Multi - hot runner control unit Z 1240 /. . . Operating instructions
Contents
1. The operation is always enabled by unit 1 master Z1240 1 Z1240 2 CAN Address 1 2 3 10 31 Z1240 3 32 Saco 3 5 20 32 19 Examples CAN Address with 3 controllers HASCO The CAN address 1 activates the master display operation for all the connected control zones All function are available from here The connected controllers slaves need a different increased CAN address from 2 to 32 The operation is reduced to ON OFF and the selection of the total display Functions as groups sequential combined heating warning and alarm parameters or Auto Power are available at a PLUS unit in the same way as at a single unit 4 1 General settings of the PLUS unit The CAN address has to be set before the connection with another unit Therefore the BUS cable may be disconnected or the other units have to be turned off After setting the CAN address the controller must be restarted The available number of zones flashes and has to be confirmed 4 2 Start of the PLUS unit After all controllers are connected and turned on the total number of zones has to be confirmed at the master The slaves indicate only the number of zones and the slave No This No results from the CAN address 1 and fixes the sequence of the slaves ZONE ZONE Example SETPOINT W SETPOINT W SETPOINT W n 22 n flashes PROCESS VALUE X PROCESS VALUE X2. 32 zonen Total 164 zonen Slave No 1 CAN Addr 2 To confirm at the master 4 3 Separation of the PLUS unit ZONE After one or more controllers of this PLUS unit have been disconnected or turned off the system has to be confirmed by the master when it is SETPOINT W completed PROCESS VALUE X For identification of the master Err flashes 4 4 How to change the PLUS unit A change of the PLUS unit results from B Change of the total of zones B Change of the number of controllers B Change of the sequence of the slaves MH Any change of address at the slaves The following start is equal to the start of a new PLUS unit 4 5 Hint to the PLUS unit All changes of the constellation of a PLUS unit will automatically delete the settings for the Alternative Channel Auto Power AP 4 to avoid wrong constellations The digital inputs are only available via the master for all controllers 20 HASCO 5 Parameters The default settings of the parameters are sufficient for general control requirements Customer s individual setpoints alarm limits operation modes etc have to be set referring to the task 5 1 Reset to standard parameters ZONE SEP Indication 0 128 A reset to default settings can be activated by the system parameter StP Reloading standard parameters overwrites all settings by the default values The LED stripe is flashing during this procedure PLUS units have to be separated for reset 5 2 Date and time
3. Group number 128 us uec sr dedo Ao pete esie 31 PARAMETER 32 Leakage current oseyi derri sekresi ME gale 31 6 Configuration of the unit 1 0oooogo Ebo Lap Speo Oawn Commissioning ooo 31 DID SWITGH is rr eb bd ee Ped ee ob ed eed 31 JUMPEN aa aia ace aeaa Starnes 32 CONNECTION uis wing aia a eu RR aca ARA Gh wee Ao ia 32 giri ai aa a asada 32 FINAS AMO ba c oso a ad ds 32 7 Technology oct Cablescarriet c 23 ig REESE Y E ECHTE 33 7 2 DOCUMENT CaSe icc idea Mes da bb vei ribs 33 Toa Power Uses 0 A whe ae ee tie 33 7 4 Protection against net voltage 0 eee 33 7 5 Rear Side ooo ic AE Ee ee ERR DTI ERR 33 Gooey e EAN ee 34 7 5 2 Warning and alarm contacts 0 0 eee 35 7 5 93 Interface socket seen 35 1 5 4 Signallight SOcKOt sese eR Rer Bea pa 35 LD 0 Power supply Socket suu peek nest Sage eae ae eae ee eas 35 la 0 0 Pas ION ME its wea ee Sho cea te ERE 36 7 6 Controllers llle 36 6 1 Control units 36x16 96X16 enumerar RR RE ee 36 6 2 Gontrol units 2x16 9 32XT10 ius de E XA eR REPPERY 36 8 Technical data eee eccone ccce eine en 37 8 1 HiritS to EMY ou oo a ee ee ee be ee Oe Oe eee 38 8 2 BERNER SEE tek ence a eS ua a ee LTEM TELE 38 SNL EE Safety MUN acs essere eea a dle A et nce ee 38 9 Transport from Z1240 36 2 0 nee 39 Declaration of EC Conformity HASCO HASCO 1 Survey of the units The units of the serie
4. 10 After plugging or unplugging of heater connectors 300 mA LC may appear for a very short moment 120mA Z1240 2x16 to Z1240 16x16 Provide measuring and supervision per zone from size Z1240 20x 128 Provide measuring and supervision per line 5 4 15 LCL parameter Leakage current level ZONE gt D Level Input limits Default value The reaction in case of leakage current may be selected by this parameter 5 4 16 SSR parameter ZONE gt D Level Input limits Default value O disabled no measuring 2 15 indicates LC by warning 0 4 25 indicates LC by alarm 3 3 indicates LC by warning and dries all zones at 100 C 212 F 4 indicates LC by alarm and dries all zones at 100 C 212 F 5 indicates LC by warning and dries only this zone at 100 C 212 F 6 indicates LC by alarm and dries only this zone at 100 C 212 F Dry out will only be activated during heat up below 100 C 212 F This parameter selects the way of triac supervision 0 Disabled no supervision 2 indicates SSr by alarm 0 2 2c indicates SSr by alarm and turns the main relay off 2 All outputs will turn off The controller may go on heating only after restart after the triac was changed 24 HASCO 5 4 17 FAH parameter Fahrenheit indication ZONE This parameter indicates the setting for F of the unit Indication O 1 O C 1 F see DIP switch PROCESS VALUE X SEER An LED beside the actual value here 229 indicat
5. 2 Input limits 0 300 C 32 573 F Default value 0 C 32 F 5 5 27 PARAMETER 27 Auto adaption PROCESS VALUE X Without function 5 5 28 PARAMETER 28 30 Reserve PROCESS VALUE X Without function 5 5 29 PARAMETER 31 Number of group 1 8 PROCESS VALUE X This parameter assembles this zone to a group The referring number of the group has to be set here Groups may be set collectively gt D Level 2 Input limits 0 8 see groups Default value 1 5 5 30 PARAMETER 32 Leakage current PROCESS VALUE X The actual sum of the leakage current of the referring line will be indicated here gt Indication 0 mA 6 Configuration of the unit 6 1 Commissioning The description for commissioning of the unit is anticipated here If the below listed steps will be carried out in the described sequence a failsafe function of the Z1240 unit is guaranteed For better understanding of the different functions we recommend to read this manual 6 1 1 Dip switch There is a 8 fold DIP switch on the processor module Here the temperature indication may be set from C to F The conversion of all programs and parameters needs some minutes after restart The logic of the digital input No 5 may get inverted here Bi Passive The outputs of the controller will be disabled by a 24VDC signal WI Aktive The outputs of the controller depend on the enable by a 24VDC signal With disabled outputs the controller will not get s
6. B Defective output board in the unit Ml Heater defective EH Sensor polarity mixed LC Alarm The line of this zone has a leakage current it might dry out at 100 C The reaction depends on settings the LCL parameter These controllers will indicate the leakage current of the concerned zones Bi The heater must dry out to avoid damages E isolation between heater and PE defective d I Alarm The current is out of supervision tolerance Ml Heater defective or partial failed E Nominal current parameter 20 correct E Tolerance parameter 21 too small dY Alarm Deviation of the output rate supervision is out of tolerance E Defective hotrunner system E Condition and age of the heaters E Values of output rate parameter 18 not correct Bi Tolerances too small parameter 19 negative temperature deviation This actual value is below the deviation alarm parameter 3 E Heating power sufficient B Sensor without contact to this zone E Heater defective B Defective output board in the unit E Classification passed BI Deviation alarm Parameter 3 too small 15 HASCO O0 0 00 0 O CO positive temperature deviation This actual value is above the deviation alarm parameter 3 gt Reason W Increase deviation alarm Parameter 3 E Classification passed Total display W X Difference gt 99K The total display cannot indicate this value Total display X Actual value 15 C Bi Temperature too low E
7. See System parameters Date Parameter 5 3 Password IC The controller is protected against unauthorised settings by the identification code IC The default code 22 unlocks the settings This code may be changed from 0 999 by the IC parameter The code will be retrieved by IC has to be set and confirmed to unlock There are 3 levels to lock the unit These are available by setting the IL parameter 1 total locking no settings possible without code 2 partial locking available are ON setpoints output rates boost standby change of operation mode change of programs and setting for AC 3 no locking all settings are available 21 HASCO 5 4 These parameters may be used for operation of the Z1240 unit The settings refer to all zones The entry will be opened by the parameter key gt 4 seconds Pressing the parameter key for 4seconds opens the entry to the system parameters This passes the zone parameters ZONE v Further parameters will be reached by the down key 5 4 4 SC parameter Slowest Channel ZONE Indication 0 128 This parameter indicates the slowest channel zone during combined heating see Ct parameter 5 4 2 Pro parameter Program ZONE The Pro parameter selects one of the 6 programs Change of the program changes the setpoints and zone parameters of all zones SETPOINT W v a Setpoints and parameters have to be set in the activated program and will be stored directly Th
