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1. See also Options menu 12 TEMP STAR Diagnosis Menu ZONE 2 10 ZONE10 I zone 12 zone 12 13 ZONE13 14 ZONE14 di agno sti cs param eter TS thermocouple LT output stage output maximum duration 03s start diagnostics stop diagnostics TON rormatmode ee 1 32 pass it wu 4 x gt 4 v e Yo Function Setting Submenus TIP options control current ITS LT Status 1 0A ok ok ok 0 9 A ok ok ok 1 0 A ok ok ok 0 9 A ok ok ok 1 0 A ok ok running NX NX XXX PROG E1 open E3 open 50 E2 reverse E4 overcurrent ejjuluuitl TEMP STAR MASTER Checks the wiring of the connected mold and indicates wiring or system errors The checks are performed for each zone separately If the connected heating system reaches the target temperature offset within the preset time the zone is O K Currently running tests are indicated for the respective zone Should wiring or system problems be detected an error message is displayed SET allows you to select the zones to be checked In this way it is possible to select only the relevant heating circuits e g after completion of repairs The temperature offset field is used for setting the temperature differential by which the temperature must be increased within the desired time interval This value can be entered via the maximum duration field The maximum 96 power output can be set manually via the2. Overtemperature mnm UNGETIEMPEFALUE a 42 een een taeda coelos a Ramp 2 K s virile Me e Ramp 1 K s TEMP STAR Touch Screen Operating Panel Menu bar display _ table parameter system options diagnostics 218 C 219 C 219 C 219 C 219 C 221 C 220 C 218 C 220 6 ente 7220 C7 722067 9056 220 7220867 S 9Q C 0 A 0 a 0 s 0 A 0 a 0 i 0 0 220 C 220 C 220 C 222 C 219 C 219 C 221 C 219 C era 220 ucHE ci guis 0 0 0 0 0 0 0 0 13 14 15 zone ZONE 18 ZONE 19 ZONE 20 ZONE ZONE22 ZONE 23 gt TONE 24 220 C 223 C 220 C 221 C 222 C 223 C 221 C 220 C 220 C 220 C 220 C 220 C 220 C 220 C 220 C 220 C 0 0 0 0 0 0 0 0 18 1 20 21 22 23 24 1 CLEAR NE25 ZONE28 ZONE 2 ONE 21 ONE 29 ZONE 30 ZONE 31 ZONE 32 204 C 196 C 200 C 203 C pose 184 C OFF OFF 200 C 200 C 200 C 200 C 200 C 180 C G C 0 2 0 0 0 0 25 26 r 27 28 29 30 31 ZONE 33 ZONE 34 ZONE 35 ZONE 36 OFF OFF OFF OFF m I I pe T compounsvecire o o 5D 9 5 S E 9 9 9 a Boost Alarm Navigation DIBIBIHIHIHIE Start Stop Standby heating Menu selection Via menu bar selection directly on the screen Help The HELP button accesses the help function of the current menu window You can open either the user manual or
3. switch disconnector that connects the device to the power supply system should always be easily accessible The device includes built in powerful fans that reliably prevent overheating of the output stage during operation The corresponding ventilation slots are located on the underside and the rear side of the device Make sure that air supply to and through these openings is not blocked Cleaning The external surfaces of the device and the operating panel may be cleaned with a soft cloth saturated with alcohol Do not use acid cleaners or scouring agents To prevent malfunction the operating panel should only be cleaned after the device has been switched off A Maintenance The device must be regularly subjected to a safety check complying with BGV A2 requirements protection against accidents It is recommended to clean the dust filters of the fans at regular intervals Replace the filters as appropriate depending on their working condition and duration of use In addition the ventilation slots should be regularly checked for obstruction and cleaned if necessary However this may only be done by qualified service personnel with adequate electrotechnical knowledge No other maintenance work is required for the device beyond the tasks specified above Should malfunction occur please contact the manufacturer Disposal Once the device has reached the end of its service life feel free to return it to the manufacturer for pr
4. IE UN T 11 ie nime 12 Pagno teo MoU m H PHm 13 Connections Oad TNO MO OUNO een 14 A ONCE ee ee ea 15 Specifications ee cet ee ee ee 15 Load Circuit Fuses RCIA ING FUSOS onon eaea E s 16 TEMP STAR Safety Notices IN WARNING Danger of electric shock AN General danger warning symbol If you see this pictogram attached to the device please refer to this documentation to determine the kind of danger involved and protect yourself from potential hazards oymbol for protective conductor ground terminal AN Safety Notices Carefully read these operating instructions prior to putting the product into service Only qualified personnel with sufficient electrotechnical knowledge may service the device Be sure to disconnect the mains plug before opening the housing When replacing fuses be sure to use the same type of fuse see Replacing Fuses Prior to plugging in the mold cables verify that all connectors have been properly connected see Connections or connection diagram for special pin assignments Check power supply cable and mold cables for potential defects on a regular basis If cable sheath is damaged be sure to use a new connecting cable Warranty All TEMP STAR plug in controllers are subject to a 2 year warranty starting on the day of shipment of the product Excluded from coverage is damage due to
