Husky Altanium Matrix2 User Manual Download

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v 1.1 — July 2015

Altanium Matrix2

Thermocouple Types and Color Codes

Summary of Contents for Altanium Matrix2

Page 1: ...Altanium Matrix2 User Guide Original Instructions...

Page 2: ...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 S...

Page 3: ...e 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...

Page 4: ...v 1 1 July 2015 Altanium Matrix2 iv Ordering Additional Manuals...

Page 5: ...7 Technical Specifications 4 1 8 Controller Lifting Instructions 5 Chapter 2 Hot Runner Temperature Control 9 2 1 Types of Temperature Control 9 2 1 1 Open Loop Control 9 2 2 Configuring Zones 9 2 2...

Page 6: ...Screen 36 4 6 1 Viewing the Supply Voltage 36 4 6 2 Configuring the Supply Voltage 39 4 7 Using Online Help 41 Chapter 5 Security and Administration 43 5 1 User Management and Security Screens 43 5 1...

Page 7: ...Setting 73 7 5 15 Zone Slave 73 7 5 15 1 Using the Automatic Slave Function 73 7 5 15 2 Manually Slaving One Zone to Another Zone 74 7 5 15 3 Changing the Regulation Mode 74 7 5 16 Setpoint Limits 75...

Page 8: ...95 9 1 1 Startup 95 9 2 Earth Leakage Wet Heater Bake Out System 96 9 2 1 Earth Leakage Limit 96 9 2 1 1 Setting the Earth Leakage Limit 96 9 2 2 Configuring the Length and Number of Bake Out Cycles...

Page 9: ...r Deviation Settings 120 10 1 10 Power Limiting 123 10 1 11 Monitor Zone Settings 123 10 1 12 Options and Licensing 124 10 1 13 Diagnostics Export 126 10 1 14 Part Counting 126 10 1 14 1 Setting Up Pa...

Page 10: ...12 2 3 1 Changing the Date and Time Range Old 158 12 2 3 2 Changing the Date and Time Range New 158 12 2 4 Changing the Zone Displayed on the Process History Screen 158 12 3 Process Targets Screen 160...

Page 11: ...Replacing the Motherboard Battery 185 15 6 Calibrating the Thermocouple Inputs 186 15 7 Cleaning the System 187 15 7 1 Cabinet 187 15 7 2 Touch Screen 187 Chapter 16 UltraSync E If Equipped 189 16 1 C...

Page 12: ...pening 204 16 6 Servo I O Screen 204 16 6 1 Inputs 205 16 6 2 Outputs 207 16 6 3 Configurable Signals 208 16 6 4 Safety Signals 209 16 7 Calibrating the UltraSync E 210 16 8 Troubleshooting 210 16 8 1...

Page 13: ...of the manual 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...

Page 14: ...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 1 1 1 Safety Signs Safety signs clearly mark potenti...

Page 15: ...wise 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 summarize...

Page 16: ...Altanium Matrix2 Operator Interface only Supply Voltage 100 to 240 VAC 10 single phase Frequency 47 to 63 Hz Power Rating 100 W typical 1 7 Technical Specifications The dimensions and weight of the c...

Page 17: ...correct lifting ability and lengths 1 Place each of the webbed straps under the controller See the table for the correct strap lengths a For single stack controllers the webbed straps go under the equ...

Page 18: ...the straps are positioned between the caster wheels and the retaining brackets under the base of the controller b Make sure the straps are not pinching or crushing any cables attached to the controll...

Page 19: ...oller is lifted 5 Place cloth or other cushioning material between the ratchet strap and the controller to keep the finish of the controller free from rubs and scratches 6 Tighten the ratchet strap 7...

Page 20: ...v 1 1 July 2015 Altanium Matrix2 8 Controller Lifting Instructions...

Page 21: ...ocouple 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 Thermocou...

Page 22: ...o 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...

Page 23: ...use the ANSI color code for all thermocouples The following table is provided as reference for hot runners and cables that follow other color code standards Amps Watts Volts Amps Volts Resistance Res...

Page 24: ...v 1 1 July 2015 Altanium Matrix2 12 Thermocouple Types and Color Codes...

Page 25: ...or damage Check that the earth ground connection is in good condition Verify the system and the mold have the same ground reference 3 2 Connecting to the Power Source To connect the power source do th...

Page 26: ...he I O box or option cables if required 3 Connect the controller to the power source 4 Switch the controller ON 5 Login to the system if required 6 Select the required mold setup 7 Verify the mold set...

Page 27: ...high definition and a wide viewing angle even in poor lighting conditions Use the touch screen to change settings on the Altanium operator interface This display is referred to as the Altanium for the...

Page 28: ...ons Altanium has a system header and a footer that are visible on every screen throughout the system Figure 4 1 Home Screen Composite 1 Controller Function Buttons 2 System Status Field 3 Navigation B...

Page 29: ...utton to place the system in standby If a timer is active the time remaining is displayed in the status bar This button is not available during ART Touch the Boost button to place the system in boost...

Page 30: ...is not included as part of the navigation history Touch the Forward button to display the next screen maximum of 10 screens forward The Home Screen is not included as part of the navigation history T...

