Altanium Delta3
User Guide
Original Instructions
Altanium Delta3
Issue: v 2.3 — September 2015
This product manual is intended to provide information for safe operation and/or
maintenance. Husky reserves the right to make changes to products in an effort to
continually improve the product features and/or performance. These changes may result in
different and/or additional safety measures that are communicated to customers through
bulletins as changes occur.
This document contains information which is the exclusive property of Husky Injection
Molding Systems Limited. Except for any rights expressly granted by contract, no further
publication or commercial use may be made of this document, in whole or in part, without
the prior written permission of Husky Injection Molding Systems Limited.
Notwithstanding the foregoing, Husky Injection Molding Systems Limited grants permission
to its customers to reproduce this document for limited internal use only.
Husky® product or service names or logos referenced in these materials are trademarks of
Husky Injection Molding Systems Ltd. and may be used by certain of its affiliated companies
under license.
All third-party trademarks are the property of the respective third-party and may be
protected by applicable copyright, trademark or other intellectual property laws and treaties.
Each such third-party expressly reserves all rights into such intellectual property.
© 2008-2015 Husky Injection Molding Systems. All rights reserved.
ii v 2.3 — September 2015
User Guide v 2.3 — September 2015
General Information
Telephone Support Numbers
North America Toll free
Europe EC (most countries)
Direct and Non-EC
Asia Toll Free
Direct:
Latin America Brazil
Mexico
For on-site service, contact the nearest Husky Regional Service and Sales office.
For non-emergency questions and issues, e-mail Husky at techsupport@husky.ca.
Husky Regional Service and Sales Offices
For the nearest location, please visit www.husky.co.
1-800-465-HUSKY (4875)
008000 800 4300
+ (352) 52115-4300
800-820-1667 or +800-4875-9477
+86-21-3849-4520
+55-11-4589-7200
+52-5550891160 option 5
Product Upgrades
Upgrades are available that can improve output, reduce cycle times, and add functionality to
Husky equipment.
To see what upgrades are available, visit www.husky.co or call the nearest Husky Regional
Service and Sales Office.
Ordering Spare Parts
All spare parts for Husky equipment can be ordered through the nearest Husky Parts
Distribution Center or online at www.husky.co.
Ordering Additional Manuals
Additional copies of this manual and other documentation can be purchased through the
nearest Husky Regional Service and Sales office.
General Information iii
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iv Ordering Additional Manuals
User Guide v 2.3 — September 2015 Table of Contents
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Telephone Support Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Husky Regional Service and Sales Offices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Product Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Ordering Additional Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Purpose of the Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Restrictions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Input Wiring (Conventional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Environmental Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Equipment Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 Controller Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 2: Hot Runner Temperature Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Types of Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.1 Open Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Configuring Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.1 Configuring a Zone for Zero Cross Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.2.2 Configuring a Zone for Phase Angle Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.3 Determining the Heater Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.4 Thermocouple Types and Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Chapter 3: Connecting the System to the Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Prior to Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.2 Connecting to the Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.3 Startup Procedure Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Chapter 4: Altanium Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 General Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.1.1 Altanium Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.1.2 Home Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.1.3 Altanium Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
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4.1.3.1 Controller Function Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1.3.2 System Status Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.1.3.3 Navigation Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1.3.4 Alarm Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.1.3.5 System and User Management Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.4 Dialog Box Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.5 System Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.6 Views Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.1.7 Temperature Control Shortcuts Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.7.1 Creating a Shortcut Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.1.8 Screen Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.2 Multi Group View Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4.2.1 Changing the Header Color. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.3 Selecting a Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.4 Printing to a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4.1 Print Report Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.5 Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
4.6 Supply Voltage Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.6.1 Viewing the Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.6.2 Configuring the Supply Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.7 Using Online Help. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chapter 5: Security and Administration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 User Management and Security Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1.1 Manage Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1.2 User Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1.3 Auto Logout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Chapter 6: Mold Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.1 Mold Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