8. about the quality of all control loops This is more sensible than the deviation AT The interpretation is calculated by the Root Mean Square of the last 10 seconds in 100 correspond with a deviation lt 0 1K Each 1 deviation from 100 corresponds with a deviation of 0 15K 0 27 F from the setpoint 2 6 Total display in the front The indication in the total display may be selected for all zones Additional information is available by the referring LEDs NS Blasted fuse Ox Triac defect OX ev 4 13 Cursor 1 XX manual mode The cursor indicates the actually operated zone These might be several when groups are selected This indication flashes to indicate selected monitor zones Monitor zones are not part of groups 2 7 Outputs ON OFF The ON OFF key enables or disables all outputs The status ON will be indicated by the green LED The outputs have to be switched ON after each start 2 seconds Plug in or out should only happen when outputs are disabled To enable outputs may be disabled by the digital input No 5 see Dip switch Leakage current gt 300mA inhibit to switch ON see parameter 32 Disabled outputs are not without voltage HASCO 2 8 Home menu setpoints The menu key returns from any level to zone 1 v a The keys beside increase the number of the zone for selection ZONE This zone will be indicated in the total display by a LED like a cursor HL A The keys beside the setpoint ind
9. as the measuring exceeds this value the actual temperature value alternates with the indication LC The indication disappears only 10seconds after falling below the limit After plugging or unplugging of heater connectors LC may appear for a very short moment If the setpoints are above 100 C the controller will dry out the hotrunner referring to the setting of the LCL parameter The controller will keep the zones at 100 C 212 F until the LC disappears and the possible humidity has vaporised see LCL parameter 16 HASCO 2 16 4 Combined heating up The combined heating shall avoid a thermal asymmetric load due to slower and faster zones Synchronous heating of all zones takes care of the tool and prevents mechanical tension and early failure All zones will be restricted in a certain temperature difference among each other Ct parameter for synchronous heating Only the slowest zone will run by maximum rate The others will be limited to go ahead with the preset temperature difference The controller is looking for the coldest zone during heat up see SC parameter ZONE The SC parameter indicates 0 if no combined heating is active SETPOINT W During the active stage the number of the slowest channel coldest zone will be indicated here The combined heating is working even during sequential heating 2 16 5 Fuse supervision The fuse supervision detects blown fuses There is no current when the controller sets the r
10. control Protocol type 2 Boost Offset National language Standby temperature Voltage line 1 Auto Adaption Frequency line 1 No of group Leakage current Frequency 2 and 3 Internal Parameters Safety hint see also chapter 8 2 1 Before connection to the mains supply the ratio of the 3 lines has to be checked against the settings of the controller Z1240 will be delivered for star Y or triangle net referring to the customer s demand It does not predict dangerous voltage at the outputs to switch off all outputs or single zones The referring plugs or the complete Z 1240 unit will have to be disconnected from the mains supply before maintenance of the connected heaters Disconnect the Z 1240 unit from the mains supply before opening Contents 1 Survey of the units page td Safety AIMS 2 44 ias cago a OEE rad s 6 T2 Type label secura aw du Pie ee i rpi rioa wee Gaede deans 6 1 3 Features and functions se eenid e a eee 7 2 Operation 2 1 Menu Keys eee has 8 2 2 NIM CICATON MR 8 2 3 BEDES KDE treie a ETT 8 2 4 SENINGS stas Gan gigs doe fo Res Kex ai oe ess ewe racial 9 2 5 LED indicator for the total display 9 2 5 1 Quality of thie control ss eee eR Pea ad eee oe ee S 9 2 6 Total display in the front llle 9 2 7 Outputs ON OFF axle eed ee ER Be ee PEE REY a 9 2 8 Home Menu setpoints sieh 10 2 9 Groups mu mE EE RR ET
11. dese b ebd hend aad dee del 18 3 5 End of diagnosis i sees bee ees x er Spe ESTEE era 18 3 6 Failure report of the diagnosis ilie 19 4PLUS unit ooo lo eee de E 19 4 1 General settings of the PLUS unit 00000 20 4 2 Start of the PLUS U It oca ane aen daa Re Rx n 20 4 3 Seperation of the PLUS unit 2 0 ee ees 20 4 4 How to change the PLUS unit 0 0000 00 eee eee 20 4 5 Hint to the PEUS UNE uu 446 542 do tes ien D da 20 HASCO 5 Parameters page 5 1 Reset to standard parameters liliis 21 5 2 Date and time a cer ia a Fide aes 21 5 3 Passwort IG chase gere ee bt ae he a ocr eS end ene ined 21 5 4 System parameters o ooccco 0 eee 22 5 4 1 SC parameter Slowest Channel 000000 eee 22 5 4 2 Pro parameter Program 0 000 eee eee 22 5 4 3 Diagnosis program ssec rae ra alias R3 A a 22 5 4 4 B t parameter Boosttime 0 00 0 ooo 22 5 4 5 AL parameter Alarm delay 0 0 000 eee 22 5 4 6 Adr parameter Address 0 0 0 ee 22 5 4 7 bAu parameter Baud rate 1 liliis 23 5 4 8 bA2 parameter Baud rate 2 0 0 00 aaan 23 5 4 8 CAn parameter CAN Bus Address 0 0 00 cece eee eee 23 5 4 9 Ct parameter Combined heating 00000 eee 23 5 4 10 AP parameter Auto Power lisse 23 5 4 11 HH parameter HH value 0 00000 ennen 24 5 4 12 CL paramete
12. temperature is not controlled when the sensor is broken When a constant output rate is set external conditions may change the actual temperature of the zone The manual mode is defined for emergency operation to keep the process temporary running The defective sensor should be replaced as soon as possible 5 4 12 HH parameter HH value ZONE gt D Level Input limits Default value The HH parameter HH value sets the upper temperature limit of the unit Overriding of the HH value activates the HH alarm HH appears in the display and the main relay 2 switches off All outputs will turn off The controller may go on heating only after restart when the actual value has decreased E the HH parameter 500 C If the HH parameter should be set below any setpoint so will these setpoints increase 932 F with the HH value 5 4 13 CL parameter classification ZONE gt D Level Input limits Default value This parameter selects the classification The classification will be passed directly after the start and creates new settings for P I and D Even manual settings may get lost when the conditions have changed meanwhile ON To save special settings the classification must be switched off O 5 4 14 LC parameter Leakage current supervision ZONE gt D Level Input limits Default value The limit for indication of leakage current has to be set here It will be measured by the sum per line 2
13. temperature supervisions L H HH as well as the deviations dL und dH are still active In case of group operation the indication of the total display changes to output rate by itself The system parameter PC may adjust constant rates to constant power output within fluctuating net voltage This is not possible for Monitor zones 2 10 3 OFF SETPOINT W The zone will be turned off without losing the settings The total display stays dark If there is still a sensor connected the temperature and triac supervisions H HH as well as S are still active when the setpoints are gt 0 2 11 Selection of the total display 2 12 Boost 2 seconds all by Xt Cursor LED marked zones 2 13 Standby 2 seconds all zones 2 14 Settings This key changes the indicators of the total display There are available Actual values setpoints deviations from the setpoint Output rate current A control quality and will be indicated by the referring LED The LED for additional information in the total display is independent of this selection When outputs are switched ON the Boost key increases the temperature of the selec ted zone or group for a short time The status will be indicated by the integrated LED The additional setpoint has to be set by zone parameter 25 the time by the system parameter b t When outputs are switched ON the Standby key sets all setpoints to a lower setpoint zone parameter 26 The st
