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Mold-Masters TempMaster XL-2 Series, User Manual

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Mold-Masters TempMaster XL-2 Series User Manual Download Page 29

XL-2 Manual 

Troubleshooting 

 

Revision 1.1 

Mold-Masters

®

 

Page 29

 

Fans 

Every Cabinet has auxiliary fans to ensure adequate cooling. If 
any fan has stopped working then first inspect the unit to see if 
there are any blockages or objects fouling the impellors. Once you 
are certain that the fan is free to rotate then proceed to check its 
supply fuse that is located on the main termination rail.  

Class 1 

1/4 

“ Glass Fuse Antisurge 

Rating 2A 

Controller Cards 

There is a protection fuse for power input on the controller card.  

Fuse Rating 

500mA 

Output Overload Protection Fuse 

On the back of 4, 12, 18 zones cabinet, there are fuses for 
protecting the heating load output.   

Class Fast 

blow 

Rating 16A 

Summary of Contents for TempMaster XL-2 Series

Page 1: ...XL 2 Series user manual revision 1 1 www moldmasters com ...

Page 2: ...uthor Authorised 1 0 July 04 First Issue DT JN 1 1 Nov 05 Re organized format DT JN Copyright 2004 Mold Masters Developments This manual is intended for use with the XL 2 Series Controller Our policy is one of continuous improvement and we reserve the right to alter product specifications at any time without giving notice ...

Page 3: ...ions 4 Safety Instructions 5 Welcome 6 Installation 7 Switching On and Off 8 Navigation 9 XL 2 Operation Diagram 12 The Controller Cabinet 13 How the XL 2 Controller Works 14 Setting up your controller 15 Running your controller 19 Customizing your controller 23 Troubleshooting 27 Appendix A 30 Index 35 ...

Page 4: ...rol Accuracy 1 C Earth Leakage Measurement Earth leakage measurement on individual cards set at 100KΩ Thermocouple input Iron Constantan Fe Con type J type K or type L Power output 16A 3600W Temperature scale Centigrade Celsius or Fahrenheit Output Overload protection 16A super quick acting FF fuse Card Diagnostics LED s Zone1 Zone2 Ground Fault T C Fault Temperature Alarm and Current Overload Ala...

Page 5: ...re a three phase supply is used then this potential may be at 380 volts or higher Safety Notices an explanation Within this manual safety instructions are marked as follows A WARNING symbol and message shown here identifies 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 th...

Page 6: ...purpose of this manual is to give you a complete understanding of how best to use the controller and to assist where there are problems or faults The Navigation section contains a brief technical description of the system components and a portrayal of the Mold Masters operating philosophy that facilitates precision temperature control The following chapters then take you carefully through the stag...

Page 7: ...lean dry environment where the ambient conditions do not exceed the following limits Ambient temperature 0 to 50 C Relative Humidity 90 non condensing When in use this equipment does not emit audible noise in excess of 10dBA Controller Tool Connections The various connections to the system using the cables supplied with the equipment are specified in Appendix A Controller Power Supplies The contro...

Page 8: ...nd that you only do this in an emergency situation A sequenced method for switching On and Off protects the controller and keeps the switched load to a minimum to extend the life of the main Isolator Switching On Once the controller card is on it gets into Run mode automatically to start heating the tool Switching Off or Shutting Down We recommend that you use the controller to shut down the heati...

Page 9: ...s Zones Switching There are two zones per controller card The two blue LEDs on the right indicate which zone s information is currently shown Zones can be switched anytime in Temperature Display Current Display or Power Output Display to show reading accordingly Use to switch between two zones to view display Function Menu In this menu you can put the controller into particular working mode Howeve...

Page 10: ... detailed explanation on each parameter in the menu In Function Menu use to scroll to Prog and then press to enter into Program Menu Scroll through the menu by using or to Top display shows menu item bottom shows setting You cannot change setting when bottom display is flashing Press to gain access for any changes by bottom display then stays Use or to change setting press to save the change Botto...

Page 11: ...s Description Increment up Change set temperature power output in manual mode or program parameter values Rotate through function and program menu Decrement down Change set temperature power output in manual mode or program parameter values Rotate through function and program menu Enter Rotate through Temperature Current and Power display Gain access and confirm program menu changes Press and hold...

Page 12: ...e Program Mode Function Menu Press Press Press 200 200C 200 025P Temperature Display Top actual temperature Bottom set temperature in ºC It shows F if temperature is in Fahrenheit Main Screens Power Output Display Top actual temperature Bottom power output 200 03 5A Current Display Top actual temperature Bottom current reading Press Press Decimal point besides top right digit indicates the power o...

Page 13: ...iers CPU multi voltage output triacs Thermocouple Amplifiers The thermocouple amplifiers have preset responses for both J and L type thermocouples The selection of sensor type can be done in Program Menu this in turn sets the differential amplifier to match the selected thermocouple type Central Processor Unit CPU The CPU provides the following facilities closed and open loop control of the zones ...

