Mold Temperature Controller

Transcription

1 Mold Temperature Controller MCJ L(LL),H,A Instruction Manual WARNING Thank you very much for purchasing our product. Please carefully read this instruction manual for correct use. During operation, keep this manual close at hand so that it can be referred to whenever necessary. How to move the main unit of the product How to move with a hoist How to move with a fork lift As shown below, loop a load lifting belt over the main unit to move with a hoist. As shown below, insert the forks of the fork lift into the fixed brackets to move. CAUTION When unpacking, use work gloves. The hoist operator must be qualified for crane operation and slinging skill. The fork lift operator must possess a license for driving large and heavy vehicles or be qualified for fork lift operations skill. When moving with a hoist, be sure to loop the belt outside the fixed bracket. When moving with a fork lift, be sure to insert the fork into the fixed bracket. Issued in April, 2001

2 Contents Since the items marked with are especially important, carefully read and understand these items before using the product. Contents Ⅰ~Ⅱ Introduction Ⅲ Chapter 1 Chapter 2 For safe use 1. Precaution headings and their meanings Safety rules About labels Precautions for use 1. Common to all models MCJ-L(LL), H model (Mold temperature control unit using water) MCJ-A model (Mold temperature control unit using oil) MCJ-H,A model Chapter 3 Checking of supplies Chapter 4 Name of each part Chapter 5 Installation Chapter 6 How to operate the temperature controller (MR-980) 1. Names of Control Panel Parts Name and function of Dip switch Monitor Items on Monitor Display Set Item and Range of Temperature Controller Modes on MONITOR Display Functions and Operation of MONITOR Display Setting of Functions Mode Setting of SV Display (changing) Setting (Changing) of High and Low Alarm Temperatures Switching Operation of Control Temperature (for reference) Auto Tuning(AT) [WO ;MCⅠ] - Ⅰ -

3 Contents Chapter 7 Preparations for operation Chapter 8 Chapter 9 Operation 1. Operating procedure for L (LL)model and H model (medium is water type) Operation procedure for A model (medium is thermal oil type) Running Operation Using Start Timer Maintenance and Check 1. Monthly Maintenance Maintenance for every three months Chapter 10 Protective devices Chapter 11 Causes and Remedies of Abnormal Condition Chapter 12 Technical Manual Chapter 13 Consumable Item List Chapter 14 Replacement Parts By Operating Voltages Chapter 15 Specifications Chapter 16 Option Supplement 1. Electric Circuit Diagram [WO ;MC II] - II -

4 Introduction 1. Product Covered This document describes how to properly perform the operations and maintenance of your Mold Temperature Controller. 2. Target Readers This document is intended for use not only by those who are using the Mold Temperature Controller made by MATSUI MFG. CO., LTD. for the first time, but also by those who had experience in using the Mold Temperature Controller and wish to ascertain any information. 3. Warranty This products was manufactured by making the full use of the state-of-the-art designing technology and best craftsmanship of MATSUI MFG. CO., LTD. If the products should have any defect that is recognizable by us, such defective part would be repaired or replaced in accordance with the applicable conditions shown below: 1) Scope The quality of our machines and devices is warranted and we will repair them and/or change parts when something should go wrong with any of them. However, there is NO warranty on the products made with our machines or devices. Any products that you cannot make perfectly when using our machines or devices, are NOT our responsibility, either. However, if while you are operating our machine or device in a normal way, there is a problem caused obviously as a result of a defect in design or in production of our machine or device, we will repair it or replace the parts free of charge within the following period. 1)-A. The relevant defective part shall be returned to us. 1)-B. This warranty shall remain valid for twelve (12) months starting on the date when the new products you purchased is delivered to you. 1)-C. Only the following parts are subject to the warranty period of six (6) months after such delivery date: 1. Electrical components and parts; 2. Sealing materials; 3. Bearings; and 4. Level gauges. 2) Exceptions to which this warranty shall not be applicable 2)-A. This warranty shall not be applied to the following exceptions: 1. Any problem resulting from an environmental change; 2. Any damage or loss attributable to a failure in the delivered our products; 3. Any deterioration (in paint or plating) as may occur from a time-course change; 4. Any sensuous phenomenon which is considered to have no effect on the quality and functions; 5. Any problem resulting from your own modification; and 6. Any lamp, fuse, and other consumable part. 2)-B. Any failure or damage attributable to any of the following causes shall not be compensated for under this warranty: 1. Acts of God such as earthquake, typhoon, and flood; accidents; and fire: 2. Use of the products in any place other than the general installation sites; 3. Failure, by intention or negligence, in observing the instructions and maintenance shown in this document; 4. Improper or wrong maintenance, service, or handling; and 5.Your own transportation, repositioning, or reinstallation of the products. [WO ;MCⅢ] - Ⅲ -