14. this zone without softstart with quickstart OQ this zone with softstart and quickstart 28 HASCO 5 5 12 PARAMETER 12 Combined heating PROCESS VALUE X The unit is provided with a sequential combined heating function This zone may be set to a sequence or disabled from the combined heating gt D Level 2 O this zone is not combined Input limits 0 8 1 8 this zone is combined Default value 1 The sequences will be heated from 8 to 1 in order The preferred heated zones have to be set to higher numbers 5 5 13 PARAMETER 13 Ramp up PROCESS VALUE X EA consistent slow heating following a ramp can be activated here The function may be reached only if the installed heater power is sufficient gt D Level 2 Input limits 0 1 1s The combined heating is not active in this case Default value O 5 5 14 PARAMETER 14 Ramp down PROCESS VALUE X EA consistent slow cooling following a ramp can be activated here The function may be reached only if the installed cooling system is sufficient gt D Level 2 Input limits O 1 1s Default value O 5 5 15 PARAMETER 15 Output rate maximum PROCESS VALUE X This parameter limits the maximum output rate of the heaters D Level 2 Input limits 0 100 96 Default value 100 5 5 16 PARAMETER 16 Output rate nominal PROCESS VALUE X The output rate for Auto Power function AP parameter 3 must be set here This parameter does not influence the controlled m
15. 50 Hz Current per zone max 16A standard Attention Take care of the max load of the supply cables Minimum load Collective Functions 1 x alarm contact alarm outputs 1 x warning contact Relay contacts max voltage 250 VAC max current 4Aatcosb 1 2A at cos 0 5 Control routines PI PD or PID with control parameters to set for all zones Serial interface isolated RS485 Protocol FES Bus version 3 03 CAN Bus Ambient conditions Operation temperature 0 50 C 32 122 F Protection IP 20 Cooling Surface temperature of the unit max 55 C 131 F Storage temperature 25 475 C 13 167 F Humidity lt 95 rel humidity no dew drop Dimensions BxHxT mm 2 8 control zones 240x 210x370 Weight 10 16 control zones 400x 210x370 20 32 control zones 450x 280x430 36 64 control zones 500x 800x500 68 96 control zones 500 x 1000 x 500 Wiring diagram is enclosed with the unit 37 HASCO 8 1 Hints to EMC Interference transmissions The unit is relieved according to EN 55011 B interference transmissions Level of acceptance Reliability class Z2 VDE 0839 Part 10 Ambient class S2 l4 E3 Suppression Ambient class 3 VDE 0843 Part 2 3 4 Degree of strength 3 with external filter 4 IEC 801 Part 2 4 5 8 2 5 2Delta net The Z1240 controllers may be supplied by a 220 230V Delta net if necessary For that purpose the links at the terminal strip inside the units have to be moved to another position The d
16. ED Current flows without any output rate 096 Wi Triac defective it is permanently closed Depending on the setting of the system parameter SSr the alarm contact changes and the main relay turns OFF together with all heaters The controller will be ready after restart and replace of the triac These controllers indicate the concerned zones as well as all other zones with identical power 1 Take out the fuses of the concerned zones 2 Turn the controller OFF ON 3 Insert the fuses one after another until this indication appears again This zone has the defective triac 4 Repeat the sequence in case of several defective triacs Current alarm with fuse LED No current while output rate gt 0 B Fuse defective E Cable or connectors defective Ml Heater defective Wi Triac defective not closing 14 HASCO 000000090 gt Reason gt Reason red Z1240 2x16 to Z1240 16x16 gt Reason ohne LED Sicherung Triac gt Reason gt gt Reason gt Reason U Alarm No line voltage for these zones detected See parameter L1 L3 or F1 F3 Bi Mains supply interrupted Internal upstream fuse blown Z1240 2x16 Z1240 16x 16 3 fuses on the controlboard Z1240 24x16 Z1240 96x 16 6 fuses in the terminal bloc L Alarm This actual value is below the Lo alarm see parameter 1 E Alarm limit too close to the setpoint B Sensor without contact to this zone E Heating power sufficient
17. HASCO Operating instructions CE Multi hot runner control unit Z1240 GB 10 11 Z6 HK Z1240 with key display Outputs ON OFF Boost ON OFF Standby ON OFF Selection total display L Alarm H Alarm O SIS vox A T HRSCO Home Zones Group selection Parameters see below a amp O Change of operation mode Control Manual OFF Selection total display 008 090 sec System Parameter Slowest Channel Program dL dH Alarm Diagnosis program xp P value Boost time tn Integral part Alarm delay tv Differential part Classification for the zone Address RS485 Factor for Baud Rate 1 Operation mode of the zone Factor for Baud Rate 2 Monitor zone CAN Bus Address JL ae Alternative zone Combined heating Softstart Combined heating 55 Auto Power HH value ET Ramp up Classification lt Ramp down Leakage current supervision Output rate maximun Leakage current limit iS e Output rate nominal Triac supervision J Output rate mean Fahrenheit indication Output rate mean nominal Overheat brake t5 05 Output rate mean tolerance Standard parameters Current nominal ID Code Current tolerance ID Level Diagnosis time Power Control Offset temperature Protocol type 1 Zero cross phase
18. Polarity mixed temperature decreases during heating 0000000 Plus unit without complete connection This indication has to be confirmed at the master of a PLUS unit after it is rebuilt completely There is no power output during this indication gt Reason M CAN Bus disconnected E CAN Bus missing the termination plug E One controller turned OFF E Assembly of the PLUS unit was changed 2 16 Zone supervision 2 16 1 Classification After switching ON the outputs the controller runs a classification The results overwrite the settings for P and D even manual settings if the classification differs from the last one The procedure will be indicated by the flashing green LED stripe It may need up to O O 090 e O O 90seconds for inert big components The classification may be disabled by the CL parameter to save special settings of the P I and D parameters The range for the start of the classification procedure is 350 C 662 F but at least 30 C 86 F below the setpoint 2 16 2 Softstart during heating up The correct running for hotrunner systems is a slow heating up at low temperatures with low output rates The Z1240 controllers are fitted with a special softstart routine This allows a smooth but efficient heating up The function can be disabled by zone parameter 11 Leakage current supervision SETPOINT W The supervision of leakage current registers leakage current from a specified value LC parameter As soon
19. Process view ON referring to selection X W X W Q I Home menu Return to zone 1 Parameters System zone param Operation mode PID Hand AUS 2 2 Indication The control indication is composed of three indicators ZONE the number of the zone here 128 the setpoint of the zone here 230 2 3 O Yt with additional LED for manual mode e Xt F the actual value of the zone here 229 LC with status failure with additional LEDs for the selected temperature indication 2 3 LED stripe A three sided LED Band signals three possible sates of supervision The changes happen synchronous with the dry alarm contacts see alarm contacts The reaction may be delayed if required see AL parameter The indications of the zones will never be delayed Green OK flashes during classification O O O O O O O Yellow Warning Red Alarm HASCO 2 4 Settings ZONE w a The keys beside the zone number select the zone or the parameter SETPOINT W v a The keys beside the setpoint set the value for the setpoint or the parameter PROCESS VALUE X Each flashing value has to be confirmed by the Enter key 2 5 LED indicator for the total display The LEDs indicate the selection for the total display Actual value C F Output rate Setpoint C F Current Deviation K Quality 2 5 1 Quality of the control The selection of the quality in the total display opens the information
20. The routine was stopped by a failure SETPOINT Wy The output of the actual zone has heated up the sensor of this zone The cursor Led of both zones are flashing gt Reason B Mixed wiring WB Sensor in wrong position B Connectors mixed Failure report 3 At the total display SETPOINT W The routine was stopped by a failure Eze MM CU The output of the actual zone does not lead any current This zone may be skipped by the up key mit der LED f r die Sicherung gt Reason No heater connected B Fuse blown B Cable defective The end of the diagnosis routine has to be confirmed by the On Off or Enter key The operation modes will get reset 2 seconds After solving the failure the routine should be started again Zones which are correct may be skipped 4 3 PLUS unit A PLUS unit consists of multiple controllers which may be collected to one unit by a CAN Bus interface The connection happens by an interface cable with termination plugs at both ends The proper function of the CAN Bus requires the connection of both plugs at the rear side of the controllers The cable has to be connected directly and the remaining plug must be covered by a further cable or by the termination plug Z1240 1 Z1240 2 Z1240 3 Termination i gt E a Termination y gt Termination Li Termination
