Mold-Masters TempMasters ME Series User Manual Download Page 1

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version 1

Original Instructions

User Manual for Me6 & Me12

Summary of Contents for TempMasters ME Series

Page 1: ...version 1 Original Instructions User Manual for Me6 Me12...

Page 2: ...RETAIN THIS SHEET Every machine leaves our factory with two levels of password protection We recommend that you remove this sheet in order to establish your own security User Password unix System Pass...

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Page 4: ...iring Check 3 8 3 6 Lockout Safety 3 9 3 7 Electrical Lockout 3 10 3 8 Energy Forms and Lockout Guidelines 3 11 3 9 Ground Connection 3 12 3 10 Disposal 3 12 3 11 Me Controller User Hazards 3 13 3 12...

Page 5: ...6 1 6 4 More about Run and Shutdown 6 2 6 5 Control Modes for All Zones 6 2 6 6 Boost Mode Individual Zones 6 3 6 7 Switch Off Individual Zones 6 5 6 8 Return a Zone to Normal Operation 6 6 6 9 Set or...

Page 6: ...13 Supplementary Fuses 7 6 7 14 Controller Cards 7 7 Section 8 Troubleshooting 8 1 8 1 Introduction 8 1 8 2 Other Possible Fault Conditions 8 4 8 3 Module Removal 8 4 Section 9 Wiring of Hot Runner Co...

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Page 8: ...sufficient understanding of electrical safety to appreciate the dangers of 3 phase supplies They should know how to take appropriate measures to avoid any danger from electrical supplies 1 2 Release D...

Page 9: ...f Measure and Conversion Factors Abbreviation Unit Conversion Value bar Bar 14 5 psi in Inch 25 4 mm kg Kilogram 2 205 lb kPa Kilopascal 0 145 psi gal Gallon 3 785 l lb Pound 0 4536 kg lbf Pound force...

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Page 11: ...am Rathinapuri Post Coimbatore T N 641027 tel 91 422 423 4888 fax 91 422 423 4800 india moldmasters com USA Mold Masters Injectioneering LLC 29111 Stephenson Highway Madison Heights MI 48071 USA tel 1...

Page 12: ...3 5581290 fax 972 3 5581293 sales asaf com Russia System LLC Prkt Marshala Zhukova 4 123308 Moscow Russia tel 7 495 199 14 51 moldmasters system com ru Belarus HP Promcomplect Sharangovicha 13 220018...

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Page 14: ...personnel in the safe operation of equipment including the use of all the safety devices Provide its personnel with all necessary protective clothing including such items as a face shield and heat re...

Page 15: ...molding machine Top view with guards removed Front view with guards removed 2 10 5 3 Top View with Guards Removed 2 5 9 1 4 7 6 9 8 Front View with Guards Removed 1 Mold area 2 Clamping mechanism are...

Page 16: ...of the plasticizing and or injection unit including nozzle Movements of parts of the power operated nozzle shutoff and their drives Over pressurization in the nozzle Thermal Hazards Burns and or scal...

Page 17: ...by hose assembly failure Possible release of fluid under pressure that can cause injury Thermal hazards associated with hot fluid Area Inside the Guards and Outside the Mold Area See Figure 3 1 area...

Page 18: ...tive equipment such as face shields and use heat resistant gloves when working around the feed inlet purging the machine or cleaning the gates of the mold Remove purged material from the machine immed...

Page 19: ...faces which could result in burns Keep flammable liquids or dust away from the hot surfaces as they could ignite Follow good housekeeping procedures and keep floors clean to prevent slips trips and fa...

Page 20: ...ressure gas or oil can cause death or serious injury Discharge all gas and hydraulic pressure before disconnecting or disassembling accumulator Warning Hot Surfaces Contact with exposed hot surfaces w...

Page 21: ...nd thermocouple connections have not been wired incorrectly Communications Interface and Control Sequence It is the customer s responsibility to verify functionality of any custom machine interface at...