5 Chapter 1 For safe use This chapter describes precautions for operation, maintenance inspection and repair, identification of headings of precautions and labels affixed to the product for using this product correctly and safely. WARNING When performing operation and maintenance inspection of this product, be sure to follow the safety precautions described in this manual. We shall assume no liability for any injury or accident caused by failing to follow these precautions. 1. Precaution headings and their meanings Heading DANGER WARNING CAUTION NOTE In this manual, indications are classified according to the degree of danger as follows: Meaning This heading is used for cases where there is a possibility that mishandling will lead to the user's death, and precautions to avoid any such occurrence are described below the heading. This heading is used for cases where there is a possibility that mishandling will lead to the user serious injury, and precautions to avoid any such occurrence are described below the heading. This heading is used for cases where there is a possibility that mishandling will lead to the user slight injury or damage to the product, and precautions to avoid any such occurrence are described below the heading. Operating procedures and explanations requiring special attention and emphasized information are described below this heading. This mark is used for handling procedures requiring special attention. This mark is used for exceptional conditions and notes in figures and tables. [WO ;MC 1] - 1 -

6 Chapter 1 For safe use 2. Safety rules WARNING 1) No modification Never modify this product on your own without our prior approval. We shall assume no liability for any modifications made without our prior approval. 2) Machine stopping procedure When finishing production or performing maintenance, stop the main machine as follows: Turn OFF the operation ON/OFF switch. Turn off the power breaker of your distribution facility. (Make sure to do this.) If you must close the medium feed valve, medium return valve, water supply valve and water discharge valve unavoidably, close them last. When restarting operations, make sure to fully open the medium feed valve, medium return valve, water supply valve and water discharge valve before starting the device. Since operating with the valves closed will create an airtight condition, which is a dangerous condition wherein pipe pressure will rise, causing an explosion, fully open the valves normally. [WO ;MC 2] - 2 -

7 Chapter 1 For safe use 3) Piping (1) Piping for draining Draining outlet also functions as the inner pressure releasing pipe. Tank will be completely enclosed by shutting the outlet. The drain side is the atmosphere discharge. Display " Normally full Open" and lock the handle when establishing water stop valve in-between the pipe. (2) Piping from the Mold Temperature Control Unit Check the conditions of the rubber pipes which are engaged in the Molding Machine and such every day before the operation especially of looseness of bases and degradation of hoses. Replace the damaged hose promptly. 4) Never use in the gas Never use this product in the combustible, explosive gas or vapor. It is dangerous very much. 5) Electric power Do not check or exchange without Matsui SDI Co., Ltd. or the employee in your company who has a good knowledge about the electricity, because the operation includes the failure or the danger. 6) Never touch inside of this product. Never touch inside of this product without Matsui SDI Co., Ltd. or your recognized person, because there is high voltage, high temperature section inside of the body. [WO ;MC 3] - 3 -

