takes precedence and if you set the Boost Temperature too high with relation to the Boost Time then the required Temperature increase may not be reached before the Timer expires and the zone returns to its normal set temperature Setting Zone Alarm limits You can set zone limits to provide a visual warning if actual temperatures go outside the nominal set points The Low and High limits may be independently set within the range of 1 to 99 C above and below the set temper ature Note High and Low limits will create an alarm at 1 more than your setting So that a Limit setting of say 10 means that an actual temperature may deviate by up to 10 without raising an alarm A zone must deviate by 11 or more before an alarm condition is generated TempMaster S6 12 Users Manual Revision1 4 H _ Mold Not Under documentation control if printed May be revised without notice Page 18 Jul 2010 Masters Electronic version available at www moldmasters com g Setting up your controller JempMaster E Mold Masters To set these limits Set Actual Power Display
28. s equipment Mold Masters Hot Runner temperature controllers are designed for use in the plastic injection moulding industry as temperature controllers for third party hot runner systems as commonly used in mould tools The controllers must not be used in residential commercial or light industrial environments Furthermore they must not be used in an explosive atmosphere or where there is a possibility of such an atmosphere developing They should be installed in a clean dry environment where the ambient conditions do not exceed the following limits e Temperature 0O to 350 e Relative Humidity 90 non condensing Controller Tool Connections The various connections to the system using the cables supplied with the equipment are specified Appendix A Equipment failure through mis wiring Before you energise the system pay special attention to how the supply to your controller is wired and how it is connected to the mold Lack of attention to detail causes errors such as e incorrect wiring of mains supply phases into the controller e crossing heater supply feeds with thermocouple inputs although this error can be eliminated by the adoption of HASCO Standard connections In such cases wiring errors have caused equipment failure Mold Masters cannot be responsible for damage caused to the controller by customer wiring and or connection errors Controller Power Supplies The control cabinet can be manufactured to accept a w
29. selected page However the information on the rest of the bottom row helps to setup the other zone parameters including zone speed and Boost and Standby temperatures DE TempMaster S6 12 Users Manual evision 1 4 Not Under documentation control if printed May be revised without notice Jul 2010 Page 13 Electronic version available at www moldmasters com TempMaster The TempMaster Console Mode Allows you to select the current running mode for the controller which may be seen on page 22 Note On the S12 only the left screen displays the Mode page Within this page you can also set four overall parameters for the controller which includes Scale Deg C or F this determines whether the zone temperatures limits etc are shown in degrees Centigrade or degrees Fahrenheit T C Type J or K this allows you to set the controller to work to either J Type on K Type thermocouples Select either to match the particular tool Contrast This allows you to set the contrast between the characters and the background The lower the percentage figure then the darker the character At 100 the characters will be invisible 50 should be acceptable for most users NOTE The Contrast may also be set if you Press the control wheel during Switch on as the alarms LEDs blink and before the main menus appear Bst Time This sets a Boost Period in seconds during which any zone that has some boost temperature configured wi
30. the wheel to select Boost and Press 4 Leave the wheel idle and it will shortly default back to the main Display page Note the system only remains in Boost for the preset Boost Time after which it returns to normal Run mode STOP To switch to the unit to Stop 1 Select the Mode page 2 Turn the wheel to select Mode and Press 3 Turn the wheel to select Stop and Press 4 Leave the wheel idle and it will shortly default back to the main Display page Note putting the system at Stop only sets the power level to zero there will still be mains voltage present at the tips DO NOT use STOP as a maintenance mode to access the tool wiring TempMaster S6 12 Users Manual Revision1 4 H Mold Not Under documentation control if printed May be revised without notice Page 22 Jul 2010 Masters Electronic version available at www moldmasters com g Running your Controller TempMaster Changing the Zone Temperature You can change zone temperatures on a zone by zone basis while the tool is auto mode 1 Turn the wheel to highlight the required zone then Press to select that zone 2 Press the wheel again to select the temperature function 3 With the current temperature setting highlighted Turn the wheel to raise or lower temperature and then Press to set it Setting Zone power levels manual working To set a zones percentage power level e C D i Turn the wheel to highlight the require
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