5. ONE14 ZONEI5 ZONE 16 259 C 259 C 257 C 259 C 257 C 261 C 261 C 262 C 260 C 0 9 ZONEi17 ZONE18 ZONE19 ZONE20 ZONE2I ZONE23 ZONE24 260 C 260 C 261 C 261 C 261 C 262 C 261 C 260 C 260 C 0 246 C za prs CS Be EXPE THES NH 245 C 0 25 ZONE 33 OFF ic ims RETIUM 8 E 5 3 9 9 2 2 a I fo Function Setting Submenus TIP ZONE 34 ZONE 35 ZONE 36 table parameter system options diagnostics 260 C 260 C 260 C 260 C 260 C 260 C 260 C 0 0 0 0 0 1 0 B E 5 8 EL 8 260 C 260 C 260 C 260 C 260 C 260 C 260 C 0 0 0 0 0 0 11 12 13 1 14 15 16 260 C 260 C 260 C 260 C 260 i 260 po 260 C 0 0 0 0 0 9 E 22 24 ZONE 32 245 C 245 C 245 C 245 C 220 C 220 C C 0 0 0 0 0 0 27 28 23 30 31 OFF OFF OFF i i ie TEMP STAR MASTER Standard view in operating mode The screen displays all control zones belonging to the controller with zone name actual value setpoint value and power output In addition the controller status the status of the alarm inputs and outputs and all active alarm messages are indicated as well Use the SET button to enter the setpoint value of your choice if ready press CLEAR to return to operating mode You can also make this setting for a whole group of control zones by selecting the corresponding zones with the GROUP f
6. Operating Instructions May 2014 Subject to technical modifications TEMP STAR MASTER HUMMEL AG Lise Meitner Stra e 2 D 79211 Denzlingen GERMANY Phone 49 0 7666 91 110 970 Fax 49 0 7666 91110 9799 Internet www hummel com TEMP STAR Table of Contents General Information Warning Symbols u02240024000ennnenenenn nenn nenne nenne nenn nennen nhan nnn nnne nna r nsu sre rna nnne sna rn rna nns 3 Sdieb Ine OLI seen ee ee 3 A UY TREES T 3 mended UCO NTDNIFENNCN 3 Cae Eao eon e nase 3 ELE 0 M OOO OO 4 unomer 4 U AI Ce gc q CE e ee ee eee 4 DVS OS UT u 4 Controller MI Fogi dB cME 5 Control Board with Load Circuit FUSES ansehen 5 TEL Dean monde ee ee 6 SOM els Ae 2 11 MEE TTE m 6 Touch Screen Operating Panel 2u002040020200000nn nenne nnnnn nenne nenne ennn nenn nnennenenne nennen 7 Man aiU Brei Rm ea 7 Display Menu uu200020senenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenen 8 Tae MENU ee ee ea en a ee 9 Parameter Menu ccccccccceccseececceeececcseeceeeeeeceeesueseeseesaeesaesaeesuesaueseesaueceesaueseeeaeeseesaeeseeeseesas 10 SYSTEM
7. e correct password in each case In the startup behaviour block the compound heating function or the optimization function can be activated or deactivated If the compound heating function is activated the fastest zone e g nozzles will wait for the slowest zone e g manifold This prevents mold stress as far as possible during the heat up process During the soft start phase the optimization function determines the best control parameters However this is required only during the initial start of each mold The display section allows you to select the basic temperature unit C or F and the interactive language of your choice Data recording e g for quality assurance purposes can be activated and deactivated in the data backup block Besides you can set the monitoring interval here The info button gives you access to a list of zones that have been activated for data recording Such activation is carried out via the actual temperature and output fields of the Parameters menu either individually or groupwise The log data is stored in a special directory and can be retrieved from there as an ASCII file Start explorer Direct access to the data management area of the operating system Error log Provides a list of all alarms that have been triggered with date and time System log Provides a list of all user actions with date and time Depending on access level not all setting options may be available
8. factory preset parameters The system parameter submenu allows you to enter global values that are valid for the entire system e g soft start parameters system parameter For entering parameter data for all zones system overview Indicates the status and the firmware version for each controller card module molds Manages mold data with change history mold memory Depending on access level not all setting options may be available See also Options menu 11 TEMP STAR Options Menu TE zero en options Kenner interval sec pin level 1 change pin channels startup behaviour compound heating optimization display temperature unit language Tempstar Visualisierung DEMO version 2 0 9 1 access access level pin level 2 change pin _ start explorer t 6 6 B 9 8 WE t9 B 9 5 E39 D 5 L9 5 Function Setting Submenus TEMP STAR MASTER There are various access levels that differ in the scope of the setting and viewing options they provide For Levels 1 and 2 4 digit numerical passwords are required Level 1 user level is intended for production Level 2 master level for parameter setting All higher access levels should only be used by system administrators The access block is used for entering the passwords for Levels 1 and 2 Once the passwords have been saved access will be possible only after entering th