6.1.1 Creating a New Mold Setup Folder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.1.2 Creating a New Mold Setup File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.1.3 Saving Changes to a Mold Setup File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1.4 Discarding Changes to a Mold Setup File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1.5 Saving the Current Mold Setup File as a New File . . . . . . . . . . . . . . . . . . . . . . . . . .54
6.1.6 Loading an Existing Mold Setup File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
6.1.7 Deleting Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1.8 Copying Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1.9 Renaming Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
6.1.10 Transferring Data to the Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.1.11 Transferring Data Using a USB Storage Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
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Chapter 7: Making Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.1 Zone Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
7.2 Creating a Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
7.3 Graphical View Screen Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
7.4 Text View Screen Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
7.4.1 Zone Selection in the Text View Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
7.4.2 Sorting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
7.5 Quick Set Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
7.5.1 Frequently Used Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
7.5.2 Zone Edit Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
7.5.3 Setpoint Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
7.5.4 Manual Standby Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
7.5.5 Manual Boost Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
7.5.6 Remote Standby Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
7.5.7 Remote Boost Fields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
7.5.8 Advanced Settings Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
7.5.9 Control Settings Fields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
7.5.10 Changing a Zone Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
7.5.10.1 Changing Multiple Zones Names. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
7.5.11 Changing a Setpoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
7.5.12 Changing the Alarm Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
7.5.13 Changing the Abort Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
7.5.14 Changing the Output Mode Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
7.5.15 Zone Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
7.5.15.1 Using the Automatic Slave Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.5.15.2 Manually Slaving One Zone to Another Zone . . . . . . . . . . . . . . . . . . . . . . . . .74
7.5.15.3 Changing the Regulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
7.5.16 Setpoint Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
7.5.16.1 Changing the Normal Setpoint and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
7.5.16.2 Changing the Manual Standby and Remote Standby Setpoint Limits . . 76
7.5.16.2.1 Changing the Manual Standby Setpoint Limits . . . . . . . . . . . . . . . . . .76
7.5.16.2.2 Changing the Remote Standby Setpoint Limits. . . . . . . . . . . . . . . . . .76
7.5.16.3 Changing the Manual Boost Setpoints and Limits . . . . . . . . . . . . . . . . . . . . .77
7.5.16.4 Changing the Remote Boost Setpoints and Limits . . . . . . . . . . . . . . . . . . . .77
7.5.17 Changing the Sensor Assignment (Thermocouple) . . . . . . . . . . . . . . . . . . . . . . . . 78
7.5.18 Changing the Priority Control Mode (PCM) Setting . . . . . . . . . . . . . . . . . . . . . . . .78
7.5.19 Changing the Earth Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
7.5.20 Changing the Automatic Manual Control (AMC) Setting . . . . . . . . . . . . . . . . . . .79
7.5.21 Changing the Output Power Limit Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
7.5.22 Changing the Zone Control from ART to PID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
7.5.22.1 Changing P, I or D Parameter Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
7.6 Active Reasoning Technology (ART) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
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7.6.1 ART Process Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.6.1.1 Using the Manual ART Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
7.7 PID Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.7.1 Typical PID Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.7.2 Possible Causes of Oscillation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Chapter 8: Mold Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.1 Testing the Mold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.1.1 Running a Mold Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.1.2 Setting the Zone Cooling Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.1.3 Setting the Maximum Test Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.2 Diagnostics Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.2.1 Test Results Screen Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
8.2.2 Automatic Thermocouple Rewiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.3 Cross-Talk Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.4 Temperature Graphs Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Chapter 9: Heating the Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.1 Heater Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.1.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
9.2 Earth Leakage/Wet Heater Bake Out System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.2.1 Earth Leakage Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.2.1.1 Setting the Earth Leakage Percentage Limit . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.2.2 Configuring the Length and Number of Bake Out Cycles. . . . . . . . . . . . . . . . . . . 96
9.3 Soft Start Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.3.1 Enabling Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.3.2 Disabling Soft Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.3.3 Adjusting the Soft Start Minimum Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.4 Alarm Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
9.4.1 Opening the Alarm Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
9.4.2 Alarm States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
9.4.3 Clearing Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
9.5 Event History Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
9.5.1 Filtering Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
9.6 Alarm and Event Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
9.7 Alarm Conditions — Warning Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
9.8 Abort Conditions — Shutdown Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
