Husky Altanium Delta3 User Manual

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 [e-mail].

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 [phone]

[phone]

[phone]

[phone] 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

v 2.3 — September 2015 Altanium Delta3

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

v

v 2.3 — September 2015 Altanium Delta3

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

vi

User Guide v 2.3 — September 2015 Table of Contents

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

vii

v 2.3 — September 2015 Altanium Delta3

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

viii

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

User Guide v 2.3 — September 2015 Table of Contents

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

ix

v 2.3 — September 2015 Altanium Delta3

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

x

User Guide v 2.3 — September 2015 Table of Contents

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

User Guide v 2.3 — September 2015 Altanium Operator Interface

4.1.3.4 Alarm Buttons

Touch the Silence Horn button to silence the audible alarm.

Touch the Alarm Status button to access the Alarm screen. The time and a
description of the highest priority active alarm will be displayed. If an alarm
is active, the Triangle Icon (Warning) will turn yellow and the background
of the button will flash red.

4.1.3.5 System and User Management Buttons

Displays the name of the current user logged in. Touch the User Log
off/Log on button to display the User Login dialog box. This button

toggles between Login and Logout

Touch the Help button to launch the PDF viewer and display the User
Guide on the screen.

Touch the Print button to open the Print dialog box containing the

available printing choices.

Alarm Buttons 19

4.1.4 Dialog Box Buttons

The following buttons are available in Altanium dialog boxes.

Table 4-1 Dialog Box Buttons

v 2.3 — September 2015 Altanium Delta3

Touch the Mold Setup Info button to display the currently loaded mold
and associated mold folder. The upper word is the name of the mold folder.
The lower word is the name of the mold setup file. Touch this area to
display the Mold Setup screen.

Touch the Language Selection button to display and select the available
screen languages.

Screen Description

Accept

Cancel

Exit

4.1.5 System Modes

The system mode is displayed in the status bar on each screen.

20 Dialog Box Buttons

User Guide v 2.3 — September 2015 Altanium Operator Interface

System Mode Description

Stop The system is stopped and no power is being applied to the heaters.

Running The system is heating up to or maintaining the normal setpoint.

Manual Standby The user pressed the Manual Standby button and the system is heating

to the manual standby setpoint.

Remote Standby An external signal has activated the remote standby mode and the

system is heating up to the remote standby setpoint.

Delay Standby The system is delaying for a set period of time before entering the remote

standby mode.

Manual Boost The user pressed the Manual Boost button and the system is heating to

the manual standby setpoint.

Remote Boost An external signal has activated the remote boost mode and the system

is heating up to the remote boost setpoint.

Delay Boost The system is delaying for a set period of time before entering Remote

Boost mode.

ART The Active Reasoning Technology (ART) tuning process is active.

Calibration A user is calibrating the thermocouple inputs for each zone.

Diagnostics The mold diagnostics process is active.

Firmware Update A firmware update is in process on the selected control cards.

Bake Out Cycle 1 The system is baking out moisture in the mold. This is the first attempt.

Bake Out Cycle 2 The system is baking out moisture in the mold. This is the second

attempt.

Bake Out Cycle 3 The system is baking out moisture in the mold. This is the third attempt.

Bake Out Cycle 4 The system is baking out moisture in the mold. This is the fourth attempt.

Bake Out Cycle 5 The system is baking out moisture in the mold. This is the fifth attempt.

Soft Start The system is heating all zones up to setpoint in a gradual and even

manner.

Soft Start to Manual
Standby

Soft Start to Remote
Standby

The user pressed the manual standby button while the system was in the
soft start process.

While the system was in the soft start process, an external signal was
activated to attempt to heat all zones up to the remote standby setpoint.

Stage x Active (Heating) All zones assigned to stage x (1-4) are heating to the stage setpoint.

Stage x Active (ART) The ART process is running on only the zones assigned to stage x.

Stage x Soaking
(Heating)

Stage x Active (Cooling) All zones assigned to stage x are cooling to the stage setpoint.

Stage x Soaking
(Cooling)

System Modes 21

After heating up, the system will maintain the stage x setpoint until the
soak timer expires.

After cooling down, the system will maintain the stage x setpoint until
the soak timer expires.

v 2.3 — September 2015 Altanium Delta3

System Mode Description

Stage 4 Running
Indefinitely

Bake Out Check The system is searching for any bake out conditions on any zone. These

Earth Leakage Check The system is searching for any earth leakage conditions on any zone.

Circuit Test The system is verifying that there are no heater circuit faults (open circuit,

4.1.6 Views Buttons

The Altanium views display zone data in various formats. Touch the desired view button to
open the associated view screen.

Table 4-2 Views Buttons

View Button Description

The system will remain in stage 4 until the user presses the Start button
to heat the zones to the normal setpoint.

bake out conditions would be less severe than a earth leakage.

short circuit, leakage or wrong heater) on any zones.

Touch the Neo2 View button to display the Neo2 View screen.

Touch the Multi Group View button to display the Multi Group View
screen, which contains zones organized into groups and allows
individual control of each group.

Touch the Graphical View button to display the Graphical View screen,
which contains a graphical representation of zone data.

22 Views Buttons

User Guide v 2.3 — September 2015 Altanium Operator Interface

Table 4-2 Views Buttons (Continued)

View Button Description

Touch the Text View button to display the Text View screen, which
contains a textual representation of zone data.

Touch the Mold Picture View button to display the Mold Picture View
screen, which provides a visualization of the mold or hot runner system
layout using an imported image file.

4.1.7 Temperature Control Shortcuts Buttons

The Altanium temperature control shortcuts buttons provide a link to the Quick Set screen
for those zones that are assigned to the associated group represented by the button. A
maximum of ten shortcut buttons can be displayed at once on the Home screen.

Table 4-3 Shortcut Button

Temperature Control

Shortcut Button

Touch the shortcut button to open the Quick Set screen and
automatically select the zones assigned to the group associated to the
shortcut.

4.1.7.1 Creating a Shortcut Button

To create a shortcut button, do the following:

Description

On the Quick Set screen, select a group of zones. Touch the Group Name parameter and
assign a group name to the selected zones. For each group created, a shortcut button
appears on the Home screen. For more information about creating a group, refer to

Section 7.2.

Temperature Control Shortcuts Buttons 23

4.1.8 Screen Buttons

The Home screen provides a single area for a user 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.

Table 4-4 Screen Buttons

Screen Description

Common Screens

v 2.3 — September 2015 Altanium Delta3

Alarms

Event History

Heat Screens

Process Targets

Process Trend

Process History

Quick Set

24 Screen Buttons

User Guide v 2.3 — September 2015 Altanium Operator Interface

Table 4-4 Screen Buttons (Continued)

Screen Description

ART Process

Zone Calibration

Zone Slot

Card Layout

Mold Diagnostics

Diagnostics Results

Energy Display

Screen Buttons 25

v 2.3 — September 2015 Altanium Delta3

Table 4-4 Screen Buttons (Continued)

Screen Description

Supply Voltage

Staging

System Configuration Screens

System Setup

Network Setup

Mold Setup

Digital I/O

User Management

26 Screen Buttons

User Guide v 2.3 — September 2015 Altanium Operator Interface

Table 4-4 Screen Buttons (Continued)

Screen Description

Servo I/O

This functionality is optional and the button appears on the Home
screen if the system is equipped with UltraSync-E control.

UltraSync-E Screens (If Equipped)

Main

Profile

Setup

4.2 Multi Group View Screen

Use the Multi Group View screen to view all user configured zone groups. Each group has
its own controls for synchronously turning all zones in the group on or off, and putting them
into standby or boost mode.

NOTE:For information about creating groups, refer to Section 7.2.

IMPORTANT!

The Stop, Start, Standby, and Boost buttons at the top left corner of the screen apply to all
zones and will override the group settings.

Multi Group View Screen 27

v 2.3 — September 2015 Altanium Delta3

Touch the column heading to sort the information in that column. A red line at the top of the
column header indicates the information is in ascending order. A red line at the bottom of
the column header indicates the information is in descending order.

NOTE:Touching the top right screen icon toggles the between a two column view and a

one column view.

Select a single zone or a block of zones to automatically open the Quick Set screen with that
zone or block of zones selected.

Figure 4-2 M ulti Group View Screen

Table 4-5 Buttons

Button Description

Expands all group information lists.

Collapses all group information lists.

28 Multi Group View Screen

User Guide v 2.3 — September 2015 Altanium Operator Interface

Table 4-5 Buttons (Continued)

Button Description

Expands the related group information list.

If this button is green, the actual temperature for all zones is within the
lower alarm limit.

If this button is black, the actual temperature for all zones is not within
the lower alarm limit.

Collapses the related group information list.

If this button is green, the actual temperature for all zones is within the
lower alarm limit.

If this button is black, the actual temperature for all zones is not within
the lower alarm limit.

Turns off the zones in that group if they are on.

Turns on the zones in that group if they are off.

Sets the zones in this group to manual standby. Multiple groups can
be place d in st andby at once. This button will be inactive if any groups
are in boost mode.

Sets the zones in this group to manual boost. Multiple groups can be
placed in boost at once. This button will be inactive if any groups are
in standby mode.

Multi Group View Screen 29

v 2.3 — September 2015 Altanium Delta3

1

Table 4-5 Buttons (Continued)

Button Description

Opens the Quick Set screen. Opening the Quick Set screen
automatically selects all zones in the group.

Opens the Color dialog box.