9. ge 0 50 C 32 122 F Metal enclosure powder coated with handles Aluminium enclosure powder coated 12 SVGA LCD display with touch screen 36 zones 460x410x450mm 60 zones 660x410x450mm WxHxD 300x240x65mm WxHxD 36 zones 32 kg 60 zones 50 kg 4 conductor three phase system 3L N PE 230 400VAC 10 32 A 50 60 Hz Overvoltage class Il CEE 32A optional 63A connector other Supplies on request approx 22kW with 32A connector 44kW with 63A connector Every 12 zones to 1 Load connector 24 pole and 1 Thermocouple connector 32 pole HAN A Fe CuNi type J Lor K Max 16A per zone load factor 80 contactless semiconductor output stage zero voltage switching max 48A per controller board 6 zones 50 500 C 122 932 F Control accuracy better 1 C if hotrunner permits 16 A FF super fast acting Plug in cards each for 6 zones with load circuit fuses Replaceable without tool 1 Alarm connector M23 12 pole 1 Panel connector M16 10 pole 2 Interface connectors SUB D 9 pole USB Ethernet VGA PS2 RS232 1 each on touch screen 15 TEMP STAR Replacing Fuses WARNING Danger of death from electric shock Before starting any work on the device be sure to pull mains plug The device may only be serviced by qualified personnel with sufficient electrotechnical knowledge 2 fuses for the main power supply are located inside the device When replacing them be sure to use fu
10. ice if ready press CLEAR to return to operating mode You can also make this setting for a whole group of control zones by selecting the corresponding zones with the GROUP function The left right buttons enable you to display the previous next block of zones for single line by line steps use the up down buttons The scroll bar on the right side of the screen can be used for direct navigation No submenus available TEMP STAR Parameters Menu parameter system options diagnostics zone no name module channel active control substitute default settings channel state temperature output actual Ur 55 setpoint 220 0 c boost loadcurrent 11a load alarm standby 50 C current limit 160A ON OFF controller parameter performance control proportional value 30 average value t9 B 9 5 E39 D E E Es Function This screen displays the parameter set for a zone This menu allows you to name zones and set the zone parameters output stage 66 3 0 e TEMP STAR MASTER Setting Zones are selected in the top left field and can be given a name in the field immediately to the right The following two fields of this line indicate first the controller board module and then the channel of this card The following line allows you to switch the zone ON and OFF or switch to a different mode of operation C stands for control mode 96 for manual operation and the measuring symb
11. improper handling wrong connection or non intended use see below Return goods must be sent to HUMMEL AG s EL Division using the original packaging postage prepaid A Intended Use The TEMP STAR plug in controllers are industrial temperature controllers designed for regulating the temperature of hot runner molds To this end the temperature of each control zone is monitored by a temperature sensor whose input is used to adjust the power output for the heating element as appropriate Using the device for other purposes may compromise its protective functions An external temperature fuse must be used for overtemperature protection in the event of malfunction The manufacturer shall not be liable for damage due to improper use of the device General Information A separate control zone is required for each load to be connected A control zone consists of a temperature sensor input and a load output including a fuse When wiring the molds be sure to assign them to the correct pins see Connections All unused control zones must be switched off A heat resistant flexible cable must be used as a connecting lead for the load circuits For the temperature sensors a special compensating lead is required Leads and cables are available as original accessories TEMP STAR oet Up Place the device on a stable level working surface at a height that makes it easy for the user to read the display and operate the unit The mains