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Chapter 10: System Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.1 System Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
10.1.1 Force Temperature Units To Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
10.1.2 Data Collection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
10.1.3 Changing the Units of Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
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10.1.4 Changing the Energy Usage and Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
10.1.5 Changing the Grid Size and the Group Offset. . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
10.1.6 Changing the Number of Zones in the System. . . . . . . . . . . . . . . . . . . . . . . . . . . .115
10.1.7 Standby Timer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
10.1.7.1 Setting the Manual Standby Duration Timer . . . . . . . . . . . . . . . . . . . . . . . . .115
10.1.7.2 Setting the Remote Standby Duration Timer. . . . . . . . . . . . . . . . . . . . . . . . .116
10.1.7.3 Setting the Remote Standby Delay Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
10.1.7.4 Changing the Remote Standby Input Mode . . . . . . . . . . . . . . . . . . . . . . . . .116
10.1.7.5 Standby Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
10.1.8 Boost Timer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
10.1.8.1 Setting the Manual Boost Duration Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . .118
10.1.8.2 Setting the Remote Boost Duration Timer . . . . . . . . . . . . . . . . . . . . . . . . . . .118
10.1.8.3 Setting the Remote Boost Delay Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
10.1.8.4 Changing the Remote Boost Input Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
10.1.8.5 Boost Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
10.1.9 Power Deviation Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
10.1.10 Power Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
10.1.11 Monitor Zone Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
10.1.12 Options and Licensing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
10.1.13 Diagnostics Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
10.1.14 Part Counting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
10.1.14.1 Setting Up Part Counting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
10.1.14.1.1 Resetting the Part Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
10.1.14.1.2 Sack Full Output Optimization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
10.1.15 Remote Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
10.1.15.1 Setting Up Remote Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
10.1.16 Zone Alarm Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
10.1.17 Mold Cooling Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
10.2 Staged Startup and Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
10.2.1 Enabling or Disabling Staged Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
10.2.2 Enabling or Disabling Staged Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
10.2.3 Staging Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
10.2.4 Setting the Staged Temperature and Power Setpoints . . . . . . . . . . . . . . . . . . . .138
10.2.5 Holding a Stage Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
10.2.6 Setting Soak Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Chapter 11: Mold Picture View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
11.1 Loading a Mold Picture View Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
11.1.1 Mapping a Network Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
11.1.2 Loading a Mold Picture View Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
11.2 Using the Mold Picture View Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
11.3 Configuring a Mold Picture View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
11.3.1 Edit Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
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11.3.2 Configuring a Zone Information Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
11.3.2.1 Creating a Zone Information Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
11.3.2.2 Moving a Zone Information Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
11.3.2.3 Editing a Zone Information Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
11.3.2.4 Creating a Leader Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
11.3.3 Changing the Color of a Leader Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
11.3.4 Deleting a Leader Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
11.3.5 Deleting a Zone Information Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
11.3.6 Exiting Edit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Chapter 12: Data Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
12.1 Process Trend Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
12.1.1 Viewing the Process Trend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
12.2 Process History Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
12.2.1 Curve Data Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
12.2.2 Setting the Timeframe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
12.2.3 Setting the Date and Time Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
12.2.3.1 Changing the Date and Time Range Old. . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
12.2.3.2 Changing the Date and Time Range New. . . . . . . . . . . . . . . . . . . . . . . . . . . .158
12.2.4 Changing the Zone Displayed on the Process History Screen . . . . . . . . . . . . .159
12.3 Process Targets Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
12.3.1 Filtering by Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Chapter 13: System Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
13.1 Configuring the Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
13.1.1 Turning an I/O Option On or Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
13.2 Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
13.3 Input/Output Connector Pin-Out Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
13.3.1 Input Base Connector ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
13.3.2 Output Base Connector ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
13.3.3 Part Count Base Connector ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
13.3.4 Remote Load Base Connector ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Chapter 14: SPI Protocol Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
14.1 SPI Command Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
14.1.1 Echo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
14.1.2 Process Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
14.1.3 Process Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
14.1.4 Alarm Active Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
14.1.5 Alarm 1 Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
14.1.6 Alarm 2 Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