21. ameter Line frequency ZONE These parameters indicate the actual net frequency of the referring lines gt Only indication Hz cps ME Line 1 for zones 1 4 7 2 Line 2 for zones 2 5 8 3 3 Line 3 for zones 3 5 9 Failed frequency will indicate U for these zones 5 4 28 Date parameter date and time ZONE The actual date and time may be indicated and set by these 5 parameters day ZONE E c P flon The settings are only required for additional options month ZONE ZONE Ac 5 hours Hours will be set in 24h mode ZONE 26 HASCO 5 5 Zone parameters Each zone has a set of 32 parameters Selection and setting of parameters as below Parameters can be reached by the parameter key In the parameter level the zone number and the parameter number are indicated with additional dots ZONE vw A The keys beside the zone number select the zone or the parameter SETPOINT W v a The keys beside the setpoint set the value for the parameter PROCESS VALUE X gt The selected number of the parameter here 2 appears in the lower display The touch on the parameter key or any other on the left leaves the parameter level The functions of the different parameters are explained in the following 5 5 1 PARAMETER 1 Lo Alarm PROCESS VALUE X The referring zone will indicate Lo alarm when the temperature falls below the value of parameter 1 This will be indicated by flashing L alternating wi
22. ate when the manual mode is activated by a broken sensor gt D Level 2 Input limits 0 4 AP 0 output rate 0 when the sensor is broken The zone remains in control Default value 0O mode and switches the outputs off AP 1 output rate mean output rate when the sensor is broken This zone changes to manual mode The mean output rate parameter 17 will be indicated This proposal has to be confirmed by the Enter key This indication asks for the output rate if no mean rate parameter 17 has been calculated before AP 2 output rate mean output rate parameter 17 like AP 1 without confirmation by the Enter key AP 3 output rate preset rate parameter 16 without confirmation by the Enter key AP 4 output rate alternative offers the input of a similar zone which will run this zone synchronously The flashing indication AC asks for the input of the alternative channel zone The input will be stored in parameter 10 and will be used for the next time without asking It is possible that several zones are linked to the same alternative zone For AP 2 3 and 4 when the AC was preset the zone changes directly to manual mode when the sensor is broken The confirmation by the operator is not required When the sensor has been returned the operation mode has to be changed to the control mode AP 1 2 and 3 offer a constant output rate 23 A ATTENTION HASCO It is important to note that the
23. atus will be indicated by the integrated LED Standby will also be finished by this key The parameter key open the entry to all parameters Zone parameters 4 seconds System parameters 12 HASCO 2 15 Indications and request via display 2 15 1 Status of the zone ZONE SETPOINT W SETPOINT W SETPOINT W SETPOINT W SETPOINT W SETPOINT W SETPOINT W SETPOINT W SETPOINT W PROCESS VALUE X 2 15 2 Alarms and reasons The decimal point in the zone number indicates the coldest zone during combined heating stage see SC Parameter P manual mode alternates with the output rate here 27 Zone is turned off P manual mode The output rate has to be set and confirmed AC Alternative Channel with Auto Power AP 4 The number of the zone has to be set and confirmed AC Alternative Channel with Auto Power AP 4 alternates with the number of the linked zone here 104 IC Identification Code The correct password has to be set and confirmed to unlock the settings n Total of zones of a PLUS unit The indicated sum has to be confirmed This indication shows that the controller is Slave 2 CAN address 3 within a PLUS unit see PLUS unit When the LED stripe changes to yellow or red the of the referring zone indicates the type of alarm The indicator for the actual value as well as the total display show the alarm alternating with the value gt Reason Conversi
24. des This key changes the operation mode for the selected zone or group among Control mode Manual mode OFF Y O gt with 3 LED at manual mode Manual mode will be indicated by the LEDs The indicators stay dark in the mode OFF In case of group operation the indication of the total display changes to setpoint or output rate by itself Each zone may run reduced operation mode by parameter 9 Bi The zone is used for simple temperature indication monitor if no outputs are available or no heater is connected E This is a special mode of a zone without installed inputs or without sensors manual Power mode But a connected sensor enables a control mode which requires a confirmation of the output rate after change to manual mode see Auto Power AP 2 10 1 Control mode SETPOINT W i The setpoint will be indicated and may be changed In case of Auto Power function the zone changes immediately to manual mode In case of group operation the indication of the total display changes to setpoint by itself This is not possible in manual mode or Auto Power without sensor 11 2 10 2 Manual mode Power SETPOINT W gt with X LED at manual mode HRSCO P flashes alternating with the actual output rate The 96 LED lights The LED in the total display indicates the manual mode The change to the manual mode proposes the last value that was used for the manual mode Parameter 16 If there is still a sensor connected the
25. eee ee ERU ERR ee See EE 10 2592 1 Operatonsot grOUDS xau Ba dois sae DRAE leia 10 2 9 2 Group assembly xad ne ae awake aida de ela bee a bea ass 11 2 9 3 Sequential Heating 0 00 a 10 2 10 Operation modes aaa ens 11 2310 d GOontrol mode ererat ien bed bt dn cba he fed edged 11 2 10 2 Manual mode Power 0 0 eee n 11 PAD NCMO P 11 2 11 Selection of the total display lile 12 2 12 Boost 3425 beum rr vro Bae oad SE ond Y ache p c AA Bla Dus 12 2 13 Standby viii e PE dd bade RE ey ea EG Opa 12 2 14 leno EP T PET 12 2 15 Indications and request via display 13 2 15 1 Status oL dle ZOllQu sevens oF ote amp eee Rr Re id 13 215 2 Alarms and reasons vs esa ey ener pennt ag a e eh eg 13 2 16 Zone supervision 00 0 ee eee 16 216 1 Classification ERROR EN eR KE 16 2 16 2 Softstart during heating up liliis 16 2 16 3 Leakage current supervision llilles ee 16 2 16 4 Combined heating up 2 ee 17 236 5 Fuse supervision ac reece ee e ek A he 17 246 6 Sensor supervision econo a Rl ew ee 17 2 16 7 Tracsupervision lle III 17 2 16 8 Output rate supervision lise 17 3 Diagnosis program is a eR Rue mac a 17 3 1 Chose the diagnosis programs 000 0c ee ee eee eee 18 3 2 Selection of ZONOS was a iau Qe ha oak Paw eee puis Qd A RRS 18 3 3 Action of the diagnosis program 6 eee ee 18 3 4 Stop and SKD ia haa isa Pier
26. eferring output Defective heaters or wiring will result in the same indication 2 16 6 Sensor supervision The controller detects missing or broken sensors The actual value will be set to E This zone may go on by the Auto Power with restricted function Mixed polarity decreases the indication down to EE and switches the controller off until restart 2 16 7 Triac supervision The triac supervision detects defective triacs as there is a current without the controller has set the referring output 2 16 8 Output rate supervision The supervision of the output rate helps to detect non regular conditions in the heater system After activation the actual mean rate parameter 17 will be compared to an individual nominal setting for the output rate parameter 18 In case of deviations greater than the tolerance parameter 19 the controller will indicate dY for the referring zone The setting O and the period of heating up no mean values available disable the supervision 3 Diagnosis program Z1240 is fit with a diagnosis program to check sensors and heaters This program is especially to use after first installation or after service As described in the following you have to choose the program select the zones and start There are single zones a group of zones or all zones available for one routine The stage runs without operation The diagnosis program recovers B Mixed sensors or heaters W Wrong polarisation of sensor
27. ere are no settings for parameters available PROCESS VALUE X Input 0 600 C The input of setpoints for a group is always relative 32 999 C l e the input is the deviation of the actual setpoint ee The input of values for the output rate of a group is always relative O Input SS cn l e the input is the deviation of the actual rate The values for the zone parameters of the groups are to set absolute The indication is always O also after the input 10 HASCO 2 9 2 Group assembly The assignment of each zone to a group is made by the parameter 31 If the assignment begins with the biggest group all zones may be set easily to this group by ALL Only the remaining zones have to be changed to the referring groups by parameter 31 one after another The contents of a group may be checked by the selection of the group in the total display Nea GB OA aa gt 00 00 00 00 00 00 00 00 Markings of a group of ED E GB ND BB gd a OC 00 00 00 00 o0 o0 00 2 9 3 Sequential heating Parameter 12 enables heating sequences that follow one another A sequence consists of one or multiple zones Before a sequence starts heating the previous one must have reached a difference of 10K below the setpoints The order of the sequence is always started from 8 and finishes at 1 The settings for these sequences should be entered after the selection of groups as the selection might be taken over see parameter 12 2 10 Operation mo