12. nly in exceptional cases and therefore should be done only by competent personnel Submenus No submenus available Depending on access level not all setting options may be available See also Options menu 10 TEMP STAR System Menu dis ET inn devices zones EDEN at _last Tostform 1 Werkseinstellung 31 03 2011 09 18 37 31 03 2011 09 18 37 table XE system diagnostics 26 05 2014 16 30 48 26 05 2014 16 30 43 nannte E n dehydration Preform_246 305 73_c out 12 05 page 1 1 Wi e 4 3 5 o e Function Setting Submenus TEMP STAR MASTER This menu allows you to manage the mold memory molds and the system parameters Besides the system overview provides information on the status and the firmware version of the various controller boards In the molds submenu all parameter values of a running mold can be managed The save as save load and delete buttons are intended to guide the user through this submenu Once all parameters have been set correctly they can be saved with save as by entering a name for the part or simply the drawing number If changes have been made to an existing mold these are saved with the save button To start control operations after the system had been switched off the appropriate program must first be loaded via the load function The read only data record Default Settings stores the
13. o the injection molding machine as well Connect the mains cable then turn on the controller via the mains switch Following initialization of the system and parameter loading the operator must decide whether to use the Setting Wizard or not The Wizard helps you to make the main settings required for starting production in just a few steps Alternatively adjust the setpoint values or load a mold program stored in the system s memory Be sure to switch off all control zones that are not used currently See Parameters menu TIP The HELP button gives you access to the Help function This function explains all the operating setting options offered in the currently active menu Following careful verification of the correctness of all settings operate the I O button to start the heating process This causes the controller to heat up all molds in a uniform manner Moist heating elements are dried in the process soft start ramp If the compound heating option is used all zones are heated up at the same speed thus reducing stress in the mold material The heat up speed of the soft start ramp can be adjusted via the Options menu When heating up molds for the first time the controller automatically determines the best control parameters for the connected heating zone Therefore to ensure optimal control results do not connect the device to warm molds ooft Start Ramp Active during start up reheating after standby or alarm
14. ol for measurement zones If you select manual operation the output power must be additionally set in 96 power output under Default Settings The measurement zones enable you to display the mold temperature and monitor mold cooling WARNING There is no mold temperature monitoring in manual operation Danger of destruction of N the connected heating system The Substitute field allows you to set an alternative sensor for providing the actual value for the zone in the event of sensor breakage In the Default Settings block you can set the setpoint value the boost temperature and the output power for manual operation in 9e The temperature reduction Standby parameter is set in the System menu as part of the system parameters The Channel State block provides information on the operating status and the current load current of the respective zone The Current Limit field allows you to set the maximum permissible output current If the set level is exceeded overcurrent alarm is automatically triggered The power output monitoring function compares the average output value to a reference value If the monitoring function is active the system detects deviations caused e g by leakages in the hotrunner system During the optimization phase the controller checks the best control parameters for all the heating elements connected These values can be overwritten by adjusting the control parameters However this leads to enhanced control accuracy o
15. oper disposal This device satisfies the essential protection requirements specified in pertinent EU Directives as of 2010 TEMP STAR View of the Device Front side Rear side Mains switch UR WC Controller board 1 Controller board 6 Load Thermocouple Alarm Controller Board with Load Circuit Fuses NN A IMPORTANT NOTICE Each controller board is designed for controlling 6 zones The cards can be inserted into any free slot Be sure to turn off the device before removing a controller board Following board exchange the device must be restarted To replace the load circuit fuses unlock the corresponding control card rotate the 4 locks by 90 then withdraw card When replacing fuses be sure to use fuses of the same type 16 AFF see Replacing Fuses m T Load circuit fuses TEMP STAR Start Up The MASTER hot runner controllers are designed for connection to a three phase power supply source see Technical Data The unit features a CEE plug for this purpose The mains switch which disconnects the device completely from the power supply is located on the rear panel After checking carefully that all connections have been made correctly connect the mold to the controller The alarm connector accessory allows you to establish a connection t