14.1.7 Alarm 1 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
14.1.8 Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
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14.1.9 Manual Percent Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
14.1.10 Open/Closed Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Chapter 15: Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
15.1 Altanium System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
15.2 Card Layout Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
15.2.1 Troubleshooting Using the Card Layout Screen. . . . . . . . . . . . . . . . . . . . . . . . . . .178
15.3 Servicing the Altanium System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
15.3.1 Altanium X/H-Series Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
15.3.2 Replacing an Intelligent Control Card (ICC2 or ICC3) . . . . . . . . . . . . . . . . . . . . . .182
15.3.3 Replacing a Blown Fuse on an Intelligent Control Card (ICC2 or ICC3) . . . . .183
15.4 Replacing an Altanium Delta3 Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
15.4.1 Disconnecting the Display Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
15.4.2 Connecting the Display Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
15.4.3 Mounting the Display Module Remotely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
15.5 Replacing the Motherboard Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
15.6 Calibrating the Thermocouple Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
15.7 Cleaning the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
15.7.1 Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
15.7.2 Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Chapter 16: UltraSync-E, If Equipped. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
16.1 Connecting the Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
16.2 UltraSync-E Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
16.2.1 UltraSync-E Home Screen Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
16.3 UltraSync-E Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
16.3.1 Control Modes Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
16.3.2 Manual Control Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
16.3.3 Ready Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
16.3.4 Control Bar Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
16.3.5 Datalog Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
16.4 UltraSync-E Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
16.4.1 Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
16.4.2 Other Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
16.4.3 Setup Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
16.4.3.1 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
16.4.3.1.1 Permit Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
16.4.3.1.2 Permit Disengaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
16.4.3.1.3 Engaged Mode Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
16.4.3.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
16.4.3.3 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
16.4.3.4 Pullback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
16.5 UltraSync-E Opening Profile and Closing Profile Screens. . . . . . . . . . . . . . . . . . . . . . .206
xi
v 2.3 — September 2015 Altanium Delta3
16.5.1 Closing Profile Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
16.5.2 Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
16.6 Servo I/O Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
16.6.1 Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
16.6.2 Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
16.6.3 Configurable Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
16.6.4 Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
16.7 Calibrating the UltraSync-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
16.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
16.8.1 Drive Fault (Error Code #) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
16.8.2 Alarm: Position Deviation Limit Exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
xii
User Guide v 2.3 — September 2015 Introduction
Chapter 1 Introduction
This User Guide includes general warnings and cautions to avoid injury to personnel and
damage to the system. These warnings and cautions are not intended to be, nor are they allinclusive to every condition or application that may occur during operation. Maintenance
and safety procedures remain the sole responsibility of the individual and his or her
company.
IMPORTANT!
Some manuals may contain addendums that detail new or updated information. Before
reading a manual, make sure to review all available addendums located at the end of the
manual.
1.1 General Safety
WARNING!
Electrical shock risk-de-energize controller prior to connecting, disconnecting or
servicing the controller, hot runner or mold.
WARNING!
Electrical hazard - risk of shock or personal injury. ALWAYS ensure that the screw on
the back of the top portion of the controller, marked with the general warning symbol,
is installed when the controller is energized. This is the grounding point for the top
cover to the chassis. Removal of this screw could cause an unsafe condition unless
proper precautions are taken such as, Lock Out Tag Out (LOTO).
WARNING!
Gas/vapor hazard – risk of respiratory injury. Certain processed materials could release
harmful gas, vapors or dust. Install an exhaust system according to local codes. Plastic
degrades with prolonged exposure to the setpoint temperature. Do not leave machine
and controller unattended.
General Safety 1
v 2.3 — September 2015 Altanium Delta3
• The system should only be installed by qualified personnel in accordance with local
codes.
• When the controller is connected to an injection molding machine, the safety of the
system is the responsibility of the integrator.
• Only persons with a thorough knowledge of the system's operation and capabilities
should operate the system.
• Read all of these instructions before connecting power and turning on the system.
• Follow all warnings and instructions marked on the system.
• Unless specifically explained in this manual or directed by Husky, do not attempt to
repair the system. Doing so could result in damage to the system, or serious personal
injury.
• Only use the specified input supply voltage that is indicated on the identification label
attached to the power input cable and/or the cabinet
NOTE:If unsure of the appropriate supply voltage, call the nearest Husky Regional
Service and Sales office.
CAUTION!
Mechanical hazard – risk of damage to the equipment. NEVER allow the fan inlets or
outlets on the unit to become blocked. Insufficient cooling airflow through the fan
inlets and outlets could damage the system.
CAUTION!
When switching OFF the system wait 30 seconds before switching the main disconnect
back ON. If you do not wait the required 30 seconds, communication issues may occur.
