Mold-Masters M2 User Manual

M2 Controller

User Manual

with TS/KTS Console

Mold-Masters (2007) Limited A Milacron Company

Original Instructions

REMOVE AND KEEP THIS

SHEET SOMEWHERE SAFE

Every machine leaves our factory with two levels of

password protection. We recommend that you remove

this sheet in order to establish your own security.

User Password - unix

System Password - linux

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Table of Contents

Section 1 - Introduction .......................................................1-1

1.1 INTENDED USE .......................................................................................................1-1

1.2 AUDIENCE ...............................................................................................................1-1

1.3 REQUIRED USER SKILLS ......................................................................................1-1

1.4 RELEASE DETAILS .................................................................................................1-1

Section 2 - Global Support ..................................................2-1

Section 3 - Safety Instructions ............................................3-1

3.1 SAFETY NOTICES - AN EXPLANATION .................................................................3-1

3.2 WHERE TO USE THIS EQUIPMENT .....................................................................3-1

3.2.1 MOLD HEATING ..............................................................................................3-1

Section 4 - Overview ............................................................4-1

4.1 SPECIFICATION ......................................................................................................4-1

4.2 HOW TO ISOLATE THE CONTROLLER .................................................................4-2

4.2.1 SWITCHING ON ..............................................................................................4-2

4.2.2 MOLD HEATING ..............................................................................................4-2

4.3 SWITCHING OFF (THE CONTROLLER) .................................................................4-3

4.4 SCREEN LAYOUT AND NAVIGATION ....................................................................4-4

4.5 MAIN PAGE ..............................................................................................................4-5

4.6 DISPLAY PAGE – OTHER SYMBOLS AND WHAT THEY MEAN ...........................4-6

4.7 DISPLAY PAGE – MONITORING (KTS SCREEN) ..................................................4-7

4.8 DISPLAY PAGE – MONITORING (TSA2 WIDE SCREEN) ......................................4-9

4.9 DISPLAY PAGE – AUTOMATIC RESIZING FOR FEWER ZONES .......................4-11

4.9.1 BIG PANELS .................................................................................................. 4-11

4.9.2 MEDIUM PANELS .........................................................................................4-11

4.9.3 NORMAL PANELS .........................................................................................4-11

4.10 DISPLAY PAGE – MONITOR (ZOOM) .................................................................4-12

4.11 DISPLAY PAGE – START, STOP AND MORE .....................................................4-13

4.12 MAIN PAGE – HOW TO SET TEMPERATURE ...................................................4-14

4.13 MORE PAGES ......................................................................................................4-16

4.13.1 EASYVIEW ..................................................................................................4-16

4.13.2 GRAPH PAGE .............................................................................................4-16

4.13.3 THE TOOLSTORE PAGE ............................................................................4-16

4.13.4 THE PICTURE PAGE ..................................................................................4-17

4.13.5 THE UTILITIES PAGE .................................................................................4-17

4.13.6 THE TESTING PAGE ..................................................................................4-18

4.13.7 THE SETUP PAGE ......................................................................................4-18

4.14 USER INPUT ........................................................................................................4-19

Section 5 - Set Up .................................................................5-1

5.1 STAGES INCLUDED IN SETTING UP A CONSOLE ...............................................5-2

5.1.1 CREATE A FIRST TOOL .................................................................................5-2

5.1.2 SET UP TOOL PARAMETERS ........................................................................5-2

5.1.3 CONFIGURE SYSTEM SETTINGS ................................................................5-2

5.1.4 SET UP OPERATING PARAMETERS ............................................................5-2

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5.2 CREATE A FIRST TOOL ..........................................................................................5-3

5.3 SETUP PAGE - CARDS THAT MAY BE DETECTED...............................................5-4

5.4 PRE-CONFIGURED SETUP VALUES .....................................................................5-5

5.5 HOW TO CONFIGURE THE CONTROL CARDS ....................................................5-6

5.6 SET THE TOOL PARAMETERS...............................................................................5-8

5.7 THE TOOL PARAMETERS ......................................................................................5-9

5.8 CONFIGURE THE TOOL & SYSTEM SETTINGS .................................................5-12

5.9 THE TOOL SETTINGS ..........................................................................................5-13

5.10 THE SYSTEM SETTINGS ....................................................................................5-18

5.11 SET OPERATING PARAMETERS........................................................................5-21

5.11.1 SELECTING ZONES ...................................................................................5-21

5.11.2 TO SET PROBE AND MANIFOLD TEMPERATURES ................................5-23

5.11.3 TO SET SPEAR (BODY AND TIP) TEMPERATURES ................................5-24

5.11.4 TO SET CAVITIES, WATER FLOWS AND CHILLERS ................................5-26

5.12 SAVE EVERYTHING TO A TOOL BANK ..............................................................5-27

5.13 SET UP EASYVIEW PAGES ................................................................................5-28

5.14 PASSWORDS AND USER ACCESS EXPLAINED ..............................................5-31

5.14.1 SET UP USER ACCESS .............................................................................5-32

5.14.2 CONFIGURE USERS ..................................................................................5-34

5.14.3 LIST CURRENT USERS .............................................................................5-35

5.14.4 USER ADMIN OPTIONS .............................................................................5-36

5.14.5 CONFIGURE USER LIMITATIONS .............................................................5-37

5.15 MELT LEAKAGE DETECTION .............................................................................5-38

5.15.1 CONFIGURING AUTO LEAKAGE DETECTION .........................................5-38

5.16 SET TIME AND DATE ..........................................................................................5-40

5.17 UTILITIES - ENERGY PAGE ................................................................................5-41

5.18 PRINT PAGE ........................................................................................................5-42