8 Chapter 1 For safe use CAUTION 1) Power source Make sure to check the specifications on the nameplate of the device. That of different supply voltage and/or frequency cannot be used. Securely ground. Use within the allowable voltage regulation (±10% of the rating). Use out of the allowable voltage range will cause malfunction, poor operation or other trouble. NOTE 1) Check and Overhaul For a long-used device, it is recommended that the product undergo our service department's inspection and overhaul (at cost) for safe equipment once every 4 to 5 years, even if you do not have any problem with its use. For inspection and overhaul, contact Matsui SDI Co., Ltd. 2) Wiping Do not wipe with petroleum base solvents. Benzine, thinner, polishing powder, etc., will damage the surface. If contamination is heavy, wipe with a soft cloth thoroughly squeezed after being moistened with 40 or less warm water. 3. About labels Labels are affixed to this product at places requiring special attention according to the degree of danger. Make sure to thoroughly understand the descriptions of warnings and cautions before performing operation. 1) Handling of labels Keep them legible until disposal of this product. If any label is dirty, wipe it with a soft cloth thoroughly squeezed after being moistened with 40 or less warm water. Never use petroleum base solvents or thinner. 2) Labeling positions For labeling positions and descriptions of warnings and cautions, see the attached drawings. [WO ;MC 4] - 4 -

9 Chapter 2 Precautions for use This chapter explains precautions specific to the product. To prevent the occurrence of danger, precautions are described with headings (See Section 1, Chapter 1) from the most important items. 1. Common to all models WARNING Internal temperature High-voltage and hot locations exist inside the operating product. Since operation with the outer casing removed will lead to trouble or an accident, never remove the casing when operating. Cautions on operation The valve and piping section come to high temperature. Never touch with your bare hands. (Touch with the gloved hands.) In the case of accidental burn, see a doctor while cooling the injury port with cool and clean water. CAUTION Environmental conditions Use the product at a place where the ambient temperature is between 0 and 40 and humidity is 85% or less. Use outside of the above conditions will cause troubles or an accident. Install a pressure gauge with appropriate scales on the primary water supply piping and water discharge piping. Initial feeding water (feeding oil) Be sure to establish feed water (feed oil) port and air vent port, and perform feeding water (feeding oil) from there when use this product for the roll jacket etc. which has over 20 L capacity. [WO ;MC 5] - 5 -

10 Chapter 2 Precautions for use CAUTION Operation condition This unit controls temperature by the continuous circulation of medium (water oil) which fed from pump. This Unit can not be used when the circulation end is open (such as water tank)and have ON-OFF control valve. Establish the air releasing port and release air when feeding medium when using this unit for Roll jacket. This may not operate if air is not released. The control panel The control panel is non-watertight structure. Do not splash water or oil. Be careful because it may cause the failure. Do not open the control panel oftener than necessary. Be careful because it may cause the failure. Protection devices All protection devices included in this unit has adjusted when shipping. Do not touch any devices, further adjustment is unnecessary. Temperature-sensing element Use the thermo couple K (CA) of no-contact model as the temperature-sensing element. Primary cooling water feeding and draining pressure Set the drain side pressure below 0.09MPa. Feed water pressure should be 0.05MPa~0.3MPa higher than drain side pressure. Pressure decrease valve should be provided when feed water pressure exceeds 0.3MPa. Set the feed water pressure of LL type below 0.2MPa. When the feed water pressure is high, solenoid valve and pump may be damaged by water hammer. [WO ;MC 6] - 6 -

