Hasco H1281-12 Operating Instructions Manual Download Page 1

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GB 05 / 21 HK

Operating instructions

H1281/...
Primezone

Control unit

Summary of Contents for H1281-12

Page 1: ...GB 05 21 HK Operating instructions H1281 Primezone Control unit ...

Page 2: ...ions clearly caused by material pro duction or design failures Repair or replacement in this case are free of charge you only pay the shipping cost to our factory No further claims or requirements can be accepted especially for consequential losses or damages Service We help you quickly and at resonable costs Just send us the device with repair order and precise description of the malfunction Care...

Page 3: ...lations can not be complete mechanical and foreign regulations Not mentioning or lis ting these rules does not mean that they have no validity Commissioning maintenance and repair work may only be performed by persons which are recognized as professionals within the meaning of current legislation VDE rules safety law for electrical equipment accident prevention legislation of the employers liabili...

Page 4: ...ys 15 5 3 Touchscreen 16 6 HASCO Touchscreen Operation System 18 6 1 Homescreen 18 6 2 Part Hotrunner view total situation 19 6 2 1 Zones view in groups 22 6 2 2 Zones detail view 23 6 3 Part Settings 33 6 3 1 Settings User 33 6 3 2 Settings Language 36 6 3 3 Settings System 37 6 3 4 Settings Zones configuration 45 6 4 Part Mould diagnosis 61 6 5 Part Real time analysis 65 6 6 Part Mould memory 67...

Page 5: ...rithm with automatic self tuning for every zone Safety load shedding for process high temperature Synchronized heating for all zones possible Boosting for frozen nozzles possible Integrated heater current monitoring Intelligent programmable soft start routine Programmable alarm settings for every zone and various self monitoring functions Standard with mould diagnosis function Mould memory and rea...

Page 6: ...ly with appropriate soft cleaning material never use solvants or abrasive detergents or material 9 Don t place the device on hot machine surfaces or near radiation sources of hot parts 10 Keep the power connection cable clear of hot parts or sharp edges 11 Disconnect the power cable immediately if it was damaged liquid or parts penetrated the device the device was damaged by falling down or other ...

Page 7: ...ns of use 4 This device must not be used in areas exposed to explosion hazards 5 Electronic scrap electronical devices and their components are subject of specific regulation concerning treatment of special refuse and may only be disposed by certified bodies 2 2 Qualification of personnel For the use and operation of this device the following requirements regarding qualification and training of th...

Page 8: ...der To 3 Administrator Scope of activities As 2 additionally configuration of system parameters such such as memory settings or interface configuration executing of back ups or software updates in coordination with the manufacturer of the device Qualification Professional training or equivalent experience trained for the operation of the actual device and its riscs and hazards by a qualified perso...

Page 9: ...onnection of all heating loads in case of process high alarm 50 C cannot be de activated Heating load alarm 0 0 19 9A adjustable Min 0 4A factory default setting Sensor inputs Thermocouple Fe CuNi type J 0 400 C or 800 C adjustable Internal zero point correction Sensor is monitored for cable breakage short circuit and polarity errors Thermocouple Ni CrNi type K adjustable internal wiring K on requ...

Page 10: ...185mm WxDxH 6 16 zones 410 x 367 x 345mm WxDxH 24 32 zones 410 x 367 x 546mm WxDxH 40 48 zones Additional width of 50mm for heat sink on each side Colour RAL9016 sik gloss Frontpanel and back RAL9016 structured other casing parts RAL2004 structured Design element frontpanel Weight depending on number of zones H1281 6 13 7 kg H1281 8 13 8 kg H1281 12 15 3 kg H1281 16 15 5 kg H1281 24 23 9 kg H1281 ...

Page 11: ...ages can be created inside the device Protective earth conductor must be provided 4 3 Connection of heaters and thermocouples Please compare the connecting diagram on the temperature controller backside near the outlet with the diagram of the mould Inappropriate connection can destroy con troller heater and TC Available mould connecting cables contain heater and FeCu Ni compensation wires for TC N...