5.18.1 USING A LOCALLY CONNECTED PRINTER ............................................5-42

5.18.2 USING A REMOTE NETWORK PRINTER .................................................5-42

5.18.3 PRINTING TO A USB MEMORY STICK ......................................................5-42

5.19 EVENT LOG AND EXPORT PAGES ....................................................................5-43

Section 6 - Operation ...........................................................6-1

6.1 LOG IN ....................................................................................................................6-2

6.1.1 LOG OUT .........................................................................................................6-2

6.2 CONTROL MODES FOR ALL ZONES .....................................................................6-3

6.2.1 CONTROL FOR INDIVIDUALLY SELECTED ZONES ....................................6-4

6.3 MORE ABOUT USING BOOST ................................................................................6-5

6.4 USE DISPLAY PAGE TO CHANGE TEMPERATURES ...........................................6-6

6.5 USE THE DISPLAY PAGE TO CHANGE MODES ...................................................6-7

6.6 MORE ABOUT SLAVING ZONES ............................................................................6-8

6.7 ABOUT EASYVIEW PAGE .......................................................................................6-9

6.8 USE EASYVIEW TO CHANGE TEMPERATURES ................................................6-10

6.9 USE EASYVIEW TO CHANGE MODES ................................................................6-11

6.10 PURGE SEQUENCE ............................................................................................6-12

6.11 PRE-SET PURGE PARAMETERS .......................................................................6-13

6.12 CHECK ZONE PAST PERFORMANCE (GRAPH) ...............................................6-14

6.12.1 INSPECTING THE LAST 5 OR 30 MINUTES ............................................6-14

6.12.2 INSPECTING THE LAST 24 HOURS ..........................................................6-15

6.13 THE EVENT LOG PAGE ......................................................................................6-16

6.13.1 BEACON AND SOUNDER EXTENSION ....................................................6-20

6.14 TRAINING AND DEMONSTRATION MODE ........................................................6-21

6.14.1 ABOUT DEMO MODE .................................................................................6-21

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6.14.2 SELECT DEMO MODE ...............................................................................6-21

6.14.3 DE-SELECT DEMO MODE .........................................................................6-22

6.15 TOOL STORE PAGE ............................................................................................6-23

6.16 CREATE A NEW TOOL ........................................................................................6-24

6.17 RENAME A USED TOOL ......................................................................................6-27

6.18 LOAD TOOL SETTINGS (LOCALLY) ...................................................................6-29

6.18.1 LOAD TOOL SETTINGS (REMOTELY) ......................................................6-29

6.19 SAVE TOOL SETTINGS .......................................................................................6-30

6.19.1 OVER-WRITING THE LAST SETTINGS WITH NEW SAVED SETTINGS .6-30

6.19.2 SAVE MODIFIED SETTINGS, WITHOUT LOSING EXISTING ONES .......6-31

6.20 DELETE A TOOL ..................................................................................................6-32

6.21 BACK-UP TOOL SETTINGS ................................................................................6-33

6.21.1 TO SAVE (BACKUP) ALL THE TOOLS: ......................................................6-33

6.21.2 TO SAVE (BACKUP) ONE SELECTED TOOL SETTING ...........................6-34

6.22 RESTORE TOOL SETTINGS ...............................................................................6-35

6.22.1 TO RESTORE ALL THE TOOLS .................................................................6-35

6.22.2 TO RESTORE A SINGLE TOOL ..................................................................6-36

6.23 SEQUENCE TOOLS AND SETTINGS .................................................................6-37

6.23.1 SETTING AN EXAMPLE STARTUP SEQUENCE FOR THIS EXAMPLE ...6-38

6.24 THE PICTURE PAGE ...........................................................................................6-39

6.24.1 TO VIEW AN IMAGE ...................................................................................6-39

6.24.2 TO LOAD A NEW IMAGE ............................................................................6-40

6.24.3 TO SAVE AN IMAGE ...................................................................................6-42

6.24.4 TO DELETE AN IMAGE ..............................................................................6-43

6.25 THE 4-CHANNEL INPUT/OUTPUT CARD:..........................................................6-44

6.25.1 DISPLAY PAGE ...........................................................................................6-44

6.25.2 QUAD WATCHDOG TIMER .......................................................................6-45

6.25.3 INPUTS ........................................................................................................6-45

6.26 OUTPUTS ............................................................................................................6-46

