Hot Runner Main Frame Manual
Contents
1. 2 35 4 5 6 7 8 00000000 00000000 9 10 11 12 13 14 15 16 13 14 15 16 17 18 19 20 22 23 24 ATHEN N cowrsocs ne ese WIRING DIAGRAM FOR CE RUNNERLESS MOLDING SYSTEM 6 NUMBERED CRIMP HEATER LEADS ON PIC CONNECTORS POWER LEADS CONNECTORS ZONE WHT WHT RED 6 9 HEATER VOLTS r ARP P UP A VM a a ay a a a a apap a a av m hl a 2 E DISTRIBUTION TUBE OR MANIFOLD HEATER ZONE 1 MOLD THERMOCOUPLE EN CONNECTORS i NV LEADS RED WHITE 0000000000 0000000000 HB CUBA CUN VU UU AURA OE EE URS aww t n TS Va a iut ni PICL12E 4 0000000000406 MOLD POWER errr INPUT CONNECTORS REAR VIEW uw BEFORE POWER IS 00000000 CONNECTED 00000000 USE OHM METER TO CHECK EACH HEATER POWER LEAD RESISTANCE TO GROUND SHOULD BE GREATER THAN 20 000 OHMS 1 C hE EE Eh CUR CUR CUR CUR AA AAA CHECK RESISTANCE BETWEEN HEATER LEADS PROBE OR NOZZLE HEATER CHECK CONNECTIONS OF RED AND WHITE LEADS TO INSURE PROPER CONNECTION TO THE CORRECT TERMINAL ES a s iD S 6 7 8 9 10 USE OHM METER TO MEASURE BETWEEN RED AND WHITE LEADS RESISTANCE SHOULD BE LOW 13 14 15 16 17 18 19 20 21 22 23 24 MZON HEATER HEATER MEASUR2. Example Module One is connected to MP N RL I Module Two is connected to MP N and RL 2 etc 12 2 0 MODULE INSTALLATION AND SECONDARY WIRING 2 1 Module Installation With the main circuit breaker in the OFF position install each module being careful to fully seat in the connectors at the rear of the slot Then press in the plastic lock at the bottom of the module 2 2 Secondary Wiring Carefully connect all heaters and thermocouples to their respective circuits making sure that there are no short circuits It is important that each thermocouple is wired to the zone that controls the associated heater 2 3 Check out We recommend using Chart 1 of our troubleshooting procedure to ensure that the control system 1s working properly See section 3 4 1 2 4 Digital Current Voltage Monitor 1 METER A dual function multi range display is used to monitor either individual zone heater current in amperes or AC voltage of each phase of a three phase input 2 VOLTS AMPS SWITCH Determine whether meter functions as an Ammeter or Voltmeter Refer to the serial number plate on the side of the mainframe to determine system input voltage requirements 3 MAIN POWER SWITCH DISCONNECT BREAKER Used to turn the system ON or OFF 4 MAIN POWER INDICATOR Illuminates to indicate the Main Power Switch is on and that input power 1 applied to the system 5 SELECTOR SWITCH Used to select which zone or AC power line 1 being moni
3. G H Connecting Input Power Check nameplate to make sure that the control system was wired at the factory for the power source to which it is to be connected It is possible to change the wiring of the control system in the field to any of the power sources shown on the diagrams on the back of the unit These diagrams are reproduced on the following pages for your convenience See Section 1 3 for instructions on how to do this re wiring Remove back panel by removing the screws around its perimeter Select input cable size and configuration based on load requirements and local electrical codes Insert AC input cable through cable clamp provided on side of mainframe Attach leads to terminal strip as shown on mainframe back panel for power source as shown on nameplate or as re wired Be sure to attach ground as shown on wiring diagram Take up excess slack in cable and secure with strain relief clamp provided on the outside of the cabinet Route AC input cable to a branch circuit disconnect switch and attach leads to the fused side of the switch Be sure the ground lead is attached to a good earth ground 1 3 1 3 1 1 3 2 Wiring Control System for Different Power Sources See diagrams following this section or on rear of cabinet for the power sources for which this control system may be wired These changes may be made without tools although a pair of long nosed pliers may be helpful Changes are made by moving th
4. ATHENN The Temperature Control Company Hot Runner Temperature Control Systems Mainframe Installation Manual TABLE OF CONTENTS Mainframe Installation Location Connecting input power Wiring for Different Power Sources Schematic A Standard Wiring Schematic European Standard Schematic C Open Delta Schematic D Single Phase Name Plate Wiring Diagrams Module Installation and Secondary Wiring Module Installation Secondary Wiring Check out Digital Current Voltage Monitor Control System Troubleshooting Temperature Oscillation Temperature Too High No Heat Indication Troubleshooting Charts Fault Classification Chart 1 Power Chart 2 Module Charts 3 4 5 Section 1 0 1 1 1 1 1 2 1 3 0 1 3 2 1 3 3 1 3 4 5 1 3 6 2 0 ZA 2 2 2 19 2 4 3 0 3 3 2 3 3 3 4 0 3 4 3 4 2 3 4 3 t yo W W W 16 16 16 16 17 17 18 19 1 0 MAINFRAME INSTALLATION Installation and service should be performed by qualified personnel only 1 1 Location The proper location is important for dependable service The control system should be located so as to allow free air movement into and out of the mainframe Consideration should be given to allow the least exposure to heat dust dirt moisture and corrosive vapors The front of the system must be readily accessible for setup and adjustment purposes 122 D E F
