Husky Altanium Neo5 User Manual

Altanium Neo5

User Guide

Original Instructions

v 1.0 — August 2018 Altanium Neo5

Issue: v 1.0 — August 2018

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.

© 2018 Husky Injection Molding Systems. All rights reserved.

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User Guide v 1.0 — August 2018 Altanium Neo5

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.

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v 1.0 — August 2018 Altanium Neo5

Page iv

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 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.8 Controller Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.8.1 C6-1 and C6-2 Lifting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.8.2 Single Stack Lifting Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.2 Operator Interface — Screens and Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

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v 1.0 — August 2018 Altanium Neo5

4.2.1 Dialog Box — Accept/Cancel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.2.2 Home Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.2.3 Header and Footer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2.3.1 Header — Controller Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

4.2.3.2 Header — System Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2.3.3 Header — Navigation Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

4.2.3.4 Footer — Alarm Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2.3.5 Footer — System and User Management Buttons. . . . . . . . . . . . . . . . . . . . . 19

4.2.4 System Screen Selections — Zone Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.2.5 System Screen Selections — Temperature Management. . . . . . . . . . . . . . . . . . . 20

4.2.6 System Screen Selections — Data Collection and Monitoring . . . . . . . . . . . . . .20

4.2.7 System Screen Selections — System Configuration. . . . . . . . . . . . . . . . . . . . . . . . 20

4.3 Supply Voltage Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Chapter 5: Security and Administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5.1 Login/Logout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.1.1 Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5.2 User Management and Security Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.2.1 Manage Users. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

5.2.1.1 Add a User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.2.1.2 Delete a User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5.2.1.3 Change a User Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.2.2 Set the Security Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

5.2.3 Enable Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Chapter 6: Mold Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

6.1 Mold Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.1.1 Saving Changes to a Mold Setup File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

6.1.2 Saving the Current Mold Setup File as a New File . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.1.3 Loading an Existing Mold Setup File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

6.1.4 Deleting Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

6.1.5 Copying Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

6.1.6 Transferring Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.1.6.1 Transferring Data to the Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.1.6.2 Transferring Data Using a USB Storage Device . . . . . . . . . . . . . . . . . . . . . . . .38

Chapter 7: Making Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

7.1 Zone Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

7.2 Creating a Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

7.2.1 Color Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2.2 Layout Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2.3 Show Group Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

7.3 Neo2 View Screen Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

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7.4 Text View Screen Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

7.4.1 Zone Selection in the Text View Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

7.4.2 Sorting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

7.5 Quick Set Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

7.5.1 Frequently Used Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

7.5.2 Zone Edit Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

7.5.3 Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

7.5.4 Setpoint Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

7.5.5 Manual Standby. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

7.5.6 Manual Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

7.5.7 Remote Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

7.5.8 Remote Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

7.5.9 Heater Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

7.5.10 Advanced Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

7.5.11 Control Settings Fields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

7.5.12 Art Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

7.5.13 Zone Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

7.5.13.1 Using the Automatic Slave Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

7.5.13.2 Manually Slaving One Zone to Another Zone . . . . . . . . . . . . . . . . . . . . . . . . .87

7.5.14 Active Reasoning Technology (ART). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

7.5.14.1 Changing the Zone Control from ART to PID . . . . . . . . . . . . . . . . . . . . . . . . . .88

7.5.14.2 Typical PID Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

7.5.14.3 Possible Causes of Oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Chapter 8: Mold Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8.1 Test Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

8.2 Running a Mold Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

8.2.1 Zone Cooling Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

8.2.2 Maximum Test Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

8.2.3 Test Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

8.3 Mold Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

8.3.1 Automatic Thermocouple Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

8.3.2 Compare Mode Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Chapter 9: Heating the Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

9.1 Heater Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

9.1.1 Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

9.2 Earth Leakage/Wet Heater Bake Out System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

9.2.1 Earth Leakage Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

9.2.2 Configuring the Length and Number of Bake Out Cycles. . . . . . . . . . . . . . . . . .100

9.3 Soft Start Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

9.3.1 Adjusting the Soft Start Minimum Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

9.4 Alarm Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

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9.4.1 Opening the Alarm Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

9.4.2 Clearing Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

9.5 Event History Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

9.5.1 Filtering Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

9.6 Alarm Conditions — Warning Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

9.7 Abort Conditions — Shutdown Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Chapter 10: System Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

10.1 System Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

10.2 Changing the Number of Zones in the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Chapter 11: Staged Startup and Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

11.1 Enabling or Disabling Staged Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

11.1.1 Setting Soak Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

11.2 Set the Stage Temperature and Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Chapter 12: Data Recording. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

12.1 Process Monitor Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

12.1.1 Viewing the Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

Chapter 13: Data Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

13.1 Select Reports Process Data and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

13.2 Report Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

Chapter 14: Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

14.1 Configure the Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

14.2 Digital I/O Connector Pin-Out Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

14.2.1 Digital Input Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

14.2.2 Digital Output Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

14.2.3 Input Connector Pin-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

14.2.4 Output Connector Pin-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

Chapter 15: Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

15.1 Servicing the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

15.2 Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

15.2.1 Cable Connections — Integrated Configuration . . . . . . . . . . . . . . . . . . . . . . . . . .134

15.2.2 Cable Connections — Freestanding Configuration . . . . . . . . . . . . . . . . . . . . . . .135

15.3 Intelligent Control Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

15.3.1 Replacing an Intelligent Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

15.3.2 Replacing a Blown Fuse on an Intelligent Control Card . . . . . . . . . . . . . . . . . . .140

15.4 Neo5 Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

15.4.1 Replacing the Touch Monitor — Integrated Configuration. . . . . . . . . . . . . . . .143

15.4.2 Replacing the MCU — Integrated Configuration. . . . . . . . . . . . . . . . . . . . . . . . . .147

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15.4.3 Replacing the Touch Monitor — Freestanding Configuration . . . . . . . . . . . . .152

15.4.4 Replacing the MCU — Freestanding Configuration . . . . . . . . . . . . . . . . . . . . . . .156

15.4.5 Replacing the Operator Interface — Freestanding Configuration. . . . . . . . . .161

15.5 Neo5 Mobile Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164

15.5.1 Installing Neo5 on the Mobile Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165

15.6 Cleaning the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

15.6.1 Mainframe (Cabinet). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

15.6.2 Touch Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

15.7 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169

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Page x

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.

v 1.0 — August 2018 Altanium Neo5

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.