Page 12: ...e wired on a 7 pin connector on the back side Default settings are one process high temperature alarm A1 pin 2 and 3 as well as one loadbreakage and leakage alarm A2 pin 4 and 5 To activate the 2nd temperature set point stand by function a 24V DC switching con tact is wired to pin 6 and 7 No external power source may be connected to this input This function can also be activated manually on the to...

Page 13: ... Touchscreen 3 Heatsink both sides 4 Fuse holders for load fuses 6 and 8 zones one side others both sides 5 USB data connector Remark For the units with 6 and 8 zones heatsink and fuseholders are only present on one side of the casing Back side small casing 6 16 zones 1 2 3 4 1 Main switch 2 Mould connectors 6 zones each 3 Alarm connector 4 Power cord ...

Page 14: ...HASCO hot runner 14 Front view high casing 24 32 zones Back side high casing 24 32 zones ...

Page 15: ...Operations manual H1281 HASCO hot runner 15 Front view triple casing 40 48 zones Back side triple casing 40 48 zones ...

Page 16: ...having finished the wiring completely switch the device on with main switch in position 1 EIN ON Before start up of the control software self test and enabling of controller operation power supply to the heating elements is locked and cannot be started 5 2 LED alarm lighting strip Above the touchscreen on the front panel of the device a bright LED lighting strip is located for a quick information ...

Page 17: ...easily find the zone s where excess temperature is present The alarm limit value A0 can only be altered by an operator with the user rights level Administrator 5 3 Touchscreen Operation of the controller is made exclusively by the touchscreen Therefore a glass touchscreen with newest technology called projected capacitive is used In opposi tion to older touchscreens with switching film on it this ...

Page 18: ...the upper right corner of the screen Back Home The Arrow or Back button will lead you to the last visited screen this can also be the homescreen if you just were there On the Homescreen the 6 main functions of the HASCO touchscreen operation sys tem can be selected Alarms Analysis Mould memory Hotrunner Mould diagnosis function Settings Operation is the most frequently used function all actual val...

Page 19: ...current situation during any operation In addition to the touchscreen the actual operational state of the system is shown by the colour of the LED alarm lighting strip see also chap 5 2 Colours on the touchscreen are the same on all menus Green Undisturbed operation Red Alarm Yellow Particular operation situation Manual powersetting measuring zone or thermocouple linked to another zone Display act...

Page 20: ...st For all zones the boost setpoint is activated for a limited period of time This Boost holding time is hold after the boost setpoint temperature is reached then every zone goes back to the last operation setpoint Boost is being activated for all zones together and if synchronized heating is active also hold until all zones have finished their boost holding time Slow zones such as e g manifolds m...

Page 21: ...zone OFF SET temperature or powersetting of the heating Group assignment of this zone see chap 6 3 4 With the buttons for display settings the screen appearance for the overview of all zones can be adapted With the NUMBER TEXT toggle switch you can toggle between the number and the name of all zones If no name is assigned to a zone the number of this zone is always being displayed With the Magnifi...

Page 22: ... indication for every zone of Actual temperature Setpoint temperature Heating load current Powersetting in and Group assignment The colours as well as the buttons are the same as in the overview of all zones Operation is made in the detail view next page touching of a zone guides you directly there Number Text Zoom overview Actual mold Act C Set C Amps Powerset Group ...

Page 23: ...de only for this zone 6 Settings Boost and Standby function only for this zone 7 Buttons zones configuration as well as copy function for inputs With the arrow keys you can roll through all zones Beside the overview of all zones this screen is the next frequently used of all Here the most important details of one given zone are shown and can also be operated or mo dified All inputs can be copied w...

Page 24: ... the following numpad Enter the desired setpoint value with the keyboard and acknowledge with Back deletes the last digit Clear deletes the whole number ESC aborts the entering process alternatively close the numpad with the red cross upper right corner Attention The entered value must be in a range between the indicated Min and Max limit values if not the value will not be accepted These limit va...

Page 25: ...of this zone without having to enter the zones configuration see chap 6 3 4 With the arrow keys you can roll trough all zones Ad 4 Display field for alarms In the display for alarms 4 different alarms are being indicated Thermocouple alarm Temperature Leakage alarm polarity interchange alarm or defect Current alarm or heature breakage If one of these alarms is present the respective zone is displa...

