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TROUBLESHOOTING

M1 Plus Controller User Manual

Содержание TempMaster M1 Plus Series

Страница 1: ...User Manual version 6 Original Instructions...

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Страница 3: ...HIS SHEET SOMEWHERE SAFE Every machine leaves our factory with two levels of password protection We recommend that you remove this sheet in order to establish your own security User Password unix Syst...

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Страница 5: ...ut Safety 3 9 3 7 Electrical Lockout 3 10 3 7 1 Energy Forms and Lockout Guidelines 3 11 3 8 Grounded Earth Connection 3 12 3 9 Disposal 3 12 3 10 M1 Plus Controller User Hazards 3 13 3 10 1 Operation...

Страница 6: ...Utilities 5 16 5 12 5 Utilities Parameters 5 17 5 13 Password Security 5 20 5 13 1 Edit the System Password 5 20 5 13 2 Edit the User Password 5 20 5 13 3 Set the Password Timer 5 20 5 13 4 Password O...

Страница 7: ...gs Locally 6 22 6 18 Save Tool Settings Remotely 6 23 6 18 1 Overwrite with Saved Settings 6 23 6 18 2 Save Old and New Settings 6 24 6 19 Delete a Tool 6 25 6 20 Backup Tool Settings 6 26 6 20 1 Back...

Страница 8: ...vidual Controller Card Diagnostics 8 1 8 2 Fault and Warning Messages 8 2 8 3 System Warning Messages 8 5 8 4 Other Issues 8 5 Section 9 Hot Runner Controller Wiring Details 9 1 9 1 Three Phase Design...

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Страница 10: ...uld have 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...

Страница 11: ...easure 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 4...

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Страница 13: ...rs com INDIAN HEADQUARTERS INDIA Milacron India PVT Ltd Mold Masters Div 3B Gandhiji Salai Nallampalayam Rathinapuri Post Coimbatore T N 641027 tel 91 422 423 4888 fax 91 422 423 4800 india moldmaster...

Страница 14: ...orway and Sweden Israel ASAF Industries Ltd 29 Habanai Street PO Box 5598 Holon 58154 Israel tel 972 3 5581290 fax 972 3 5581293 sales asaf com Russia System LLC Prkt Marshala Zhukova 4 123308 Moscow...

Страница 15: ...s 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 r...

Страница 16: ...hazard areas 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 area 3...

Страница 17: ...ticizing 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 scalds due to op...

Страница 18: ...embly 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 10 Crushing...

Страница 19: ...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...

Страница 20: ...nts are hot surfaces 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 sli...

Страница 21: ...pressure 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...

Страница 22: ...that the power and thermocouple connections have not been wired incorrectly Communications Interface and Control Sequence It is the customer s responsibility to verify functionality of any custom mac...

Страница 23: ...components before performing any maintenance to avoid potential risk of electrical shock Often power sources are inadvertently turned on or valves are opened mistakenly before maintenance work is comp...

Страница 24: ...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...

Страница 25: ...attachments and tag valves Bleed off excess 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 power...

Страница 26: ...tem to be disposed of is free 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 electri...

Страница 27: ...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 page...

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Страница 29: ...Burst fired or zero voltage crossover Output Overload Protection High speed semiconductor fuse links Overload Protection Miniature Circuit Breaker Printer Output Connector USB port Relative Humidity...

Страница 30: ...ensor type which in turn sets the CPU linearization to match the selected thermocouple type 4 2 3 Central Processor Units CPUs The CPU provides the following facilities closed and open loop control of...

Страница 31: ...rrent health status Control Side command buttons that change from page to page Navigation The Main page has a Menu button at the bottom of the side buttons that activates the navigation screen All oth...

Страница 32: ...t Deviation for Set Temperature Actual temperature is green text on black background Warning Zone Deviation exceeds first stage Warning Actual temperature is black text on a yellow background Alarm Zo...

Страница 33: ...nd Set Temperature 3 Touch again to show 60 zones Each zone shows name and Actual Temperature 4 Touch button again to show the Data page which displays the setup and data for all of the zones A fixed...

Страница 34: ...d More Options Button 1 can appear as Run Stop or Startup Shutdown Button 2 is Mode Choose Mode to reveal all other Run mode options 4 6 M1 Plus Controller User Manual OVERVIEW 2021 Mold Masters 2007...