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• 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.

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User Guide v 1.0 — August 2018 Altanium Neo5

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/Yellow Green

Line Black Black

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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 Neo5
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: OVII

1.6 Equipment Ratings

Ratings for the entire Neo5 can be found on the nameplate attached to the back of the
controller.

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The following are the equipment ratings for the Neo5 operator interface only:

• Supply Voltage: 100 to 240 VAC +/- 10%, single phase

• Frequency: 47 to 63 Hz

• Power Rating: 130 W

User Guide v 1.0 — August 2018 Altanium Neo5

1.7 Weights and Dimensions

The technical specifications (weights and dimensions) for the most common Altanium Neo5
configurations are shown below.

Dimensions Weight

Neo5 Operator Interface • Width: 278 mm (11 in)

• Length: 363 mm (14 in)

• Height: 324 mm (13 in)

Neo5 C6-1 • Width: 289 mm (11.4 in)

• Length: 331 mm (13 in)

• Height: 550 mm (21.7 in)

Neo5 C6-2 • Width: 289 mm (11.4 in)

• Length: 331 mm (13 in)

• Height: 777 mm (30.6 in)

Neo5 Single Stack • Width: 450 mm (17.7 in)

• Length: 560 mm (22 in)

• Height: 1512 mm (59.5 in)

• Controller: 7.25 kg (16 lb)

• With shipping container:

3 kg (27 lb)

• Controller: 25.40 kg (56 lb)

• With shipping container:

40.82 kg (90 lb)

• Controller: 35.38 kg (78 lb)

• With shipping container:

59.87kg(132lb)

• Controller: 65.32 kg (144 lb)

• With shipping container:

133.36 kg (294 lb)

1.8 Controller Lifting Instructions

The recommended lifting method varies depending on whether the Altanium Neo5 is a C6­1, C6-2, or single stack (freestanding) controller.

1.8.1 C6-1 and C6-2 Lifting Instructions

Use the steps that follow to correctly lift a Neo5 C6-1 or C6-2.

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1.8.2 Single Stack Lifting Instructions:

Do the steps that follow to lift the single stack Neo5.

Lifting devices (crane or forklift) and straps vary in lifting ability and lengths. See the table
that follows for the correct lifting ability and lengths.

v 1.0 — August 2018 Altanium Neo5

Altanium Controller

Neo5 Single Stack Two, 2.44 m x 25.4 mm

Webbed Straps Rated 2903

kg (6400 lb)

(8 ft x 1 in.)

Ratchet Strap

One, 1.52 m (5 ft) 227 kg (500 lb)

Lifting Device (Lifting

Ability)

1. Place each of the webbed straps under the controller. See the table above for the correct
strap lengths.

a. For a single stack Neo5, the webbed straps go under the equipment from left to

right.

2. Bring the straps up and above the Neo5 and attach them to the lifting device.

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a. Make sure the straps are positioned between the caster wheels and the retaining

brackets under the base of the controller.

User Guide v 1.0 — August 2018 Altanium Neo5

b. Make sure the straps are not pinching or crushing any cables attached to the Neo5.

3. Use the lifting device to apply enough upward force on the straps to remove the slack,

but do not lift the Neo5 at this time.

4. Place the ratchet strap around the top of the Neo5, 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 Neo5 is lifted.

5. Place cloth or other cushioning material between the ratchet strap and the Neo5 to keep
the finish free from rubs and scratches.

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6. Tighten the ratchet strap.

7. Use the lifting device to slowly lift the Neo5 off the ground a few inches.

8. Check the webbed and ratchet straps to make sure that the Neo5 will not tip.

9. Move the Neo5 to the new location.

10. At the new location, slowly lower the Neo5 to the ground.

11. Remove the ratchet straps, cushioning material and webbed straps.

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Chapter 2 Hot Runner Temperature Control

This guide is designed to make sure that users receive the maximum possible benefit from
the use of the Neo5.

The Neo5 was 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 consistent and repeatable with respect to the process setpoint. The closer to the setpoint
the process temperature is maintained, 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

Controllers use 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, but not actually part of the single heater

assembly. The external thermocouple may 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. Neo5 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, because the size of the tip heater
is too small for an internal thermocouple.

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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
Neo5 can be set up to achieve this by using either Zero Cross Control or Phase Angle Control.

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 Neo5 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 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.

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The Neo5 will provide wattage, resistance or amperage information for heaters, if equipped
with X ICC
Law. The diagram and formulas that follow demonstrate how.

2

or H ICC3 cards. Alternatively, this information can be determined using Ohm’s

User Guide v 1.0 — August 2018 Altanium Neo5

WARNING!

Electrical hazard– risk of death or serious injury. Disconnect all electrical power from
the mold and controller prior to performing this test.

1. Using a multimeter, set the selector to measure resistance.

2. Connect the (red) positive lead to the first wire from the heating element and connect

the (black) negative lead to 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).

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 voltage

Resistance

Amperage

Watts

24 V 110 V 208 V 220 V 240 V

20 Ω 20 Ω 20 Ω 20 Ω 20 Ω

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

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2.4 Thermocouple Types and Color Codes

The Neo5 uses 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.