Page 26: ...nation of the different operational modes Auto Normal operation of the temperature control Heating power is automatically adjusted in a way that setpoint temperature of this zone is reached as quickly as practicable and then hold precisely With the intelligent control characteristic overshot is securely avoi ded No operators action is needed to ensure automatical adaptation Autotuning or similar M...

Page 27: ...ontinuously set to 0 no heating power is generated The associated power outlet at the connector of this zone is not being charged with heating voltage but may be bearing high voltage for measuring purpose for short pe riods of time For another tool this choice can be switched back again Heating OFF The heating power of this zone is neing switched off Bringing it back into service is done by choosi...

Page 28: ...0 C gives a Boost setpoint of 210 C The boost setpoint is manually activated by choosing the temporary boost via the touchscreen Upon reaching of the boost setpoint temperature is held for a program mable time then automatically brought back to the normal setpoint The boost function is only available during normal operation not in stand by operation De activation of the boost is done by entering a...

Page 29: ...ne to others and finally open the zones configuration with the button Settings see chap 6 3 4 Grouping of zones Each zone can be assigned to one of 5 groups Tip Nozzle Man Manifold A Group A B Group B C Group C Pressing the key Group configuration opens the following dialogue window Select first on the right side the group whose zones must be configurated Then the actual zones belonging to this gr...

Page 30: ...or Also you can de activate manually the assignment to a group by pressing the key Suspend grouping Assigment to one of the 3 manual groups A up to C is arbitrary and shall persist until an operator changes it again Assignment to one of the groups is part of the zones configuration and shall be saved into the mould memory When loading a set of para meters from the mould memory you don t have to re...

Page 31: ...een marked in red on the picture below The zones of this group are then marked in green see below zones 1 8 This selection can be modi fied as needed by touching additional zones or de selecting zones of the initial group The zone from which shall be copied is marked in light colour see example above zone 1 Furthermore zones switched off are marked in grey see example above zo nes 9 24 Finally the...

Page 32: ...with the Back button orange arrow in the upper right corner of the copy window without copying anything Settings This key is locked for normal users during current operation shown as all locked keys by a grey representation For user with the right level Shift leader or higher this but ton leads you to to zones configuration see chap 6 3 4 Locked keys guide you directly to the user settings menu se...

Page 33: ...he operator see below Functions not admitted with the actual user right level are shown in grey colour see examples below System and Zones configuration The actual software version is shown on the right side of the screen please always mention it when calling for questions 6 3 1 User This function leads you to the user management section tree levels of user rights are available User normal operato...

Page 34: ...el Admin additional system and IT parameters are accessible which can stop the current operation when modified in a wrong way With lower user right levels functions may be locked indicated by a grey representation see also page 33 If the user is logged in as Administrator two functions are accessible not allowed to other users Modification of passwords Change of the user level when starting the sy...

Page 35: ...281 HASCO hot runner 35 Change user rights at start up When selecting this function the following menu opens where the user right level when starting up the system can by modified Factory default Operator Choose Start user ...

Page 36: ...words in all screens and menus are then adapted accordingly The active language is also shown on the upper right side of the homescreen see chapter 6 1 Adapting the active language is allowed in all user levels Available languages fill several pages on the screen toggle between them with the arrow keys Language Language ...

Page 37: ... system function of the industrial computer used in this unit all time relevant program functions use it This is of particular significance for functions with date time stamp such as e g the alarm history If the system time is changed e g as the unit is placed in another time zone of the world all new system entries get then the new system time Please take that fact into account when analy sing ti...

Page 38: ... Then enter the actual values for date and time by pressing the relevant data field By doing so the already known numpad opens enter the desired numbers and close the numpad with the red cross Finally quit the dialogue with the red cross Temperature control sensor type When pressing the Sensor type key the following dialogue appears Sensor Type ...

Page 39: ...update is not successfull or if the new software does not fullfill the expectations of the user a previous software version must be installed by another software update Attention It is highly recommended to perform a software update only in close collaboration with the manufacturer e g during a conference call Procedure To perform a software update you need to prepare first a functional upgrade da...