Page 22: ...to avoid potential risk of electrical shock Often power sources are inadvertently turned on or valves are opened mistakenly before maintenance work is completed resulting in serious injuries and fatal...

Page 23: ...nergized and appropriately locked out This can include gravity compressed air hydraulics steam and other pressurized or hazardous liquids and gases See Table 3 3 6 When the work is completed prior to...

Page 24: ...ss air If pressure cannot be relieved block any possible movement of machinery Kinetic Energy Energy of a moving object or materials Moving object may be powered or coasting Blades Flywheels Materials...

Page 25: ...e from fluids In the case of hydraulic needle valve systems drain the oil from the lines and cylinders and dispose it in an environmentally responsible manner 3 The electrical components are to be dis...

Page 26: ...ted to disconnect the total load current during switch on and switch off The main power switch can be locked using a padlock applied under the lockout tagout procedure found in 3 6 Lockout Safety on p...

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Page 28: ...ired or zero voltage crossover Output Overload Protection High speed semiconductor fuse links Overload Protection Miniature Circuit Breaker Tool Transfer Connector USB port Relative Humidity Limit 90...

Page 29: ...sor type which in turn sets the CPU linearization to match the selected thermocouple type 4 5 Central Processor Units CPUs The CPU provides the following facilities closed and open loop control of the...

Page 30: ...ayed at maximum size Control The side command buttons change from page to page Information The bottom row shows on the left the Mode window on the right the Status window 4 3 2020 Mold Masters 2007 Li...

Page 31: ...lied Current Actual temperature is green text on black background Warning Zone Deviation exceeds 1st stage Warning Actual temperature is black text on a yellow background Alarm Zone Deviation exceeds...

Page 32: ...Main Page Change Modes The main page shows all available modes Confirmation is required to choose a new mode 4 5 2020 Mold Masters 2007 Limited All Rights Reserved OVERVIEW Me6 Me12 Controller User Ma...

Page 34: ...r basic numeric input Keypad 2 is an extended keypad which adds Value Keys Set Add and Subtract to set temperature Mode Keys Auto Manual and Boost to set working mode 4 14 Screen Saver The screen back...

Page 35: ...oller and molding machine before installation of the controller into the system There are unguarded terminals inside the cabinet which may have a dangerous potential across them Where a three phase su...

Page 36: ...the Controller The following options apply universally for every tool NOTE The tool settings may be different for different tools For example Tool 1 may display temperatures in C and Tool 2 may displa...

Page 37: ...es may be set to show as either Celsius or Fahrenheit f Password Control allows you to disable passwords so that all operations may be available for open control g Earth Leakage allows you to disable...

Page 38: ...f the controller 1 Choose Tool to open the ToolStore page 2 Choose Setup to open the Setup Tool page If prompted enter the System password 3 Choose Config to display the configuration options 5 4 2020...

Page 39: ...Temperature to limit the highest temperature to which any zone may be raised NOTE The Maximum Temperature that is permitted is 450 C or 842 F Maximum Power to limit the highest power to which any zone...

Page 40: ...y tool 1 Choose Tool to open the ToolStore page 2 Choose Setup to open the Setup Tool page If prompted enter the System password 3 Choose one or more zones to see new command buttons Choose Set to vie...

Page 41: ...nes so they do not show on the main page Speed zones can be set to Auto detect Fast Medium or Slow Sensor allows you to match the controller to either a J type or K type thermocouple 5 Choose an optio...

Page 42: ...5 6 Set the Temperature 1 Choose the first zone 2 Choose the last zone 3 Choose Range 4 Choose Set 5 8 2020 Mold Masters 2007 Limited All Rights Reserved SETUP Me6 Me12 Controller User Manual...

Page 43: ...now displayed on the Main page NOTE The zones may individually show an alarm if the new set temperature is significantly different from the actual temperature The system sees this as a temporary condi...

Page 44: ...nly one upper and one lower alarm setting each gives a visual warning at a halfway point If a High alarm is set to 10 degrees then a Warning will show at 5 degrees The same is applicable for the under...