28. es always the type of temperature xt C measuring 5 4 18 Brake parameter Overheat brake ZONE This parameter sets an additional brake for aggressive control loops In spite of fast answers to disturbances the brake will prevent overheating during gt D Level 2 heat up Input limits 1 20 Disabled no brake Default value 2 2 20 Brake factor 5 4 19 Std parameter Standard parameters ZONE A reset of all settings can be started by this parameter gt D Level 4 1 Reload the standard parameters Input limits 0 1 Default value 0 Std is only available by the code Reloading standard parameters overwrites all settings by the default values The procedure needs more than 5 minutes for all zones programs and parameters PLUS units have to be separated for reset 5 4 20 IC parameter ID Code ZONE A new password will be set here This password has to be entered when asked to unlock the unit After the setting of a new password the unit will be unlocked gt D Level 4 A three digit entry code ID Code will be set here This code unlocks the controller Input limits 0 999 Default value 22 IC is only available by the code 5 4 24 IL parameter ID Level ZONE The IL parameter disposes of the level of lock which inhibits the input of settings gt D Level 4 T Only setpoints and operation mode are unlocked Input limits 3 9 2 All parameters are locked Default value 2 3 No locking except level 4 IL
29. ey are always available with the referring program gt ID Level 2 Input limits 1 6 The program is not enabled as long as the number flashes in the display Default value 1 5 4 3 Diagnosis program ZONE The diagnosis program will be started by the setting of 1 in this parameter The selection of zone or group will follow before the diagnosis starts gt D Level 2 Input limits 0 1 see diagnosis program Default value O 5 4 4 B t parameter Boost time ZONE This parameter sets the time for the increase of temperature The value of temperature has to be set in parameter 25 gt D Level 2 Input limits 0 600s The boost mode has to be started by the boost key Default value 60s 5 4 5 AL parameter Alarm delay ZONE When an alarm occurs at a zone the activation of the LED stripe and the relay contacts may be delayed for a certain time The setting of O activates the alarms immediately gt ID Level 2 without delay Input limits 0 60s Other values in seconds cause a delay time Default value Os 5 4 6 AAdr parameter Address ZONE An interface RS485 is part of the basic equipment of the Z 1240 units Up to 32 units may be controlled together via the bus To communicate with the units it is necessary to define an address for each unit gt ID Level 2 Take care that two units will never get the same address Otherwise an undisturbed Input limits 1 32 communication will not be possible Defau
30. for the actual zone Just this zone has to heat up for 5 during this time PROCESS VALUE X This section indicates the actual temperature of this zone Examples SE ZE O ER o RE 1 Zone ready or not checked 3 Zone not selected 2 Zone diagnosis in manual mode 4 Zone selected waiting for 1 2 flashing 3 4 diagnosis 3 4 Stop and skip ZONE a Besides the indicated zone the up key may jump to the next zone of the selection Skipped zones are treated as correct This may be used when the diagnosis has to be repeated The repeat of passed zones is only possible by restart of the routine SETPOINT W SETPOINT W This alternating indication shows that the diagnosis does not run Stop Start of the referring zone The countdown restarts with each start This manipulation may help to increase the temperature for 5 at inert zones ol 3 5 End of Diagnosis ZONE SETPOINT W The routine was finished without fault PROCESS VALUE X Confirms the diagnosis program and resets all operation modes 18 HASCO 3 6 Failure report of the diagnosis The program stops with the first detected failure ZONE Failure report 1 SETPOINT W The routine was stopped by a failure SETPOINT WW The actual zone was not able to heat up sufficiently during the countdown gt Reason M Diagnosis time too short MH Sensor in wrong position M Sensor cable shorted MH Heater defective Failure report 2 SETPOINT W
31. front indicate the status e g TX flashing function of the interface 5V supply voltage P gt g L A cg 10 Ow Ll O Qe nO Ow L nO Os L nO Ow S MO OR 20 u e Es 39VLIOA LIN MO Or n HO One g 2 iggd 55 Input module Processor module Voltage module with sensor fuses with DIP switches on side The input modules have to be set to previous address in case of exchange 7 6 1 Control units 2x16 32x16 The compact internal board includes all functions of greater Z 1240 The jumpers and DIP switches are to find on this board bearing the same functions These units may be opened by the cover after loosening the 2 screws below the display frame 36 HASCO 8 Technical Data Control voltage Selectable 3x190 400VAC N PE 3x110 230VAC PE Operating voltage 5 15 Tolerance for peaks 15 Control voltage electronics 1x0 8A medium inert 5 x 20mm Control voltage internal 1x 4A medium inert 6 3 x 32 mm power outputs each 16 A super fast 6 3 x 32 mm Thermocouple inputs Fe CuNi Typ J 0 700 C 999 F Temperature deviation by Depending on length and wire cable resistors diameter Temperature compensation internal Accuracy 0 25 K Temperature actualisation 4x 128 second Controller outputs Bistable electrical isolated per zone 1x heating 230V contact Reaction of controller 10ms at
32. function may be inverted See jumper The control voltage 230VAC is also available at this socket for the supply of external signallers The voltage may be switched by the dry contacts Warning contact The warning contact sets a warning which informs the operator that the process is disturbed An immediate action of the operator is not absolutely necessary The dry contact is available at pin 1 and pin 3 of the socket at the rear side The contact is normally closed NC The contact will be activated together with the yellow LED stripe with one of the following warnings broken sensor only if AP parameter 1 2 3 4 positive temperature deviation negative temperature deviation current deviation leakage current depending on the setting deviation of output supervision separation of PLUS units Alarm contact The alarm contact sets a main alarm which requires the action of the operator This dry contact is available at pin 4 and pin 5 of the socket at the rear side The contact is normally closed NC The alarm contact will be activated together with the red LED stripe with one of the following alarms broken sensor only if AP parameter 0 shorted sensor Triac supervision alarm leakage current alarm absolute high temperature H alarm absolute low temperature L alarm overriding of the HH parameter HH alarm leakage current depending on the setting separation of PLUS units Warning alarm contact socket Function No
33. functions which are described in the following E Total display for all zones Selectable indication for all zones with single failure messages E LED stripe for permanent signalling A 270 around LED stripe indicates 3 status of supervision to see from far away El Control loop identification by classification The controller recognises slow from very fast zones by itself E Softstart for hot runners Cold zones will be heated carefully E Combined heating All zones will wait for the slowest channel to heat up E Boost function Increase of temperatures of groups or single zones for set times E Standby function Decrease of temperature to a set value BW Auto Power function This zone will change to manual mode in case of broken sensor thermocouple EH 8 groups of zones Individual groups may be recorded for collective changes and settings E 6 Programs with setpoints and zone parameters A certain profile may be acessed by external digital signal ll Current measuring and supervision The heater currents are measured for each zone and may be supervised B Leakage current supervision with fast dry out In case of leakage current the setpoint of all zones might be reduced to 100 C 212 F B Monitor zones Individual zones can be used just for indication and supervision EH Supervision of output rate against entered values E Net voltage protection for the sensor inputs High voltage at the sensor inputs will blow the referrin
34. g fuses B Puls package or phasecut control The outputs may be controlled in both ways or in a mix of these E Sensor control Broken sensor thermocouple or reversal polarity will be detected and indicated B Fuse control A blown heater fuse will be detected and indicate by LED B Triac control A defective triac will be detected and indicated by LED El Control quality The control quality may be observed for each zone during the process E Interface for computers Useful for protocols important for ISO 9000 remote operation and supervision B PLUS unit Several controllers operate as a single unit via CAN bus interface E Quality There is a sensible interpretation of all zones available B Diagnosis All zones can be checked by diagnosis program E Sequential heating Selections of zones may be heated in sequence one after another 2 Operation The operation display in the top has keys indicators and LED stripe ee HAS CO ESSEN ZONE D WES cc 2 81 iT 6 SETPOINT 4 3 81 vo F y 4 PROCESS VALUE X O2 ED Menu keys Indicators Settings with LED 2 1 Menu keys The menu keys activate a function or select a menu for operation by the setting keys The referring LED besides the menu key indicates the selected function Rey Fenton e 222222 Outputs ON OFF Outputs active disabled Boost ON OFF Sn Temperature increase Standby ON OFF ON Temperature decrease