Page 40: ...e front panel Otherwise the key is shown in grey and cannot be operated If a functioning USB memory device is connected and recognized and the OK key is operated but no appropriate program data file is found another warning menu ap pears When all functional requirements are fulfilled the complete software update process is now executed automatically afterwards the system is operational without any...

Page 41: ...nly be used in particular cases and with previous consultation of the manufacturer of the unit When pressing the Control configuration key the following dialogue appears For normal control operation Automatic must be selected Is this done the auxiliary control program Mode 1 Mode 2 or Mode 3 actually selected by the system is displayed both by a orange colour of the key If Automatic is disabled an...

Page 42: ... for one single zone They may be copied as all other data entries to one several or all other zones as described on page 31 Unit change C F To change the unit of all temperature values press the button C F The following dialogue menu ones All temperature values also setpoints in the mould memory are automatically transfor med into the respective other unit and displayed accordingly ...

Page 43: ...vice away from the controller in a safe place or to perform another back up routine also for this memory device Not doing this means a total loss of mould data in the case of a damage of the control ler e g fire or damage of the internal memory device so all mould data must then be re entered manually For data saving on an external memory device as well as re loading the mould memory from this dev...

Page 44: ...stems own WiFi Switch your device to the Settings WiFi page check for available networks Now it must show the network name displayed on the left side of the HASCO screen in the example shown here above it is HASCO_WLAN Then enter the pass word shown there as well in this example HASCO2020 and press connect on your device A warning No intenet connection on this network or so may be shown The range ...

Page 45: ... from level Set up shift leader and higher 1 4 3 2 6 5 1 Display zone number and name arrow keys 2 Altering zones name and Autonaming 3 Function group configuration Setpoints grouping as well as copy function 4 Function group heating Softstart guided and sequencial heating 5 Thermocouple failure operation 6 Alarm configuration Load shedding temperature current and leakage alarm The entry of data d...

Page 46: ... displayed if a name is assigned Display and functions are identical with the screen Zones detail view see chap 6 2 2 Ad 2 Zones name and Autonaming Manual entry of a name for a zone When pressing this button an alphanumerical keyboard opens After having typed the desired name or number save with Change name ...

Page 47: ...bers with the keyboard and close with Autonaming The Autonaming function saves the time and effort needed to manually number a greater number of zones whose names shall only differ by a consecutive number Example Manifold to be numbered continuously from Man 1 up to Man 4 To do so enter first a the name without number as described previously For common names use the quick choice function The name ...

Page 48: ... top of the screen window You also can skip zones which are part of another group eg manifolds headers bushings etc Acknowledge with the button then the autonaming of the row commences starting with number 1 The order of the numbering cannot be changed Ad 3 Function group configuration Editing Setpoints When pressing this button the following dialogue menu opens where additional set points accessi...

Page 49: ... for the boost operation of this zone boost function for a temporary temperature increase The boostaddition is than added by the system to the normal operation setpoint of this zone Example Setpoint 200 C Boostaddition 10 C gives a Boost setpoint of 210 C The boost setpoint is manually activated by choosing the temporary boost via the touchscreen Upon reaching of the boost setpoint temperature is ...

Page 50: ...ins power eg if only a power outlet of a lower wattage is available In this case it is normally sufficient to limit the power setting of the high output zones eg manifolds The required duration for heating up the mould increases linearly with limiting of the power setting that s why using this method must only be done in particular cases Group configuration When pressing this button the group conf...

Page 51: ... see example above General remarks about softstart During the softstart the controllers output response is limited to a preselected softstart powersetting in order to achieve a slow baking out of high performance hea ting cartridges Once the process value reaches the softstart setpoint it remains stable at this value for a preselected softstart duration time At the end of this period the process v...

Page 52: ...ture at approximately the same time This avoids that quick zones e g the hot tips reach their setpoint temperature much earlier than slower ones e g the manifolds which could cause baking of the material in the tips or even a damage of the hotrunner system If there is a big difference in heating power between tips and manifold and or a very temperature sensitive material use in doubt always this f...