4.2.1 Changing the Header Color

Users can assign a header color to a group displayed on the Multi Group View screen. For
more information about creating a group, refer to Section 7.2.

To change the header color, do the following:

1. On the Multi Group View screen, touch the Color Change button.

Figure 4-3 M ulti Group View Screen

1. Color Change Button

30 Changing the Header Color

User Guide v 2.3 — September 2015 Altanium Operator Interface

2. Touch the desired color.

Figure 4-4 Color Change Dialog Box

3. Touch the Accept button.

Changing the Header Color 31

4.3 Selecting a Language

11

2

Altanium screens are available in several languages. The default language is English. Each
screen contains a globe icon which displays the available languages.

To select a language, do the following:

1. Touch the Language Selection button. The Language dialog box appears.

v 2.3 — September 2015 Altanium Delta3

Figure 4-5 Language Selection

1. Current Language/Language Selection 2. Language Selection Button

2. Touch the desired language.

32 Selecting a Language

User Guide v 2.3 — September 2015 Altanium Operator Interface

Figure 4-6 Language Selection Dialog Box

3. Touch the Close button.

4.4 Printing to a File

To open the Print dialog box, touch the Print button on any Altanium screen. For more
information, refer to Section 4.1.3.4. Files will be saved in System\Reports folders.

To print a single file, do the following:

1. Touch the Print button.

2. Select the desired report type.

3. Select the desired file format.

4. Touch the Accept button to save the selected content to a System\Reports folder.

5. Copy the content saved to a USB drive or Network as desired.

Continuous Printing allows the user to set up print reports at specified intervals. Users can

select the type of report to be generated (Reports Type) and File Format. Users can also
specify print interval and duration time. Files will be generated after each interval timer
expires. At the specified duration time, or when the user clicks the “Stop” button, continuous
printing will be terminated. The generated files contain the same information as with single
file printing.

To print to a file using the Continuous Printing feature, do the following:

1. Expand the Continuous Printing button.

2. Select the desired report type.

3. Select the desired file format.

4. Select the desired print interval.

5. Select the desired print duration.

Printing to a File 33

v 2.3 — September 2015 Altanium Delta3

6. Touch the Start button to initiate the continuous printing.

7. Copy the content saved to a USB drive or Network as desired.

Figure 4-7 P rint Dialog Box

Table 4-6 Print Dialog Box Item Descriptions

Item Description

Report Type Select the types of information to print:

• Zone Information - Brief

• Zone Information - Full

• Diagnostics Results

• Setup

• Screen Image

File Format Select the file format to print. Select one of the following:

• .TXT format

• .CSV format

Accept Button Saves changes made in the print dialog box and starts the printing

process.

Cancel Button Cancels the selected printing request.

34 Printing to a File

User Guide v 2.3 — September 2015 Altanium Operator Interface

4.4.1 Print Report Descriptions

This section provides a description of each print report.

Generated files will automatically be saved to one of the following paths:

• System\Reports\Zones

• System\Reports\Diagnostics

• System\Reports\Setups

• System\Reports\Screens

Print Report Type Description

Brief Zone Information From the Text View screen, print the following columns to file:

• zone number

• setpoint and units

• actual temperature and units

Detailed Zone Information From the Text View screen, print the following to file:

• Zone Number

• Zone Name

• Setpoint

• Temperature

• Power

• Amperage

• Alarm Limit

• Abort Limit

• Regulation Mode

• Watts

• 240V Watts

• Volts AC

• Resistance

Diagnostics Results From the Test Results screen, print the following to file:

• Zone Number

• Zone Name

• Sensor

• Fuses

• T/C

• Amperage

• Volts AC

• Watts

• Resistance

• Wiring

• Isolation

• Earth Leakage

• Bake Out

• Time

Print Report Descriptions 35

v 2.3 — September 2015 Altanium Delta3

Print Report Type Description

Mold Setup Configuration • Zone Number

• Zone Name

• Setpoint

• Minimum Setpoint Limit

• Maximum Setpoint Limit

• Power Limit

• Alarm

• Abort

• AMC

• PCM

• Regulation

• Manual Standby Setpoint

• Remote Standby Setpoint

• Manual Boost Setpoint

• Remote Boost Setpoint

• Sensor input

• Slave To

• Output (Zero Cross or Phase Angle)

• Earth Leakage Enable

• Control (PID or ART)

• P (Proportional)

• I (Integral)

• D (Derivative)

Screen Image Saves the current user interface screen to file in an image file format

4.5 Network Settings

On the Network Setup screen, the user can enter the network path for the shared network
folder for uploading files from or downloading files to the controller, in the format
\\server\shared folder. The controller uses the following network user credentials:
User Name: husky
Password: husky

To modify the network settings, do the following:

1. On the Home screen, touch the Network Setup button.

2. Touch the Network Locations field and enter the required information.

3. Touch the Accept button.

(.png).

36 Network Settings

User Guide v 2.3 — September 2015 Altanium Operator Interface

Figure 4-8 Network Setup

4.6 Supply Voltage Screen

The Supply Voltage screen displays a graphical view of the phase pairs based on the Supply
Configuration parameter selected in the System Setup screen:

• Delta 3PH

• Wye 3PH+N

• Single Phase

• Integrated TX

4.6.1 Viewing the Supply Voltage

To view the Supply Voltage screen, do the following:

On the Home screen, touch the Supply Voltage button. The Supply Voltage screen
displays for the type of configuration selected.

Supply Voltage Screen 37

v 2.3 — September 2015 Altanium Delta3

Figure 4-9 Wye 3PH+N Supply Voltage Screen

Item Description

Schematic The image is a visual representation of the supply configuration

Zone # Zone number of all the zones associated with a phase pair

Phase Pair Phase pair label associated with the supply configuration graphic

Volts The average voltage value for all the zones associated with a phase

Amps The average amperage value for all the zones associated with a phase

NOTE:The amperage value displayed shows one decimal place for systems with ICC

installed and two decimal places for systems with ICC
and amperage values display “---” if the voltage and amperage is not calibrated for all
the zones associated with a particular phase. The amperage value also displays “---” if
all of the zones associated with a particular phase are XL or HL cards.

3

cards installed. Both voltage

2

cards

38 Viewing the Supply Voltage

User Guide v 2.3 — September 2015 Altanium Operator Interface

Figure 4-10 Delta 3PH Supply Voltage Screen

Figure 4-11 Single Phase Supply Voltage Screen

Viewing the Supply Voltage 39

v 2.3 — September 2015 Altanium Delta3

Figure 4-12 Integrated TX Supply Voltage Screen

4.6.2 Configuring the Supply Voltage

The Altanium system is configured at the factory for the supply configuration. If the system
is shipped to another location where the power configuration is different (for example:
another country), the setting may need to be changed.

To configure the supply voltage, do the following:

1. On the Home screen, touch the System Setup button.

2. Under Voltage Settings, touch the Supply Configuration field.

40 Configuring the Supply Voltage

User Guide v 2.3 — September 2015 Altanium Operator Interface

11

Figure 4-13 System Setup Screen

1. Supply Configuration Field

3. Select the correct supply configuration.

Figure 4-14 Supply Configuration Dialog Box

Configuring the Supply Voltage 41

4.7 Using Online Help

The online help consists of a pdf file of the Altanium Delta3 User Guide.

To use the online Help, do the following:

1. Touch the Help button on any Altanium screen.

2. To close the pdf file, touch the Exit button.

v 2.3 — September 2015 Altanium Delta3

42 Using Online Help

User Guide v 2.3 — September 2015 Security and Administration

Chapter 5 Security and Administration

This chapter describes user management functions.

5.1 User Management and Security Screens

Roles are assigned to allow users access to different features by limiting certain screens to
each role level.

Table 5-1 User Roles

Role Definition

Operator Edit screen data as defined by Administrator

Supervisor Edit screen data, including extended

responsibility of certain screens as defined by
Administrator

Administrator All the features of Supervisor plus the ability to

create, delete, rename and assign all roles

The system administrator manages users and controls security settings for each user.
Administrators have the ability to add a user, change a user password, and delete a user using
the User Management screen.

To manage users and control user security settings, do the following:

1. Log in with Administrator privileges.

2. On the Home screen, touch the User Management button.

User Management and Security Screens 43

v 2.3 — September 2015 Altanium Delta3

1

3. Touch the Screen Security button.

Figure 5-1 User Management Screen

1. Screen Security Button

44 User Management and Security Screens

User Guide v 2.3 — September 2015 Security and Administration

4. On the Security screen, select a user type (Administrator, Supervisor, Operator, or
Default User) for each of the following settings.

Figure 5-2 Security Screen

User Management and Security Screens 45

v 2.3 — September 2015 Altanium Delta3

Table 5-2 Security Screen

Item Description

Enable User Security Permission to enable/disable the user security feature.

Basic Controller
Operation

Clear Inactive Alarms Permission to clear audible alarms on the Alarms screen.

Reset Alarms Permission to reset audible alarms on the Alarms screen.

Auto Logout Permission to configure the auto logout parameter in the User

Machine Units Permission to change the controller units of measurement and Force

Process Limits Edit Permissions to operate functions on the Process Targets screen; however,

Printing Permission to operate the print feature.

Network Setup Permission to operate the network setup functions and the dashboard

Remote Access Permission to operate the Remote Service Assistant utility on the

Digital I/O
Configuration

Permissions to operate the major controller function buttons: Start,
Standby, and Boost. Stop is always available. This setting also grants
permission to operate the UltraSync-E Control mode buttons. For more
information about buttons, refer to Section 4.1.3.