35. gram signal or the referring key Via Digit in On Off all outputs are disabled for the duration of the signal The powered input see below for the logic of the signalsdepending on DIP switch 2 ON MH disables all outputs BI disables the start key for ON MH erases the LED near the start key With the end of the signal the previous status returns The inputs are compatible to PLC voltage of 13 30 VDC at a typical consumption of ca 8 5 mA HASCO Contact IS A 1 Program No 1 igit In P1 DC Program No 3 igit In P3 DC Disable Enable outputs igit In On Off DC Standby no Standby igit In Standby DC Program No 2 igit In P2 Program No 4 igit In P4 Program No 5 may be inverted by igit In P5 DIP switch 2 Program No 6 igit In P6 Logic of the signals at DIP switch 2 ON In this position the controller may be used without external enable On Off In this position the remote operation will be failsafe Digit In On Off There is no output Digit In Stdby without enable by On Off For normal Digit In P1 operation without T standby there are Digit In Pn 2 signals required gt Leistung gt Standby 34 HASCO 7 5 2 Warning and alarm contacts The Z1240 units are fitted with 2 alarm contacts The dry contacts for warning and alarm are available via socket at the rear side The
36. he handles at each side may be used as shown in the drawing to lift the controller with appropriate ropes 38 01 12 1 25s 14 by HASCO Postfach 1720 D 58467 L denscheid Alterations reserved HASCO EC Standards Declaration of EC Conformity EC standards referring design production and distribution The precondition is the conventional use of the product as well as the consideration of start up If product or accessory will be modified without our agreement this declaration is invalid Description of product Multi hot runner control unit Type name Z1240 Standards 2004 108 EG EC Standard Electromagnetic Tolerance 2006 95 EG EC Standard Electrical Appliance Applied standards EN 60204 Teil 1 Electrical equipment for machinery as far as applicable EN 61000 6 1 EMC immunity EN 61000 6 3 EMC radiation ra lu gro LEE Mag Christoph Ehrlich Andr Kabbert Chief Executive Officer Executive Vice President L denscheid november 2011 HASCO Postfach 1720 D 58467 L denscheid Tel 02351 9570 Fax 02351 957237 www hasco com info hasco com
37. he inputs of the NSS module the internal fast fuses will blow The voltage will be contacted to the ground The controller will indicate a broken sensor for this zone The referring zone will be reset after replacement of the fuses These are special fuses which are plugged on the specially designed NSS module The user may replace by himself There are spare fuses inside the original Z 12407 unit To change the fuses the front connectors of the referring module have to be unplugged Then the module may be released The cover at the side shows the position of the different fuses After lifting off the cover the fuses may get changed The cover has to be tightened before replacing the module 7 5 Rear side At the rear side of the controllers there are the connectors for sensors and heaters the supply for an operation monitor the data interface the digital inputs 2 sockets for an optional signaller top and the dry contacts bottom 33 7 5 1 5 5 1 Digital inputs The unit is fitted with 8 digital inputs These may be used for remote change of the programs 1 6 A short impulse min 100 ms at the digital input activates the referring program A continuous signal at the digital input inhibits the change of programs by the keys or via interface For assignment of the 15 pin plug see below Via Digit in Standby the controller may be set to standby mode This stage will be finished by a pro
38. icator select a setpoint value v a The range is from a disabled zone to the Hl value see Hl parameter The upper limit is preset by the HH value see HH parameter 2 9 Groups To operate via groups these have to be defined before It simplifies all further settings and operation to define and configure the groups before This separates the nozzles from manifolds or different components from one another The real advantage is the common operation All settings are available for groups in the same way as single zones setpoints operation mode parameters boost standby The assembly of groups has to be set via zone parameter 31 Important hints are to find among Installation of groups 2 9 1 Operation of groups PROCESS VALUE X The keys beside the zone number select the groups below zone 1 v a Here group 1 The zones of the group are indicated in the total display by the LED for the operated zones gt mit 3 Cursor LEDs A group may be operated just like a single zone setpoint operation mode zone para meters boost standby The assembly of the groups has to be set by the zone parameter 31 ZONE v a There is a selection of all zones available below group 8 This is independent of the groups PROCESS VALUE X This indicates that there is no zone belonging to the referring group or the setpoints output rates or operation modes are different within this group In case of different operation modes th
39. is only available by the code 5 4 22 PC parameter Power Control ZONE The PC parameter activates the reference voltage for the balance of the power in manual mode Constant output rates will be adjusted to contant power output in gt ID Level 2 case of fluctuating net voltage Input limits 0 1 0 No settings men Default value 0 1 Detection of the reference voltage followed by the indication Indication e g 226 VAC of the value A new reference voltage may be detected by repetition of the setting 1 25 HASCO 5 4 23 tP1 parameter Protocol type 1 ZONE The parameter tP1 defines the type of protocol for the rear side interface RS485 1 gt ID Level 4 O FES for MCScontrol Visual Fecon Paracon Inputs limits 0 1 1 special protocol Default value O 5 4 24 tP2 parameter Protocol type 2 LEPE The parameter tP1 defines the type of protocol for the rear side interface RS485 2 gt ID Level 4 O FES for MCScontrol Visual Fecon Paracon Inputs limits 0O 1 1 special protocol Default value O 5 4 25 LAn parameter Language An without function gt D Level 4 Inputs limits 0 3 Default value O 5 4 26 L1 3 parameter Line voltage ZONE These parameters indicate the actual voltage of the referring lines gt Only indication VAC LE Line 1 for zones 1 4 7 2 Line 2 for zones 2 5 8 d Line 3 for zones 3 5 9 Failed line voltage will indicate U for these zones 5 4 27 Fri 3 par
40. lt value 1 A PLUS unit sets all following addresses by the master For operation with the monitor the first address has to be 1 22 HASCO 5 4 7 bAu parameter Baud rate 1 ZONE This parameter sets the baud rate for the transmission via interface RS485 gt ID Level 2 1 9 600 baud 4 57 600 baud Input limits 1 5 2 19 200 baud 5 115 200 baud Default value 2 3 38 400 baud 5 4 8 bA2 Parameter Baud rate 2 ZONE This parameter sets the baud rate for the transmission via interface RS485 2 gt ID Level 2 1 9 600 baud 4 57 600 baud Input limits 1 5 2 19 200 baud 5 115 200 baud Default value 2 3 38 400 baud 5 4 9 CAn parameter CAN Bus Address ZONE To enable a CAN Bus interface for several controllers for a PLUS unit different addresses have to be set here gt D Level 2 Input limits 1 32 1 This controller is the master with operation for all linked controllers Default value 1 2 32 These controllers will be indicated as slave n 1 31 in a PLUS unit See also PLUS unit 5 4 10 Ct parameter Combined heating ZONE The maximum temperature difference to the slowest zone may be defined here for the combined heating gt ID Level 2 The combined heating may be switched off for each zone separately by parameter 13 Input limits 190 82 P 100 C Default value 25 C 45 F See combined heating 5 4 11 AP parameter Auto Power ZONE The AP parameter cancels the selection of output r
41. ode gt D Level 2 Input limits 0 100 Ifthis zone has already operated in manual mode the output rate was set here for Default value 100 proposal for the next change to manual mode 5 5 17 PARAMETER 17 Output rate mean PROCESS VALUE X This parameter will define itself during normal control mode It stores the long period average of the output rate during the control mode gt Indication 0 100 0 after start The value will be set only 2 min after controlling within the tolerance range parameter 3 5 5 18 PARAMETER 18 Output rate mean nominal PROCESS VALUE X This nominal setting will be compared to the actual mean rate parameter 17 Deviations will be indicated by dy gt ID Level 2 O no output rate supervision Input limits 0 100 gt 0 this value will get supervised Default value O see output rate supervision 29 HASCO 5 5 19 PARAMETER 19 Output rate mean tolerance PROCESS VALUE X The tolerance for the output rate deviation parameter 18 has to be set here Within the tolerance range no warning dY will be indicated gt D Level 2 Input limits 0 100 see parameter 18 Default value O 5 5 20 PARAMETER 20 Nominal current PROCESS VALUE X The nominal value of the current of this heater may be set here for supervision of the tolerance range of parameter 21 gt D Level 2 o Input limits 0 0 O no heater current supervision 25 0 A gt 0 this value will get supervised Defa