Page 53: ...p one by one Every group is heated until a predefined temperature is reached then waits for a given delay time if set then the next group starts its heating in the same manner The desired groups for sequential heating up must be defined prior to setting up the heating sequence see zones configuration Parameter Autogrouping Typically heating up of manifolds and tips is separated If more groups must...

Page 54: ...zones are heated until their respective setpoint temperature is reached Ad 5 Thermocouple failure operation In this sub menu is defined how the system must react in case of a defect thermo couple By pressing the associated key the following dialogue opens OFF When thermocouple failure occurs an alarm is given in the detail view of this zone Thermocouple failure is indicated see also chap 6 2 2 The...

Page 55: ...display Attention This zone is now heated with constant powersetting maintaining the desired process temperature must now be ensured by the operator Coupling When thermocouple failure occurs this zone is coupled to another one with working thermocouple By pressing this key the following dialogue opens To activate coupling touch the display field Zone antippen enter the number of the reference zone...

Page 56: ...or the coupled zone in the zone overview as well as in the zone detail view To de activate the coupling select another mode in the Thermocouple failure opera tion menu The actually active mode for Thermocouple failure operation is indicated by an orange coulouring of the respective button in the menu The same is true for the cho sen mode within the function group Heating Ad 6 Alarm configuration I...

Page 57: ...00 C Limit value 50 C means load shedding at 250 C After having finished close the menu with the red cross Attention The safety loadshedding alarm total heating switching off at high temperature in the mould can only be altered for operators with user right level administrator see also description on page 17 For all other users the key is locked see also example on page 33 Temperature alarm When p...

Page 58: ...s shown by an orange colou ring of the button If the output is inverted the alarm relay is then closed if no alarm is present This type of signal is needed for some injection presses for release of the pro cess All temperature alarms of all zones are operating the common alarm A1 which is wired to a floating contact on the alarm connector on the back of the device see chapter 4 4 Is the temperatur...

Page 59: ... indicated by an orange colouring of the key Leakage alarm To monitor the actual powersetting of all active zones a maximum alarm powersetting in can be set If this alarm threshold value is reached in one or more zone s lea kage alarm is switched All leakage alarms of all zones are operating also the common alarm A2 as does the heater current alarm which is wired to a floating contact on the alarm...

Page 60: ...ations That s why the leakage alarm threshold value must be determined manually e g by observing the average heating powersetting for a duration of about one hour under comparable operation circumstances Rule of thumb Dubble the average powersetting Example Heating powersetting tip zones 5 10 Recommended alarm threshold value 20 For detail observation of the heating powersetting it may be wise to ...

Page 61: ...tinuously during current operation and does not require a mould diagnosis The mould diagnosis is a separate function of the HASCO controller and can only be performed outside current operation The continuous heating is switched off no production can be run during mould diag nosis For this reason a warning menu appears after selection of the mould diagnosis which must be acknowledged After acknowle...

Page 62: ...hed yet Attention As all zones are checked separately one by one in several steps the whole diagnosis can take up to half an hour in exceptional cases even longer After start up of the diagnosis no input is required the presence of an operator is not necessary Ongoing execution of the diagnosis is shown by a running symbol rotating star lower right corner When the mould diagnosis is finished succe...

Page 63: ...shown as a table press Enhanced view to do so button see previous page The enhanced view gives immediately the result for every zone with a symbol but depending on the total number of zones you must use the roll bars on the right side to see all zones Also in the enhanced view you can access the detail result by pressing the associated zone field see above 1 2 3 4 5 6 7 8 9 10 11 12 Testing time T...

Page 64: ...readsheet or database software programs example below shows zones 1 10 The memory device is connected via the USB port on the front of the device Attention Given the USB interface definition any USB port is hasardous as well from the hard ware EMV as from the software standpoint Please consider this when defining rules of access to the unit Download result Mould diagnosis 05 10 2020 16 02 21 Zone ...