5. E BETWEEN EACH VOLIS e WAITS MEASURED HEATER POWER LEAD AND MARKED X MARKED MARKED RESISTANCE EACH THERMOCOUPLE LEAD ON HEATER ON e ON OHMS RESISTANCE SHOULD BE HEATER HEATER GREATER THAN 20 000 OHMS 240 VOLTS X 240 VOLTS 820 WATTS amp 70 OHMS NOTE All grounds must be connected to mold to ensure operator safety Input Power Wiring Diagram Option A 208 240 Vac 3 Phase 4 Wire Delta or Power Distribution System 4 WIRE 3 X 208 240 CONTINUE ZONE ZONE ZONE ZONE ZONE ZONE 6 4 2 Each module is powered from one of the three phases Module One for example is powered from Phase 1 which is supplied by RL 1 and SL 2 Module Two 15 powered from Phase 2 which is supplied by SL 2 and TL 3 Module Three is powered by Phase 3 which is supplied by RL 1 and TL 3 At this point the sequence repeats itself For example Module Four is connected the same as Module One to RL 1 and SL 2 and Module Five is connected the same as Module Three to RL 1 and TL 3 Module Seven is then connected to the same phase as Modules One and Four etc This method of connection ensures the greatest likelihood of line balance Input Power Wiring Diagram Option B 380 415 Vac 3 Phase 5 Wire Y Power Distribution System 5 WIRE 3 X 415 240 MP N L CONTINUE ZONE ZONE ZONE ZONE ZONE ZONE 6 5 4 3 1 BLOCK 2254 ol CIRCUIT BREAKER eis CAUTION NOTE The voltages fro
6. a n n n j f j j j j f j f j j j j j j j j 4 2 MOLD POWER eee INPUT CONNECTORS REAR VIEW WIRING CONNECTIONS ASA TUA UA VA UA AU AAA AAA UA AA A AAA UB UB UB UB CUBA UU US UU UU UU SUUS PROBE OR Qu TERMINALS NOZZLE Z HEATER O N E A C TERMINALS 9 ROW B TERMINAL 8 IS NOT USED 12 HEATER HEATER HEATER VOLTS VOLTS WATTS MEASURED MARKED X MARKED MARKED C RESISTANCE ON ON e ON OHMS HEATER HEATER HEATER 240 VOLTS X 240 VOLTS 820 WATTS CC 70 OHMS NOTE All grounds must be connected to mold to ensure operator safety m THERMOCOUPLE T C ONLY WHITE RED BEFORE POWER IS CONNECTED e AW SE OHM MEIER TO CHECK EACH HEATER POWER LEAD RESISTANCE TO GROUND SHOULD BE GREATER THAN 20 000 OHMS CHECK RESISTANCE BETWEEN HEATER LEADS gt CHECK GCONNEGTIONS OF RED AND WHITE LEADS TO INSURE PROPER CONNECTION TO THE CORRECT TERMINAL USE OHM METER TO MEASURE BETWEEN RED AND WHITE LEADS RESISTANCE SHOULD BE LOW MEASURE BETWEEN EACH HEATER POWER LEAD AND EACH THERMOCOUPLE LEAD RESISTANCE SHOULD BE GREATER THAN 20 000 OHMS DISTRIBUTION TUBE OR MANIFOLD HEATER ZONE 1 TITLE 12 24 99 RELEASED FOR PRODUCTION HOTRUNNER SYSTEM CUSTOMER WIRING ww 8094005001 REVISIONS 02 24 99 N A MOLD THERMOCOUPLE CONNECTORS REAR VIEW 0000000000 13 14 15 16 17 18 19 20 21 22 23 24
7. e wires that run from the control module connectors to the various power buses Schematic If the power source is not specified the control system will be wired for Schematic A or 208 240 volt 4 wire three phase power at the factory This is standard in the U S and Canada For purposes of these instructions it is assumed that the control system 1s being changed from Schematic A to the other schematics Schematic Schematic 1s used in most countries in Europe it 1 for 380 415 or 220 240 volt 5 wire three phase power To make these changes it is necessary to move the wire from pin 7 on each module connector to bus MP N In addition move one of the black wires from the fan to bus MP N If the system has a C V monitor move the yellow green blue and eray wires from the flat cable to MP N Take one pilot light wire from the back of the main circuit breaker and extend it to bus MP N This arrangement is also valid for running the control system on 120 208 when 120 volt heaters are used The control modules and C V monitor must have their power transformer connections changed to 120 volts The pilot light wiring does not have to be modified Please note that the large power wires that run from the AC power input block to the circuit breaker to the distribution buses are not the correct colors for European use If the control system is to be used permanently in Europe these wires should be changed A kit wi