42. on C F The time for conversion of all programs and parameters may take some minutes during the re start after the change Sensor failure This sensor has a failure In case of mixed polarity the main relay will trip at 15 C 5 F and can only restart after OFF ON Temperatures too low lt 15 C 5 F are indicated like display overflow B Temperature lt 15 C Bi Polarity of the thermocouple mixed up at the terminal points 13 HASCO gt Reason gt Reason gt Reason with Xt LED for Triac failure gt Reason Z1240 2x16 to Z1240 16x16 gt Solving gt Disconnect from the mains supply before opening with Xt LED for fuses gt Reason Broken sensor There is no input signal from the sensor E Sensor connected BW Sensor wiring OK E Sensor plugs OK ll Check the NSS fuses inside the unit E No Auto Power function AP O HH Alarm This actual value is above the HH parameter All outputs get switched off The controller will go on heating only after restart when the actual value has decreased the HH parameter gt Not for monitor zones E Setpoint too close to the HH value E Heating externalty E Triac defective H Alarm This actual value is above the H alarm parameter 2 All outputs get switched off until the actual value decreases below the H alarm E Alarm limit too close to the setpoint E Heating externalty E Triac defective Current alarm with Triac L
43. ontroller 6 1 4 Heat up Turn ON the unit Set setpoints Switch the outputs ON After classification the zones rise to the setpoint temperature The relevant features like softstart combined heating leakage current supervision and dry out are enabled These functions may be disabled 6 1 5 Finalisation B Define password and identification level To inhibit unauthorised operation the password IC parameter may be changed For this reason the level of identification IL Parameter may be changed 32 HASCO 7 Technology 7 1 Cable carrier At the rear side of the display of units greater than Z1240 36x 16 there are 2 cable holders to pull out These are provided for the supply cable 7 2 Document case On top of units greater than Z 1240 36 x 16 there is a document case below the cover This may be used for a notebook There is a cable entry in the rear wall 7 3 Power fuses The fuses for the outputs are to find on both sides of the units The fuses must comply to the quality FF The strength of the fuses may vary referring to the fitting The standard is 16A FF 7 4 Protection against net voltage The units of the Z1240 series are fitted with a fuse module to protect against net voltage NSS module These modules protect the sensitive electronics for the sensor inputs against unacceptable high voltage Such voltage may occur by mixed wiring or by defective heaters As soon as a voltage higher than 6V is put to t
44. r Classification iis ee 24 5 4 18 LC parameter Leakage current supervision 24 5 4 14 LCL parameter Leakage current level 0 00000 eee 24 5 4415 SSR parameten iu doce ate uus dup CR dos Pee eae ak OP EY 24 5 4 16 FAH parameter Fahrenheit indication 2 2000 25 5 4 17 Brake parameter Overheat brake lsss eee eee 25 5 4 18 Std parameter Standard parameter iiis llle 25 5 4 19 IC parameter ID Code 00 0 eene 25 5 420 IL parameter ID Level 0 00 0 BB 25 5 4 24 PC parameter Power Control 0 000 cee eee 25 5 4 23 tP1 parameter Protokol type 1 0 0 0 eee 26 5 4 24 tP2 parameter Protokol type 2 0 eee 26 5 4 25 LAn parameter Language cece eee eee 26 5 4 22 L1 3 parameter Line voltage 00 0 ee 26 5 4 23 Fri S parameter Line frequency iliis 26 5 4 24 Date parameter date and time 0 0000 eee 26 5 5 Zone parameters 2e lom Re eh Sees 27 5 5 1 PARAMETER 1 LOA PM gob be E OS data TR 27 5 5 2 PARAMETER 2 HAIAN 2 nt Ep rdr boned dk Dad bbe edd 27 5 5 8 PARAMETER 3 DEVIATION 2 ud rd ok bee e e darsi sooo utet 27 5 5 4 PARAMETER 4 Psgap for heating 21s c EE Ses ERR oed ees 27 5 5 5 PARAMETER 5 I gap for heating isses ae es 27 5 5 6 PARAMETER 6 D g p for heating 5 i whee a Ale de e Rees 28 5 5 7 PARAMETER 7 Classifica
45. rawing with the correct positions is to find with the technical documents 8 2 1 A afety hints The supply from a triangle net without neutral wire N has to comply with the local regulations for the installation of electrical equipment Z1240 controllers are basically fit with one fuse to protect against short in the load circuit and against short of one line to PE In option there is an additional fuse per zone inside the unit to protect for triangle supply even the 2nd line against short to PE Retrofitting is possible The parameters for H and HH alarm limits should be generally adjusted to the production requirements to prevent faulty heating Z1225 connecting cables and Z1227 connecting housings are to be used for the electrical connections power and thermocouple connections between control unit and the tool This will ensure optimum controlling accuracy The control units are matched to the HASCO range of standard elements No guarantee can be given for trouble free functioning if components from other companies are used The Z1225 power signal cables must be regularly checked for mechanical damage and replaced as necessary The devices must be located such that sufficient ventilation and cooling is available The controllers must be protected from moisture and wet The devices must be applied in a technically meaningful way A Unplug the unit when changing the fuse A 9 Transport from Z 1240 36 x 16 T
46. s E Shorted sensors As this function supervises the condition of the heaters a certain increase of temperature is required during a certain time it is helpful to use the diagnosis program also when irregularities occur during normal operation The period of supervision will be set by the program itself It may be preset by the parameter 22 to heat up extreme control loops for 5 Selected zones will not be checked M if the setpoint O Wi if no sensor is recignised E Wi if the zone is turned OFF During the diagnosis all zones with a sensor even from the selection excluded zones will be supervised by the diagnosis 17 HASCO 3 1 Chose the diagnosis program ZONE The diagnosis program will be started by the setting of 1 in this parameter 4 The confirmation changes directly to the selection of the zones SETPOINT W ER amp 9 PROCESS VALUE X 3 2 Selection of zones ZONE a There are single zones a previously collected group of zones or all zones available for this routine E Q SETPOINT W SETPONT INT This alternating indication shows that the diagnosis does not run PROCESS VALUE X Start of the diagnosis program ol 3 3 Action of the diagnosis program The diagnosis program runs automatically through the selected zones and may be observed in the display ZONE ZONE This section indicates the actually powered zone here zone No 24 SETPOINT W This section shows the countdown
47. s Z1240 are based on two variations 8 16 or 32 zone controllers are designed for table use 64 96 or 128 zone cabinets are fitted with wheels cial aaa ye aaae en n m ome m NN onos 5 Main switch in the front Main switch on the rear side Control unit size 36x16 96x16 Control unit size 2x16 24x16 1 1 Safety hints The Z1240 units have to be connected to the specified mains supply The local and the general rules have to be observed for the installation and operation The units have to be wired and commissioned by authorised persons Maker and vendor of the unit are not liable for direct and indirect damage or loss due to wrong handling It does not predict dangerous voltage at the outputs to switch off all outputs or single zones The referring plugs or the complete Z 1240 have to be disconnected from the mains supply before working at the connected heating elements Disconnect the Z 1240 unit from the mains supply before opening 1 2 Type label The type label is bound on the right hand side of the controller It indicates the type with the number of zones the data for the electrical connection and maker s information Typ Z1240 64 x16 MCS64 Ser Nr 12009 Bj 45 09 Netzanschluss eY 230 400 VAC e50 Hz A115 230 VAC 60 Hz 3x63 A Schutzklasse IP 20 Thermof hler Fe CuNi Typ J Made in Germany C HASCO www hasco com HASCO 1 3 Features and functions All units include the same