Page 65: ...meters with time can be shown and analysed as a diagram Here first the parameters Setpoint Proces value actual temperature and Powersetting heating power are shown for all zones as bargraphs If the control behaviour of a given zone shall be analyzed in detail pressing the zone button opens a curve showing that zone see next page ...

Page 66: ...scroll through all zo nes Toggle between process value setpoint and powersetting by pressing the respective button underneath the zone number field For an enlarged view of the curve use the Pinch to zoom function see chap 5 3 By pressing the button upper right side you get back to the overview of all zones ...

Page 67: ...erage mould should work at first instance with those settings Another position is taken by the actual BACK UP This is created automatically by the system and updated every 5 minutes without any intervention of the operator It is al ways loaded when restarting the system Attention When a mould is loaded from the memory also the default settings all actual para meters are overwritten and so lost If ...

Page 68: ...meters but also any other name To change the name hit the button with the name field Enter the desired name for the new mould as already described for the zone name see page 46 and close the menu with the red cross Loading a set of parameters 1 Choose the desired mould the name is then marked in ORANGE Keyboard Werkseinstellung Reset H1281 Backup HASCO Mold 1 HASCO Mold 2 Mold data set ...

Page 69: ...diately after the button is hit no confirmation is asked Overwriting a set of parameters 1 Choose the desired mould the name is then marked in ORANGE 2 Press Replacing mould see above 3 Acknowledge with This function must only be used if the stored data saved under this name will certainly not be needed anymore If they might be usefull at a later moment you better store the actual version under a ...

Page 70: ...ed mould the name is then marked in ORANGE 2 Press Deleting mould see previous page 3 Acknowledge with Attention Deleting a mould from the memory removes all associated parameters and settings irrevocably The factory default RESET values can t be removed or overwritten ...

Page 71: ...er having choosen the program a list of all actual alarms appears first If an alarm dissappears problem solved this alarm is also automatically deleted from the list To view all alarms also the previous ones press the button History below the list see above and next page This choice is confirmed by an orange colour of the button ...

Page 72: ...HASCO hot runner 72 Log Phase L1 is missing Phase L2 is missing Phase L3 is missing Temperature alarm zone 1 Current alarm zone 1 Temperature alarm zone 2 Current alarm zone 2 Alarm ...

Page 73: ...cal grouping of zones 29 30 Autonaming automatical numbering of zones 47 B Backup mould memory 43 Boost function 20 C Copying of data entries 31 Control configuration Temperature control 41 Coupling of a zone see leading zone 55 csv data file 64 Current alarm 25 58 Curve tracing see real time analysis 65 D Data export 64 E Export result mould diagnosis 64 H Heating current 21 24 High temperature a...

Page 74: ...P Password see user rights 34 Password change 35 PIN Code 34 Powersetting control zone 21 24 Powersetting limitation 49 50 R Real time analysis 65 Reference zone 55 S Sequential heating up 53 Safety loadshedding 17 Setpoint temperature zone 21 24 Setpoint limitation 49 50 Single zone view 23 Softstart 45 51 Software Update 39 ff Software version number 33 Standby 20 Synchronised heat up see zones ...

Page 75: ...port 43 64 User rights 33 User rights at system start up 35 W Wifi operation of the system remote control 44 Z Zones configuration 45 Zone copying parameters 31 Zone coupling to another 55 Zone enter name 46 Zones group view 22 Zone switching on off single 26 27 Zone switching on off all 20 Zones synchronisation see synchronised heat up 52 ...

Page 76: ...d if properly used the following EU directives EU Low voltage directive 2014 35 EU EU Directive for electromagnetic compatibility 2014 30 EU EU Directive for limitation of hazardous substances in electric and electronic devices RoHS 2011 65 EU Applicable harmonized norms EN 60204 Part 1 EN 61000 6 1 EN 61000 6 3 This declaration is binding for the distributor HASCO Hasenclever GMBH Co KG Römerweg ...

Page 77: ...Built to Control ...

Page 78: ...GmbH CoKG Postfach 1720 D 58467 Lüdenscheid T 49 2351 957 0 F 49 2351 957 237 info hasco com www hasco com Subject to technical modifications Please always check all the data against the product information we publish on the internet ...

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