Page 31: ...nd of the button will flash red Displays the name of the current user logged in Touch the User Log off Log on button to display the User Login dialog box This button toggles between Login and Logout T...

Page 32: ...by setpoint Delay Standby The system is delaying for a set period of time before entering the remote standby mode Manual Boost The user pressed the Manual Boost button and the system is heating to the...

Page 33: ...ating 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 After heating up t...

Page 34: ...display the Multi Group View screen which contains zones organized into groups and allows individual control of each group Touch the GraphicalView button to display the GraphicalView screen which con...

Page 35: ...and assign a group name to the selected zones For each group created a shortcut button appears on the Home screen For more information about creating a group refer to Section 7 2 4 1 8 Screen Buttons...

Page 36: ...July 2015 Altanium Matrix2 24 Screen Buttons Process Targets Process Trend Process History Heat Screens Quick Set ART Process Zone Calibration Zone Slot Table 4 4 Screen Buttons Continued Screen Descr...

Page 37: ...v 1 1 July 2015 Altanium Operator Interface Card Layout Mold Diagnostics Diagnostics Results Energy Display Supply Voltage Staging System Configuration Screens System Setup Table 4 4 Screen Buttons C...

Page 38: ...Mold Setup Digital I O User Management Servo I O This functionality is optional and the button appears on the Home screen if the system is equipped with UltraSync E control UltraSync E Screens If Equ...

Page 39: ...red line at the top of the column header indicates the information is in ascending order A red line at the bottom of the column header indicates the information is in descending order NOTE Touching t...

Page 40: ...ttons Button Description Expands all group information lists Collapses all group information lists Expands the related group information list If this button is green the actual temperature for all zon...

Page 41: ...on Turns on the zones in that group if they are off Sets the zones in this group to manual standby Multiple groups can be placed in standby at once This button will be inactive if any groups are in bo...

Page 42: ...n the Multi Group View screen For more information about creating a group refer to Section 7 2 To change the header color do the following 1 On the Multi Group View screen touch the Color Change butto...

Page 43: ...uages The default language is English Each screen contains a globe icon which displays the available languages To select a language do the following 1 Touch the Language Selection button The Language...

Page 44: ...ous Printing allows the user to set up print reports at specified intervals Users can select the type of report to be generated Reports Type and File Format Users can also specify print interval and d...

Page 45: ...t Dialog Box Item Descriptions Item Description Report Type Select the types of information to print Brief Zone Information Detailed Zone Information Diagnostics Results Mold Setup Configuration Scree...

Page 46: ...f Zone Information From the Text View screen print the following columns to file zone number setpoint and units actual temperature and units Detailed Zone Information From the Text View screen print t...

Page 47: ...he Home screen touch the Network Setup button 2 Touch the Network Locations field and enter the required information 3 Touch the Accept button Mold Setup Configuration Zone Number Zone Name Setpoint M...

Page 48: ...ed on the Supply Configuration parameter selected in the System Setup screen Delta 3PH Wye 3PH N Single Phase Integrated TX 4 6 1 Viewing the Supply Voltage To view the Supply Voltage screen do the fo...

Page 49: ...d with a particular phase The amperage value also displays if all of the zones associated with a particular phase are XL or HL cards Figure 4 9 Wye 3PH N Supply Voltage Screen Item Description Schemat...

Page 50: ...v 1 1 July 2015 Altanium Matrix2 38 Viewing the Supply Voltage Figure 4 10 Delta 3PH Supply Voltage Screen Figure 4 11 Single Phase Supply Voltage Screen...

Page 51: ...supply configuration If the system is shipped to another location where the power configuration is different for example another country the setting may need to be changed To configure the supply vol...

Page 52: ...y 2015 Altanium Matrix2 40 Configuring the Supply Voltage 3 Select the correct supply configuration Figure 4 13 System Setup Screen 1 Supply Configuration Field Figure 4 14 Supply Configuration Dialog...

Page 53: ...nium Operator Interface 4 7 Using Online Help The online help consists of a pdf file of the Altanium Matrix2 User Guide To use the online Help do the following 1 Touch the Help button on any Altanium...

Page 54: ...v 1 1 July 2015 Altanium Matrix2 42 Using Online Help...

Page 55: ...Administrators have theability to add a user changea userpassword anddeletea userusing the User Management screen To manage users and control user security settings do the following 1 Log in with Admi...

Page 56: ...2 44 User Management and Security Screens 4 On the Security screen select a user type Administrator Supervisor Operator or Default User for each of the following settings Figure 5 1 User Management Sc...

Page 57: ...ic Controller Operations Permissions to operate the major controller function buttons Stop Start Standby and Boost Stop is always available This setting also grants permission to operate the UltraSync...

Page 58: ...enables the options a user has purchased Multi Group Operations Permission to operate the Multi Group screen functions Mold Picture View Edit Permission to use the edit function on the Mold Picture Vi...

Page 59: ...ote Boost sections on the Quick Set screen Earth Leakage Fault Enable Permission to select and clear the System Earth Leakage Enable check box on the System Setup screen Earth Leakage Fault Setup Perm...