1.1.1 Safety Signs
Safety signs clearly mark potentially hazardous areas in or around equipment. For the safety
of personnel involved in equipment installation, operation and maintenance, use the
following guidelines:
The following safety symbol may appear on safety signs:
NOTE:Safety signs may include a detailed explanation of the potential hazard and
associated consequences.
2 Safety Signs
User Guide v 2.3 — September 2015 Introduction
Safety Symbol General Description of Symbol
General
This symbol indicates a potential personal injury hazard. It is usually
accompanied by another pictogram or text to describe the hazard.
Hazardous Voltage
This symbol indicates a potential hazard that may cause death or serious injury
and will appear on any panel that, if removed, will expose the user to more
than 40 VAC.
1.2 Purpose of the Equipment
Husky controllers are designed to control the process temperature for injection molding
applications only.
Contact your nearest Husky Regional Service and Sales office if you plan to use a Husky
product for anything other than its intended use.
1.3 Restrictions of Use
Husky injection molding equipment must never be:
• used for any purpose other than that described in Section 1.2, unless otherwise
approved by Husky
• operated or serviced by personnel unfamiliar with the inherent risks and necessary
precautions related to controllers
1.4 Input Wiring (Conventional)
The following table summarizes the wiring conventions used.
Description Wire Color
Neutral Blue
Earth/Ground Green Green/Yellow
Line Black Black
Purpose of the Equipment 3
v 2.3 — September 2015 Altanium Delta3
Description Wire Color
Line Brown Red
Line Gray White
DANGER!
Electrocution and/or mechanical hazard - risk of death or serious injury and possible
damage to the equipment.
Incorrectly wiring the controller could cause death or serious injury and/or damage to
the controller or hot runner. Only qualified personnel should connect the electrical
power supply. All work must conform to applicable local electrical codes.
1.5 Environmental Operating Specifications
The following are the environmental operating specifications for the Altanium Delta3
operator interface:
CAUTION!
Mechanical hazard – risk of equipment damage. Falling or spraying liquid, including oil
or water, could damage the equipment. Do not spray wash.
• For Indoor use only.
• Operating Temperature: 5 to 40 °C (41 to 104 °F)
• Operating Humidity: 0% to 90% RH, Non-Condensing
• Altitude: up to 2000 m (6562 ft)
• Pollution Degree: PD2
• Overvoltage Category: OVIII
1.6 Equipment Ratings
Ratings for the entire Altanium Controller can be found on the nameplate attached to the
back of the controller.
The following are the equipment ratings for the Altanium Delta3 operator interface only:
• Supply Voltage: 100 to 240 VAC +/- 10%, single phase
• Frequency: 47 to 63 Hz
• Power Rating: 130 W
4 Environmental Operating Specifications
User Guide v 2.3 — September 2015 Introduction
1.7 Technical Specifications
The dimensions and weight of the controller can change based on the controller
configuration.
The following are the technical specifications for the Altanium Delta3 operator interface only:
Dimensions Weight
• Width: 330 mm (13 in)
• Length: 280 mm (11 in)
• Height: 380 mm (15 in)
1.8 Controller Lifting Instructions
Use the follow steps when lifting the Altanium controller. The lifting device (crane or forklift)
and straps that are used vary in lifting ability and lengths, depending on whether the
Altanium is a single, double, or triple stack controller. See the table that follows for the correct
lifting ability and lengths.
Altanium
Controller
Single Stack Two, 2.44 m x 25.4 mm
Double Stack Two, 3.66 m x 25.4 mm
Webbed Straps Rated
2903 kg (6400 lb)
(8 ft x 1 in.)
(12 ft x 1 in.)
• Controller: 6.8 kg (15 lb)
• With shipping container: 10 kg (22 lb)
Ratchet Strap
One, 1.52 m (5 ft) 227 kg (500 lb)
One, 1.83 m (6 ft) 454 kg (1000 lb)
Lifting Device
(Lifting Ability)
Triple Stack Two, 3.66 m x 25.4 mm
(12 ft x 1 in.)
One, 2.44 m (8 ft) 907 kg (2000 lb)
1. Place each of the webbed straps under the controller. See the table for the correct strap
lengths.
a. For single stack controllers, the webbed straps go under the equipment from left to
right.
b. For double and triple stack controllers, the webbed straps go under the equipment
from front to back.