6.27 DEFAULT INPUT/OUTPUT SELECTION AND CONNECTOR PIN TABLE .........6-47

6.28 HOW TO USE THE IO5 CARD FOR REMOTE TOOL SELECTION....................6-48

6.29 DYNAMIC REMOTE TOOL LOAD PROCESS .....................................................6-49

Section 7 - Maintenance.......................................................7-1

7.1 PRINT OUT FACILITY (TO PRINTER) .....................................................................7-2

7.1.1 OPTION 1 - A SCREEN PICTURE .................................................................7-2

7.1.2 OPTION 2 - TABLE FORMAT ..........................................................................7-2

7.2 PRINT OUT TO FILE ................................................................................................7-3

7.3 EXPORT FACILITY ..................................................................................................7-5

7.4 SELF DIAGNOSTIC TESTS .....................................................................................7-7

7.4.1 WHY YOU MAY NEED TO CHANGE YOUR TEST PARAMETERS ...............7-7

7.5 HOW TO RUN A SELF DIAGNOSIS TEST ..............................................................7-8

7.5.1 TO SELECT SOME ZONES ............................................................................7-8

7.5.2 TO SELECT EVERY ZONE .............................................................................7-8

7.6 SYSTEM DIAGNOSIS RESULTS...........................................................................7-10

7.7 HOW TO INTERPRET THE TEST RESULTS ........................................................7-10

7.7.1 SATISFACTORY TEST ..................................................................................7-11

7.7.2 UNSATISFACTORY TEST .............................................................................7-11

7.8 SERVICING AND REPAIRING YOUR CONTROLLER ..........................................7-12

7.8.1 REPLACEMENT PARTS ...............................................................................7-12

7.8.2 CLEANING AND INSPECTION .....................................................................7-12

7.9 HOW TO UPGRADE THE CONSOLE SOFTWARE ..............................................7-13

7.9.1 PREPARATION .............................................................................................7-13

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7.9.2 PROCEDURE ................................................................................................7-13

Section 8 - Troubleshooting ................................................8-1

8.1 FAULT AND WARNING MESSAGES .......................................................................8-1

8.2 SYSTEM WARNING MESSAGES ...........................................................................8-4

8.3 INDIVIDUAL CONTROLLER CARD DIAGNOSTICS ...............................................8-4

8.4 TOUCHSCREEN - REMOVAL AND RECONNECTION ..........................................8-5

8.4.1 REMOVING A CONSOLE ................................................................................8-5

8.4.2 RECONNECTING A CONSOLE ......................................................................8-6

8.5 OTHER PROBLEMS WITH THE TOOL ...................................................................8-7

8.6 M2 FUSES ................................................................................................................8-9

8.6.1 REPLACEMENT FUSES .................................................................................8-9

Appendix A - HRC Wiring Details ....................................... A-1

Appendix B - Optional Cards ..............................................B-1

Appendix C - Network Information ....................................C-1

Appendix D - Water Manifolds ............................................ D-1

Appendix E - Sequence Valve Gate ................................... E-1

VII

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Section 1 - Introduction

1.1 Intended Use

This manual is intended for use with the M2-Series Controller together with either the TS or KTS Console

It is written and prepared for Software Version – 14th January 2014

Mold-Masters Hot Runner Controllers such as this M2 series have been designed as a multi channel temperature controller for use in Hot Runner plastic molding equipment. They use feedback from thermocouples within the nozzles and manifolds to give precise closed-loop temperature control.

Any other uses would fall outside the engineered intent of this machine which may be a safety hazard and would void any and all warranties.

This manual is designed to cover most system common congurations. If you need additional information specic to your system please contact your repre-

sentative or a Mold-Masters ofce whose location can be found in the “Global Support” section.

1.2 Audience

This manual is written for use by skilled persons who are familiar with Hot Runner Controllers and their terminology.

INTRODUCTION

1.3 Required User Skills

Operators should be familiar with plastic injection molding machines and the controls of such equipment.

Maintenance persons should have sufcient understanding of electrical safety

to appreciate the dangers of 3-phase supplies. They should know how to take appropriate measures to avoid any danger from electrical supplies.

BEFORE YOU OPERATE THE CONTROLLER

We recommend that you read the manual fully before connecting up or using the controller.

We recommend that you run a Self Diagnostic routine on page 7-8 to check that all zones are correctly sequenced and that there is no cross-wiring between zones or between heater outputs and thermocouple inputs.

1.4 Release Details

Document Id Release Date Version

M2K_UM_EN_V3_3 01 October 2014 3

Our policy is one of continuous improvement and we reserve the right to alter

product specications at any time without giving notice.