Page 60: ...onfigure all the parameters in the Remote Load Setup dialog This option must be purchased before the user can access this dialog SPI Permission to configure parameters in the SPI area of the System Se...

Page 61: ...de timer will log the user off if there is no touch screen activity within a specified timeout period The default setting is five minutes The minimum value is 10 seconds To change the auto logout time...

Page 62: ...ltanium Matrix2 50 Auto Logout 3 Touch the timer and enter the desired value To edit settings for specified users use the Screen Security screen Figure 5 4 Manage Users 1 Auto Logout Timer 2 Screen Se...

Page 63: ...Mold Setup Screen The Mold Setup screen is used to store and manage files such as mold setups images documents and reports Files are organized in a tree structure and are stored in mold system and us...

Page 64: ...uments contained within the selected system folder Users Folder Touch the users folder to display files associated with a given operator Table 6 2 Mold Setup Screen Button Descriptions Button Descript...

Page 65: ...this New Setup file by first copying Touch the Discard Changes button to revert the currently loaded mold setup file to the state after it was last saved using the Save Mold Setup button All unsaved c...

Page 66: ...ccept button All changes have now been permanently saved to the currently loaded Mold Setup File 6 1 4 Discarding Changes to a Mold Setup File All changes to a mold setup file are held in the system s...

Page 67: ...following 1 On the Mold Setup screen touch the file or folder to be deleted 2 Touch the Delete button 3 A message appears asking to confirm the deletion To continue touch the Accept button To cancel...

Page 68: ...d Setup screen The network folders disappear when a USB device is plugged in 6 1 11 Transferring Data Using a USB Storage Device Altanium data can be transferred using USB disks or USB CD ROM drives W...

Page 69: ...lti Group View Graphical View Text View Quick Set Art Process Mold Diagnostics Results Zone Calibration Zone Slot Staging Zone can also be selected from the following screens Neo2 View Mold Diagnostic...

Page 70: ...the following 1 On the Quick Set screen touch and hold the first zone to select for one second 2 Touch the last zone to select All zones in between will be selected and highlighted in yellow 3 Touch...

Page 71: ...ted zones highlighted 7 3 Graphical View Screen Overview The Graphical View displays zones in a graphical format It is designed to provide an easy way to view the overall status of the mold without ha...

Page 72: ...v 1 1 July 2015 Altanium Matrix2 60 Graphical View Screen Overview Figure 7 3 Graphical View Screen Split Screen Mode 1 Config Button 2 Zone Bars 3 Amperage Bars 4 Power Bars 1 2 3 4...

Page 73: ...The red and blue areas in the zone bar represents the abort window A blank gray bar indicates that the zone is turned off Amperage Bars The amperage bars directly below the zone bars are light blue Th...

Page 74: ...on Touch this button to toggle between displaying zones in split or full screen mode In split screen mode zone graphs are displayed in two groups one on the top and one on the bottom In full screen mo...

Page 75: ...iew The Text View screen displays zone information in a textual format It is used to access detailed data for each zone and provides the most comprehensive view of the process This screen can be acces...

Page 76: ...ared Abort Abort window Degrees above and below setpoint before an abort condition is declared Regulation Control mode Auto T C control Manual Fixed output Monitor Temperature only No power output Wat...

Page 77: ...be in ascending or descending order A red line denotes the current sorting Information can be sorted according to the dynamic columns for example current Amps voltage VAC etc This can be helpful when...

Page 78: ...ad for adjusting the percentage of power output when a zone s is in Manual regulation Zone On Off Touch this field to turnthe selected zoneON orOFF Adialog appears and allows the user to choose a valu...

Page 79: ...used to create group views in the Multi Group View as well as create a Shortcut Icon button in the Shortcut section on the Home screen Zone Locked Unlocked Touch this field to display a dialog to lock...

Page 80: ...until the timer expires or the user touches the Standby button again Possible values are 0 100 The default value is 10 Power Minimum Limits the range that can be entered for Standby power Power Maxim...

Page 81: ...pires or the input is inactive Possible values are 0 100 The default value is 10 Power Minimum Limits the range that can be entered for Remote Standby Power Power Maximum Item Description Temperature...

Page 82: ...ips manifold or sprue These settings are used to configure the power deviation alarm AMC Automatic Manual Control Automatic Manual Control AMC allows Altanium to automatically apply a manual power out...

Page 83: ...aming multiple zones To select commonly used zone names use the following keys zone probe tip nozzle sprue manifold bridge valve gate not used 3 Touch the Accept button 7 5 10 1 Changing Multiple Zone...

Page 84: ...7 5 12 Changing the Alarm Window Specify how many degrees above or below the setpoint to initiate the alarm The default setting is 6 C 10 F Alarm Example Setpoint 300 F Alarm 10 F An alarm is initiat...

Page 85: ...ost vulnerable components in the mold are the thermocouples If a thermocouple fails Altanium will initiate an alarm and display an error on the Alarm screen for the affected zone At this point there a...

Page 86: ...ed average power output to the heater If AMC is Off Priority Control Mode PCM is activated and shuts down either the zone or the system based on the PCM directive 7 5 15 2 Manually Slaving One Zone to...