Page 14: ...t a predetermined value in program parameter r1 Power is slowly increased until the correct rate of rise is achieved 2 At ramp temperature rE the dwell time rt is activated 2minutes this permits any residual moisture in the heating elements to be eliminated After all zones reached to ramp temperature they will start heating up together again 3 The controller continues to ramp up the temperature to...

Page 15: ...if you are reconfiguring your controller to a new tool or environment then you may need this chapter of the manual This initial set up is detailed here in easy to follow steps that help you to become familiar with your new equipment What is covered in this section Setting your preferred Temperature Unit Matching Sensor Types Setting the Required Temperatures Setting Boost Level Setting Standby Lev...

Page 16: ...ent types of probe sensors J type and L type with different characteristics The sensor type is normally configured to a J type before leaving the factory and should only need to be altered in rare circumstances Changes in this parameter apply to both zones of the controller card 1 From the Temperature Display Screen press and hold for at least 2 seconds until you get into Function Menu 2 Use to sc...

Page 17: ...will see the bottom display flashing 4 Press to get access to change parameter setting The bottom display should stay 5 Use or change to your desire setting 6 Press to store the change The bottom display should be flashing again 7 To return to Temperature Display Screen by pressing Setting Standby Level Before you activate Standby function you must first configure the amount When standby is activa...

Page 18: ...to Function Menu 2 Use to scroll to Prog Press to get into Program Menu 3 The first parameter in Program Menu is Ot You will see the bottom display flashing 4 Press to get access to change parameter setting The bottom display should stay 5 Use or change to your desire setting 6 Press to store the change The bottom display should be flashing again 7 Press to get back to Temperature Display Screen S...

Page 19: ... appropriate run mode for the machine according to whether the tool is working or waiting It may also be necessary to make changes to the heater temperatures and using the graphical display of recent performance may help such decisions What is included in this section Run Mode Off Mode Standby Mode tdn Manual Mode Hnd open loop control Boost Mode tUP how to apply a short increase Changing Set Temp...

Page 20: ...to Setting Standby Level Once standby mode is activated both zones would be reducing to standby temperature 1 From the Temperature Display Screen press and hold for at least 2 seconds until you get into Function Menu 2 Use to scroll to tdn 3 Confirm your decision by pressing to activate this function or to exit without changing operating mode 4 Once standby mode is enabled top display is alternati...

Page 21: ...his mode use to switch to another zone repeat the above steps again Note This feature cannot be disabled completely by setting EHd in program menu to 0 for preventing accidental change of mode Boost Mode tUP This mode provides a means of temporarily boosting the zone temperature for 2 minutes To determine the increment refer to Setting Boost Up Level 1 From the Temperature Display Screen press and...

Page 22: ...tomatically in Temperature Display Screen 1 From the Temperature Display Screen press and hold for at least 2 seconds until you get into Function Menu 2 Use to scroll to Prog Press to choose Program Menu 3 Use to scroll to dSP You will see the bottom display flashing 4 Press to get access to change parameter setting The bottom display should stay 5 Use button to change to setting to 1 to enable th...

Page 23: ...er Program Menu is where you may set controller to different output alarm temperature alarm limits heating characteristics and other special operating mode What is included in this section Functions of Menu Items Viewing current item parameters Changing menu item parameters Recalling factory settings ...

Page 24: ...T Ramp1 end temperature rE 120ºC or 248ºF 120 160ºC or 248 320ºF Ramp1 temperature r1 1ºC 6s or 1ºF 4s 1ºC 10s 1ºC 6s or 1ºF 6s 1ºF 4s Ramp2 temperature r2 1ºC 3s or 1ºF 2s 1ºC 10s 1ºC 1s or 1ºF 6s 1ºF 1s Dwell time at Ramp1 end temperature rt 2min 1 10min SPECIAL OPERATING MODE Control mode at thermocouple leakage not 1 0 1 Manual mode enable EHd 1 0 1 Standby mode enable Etd 1 0 1 Boost mode ena...

Page 25: ...t to switch the XL 2 into Standby Mode remotely as long as Menu Item El is set to 1 To disable this feature simply set its value to 0 Soft Start Items Parameters in Soft Start will define the heating profile Controller will have a virtual model built to map the tool and heater characteristics these parameters do not need to be adjusted unless there is an unusual large heating plate Special Operati...

Page 26: ...et into Function Menu 2 Use to scroll to Prog then press button to enter Program Menu 3 Use or scroll to your desire item You will see the bottom display flashing 4 Press to get access to change parameter setting The bottom display should stay 5 Use or change to your desire setting 6 Press to save the change The bottom display should be blinking again To exit from Program Menu without changing set...