8. he electrical service entrance as possible and not to the molding machine where the motors and solenoids cause electrical interference 3 4 00 CONTROLLER TROUBLESHOOTING CHARTS 3 4 1 CONTROLLER TROUBLESHOOTING CHART 1 FAULT CLASSIFICATION Turn on Main Breaker and all Module Power Switches Are all Pilot No Lights ON Set Mode to Closed Loop and Set Temp of all zones and allow system to stabalize 3 4 2 CONTROLLER TROUBLESHOOTING CHART 2 POWER Turn Main Breaker and all Module Breakers Verify that power is available at all legs and that Mainframe is wired for Power being supplied Yes Are all Power END Pilot Lights Yes Replace Module Fuses wiring that blew fuse No Is pilot light on if blown Repair Module ON problem in Customer s Swap Module with known good unit Is pilot light on Module ON NO Trouble shoot frame for Wiring Problem 3 4 3 CONTROLLER TROUBLESHOOTING CHART 3 MODULE Turn on Module Set Temp Set to Closed Loop Turn off other Modules Allow to Stabilize Yes Is Operation Normal END Return defective Module for repair END Heat from adjacent Yes zone is affecting this zone Triac shorted T C not wired to this zone repair as needed Does panel indicate Over Temperature 3 4 3 CONTROLLER TROUBLESHOOTING CHART 4 MODULE Heaters not connected Yes too small or bu
9. m line to line in this system are 380 to 415 volts Severe damage to module and mainframe could result if this type of AC input system is connected in the 208 240 Vac configuration This type of power distribution is very uncommon in the United States but is the most common system used in other countries WARNING If export of this system is intended make sure that the wiring is reconfigured for the country where it is to be used Please note that the 380 415 volt Power Distribution System is the same as the 208 240 Vac Y connection except for the voltage levels and the use of the MP N to develop the 240 volts from the 380 415 volt system Note that all modules in this system have one line connected to MPN and the other side connected to one of the 3 phase lines Example Module One is connected to Phase 1 which is supplied by RL I and MP N Module Two is connected to Phase 2 which is supplied by SL 2 and MP N Module Three is connected to Phase 3 which is supplied by TL 3 and MP N Module Four starts the sequence over again It is connected to Phase 1 RL 1 and MP N etc 10 Input Power Wiring Diagram Option C 240 Vac Single Phase 4 Wire Power Distribution System 4 WIRE 1 X 440 220 CONTINUE R L1 ZONE ZONE ZONE ZONE ZO 6 5 4 3 NE ZONE 220 1 2 9 440 S L2 The 240 volt single phase connection only uses two power lines plus ground CAUTION Only power conductors should be connected thro
10. onditions These problems are often more difficult to diagnose and to repair Outlined below are some of the common problems we have found 3 Temperature Oscillation This is usually caused by the location of the thermocouple being too far away from the heater it is controlling In order to provide proper control the thermocouple should be located between one half and one inch of its heater Oscillation during processing can also be caused if the melt temperature is significantly above or below the setpoint of the zone 3 2 Temperature Too High This 1s usually caused either by heat from an adjacent zone or from having the melt temperature above the setpoint of that zone This problem is also caused if the TC is not wired to the same control module as the corresponding heater 3 3 No Heat Indication Some of the hardware problems that cause this indication are described in the chart section of this procedure It 1s also the indication that appears when something has occurred electrically to upset the microprocessor in the control module It corresponds to the Tilt light on a pinball machine It is reset by turning the power switch on the module off and then on A random occurrence is not cause for concern Should it happen regularly however it indicates that there is more interference on the power line to the control system than the filtering in the power supply can accommodate The solution usually is to connect the controller as close to t
11. rned out T C not wired to Does panel indicate Under Temperature this zone shorted or defective repair as NO needed Does panel indicate Check T C and wiring T C open repair or replace NO Does panel indicate C T C wiri T C reversed orrect wiring No Heaters not connected to this zone Heaters too small or burned out T C too far from heaters Does panel indicate no heat Rock Power Switch to re set controller intermittant electrical conditions can cause this indication No 20 3 4 3 CONTROLLER TROUBLESHOOTING CHART 5 MODULE cont Heaters grounded repair wiring or Does panel indicate Yes replace heaters Ground Fault mad Heaters wet use Compustep to dry out NO T C shorted or not Yes wired to correct Is temperature of heated component above module set point zone Triac shorted Correct E END 21 NOTES 22 NOTES 23