1-1

GLOBAL SUPPORT

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Section 2 - Global Support

Manufacturing Facilities

GLOBAL HEADQUARTERS

CANADA

Mold-Masters Limited 233 Armstrong Avenue Georgetown, Ontario Canada L7G 4X5 tel: +1 (905) 877 0185 fax: +1 (905) 873 2818 info@moldmasters.com

SOUTH AMERICAN

HEADQUARTERS

BRAZIL

Mold-Masters do Brasil Ltda. Estrada Municipal Mineko Ito, nº4305 Loteamento Industrial Veccon Zeta

- Sumaré / SP CEP: 13178-903 tel: +55 19 3518-0699 fax: +55 19 3518-0699 moldmasters@moldmasters.com.br

EUROPEAN HEADQUARTERS

GERMANY

Mold-Masters Europa GmbH Postfach/P.O. Box 19 01 45 76503 Baden-Baden, Germany

Neumattring 1 76532 Baden-Baden, Germany

tel: +49 7221 50990 fax: +49 7221 53093 europe@moldmasters.com

INDIA

Mold-Masters Technologies Private Limited # 247, Alagesan Road, Shiv Building, Saibaba Colony. Coimbatore T. N. India 641 011 tel: +91 422 423 4888 fax: +91 422 423 4800 mmtplinfo@moldmasters.com

ASIAN HEADQUARTERS

CHINA/HONG KONG/ TAIWAN

Mold-Masters (KunShan) Co, Ltd Zhao Tian Rd Lu Jia Town, KunShan City Jiang Su Province People’s Republic of China tel: +86 512 86162882 fax: +86 512-86162883 mmc-sales@moldmasters.com

JAPAN

Mold-Masters K.K. 1-4-17 Kurikidai, Asaoku Kawasaki, Kanagawa Japan, 215-0032 tel: +81 44 986 2101 fax: +81 44 986 3145 info@mmkk.co.jp

UNITED KINGDOM

Mold-Masters (UK) Ltd Netherwood Road Rotherwas Ind. Est. Hereford, HR2 6JU United Kingdom tel: +44 1432 265768 fax: +44 1432 263782 uk@moldmasters.com

Regional Ofces

AUSTRIA / East and South

East Europe

Mold-Masters Handelsges.m.b.H. Pyhrnstrasse 16 A-4553 Schilerbach Austria tel: +43 7582/51877 fax: +43 7582/51877 18

ofce@moldmasters.at

U.S.A.

Mold-Masters Injectioneering LLC 103 Peyerk Court Romeo, MI 48065, USA tel: +1 800 450 2270 (USA only) tel: +1 (586) 752-6551 fax: +1 (586) 752 6552 mmi-inq@moldmasters.com

CZECH REPUBLIC

Mold-Masters Europa GmbH Hlavni 823 75654 Zubri Czech Republic tel: +420 571 619 017 fax: +420 571 619 018

cz@moldmasters.com

FRANCE

Mold-Masters France ZI la Marinière, 2 Rue Bernard Palissy 91070 Bondoue tel: +33 1 82 05 00 80 fax: +33 1 82 05 00 83 fr@moldmasters.com

2-1

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Regional Ofces - contd.

GLOBAL SUPPORT

KOREA

MM Systec Company, Ltd J-502, Kuro Distribution Business Center 636-62, Kuro-Dong, Kuro-Ku, Seoul, Korea tel: +82 2 2634 9453/4 fax: +82 2 2634 9608 e-mail: kyungins@hanmir.com

MEXICO

Intec-Plast S.A. de C.V. 185 Av. Once Bod 8 Col. San Juan, Xalpa Iztapalapa 09850 México City, D.F. tel: +52 55 5612 2302 tel: +52 55 5614 6371 fax: +52 55 5612 2312 e-mail: intecplast@att.net.mx

SINGAPORE / MALAYSIA INDONESIA / THAILAND

Mold-Masters Singapore PTE. Ltd. No 48 Toh Guan Road East #06-140 Enterprise Hub Singapore 608586 Republic of Singapore tel: +65 6261 7793 fax: +65 6261 8378

SPAIN

TEIN INGIENER, S.L. C/ Sepúlveda 32 08015 - Barcelona - Spain tel: +34 93 289 05 10 fax: +34 93 289 05 11 e-mail: sandra.romero@tein-moldmasters.

com

mmsinfo@moldmasters.com

International Representatives

ARGENTINA

Sollwert S.R.L.

La Pampa 2849 2∫ B

C1428EAY Buenos Aires Argentinia tel: +54 11 4786 5978 fax: +54 11 4786 5978 Ext. 35

sollwert@bertel.com.ar

AUSTRALIA

Comtec I P E 1084 South Road, Edwardstown, South Australia 5039 PO Box 338, Magill, South Australia 5072 tel: +61 8 8374 4633 fax: +61 8 8299 0892 bparrington@comtecipe.com

BULGARIA

Mold-Trade OOD 62, Aleksandrovska St. Ruse City Bulgaria tel: +359 82 821 054 fax: +359 82 821 054 contact@mold-trade.com

POLAND

Mold-Masters Europa GmbH ul. Ratuszowa 11 - lok. 72 03-450 Warszawa Poland tel: +48 22 619 0630 fax: +48 22 619 0243

e-mail: pl@moldmasters.eu

TURKEY

MMG Consulting & Engineering Yesil Çesme Sok No:30/3 Çiftehavuzlar 81060, Istanbul, Turkey tel: +90 216 357 0783 fax: +90 216 385 0656

mmgevrek@superonline.com

DENMARK, NORWAY, SWEDEN

H. & G. Englmayer A/S Skenkelsoevej 9, Postbox 35 DK - 3650 Oelstykke, Denmark tel: +45 46 733847 fax: +45 46 733859 support@englmayer.dk

FINLAND

Oy Scalar Ltd. Viertolantie 12 11120 Riihimaki, Finland tel: +358 10 387 2955 fax: +358 10 387 2950

info@scalar.