Code Type

J Iron/ Constantan/ (Copper-

Nickel)

K Nickel- Chromium/ Nickel-

Aluminum

International Color

Code (BS4937 Part

30:1993)

Overall Black Overall Black Overall Black Overall Blue

+ ve - ve + ve - ve + ve - ve + ve - ve

Black White Yellow Blue White Red Red Blue

Overall Green Overall Red Overall Yellow Overall Green

+ ve - ve + ve - ve + ve - ve + ve - ve

Green White Brown Blue Yellow Red Red Green

BRITISH

(BS1843:1952)

U.S.

ANSI

GERMAN

DIN

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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.

• Make sure that the cooling fan is free from obstruction

• 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

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. The resistance must be less than 1 Ω.

3. Make sure that the main input power disconnect is in the OFF position.

4. Connect the controller to the power source.

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3.3 Startup Procedure Checklist

WARNING!

Trip hazard – risk of death or serious injury. Make sure that all the cables between the
controller and all the external devices and/or equipment are marked clearly. Or route
the cables so that no one will trip over the cables.

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.

v 1.0 — August 2018 Altanium Neo5

5 Login to the system (if required).

6 Select the required mold setup.

7 Verify that the mold setup is the correct. Check 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 Neo2 View

or the Text View screens.

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.

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Chapter 4 Altanium Operator Interface

This chapter gives a brief overview of the functionality of the Neo5 operator interface.

4.1 General

The operator interface consists of a touch-sensitive display screen.

The Neo5 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.

WARNING!

Pinch Point Hazard – keep hands and fingers clear of the Neo5 touch monitor hinge
mechanism.

CAUTION!

Mechanical hazard – risk of equipment damage. Only use your finger to operate the
touch screen. Do not use a screwdriver, pen, or any other tool to touch the screen
because they may damage the touch screen.

Use the touch screen to move from screen to screen, enter data, and operate the hot runner
system.

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4.2 Operator Interface — Screens and Buttons

4.2.1 Dialog Box — Accept/Cancel Buttons

At the bottom of each screen, where you have entered new data, touch to save new or
changed data.

If you want to close the dialog box (no changes) touch .

4.2.2 Home Screen

The Home screen is the screen you use to navigate to all the other screens in the system. The
system screen selections on the Home screen are organized into four groups (rows): Zone
Views, Temperature Management, Data Collection and Monitoring, and System
Configuration.

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4.2.3 Header and Footer

The home screen has a header

and a footer.

The same header and footer appears on each screen.

4.2.3.1 Header — Controller Function Buttons

Button Description

.

Stop - Removes the power from all the zones, regardless of system
condition.

Start - Applies power to the zones that have a setpoint.

Standby button - Places the system in standby. If a timer is active, the time

remaining is displayed in the system header.

NOTE: You cannot put the system in standby during the ART process.

Boost button - Places the system in boost mode. If a timer is active, the
time remaining is displayed in the system header.

NOTE: You cannot put the system in boost mode during the ART process.

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4.2.3.2 Header — System Status Indicators

Indicator Description

At Temperature:

• Flashes when the zones are heating up to the setpoint temperature.

• Solid when all automatic zones are ‘At temperature’.

°F

• Off when the controller is stopped.

• Shows that the temperature values are given as °C or °F.

Company Name is displayed.

System Mode - For a description of each system mode, refer to the Table

at the end of this Chapter.

System Timer - If applicable, displays the time remaining on the timer.

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4.2.3.3 Header — Navigation Buttons

Button Description

Back - Displays the previous screen (maximum of 10 screens back).

Forward - Moves to the last screen that was displayed (maximum of 10

screens forward).

Home - Goes to the Home screen.

System Setup button - Goes to the System Setup screen.

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4.2.3.4 Footer — Alarm Buttons

Silence Horn - Stops the audible alarm.

Alarm Reset - Changes an alarm from active to inactive.

Alarm Status - The time and a description of the highest priority active

alarm is displayed. If an alarm is active, the Triangle Icon will turn red.

4.2.3.5 Footer — System and User Management Buttons

Log off/Log on - Shows the name of the current user who is logged in.
Touch to Login or Logout.

Language Selection - Shows the language screen.

Choose a language, then touch, .

Save - Saves a screen shot, report or process data on the internal hard
drive, or other user defined location.

Mold Setup Info button - Goes to the file management screen to
display the currently loaded mold and associated mold folder. The first
word is the name of the mold folder. The second word is the name of
the mold setup file.

Shows the date and time. Touch this field to show the Set Date and
Time dialog boxes.

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4.2.4 System Screen Selections — Zone Views

4.2.5 System Screen Selections — Temperature Management

4.2.6 System Screen Selections — Data Collection and Monitoring

4.2.7 System Screen Selections — System Configuration

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4.3 Supply Voltage Screen

The Supply Voltage screen displays a graphical view of how the input supply voltage is
wired. A table shows how the zones are connected to the input power.

On the Home screen, select

.

Item Description

Schematic The image is a visual representation of the supply configuration

Zone # Shows what phase pair the zone is connected to

Phase Pair Phase pair label associated with the supply configuration schematic

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

Amps The 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

3

cards installed. Both voltage

2

cards

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.

The supply configuration is selected on the System Setup screen. The supply voltage can be
wired in four different configurations.

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System Modes Table

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 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 Boost button and the system is heating to
the boost 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 Calibrates 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

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

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Soft Start to Remote
Standby

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)

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

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

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System Modes Table (Continued)

System Mode Description

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

Stage x Soaking
(Cooling)

Stage 4 Running
Indefinitely

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

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

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

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

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

conditions would be less severe than a earth leakage.

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

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Chapter 5 Security and Administration

This chapter describes the user management functions.

5.1 Login/Logout

5.1.1 Login

1. In the footer, touch the Log off/Log on button .

2. If logging in:

a. Use the keyboard to type in your user name, then .