12. th instructions is available from the factory Control systems can be furnished with European colors at no charge if specified at time of order 1 3 3 1 3 4 1 3 5 Schematic This configuration is called Open Delta and is found in some areas of the United States To change to this configuration it is necessary to move the wire from pin 7 on each module connector to bus MP N Move one of the black fan wires to MP N Remove the rest of the wires from TL 3 and split them between RL I and SL 2 to balance the load If the system has a C V Monitor move the yellow green blue and gray wires from the flat cable to MP N Take one pilot light wire from the back of the main current breaker and extend it to bus MP N Schematic D This schematic is for single phase operation Move all of the wires from pin 6 of each module connector to move all of the wires from pin 7 to SL 2 Nameplate Be sure to change the data on the nameplate to reflect changes made in the wiring 1 3 6 Wiring Diagram CONTROLLER POWER Standard 30 Multizone Controllers are wired this way unless otherwise specified European Standard Open Delta Single Phase GROUND WIRING DIAGRAM FOR RUNNERLESS MOLDING SYSTEM 6 NUMBERED CRIMP HEATER LEADS ON PIC CONNECTORS POWER LEADS CONNECTORS LaLa a a ar arm VA AP A P A A A AP A AV AV AV AV AV A AV A gt VM T E E AV AV AV AV URBS N AN a
13. tored In the R LI S L2 or T L3 positions the meter will indicate AC voltage of the line selected The VOLTS AMPS switch MUST be in the VOLTS position to read AC input voltage To measure individual zone current place the VOLTS AMPS switch in the AMPS position and select the zone to be monitored with the SELECTOR SWITCH For systems that exceed 23 zones place the switch in the 24 position and use the SELECTOR SWITCH in the upper cabinet to monitor zones 24 and higher WIRING 3 WIRE 208 240 Vac Ll brown blue violet L2 red yellow gray L3 green orange 4 WIRE 380 Vac Ll brown violet L2 red L3 orange NEUTRAL yellow green blue gray 3 0 CONTROL SYSTEM TROUBLESHOOTING These procedures assume that your temperature control system has been installed in accordance with the installation instructions Be sure that all wiring has been correctly done and that the power being supplied is the same as specified on the nameplate on the controller frame Problems that arise may be divided into two groups The first 1s associated with the controller itself the wiring heaters and thermocouples This group is characterized by abnormal indications on the controller modules such as blinking lights and displays or pilot lights off We have devel oped a set of troubleshooting charts to help you locate these problems The second group of problems are associated with design of the mold and hot runner system or with processing c
14. ugh the circuit breaker Never make ground connections through a circuit breaker Notice that the output of the circuit breaker is connected to terminal strips RL 1 SL 2 Also notice that ground is common with MP N in this system All modules in this system have to be connected to MP N and either RL 1 or SL 2 Line balance is achieved by alternating between RL 1 and SL 2 Example Module One is connected to MP N RL 1 Module Two is connected to MP N and SL 2 etc 11 Input Power Wiring Diagram Option D 208 240 Vac Single Phase 3 Wire 120 Vac Single Phase 4 Wire Power Distribution System 3 WIRE 1 208 240 CONTINUE CONTINUE 4 WIRE 1 X 110 OR 120 ZONE ZONE ZONE ZONE ZONE ZONE R L1 3 2 1 3 1 n TO Mp N The above diagram depicts two different wiring configurations One 1s 208 240 volt single phase 3 wire Note that lines RL I and SL 2 are connected through the circuit breaker to the appropriate terminal strips All modules in this system will be connected between RL 1 and SL 2 MP N is common with ground and is not connected through the circuit breaker In the 120 volt connection module connections shown within the dotted area the 120 volts 1s developed between RL 1 and MP N SL 2 and MP N Again ground and MP N are not connected through the circuit breaker Each module in this system will be connected to MP N and either RL 1 or SL 2 Line balance is achieved by alternating between RL 1 and SL 2
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