ITALY

Commerciale Isola SPA Via G.B. Tiepolo 3 35010 Cadoneghe, (Padova) Italy tel: +39 49 706600 fax: +39 49 8874231 info@com-isola.it

VIETNAM

Mold-Masters Singapore PTE. Ltd. No 48 Toh Guan Road East #06-140 Enterprise Hub Singapore 608586 Republic of Singapore tel: +65 6261 7793 fax: +65 6261 8378 mmsinfo@moldmasters.com

GREECE

Ionian Chemicals S.A. 21 Pentelis Ave. 15235 Vrilissia Athens Greece tel: +30 210 6836918-9 fax: +30 210 6828881 m.pavlou@ionianchemicals. gr

PORTUGAL

Gecim LDA Rua Fonte Dos Ingleses, No 2 Engenho 2430-130 Marinha Grande, Portugal tel: +351 244 575600 fax: +351 244 575601 gecim@gecim.pt

IRELAND

Bray Engineering Services Mr. Liam Shortt Unit F3 Network Enterprise Business Park Kilcoole, Co. Wicklow, Ireland tel: +353 1 201 5088 fax: +353 1 201 5099 info@BrayEngineeringServices.com

ROMANIA

Tehnic Mold Trade SRL Str. W. A Mozart nr. 17 Sect. 2 020251 Bucharesti Romania tel: +4 021 230 60 51 fax : +4 021 231 05 86 contact@matritehightech.ro

ISRAEL

ASAF INDUSTRIES Ltd. 29 Habanai Street PO Box 5598 Holon 58154 Israel tel: +972 3 5581290 fax: +972 3 5581293 sales@asaf.com

RUSSIA

PORTMOLD Company LC Gefsimanskie prudy 4, 141307 Sergiev Posad Russia tel: +7 8 495 743 48 65 fax: +7 8 496 549 25 26 moldmasters@portmold.ru

2-2

GLOBAL SUPPORT

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Trademarks & Patents

ACCU-VALVE, DURA, FLEX-DURA FLEX-SERIES, FUSION-SERIES, HOT EDGE, INJECTIONEERING, MASTERPROBE, MASTER-SHOT, MOLD-MASTERS, MELT-DISK, MOLD-MASTERS ACADEMY, MASTER-SERIES, MASTERSOLUTION, MASTERSPEED, MERLIN, MOLD-MASTERS SYSTEM, MPET, SCAN-MASTER, STACK-LINK, are the registered trademarks of MOLD-MASTERS (2007) LIMITED.

Information contained herein is, to our best knowledge, true and accurate, but all recommendations or suggestions are made without guarantee. Since the conditions of use are beyond our control, Mold-Masters disclaims any liability incurred in connection with the use of our products and information contained herein. No person is authorized to make any statement or recommendation not contained herein, and any such statement or recommendation so made shall not bind Mold-Masters. Furthermore, nothing contained herein shall be con-

strued as a recommendation to use any product in conict with existing patents covering any

products or its use, and no license implied or in fact granted herein under the claims of any patents.

No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage and retrieval system without

permission in writing from the publisher. All details, standards and specications may be altered in accordance with technical development without prior notication.

May be manufactured under one or more of the following U.S. Patents:

5284436, 5299928, 5312242, 5326251, 5334008, 5334010, 5346388, 5366369, 5366370, 5387099, 5405258, 5421716, 5427519, 5429491, 5437093, 5441197, 5443381, 5460510, 5474440, 5494433, 5496168, 5507635, 5507636, 5536165, 5591465, 5599567, 5614233, 5641526, 5644835, 5652003, 5658604, 5695793, 5700499, 5704113, 5705202, 5707664, 5720995, 5792493, 5795599, 5820899, 5843361, 5849343, 5853777, 5935615, 5935616, 5935621, 5942257, 5952016, 5980236, 6009616, 6017209, 6030198, 6030202, 6062841, 6074191, 6077067, 6079972, 6095790, 6099780, 6113381, 6135751, 6162043, 6162044, 6176700, 6196826, 6203310, 6230384, 6270711, 6274075, 6286751, 6302680, 6318990, 6323465, 6348171, 6350401, 6394784, 6398537, 6405785, 6440350, 6454558, 6447283, 6488881, 6561789, 6575731, 6625873, 6638053, 6648622, 6655945, 6675055, 6688875, 6701997, 6739863, 6752618, 6755641, 6761557, 6769901, 6776600, 6780003, 6789745, 6830447, 6835060, 6840758, 6852265, 6860732, 6869276, 6884061, 6887418, 6890473, 6893249, 6921257, 6921259, 6936199, 6945767, 6945768, 6955534, 6962492, 6971869, 6988883, 6992269, 7014455, 7018197, 7022278, 7025585, 7025586, 7029269, 7040378, 7044191, 7044728, 7048532, 7086852, 7105123, 7108502, 7108503, 7115226, 7118703, 7118704, 7122145, 7125242, 7125243, 7128566, 7131832, 7131833, 7131834, 7134868, 7137806, 7137807, 7143496, 7156648, 7160100, 7160101, 7165965, 7168941, 7168943, 7172409, 7172411, 7175419, 7175420, 7179081, 7182591, 7182893, 7189071, 7192268, 7192270, 7198740, 7201335, 7210917, 7223092, 7238019, 7244118, 7252498, 7255555, 7258536, 7270538, 7303720, 7306454, 7306455, 7314367, 7320588, 7320589, 7320590 7326049, 7344372, 7347684, 7364425, 7364426, 7370417, 7377768, 7381050, 7396226, 7407379, 7407380, 7410353, 7410354, 7413432, 7416402, 7438551, 7462030, 7462031, 7462314, 7465165, 7470122, 7507081, 7510392, 7513771, 7513772, 7517214, 7524183, 7527490, 7544056, 7547208, 7553150, 7559760, 7559762, 7565221, 7581944, 7611349, 7614869, 7614872, 7618253, 7658605, 7658606, 7671304, 7678320, 7686603, 7703188, 7713046, 7722351, 7731489, 7753676, 7766646, 7766647, 7775788, 7780433, 7780434, 7794228, 7802983, 7803306, 7806681, 7824163, 7845936, 7850442, 7874833, 7877163, 7891969, 7918660, 7918663, 7931455, 7963762, 7988445, 7998390, 8062025, 8066506, 8113812, 8142182, 8152513, 8167608, 8202082, 8206145, 8210842, 8241032, 8280544, 8282386, 8308475, 8308476, 8328546, D525592, RE38265, RE38396, RE38920, RE39935, RE40478, RE40952, RE41536E, RE41648E+ Pending.

2-3

SAFETY INSTRUCTIONS

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Section 3 - Safety Instructions

The M2-Series Controller is an electrical distribution and control device which is designed to be safe during normal operation.

It is essential that the user DOES NOT open the cabinet without rst

ISOLATING the mains supplies to the equipment - there may be terminals inside the cabinet which may have a dangerous potential across them.

Where a three-phase supply is used then this potential may be at 380 volts or higher.

3.1 Safety Notices - an explanation

A WARNING symbol and message, shown here, identies where

there may be a hazardous situation which, if not avoided, may result in death or injury to personnel.

Most warnings pertain to electrical aspects and you must comply with them to minimise any personal danger.

CAUTION

A CAUTION identies where there may be a hazardous situation

which, if not avoided, may result in damage to property.

Caution warnings present no personal danger, but may cause the equipment to fail or lose its memory.

3.2 Where to use this equipment

The display console and controller cabinet together are designed for use in the plastic injection moulding industry as temperature controllers for third party hot runner systems as commonly used in mold tools. They must not be used in residential, commercial or light-industrial environments. Furthermore, they must not be used in an explosive atmosphere, or where there is a possibility of such an atmosphere developing.

The HRC cabinet and Touch Screen console should be installed in a clean dry environment where the ambient conditions do not exceed the following limits:

• Temperature 0 to +35°C.

• Relative Humidity 90% (non-condensing)

3-1

SAFETY INSTRUCTIONS

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3.3 Check your wiring

Before you energise the system, pay special attention to how the supply to your controller is wired and how it is connected to the mold.

Lack of attention to detail causes errors such as:

• Incorrect wiring of mains supply phases into the controller.

• Crossing heater supply feeds with thermocouple detection (although this error can be eliminated by the adoption of Mold-Masters Standard connections).

In such cases wiring errors have caused equipment failure.

Mold-Masters (UK) Ltd. cannot be responsible for damage caused to the controller by customer wiring and/or connection errors.

3.4 Mold Heating

After the consoles have started and the main display screen is visible then the controller may, or may not, start to heat up the zones; it

depends on how the Console Startup option is congured. (See page

5-19.) If Console startup is set to “Stop” then the tool remains at zero pow-

er and at room temperature. If it set to any of the other three options (Startup, Standby, or Run) the controller applies power to the zones so that they heat up.

3-2

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Section 4 - Overview

4.1 Specication

The following are general specications. The actual controller/console supplied may have contractual variations and differ in some specied

options.

Supply Voltage 415Vac 3 phase 50/60Hz with neutral, Other

available include 240/380/400 and 480 volts in

Star or Delta conguration.