Management screen

Temperature Units parameter on the System Setup screen.

the Default user has permission to change the Grid Selection field.

application parameters on the Network Setup screen.

Network Setup screen.

Permission to configure the digital I/O on the Digital I/O screen.

Log Transfer Permission to download in the event log or data log in the Log Transfer

section of the System Setup screen.

Options and
Licensing

Multi Group
Operations

Mold Picture View
Edit

ART Process Permission to operate the ART screen functions.

Mold Diagnostic
Operations

Energy Permission to manage the Altanium energy settings on the Energy

Staging
Configuration

Global Output Power
Limit

Permission to load a license file that enables the options a user has
purchased.

Permission to operate the Multi-Group screen functions.

Permission to use the edit function on the Mold Picture View screen.

Permission to operate the Mold Diagnostic screen functions.

Display screen.

Permission to configure all the parameters in the Staging screen.

Permission to configure the global output power limit parameter in the

System Setup

screen

46 User Management and Security Screens

User Guide v 2.3 — September 2015 Security and Administration

Table 5-2 Security Screen (Continued)

Item Description

Monitor Zone
Settings

Part Counting Setup Permission to setup part counting on the System Setup screen.

Temperature
Calibration

Autoslave Enable Permission to enable the autoslave function on the System Setup screen.

Autoslave Setup Permission to set up autoslave settings on the System Setup screen.

Soft Start Enable Permission to enable soft start on the System Setup screen.

Soft Start Setup Permission to set up soft start on the System Setup screen.

Mold Setup Auxiliary
Actions

Mold Setup Load
Action

Mold Setup Save
Action

Quick Set Advanced
Options

Permission to configure the parameters in the Monitor Zone Settings area
of the System Setup screen.

Permission to use the parameters in the Calibration screen to calibrate
temperatures.

Permission to view files (mold setups, images, txt files and PDF documents)
and operate the following buttons on the Mold Setup screen: Create
Folder, Delete, Copy, Paste, and Rename.

Permissions to load a mold setup configuration file and to create a new
mold setup configuration file on the Mold Setup screen.

Permission to save changes to the mold setup files and use the Save As
function on the Mold Setup screen.

Permissions to make changes to the fields in the following sections on the

Quick Set screen: Frequently Used, Zone Edit, Advanced Options, and
Control Settings.

Quick Set
Temperature
Setpoints Options

Quick Set Standby
and Boost Setpoints
Options

Earth Leakage Fault
Enable

Earth Leakage Fault
Setup

Bake Out Enable Permission to enable the bake out function on the System Setup screen.

Bake Out Setup Permission to configure the bake out function on the System Setup

Permission to change the fields in the Setpoint Limit section on the Quick
Set screen.

Permission to change the fields in the Manual Standby, Manual Boost,
Remote Standby and Remote Boost

Permission to select and clear the Earth Leakage Fault Enable check box
on the System Setup screen.

Permission to operate the following parameters on the System Setup
screen:

• Earth Leakage Limit field

• Earth Leakage Limit Default Value field

• Earth Leakage Minimum Limit field

• Display Earth Leakage Reading checkbox

• Circuit Overload Enable checkbox

• Circuit Test Enable checkbox.

screen.

sections on the Quick Set screen.

User Management and Security Screens 47

v 2.3 — September 2015 Altanium Delta3

Table 5-2 Security Screen (Continued)

Item Description

Thermocouple
Reading

Power Deviation Permission to select the Setup Alarm button in the Power Deviation

Zone Slot
Configuration

Zone Alarm Control Permission to configure all the parameters in the Zone Alarm Control area

Mold Cooling Enable
Limit

Remote Load Setup Permission to configure all the parameters in the Remote Load Setup

SPI Permission to configure the SPI parameters on the System Setup screen.

Wattage Voltage Permission to change the wattage voltage parameter on the System

Supply Configuration Permission to select a parameter for the supply configuration on the

Permission to select and clear the Display Thermocouple Reading for
Manual Zones check box on the System Setup screen.

section on the System Setup screen.

Permissions to operate the Zone Slot Configuration fields on the System
Setup screen and the fields on the Zone Slot Configuration screen.

of the System Setup screen.

Permission to change this parameter in the Mold Cooling Enable area of
the System Setup screen.

dialog. This option must be purchased before the user can access this
dialog.

Setup screen.

System Setup screen.

5.1.1 Manage Users

HMI Administrators have the ability to create a user, change a user’s password, and delete a
user using the User Management screen.

To manage users, do the following:

1. Log in with Administrator privileges.

2. On the Home screen, touch the User Management button.

3. Choose the desired function.

4. Fill in the fields as applicable.

48 Manage Users

User Guide v 2.3 — September 2015 Security and Administration

1

2

3

Figure 5-3 Manage Users

1. Add User 2. Change User Settings 3. Delete User

5.1.2 User Preferences

If a user is logged into the system and makes changes to the unit of measurement or
language selection, these values will be saved to that user’s profile after logout and will be
recalled the next time the same user logs in again.

Table 5-3 Manage Users Buttons

Button Description

Touch the Add User button to add a user to the system.

Touch the Change User Settings button to modify the user name,
password or user role for a given user.

Touch the Delete User button to remove a user from the system.

User Preferences 49

5.1.3 Auto Logout

1

2

A system-wide timer will log the user off if there is no touch screen activity within a specified
timeout period. The default setting is five minutes. The minimum value is 10 seconds.

To change the auto logout timeout period, do the following:

1. Log in with Administrator privileges.

2. On the Home screen, touch the User Management button.

3. Touch the timer, and enter the desired value.

To edit settings for specified users, use the Screen Security screen.

v 2.3 — September 2015 Altanium Delta3

Figure 5-4 Manage Users

1. Auto Logout Timer 2. Screen Security Button

50 Auto Logout

User Guide v 2.3 — September 2015 Mold Setups

Chapter 6 Mold Setups

A mold setup contains the process parameters required by Altanium to operate the hot
runner system for that particular mold. On the Home screen, touch the Mold Setup button
to open the Mold Setup screen. This screen can also be accessed from any screen by
touching the Mold Setup Info button in the system footer.

6.1 Mold Setup Screen

The Mold Setup screen is used to store and manage files such as mold setups, images,
documents and reports. Files are organized in a tree structure and are stored in mold, system
and user folders. Each mold folder allows the storage of mold setups, images and documents
associated with that specific mold. The screen is divided into two panes. The left side
contains all directories that are on the systems local hard drive and the right side displays all
available directories and files from an external source, such as a USB disk or a network file
share.

Figure 6-1 M old Setup Screen

Mold Setup Screen 51

v 2.3 — September 2015 Altanium Delta3

Table 6-1 Mold Setup Screen Item Descriptions

Item Description

File Tree The local drive holds all stored data contained within the Mold Setup

screen. To assist in better organizing and storing files, there are three root
directories included by default. They are the Mold folder, System folder
and Users folder.

USB storage devices and network folders are displayed by default on the
right, when connected to the system.

Molds Folder The Molds folder is used to manage files associated with a given mold by

storing them in user defined sub folders. The Default folder is located
within this directory and contains the master mold file that contains the
factory default settings.

System Folder Touch the System folder to display all reports and documents contained

within the selected system folder.

Users Folder Touch the Users folder to display files associated with a given operator.

Table 6-2 Mold Setup Screen Button Descriptions

Button Description

Touch the Help button for a description of the mold setup icons.

Touch the New Folder button to create a new tool (mold) subfolder in the
Molds main folder.

Touch the New Mold Setup button to create a new mold setup file. All
new mold setup files are created based on the settings contained in the
Default mold setup file. This button is not enabled unless a mold folder is
selected.

Touch the Load Mold Setup button to load a mold setup file. This button
is not enabled unless a mold setup file is selected. The Default setup file
cannot be loaded directly.

Touch the Save Changes button to permanently save all changes to the
currently loaded mold setup file. This action only pertains to the loaded
mold setup file regardless of what is selected on the screen.

Touch the Save As button to save the currently loaded mold setup file
with a new name. This action only pertains to the loaded mold setup file
regardless of what is selected on the screen.

52 Mold Setup Screen

User Guide v 2.3 — September 2015 Mold Setups

Table 6-2 Mold Setup Screen Button Descriptions (Continued)

Button Description

Touch the Discard Changes button to revert the currently loaded mold
setup file to the state after it was last saved (using the Save Mold Setup
button). All unsaved changes will be discarded. This action only pertains to
the loaded mold setup file regardless of what is selected on the screen.

Touch the Copy button to copy mold setups, images or documents.

Touch the Paste button to paste copied mold setups, images, documents
or notes from one folder or device to another.

Touch the Delete button to delete a mold folder, mold setup, image or
document. A confirmation message is shown. This button is not available
unless a folder or file is selected.

Touch the Rename button to display a keyboard to rename a mold folder,
mold setup, image, note or document. This button is not enabled unless a
file or folder is selected.

Touch the Preview button to display mold setup files, images, and
documents.

6.1.1 Creating a New Mold Setup Folder

Use a Mold Setup folder to store multiple mold setup files.

To create a new Mold Setup folder, do the following:

1. Touch the New Folder button.

2. Enter the name of the new mold folder.

3. Touch the Accept button.

The new Mold Setup folder is now displayed under the Molds directory.

6.1.2 Creating a New Mold Setup File

Once a Mold Setup folder has been created, a new mold setup file can be added to it.

When a new mold setup file is created, and the Default folder contains only the Default mold
setup file, the factory default setup file is copied and used as a starting point.