Page 87: ...ld and enter a value 3 Touch the Accept button 4 Touch the Temperature Maximum field and enter a value 5 Touch the Accept button 6 Touch the Power Minimum field and enter a setpoint value 7 Touch the...

Page 88: ...n 8 Touch the Power Setpoint field and enter a value 9 Touch the Accept button 10 Touch the Power Minimum field and enter a value 11 Touch the Accept button 12 Touch the Power Maximum field and enter...

Page 89: ...a value 5 Touch the Accept button 6 Touch the Temperature Maximum field and enter a value 7 Touch the Accept button 8 Touch the Power Setpoint field and enter a value 9 Touch the Accept button 10 Tou...

Page 90: ...hutdown sequence Specify what to shut down if this happens In the case of an Abort condition if the PCM is set to Zone the controller will stop applying power output to the defective zone and continue...

Page 91: ...o the following 1 Touch the zone to be changed 2 Under Advanced Settings touch the AMC Automatic Manual Control field 3 Select On or Off 7 5 21 Changing the Output Power Limit Setting The Output Power...

Page 92: ...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 Altan...

Page 93: ...sents a zone that has already been ARTed A question mark represents a zone that is not ARTed Table 7 4 ART Process Screen Button Descriptions Button Description Start ART Process Touch the Start ART P...

Page 94: ...best at setpoint Use this function sparingly and only permit highly qualified individuals to use it The molding process may be interrupted if ART is run on several zones at one time but this is rare...

Page 95: ...ow Manifolds or heaters with externally located thermocouples 075 003 150 Slow Table 7 7 Possible Causes of Oscillation Cause Description P too large Power change too great per C of temperature change...

Page 96: ...v 1 1 July 2015 Altanium Matrix2 84 Possible Causes of Oscillation...

Page 97: ...ed Diagnostics can also be used to analyze the thermal isolation between all the cavities in the mold 8 1 Testing the Mold To test the mold do the following 1 On the Home screen touch the Mold Diagnos...

Page 98: ...Wiring check box to test whether for the selected zones thermocouple and heater pairings are correct 1 to 1 and 2 to 2 etc A wiring test will test the following Before conducting the cross talk test A...

Page 99: ...ers sensors wiring By default all tests are selected 11 Touch the Run Test button 8 1 2 Setting the Zone Cooling Time On some molds it may be necessary for the Altanium controller to wait a certain pe...

Page 100: ...and result in a failed test Operators can set the maximum test time for each zone to accommodate different types of heaters To set the maximum test time do the following 1 On the Mold Diagnostics scr...

Page 101: ...t zone is operating correctly Fuse values are displayed as follows Question Mark indicates the fuse for the zone was not tested Check Mark indicates the fuse for the zone passed the test X indicates t...

Page 102: ...or assignment does not match the cross talk findings test will fail Wiring values are displayed as follows Check mark indicates the zone passed the wiring test X indicates the zone failed the wiring t...

Page 103: ...st and shows 100 but zone 10 shows 60 If zone 9 increased 10 degrees during the test zone 10 increased 60 of this 10 degrees or 6 degrees without having any energy applied To view the cross talk infor...

Page 104: ...ne to display the temperature and status of the location touched The purplegraphlinezone informationis displayed in the Heat Up and Cool Down portion of the Temperature Graphs screen Use the Previous...

Page 105: ...period Total Decrease The decrease in temperature of the zone during the cool down period Time Duration The time spent cooling the zone Table 8 3 Temperature Graphs Screen Button Descriptions Button D...

Page 106: ...v 1 1 July 2015 Altanium Matrix2 94 Temperature Graphs Screen...

Page 107: ...t routine is activated This test is critical for detecting the following heater circuit faults WARNING Please read this entire manual before attempting to startup the system Call the nearest Husky Reg...

Page 108: ...nst the minimum limit and the lower of the two values is applied For H Cards ICC3 The cards include a sensor specifically for monitoring leakage current in the heater circuit on a continuous basis The...

Page 109: ...value 3 Touch the Accept button To configure the number of bake out cycles do the following 1 On the System Setup screen in the Bake Out section touch the Number of Bake Out Cycles field 2 Enter the d...

Page 110: ...indow is maintained throughout the soft start process and determines the gap between the coldest and hottest zones Generally lowering the soft start limit value decreases this gap contributing to grea...

Page 111: ...Clear Inactive Alarms Button Table 9 1 Alarm Screen Button Descriptions Button Description Silence Horn Clears the audible alarm Reset Alarms Resets the alarm light and error message Clear Inactive A...

Page 112: ...he Silence Horn button To reset the alarm light and acknowledge the alarm touch the Reset Alarms button Alarm State Description Active When an alarm first occurs it is assigned the active state Inacti...

Page 113: ...he Event History screen and Alarm Summary screen refer to Section 9 7 For a description of the abort conditions displayed on the Event History screen and Alarm Summary screen refer to Section 9 8 Figu...

Page 114: ...r on the Alarm screen and the Event History screen Date Time Date and time that the event was triggered Source Cause of the event Description Description of the event Mold Indicates the mold that is a...

Page 115: ...in automatic control mode The system has AUTOMATICALLY SLAVED this zone to another one using data it collected before the thermocouple became faulty The faulty zone is now being controlled by the powe...