Voltage Bandwidth Stable within 20% supply voltage swing

Supply ground-leakage trip 300mA (note: this is for tool protection)

Unit Overload protection Miniature Circuit Breaker

Output overload protection 15A super-quick acting (FF) fuse on both legs

Power output 15A/3600W per zone

Ground Fault Detection 40mA per zone

Thermocouple input Type ‘J’, or type ‘K’

Control Method Self tuning PID

Soft-Start with Auto Tune Unique low voltage method for heater safety

Temperature scale Centigrade (Celsius) or Fahrenheit

Operating Range 0 - 472°C or 32 - 882°F

Control Accuracy +/-1°C

Printer Output Connector USB Port

Data Communications RS-232 serial, DB9 male connector

Communication Protocol SPI, VNC and client over Ethernet

Alarm Output Closing volt-free contacts - 5A max 230V

Remote Input Voltage free pair to signal Boost or Standby

Interface Full colour LCD touch screen (choice of sizes)

Case Details Heavy duty metal cabinet with swing up console

Sizes in mm

M2XS: 310w × 450d × 450h

M2S : 360w × 450d × 800h

M2M: 450w × 540d × 860h

M2L: 450w × 540d × 1330h

OVERVIEW

Filter Option

In countries where noise across power lines is a concern,

Mold-Masters recommends that you t the model 63AYC10B in-line lter which is supplied by TC Connectivity.

4-1

OVERVIEW

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4.2 How to Isolate the Controller

The main Power Switch is sufciently rated to disconnect the total

load current during switch On and switch Off. To prevent its operation, during maintenance, you can use a suitably-sized padlock, or similar device, to lock the switch in the Off position.

4.2.1 Switching On

Main Cabinet

Switch ON the Main Isolator to energise the main cabinet.

KTS Console

The KTS Console has a main On/Off switch, at the rear right-hand side of the

console case, which is normally left switched “on”.

If left on then the console will start its boot up sequence as the cabinet is powered up.

If the cabinet is switched on and the console does not start then check this switch has not been turned off.

Console Switch

TSA2 Console

The TSA2 Console has a non-latching push button at the bottom right hand side of the screen. After switching on the main cabinet on you then need to

briey press the start button until it illuminates. Release the button and the

console will start its normal boot-up sequence.

Console Switch

4.2.2 Mold Heating

After the consoles have started and the main display screen is visible then the controller may, or may not, start to heat up the zones; it

depends on how the Console Startup option is congured. (on page

5-19.) If Console startup is set to “Stop” then the tool remains at zero pow-

er and at room temperature. If it set to any of the other three options (Startup, Standby, or Run) the controller applies power to the zones so that they heat up.

4-2

OVERVIEW

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4.3 Switching Off (the Controller)

We recommend that you use the console to shut down the heating load, and only use the main isolator to switch off a dormant controller.

1. Shut down the heating.

On the Display page, choose [Stop] to reduce the heating to zero.

2. Shut down the Console

On the Utils page, choose [Exit] to shut down the Console Computer.

3. Shut down the Controller

Finally, use the <Main Power Switch> to isolate all the power to the whole system.

4-3

OVERVIEW

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4.4 Screen Layout and Navigation

This page introduces the console to show what functions are available and what information is given.

Navigation - Top of page

Top tabs to switch between the different pages.

Control - Side of page

Contains various command buttons that change from page to page.

Monitor & Information - Bottom of page

The lower left side shows Run Mode while the centre has messages, such as prompts when a password is required. On the right is operator name or admin-level, and lastly the controller health status.

4-4

OVERVIEW

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4.5 Display Page

Can be used for

• Monitor – observe zone condition.

• Control – Start/Stop & Boost/Standby immediately available. All

other (“Standby, Shutdown, Stop“) available if you choose [

Mode].

• Set – select any one or more zones to get [ alter zone set-point or run modes.

Monitoring

This Healthy Zone shows:

Zone Name (user congurable)

Actual Temperature (may be Coarse at

whole degree steps or Fine at tenth of a degree steps)

Scale and Set Temperature

Applied Power (%)

Applied Current (Amps)

Deviation - between Actual & Set Temperature

Warning Zone

Deviation exceeds 1st stage (Warning)

Set] function to set or

Green text on Black background

Black Text on Yellow Background

Alarm Zone

Deviation exceeds 2nd stage (Alarm)

Fatal Error

Problem detected. (See details.)

Zone Off

Individual zone switched off

page 6-37 for

White text on Red Background

4-5

OVERVIEW

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4.6 Display Page – other Symbols and what

they mean

The previous page shows the more common parameters that you expect to see on a temperature controller – however there are more values or quantities which are as listed here:

Parameters that are Set

Temperature

Degree C Degree F

Flow (monitoring coolant ow with analogue or digital devices)

Gallons per minute Litre per minute

Pressure (monitoring coolant pressure with analogue devices)

Bar PSI

Other

Percentage (a set percent-

age power output for a zone

with no thermocouple or

closed loop)

Parameters that are Measured (and displayed)

(seen in lower half of panel)

Percentage (power output for

that zone)

Delta (a “difference” symbol

used when comparing ow

or pressure between two

points)

Reynolds Number

(an indication of the quality

of coolant ow in a circuit)

Ampere (Cur-

rent measured

in a zone)

Ohms (Resist-

ance value of

a zone cal-

culated from

stated voltage

and measured

current)

Blank (no quan-

tity currently on

display

4-6

OVERVIEW

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4.7 Display Page – Monitoring (KTS screen)

The basic page shows 40 zones where each zone shows: Title, Actual, Set, Power, Current and Temperature Deviation.