Creating a New Mold Setup Folder 53

v 2.3 — September 2015 Altanium Delta3

If the Default folder contains a user supplied setup file named “New Setup”, the new setup
file is a copy of the 'new setup' file. The user can create this 'New Setup' file by first copying
an existing setup file, renaming the file to 'New Setup' then copying the file to the Default
folder. The intention is to provide a user specified starting point for all setup files instead of
the factory default.

To create a new mold setup file, do the following:

1. On the Mold Setup screen, touch the desired mold folder.

2. Touch the New Mold Setup button. A dialog box will open.

3. Enter the name of the new mold setup.

4. Touch the Accept button.

6.1.3 Saving Changes to a Mold Setup File

Once a Mold Setup file has been loaded, any changes made to it can be permanently saved.

To permanently save changes to a Mold Setup file do the following:

1. On the Mold Setup screen, touch the Save Changes button. This will display the Mold
Setup - Save dialog box for confirming the mold and name of the file that the changes

are to be saved to.

2. Touch the Accept button.

All changes have now been permanently saved to the currently loaded Mold Setup File.

6.1.4 Discarding Changes to a Mold Setup File

All changes to a mold setup file are held in the system's data base until they are permanently
saved or discarded. Discarding changes will take the mold setup file back to its state after that
last save was performed.

To discard changes to a Mold Setup file, do the following:

1. On the Mold Setup screen, touch the Discard Changes button. This will display the
Mold Setup - Discard dialog box for confirming the mold and name of the file that the

changes are to be discarded from.

2. Touch the Accept button.

All changes have now been permanently discarded from the currently loaded Mold
Setup File.

6.1.5 Saving the Current Mold Setup File as a New File

Once a Mold Setup file has been loaded, it can be saved as a new file.

To save the currently loaded Mold Setup file as a new file, do the following:

1. On the Mold Setup screen, touch the Save As button. This will display the Mold Setup

- Save As dialog box for confirming the mold and new name of the file.

2. Touch the Accept button.

54 Saving Changes to a Mold Setup File

User Guide v 2.3 — September 2015 Mold Setups

6.1.6 Loading an Existing Mold Setup File

After a Mold Setup file has been created it is automatically loaded as the current Mold Setup
in the system.

To load a different Mold Setup, do the following:

1. On the Mold Setup screen, select the Mold Setup folder that contains the Mold Setup
file to be loaded.

2. Touch the name of the mold setup file to be loaded.

3. Touch the Load Mold Setup button to load the selected mold setup.

Once a mold setup is loaded, its name will be displayed at all times on the Mold Setup
Info button in the System Footer.

6.1.7 Deleting Files

When a file or folder is no longer required on the internal disk, it can be deleted.

To delete a file or folder, do the following:

1. On the Mold Setup screen, touch the file or folder to be deleted.

2. Touch the Delete button.

3. A message appears asking to confirm the deletion. To continue, touch the Accept
button. To cancel the deletion, touch the Cancel button.

6.1.8 Copying Files

Mold setups, images, documents or notes can be copied from one folder or device to
another. Only files from folders with the same name or type can be copied into that folder.
For example: a mold setup file can be pasted only into a mold setup folder.

To copy and paste a file, do the following:

1. On the Mold Setup screen, touch the file to be copied.

2. Touch the Copy button.

3. Navigate to the destination folder, and then touch the Paste button to create a copy of

the file.

6.1.9 Renaming Files

To rename a file or folder, do the following:

1. On the Mold Setup screen, touch the file or folder to be renamed.

2. Touch the Rename button and enter the new name.

3. Touch the Accept button to save the name of the file.

Loading an Existing Mold Setup File 55

v 2.3 — September 2015 Altanium Delta3

6.1.10 Transferring Data to the Network

Use the Mold Setup screen to transfer Altanium data to the network. When Altanium is
connected to the network, the network folder structure appears by default on the Mold
Setup screen. The network folders disappear when a USB device is plugged in.

6.1.11 Transferring Data Using a USB Storage Device

Altanium data can be transferred using USB disks or USB CD-ROM drives. When one of these
devices is plugged into the USB port, the folder structure of the USB storage device appears
on the right side of the Mold Setup screen. The icon disappears when the device is
unplugged. To load the files, copy and paste files from the USB disk to the local drive.

56 Transferring Data to the Network

User Guide v 2.3 — September 2015 Making Adjustments

Chapter 7 Making Adjustments

Adjustments can be made to the process settings for a mold setup before starting the mold,
or while the mold is running. This chapter explains how to use Altanium to monitor and
modify the system.

Altanium allows zone data to be displayed in different graphical and textual formats. These
include tabular views, images with text assigned to them and views that are divided into
groups of zones.

7.1 Zone Selection

Multiple zones can be selected from the following screens:

• Multi Group View

• Graphical View

• Text View

• Quick Set

• Art Process

• Mold Diagnostics Results

• Zone Calibration

• Zone Slot

• Staging

Zone can also be selected from the following screens:

• Neo2 View

• Mold Diagnostics

• Process Targets

There are three methods to select zones within a screen:

• Touching an individual zone element. The individual zone will become selected.

• Touching the Select All button to select all the available zone elements.

• Using the Block function. The block function works by touching and holding a zone

element for up to a second. This will highlight the zone yellow and/or place a gray
border around it. A user can then touch any other zone element within the screen and
the block of zones between the first and second selections will automatically be
selected.

Zone Selection 57

v 2.3 — September 2015 Altanium Delta3

132

1

Figure 7-1 Zone Selection

1. Blocked Zone 2. Select All Button 3. Clear All Button

7.2 Creating a Group

Use the Quick Set screen to select multiple zones to form a group.

To create a group, do the following:

1. On the Quick Set screen, touch and hold the first zone to select for one second.

2. Touch the last zone to select. All zones in between will be selected and highlighted in

yellow.

3. Touch the Zone Edit button.

4. Touch the Group Name field and enter a group name.

58 Creating a Group

User Guide v 2.3 — September 2015 Making Adjustments

1

2

A shortcut to the newly created group appears on the Home screen and is displayed
with the selected zones highlighted.

Figure 7-2 Quick Set Screen

1. Zone Edit 2. Group Name

7.3 Graphical View Screen Overview

The Graphical View displays zones in a graphical format. It is designed to provide an easy
way to view the overall status of the mold without having to sort through detailed data. This
screen can be accessed by touching the Graphical View button on the Home screen.

Graphical View Screen Overview 59

v 2.3 — September 2015 Altanium Delta3

1

2

3

4

Figure 7-3 Graphical View Screen - Split Screen Mode

1. Config Button 2. Zone Bars 3. Amperage Bars 4. Power Bars

60 Graphical View Screen Overview

User Guide v 2.3 — September 2015 Making Adjustments

Item Description

Temperature Bars Each individual bar on the screen represents a single zone of temperature

control. Each bar is labeled above with the zone number. The text shown
at the base of each bar is the actual temperature for that zone.

The different colors in each bar have a different meaning.

• The green area represents the molding window.

• The white hairline represents the setpoint.

• An arrow represents the actual temperature.

• If the arrow is yellow, the temperature is not within the graph

range.

• If the arrow is black and splits the line, the temperature is at the
setpoint.

• The yellow area in the zone bar represents the alarm window

• The red and blue areas in the zone bar represents the abort window.

• A blank gray bar indicates that the zone is turned off.

Amperage Bars The amperage bars, directly below the zone bars, are light blue. These

show the amperage being drawn by each heater. The text shown at the
base of each bar is the actual current reading for that zone.

Power Bars The power bars are located directly below the amperage bars. These

show the percentage of power being applied to the heater. The text at
the base of each bar is the actual power output percentage being
delivered to that zone.

• If a zone is in Auto (closed loop) regulation, the bar will fill with
orange depending on the percentage of power output.

• If a zone is in Manual (open loop) regulation, the bar will fill with
green depending on the percentage of power output.

• If a zone is set to Monitor mode, the bar will remain grey (there is no
power output for zones set to Monitor mode).

Graphical View Screen Overview 61

v 2.3 — September 2015 Altanium Delta3

Table 7-1 Graphical View Screen Button Descriptions

Button Description

Config Button Touch this button to toggle between displaying zones in split or full

screen mode. In split screen mode, zone graphs are displayed in two
groups, one on the top and one on the bottom. In full screen mode the
zone graphs take up the whole viewing area.

Scroll Bar Use the scroll bar to scroll between pages within a screen. If all of the

available data fits with in a single page, then the scroll bar will not be
displayed.

Select All Touch this button to select all zones in the system. This will navigate to

the Quick Set screen

Clear All Touch this button to clear all zone selections.

The Graphical View screen displays a maximum of 48 zones of information in split screen
mode and 24 zones in full screen mode. Touch and drag the scroll bar to bring additional
zones into view. The system always displays up to 24 or 48 zones at one time, depending on
the screen mode.

Figure 7-4 Graphical View Screen - Full Screen Mode

62 Graphical View Screen Overview

User Guide v 2.3 — September 2015 Making Adjustments

7.4 Text View Screen Overview

The Text View screen displays zone information in a textual format. It is used to access
detailed data for each zone and provides the most comprehensive view of the process. This
screen can be accessed by touching the Text View button on the Home screen.

Figure 7-5 Text View Screen - Split Screen Mode

Text View Screen Overview 63

v 2.3 — September 2015 Altanium Delta3

Table 7-2 Text View Screen Button Descriptions

Button Description

Zone Row Each row in the Text view represents a heating zone in the system.