Page 45: ...pad 7 Enter the amount by which the temperature must rise or fall to trigger an alarm NOTE Temperature limits are applicable to the current scale A High limit of 10 in Celsius automatically becomes 18...

Page 46: ...res The Boost period is user configurable To set the Boost period see section 5 4 Set the Global Parameters 1 Choose Tool to open the ToolStore page 2 Choose Setup to open the Setup Tool page If promp...

Page 47: ...se Edit from the Boost panel 7 Enter the required Boost temperature NOTE The maximum permitted Boost temperature is 100 C or 180 F 8 Choose Backl to return to the Main page 5 13 2020 Mold Masters 2007...

Page 48: ...e 2 Choose Setup to open the Setup Tool page If prompted enter the System password 3 Choose one or more zones using one of the following methods Choose one zone at a time until you have selected all t...

Page 49: ...Standby temperature NOTE The maximum permitted Standby temperature is 100 C or 180 F 7 Choose Back to return to the Main page 5 15 2020 Mold Masters 2007 Limited All Rights Reserved SETUP Me6 Me12 Co...

Page 50: ...tool slot then choose New 3 Enter the Tool Name and choose the Enter button NOTE The maximum length allowed for a tool name is 12 characters 4 Choose Load and OK to accept the new tool 5 16 2020 Mold...

Page 51: ...e ToolStore page to see the new tool with the new name 6 Choose Back to return to the Main page with the new tool saved 5 17 2020 Mold Masters 2007 Limited All Rights Reserved SETUP Me6 Me12 Controlle...

Page 52: ...o a all user level functions b reconfigure the settings for a new tool c restore and delete tools 5 12 2 Password Disabled If the password option is set to Disabled then all functions that would norma...

Page 53: ...rd Control 1 Choose Tool 2 Choose Setup If prompted enter a password NOTE Either the User or System password can be used 5 19 2020 Mold Masters 2007 Limited All Rights Reserved SETUP Me6 Me12 Controll...

Page 54: ...Password Control 6 Choose Enable to have a higher level password control or Disable for Open control 7 Choose Enter to accept the setting or Back to return to the Main page 5 20 2020 Mold Masters 200...

Page 55: ...ired to Main Run Stop Change Modes Change display options Go to Zoom or Graph page Set Alter temperatures or modes Zoom View only No other function except zone up or down Graph View only No other func...

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Page 57: ...tal load current during switch on and switch off To prevent its operation during maintenance you can use a suitably sized padlock or similar device to lock the switch in the off position 6 2 Switch On...

Page 58: ...w mode Table 6 1 Control Modes for All Zones Operation Available By Description BOOST Mode Button Temporarily raises the temperature of all zones that have any Boost temperature configured When the Bo...

Page 59: ...for a preset user configurable period 1 Choose any one or more zones 2 Choose Set 3 Enter a password NOTE Either the User or System password can be used The keypad is displayed 4 Choose Boost and set...

Page 60: ...to the Main page and the boosted temperature is shown The zone returns to normal temperature after the preset Boost time 6 4 2020 Mold Masters 2007 Limited All Rights Reserved OPERATION Me6 Me12 Cont...

Page 61: ...1 Choose any one or more zones 2 Choose Set 3 Enter a password NOTE Either the User or System password can be used The keypad is shown 6 5 2020 Mold Masters 2007 Limited All Rights Reserved OPERATION...

Page 62: ...o the Main page to check that the selected zone is switched off 6 8 Return a Zone to Normal Operation 1 Choose the zone 2 Choose Set 3 On the keypad choose On 6 6 2020 Mold Masters 2007 Limited All Ri...

Page 63: ...Choose the last zone 3 Choose Set NOTE Temperature and power settings have preset limits as described in section 5 4 Set the Global Parameters 4 Enter the password 6 7 2020 Mold Masters 2007 Limited...

Page 64: ...ture by The new set temperatures are shown on the Main page NOTE The zones may individually show an alarm if the new set temperature is significantly different from the actual temperature The system i...