Страница 35: ...ew or recently maintained system The Utilities page gives access to these features an Exit button to shut down the system a Config button to setup system parameters see Configure the Control Cards on...

Страница 36: ...ed The SetUp page is used to setup and configure various global and specific tool parameters The Help pages offer user help 4 8 M1 Plus Controller User Manual OVERVIEW 2021 Mold Masters 2007 Limited A...

Страница 37: ...put Keypad 1 for basic numeric input Keypad 2 is an extended keypad which adds Value Keys Set Temp Add and Subtract to set temperature Mode Keys Auto Manual and Slave to set working mode Keypads 3 and...

Страница 38: ...hine before installation of the controller into the system DO NOT enter the cabinet without first ISOLATING the supplies There are unguarded terminals inside the cabinet which may have a dangerous pot...

Страница 39: ...ticular tool All values are configured on a zone by zone basis to allow for precise settings All the values on the SetUp page are stored with the tool setting that is currently selected on the Tool pa...

Страница 40: ...the SetUp page opens and the controller parameters can be configured for this tool NOTE If the system has any problem running the detect sequence it may report Auto Detect Failed and ask if you want...

Страница 41: ...alarms Example if you have six cards offering 36 control zones but are only using 32 actual zones it is best to set the last four zones to Not Used so they do not display false alarms such as T C Fail...

Страница 42: ...lues may be changed to suit each tool Table 5 2 Pre Configured Setup Values Parameter Probe and Manifold Cards Other Monitoring Cards Alarm Hi and Lo 25 C or 45 F 25 C or 45 F Alias blank blank Analog...

Страница 43: ...the controller parameters 2 Choose List for an overview of controller parameters and how they are currently set NOTE Parameters can have either Value settings use the Edit button to bring up a keypad...

Страница 44: ...its previous state when the signal is removed If this option is selected then you can also use the Input Timer option to defer the Standby condition for a preset time AUTO STANDBY prevents the Input...

Страница 45: ...If there are no current measuring coils the option should be set to percent otherwise the Power Current display will show zero for controllers with spear probes Also chooses if amps or percentage pow...

Страница 46: ...s to hold off the action of successive groups during a Staged Shutdown Sets the time that successive zone groups must wait before each switches off Setting this option to zero makes the Shutdown Timer...

Страница 47: ...5 10 Set the Tool Parameters 1 Choose the zones 2 Choose the parameter 3 Choose Set 4 Set the value 5 10 M1 Plus Controller User Manual SETUP 2021 Mold Masters 2007 Limited All Rights Reserved...

Страница 48: ...er facility Analogue Sensor Type Configures analogue inputs to match analogue flow sensors Boost temperature Sets the increase in temperature when Boost is selected The maximum Boost value is 250 C or...

Страница 49: ...asured and displayed temperature to compensate if a thermocouple is not close enough to the probe tip The highest T C Offset temperature is 75 C or 135 F T C Open Mode Chooses a response for any zone...

Страница 50: ...e Operating Parameters 5 12 1 Choose Zones 1 Choose the first zone 2 Choose the last zone 3 Choose Range 4 Choose Set 5 13 SETUP 2021 Mold Masters 2007 Limited All Rights Reserved M1 Plus Controller U...

Страница 51: ...or Esc to leave the page without making any changes 5 12 2 Set Probe and Manifold Temperatures 1 Choose Set 2 Choose Auto Set the Operating Parameters continued 5 14 M1 Plus Controller User Manual SET...

Страница 52: ...ear the last input 4 Choose Ent to confirm the settings or Esc to leave the page without making any changes Set the Probe and Manifold Temperatures continued 5 15 SETUP 2021 Mold Masters 2007 Limited...

Страница 53: ...access to parameters and also lists the current software version The Software Version parameter always shows the version date and it is not configurable It will update automatically if the software i...

Страница 54: ...reen remains visible The maximum period for Blanking Delay is 98 minutes Blanking Delay will remain permanently visible if set to 99 minutes Calibrate Touch Sets the screen response to align with poin...

Страница 55: ...o initiate a system alarm notification in the lower status window At the same time it energizes the Alarm Relay for remote signaling Paper Size Chooses A4 or letter sized printer paper Password Timer...