Touching anywhere within the row will navigate to the Quick Set screen

Column Header Each header in the Text view indicates what information is being

displayed in each column. Touching the header will sort the values in the
column by ascending or descending order. This is indicated by a red line
at either the top of bottom of the header cell. The available parameters
are as follows:

• Zone = Zone number

• Name = Zone name

• Setpoint = Zone setpoint

• Temp = Actual temperature of zone

• PWR = Power output to the heater

• Leakage = Earth leakage (This column is only displayed when H

cards are installed and the value has been selected for viewing in
the system setup screen)

• Amps = Current draw of heater (Values in this column are
suppressed for XL and HL cards)

• Alarm = Alarm window (Degrees above and below setpoint before
an alarm condition is declared)

• Abort = Abort window (Degrees above and below setpoint before
an abort condition is declared)

• Regulation = Control mode (Auto = T/C control, Manual = Fixed %
output, Monitor = Temperature only - No power output)

• Watts = Calculated wattage of each heater (Values in this column
are suppressed for XL and HL cards)

• 220VW = Derated heater wattage based on supply voltage vs.
design voltage (Values in this column are suppressed for XL and HL
cards)

• VAC = Output voltage to heaters (RMS voltage calculation based on
the power percentage being applied to the heater)

% Power X Input Voltage (Values in this column are suppressed for

XL and HL cards)

• Resistance = Calculated ohm reading for each zone (Must run mold
diagnostics first) (Values in this column are suppressed for XL and
HL cards)

Config Touch this button to toggle between the split and full screen views. The

split view configures the screen in two sections of 18 zones to maximize
the number of zones that can be viewed on a page, while the full view
reduces the number of zones to 18, but increases the available zone
parameters that can be viewed

Scroll Bar Use the scroll bar to scroll between pages within a screen. If all of the

available data fits with in a single page, then the scroll bar will not be
displayed

64 Text View Screen Overview

User Guide v 2.3 — September 2015 Making Adjustments

Table 7-2 Text View Screen Button Descriptions (Continued)

Button Description

Select All Touch this button to select all zones in the system. This will navigate to

the Quick Set screen

Clear All Touch this button to clear all zone selections

Figure 7-6 Text View Screen - Full Screen Mode

7.4.1 Zone Selection in the Text View Screen

Use the Text View screen to select one or multiple zones.

• To view one zone, touch the desired zone text.

• To view multiple zones, touch and hold the first zone for one second. Then touch the last

zone.

7.4.2 Sorting

Information can be sorted on the Text View screen by selecting the header field of each
column. Sorting can be in ascending or descending order. A red line denotes the current
sorting.

Zone Selection in the Text View Screen 65

Information can be sorted according to the dynamic columns (for example, current (Amps),
voltage (VAC), etc.). This can be helpful when trying to figure out which zone is drawing the
most current at any moment. The ability to select column headings in order to sort
information is used throughout Altanium.

7.5 Quick Set Screen

Use the Quick Set screen to change any of the available zone settings. On the Home screen,
touch the Quick Set button.

v 2.3 — September 2015 Altanium Delta3

Figure 7-7 Quick Set Screen

66 Quick Set Screen

User Guide v 2.3 — September 2015 Making Adjustments

7.5.1 Frequently Used Fields

Item Description

Temperature Setpoint Touch this field to display a keypad for adjusting a zone(s) setpoint in

Auto or Monitor regulation.

Power Setpoint Touch this field to display a keypad for adjusting the percentage of

power output when a zone(s) is in Manual regulation.

Zone On/Off Touch this field to turn the selected zone ON or OFF. A dialog appears and

allows the user to choose a value. The default is ON.

Regulation Mode This setting allows users to set the regulation mode for the selected zone.

AUTO or Automatic (closed loop) means the system will use a
thermocouple to control the temperature. MAN or Manual (open loop)
means the system will only apply power (0 to 100%) to the heater and not
look for thermocouple feedback. MON or Monitor means the system will
only monitor the temperature of a thermocouple (no power output).

Alarm Window Touch this field to display a keypad for adjusting the upper and lower

alarm limits.

Abort Window Touch this field to display a keypad for adjusting the upper and lower

7.5.2 Zone Edit Fields

Item Description

Zone Name Touch this field to display a keyboard for assigning a custom name to a

Group Name Touch this field to define a name for a group of selected zones. All zones

Zone Locked/Unlocked Touch this field to display a dialog to lock or unlock zone(s). If a zone(s) is

Display/Hide Zone Touch this field to display a dialog to display or hide a zone(s). If hide is

abort limits.

zone or group of zones.

assigned a group name are used to create group views in the Multi Group
View as well as create a Shortcut Icon button in the Shortcut section on
the Home screen.

locked, it will prevent any changes from being made to it from the Quick
Set screen.

selected, the zone(s) will be removed from all the Zone Data View
screens.

Frequently Used Fields 67

7.5.3 Setpoint Limits

Item Description

v 2.3 — September 2015 Altanium Delta3

Temperature Minimum

Temperature Maximum

Power Minimum

Power Maximum

7.5.4 Manual Standby Fields

Item Description

Temperature The temperature all zones are set to when the Standby button is

Temperature Minimum

Temperature Maximum

Power The power output all zones are set to when the Standby button is

The minimum and maximum values limit what temperature the
temperature setpoint can be changed to.

The minimum and maximum values limit what temperature the power
setpoint can be changed to.

touched. This setting can be used to lower all zone temperatures to their
manual standby temperature setpoint until the timer expires or the user
touches the Standby button again. Possible values are 0 to 500°C or 32 to
932°F. The default value is 121°C or 250°F.

Limits the range that can be entered for Standby temperature.

touched. This setting can be used to lower all zone power setpoints to
their manual standby power setpoint until the timer expires or the user
touches the Standby button again. Possible values are 0% – 100%. The
default value is 10%.

Power Minimum

Limits the range that can be entered for Standby power.

Power Maximum

7.5.5 Manual Boost Fields

Item Description

Temperature The temperature all zones are set to when the Boost button is touched.

This setting raises all zones to their manual boost setpoint until the timer
expires or the user touches the Boost button again. Possible values are 0
to 500°C or 32 to 932°F. The default value is No Change.

Temperature Minimum

Limits the range that can be entered for Boost Temperature.

Temperature Maximum

68 Setpoint Limits

User Guide v 2.3 — September 2015 Making Adjustments

Item Description

Power The power values all zones are set to when the Boost button is touched.

This setting raises all zones to their manual boost setpoint until the timer
expires or the user touches the Boost button again. Possible values are
0% – 100%. The default value is 90%.

Power Minimum

Power Maximum

7.5.6 Remote Standby Fields

Item Description

Temperature Remote standby is initiated via a digital input signal from the IMM. This

Temperature Minimum

Temperature Maximum

Power Remote standby is initiated via a digital input signal from the IMM. This

Limits the range that can be entered for Boost power.

setting lowers all zones to their remote standby setpoint until the timer
expires or the input is inactive. Possible values are 0 to 500°C or 32 to
932°F. The default value is 121°C or 250°F.

Limits the range that can be entered for Remote Standby Temperature.

setting lowers all zones to their remote standby setpoint until the timer
expires or the input is inactive. Possible values are 0% – 100%. The default
value is 10%.

Power Minimum

Power Maximum

7.5.7 Remote Boost Fields

Item Description

Temperature Remote boost is initiated via a digital input signal from the IMM. This

Temperature Minimum

Temperature Maximum

Power Remote boost is initiated via a digital input signal from the IMM. This

Limits the range that can be entered for Remote Standby Power

setting raises all zones to their remote boost setpoint until the timer
expires or the input is inactive. Possible values are 0 to 500°C or 32 to
932°F. The default value is No Change.

Limits the range that can be entered for Remote Boost Temperature.

setting raises all zones to their remote boost setpoint until the timer
expires or the input is inactive. Possible values are 0% – 100%. The default
value is 90%.

Remote Standby Fields 69

Item Description

Power Minimum

Power Maximum

7.5.8 Advanced Settings Fields

Item Description

Output Power Limit Touch this field to display a keypad for adjusting the maximum

Slaved To Zone Slaving is sometimes necessary when a zone's thermocouple fails during

v 2.3 — September 2015 Altanium Delta3

Limits the range that can be entered for Remote Boost Power.

percentage of power output that the system will be allowed to deliver to
a zone(s).

normal operation. Once a master zone is specified, the zone is able to
continue operation. The Slave To setting allows users to use the master
zone's power output percentage for the selected zone. A value of None
means that the selected zone is not slaved to any other zone.

Thermocouple
Assignment

Output Mode Changes the power output modulation for a zone during normal

Heater Type Select one of the following heater types: none, tips, manifold, or sprue.

AMC - Automatic
Manual Control

PCM - Priority Control
Mode

Earth Leakage Enable Allows users to turn on and off the Earth Leakage checking feature for

7.5.9 Control Settings Fields

Item Description

The number of the thermocouple to which the zone is connected.

operation. Choices are Zero Cross or Phase Angle.

These settings are used to configure the power deviation alarm.

Automatic Manual Control (AMC) allows Altanium to automatically apply
a manual power output percentage to a heater based on a historical
average in the event a thermocouple fails.

The Priority Control Mode (PCM) controls how the controller will react in
the case of an abort condition.

each zone.

Control Mode ART automatically adjusts the control algorithm to suit different heater

requirements. If a zone is not controlling properly the system allows users
to switch from the automatically adjusted ART algorithm to an algorithm
that can be manually adjusted (PID).