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b. Type in your password, then .

If logging out:

3. On the logout dialog box , touch .

5.2 User Management and Security Screens

All users are assigned a role. There are three different roles. Each role is customized by the
administrator. The administrator decides what features each user can access.

The three roles are:

• Operator

• Supervisor

• Administrator.

From the Users screen, the administrator can add or delete a user or change a user’s
password. The administrator also controls security settings. The security settings give or
deny access to the different features of the Neo5.

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5.2.1 Manage Users

To create/delete a user or change a user’s password, do the steps that follow:

1. On the Home screen, in the systems configuration row, select .

2. On the top of the User screen, if necessary, select .

5.2.1.1 Add a User

1. In the left side column select .

2. Use the keyboard or drop down menus to enter in the data that follows:

• User Name:

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• Full Name:

• User Role:

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• Password:

• Language:

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• Units:

• Functionality:

• Auto Logout Time:

When there is no activity for the time entered in the Auto Logout Time dialog box, the
Neo5 will automatically logout the user. The default time is 5 minutes. The minimum is
10 seconds.

3. The Add a User screen will automatically move to next data screen after you select

. When you enter the auto logout time and touch , the user will be added to

the User Management screen.

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5.2.1.2 Delete a User

1. Select the user in the User Name column.

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1. Select in the left hand column.

2. Select on the Delete User screen.

3. The user is deleted.

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5.2.1.3 Change a User Password

1. Select the user in the User Name column.

2. Select .

3. In the Password screen, use the keyboard to enter the new password.

4. After you select , the confirm password screen will show.

5. Enter the password again, then . The password is changed.

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5.2.2 Set the Security Settings

1. On the Home screen, in the systems configuration row, select .

2. On top of the User screen, if necessary, select .

3. On the Screen Security screen, assign a role (operator, supervisor or administrator) to

each function.

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4. On the File Management tab, touch the to open the drop down menu.

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5. Touch the box to the right of the function/screen name to show the dialog box.

6. Select a user role, then .

The Users tab is greyed out because only the administrator can manage users. Refer to

Section 5.2.1.

7. Assign a user role for each function/screen in the remaining tabs on the Screen Security
screen.

When Operator is selected, the supervisor and administrator roles also have access to
the function/screen.

When Supervisor is selected, the operator cannot access that function/screen.

When Administrator is selected, the supervisor and operator cannot access that
function/screen.

5.2.3 Enable Security

You must put a check mark in the Enable Security box to apply all the security settings. The
default is Enable Security. You can touch the box and remove the check mark. This will
disable all the security settings and all users will have access to all functions/screens.

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Chapter 6 Mold Setups

The mold setup has the process parameters necessary to operate the hot runner system.

6.1 Mold Setup Screen

The Mold Setup screen stores and manages files such as mold setups, images, documents
and reports. Files 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 Neo5
hard drive and the right side displays all available directories and files from an external
source, such as a USB or a network file share.

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1. To access the mold setup screen, on the home screen in the System Configuration row
select File Management.

Or

2. Touch in the footer of any screen.

will show, in the left pane, mold setup files

stored in the mold folders, if molds is selected.

will show, in the left pane, image files stored in

the mold folders, if molds is selected.

will show all Comma Separated Value (CSV)

files stored in the mold folders in the left pane, if molds is selected.

will show all available file types stored in the

molds folders in the left pane, if molds is selected.

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If molds is selected, all the mold folders will be shown in the left hand pane.

If system is selected, the Reports folder, containing all system files will be shown.

3. Touch, , Details to expand display files in a tabular layout with file name, file size,
and the date and time last modified.

4. Select USB to display the contents of a connected USB device.

5. Select Network to display the contents of a network folder if the system is configured for

a network.

Button Description

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

Touch the New Mold Setup or Mold Folder button to create a new mold
setup file or mold folder. This button is not enabled if system is selected.

Touch the Copy button to copy mold setups, images, or CSV files from one
folder or device to another.

Touch the Delete button to delete a mold folder, mold setup, image or
CSV file. 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, or CSV file. This button is not enabled unless a file or
folder is selected.

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

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6.1.1 Saving Changes to a Mold Setup File

Once a Mold Setup file has been loaded, you can permanently save changes made to it.

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 . Changes are saved.

6.1.2 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 steps that follow:

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

2. Enter the new mold name, then .

6.1.3 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.

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6.1.4 Deleting Files

When a file or folder is no longer required on the internal hard drive, you can delete it.

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 . To cancel

6.1.5 Copying Files

You can copy mold setups, images, or CSV files from one folder or device to another.

To copy and paste a file, do the following:

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

2. Touch .

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the deletion, touch .

3. Navigate to the destination folder or pane, touch anywhere in the pane or folder.

6.1.6 Transferring Data

6.1.6.1 Transferring Data to the Network

Use the Mold Setup screen to transfer data to the network. When connected to the network,
the network folder structure appears by default in the right pane of the Mold Setup screen.

6.1.6.2 Transferring Data Using a USB Storage Device

You can transfer data using USB disks or USB CD-ROM drives. Select the USB button on the
Mold Setup screen. When a USB device is plugged into the USB port, the folder structure of
the USB device appears in the right pane of the Mold Setup screen. The folder structure
disappears when the device is unplugged. Follow the copy and paste steps to move files
from the USB device to the local hard drive, or from the local hard drive to the USB device.

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Chapter 7 Making Adjustments

You can make adjustments to the process settings for a mold setup before starting the mold,
or while the mold is running. This chapter explains how to use, monitor and modify the
system.