Page 116: ...ntrol Card Over Temperature A control card temperature has exceeded 76 C 170 F Fuse 1 Blown Fuse 1 on this Intelligent Control Card ICC2 or ICC3 has blown and needs replacing Fuse 2 Blown Fuse 2 on th...

Page 117: ...from the thermocouple have been switched or the connections are reversed As power is applied the temperature goes down instead of up Correct this situation at the point where the wires are reversed R...

Page 118: ...v 1 1 July 2015 Altanium Matrix2 106 Abort Conditions Shutdown Errors...

Page 119: ...etting some of the most commonly used system wide preferences To display the System Setup screen touch System Setup on the Home screen Items in this screen depend on the access rights of the user and...

Page 120: ...ble 10 1 System Setup Screen Item Descriptions Item Description Serial Number The Serial Number is for informational purposes only It is a number assigned to the system when it is manufactured Husky s...

Page 121: ...lost Standby or Boost mode continues until the duration timer elapses On Off Includesa delaytimer If the D I signal islost the controller returns to the running state Direct System enters Standby unt...

Page 122: ...Leakage Fault Limit Default Value The value the system will use to determine the earth leakage limit if diagnostics have not been run on a zone Only displayed if ICC2 cards are installed The paramete...

Page 123: ...fies the amount of time the zones are given to achieve the bake out setpoint If the time period expires a warning message displays the problem and what happens when the warning message is acknowledged...

Page 124: ...The number of degrees over the setpoint the Maximum Temperature Alarm is activated No Response Limit A global setting that determines how long the system should apply 96 power or greater without a 5...

Page 125: ...dash is shown then the user may select any of the temperature unit choices in the units dialog To select the temperature units of measure do the following 1 On the System Setup screen under User Setti...

Page 126: ...n 2 Change the desired units of measure 3 Touch the Exit button NOTE If Altanium is forced to a specified setting only administrators can change the units of measure 10 1 4 Changing the Energy Usage a...

Page 127: ...on 5 Touch the Accept button 10 1 6 Changing the Number of Zones in the System Users may need to add or remove zones to an existing mold setup If the mold running has fewer control zones than listed o...

Page 128: ...ay timer is a feature available with remote standby Use the remote standby delay timer to protect the material from burning if the molding machine is stopped for a specified period If the remote stand...

Page 129: ...te Standby Operational Description Manual Time Delay Time Remote Time Input Mode Cycle Enabled Operation STANDBY Button Select 0 00 00 0 00 00 Trigger System will not enter Standby since no timers are...

Page 130: ...tton 10 1 8 2 Setting the Remote Boost Duration Timer The input option settings determine how the system reacts when it receives remote boost input NOTE If the system is not equipped with remote boost...

Page 131: ...n the format HHMMSS 3 Touch the Accept button 10 1 8 4 Changing the Remote Boost Input Mode The remote boost input mode setting is enabled based on one of three settings trigger on off or direct To ch...

Page 132: ...iption Manual Time Delay Time Remote Time Input Mode Operation Boost Button Select 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 immediatel...

Page 133: ...Power Deviation Settings 121 User Guide v 1 1 July 2015 System Setup Screen Figure 10 4 System Setup Screen Power Deviation 1 Power Deviation Area Figure 10 5 Power Deviation Dialog Box 1 1...

Page 134: ...determine the tolerance value that will be used for declaring an error This value will only be used if the value calculated by the system cannot be used The default value is 10 and the range is from 1...

Page 135: ...miting touch the Global Output Power Limit field 2 Enter the desired limit 3 Touch the Accept button 10 1 11 Monitor Zone Settings Allow Monitor Regulation For Selection This parameter allows the user...

Page 136: ...able options are included with each controller via the Digital I O screen For information on configuring options refer to Section 13 1 Users can purchase additional options such as 8 I Os All I Os Rem...

Page 137: ...ing information do the following 1 On the System Setup screen under Options and Licensing select Update License 2 Upload the new license as applicable 3 Once updated a confirmation dialog box appears...

Page 138: ...ox appears 2 Select Assign Heater Types if not previously done This will bring up the Quick Set screen For more information refer to Section 7 5 8 NOTE The Heater Type parameter must be set to Tips fo...

Page 139: ...Parts in Sack parameter and Parts display on the system header to zero when the current part count is greater than or equal to the sack full limit For more information on configuring digital inputs o...

Page 140: ...is set to Zone on the Quick Set screen To allow the system to optimize the sack full limit do the following 1 On the Quick Set screen set the PCM Priority Control Mode to Zone The system will automati...

Page 141: ...of Six binary inputs allowing the user to assign a mold setup to each one of 63 possible combinations Eight binary inputs allowing the user to assign a mold setup to each one of 255 possible combinat...

Page 142: ...rent mold setup When a request has been initiated to load another mold setup the system will use this parameter to either save or discard the changes 4 Select any of the 63 rows that do not already ha...

Page 143: ...select the desired row and press the Clear Mold Setup button NOTE A mold setup cannot be assigned to more than one remote load ID If the user attempts to do this the previous association will be remov...