Page 65: ...ternative to running in Auto mode closed loop working 1 Choose the first zone 2 Choose the last zone 3 Choose Set 4 Enter a password NOTE Either the User or System password can be used 6 9 2020 Mold M...

Page 66: ...and enter the percentage Choose Ent NOTE Temperature and power settings have preset limits as described on page 5 5 6 10 2020 Mold Masters 2007 Limited All Rights Reserved OPERATION Me6 Me12 Controlle...

Page 67: ...similar temperature 1 Choose any zone to display the Command buttons 2 Choose Set 3 Enter a password NOTE Either the User or System password can be used 4 Choose Slave Enter the number of a healthy z...

Page 68: ...ing normally STOP White text on blue The System has been shut down and the heaters are below 90 C 194 F STANDBY Yellow text on black Any zones with Standby temperatures configured have been reduced in...

Page 69: ...roller is running normally WARNING Black text on yellow A zone s temperature exceeds the warning limits ALARM White text on red This shows either a fatal error or that a zone s temperature exceeds ala...

Page 70: ...ssages see Table 8 1 The error message is white text on red background 6 16 Alarm Extensions There is a ring of LEDs in the Alarm light in the upper left of the front of the console that act as an ala...

Page 71: ...by the names within their boxes 6 18 Choose a Tool 1 Choose a tool slot The border of the box turns to blue to indicate that it has been chosen 2 Choose Load Choose OK to confirm use of this tool 3 Ch...

Page 72: ...temperature is selected and loaded then the tool will immediately change to run at the new incoming temperature setting 1 Choose a tool 2 Choose Load 3 Enter the System password 4 Choose OK to load th...

Page 73: ...ed Tool Settings If you need to use different tools for different applications you must create new tools to hold the different settings 1 Choose a blank tool slot 2 Choose Save 3 Enter the System pass...

Page 74: ...OK to confirm 10 Leave this page and make all necessary changes This process creates a new tool with new settings To restore the original tool settings return to the ToolStore page and choose the ori...

Page 75: ...leted 2 Choose Delete NOTE If you try to delete the current tool a warning panel appears telling you that you cannot delete the current tool 3 Press OK to return to the ToolStore page 4 Choose the too...

Page 76: ...6 Choose OK to confirm 7 Return to the ToolStore page to check that the unwanted tool has been deleted 6 20 2020 Mold Masters 2007 Limited All Rights Reserved OPERATION Me6 Me12 Controller User Manual...

Page 77: ...ansferred to another controller for use 1 Insert the memory stick 2 Choose the tool to backup 3 Choose Backup NOTE If there is a problem saving to the memory stick a warning message is displayed Repea...

Page 78: ...slot will be overwritten with the information from the memory stick 6 25 Restore a Tool 1 Insert the memory stick 2 Choose a blank tool slot 3 Choose Restore 4 Remove the memory stick 6 22 2020 Mold M...

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Page 80: ...serves that a the temperature of the zone under test does not reduce further which would indicate a reversed thermocouple on that zone b the zone under test rises sufficiently to a set level if not it...

Page 81: ...t the controller is connected to the tool if it is not in use for production 1 Choose Tool 2 Choose Setup If prompted enter the System password 3 Choose Test 4 Choose OK to start the test 7 2 2020 Mol...

Page 82: ...test sequence the controller will build a test result page to show how the test progressed for each zone Any zone that fails a test is highlighted by a red button marker followed by a brief explanati...

Page 83: ...rror messages Heater T C Common with Zone NN Crosswiring fault between displayed zones Could be either heater or thermocouple wiring at fault Heating Test Failed Temperature did not rise by the set nu...

Page 84: ...ection Any excess dust that has entered into the cabinet may be removed with a light brush and vacuum cleaner If the equipment is subject to vibration then we recommend that you use an insulated screw...

Page 85: ...safe to attempt to repair or replace the fuse without first isolating the circuit CAUTION There is a miniature circuit breaker that offers general overcurrent protection for the complete unit 7 12 Rep...