11 Chapter 2 Precautions for use CAUTION Pump pressure for use Use the pump with prescribed pressure or less that indicated in Table 2.1. Perform the adjustment of pressure by the pressure regulating valve on the back of the unit. Table 2.1 Model Prescribed pressure (50Hz/60Hz) MCJ-15 MCJ-30 MCJ MPa 0.35 MPa 0.40 MPa The usage is effected by the drain side pressure (back pressure) or feeding pressure of cooling water during using the L(LL) model and H model under 85. As a result, [Pressure of pressure meter of this unit]=[pump pressure]+[back pressure or feed water pressure]. Subtract the back pressure or feed water pressure from the pressure indicated pressure meter is the [pump pressure] value. The effect of the feeding pressure of cooling water can be judged by increasing and moving the indicator of the pressure meter in a clockwise direction when the water supply solenoid valve is open in the cooling operation. The back pressure indicated by the pressure gauge value when stop of the unit. Inside of system is closed structure during using the H model over 85. So the usage is effected by the steam pressure of water caused by increasing temperature. As a result, [Pressure of pressure meter of this unit]=[pump pressure]+[steam pressure of water]. Subtract the [steam pressure of water] from the pressure indicated to the pressure meter is the [pump pressure] value. [Steam pressure of water] is indicated to the pressure meter during suspending this unit [WO ;MC 7]

12 Chapter 2 Precautions for use 2. MCJ-L(LL), H model (Mold temperature control unit using water) WARNING Available temperature range Control the medium temperature within the available temperature range shown in Table 2.2. Since operation outside of the available temperature range will lead to trouble or an accident, never allow this. Table 2.2 Model Medium Available temperature range MCJ-L(LL) Soft water Water supply temperature + 10 ~ 95 (Max.) MCJ-H Soft water Water supply temperature + 10 ~ 120 (Max.) CAUTION Piping material [WO ;MC 8] Referring to Table 2.3, choose suitable piping material according to the working temperature. Table 2.3 Reference Available temperature Minimum bending radius 3 Service life Piping material ( ) ( mm ) (h) 1 Rubber hose (for 4000 L,LL) (Approx. 1 year) only for warm water 1 Rubber hose (for H) only for warm (Approx. 1 year) water 2 Teflon hose 6000 for hot (Approx. 1.5 years) water and oil 1: Standard accessory of the product 2: Option accessory *Teflon hose only *Teflon hose + SUS blade *Teflon hose + SUS blade + SUS spring Three types above are available

13 Chapter 2 Precautions for use 3: Check the degradation of hose and replace it as a guide of listed time. Carefully read the instructions enclosed with the hose for installation. [WO ;MC 9] - 9 -

14 Chapter 2 Precautions for use CAUTION Quality of the medium Use clean soft water including no impurities such as sand, clay or refuse and satisfying the water quality standards shown in Table 2.4. Low water quality will result in problems such as: Drop in heat exchanger effectiveness due to scales sticking to the heater and breakage of the heater wire Breakage or stoppage of the pump due to scales caught in it Decrease in water quantity due to blocked watercourse in piping Abnormal wear of the mechanical seal of the pump Problems caused by water quality shall be repaired at cost even during the warranty period. Table 2.4 Water quality standards (by JRA ) Item Make-up water Trends Corrosion Scale ph [25 ] 6.0~8.0 Conductivity [25 ] (μs/ cm ) 200 or less Total hardness (mgcaco 3 /L) Chloride Cl - (mgcl - /L) 50 or less Sulfuric acid SO 2-4 (mgso 2-4 /L) Iron Fe (mgfe/l) 0.3 or less Acid consumption [ph4.8] (mgcaco 3 /L) 50 or less Ionic silica SiO 2 (mgsio 2 /L) 30 or less Sulfide S 2- (mgs 2- /L) Not to be Ammonium NH + 4 (mgnh + 4 /L) detected. [WO ;MC 10]

15 Chapter 2 Precautions for use 3. MCJ-A model (Mold temperature control unit using oil) WARNING No fire Do not hold a flame around the unit because of using thermal oil for medium. Available temperature range Control the medium temperature within the available temperature range shown in Table 2.5. Since operation outside of the available temperature range will lead to trouble or an accident, never allow this. Table 2.5 Model Medium Available temperature range MCJ-A thermal oil for medium 60 ~ 160 (Max.) CAUTION Piping material Referring to Table 2.6, choose suitable piping material according to the working temperature. Table 2.6 Reference Available temperature Minimum bending radius 2 Service life Piping material ( ) ( mm ) (h) 1Teflon hose for hot water and oil (Approx. 1.5 years) 1: Option accessory *Teflon hose only *Teflon hose + SUS blade *Teflon hose + SUS blade + SUS spring Three types above are available. 2: Check the degradation of hose and replace it as a guide of listed time. Carefully read the instructions enclosed with the hose for installation. [WO ;MC 11]