Neo5 allows zone data to be displayed in different graphical and textual formats. These
include tabular views, images, 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

• Text View

• Quick Set

• Neo2 View

• Staging

• Mold Test

• Mold Test Results

• Zone Calibration

• Zone Slot Configuration

• CAN Info

1. You can select zones four ways:

a. Touch a zone. The zone is selected.

b. Touch . This selects all the available zones.

c. Use the Block function. Touch and hold a zone element for more than a second. This

will highlight the zone green. Then touch another zone. All the zones between the
start and end zone are highlighted (selected).

d. Touch a zone and drag your finger. All the zones that your finger passes over are

selected. This is a zone selection option on all the screens except the Neo2 view.

2. Touch to reset all the selected zones.

3. When a zone is selected it will turn yellow.

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7.2 Creating a Group

1. On the Home screen, select

2. On the Groups button, touch to open the drop down menu.

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.

3. Assign names to one or more of the Group (1 thru 10) Name holders.

a. Touch the field to the right of the Group 1 Name.

b. Use the keyboard to enter in the Group 1 Name, then .

c. As necessary, do steps 3.a. and 3.b. to enter the Group 2 thru Group 10 Names.

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4. Select the zones that you want to be in a group.

5. Touch the field to the right of Group.

6. From the list in the Group dialog box, touch the Group Name that you want to give to

the selected zones, then .

7. A Group selector button for that group will be displayed at the bottom of the screen.

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8. As necessary, do steps 3 thru 6 again to assign zones to the remaining groups.

9. To delete a group, touch the box to the right of the Group X Name.

10. On the Group Name Keyboard screen, touch to delete the name, then .

The group name will be at the bottom of all the quick set screens. When you touch the
group name you can set or change the parameter for all the zones in the group at one
time.

You can make a maximum of 10 groups.

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On the home screen, in the zone views row, select

.

All the groups that were set up in the Quick Set groups screen will be shown.

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If you touch the screen will go to the full screen view.

7.2.1 Color Code

You can color code the groups.

1. On the header bar select .

2. On the Select a Color dialog box, select the color, then .

Touch to go back to the half screen view.

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The header bar for that zone will change to the color selected.

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7.2.2 Layout Order

You can also choose a layout order for the groups.

1. Select ,

2. Touch the clear previous button or clear all button to clear the numbers.

3. Touch the box for the group that you want to be at the top (1st position) on the multi-

group view.

4. Continue to touch the boxes to put the groups in the order that you want to see them,

then .

The groups will be arranged with the number 1group on top (in the full view screen). In
the half screen view, the groups are arranged top to bottom and left to right.

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7.2.3 Show Group Details

1. Touch in the header of the group to show the group details.

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2. Touch to show the details of all the groups.

3. Touch to collapse all the group details or touch to collapse only that

group’s details.

4. Touch to go to the Quick Set screen.

7.3 Neo2 View Screen Overview

The Neo2 View shows the 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.

On the Home screen, select the .

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NOTE: Heat OFF.

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NOTE: Heat OFF/zones cooling/zones 1 and 2 are switched OFF.

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NOTE: Heat ON/zones (green) at temperature/zones (white) are not at temperature/zone 1

is slaved to zone 24/zones 9, 17, and 25 - switched OFF.

Item Description

Temperature Bar The bar in each zone shows the temperature of the zone.

Segments of the bar are color coded.

• 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.

• The arrow turns black when the temperature is in the range of the

graph and moves up until it gets to the set point.

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

• The red and blue areas in the zone bar represent the high (red) and low

(blue) abort windows.

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

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Touch the button and the screen will toggle to the screen below. This screen only

shows the temperature of the zone.

Touch the button again to toggle back to the graphical view.

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7.4 Text View Screen Overview

The Text View screen displays zone information in a tabular format. Detailed data for each
zone is shown in each row of the table. This provides the most comprehensive view of the
process.

1. On the Home screen, select

.

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Column Header 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.
Refer to 7.5.

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

displayed in each column.

• Zone = Zone number

• Name = Zone name

• Setpoint = Zone setpoint

• Temp = Actual temperature of zone

• PWR = Power output to the heater

• Amps = Current draw of heater (values in this column are

suppressed for XL and HL cards)

• Leakage = Earth leakage. This column is only displayed if the
Display Earth Leakage Reading is selected in the Earth Leakage
section of the system setup screen

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

• 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)

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

• Ohms = Calculated full load ohms of the heater, based on the circuit
test results (values in this column are suppressed for XL and HL
cards)

• Full Load = Calculated full load wattage of the heater, based on the
circuit test results (values in this column are suppressed for XL and
HL cards)

• Volts = Measured line voltage that supplies power to each heater

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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

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7.4.1 Zone Selection in the Text View Screen

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

1. To view one zone, touch anywhere in the row of that zone.

2. To view multiple zones, touch and hold the first zone. Then drag up or down to the last

zone. All zones between the two zones are selected.

3. The view will automatically go to the Quick Set screen.

7.4.2 Sorting

You can sort column data on the Text View screen and all other screens that have column
headers. Touch the header field. The ascending or descending arrows ( )appear
next to the column header name. Touch the column header to reverse the order.

Information can be sorted according to the dynamic columns (for example, current (Amps),
voltage (Volts), etc.). This can help you when trying to figure out which zone is drawing the
most current at any moment.

7.5 Quick Set Screen

Use the Quick Set screen to change the zone settings.

On the Home screen, select

NOTE: When you select a zone in the Neo2, Multi-Group, or Text view screens the Quick

Set screen will automatically show.

.

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Select the zone, zones, or groups that you want to change or enter data.

To expand each tab, touch .

7.5.1 Frequently Used Fields

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Touch the box to the right of the parameter to display a keyboard or menu.

Temperature Setpoint — Use the keypad to enter the zone(s) temperature setpoint in Auto
or Monitor regulation.