Page 86: ...ed fuses CAUTION Figure 7 1 Only use ceramic body fuses The controller card has protection fuses for the heating load output Table 7 3 Output Fuse Type Fuse 32 mm Ceramic FF Ultra Fast Rating 15 A 7 7...

Page 87: ...features that provide an early diagnosis of faults in the control system the tool heaters and thermocouple sensors If the system detects any abnormal condition it displays a warning message on the Ma...

Page 88: ...e control card GND The system has detected an earth fault Check the heater wiring for a low impedance path to earth LINE No mains supply synchronization pulses being received The three phase supply is...

Page 89: ...Setup page For immediate recovery slave that control zone to an adjacent zone OR change to open loop control When the controller is free check to see whether the input fuse on the control card has rup...

Page 90: ...faulty heater We recommend that all earth connections be tested 8 2 2 Ground Fault Detection Ground fault detection detects any fault caused by earth leakage current Earth faults can occur if a tool h...

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Page 92: ...troller CAUTION The following standards only apply to controllers wired to Mold Masters standard Other specifications may have been stated when the controller was ordered Please refer to the supplied...

Page 93: ...er to disconnect the controller from the power source 1 Unscrew the terminal cover from the right side panel 2 Remove the 6 position jumper from the terminal cover 3 Remove the 3x2 position jumpers fr...

Page 94: ...e terminal block 5 Place the 3x2 position jumpers in the terminal cover 6 Screw the terminal cover onto the controller 9 3 2020 Mold Masters 2007 Limited All Rights Reserved WIRING OF HOT RUNNER CONTR...

Page 95: ...er to disconnect the controller from the power source 1 Unscrew the terminal cover from the right side panel 2 Remove the 3x2 position jumpers from the terminal cover 3 Remove the 6 position jumper fr...

Page 96: ...the terminal block 5 Place the 6 position jumper in the terminal cover 6 Screw the terminal cover onto the controller 9 5 2020 Mold Masters 2007 Limited All Rights Reserved WIRING OF HOT RUNNER CONTR...

Page 97: ...eeting alarm conditions the relay is held on for about 15 seconds after the alarm condition is cleared The contacts are rated for 5 A at 240 V Table 9 1 Alarm Output Auxiliary Input Pin Connection Inp...

Page 98: ...s such as backup and restore tool settings save tool test results Table 9 2 Pin Connections Pin Connection 1 VCC 2 D 3 D 4 GND Figure 9 2 USB port 9 7 2020 Mold Masters 2007 Limited All Rights Reserve...

Page 99: ...R3 R4 R5 R6 GND R1 1 L 2 N R2 3 L 4 N R3 5 L 6 N R4 7 L 8 N R5 9 L 10 N R6 11 L 12 N T C 1 13 14 T C 2 15 16 T C 3 17 18 T C 4 19 20 T C 5 21 22 T C 6 23 23 Maximum 230Vac 16A Zone Pin Figure 9 3 6 zo...

Page 100: ..._ _ _ _ Zone Pin T C1 1 13 T C 2 2 14 T C 3 3 15 T C 4 4 16 T C 5 5 17 T C 6 6 18 T C 7 7 19 T C 8 8 20 T C 9 9 21 T C 10 10 22 T C 11 11 23 T C 12 12 24 Figure 9 5 12 48 zone pairs of HANE24E wired...

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Page 102: ...rature Limits 5 10 O Operating Modes 6 2 6 3 P Password Override 5 20 R Restoring Tool Settings 6 24 S Safety Lockout 3 10 Safety Instructions 3 1 Safety Symbols General Descriptions 3 8 Screen Layout...

Page 103: ...AN tel 81 44 986 2101 e japan moldmasters com U S A tel 1 248 544 5710 e usa moldmasters com MEXICO tel 52 442 713 5661 sales e mexico moldmasters com UNITED KINGDOM tel 44 1432 265768 e uk moldmaster...

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Mold-Masters TempMasters ME Series, User Manual

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