Page 144: ...the system has to stay in an error condition before it is declared an alarm The default value is 2 seconds and the valid range is from 2 to 60 seconds Maximum Temperature Limit This value is interpre...

Page 145: ...ch the Mold Cooling Enable field 2 Enter the desired value 3 Touch the Accept button No Response Limit This is a global setting that determines how long the system should apply 96 power or greater wit...

Page 146: ...t be heated and cooled in a specific order to prevent problems such as misalignment and leaking 10 2 1 Enabling or Disabling Staged Startup Users can enable or disable the staged startup feature on th...

Page 147: ...d to control how the temperatures in the system cool down To enable or disable staged shutdown do the following 1 On the Staging screen do the following To enable staged shutdown select the Staged Shu...

Page 148: ...v 1 1 July 2015 Altanium Matrix2 136 Staging Screen Figure 10 18 Staging Screen Startup and Shutdown...

Page 149: ...ed all zones in the last assigned stage will not change to their normal setpoint once all zones have achieved the stage setpoint and the soak timer has expired Stage x Soak Timer The amount of time at...

Page 150: ...Hold button 10 2 6 Setting Soak Timers At the end of each stage during staged startup or shutdown when all zones have reached their stage setpoints they can be left to soak for a specified time befor...

Page 151: ...Guide v 1 1 July 2015 System Setup Screen 2 Enter the time required in the format HHMMSS Soak timers have a range of 00 00 00 to 23 59 59 3 Touch the Accept button 4 Repeat the steps above for each st...

Page 152: ...v 1 1 July 2015 Altanium Matrix2 140 Setting Soak Timers...

Page 153: ...is mapped to a valid network drive To map a network drive do the following 1 On the Home screen touch the Network Setup button 2 In the Network Locations field type a valid network location 11 1 2 Loa...

Page 154: ...utton 4 Touch the Change View Settings button 5 Touch the Select File Name button Figure 11 1 Mold Picture View Screen 1 Edit Button 2 Views Figure 11 2 Mold Picture View Screen in Edit Mode 1 Change...

Page 155: ...SB button to navigate to a graphic stored on the USB drive 7 Navigate to the desired image 8 Select the desired image 9 Touch the Accept button NOTE To automatically increase the size of the image to...

Page 156: ...Button 5 Original Size Button 6 Mold Picture View Graphic 7 Views Toolbar Button Definition Zoom Out Button Demagnifies the mold picture view graphic Zoom In Button Magnifies the mold picture view gr...

Page 157: ...e uploaded mold picture view graphic To configure the Mold Picture View make sure Altanium is in Edit mode To hide show the Edit toolbar touch the screen Figure 11 5 Mold Picture View Screen in Edit M...

Page 158: ...displayed on a Zone Information Panel can be chosen from the following list Zone Name Current Temperature Setpoint Actual Temperature Power Output Amperage NOTE Actual earth leakage is an option when...

Page 159: ...el Once a Zone Information Panel is created it can be placed anywhere on the mold picture view graphic To move a Zone Information Panel do the following 1 Make sure Mold Picture View is in Edit mode 2...

Page 160: ...rds are installed and the display earth leakage parameter is set To change the content displayed on a zone information panel do the following 1 Make sure Mold Picture View is in Edit mode 2 On the Mol...

Page 161: ...ure Power Output or Amperage 5 Touch the Accept button 11 3 2 4 Creating a Leader Line Create leader lines to clarify the connection between a Zone Information Panel and the associated heat zone Creat...

Page 162: ...ch the desired color 5 Touch the Accept button 11 3 4 Deleting a Leader Line To delete a Leader Line do the following 1 Make sure Mold Picture View is in Edit mode 2 Touch and drag the Leader Line to...

Page 163: ...elete button or off the mold picture view graphic or 3 Select the Zone Information Panel and touch the Delete button 11 3 6 Exiting Edit Mode To exit Edit mode do the following 1 Make sure Mold Pictur...

Page 164: ...v 1 1 July 2015 Altanium Matrix2 152 Exiting Edit Mode...

Page 165: ...a mold and view recorded data If an error has occurred while the system was recording review the behavior of the system at the time of the error to search for potential causes 12 1 Process Trend Scre...

Page 166: ...v 1 1 July 2015 Altanium Matrix2 154 Viewing the Process Trend Figure 12 1 Process Trend Screen 1 Variable Selection Button 1...

Page 167: ...ture fluctuations setpoint values pressures positions and times A detailed textual representation is offered for specific times Available process variables for heat zones Actual Current Actual Earth L...

Page 168: ...een 1 Process Variable 2 Graph Section 3 Timeframe Table 12 1 Process History Screen Item Descriptions Item Description Process Variable The process variable shown in the process history Graph Section...

Page 169: ...ange To change the timeframe do the following 1 On the Process History screen touch the Timeframe field Figure 12 4 Process History Screen 1 Curve 2 Curve Data Point 3 Midline 4 Description of Data Ta...

Page 170: ...te value will be adjusted automatically to maintain the Timeframe value 12 2 3 2 Changing the Date and Time Range New Changing the date and time range end will automatically update the date and time r...

Page 171: ...uide v 1 1 July 2015 Data Recording 2 Touch the Minimize Maximize button 3 Select the desired heat zone or process Figure 12 6 Process History Screen 1 Variable Selection Button Figure 12 7 Process Hi...