P-Proportional This is the proportional term value used by the control algorithm.

Possible values are: 0 – 250.

70 Advanced Settings Fields

User Guide v 2.3 — September 2015 Making Adjustments

Item Description

I-Integral This is the integral term value used by the control algorithm. Possible

values are: 0 – 250.

D-Derivative This is the derivative term value used by the control algorithm. Possible

values are: 0 – 250.

7.5.10 Changing a Zone Name

Customize the name of each zone in the system to make it easier to find and make changes.
Rename each zone to correspond with a cavity, gate, probe or manifold, or to any
appropriate name.

To rename a zone, do the following:

1. Touch the zone to be renamed.

2. Touch the Zone Name field and enter a new zone name.

NOTE:Refer to Section 7.5.10.1 for information about renaming multiple zones.

To select commonly used zone names, use the following keys:

• zone

• probe

• tip

• nozzle

• sprue

• manifold

• bridge

• valve gate

• not used

Figure 7-8 Zone Name Dialog Box

3. Touch the Accept button.

Changing a Zone Name 71

v 2.3 — September 2015 Altanium Delta3

7.5.10.1 Changing Multiple Zones Names

Use the Auto+ button to rename and number multiple zones. The Auto+ button will number
the selected zones from 001 to n, where n is the number of zones selected. For example, if
renaming 7 zones, the Auto+ button will rename the zones sequentially from 001 to 007.

To number and rename multiple zones, do the following:

1. Select the zones to be renamed.

2. Touch the Zone Name field and enter a new zone name for all the selected zones.

To select commonly used zone names, use the following keys:

• zone

• probe

• tip

• nozzle

• sprue

• manifold

• bridge

• valve gate

• not used

3. To rename and number all the selected zones, touch the Auto+ button.

7.5.11 Changing a Setpoint

The setpoint temperatures for each of the heaters in the mold must be specified. The default
setting is 177 °C (350 °F).

To change a setpoint of a zone:

1. Touch the zone to be changed.

2. Touch the desired setpoint field and enter a new setpoint value

3. Touch the Accept button.

7.5.12 Changing the Alarm Window

Specify how many degrees above or below the setpoint to initiate the alarm. The default
setting is 6 °C (10 °F).

Alarm Example: Setpoint = 300 °F, Alarm = 10 ° F

An alarm is initiated above 310 °F or below 290 °F. If the setpoint is changed to 350°F, the
alarm will be initiated above 360 °F or below 340 °F. The setting always represents an amount
above and below the current setpoint.

To change the alarm setting for a zone:

1. Touch the zone to be changed.

2. Touch the Alarm Window field and enter a new value.

3. Touch the Accept button.

72 Changing Multiple Zones Names

User Guide v 2.3 — September 2015 Making Adjustments

7.5.13 Changing the Abort Window

Specify how many degrees above or below the setpoint to initiate the abort and shut down.
The default setting is 11 °C (20 °F).

Abort Example: Setpoint = 300°F, Abort = 20°F.

The abort will be initiated above 320 °F or below 280 °F and shut the zone or the system down
based on the PCM directive. If the setpoint is changed to 350 °F, the abort will be initiated
above 370 °F or below 330 °F. The setting always represents an amount above and below the
current setpoint.

To change the abort setting for a zone:

1. Touch the zone to be changed.

2. Touch the Abort Window and enter a new value.

3. Touch the Accept button.

7.5.14 Changing the Output Mode Setting

In hot runner temperature control systems, there are two different methods for switching
power output to the heaters; Zero Cross Control or Phase Angle Control. Each method has its
own set of advantages, but generally they offer very similar results.

Altanium provides the flexibility to run each zone in either mode. The default setting is Zero
Cross for all zones.

To change the output setting for a zone, do the following:

1. On the Quick Set screen, touch the zone to be changed.

2. Touch the Output Mode field to toggle between the Zero Cross and Phase Angle

7.5.15 Zone Slave

Some of the most vulnerable components in the mold are the thermocouples. If a
thermocouple fails, Altanium will initiate an alarm and display an error on the Alarm screen
for the affected zone. At this point there are three choices:

1. Stop molding, remove the mold and repair the fault. This may not be desirable or even

2. Switch the zone to Manual control mode and continue processing. This has limitations

modes.

possible.

as Manual mode is not able to compensate for changes in the process that affect the
heater's power requirements, i.e. shear heat.

3. Slave the faulty zone to another. Due to the symmetry in the design of hot runner molds,
frequently there are other zones that have very similar thermal characteristics as the
faulty zone. Altanium can apply the power output from a fully functioning zone to the
zone with the defective thermocouple. This means that any processing changes that
affect the power requirements of the heaters are automatically applied to the defective
zone. It is similar to repairing the defective thermocouple without ever opening the
mold.

Changing the Abort Window 73

v 2.3 — September 2015 Altanium Delta3

7.5.15.1 Using the Automatic Slave Function

If a thermocouple malfunctions during operation of the mold, the Altanium Auto-Slave
function will take over. Altanium constantly monitors the heaters in the mold and stores
comparative data. This data is used to select an almost identical Master/Slave relationship for
every zone in the mold. If a thermocouple fails, Altanium will initiate an alarm and display an
error on the Alarm screen.

Based on the comparative data stored, the system knows which zone to slave the faulty zone
to so that it continues to operate in a closed loop control mode.

The only requirement is to see the error, then clear and reset the alarm. On the Neo2 View,
Multi Group View, Graphical View and Text View screens, the number toggles between
the original zone number and the zone to which it is slaved.

Once the error is cleared and reset, the slave value is persisted to the database. The Quick Set
screen for that zone displays the zone it is slaved to. The Automatic Slave function can be
disabled in the System Setup screen.

If the automatic slaving function is unable to find a suitable partner, the Automatic Manual
Control (AMC) function is activated. If AMC is set to On, the system automatically switches the
bad zone into Manual mode applying a calculated average power output to the heater. If
AMC is Off, Priority Control Mode (PCM) is activated and shuts down either the zone or the
system based on the PCM directive.

7.5.15.2 Manually Slaving One Zone to Another Zone

If a thermocouple is about to fail, it can be slaved to another zone before it fails completely.

To manually slave one zone to another:

IMPORTANT!

Choose a master zone with similar heater characteristics. For example, a user may not want
to slave a manifold zone to a tip zone. A zone cannot be slaved to itself; if this is attempted,
Altanium will ignore the changes.

1. On the Quick Set screen, touch the zone to slave.

2. Touch the Slave To Zone field and enter the zone number of the master zone.

3. Touch the Accept button.

On the Neo2 View, Multi Group View, Graphical View and Text View screens, the color of
the manual-slaved zone changes from white to dark blue and the zone and name toggles
between the original zones information and the zone to which it is slaved.

7.5.15.3 Changing the Regulation Mode

Each zone can run in one of three regulation modes. The default setting is Automatic.

74 Using the Automatic Slave Function

User Guide v 2.3 — September 2015 Making Adjustments

Regulation

Mode

Auto In Automatic (closed loop) mode, the system will use a thermocouple to

control the temperature.

Man In Manual (open loop) mode, the system will only apply power (0 to 100%) to

the heater and not look for sensor feedback.

Mon In Monitor mode, the system will only monitor the temperature of a

thermocouple (no power output).

To change the zone regulation:

1. On the Quick Set screen, touch the zone to be changed.

Description

CAUTION!

If a zone is placed in Monitor mode by mistake, the system will give no power output
to that heater.

2. Touch the Regulation Mode field. A d ial og wi ll a ppea r wi th th e th ree mode cho ices The

user can either select one of them or cancel the operation.

7.5.16 Setpoint Limits

Altanium allows users to set a specific range where the operator is prevented from changing
the setpoint beyond these limits.

7.5.16.1 Changing the Normal Setpoint and Limits

On the Quick Set screen, in the Setpoint Limits section, specify the temperatures to heat the
heaters in the mold. The default setting is 177 °C (350 °F).

To change a normal setpoint and setpoint limits for a zone, do the following:

1. Touch the zone to change.

2. Touch the Temperature Minimum field and enter a value.

3. Touch the Accept button.

4. Touch the Temperature Maximum field and enter a value.

5. Touch the Accept button.

6. Touch the Power Minimum field and enter a setpoint value.

7. Touch the Accept button.

8. Touch the Power Maximum field and enter a setpoint value.

9. Touch the Accept button.

Setpoint Limits 75

v 2.3 — September 2015 Altanium Delta3

7.5.16.2 Changing the Manual Standby and Remote Standby Setpoint Limits

It may be necessary to lower the temperatures in the mold for a period of time. This can be
done on the system header by selecting the Manual Standby button (or Remote Standby
from a remote location as an option) without needing to change the normal setpoint. Specify
the desired temperatures for the heaters in the mold to cool down to when the system is in
Standby; both manual standby and remote standby. The default setting for both the manual
and remote standby setpoints is 121 °C (250 °F).