2. Bring the straps up and above the Altanium controller and attach them to the lifting
device.
Technical Specifications 5
v 2.3 — September 2015 Altanium Delta3
Figure 1-1 Attaching Straps to Lifting Device
a. Make sure the straps are positioned between the caster wheels and the retaining
brackets under the base of the controller.
Figure 1-2 P ositioning Straps
b. Make sure the straps are not pinching or crushing any cables attached to the
controller.
6 Controller Lifting Instructions
User Guide v 2.3 — September 2015 Introduction
Figure 1-3 Checking Cables
3. Use the lifting device to apply enough upward force on the straps to remove the slack,
but do not lift the controller at this time.
4. Place the ratchet strap around top of the controller, holding the four ends of the
webbed straps. Do not tighten the ratchet strap at this time.
NOTE:The ratchet strap keeps the controller from tipping when the controller is lifted.
5. Place cloth or other cushioning material between the ratchet strap and the controller to
keep the finish of the controller free from rubs and scratches.
Figure 1-4 Protecting the Controller Finish
6. Tighten the ratchet strap.
7. Use the lifting device to slowly lift the controller off the ground a few inches.
8. Check the webbed and ratchet straps to ensure the controller will not tip.
9. Move the controller to the new location.
10. At the new location, slowly lower the controller to the ground.
11. Remove the ratchet straps, cushioning material and webbed straps from the controller.
Controller Lifting Instructions 7
v 2.3 — September 2015 Altanium Delta3
8 Controller Lifting Instructions
User Guide v 2.3 — September 2015 Hot Runner Temperature Control
Chapter 2 Hot Runner Temperature Control
This guide is designed to ensure that users receive the maximum possible benefit from the
use of the Altanium Hot Runner Control Systems.
The Altanium controllers were designed as a processor's tool for hot runner molding. The
fundamental criteria required to operate a hot runner mold is controlling the process
temperature so that it is as consistent and repeatable as possible with respect to the process
setpoint. The closer to the setpoint the process temperature is maintained at, the lower the
setpoint temperature may be set. This equates to less cooling time required (energy in energy out), and faster cycle times.
2.1 Types of Temperature Control
The Altanium controller uses two basic types of control:
• Open loop control with no thermocouple feedback.
• Closed loop control with thermocouple feedback. Closed loop can be sub-categorized
as follows:
• Internal Thermocouple - Located inside and as part of the heater assembly.
• External Thermocouple - Located close to but not actually part of a single heater
assembly, and may even be allocated to a group of heaters to form a zone.
2.1.1 Open Loop Control
Without a thermocouple, it is not possible to control the temperature inside the mold, only
the amount of power supplied to the heater. Altanium maintains this power output
accurately with a resolution of 0.1%. This method of control is called manual regulation.
Open loop control is normally associated with tip heaters, where the physical size of the tip
precludes the use of an internal thermocouple.
2.2 Configuring Zones
In an effort to match the energy input requirements of differing types of loads, it is necessary
for the output power delivered to the heaters to be adjusted over a range of 0 to 100%. The
Altanium controller can be set up to achieve this by using either Zero Cross Control or Phase
Angle Control.
Types of Temperature Control 9
v 2.3 — September 2015 Altanium Delta3
2.2.1 Configuring a Zone for Zero Cross Control
This method defines how the power to each heater is averaged over a period of time. This is
achieved by switching between complete half cycles of the heater supply voltage using a
snubberless TRIAC as a switching device.
2.2.2 Configuring a Zone for Phase Angle Control
This method defines how the power to each heater is adjusted, by varying the point in each
half cycle at which the snubberless TRIAC (switching device) is turned on.
In either control method, the Altanium controller recalculates the power output
requirements for the entire system every 250 milliseconds to obtain the maximum control
resolution. By combining either of the above control methods with the Active Reasoning
Technology (ART) control algorithm, it is possible to achieve accurate temperature control
with the expectation of control accuracy of ± 1 digit under steady state conditions.
2.3 Determining the Heater Size
Hot runner molds can have a number of different types of heating elements:
• Integral, which is a part of the probe.
• Cartridge, which is slid into the probe or directly into the mold steel.
In the manifold, a series of cartridge heaters or bent tubular style heaters are normally used.