Page 172: ...use limits check box and Altanium will trigger an alarm if the process variable is not within the lower and upper limits Critical Controller may stop if the process variable is not within the lower an...

Page 173: ...controller will stop if any critical process variable is not within the lower and upper limits Digital Output On If selected a digital output will trigger if any process variable is not within the lo...

Page 174: ...v 1 1 July 2015 Altanium Matrix2 162 Filtering by Units...

Page 175: ...n of hardware and software options that can be used to complement the system 13 1 Configuring the Digital I O Use the Digital I O screen to configure the digital I O On the Home screen touch the Digit...

Page 176: ...urn off 13 2 Cable Connections With the exception of the USB connection on the front of the Matrix2 display all cables are connected to the back of the Matrix2 display The insulation level of control...

Page 177: ...Cable Connection Description Ethernet User interface to customer networks DC 24V Out Option for future use EtherCAT if equipped Communication to UltraSyncE Gen2 system Input Configurable digital inpu...

Page 178: ...e boost Input C BLK Remote start Input D BLK WHT Cooling lines not enabled Input E BLU Manual boost Input F BLU WHT Remote Stop Input G BLU BLK 24V Input H GRN 24V Input J GRN BLK 24V Input K GRN WHT...

Page 179: ...mmunications error Output T BLK RED Mold cooling enable Output U RED BLK Mold cooling enable Output V RED WHT Process outside limit Output W WHT RED Process outside limit Output X GRN BLK Output Y GRN...

Page 180: ...A WHT Load setup Remote Load B WHT BLK Setup B0 Remote Load C BLK Setup B1 Remote Load D BLK WHT Setup B2 Remote Load E BLU Setup B3 Remote Load F BLU WHT Setup B4 Remote Load G BLU BLK Setup B5 Remot...

Page 181: ...valent functions in the system 14 1 SPI Command Summary The SPI commands supported by the system are listed below The system supports the defined poll and select functions for each command If a select...

Page 182: ...lt in an invalid data error in response to a polled function Invalid zone number Summary This command is used to read the actual temperature of a specified zone It is valid for zones in all regulation...

Page 183: ...d zone number Summary This command is used to set and read the abort window value for a single zone The abort window is used only for zones with Auto or View regulation Errors The following conditions...

Page 184: ...w Alarm 1 Alarm under temperature 4 High Alarm 1 Alarm over temperature 5 Low Alarm 2 Abort under temperature 6 High Alarm 2 Abort over temperature 7 Open T C Alarm Lost thermocouple 8 Reverse T C Ala...

Page 185: ...value less than the minimum allowed percentage A value greater than the maximum allowed percentage The following conditions result in an invalid data error in response to a polled function Invalid zon...

Page 186: ...v 1 1 July 2015 Altanium Matrix2 174 Open Closed Loop...

Page 187: ...tems are based around a modular concept The two major components for the X H Series systems are the Altanium operator interface and the X Series 12 zone card cage or H Series 24 zone card cage Both X...

Page 188: ...en the card is not installed or an error of some kind has happened with the card The card type is dictated by the color of the card on screen XL and HL cards are black X and H cards are Silver and XE...

Page 189: ...Alarm Active and Zone Alarm Inactive 3 Touch the Exit button A list of Active and Inactive faults will be displayed 4 Select the applicable error and then touch the Card Layout button A screen detail...

Page 190: ...o six Intelligent Control Cards which are plugged into the Passive Backplane The number of passive backplanes and Intelligent Control Cards the system contains is based on the number of zones ordered...

Page 191: ...ut Located inside each card cage are one to six Intelligent Control Cards ICC2 or ICC3 and a single Passive Backplane Figure 15 6 X H Series Card Cage IMPORTANT Although they look similar ICC2 and ICC...

Page 192: ...driver between the silver post and the ledge on the cabinet and gently pry the board out Figure 15 8 Figure 15 7 Altanium Main Power Switch 1 Main Power Switch 1 WARNING Electrical and mechanical haza...

Page 193: ...the following 1 Locate the Card Cage that contains the faulty ICC2 or ICC3 Use the on screen Card Layout feature to assist in locating the card 2 Loosen the upper and lower slotted screws on the heat...

Page 194: ...f the display input power is correctly connected and all three phase indicators are lit the display is probably faulty 15 4 1 Disconnecting the Display Module To disconnect the display module do the f...

Page 195: ...ex wrench provided with the controller 4 Disconnect the interface plate from the mainframe Place the interface plate on a flat surface IMPORTANT A minimum of 2 people are required to perform this proc...

Page 196: ...s to the mainframe NOTE The main power for the Altanium display module can only come from the mainframe Display Power connection 15 4 3 Mounting the Display Module Remotely The display module can be m...

Page 197: ...the Motherboard Battery Motherboard uses a Button Cell CR2032 battery To replace the motherboard battery do the following 1 Disconnect power from the controller 2 Remove the display module back cover...

Page 198: ...le Inputs The system has been factory calibrated and in most cases it is not necessary to recalibrate until Altanium has been running for one year If calibration is necessary contact the nearest Husky...