Up and Down Arrows

Up arrow, , indicates the setpoint will increase by the entered amount. The
number below the arrow is the maximum numerical value that can be input in the dialog
window without exceeding the maximum limit of the setpoint.

NOTE: A maximum setpoint limit must be entered, refer to Section 7.5.4, before this button

becomes active.

Down arrow, , indicates the setpoint will decrease by the entered amount. The
number below the arrow is the maximum numerical value that can be input in the dialog
window without going below the minimum limit of the setpoint.

NOTE: A minimum setpoint limit must be entered, refer to Section 7.5.4, before this button

becomes active.

Use the and arrows to add or subtract a specified amount from the current
setpoint.

1. In the Normal Temperature Setpoint dialog box, touch the or button.

NOTE: The two buttons are at first greyed out.

2. With the keypad, enter in the amount that you want to add or subtract from the current

setpoint. For example, 5 degrees.

NOTE: After you enter the amount the or buttons will become active, not

greyed out.

3. Touch the button with the arrow. 5 degrees will be added to the current setpoint.

The dialog box will disappear. You will return to the Quick Set screen, and the setpoint
shown in the selected zones will increase by 5 degrees.

4. Touch the button with the arrow, and the current setpoint will decrease by 5

degrees. The dialog box will disappear. You will return to the Quick Set screen, and the
setpoint shown in the selected zones will increase by 5 degrees.

5. The number in the button is the maximum value that you can enter with the keypad to

use the up and down arrows.

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Power Setpoint — Use the keypad to adjust the percentage of power applied when the zone(s) is in
Manual regulation.

Zone On/Off — Turns the selected zone(s) ON or OFF. The default is ON.

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Regulation — Sets the regulation mode for the selected zone(s). AUTO or Automatic (closed loop) uses
the thermocouple feedback to control the temperature. Manual (open loop) means the system will
only apply power (0 to 100%), user selected, to the heater and not look for thermocouple feedback.
Monitor means the system will only monitor the temperature of the zone (no power applied to
heater).

Alarm Window — Use the keypad to adjust the upper and lower alarm limits.

Abort Window — Use the keypad to adjust the upper and lower abort limits.

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7.5.2 Zone Edit Fields

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Touch the box to the right of the zone name button.

Use the keyboard to name the zone(s) or groups. Eight common zone name tabs are above
the keyboard. Touch the common name tab to assign that name to the zone(s).

All the zones in group husky #1 have been assigned the zone name, valve gate.

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After you name all the zones, touch Auto+. Auto+ assigns a number, in sequential order, to
all the zones.

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Touch the box to the right of the locked/unlocked button.

In the dialog box select lock or unlock, then . If a zone(s) is locked, you cannot make
changes from the Quick Set screen.

All zones are displayed.

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7.5.3 Groups

Refer to Section 7.2.

7.5.4 Setpoint Limits

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Setpoint Range — Use the minimum and maximum dialog boxes to set the range for the
temperature setpoint. Example: If the Minimum is set to 100°F and the Maximum to 600°F,
you will not be able to enter a setpoint that is less than 100°F or more than 600°F.

Power Range — Use the minimum and maximum dialog boxes to set the power range.

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7.5.5 Manual Standby

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Manual Standby Temperature Setpoint — The temperature all zones are set to when you

select . Manual Standby lowers the temperatures of all the zones to the setpoint until

the timer expires or you touch again.

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Manual Standby Temperature Range — Use the minimum and maximum dialog boxes to set
the manual standby temperature range.

Manual Standby Power Setpoint — The power level that all zones are set to when you select

. Manual Standby lowers the power level to all the zones to the setpoint until the timer

expires or you touch again.

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Manual Standby Power Range — Use the minimum and maximum dialog boxes to set the
manual standby power range.

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Duration Timer — In the dialog box, set the time that the zones will stay in the manual
standby mode.

NOTE: This is a system setting that applies to all the zones.

Manual Standby Operational Description

Manual Time

0:00:00 ---- ---- ---- System enters Standby indefinitely.

X:XX:XX ---- ---- ---- System remains in Standby until the timer

Delay

Time

To cancel the manual standby duration timer at any time, touch the Start or Stop buttons.

Remote

Time

Input Mode Operation - STANDBY Button Select

expires.

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7.5.6 Manual Boost

Manual Boost Temperature Setpoint — The temperature all zones are set to when you select .

Manual boost increases the temperature of all the zones to the manual boost temperature setpoint

until the timer expires or you touch again. The default value is No Change.

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Manual Boost Temperature Range — Use the minimum and maximum dialog boxes to set
the manual boost temperature range.

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Manual Boost Power Setpoint — The power level that all zones are set to when you select

. Manual Boost increases the power level of all the zones to the setpoint until the timer

expires or you touch again. The default value is 90%.

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Manual Boost Power Range — In the dialog boxes, set the minimum and maximum manual
standby power range.

Manual Boost Duration Timer — In the dialog box, set the time that the zones will stay in the
manual boost mode.

Manual Boost Operational Description

Manual Time

0:00:00 ---- ---- ---- System enters Boost indefinitely.

X:XX:XX ---- ---- ---- System remains in Boost until the timer

Delay
Time

Remote

Time

Input Mode Operation - BOOST Button Select

expires.

Manual Boost can be cancelled at any time by touching the Start or Stop buttons.

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7.5.7 Remote Standby

Remote Standby is activated with a digital input to the Neo5 from a remote location on the
IMM.

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Remote Standby Temperature Setpoint — The temperature all the zones are set to when a
remote standby signal is received. Remote standby lowers the temperature of all the zones
to the setpoint until the timer expires or the remote standby signal is removed.

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Remote Standby Temperature Range — Use the minimum and maximum dialog boxes to set
the remote standby temperature range.