Page 27: ...ee that there is no fraying or damage to cable insulation External cables should be checked to see that there has no damage to the flexible conduit plugs or sockets If the flex has been squashed if there is visible damage or if there are any exposed conductors then for your own safety it must be replaced If the equipment is subject to vibration then we recommend that you use an insulated screwdriv...

Page 28: ...e or alternatively a faulty heater We recommend that all earth connections be tested Not able to set a Higher Temperature This problem can occur if you try to set the temperature above the limits Check the Max Temp setting tLi in Program Menu and revise it if necessary Ground fault detection The Ground fault detection detects any fault caused by earth leakage current Earth faults can be caused if ...

Page 29: ...he impellors Once you are certain that the fan is free to rotate then proceed to check its supply fuse that is located on the main termination rail Class 1 1 4 Glass Fuse Antisurge Rating 2A Controller Cards There is a protection fuse for power input on the controller card Fuse Rating 500mA Output Overload Protection Fuse On the back of 4 12 18 zones cabinet there are fuses for protecting the heat...

Page 30: ...Appendix A XL 2 Manual Page 30 Mold Masters Revision 1 1 Appendix A XL 2 Wiring Standards ...

Page 31: ...r at the terminal blocks Cable Marking Supply Description R Phase 1 black S Phase 2 brown T Phase 3 black N Mp1 Mp2 Mp3 Neutral blue Earth Symbol Earth green yellow For American Delta 240V Use 4 conductors Change jumper settings by joining R MP3 S MP1 and T MP2 at the terminal blocks Do not link all MP1 MP2 and MP3 together Cable Marking Supply Description L1 Phase 1 black L2 Phase 2 brown L3 Phas...

Page 32: ...cular model Pin Connection Input Output 2 Auxiliary Input signal 3 Auxiliary Input Gnd Standby Port 1 2 3 4 Pin Connection Input Output 1 Alarm 220v contact 1 100mA 4 Alarm 220v contact 2 100mA Alarm Port 1 2 3 4 1 5 Serial Port A male 9 way D panel connector is provided for an RS 485 serial port It can communicate with a remote computer for data collection The pin outs are as follows Pin Connecti...

Page 33: ...r GND Delta 4 wires S ystem R S T Mp1 Mp2 Mp3 J4 Use 3 stand offs to install Interconnected Jumper J4 Do not install J1 J2 J3 Connect Neutral Blue conductor to Mp2 Use black brown black for 3 phases and Green for GND WYE S T AR5 wires Systems EUROPEAN S T AR380v PHAS E PHAS E 220v PHAS E NEUT RAL AMERICAN DELT A 220V PHAS E PHAS E INS T RUCT ION HOWT O CONVERTDEL T A WY E FORS INGLEBREAKERS Y S T ...

Page 34: ...Appendix A XL 2 Manual Page 34 Mold Masters Revision 1 1 Plugs Configuration PART MPLUG 12 12 18 ZONES ...

Page 35: ...10 Program Menu Items Changing 26 Program Menu Items Description 25 Program Menu Items Restoring 26 Program Menu Items Table 24 Program Menu Items Viewing 26 Run Mode 20 Safety Instructions 5 Sensor Type Selecting 16 Set Temperature Changing 22 Special Operating Mode 25 Special Operating Modes 9 Specific faults 28 Specifications 4 Standby level setting 17 Standby Mode 20 Starting before switching ...

Page 36: ...a Veneza Sumaré São Paulo Brasil CEP 13178 440 tel 55 19 3922 4265 fax 55 19 3922 4266 email moldmasters moldmasters com br facilities regional offices Mold Masters global support China Mold Masters Kun Shan Co Ltd Zhao Tian Rd Lu Jia Town Kun Shan City Jiang Su Province People s Republic of China tel 86 512 86162882 fax 0512 86162883 email MMC Sales moldmasters com Canada Mold MastersLimited 233 ...

Page 37: ... in System J 502 Kuro Distribution Business Center 636 62 Kuro Dong Kuro Ku Seoul Korea tel 82 0 2 2634 9453 4 fax 82 0 2 2634 9608 email kyungins hanmir com Romania International Mold Trade Co SRL Str Constantin Aricescu Nr 21 Bl 20 Sc 2 Apt 20 Bucharest Sector 1 Romania tel fax 40 21 231 7843 email roman dial kappa ro Turkey MMGConsulting Engineering Yesil Çesme Sok No 30 3 Çiftehavuzlar 81060 I...

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Page 39: ... DURA DURA FEMTO SHOT DURA PICO SHOT DURA CENTI SHOT DURA DECI SHOT DURA HECTO SHOT DURA MEGA SHOT FLEX DURA HOT EDGE INJECTIONEERING MASTER PROBE MASTER SHOT MOLD MASTERS MOLD MASTERS ACADEMY MOLD MASTERS SYSTEM SCAN MASTER TEMP MASTER MERLIN are the registered trademarks of MOLD MASTERS LIMITED ...

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