7.5.16.2.1 Changing the Manual Standby Setpoint Limits

To change a standby setpoint and standby setpoint limits for a zone, do the following:

1. Touch the zone to be changed.

2. Touch the Temperature Setpoint field and enter a value.

3. Touch the Accept button.

4. Touch the Temperature Minimum field and enter a value.

5. Touch the Accept button.

6. Touch the Temperature Maximum field and enter a value.

7. Touch the Accept button.

8. Touch the Power Setpoint field and enter a value.

9. Touch the Accept button.

10. Touch the Power Minimum field and enter a value.

11. Touch the Accept button.

12. Touch the Power Maximum field and enter a setpoint value.

13. Touch the Accept button.

7.5.16.2.2 Changing the Remote Standby Setpoint Limits

To change a remote standby setpoint and remote standby setpoint limits for a zone, do the
following:

1. Touch the zone to be changed.

2. Touch the Temperature Setpoint field and enter a value.

3. Touch the Accept button.

4. Touch the Temperature Minimum field and enter a value.

5. Touch the Accept button.

6. Touch the Temperature Maximum field and enter a value.

7. Touch the Accept button.

8. Touch the Power Setpoint field and enter a value.

9. Touch the Accept button.

10. Touch the Power Minimum field and enter a value.

11. Touch the Accept button.

76 Changing the Manual Standby and Remote Standby Setpoint Limits

User Guide v 2.3 — September 2015 Making Adjustments

12. Touch the Power Maximum field and enter a setpoint value.

13. Touch the Accept button.

7.5.16.3 Changing the Manual Boost Setpoints and Limits

It may be necessary to raise the temperatures in the mold for a period of time. This can be
done on the system header by selecting the Manual Boost button (or Remote Boost from a
remote location as an option) without needing to change the normal setpoint. Specify the
temperatures to heat the heaters in the mold to when the system is in Boost. The default
setting is no chg (no change) which means nothing will happen when Boost is activated.

To change a boost setpoint and boost setpoint limits for a zone, do the following:

1. Touch the zone to be changed.

2. Touch the Temperature Setpoint field and enter a value.

3. Touch the Accept button.

4. Touch the Temperature Minimum field and enter a value.

5. Touch the Accept button.

6. Touch the Temperature Maximum field and enter a value.

7. Touch the Accept button.

8. Touch the Power Setpoint field and enter a value.

9. Touch the Accept button.

10. Touch the Power Minimum field and enter a value.

11. Touch the Accept button.

12. Touch the Power Maximum field and enter a setpoint value.

13. Touch the Accept button.

7.5.16.4 Changing the Remote Boost Setpoints and Limits

To change a remote boost setpoint and remote boost setpoint limits for a zone, do the
following:

1. Touch the zone to be changed.

2. Touch the Temperature Setpoint field and enter a value.

3. Touch the Accept button.

4. Touch the Temperature Minimum field and enter a value.

5. Touch the Accept button.

6. Touch the Temperature Maximum field and enter a value.

7. Touch the Accept button.

8. Touch the Power Setpoint field and enter a value.

9. Touch the Accept button.

10. Touch the Power Minimum field and enter a value.

11. Touch the Accept button.

Changing the Manual Boost Setpoints and Limits 77

v 2.3 — September 2015 Altanium Delta3

12. Touch the Power Maximum field and enter a setpoint value.

13. Touch the Accept button.

7.5.17 Changing the Sensor Assignment (Thermocouple)

The Sensor setting allows the operator to assign any thermocouple to control any heater.
This is important in the instance where there may be mis-wired thermocouples or heaters in
the mold.

For example, heater number 1 may be connected to thermocouple 5 and heater number 5
may be connected to thermocouple number 1. In this instance, the operator can manually
switch the thermocouple inputs by changing the Sensor number in the Sensor field to the
appropriate number.

NOTE:Altanium automatically accounts for mis-wired molds during Mold Diagnostics. This

usually eliminates the need to make any adjustments.

To change the sensor assignment for a zone, do the following:

1. Touch the zone to be changed.

2. In the Advanced Settings section, touch the Thermocouple Assignment field and

enter a value.

3. Touch the Accept button.

7.5.18 Changing the Priority Control Mode (PCM) Setting

If there is a malfunction during normal operation, the software will make every attempt to
circumvent the problem. If this is impossible, it will initiate a shutdown sequence. Specify
what to shut down if this happens.

In the case of an Abort condition, if the PCM is set to Zone, the controller will stop applying
power output to the defective zone and continue to operate all other zones as normal. If the
PCM is set to System, the controller will shutdown all power output to the mold (if the failure
occurs on this zone). The PCM is zone selectable, so one zone may only shut itself OFF and
another may shut down the mold. This setting is dependent on the zone and how critical it
is to the mold. Usually the cavities are set to Zone, and the manifolds are set to System. The
default setting is System on all zones.

To change the PCM setting for a zone, do the following:

1. Touch the zone to be changed.

2. Under Advanced Settings, touch the PCM - Priority Control Mode field to turn the
PCM to Zone or System.

The optional Priority Control Mode (PCM) Digital Output

If the PCM digital output option is turned on, it will be activated ONLY when a zone set to
System experiences an abort condition. It will remain in this state until the PCM error is reset.

78 Changing the Sensor Assignment (Thermocouple)

User Guide v 2.3 — September 2015 Making Adjustments

7.5.19 Changing the Earth Leakage Check

When Started, Altanium checks for earth leakage conditions on every heater in the mold
simultaneously. When necessary, it will initiate a low voltage, phase angle bake out on the
faulty zone(s) to try to bake the moisture out of the heater(s).

Altanium allows users to turn Earth Leakage Check On or Off for the each zone. The default
setting is “On” for all zones. Turning Earth Leakage Check off is only necessary under very
special circumstances. To turn the Earth Leakage Check off globally for the entire system,
please call the nearest Husky Regional Service and Sales office.

7.5.20 Changing the Automatic Manual Control (AMC) Setting

If a thermocouple malfunctions during normal operation, Altanium can automatically apply
a manual power output percentage to the heater, based on the information gathered before
the thermocouple failed. This feature is called Automatic Manual Control (AMC).

If a thermocouple fails and AMC is turned ON, the control changes the failed zone into
manual mode and sets a manual power output, based on the previously recorded average
power output to that heater. If AMC is turned OFF, the control skips to PCM (Priority Control
Mode) and performs the designated task. The default setting is ON for all zones.

To change the AMC setting for a zone, do the following:

1. Touch the zone to be changed.

2. Under Advanced Settings, touch the AMC - Automatic Manual Control field.

3. Select On or Off.

7.5.21 Changing the Output Power Limit Setting

The Output Power Limit setting allows users to set the maximum amount of power that can
be delivered to the heaters. The default power limit for all zones is 100%.

To change the Output Power Limit setting for a zone, do the following:

1. Touch the zone to be changed.

2. Under Advanced Options, touch the Output Power Limit field.

3. Select a value between 0% and 100%.

4. Touch the Accept button.

7.5.22 Changing the Zone Control from ART to PID

Altanium can automatically adjust the control algorithm to suit different heater
requirements. This control method is referred to as Active Reasoning Technology (ART). In
some cases, it may be necessary to switch from the automatically adjusted ART algorithm to
an algorithm that can be manually adjusted. This control method is referred to as PID. When
switching a zone from ART control to PID control, the user can manually enter values for the

Changing the Earth Leakage Check 79

v 2.3 — September 2015 Altanium Delta3

Proportional, Integral and Derivative parameters. The default control mode for all zones is
ART.

To toggle the zone control between ART and PID:

1. Touch the zone to be changed.

2. Under Control Settings, touch the Control Mode field.

3. Select ART or PID.

7.5.22.1 Changing P, I or D Parameter Values

If rerunning ART on a zone has been attempted, and the required control has not been
achieved, switch the zone to PID control and adjust the individual PID parameters to achieve
the required control.

IMPORTANT!

The zone can be switched back to ART without losing information. The default settings for
the PID are P-15, I-10 and D-2 on all zones.

To change the PID settings:

1. Touch the zone to be changed and switch the control mode to PID.

2. Touch the fields containing the values for the P, I or D parameters to display a keypad.

3. Enter the new value for the P, I or D parameter, and touch the Accept button.

4. If necessary, repeat the previous two steps to adjust the other PID parameters.

7.6 Active Reasoning Technology (ART)

Active Reasoning Technology (ART) is the science of applying microprocessor-based control
systems to automatic decision making. It is a control method directed at an active or
continuous learning process, which is tolerant to faulty functions and incorrect operation by
intentionally circumventing the incorrect operation or failure.

Active Reasoning software combined with integrated hardware disseminates information
and makes better process decisions than any modular single input, single output controller.
The ability of all zones to interact with one another and understand the effects of that
interaction is paramount. Totally automatic control is one advantage. During Altanium
startup, the control looks at all zones individually, then looks at comparisons of all zones and
determines any interaction between them. It tests for any earth leakages individually and as
a whole. It then creates the necessary bake out and soft start routines to successfully and
evenly heat the mold.

80 Changing P, I or D Parameter Values

User Guide v 2.3 — September 2015 Making Adjustments

7.6.1 ART Process Screen

The ART Process screen is used to initiate the Active Reasoning Technology self tuning
process and monitor its progress. This screen will appear automatically after touching START
if any zone in the currently loaded mold setup has not completed the ART process. The
process can be manually initiated for any zones that it is felt are not controlling properly.

When ART is running, the system cannot be modified using the Start, Standby and Boost
buttons. Touch the Cancel Art buttons to return to normal operation or touch the Stop
button to cancel the ART process and stop the controller. Normal navigation is disabled until
ART completes. Pending zones will undergo the ART process the next time the system is
started.

Figure 7-9 ART Process Screen

Table 7-3 ART Process Screen Item Descriptions

Item Description

Status Text The current ART status.

Zone Selection Grid The selection grid indicates the status of each zone.

Yellow represents a zone that is selected.

A yellow caution triangle marks a zone that cannot be ARTed (for
example, a zone set to manual regulation mode or a zone with errors).