16. output field J Clicking the start diagnostics field starts the check and clicking stop diagnostics terminates it Given 60 zones the diagnostic process can take several hours if the time range is utilized No submenus available Recording the results of the diagnosis helps you to identify defective heating zones later by assessing deviations from the power output 13 TEMP STAR Connections according to DIN 16765 A Load 24 pole 1 13 25 37 49 1 13 12 24 36 48 60 12 24 2 14 26 38 50 2 10 12 24 36 48 60 20 28 14 Connections TEMP STAR Alarm connector 12 pole Mating connector or alarm cable see accessories Alarm Output 1 overtemperature 2 undertemperature max SELV 33VAC 70VDC 2A Stop machinery Release production em Tenor fem r Input 1 Standby 2 Boost Specifications Working conditions Controller housing Touch screen housing Controller dimension Touch dimension Weight Power supply Connected load Mold connections Thermocouple Power output Control range Load circuit fuses Controller boards Connections 10 12 green yellow E2 Boost Switch contact To be operated only in closed rooms Altitude max 2000m Relative humidity up to 80 at 30 C 86 F Avoid moisture condensation Pollution severity level 2 Operating 10 40 C 50 104 F Stora
17. ses of the same type rating Each control card is designed for controlling 6 zones For assignments see below To replace the load circuit fuses unlock the controller board rotate lock by 90 and withdraw card Use the auxiliary tool attached to rear panel of housing to exchange the fuses as illustrated below Be sure to use only replacement fuses of the same type To reassemble the device proceed in reverse order Removing fuses Installing fuses x ooo oo gt aQ a Taso 4 eva ra aes E220 Sos 23 4 BN NUN 25 5 26 5 28 5 a 5 30 5 31 6 32 6 33 e aje 35 6 36 e 38 7 39 7 40 7 gt 16
18. the Setting Wizard Setpoint Can be entered directly via the Parameters menu In the Display or Table menu select the zone of your choice and then SET to adjust the setpoint value For groups see Group Zones OFF You can deactivate zones individually via the Parameters menu Group Select first zone and last zone then use the GROUP button to create a group You can add additional zones at your choice Use the SET button to set the setpoint value then click CLEAR to return to normal operation Button F1 allows you to define designate and mark groups e g for multi component molds F2 highlights the 6 variable groups Start operation To activate the heating function click the I O button Boost Temporary temperature increase either with Boost button or via alarm connector Standby Temperature reduction for all active zones with Standby button or via alarm connector Alarm The Alarm button allows you to call up all currently active alarm messages Print The PRINT button allows you to print the current screen content Turn off First terminate all control processes with the I O button Click the END button to close the operating system then turn off the device via the mains switch TEMP STAR Display Menu display ZONE1 ZONE2 ZONE3 ZONE4 ZONES ZONE amp ZONE ZONE8 261 C 261 C 257 C 260 C 260 C 261 C 256 C 259 C 260 C 1 2 ZONE9 ZONE10 ZONE1I ZONEI2 ZONE13 Z
19. unction The left right buttons enable you to display the previous next block of 36 zones for single line by line steps use the up down buttons No submenus available The 96 power output bargraphs give you an overview of the connected heat load nozzle or manifold Once the set setpoint value has been reached the output should be no higher than 80 If higher the capacity of the heating system is probably insufficient The GROUP and F1 fixed group functions enable you to designate and mark the respective systems when using multi component molds These systems can then also be modified and started separately F2 highlights the groups and displays them separately TEMP STAR Table Menu 2lee ej ojmromi 12 ZONE 12 13 ZONE 13 14 ZONE 14 15 ZONE 15 16 ZONE 16 17 ZONE 1 18 ZONE 18 19 ZONE 19 20 ZONE 20 W 4 3 5 5 v e Yo Function Setting Submenus ZONE 10 ZONE 11 parameter system options diagnostics SET 4 m name temp setpoint output control current boost standby 4 a G e G G G TEMP STAR MASTER This screen displays all control zones with zone name actual value setpoint value power output temperature unit load current boost and standby temperatures In addition the controller status the status of the alarm inputs and outputs and all active alarm messages are indicated as well Use the SET button to enter the setpoint value of your cho
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