To view more zones:

1. Use [

Page p] or [Page q] to scroll up and down to see other

zones.

2. Choose [

Display] button to show more zones 70 Zones - each

zone shows Title, Actual and Set .

3. Touch it again to show 110 Zones - each zone shows Title and Actual.

4-7

OVERVIEW

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Display Page – Monitoring - contd.

4. Touch it again to show 160 Zones - each zone shows Actual Temperature.

5. Touch it again to show the Data page which shows the setup and data for all the console zones.

4-8

OVERVIEW

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4.8 Display Page – Monitoring (TSA2 wide

screen)

The TSA2 has a wide screen format which offers more zones on the display page. Other pages appear similar to the standard format KTS which are used throughout the rest of the manual.

The basic page shows 80 zones where each zone shows: Title, Actual, Set, Power, Current and Temperature Deviation.

To view more zones:

1. Use [

Page p] or [Page q] to scroll up and down to see other

zones.

2. Choose [

Display] button to show more zones 144 Zones - each

zone shows Title, Actual and Set.

3. Touch it again to show 224 Zones - each zone shows Title and Actual.

4-9

OVERVIEW

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Display Page – Monitoring - contd.

4. Touch it again to show 240 Zones - each zone shows Actual Temperature.

5. Touch it a last time to show the Data page which shows the setup and data for all the console zones.

4-10

OVERVIEW

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4.9 Display Page – automatic resizing for fewer zones

Both the TSA-Wide and the KTS can resize individual zone panels if

there are not enough zones within the tool to ll the rst page.

4.9.1 Big Panels

12 zones or less in KTS - 30 zones or less in TSA-wide.

4.9.2 Medium Panels

24 zones or less in KTS - 48 zones or less in TSA-Wide.

4.9.3 Normal Panels

40 zones or less in KTS - 80 zones or less in TSA-Wide.

4-11

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4.10 Display Page – Monitor (Zoom)

1. Touch any zone and choose [Zoom].

2. This opens the Zoom page which shows:

a) Zone Settings. b) Recent Temperature Deviation. c) Zone Power Levels (Historical).

OVERVIEW

4-12

OVERVIEW

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4.11 Display Page – Start, Stop and more

Button 1 - Can appear as [Run/Stop] or [Startup/Shutdown] or

[Sequence/Stop].

Button 2 - Can appear as [Boost] or [Standby].

Button 3 – Mode - Reveals all of the run mode options.

4-13

OVERVIEW

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4.12 Display Page – How to set Temperature

The following shows how to set the temperatures of one or more zones.

1. Choose one zone.

2. Choose another.

3. Choose [ selected.

4. Choose [

Range] to include those zones between rst and last

Set] and, if prompted, enter the User Password.

4-14

OVERVIEW

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Display Page – How to set Temperature - contd.

5. Choose [Mode] bar to set zone as:

a) Closed (Auto Temperature). b) Open (Manual Power). c) or Slave (to another zone).

6. Choose [

Value] bar to Set, Raise or Lower temperatures.

4-15

OVERVIEW

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4.13 More Pages

4.13.1 EasyView

Shows zone temperature and their position in the tool. It also shows Zone Status and can be used to Set zone temperatures.

4.13.2 Graph page

Shows graphs, of temperature versus time, for up to 20 zones at a time.

4.13.3 The ToolStore page

This is a tool bank in which you can store up to 200 tool congurations.

4-16

OVERVIEW

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4.13.4 The Picture page

Save, and display, up to 20 drawings or pictures.

4.13.5 The Utilities page

Contains several sub pages:

a) System- change the passwords and the system clock. b) Energy - display of recent energy consumption over time. c) Printer - select a driver for your printer. d) Event Log - to nd changes that have been made to the con-

troller settings.

e) Network - set up the Controller to communicate over a net-

work.

f) Export - obtain historical performance data for any zones over

the last 24 hours.

g) Remote - view any other networked computer via a Virtual Net-

worked Computer (VNC) protocol and set up a remote Master IP address.

h) Quad IO - set up Quad IO card Inputs and relay outputs.

4-17

+ 149 hidden pages

Mold-Masters M2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Section 1 - Introduction

1.1 Intended Use

1.2 Audience

1.3 Required User Skills

1.4 Release Details

Section 2 - Global Support

Section 3 - Safety Instructions

3.1 Safety Notices - an explanation

3.2 Where to use this equipment

Section 4 - Overview

4.2 How to Isolate the Controller

4.2.1 Switching On

4.2.2 Mold Heating

4.3 Switching Off (the Controller)

4.4 Screen Layout and Navigation

4.7 Display Page – Monitoring (KTS screen)

4.9 Display Page – automatic resizing for fewer zones

4.9.1 Big Panels

4.9.2 Medium Panels

4.9.3 Normal Panels

4.10 Display Page – Monitor (Zoom)

4.11 Display Page – Start, Stop and more

4.13 More Pages

4.13.1 EasyView

4.13.2 Graph page

4.13.3 The ToolStore page

4.13.4 The Picture page

4.13.5 The Utilities page