The wire inside an element is typically made of nickel-chrome, which is then surrounded by
magnesium oxide. The size of this wire and number of turns determine its resistance, which
in turn determines its wattage (the amount of energy). This determines its performance in
the mold. Undersize heating elements (too little wattage) create a serious problem when the
control asks for power and none is available. In almost all cases it is better to be oversize than
undersize in a hot runner mold.
The Altanium controller will provide wattage, resistance or amperage information for
heaters, if equipped with X ICC
determined using Ohm’s Law. The diagram and formulas that follow demonstrate how.
WARNING!
Electrical hazard– risk of death or serious injury. Disconnect all electrical power from
the mold and controller prior to performing this test.
2
or H ICC3 cards. Alternatively, this information can be
1. Using a multimeter, set the selector to measure resistance.
2. Place the (red) positive lead onto the first wire from the heating element and place the
(black) negative lead from the meter onto the second wire (these may be pins on a
connector, or the zone output fuses in the system as long as they are connected to the
heating element).
10 Configuring a Zone for Zero Cross Control
User Guide v 2.3 — September 2015 Hot Runner Temperature Control
The meter will now display a resistance in ohms. Note this measurement on a piece of
paper.
Ohm's Law says:
Amps = Watts / Volts Amps = Volts / Resistance
Resistance = Volts / Amps Watts = Volts x Amps
Example: If the resistance is 12.5 ohms, and the input voltage is 240 volts, divide 240 by
12.5 to calculate the maximum amperage draw on that heating element:
240 / 12.5 = 19.2 amps
19.2 Amps x 240 volts = 4,608 watts.
In hot runner molding, some portions of Ohm's law are more useful than others. We have
only presented here those laws that apply.
Input
24 V 110 V 208 V 220 V 240 V
voltage
Resistance
Amperage
Watts
20 20 20 20 20
1.2 A 5.5 A 10.4 A 11.0 A 12.0A
28.8 W 605.0W 2163.2 W 2420 W 2880 W
2.4 Thermocouple Types and Color Codes
Altanium controllers use the ANSI color code for all thermocouples. The following table is
provided as reference for hot runners and cables that follow other color code standards.
International
Code Type
J Iron/ Constantan/ (Copper-
Nickel)
Color Code
(BS4937 Part
30:1993)
Overall Black Overall Black Overall Black Overall Blue
+ ve - ve + ve - ve + ve - ve + ve - ve
BRITISH
(BS1843:1952)
U.S.
ANSI
GERMAN
DIN
Black White Yellow Blue White Red Red Blue
K Nickel- Chromium/ Nickel-
Aluminum
Thermocouple Types and Color Codes 11
Overall Green Overall Red Overall Yellow Overall Green
+ ve - ve + ve - ve + ve - ve + ve - ve
Green White Brown Blue Yellow Red Red Green
v 2.3 — September 2015 Altanium Delta3
12 Thermocouple Types and Color Codes
User Guide v 2.3 — September 2015 Connecting the System to the Mold
Chapter 3 Connecting the System to the Mold
This chapter outlines various checks to make prior to starting up the system.
3.1 Prior to Startup
DANGER!
Electrocution hazard– contact with hazardous voltages will cause death or serious
injury. Make sure that the system is completely disconnected from the power source.
• Clean up any water, oil, dirt, cleaning fluids etc. that may have spilled during a mold
change or since the last production run.
• Make sure the display module is mounted to either the controller or remotely. For more
• information, refer to Section 15.4.2 or Section 15.4.3.
• Make sure the cooling fan is free from obstructions.
• Check all of the cable connections between the system and the mold (if required). Make
sure all of the cables are free from wear or damage.
• Check that the earth/ground connection is in good condition. Verify the system and the
mold have the same ground reference.
3.2 Connecting to the Power Source
To connect the power source, do the following:
DANGER!
Electrocution hazard– contact with hazardous voltages will cause death or serious
injury. Make sure that the system is completely disconnected from the power source.
1. Connect the thermocouple and power output cables (if required).
2. Using an Ohmmeter, touch one test lead to the mold and the other to the mold ground
terminal on the system. Resistance must be less than 1 .