Страница 56: ...on the Display page Floating point scale displays temperature to within one tenth of a degree Integer scale rounds the displayed temperature to the nearest whole degree User Password If set to Enable...

Страница 57: ...5 13 2 Edit the User Password 1 Choose Menu and open the Utilities screen 2 Choose Edit User Password 3 Choose Set 4 Enter the existing System password 5 Enter the new User password 6 Re enter the ne...

Страница 58: ...hose functions that would normally need a User Level 1 password become Open level and no longer require any password to access Only those higher functions that require a System Level 2 password retain...

Страница 59: ...equired to Main Run Stop Change Modes Change display options Go to Zoom or Graph page Set Alter temperatures or modes Zoom Set Alter temperatures or modes Graph View Keys Print Tools Export Exit shut...

Страница 60: ...suitable printer driver 5 Choose Local for the printer connection then OK 6 Choose Paper Size 7 Choose Set to see the Paper size selection panel 8 Choose A4 or Letter and choose OK 9 Choose Back to r...

Страница 61: ...it and let it power down the console before you turn the main isolator to off 5 17 3 Quad IO This is a digital Input Output card that offers up to four separate inputs and outputs to facilitate remote...

Страница 62: ...n The main isolator is a rotary switch on the M1 48 and a switched breaker on the smaller M1 12 and M1 24 controllers 6 1 1 Switch On Switching on the main isolator for the controller energizes the ca...

Страница 63: ...isolator On the smaller M1 12 or M1 24 controllers use the breaker switch Switch Off Shutdown continued 6 2 Control Modes for All Zones WARNING Choosing Stop mode does not remove voltage from the hea...

Страница 64: ...STOP mode STANDBY Mode Button Reduces the temperature of all zones that have any Standby Temperature configured on the SetUp page Temperature remains reduced until Run command is given STARTUP Button...

Страница 65: ...o raise the overall temperature Choose Plus To lower the overall temperature Choose Minus 4 Enter the temperature setting or change 5 Choose Ent to set the required temperature or Esc to leave the pag...

Страница 66: ...ose Manual and set percentage power To Slave a zone Choose Slave and choose a similar master zone from the Zone list To return to Auto mode Choose Auto and enter the required zone temperature 4 Choose...

Страница 67: ...ing power is removed regardless of whether the zones actually reach the configured Boost temperature NOTE Boost only raises the temperatures of those zones that have a Boost temperature configured Boo...

Страница 68: ...ed to another zone For example if zone 2 is currently slaved to zone 3 you cannot slave zone 1 to zone 2 The leading zone must already be a healthy zone 3 You cannot choose a zone that creates a loop...

Страница 69: ...d uses a proprietary purge agent 1 Choose Purge from the Mode dropdown menu The screen changes and guides the operator through the seven steps The Boost function is initiated and the normal Boost time...

Страница 70: ...operator is told to run using the purging material This setting is only applicable to the chemical purging process The maximum value for this setting is 1000 Purge Material The amount of purging mate...

Страница 71: ...les is five cycles If five cycles seems to be insufficient for your tool please contact your supplier for further advice Soak Time The wait period that the operator is to hold the purge material in th...

Страница 72: ...Up and ZoneDn buttons are used to browse other zones without returning to the Main page 6 10 Graph a Zone s Past Performance The controller can record the past 30 minutes of temperature history and di...

Страница 73: ...axes 5 Use the four Zoom keys to expand time of temperature scales Drag either scale to shift the display NOTE Once any zoom is used the graph freezes in time and does not update Graph a Zone s Past...

Страница 74: ...x Any zones with Standby temperatures configured have been reduced in temperature until the next command is given STARTUP The system has been started in a homogenous or staged heat rise It will switch...

Страница 75: ...mode to prevent slower systems such as Master Follow from raising unnecessary alarms Once at their set temperature systems will switch to Run mode and the alarm becomes active 6 11 3 Identify Zone Ala...

Страница 76: ...ard in sequence FAULT Should normally be unlit It lights up to show that one zone on the card has detected an error The nature of that error is displayed in the particular zone on the console A list o...

Страница 77: ...e its current connection setting 2 Choose Connection and then Set 3 Choose Demo Mode in the Select Connection option box 4 Accept the warning that this option will disable the console 6 16 M1 Plus Con...