Remote Standby Power Setpoint — The power level all zones are set to when a remote
standby signal is received. Remote standby lowers the power levels to all the zones to the
setpoint until the timer expires or the remote standby signal is removed.

Remote Standby Power Range — Use the minimum and maximum dialog boxes to set the
remote standby power range.

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Duration Timer — In the dialog box, enter the time that the zones will stay in the remote
standby mode.

NOTE: The Duration Timer, Remote Standby Delay, and Input Mode are system settings that

apply to all the zones.

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Remote Standby Delay — In the dialog box, enter the time that you want the system to wait
from the time it receives the remote standby signal to when it enters the standby mode.

Input Mode — Set to one of the three modes.

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Remote Standby Operational Description

Manual

Time

---- 0:00:00 0:00:00 Trigger System will not enter Standby since no

---- 0:00:00 X:XX:XX Trigger System immediately enters and remains in

---- X:XX:XX X:XX:XX Trigger System delays for specified time and then

---- X:XX:XX 0:00:00 Trigger System delays for specified time and then

---- X:XX:XX X:XX:XX Trigger System delays for specified time and then

---- X:XX:XX 0:00:00 Trigger System delays for specified time and then

Delay Time

Remote

Time

Input Mode Operation - STANDBY Button Select

timers are set.

Standby until the timer expires.

enters Standby until the timer expires.

enters Standby indefinitely.

enters Standby until the timer expires. If the
input signal changes state while delay timer
is active, the delay timer is reset to the
specified value.

enters Standby indefinitely. If the input
signal changes state while the delay timer is
active, the delay timer is reset to the
specified value.

---- 0:00:00 0:00:00 ON/OFF System enters Standby until the input signal
is not active.

---- 0:00:00 X:XX:XX ON/OFF System enters Standby until the input signal
is not active or the timer expires.

---- X:XX:XX X:XX:XX ON/OFF System delays for specified time and then
enters Standby until the signal is not active
or the timer expires.

---- X:XX:XX 0:00:00 ON/OFF System delays for specified time and then
enters Standby until the input signal is not
active.

---- ---- ---- Direct System enters Standby until the input signal
is not active. If the input signal is active
when the system is started, it will
immediately go into Standby mode.

To cancel the remote standby duration timer at any time, touch the Start or Stop buttons
(only when in the Trigger or ON/OFF modes).

Reset Delay Timer in Direct Mode:

The Reset Delay Timer is only used when in Direct Mode and while the delay timer is in
progress.

If enabled, , the Reset Delay Timer allows you to reset the delay timer by touching the
Standby button in the system header.

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7.5.8 Remote Boost

Remote boost is activated with a digital input to the Neo5 from a remote location on the IMM.

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Remote Boost Temperature Setpoint — The temperature all zones are set to when a remote
boost signal is received. Remote boost increases the temperature of all the zones to the
remote boost temperature setpoint until the timer expires or the remote boost signal is
removed.

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Remote Boost Temperature Range — Use the minimum and maximum dialog boxes to set
the remote boost temperature range.

Remote Boost Power Setpoint — The power level that all zones are set to when a remote
boost signal is received. Remote boost increases the power level of all the zones to the
setpoint until the timer expires or the remote boost signal is removed.

Remote Boost Power Range — Use the minimum and maximum dialog boxes to set the
remote boost power range.

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Duration Timer — In the dialog box, enter the time that the zones will stay in the remote
boost mode.

NOTE: The Duration Timer, Remote Boost Delay, and Remote Boost Input Mode are system

settings that apply to all zones.

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Remote Boost Delay — In the dialog box, enter the time that you want the system to wait
from the time it receives the remote boost signal to when it enters the boost mode.

Remote Boost Input Mode — Set to one of the three modes.

Remote Boost Operational Description

Manual

Time

---- 0:00:00 0:00:00 Trigger System will not enter Boost since no timers are set.

---- 0:00:00 X:XX:XX Trigger System immediately enters and remains in Boost

Delay

Time

Remote

Time

Input
Mode

Operation - Boost Button Select

until the timer expires.

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Remote Boost Operational Description (Continued)

Manual

Time

---- X:XX:XX X:XX:XX Trigger System delays for specified time and then enters

---- X:XX:XX 0:00:00 Trigger System delays for specified time and then enters

---- 0:00:00 0:00:00 ON/OFF System enters Boost until the input signal is not

---- 0:00:00 X:XX:XX ON/OFF System enters Boost until the input signal is not

---- X:XX:XX X:XX:XX ON/OFF System delays for specified time and then enters

---- X:XX:XX 0:00:00 ON/OFF System delays for specified time and then enters

---- ---- ---- Direct System enters Standby until the input signal is not

Delay

Time

Remote

Time

Input
Mode

Operation - Boost Button Select

Boost until the timer expires.

Boost indefinitely.

active.

active or the timer expires.

Boost until the input signal is not active or the
timer expires.

Boost until the signal is not active.

active. If the input signal is active when the system
is started, it will immediately go into Standby
mode.

Remote Boost can be cancelled at any time by touching the Start or Stop buttons (only when
in the Trigger or ON/OFF modes).

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7.5.9 Heater Types

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1. Assign names to one or more of the Custom Heater Types (1 thru 8).

a. Touch the field to the right of the Custom Type 1. The Custom Heater Type Name

keyboard screen will be displayed.

b. Use the keyboard to enter in the heater type name or select one of the nine heater

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type names, then .

c. As necessary, do steps 1.a. and 1.b. to enter the Custom Type 2 thru Custom Type 8

names.

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2. Select the zones that you want assigned to a specific heater type.

3. Touch the field to the right of Heater Type.

4. From the drop down list, in the Heater Type dialog box, touch the heater type that you

want to assign to the selected zones, then .