Prior to Startup 13
v 2.3 — September 2015 Altanium Delta3
3. Make sure the main input power disconnect is in the OFF position.
4. Connect the controller to the power source.
3.3 Startup Procedure Checklist
Item Step
1 Connect power/thermocouple cables between the mold and controller (if
required).
2 Connect the I/O box or option cables (if required).
3 Connect the controller to the power source.
4 Switch the controller ON.
5 Login to the system (if required).
6 Select the required mold setup.
7 Verify the mold setup is the correct one by checking the name and setpoints in
the preview window.
8 Correct any faults found during diagnostics.
9 Touch START to run the system.
10 Check that the controller is functioning correctly by monitoring the Graphical
View/Text View screen.
NOTE:There are no controller to mold interconnection details included in this User Guide.
If this information is required, please call the nearest Husky Regional Service and Sales
office.
IMPORTANT!
When turning off the system, wait 30 seconds before turning the main disconnect switch
back on. Turning the system off and on incorrectly may result in system communication
problems.
14 Startup Procedure Checklist
User Guide v 2.3 — September 2015 Altanium Operator Interface
Chapter 4 Altanium Operator Interface
This chapter provides a brief overview of the functionality of the Altanium system and
provides information about the following:
• Altanium operator interface
• Altanium buttons
• Altanium status
• Language selection
4.1 General Layout
The operator interface consists of a touch-sensitive display screen.
4.1.1 Altanium Operator Interface
The Altanium operator interface is a high-resolution color LCD display covered by a
transparent touch screen. This display offers the advantages of high definition and a wide
viewing angle, even in poor lighting conditions.
CAUTION!
Mechanical hazard – risk of equipment damage. Use a finger to operate the touch
screen. Do not use a screwdriver, pen, or any other tool to touch the screen as this may
damage the touch screen.
Use the touch screen to change settings on the Altanium operator interface. This display is
referred to as the Altanium for the remainder of this guide.
4.1.2 Home Screen
The Home screen provides a single area to navigate to all other screens in the system. The
Home screen can be accessed from any other screen in the system by touching the Home
button in the system header. The system screen selections on the Home screen are organized
into five groups: Temperature Control Views, Temperature Control Shortcuts, Common
screens, Temperature Control screens, and System Configuration screens.
General Layout 15
v 2.3 — September 2015 Altanium Delta3
2
5
4
31
Figure 4-1 Home Screen
1. Controller Function Buttons 2. System Status Field 3. Navigation Buttons 4. Alarm
Buttons 5. System and User Management Buttons
4.1.3 Altanium Buttons
Altanium has a system header and a footer that are visible on every screen throughout the
system.
16 Altanium Buttons
User Guide v 2.3 — September 2015 Altanium Operator Interface
4.1.3.1 Controller Function Buttons
Button Description
Touch the Stop button to switch off the power to all zones, regardless of
system condition.
Touch the Start button to switch on the power to the zones that have a
setpoint displayed.
Touch the Standby button to place the system in standby. If a timer is
active, the time remaining is displayed in the status bar. This button is not
available during ART.
4.1.3.2 System Status Field
Button Description
Touch the Boost button to place the system in boost mode. If a timer is
active, the time remaining is displayed in the status bar. This button is not
available during ART.
At Temperature indicates the following:
• Flashes when the controller is heating zones up to the setpoint
temperature.
• Solid when all automatic zones are ‘At temperature’.
• Off if the controller is in the ‘Stop’ state.
Company Name is displayed.
Controller Function Buttons 17
Button Description
4.1.3.3 Navigation Buttons
Button Description
v 2.3 — September 2015 Altanium Delta3
System Mode. For a description of each system mode, refer to
Section 4.1.5.
System Timer. Displays the timer value.
Touch the Back button to display the previous screen (maximum of 10
screens back). Note: The Home Screen is not included as part of the
navigation history.
Touch the Forward button to display the next screen (maximum of 10
screens forward). The Home Screen is not included as part of the
navigation history.
Touch the Home button to display the Home screen.
The Screen Indicator displays an Icon of the screen that is currently being
viewed. If a Zone Data screen (Neo2 View, Multi Group View, Graph View,
or Text View) is displayed, this becomes a Configuration button that when
touched changes the screen to display more or less zone information.
18 Navigation Buttons
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