Страница 78: ...e selection procedure 1 Choose the current tool 2 Choose Connection and Set 3 Choose the original setting that was noted at step 2 while selecting Demo mode previously 6 17 OPERATION 2021 Mold Masters...

Страница 79: ...a tool that is currently in use and that has no changes to any settings red a tool that is in current use but which has been changed from its stored settings 3 Description a user configurable text fi...

Страница 80: ...ations then you will need to create new tools to hold the alternative settings 1 Choose a blank tool slot and then choose Save 2 Use the keyboard and name the new tool 3 Open the SetUp page 6 19 OPERA...

Страница 81: ...input new values 6 Finish the changes required for the new tool then return to the Tool page and choose Save 6 16 Rename an Existing Tool 1 Choose the relevant tool tab Create a New Tool continued 6 2...

Страница 82: ...2 Choose the Set button 3 Edit the name 4 Choose Enter Rename an Existing Tool continued 6 21 OPERATION 2021 Mold Masters 2007 Limited All Rights Reserved M1 Plus Controller User Manual...

Страница 83: ...t the new incoming temperature setting 1 Choose the required tool 2 Choose Load If the Load button is greyed out then the option to be able to change tools while in Run mode has been disabled See Allo...

Страница 84: ...ettings 6 18 1 Overwrite with Saved Settings If the new settings are satisfactory then they can be saved into the same tab in the ToolStore 1 Choose the tool 2 Choose Save 3 Choose OK 6 23 OPERATION 2...

Страница 85: ...nal settings the new settings must be created and saved into a new tool tab in the ToolStore 1 Choose a blank tool tab 2 Choose Save 3 Choose OK 4 Type in a new tool name and choose Ent 6 24 M1 Plus C...

Страница 86: ...us settings Ensure that you are deleting the correct tool CAUTION 1 Choose the unwanted tool 2 Choose Delete 3 Choose OK 4 Return to ToolStore page to check that unwanted tool has been deleted 6 25 OP...

Страница 87: ...re recovery or can be transferred to another controller for use 6 20 1 Backup All Tools 1 Open the ToolStore page 2 Insert memory stick and wait until it is ready to use 3 Choose Backup 4 Wait about 1...

Страница 88: ...ert memory stick and wait until it is ready to use 2 Choose the tool to backup 3 Choose Backup 4 Wait about 10 seconds then remove the memory stick 6 27 OPERATION 2021 Mold Masters 2007 Limited All Ri...

Страница 89: ...cted tool bank or slot will be overwritten with the information from the memory stick 6 21 1 Restore All Tools 1 Open the ToolStore page 2 Insert the memory stick with the data and wait until it is re...

Страница 90: ...he memory stick then wait until it is ready to use 2 Choose the Tool tab 3 Choose Restore 4 Wait about 10 seconds then remove the memory stick 6 29 OPERATION 2021 Mold Masters 2007 Limited All Rights...

Страница 91: ...ost Puts the Controller into BOOST mode Inactive This input will not be used and remains inactive Machine OK When closed console can go to RUN mode or STARTUP mode When opened the console is put into...

Страница 92: ...tive Output will not be used and remains inactive Inj Disable Output is seen if the system is idle Output is cleared once the system has started up and gone into Run mode Output is given if system has...

Страница 93: ...Default Output Function Input 1 1 Input 1 Go to RUN mode Input 1 2 NO Contact 1 3 Output 1 Injection Disable MC Contact 1 4 NC Contact 1 5 Input 2 6 Input 2 Go to STANDBY mode Input 2 7 NO Contact 2 8...

Страница 94: ...rintout Page Printout Main Prints out the zone name actual and set temperatures and power level for all zones regardless of how the main page display is currently set Tool Chooses any tool and prints...

Страница 95: ...eparated value form and then compressed into a zip file 1 Insert a memory stick and wait until it is ready to use 2 Choose Utilities page and choose Export 3 Choose the First Zone and pick the first z...

Страница 96: ...eet NOTE Performance data can be autoarchived If the Auto Archive option is on and a memory stick is left plugged into the console then historic data is written to that memory stick every 30 minutes E...

Страница 97: ...screen The stylus should be held in position for a couple of seconds to provide a good reading for calibration 1 On the Utilities page choose Calibrate Touch and then choose Set 2 Choose Enable and c...