48. settings of parameters 1 3 Input limits Q 2 Deviations are only available when the setpoint gt 0 C 32 F Default value O 0 controller fil monitor zones will be used for simple indication when no outputs are available or no heater is connected 2 Manual power mode for this zone when no inputs are available at the controller However a sensor will enable a control mode without confirmation after change to manual mod see Auto Power AP The cursor LED flashes in the total display when a monitor zone is selected 5 5 10 PARAMETER 10 Alternative zone PROCESS VALUE X This parameter enables to select an alternative channel for the Auto Power mode AP 4 gt D Level 2 The number of the referring zone will be set here after ACz It is available for the next Input limits 1 128 case of a broken sensor Default value O O or this zone no preset 1 128 this zone delivers the output rate in case of a broken sensor The input limit for PLUS units is the total number of zones In case of changes of variations of the PLUS unit this parameter will be reset to O 5 5 11 PARAMETER 11 Softstart PROCESS VALUE X The unit is provided with a softstart routine for smooth heating This may be enabled or disabled here gt D Level 2 0 this zone without softstart Input limits 0 3 Ws this zone with softstart Default value 1 A quickstart with occasional overheating is available for tasks with very inert control loops 2
49. t powered see jumper 3 Warning contact NC Alarm contact NC Output power 230VAC 4A 7 5 3 Interface socket Hint of interface If several controllers Z 1240 are connected to a single monitor address the addressing see Adr Parameter has to start by 1 and must be numbered consecutive The Baud rate for the data transmission has to be adapted by the bAu Parameter if necessary 7 5 4 Signal light socket This socket is designed for an external signal light to be activated together with the functions of the LED stripe Lema hmm 1 uu Warning yellow 230VAC Alarm red 230VAC N 7 5 5 This socket is designed for the net supply of a monitor 35 HASCO 7 5 6 Pin assignment The following examples are valid for the basic version of the Z 1240 units Units with specified rear boards are not mentioned here Specified lists are to find inside the units Z1240 24x16 Z1240 48x16 LY wa xx 230 V 230 V ae ae EON al ss gw lts 1617 18 19 20121 2 13 2 Fe CuNi Fe CuNi LE A A ETT Allocation of pin connection according to DIN 16765 7 6 Controllers The controllers inside the units are differently designed Depending on the number of zones Z 1240 operates a system of one single or multiple processors 7 6 1 Control units 36x16 96x16 The modules are mounted inside the unit onto a rail that includes the interface connection The LED in
50. tarted by the menu key A temporary disabling will not generally reset this start mode The controller has to be turned off before removal of the module as well as before change 31 HASCO 6 1 2 Jumper There is a block of 2x5 jumpers on the processor module The default settings are marked 1 REP NC Warn contact failsafe OK closed 2 REP NO Warn contact for lamp horn OK open 3 AL NC Alarm contact failsafe OK closed 4 ALNO Alarm contact for lamp horn OK open 5 Gn Lo Green LED stripe damped 6 Gn Hi GreenLED stripe bright 7 Ye Lo Yellow LED stripe damped 9 Ye Hi Yellow LED stripe bright 9 Rd Lo Red LED stripe damped 10 Rd Hi Red LED stripe bright The controller has to be turned off before removal of the module as well as before change 6 1 3 Connection Check the mains supply conditions The terminals inside the controller have to be linked either for star Y net with neutral 8x400VAC N PE or for triangle net 3x230VAC PE The referring specification will be delivered with the unit Connection of all heater and sensor cables A signaller may be connected by the alarm warning contact of the unit ATTENTION Take care of the maximum load of the contacts see technical data MH Connection of external digital signals and interface for computer control if required HM Connection to the 3phase mains supply The pin assignment has to be taken from the table inside the c
51. ter 5 allows to adjust the integral part of the controller in seconds This component of the controller increases or decreases the output rate with the gt D Level 2 defined speed according to a possible deviation Input limits 0 999s for tn 0 I part is disabled Default value 80 0s Settings of this parameter will be adapted after classification 27 HASCO 5 5 6 PARAMETER 6 D gap for heating PROCESS VALUE X Parameter 6 allows to adjust the differential part of the controller This component of the controller brakes the output rate for the stored time if the actual value approaches the gt ID Level 2 setpoint with too high speed Input limits 0 999s for tv 0 D part is disabled Default value 16 0s Settings of this parameter will be adapted after classification 5 5 7 PARAMETER 7 Classification of the zone PROCESS VALUE X The type of classification will be indicated by the parameter Settings are not possible gt Indication 0 9 5 5 8 PARAMETER 8 Operation mode of the zone PROCESS VALUE X The 3 operation modes are to set by the parameter or by the referring key in the display gt Indication 0 9 0 OFF 1 Manual mode 2 Control mode 5 5 9 PARAMETER 9 Monitor zone PROCESS VALUE X This parameter enables to select a zone for controller purpose or for simple indication A Monitor zone will be excepted from the group Monitor zones can be used for gt D Level 2 supervision by the
52. th the actual value gt D Level 2 Input limits 0 600 C At the same time the alarm contact switches 32 999 F Default value 0 C 5 5 2 PARAMETER 2 H Alarm PROCESS VALUE X The referring zone will indicate H alarm when the temperature reaches the value of parameter 2 This will be indicated by H alternating with the actual value gt D Level 2 Input limits 0 600 C The alarm contact switches and the main relay turns all heaters off After decrease of 32 999 F the temperature the outputs will be powered again Default value 400 C 752 F 5 5 8 PARAMETER 3 Deviation PROCESS VALUE X As soon as an actual value will deviate for more than the value of this parameter the referring zone will indicate deviation This will be indicated by flashing dL or dH D Level 2 alternating with the actual value Input limits 1 600K Default value 15K At the same time the warning contact switches 5 5 4 PARAMETER 4 P gap for heating PROCESS VALUE X Parameter 4 allows adjustment of the proportional part of the control loop in percent That means that a pure P controller slowly decreases the output rate proportionally gt D Level 2 When the actual value the setpoint the rate will be reduced to 0 Input limits 0 100 96 for xp 0 P part is disabled Default value 5 Settings of this parameter will be adapted after classification 5 5 5 PARAMETER 5 I gap for heating PROCESS VALUE X Parame
53. tion of the zone 00 0 28 5 5 8 PARAMETER 8 Operation mode of the Zone 28 5 5 9 PARAMETER 9 Monitoring channel llle 28 5 5 10 PARAMETER 10 Alternative channel 0 00 0002 c eee eee ee 28 5 5 11 PARAMETER 11 SOSTA qx Ke te eee eae OR UU re 28 5 5 12 PARAMETER 12 Combined heatlrig guter 9 Eee PER 29 5 5 13 PARAMETER 13 O MESE 29 5 5 14 PARAMETER 14 Ramp GOWN ais sr edie ace s wk De ele as XE we Syed 29 5 5 15 PARAMETER 15 Output rate MAXIMUM ck nteger Rr eed niria 29 5 5 16 PARAMETER 16 Output rate nominal 1 eee 29 HASCO 5 5 19 5 5 20 5 5 21 5 5 22 5 5 23 5 5 24 5 5 25 5 5 26 5 5 27 5 5 28 5 5 29 5 5 30 PARAMETER 17 Seite Output ratemean 2s sc ee EXTRA 29 PARAMETER 18 Output rate mean nominal lessen 29 PARAMETER 19 Output rate mean tolerance ce eee 30 PARAMETER 20 Curent NOMI x i cs nce tate du babe E RICE ATE RU d 30 PARAMETER 21 Current tolerance nanen setate ra e Re enea DE Ni 30 PARAMETER 22 DiAgMOSIS ME ind gone a a Rubr aa 30 PARAMETER 23 Offset temperature illie ee 30 PARAMETER 24 Zero cross phase control lille 30 PARAMETER 25 Boost offset i leues elu aye ee Y x ee 30 PARAMETER 26 Standby temperature 1 0 0 2 0c eee 31 PARAMETER 27 Auto adaption 2 0 ce ee nes 31 PARAMETER 28 30 acsi P 31 PARAMETER 31
54. ult value 0 0A 5 5 21 PARAMETER 21 Current tolerance PROCESS VALUE X The tolerance for supervision of heater current parameter 20 has to be set here The current will be supervised by the tolerance range of parameter 21 D Level 2 Input limits 0 0 16 0A Default value 0 5A 5 5 22 PARAMETER 22 Diagnosis time PROCESS VALUE X Independent of the internal determined value the duration of the diagnosis may be set here to the heat up for 5K 9 F gt D Level 2 Input limits 0 600 s Default value Os 5 5 28 PARAMETER 23 Offset Temperature PROCESS VALUE X This parameter will shift the temperature indication of this zone The actual temperature and the setpoint will be calculated with the referring gt D Level 4 offset against the real temperature Input limits 99 100K Default value OK 5 5 24 PARAMETER 24 Zero cross phase control PROCESS VALUE X The output may be controlled by pulspackets or phasecut or a dynamic mix of both The selections are gt D Level 2 O Pulspackets Input limits 0 2 1 Phasecut Default value O 2 Mixed 5 5 25 PARAMETER 25 Boost Offset PROCESS VALUE X The increase of temperature during the boost stage has to be set here by relative values gt D Level 2 Input limits 0 50K Default value OK 30 HASCO 5 5 26 PARAMETER 26 Standby temperature PROCESS VALUE X The decrease in temperature for standby has to be set here by absolute values gt D Level
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