An hourglass indicates ART is in progress.

A green check mark represents a zone that has already been ARTed.

A question mark represents a zone that is not ARTed.

ART Process Screen 81

v 2.3 — September 2015 Altanium Delta3

Table 7-4 ART Process Screen Button Descriptions

Button Description

Start ART Process Touch the Start ART Process button to start the ART process.

Cancel ART Process Touch the Cancel ART Process button to stop the ART process.

Reset ART Process Touch the Reset ART Process button to reset the ART parameters for the

selected zones. The next time the system is started, it will perform the
ART process on those zones again.

Edit ART Values Touch the Edit ART Values button to open the Edit Art Values dialog

box and view/change the ART parameters. ART values can be changed
one zone at a time, while the controller is running.

Table 7-5 ART Status Descriptions

Symbol Description

? The question mark indicates ART has not been started or a zone has not

been ARTed.

X The X indicates a problem with the zone. This problem is preventing the

ART process from beginning.

Hourglass An hourglass indicates that the ART process is underway.

Checkmark A checkmark indicates that the ART process is complete.

7.6.1.1 Using the Manual ART Function

Due to a change to a particular zone, such as the replacement of a heating element or
thermocouple, an operator may need to reset the ART parameters for that zone. Poor control
of the zone may also lead an operator to make this decision. For example, the temperatures
may be consistently swinging over and under setpoint, yet not triggering an alarm. This is not
to be confused with shear heat from the material, which appears as sudden increases in
temperature with no undershoot.

Once the system is started, the ART process automatically begins on all zones that have not
yet undergone the ART process. If a particular zone is not controlling properly when it has
reached its setpoint, ART can manually be run on that zone.

When ART is run manually on a zone, Altanium deletes its knowledge base on that zone and
recalculates the control process. It then stores this data and uses it to calculate the proper
output to control this zone best at setpoint. Use this function sparingly and only permit
highly qualified individuals to use it. The molding process may be interrupted if ART is run on
several zones at one time, but this is rare. It is best to run ART on a zone once it is at setpoint.

To manually run ART on a zone, do the following:

NOTE:The system must be in RUN mode before the ART process can start.

1. Select the zone or zones to manually ART.

2. Touch the Start ART Process button to begin the ART analysis on the selected zone(s).

82 Using the Manual ART Function

User Guide v 2.3 — September 2015 Making Adjustments

When all selected zones complete the ART process, a checkmark will appear for each
zone.

3. To cancel the ART process at any time, touch the Cancel ART Process button.

7.7 PID Control

Altanium offers the choice of using ART (automatic tuning), or PID (manual tuning). To use
PID on a zone or zones, the following provides a simple explanation of each parameter (P, I,
and D).

7.7.1 Typical PID Values

The following is a list of some typical PID values.

Table 7-6 PID Values

Proportional Integral Derivative Type Example

015 010 002 Fast Probes or heaters with internally located

050 020 000 Fast

020 010 000 Fast

015 015 000 Fast

020 007 100 Medium Probes or heaters with internally located

020 005 200 Medium

100 003 000 Slow Manifolds or heaters with externally

075 003 150 Slow

7.7.2 Possible Causes of Oscillation

It is possible to set the control terms incorrectly, inducing an oscillation. The following are the
most common causes:

Table 7-7 Possible Causes of Oscillation

thermocouples

thermocouples (larger mass)

located thermocouples

Cause Description

"P" too large Power change too great per °C of temperature change.

"I" too large Power changing too quickly for the process to follow it.

PID Control 83

v 2.3 — September 2015 Altanium Delta3

Table 7-7 Possible Causes of Oscillation (Continued)

Cause Description

"D" too large Stepped power change too large for the rate of change of temperature.

Shear An important issue often overlooked is the effect of shear in the material as

it passes through the gating area. This can cause rises in temperature in
excess of 33 °C (60 °F) under severe conditions. Therefore, if large
temperature variations occur during molding, it is worth plotting this
variation against the molding cycle time. As the controller cannot initiate
additional cooling, it is only possible to minimize this effect with properly
selected PID terms.

84 Possible Causes of Oscillation

User Guide v 2.3 — September 2015 Mold Diagnostics

1

2

3

Chapter 8 Mold Diagnostics

Diagnostics is a useful tool for troubleshooting problems with a mold or for verifying the
wiring integrity of a mold after maintenance has been performed. Diagnostics can also be
used to analyze the thermal isolation between all the cavities in the mold.

8.1 Testing the Mold

To test the mold, do the following:

1. On the Home screen, touch the Mold Diagnostics button.

2. Make sure Altanium is in the stop state.

3. Select the desired zone(s).

4. Select the check box(es) for the desired test(s).

5. Touch the Run Test button.

Figure 8-1 Mold Diagnostics Screen

Testing the Mold 85

1. Run Test 2. Stop Test 3. View Test Results

v 2.3 — September 2015 Altanium Delta3

Table 8-1 Mold Diagnostics Screen Field and Button Descriptions

Field/Button Description

Validate Zone After The number of degrees that a zone must heat above its starting

temperature to pass a test.

Zone Cooling Time The amount of time to wait after completing a previous test before

starting the next test.

Maximum Test Time The maximum test duration.

Heaters Select the Test Heaters check box to test whether the selected zones are

drawing current. A heater test will test the following:

• During heating, will record the maximum current and voltage, and
will calculate the resistance.

• Test for any blown fuses.

Sensors Select the Test Sensors check box to test whether the selected zone’s

thermocouple sensor is functioning properly. A sensor test will test the
following:

• Test sensor operation. For example, if a thermocouple is lost or
reversed.

Wiring Select the Test Wiring check box to test whether, for the selected zones,

thermocouple and heater pairings are correct (1 to 1 and 2 to 2, etc.). A
wiring test will test the following:

• Before conducting the cross talk test, Altanium will wait for the
temperature to be below the threshold for the cross talk test.

• During heating, will record the maximum current and voltage, and
will calculate the resistance.

• Test for the effectiveness of cross talk.

Run Test Touch the Run Test button to start the selected tests. Only the selected

zones will be tested.

Stop Test Touch the Stop Test button to stop the test. A test that has been

completed will be persisted to the database. The test results can be
reviewed at a later time.

View Test Results Touch the View Test Results button to open the Test Results screen.

This can be done anytime during the test after the first zone has been
tested, or after the test is completed.

Test Status The current status of the test. During the test, it will display the zone that

is being tested.

Start Time The time that the test was started.

Elapsed Time The amount of time that has passed since the test was started.

86 Testing the Mold

User Guide v 2.3 — September 2015 Mold Diagnostics

8.1.1 Running a Mold Diagnostics Test

Before beginning the automated mold diagnostics test, do the following:

1. Before connecting any power to the controller or the mold, clean the mold and its
surroundings.

CAUTION!

Risk of damage to the equipment — Do not rely on the possibility of a ground in the
mold cables. Using a length of suitable wire, attach the mold to the mold ground
connector on the Altanium mainframe.

2. For safety, verify the controller and mold share the same ground.

3. Check the mold wiring to verify there are no bare wires, frayed ends or cut insulation.

4. If thermocouple and power cables are present, connect them from the controller to the

mold, checking them for a clean fit.

5. Connect the Altanium mainframe to the main input power and turn it ON via the main
disconnect.

6. Log in to Altanium and load a mold setup.

7. Verify the zones to test are turned ON. Any zones turned OFF will not be tested.

8. On the Home screen, touch the Mold Diagnostics button.

9. Select the desired zone(s).

10. Select the test(s) to perform (heaters, sensors, wiring). By default, all tests are selected.

11. Touch the Run Test button.

8.1.2 Setting the Zone Cooling Time

On some molds, it may be necessary for the Altanium controller to wait a certain period
before moving on to test the next zone. This additional time is needed in cases where, after
the power has been removed, the thermocouple continues to heat longer than expected.
This is common with large manifolds. If Altanium started testing the next zone before the
previous zone's temperature stopped increasing, this could affect the test results.

To set the zone cooling time, do the following:

1. On the Mold Diagnostics screen, select the zone(s) to change.

2. Touch the Zone Cooling Time field.

3. Enter the zone cooling time in the format displayed (HHMMSS).

4. Touch the Accept button.

NOTE:The default setting is 10 seconds. Each mold setup can have its own set of delay

times.

Running a Mold Diagnostics Test 87

v 2.3 — September 2015 Altanium Delta3

1

2 3

8.1.3 Setting the Maximum Test Time

On some molds, if there is a thermocouple wiring problem, a heater could be damaged
during test. Specifically, some heaters in some configurations may not support the peak
temperatures reached when full power is applied for the default test time. An extreme
example is testing a hot runner without the cavity plate in position. If the heater is large, a
short test time may not be long enough to heat up and result in a failed test. Operators can
set the maximum test time for each zone to accommodate different types of heaters.

To set the maximum test time, do the following:

1. On the Mold Diagnostics screen, select the zone(s) to change.

2. Touch the Maximum Test Time field.

3. Enter the maximum test time in the format displayed (HHMMSS).

4. Touch the Accept button.

NOTE:The default setting is 2 minutes. Each mold setup can have its own set of maximum

test times.

8.2 Diagnostics Results

To review the diagnostic test results, do the following:

On the Home screen, touch the Diagnostics Results button to open the Test Results
screen.

Figure 8-2 Test Results Screen

1. Rewire 2. Cross-Talk 3. Temperature Graphs

88 Setting the Maximum Test Time