Страница 98: ...see that none experience a significant temperature rise 2 It heats the first zone and checks to see that a the first zone rises sufficiently to qualify as a Good Rise if not it increases the applied...

Страница 99: ...f Diagnostic Test The diagnostic routine may be performed at any time that the controller is connected to the tool provided that it is not in use for production The other panels on the page give feedb...

Страница 100: ...uicker power check only This heats the zones to see current draw but does not check zone interaction 6 Choose Start and note that a Test progress for each zone is shown in the upper right panel b Test...

Страница 101: ...esults 7 7 1 Satisfactory Test If the diagnostic test finds no fault with any zone then the message Zone Test OK is displayed 7 7 2 Unsatisfactory Test If the test detects any problems then it display...

Страница 102: ...r or thermocouple wiring at fault Heating Test Failed Temperature did not rise by the set number of degrees within the heating period This may be caused by an open circuit heater a pinched shorted or...

Страница 103: ...Inspection 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 s...

Страница 104: ...to the mains voltage supply and it is not 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...

Страница 105: ...utput If the TC LED indicator shows an open thermocouple circuit this may indicate that the input fuse has ruptured Table 7 4 Input Fuse Type Fuse Nano Ceramic Very Fast Rating 62 mA If the fuse LED i...

Страница 106: ...arm If the system detects a malfunction in one or more of the control zones then it displays an error message on the Main page in place of a temperature value See Table 8 1 Fault and Warning Messages...

Страница 107: ...he start of Section 8 IMPORTANT A fuse can only fail due to a fault external to the controller Identify and rectify the fault before replacing the fuse Note If the fuse in question is mounted on a con...

Страница 108: ...LINK fatal error in place of the actual temperature Check that the network link is good and or the remote controller is still switched on and available LOAD No load on that zone Only occurs when in ma...

Страница 109: ...load current In such a condition you have lost control of the load and cannot switch it off from the console The TRC alarm flags up the fault state which relies on operator intervention to manually sh...

Страница 110: ...e selected zone is the same as that on the slave zone TEST Displayed when the zone is in Diagnostic Test mode WARN Displayed if a temperature interaction is found between zones during a test 8 4 Other...

Страница 111: ...Backup 5 Choose Export on the Utilities page 6 Choose the First and Last Zones to include all zones Other Issues continued 8 6 M1 Plus Controller User Manual TROUBLESHOOTING 2021 Mold Masters 2007 Li...

Страница 112: ...rt 8 Wait about 10 seconds then remove the memory stick 9 Copy the files to a personal computer and email them to help moldmasters com 8 7 TROUBLESHOOTING 2021 Mold Masters 2007 Limited All Rights Res...

Страница 113: ......

Страница 114: ...controller 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 suppli...

Страница 115: ...terminal Refer to Figure 9 1 R MP1 S T MP3 MP2 BLACK BLACK BROWN BLUE This wire will need to be connected to an MP on the terminal block Figure 9 1 Connect the neutral position shown by blue arrow 2...

Страница 116: ...ght terminal Refer to Figure 9 3 BLACK BLACK BROWN BLUE This wire will need to be disconnected and made safe R S T MP3 MP2 MP1 Figure 9 3 Remove the neutral position shown by blue arrow 2 Install the...

Страница 117: ...ed The contacts are rated for 5A at 240V Table 9 1 Alarm Output Auxiliary Input Pin Connection Input Output 1 Auxiliary Input signal Standby 2 Auxiliary Input ground 3 Alarm 240v contact 1 Normally Op...

Страница 118: ...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 6 6 zone only single HAN24E to HASCO Standard 56 mm 32 mm...

Страница 119: ..._ _ 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 8 12 48 zones pairs of HAN24E wired to Mo...

Страница 120: ...rd HRC Control Card HRC Control Card HRC Control Card Voltage Free alarm Contacts Heater Outputs to Tool Thermocouple Inputs from Tool Mains Power Distribution Supply Control Cabinet Keyboard Memory S...

Страница 121: ...tive Times 5 21 Password Options 5 21 Password Override 5 20 Power Mode 5 8 Print Out Facility 7 1 Purge Sequence 6 7 R Rename a Tool 6 20 S Safety Lockout 3 10 Safety Instructions 3 1 Safety Symbols...

Страница 122: ...ters com JAPAN 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 u...

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