5. As necessary, do steps 2. thru 4. again to assign heater types to other zones or groups.

7.5.10 Advanced Settings

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Output Power Limit — In the dialog box, enter the maximum percentage of output power
that will be supplied to heat the zones.

Slaved to Zone — In the dialog box, enter the zone number that the selected zone will be
slaved to. If the selected zones thermocouple fails, Neo5 will use the power output of the
zone that it is slaved to. This will let the selected zone function without an operating
thermocouple. Refer to Section 7.5.13.

Sensor Input — In the dialog box, enter the number of the thermocouple that is connected
to the zones. The match zone button will select the thermocouple with the same number as
the zone.

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Output Mode — In the dialog box, you can choose what type of output mode that will be
used to control the zones. Choose zero cross or phase angle.

PCM - Priority Control — In the dialog box, select zone or system. In an abort condition Neo5
will remove power from the zone if the malfunctioning zone is set to Zone or go into stop
mode if the malfunctioning zone is set to system.

AMC — Automatic Manual Control (AMC). If the zones thermocouple fails, Neo5 will
automatically apply a manual power output percentage to heat the zone, if AMC is set to On.
Neo5 software will use a historical average to calculate the manual power output
percentage.

Earth Leakage Check — In the dialog box, set the earth leakage check to On or Off. The
default setting is On.

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Earth Leakage Limit — In the dialog box, enter the limit, in Amps. The limit is the threshold
where Neo5 will give an Earth Leakage Alarm.

No Response Limit — This is a global setting that determines how long the system should
apply 96% power or more without a 5 degree rise in the temperature before it is declared an
alarm condition. The default value is 4 minutes and the valid range is 2 to 15 minutes.

No Heater Detected Enable — The No Heater Detected Alarm supplies instantaneous
fe edback that a heater has fail ed or is no lon ger connected to the circuit. Touch the No Heater
Detected Enable box to enable the No Heater Detected feature.

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No Heater Limit — This limit is used by the system to determine if a heater is still connected
to the zone. If the current measurement of the zone is below the limit for more than 10
seconds, the No Heater Alarm will be activated.

7.5.11 Control Settings Fields

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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 to 250.

I-Integral — This is the integral term value used by the control algorithm. Possible values are
0 to 250.

D-Derivative — This is the derivative term value used by the control algorithm. Possible
values are 0 to 250.

PID values are set in the ART settings drop down menu.

7.5.12 Art Settings

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ART

• Reset — Resets the ART parameters for the zones. At the next start operation, the zones
will go through the ART process.

NOTE: Reset can be selected regardless of the system mode.

• Re-ART — Reruns the tuning process on the selected zones.

NOTE: The system must be in run mode before a zone can be Re-ARTed.

• Cancel — Stops the ART process.

NOTE: The system must be in run mode before the ART process can be canceled.

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Minimum P — In the dialog box, enter the minimum Proportional (P) value.

Minimum I — In the dialog box, enter the minimum Integral (I) value.

Minimum D — In the dialog box, enter the minimum Derivative (D) value.

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Default P — In the dialog box, enter the default P value.

Default I — In the dialog box, enter the default I value.

Default D — In the dialog box, enter the default D value.

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ART Offset — The ART Offset is the number of degrees that the actual temperature has to be
below the normal setpoint for all the zones before the system starts the ART process.

7.5.13 Zone Slave

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Some of the most vulnerable components in the mold are the thermocouples. If a
thermocouple fails, an alarm will sound and an error is logged on the Alarm screen. When
this occurs you can do 1 of the 3 steps that follow:

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

2. Switch the zone to Manual control mode and continue processing. This has limitations
as Manual mode is not able to compensate for changes in the process that affect the
heater's power requirements, for example, 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. Neo5 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.

7.5.13.1 Using the Automatic Slave Function

If a thermocouple malfunctions during molding operation, the Auto-Slave function will take
over. Heaters are continuously monitored and comparative data is stored. This data is used
to select an almost identical Master/Slave relationship for every zone in the mold.

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Based on the stored comparative data, 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, and Text View screens, the zone number switches between the original
zone number and the zone to which it is slaved.

Once the error is cleared and reset, the slave value is stored 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.

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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 setting.

7.5.13.2 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.

1. On the Quick Set screen, select the zones that need to be slaved.

2. Open the Advanced Settings drop down menu.

3. Touch the box to the right of the Slave To Zone button. Enter the zone number that the

selected zone will be slaved to, then .

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

7.5.14 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 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.

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7.5.14.1 Changing the Zone Control from ART to PID

The control algorithm is automatically adjusted 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, you can manually enter values for the Proportional, Integral and
Derivative parameters.

7.5.14.2 Typical PID Values

The following is a list of some typical PID values.

PID Values

Proportional Integral Derivative Type Example

015 010 002 Fast Probes or heaters with internally located

050 020 000 Fast

thermocouples

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

7.5.14.3 Possible Causes of Oscillation

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

Possible Causes of Oscillation

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.

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

thermocouples (larger mass)

located thermocouples

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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.

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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. You can also use
diagnostics to analyze the thermal isolation between all the cavities in the mold.

8.1 Test Settings

NOTE: The settings are set to their default values at the factory. The settings can be changed

if necessary. The steps that follow are not mandatory and only need to be done once,
unless additional changes are necessary in the future.

Before you run a test you must enter in the test parameters in the Settings screen.

1. On the Home screen, select

.

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2. On the mold test screen, select settings.

3. Touch the box to the right of the validate Zone After button.

4. On the Validate Zone After dialog box, enter the temperature, then . This is the

temperature rise in degrees that a zone must reach before it is considered an
operational zone.

5. Touch the box to the right of the Fixed Start Setpoint button.

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