Page 199: ...n soft lint free cloth This removes dust and other particles 3 If necessary apply a small amount of non ammonia non alcohol based glass cleaner onto a clean soft lint free cloth and wipe the screen CA...

Page 200: ...v 1 1 July 2015 Altanium Matrix2 188 Touch Screen...

Page 201: ...nals 2 Using the electrical schematics for the controller and the machine connect the X 100 cable to the machine Some modifications to the machine may be required to connect the cables to the appropri...

Page 202: ...nc E Home Profile and Setup screens 16 2 1 UltraSync E Home Screen Buttons Use the UltraSync E Home screen buttons to open the following UltraSync E screens UltraSync E Home screen UltraSync E Opening...

Page 203: ...On the Home screen touch the Home button to open the Home screen Button Description Use the UltraSync E Home button to open the UltraSync E Home screen Use the UltraSync E Profile button to open the U...

Page 204: ...igure 16 2 UltraSync E Home Screen 1 Control Modes Buttons Drop Down 2 Control Bar 3 Control Bar Status Indicators 4 Command Buttons 5 UltraSync E Home Screen Tab 6 UltraSync E Opening Profile Tab 7 U...

Page 205: ...nc E into Engaged mode Disengaged Button Activates Disengaged mode where UltraSync E is controlled by the operator using the Altanium user interface Disabled Button The UltraSync E servo system is dis...

Page 206: ...m this is the state of the At Temperature digital input Soak Time Remaining Indicates the time remaining on the soak timer countdown Soak Time Done Soak time countdown is complete Servo Drive Enabled...

Page 207: ...user level is sufficient and UltraSync E is not engaged 16 4 1 Monitoring Peak Open Force Peak force during the last open motion Peak Close Force Peak force during the last close motion Item Descripti...

Page 208: ...ce Limit The force limit used after the Relax Delay has expired This force limit should be set lower than the operating force limits Its purpose is to reduce energy consumption and prevent overheating...

Page 209: ...n This configurable input signal must be TRUE to initiate valve stem calibration The signal type choices are digital input and none If the input is lost during calibration the calibration sequence is...

Page 210: ...ur such as when the IMM is still auto cycling and injecting plastic into the mold with the stems closed The signal is configured with two anded conditions The default conditions are None None 16 4 3 1...

Page 211: ...e security level One Trigger Valve stems open after the Open Command signal is active and the stem open delay timer is complete Valve stems stay open until the stem close delay timer is complete Clamp...

Page 212: ...g the entire Matrix2 controller To perform a parameter set download select the desired motor and touch the Download button The status of the active parameter set is displayed in a text box as follows...

Page 213: ...y The delay timer starts when the valve stems reach the closed position When the delay timer expires the pullback motion begins Duration The duration timer starts when the pullback motion begins When...

Page 214: ...Profile Screens 16 5 UltraSync E Opening Profile and Closing Profile Screens Use the UltraSync E Opening Profile and Closing Profile screens to setup and view the motion profiles used to open and clos...

Page 215: ...50 mm s Acceleration The acceleration limit of the step May not be achieved depending on travel distance of the step 1 mm s 2 500 mm s 2 500 mm s 2 Deceleration The deceleration limit of the step May...

Page 216: ...and safety signals that run between the UltraSync E controller and IMM On the Home screen touch the Servo I O button Item Description Duration The elapsed time of the last valve stem close motion Pea...

Page 217: ...The signal selected determines the function of the output Function Name of the function that the input signal performs Normally The inputs and outputs can be set as normally open or normally closed T...

Page 218: ...into manual or disabled mode 21 22 External At Temperature Active when all heat zones are within their defined tolerance range This is used to trigger a soak timer which when complete enables the ope...

Page 219: ...tacts are opened when an immediate stop is required for the machine due to a fault or alarm on the controller 7 8 Ready and Engaged Active when controller is enabled with no faults in auto engaged mod...

Page 220: ...hat the condition is true when the indicator is illuminated Condition These are anded conditions that must all be true for the configurable signal to become active Name Name given to the configurable...

Page 221: ...s IMM E Stop OK The switch contact must be OPEN when the IMM emergency stop device is being actuated Opening the switch contact causes emergency stop of valve gate stem movement 19 20 IMM Safety Gates...

Page 222: ...apter contact Husky Technical Support or the nearest Husky Regional Service and Sales office for assistance 16 8 1 Drive Fault Error Code This fault from the servo drive system can occur for a variety...

Page 223: ...e A Cycle power to the drive check wiring to module replace module 50 Error in module C Cycle power to the drive check wiring to module replace module 51 Error in module D Cycle power to the drive che...

Page 224: ...perature sensor Check to make sure black encoder cable is not damaged and is connected to the motor Replace encoder cable if necessary 87 Safety relay off or defective Could be displayed when safety g...

Page 225: ...15 Cable break encoder 1 Check to make sure black encoder cable is connected between motor and drive and not damaged 123 Field angle error Check black encoder cable for shield damage 146 Encoder modul...

Page 226: ...omplete the motion To troubleshoot this fault Review the concurrent alarms on the alarm page or in the Event log to determine when the fault occurred Was it during opening closing or while holding an...

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