16 Chapter 2 Precautions for use CAUTION Quality of medium Use the supply thermal oil which foreign body or contaminant is not mixed in. If using thermal oil which mix a small amount of foreign body in, be sure to remove it with foreign body separator or filter before feeding. Recommended oil---idemitsu KOSAN Dafny thermic oil 32 (Viscosity grade ISO VG32) Be aware that the ambient temperature varies with thermal oil. Replacement guideline---changing all of the oil once a year is recommended. Volume of feeding thermal oil Do not feed thermal oil over the prescribed volume. If operating in the state of feeding oil over the prescribed volume, due to the thermal expansion of oil as the temperature increase, the thermal oil will become larger than the expansion tank capacity and drain out of the overflow outlet. If such a phenomenon occur, put a vessel at the overflow outlet to prevent splashes of the thermal oil and collect them. Be careful when also replacing the mold, the thermal oil in the hose may drain out of the overflow outlet as above. Table 2.7 Model Volume of thermal oil of the main body MCJ-15 Approx., 4.5L MCJ-30 Approx., 5.0L MCJ-60 Approx., 8.0L Figure 2.1 Level gauge on the back of the unit (level indicator) The midpoint position indicates prescribed volume. Guideline for the volume of feeding thermal oil [WO ;MC 12]

17 Chapter 2 Precautions for use 4. MCJ-H,A model CAUTION Fixing of the water discharge piping If the H type or A type is used at high temperature, steam may shoot from the water discharge port upon cooling, therefore fix the water discharge piping to the water discharge ditch to prevent accidents. Figure 2.2 [WO ;MC 13]

18 Chapter 3 Checking of supplies Name of equipment Main body of the unit With power cord 4 m Make sure that the equipment of your model are complete. (Check the nameplate of the unit.) State of delivery Remove the polyester cover and check to be sure that it is the model which you purchased. Figure 3.1 Only A model has one Nameplate Power cord * Piping hose (rubber hose) L(LL),H model *0.3 m hose 2 pieces *3 m hose 4 pieces *Adapter nipple 3/8B-3/8B 4 pieces 3/8B-1/4B 8 pieces 60L (LL),H model *0.5 m hose 4 pieces *3 m hose 8 pieces *Adapter nipple 3/8B-3/8B 8 pieces 3/8B-1/4B 16 pieces *Thermal oil (only A model) Name: Dafny thermic oil 32 (IDEMITSU KOSAN) Capacity: 5 L (15A) : 10 L (30A 60A) These are packed in the corrugated cardboard case. Open the corrugated cardboard case and check to be sure that the hoses are complete to the model. NOTE 1. "Hose instruction manual" is packed in the corrugated cardboard case. Please read the manual thoroughly before using the unit. 2. A hose isn't attached to the type A.(Option) This is in the polyethylene can. Figure 3.2 *Above parts is standard type. It will vary with customers' convenience. [WO ;MC 14]

19 Chapter 4 Name of each part Unit Figure 4.1 Caution label Thermal oil feeding port(plug of expansion tank) Only A model has one Control panel door Temperature controller setting panel Caution label Power breaker Caution label Name plate Pump pressure gauge Power cord Figure 4.2 Pressure control valve Caution label Oil gauge Only A model has one Figure 4.2.1(Standard type) Label of each part Medium return valves Medium supply valves Oil overflow port Only A model has one Name label Water outlet Drain port Water supply port [WO ;MC 15]

20 Chapter 4 Name of each part Inside of the control panel Figure 4.3 Electromagnetic switch (MS-1) Thermal relay (OCR-1) Back face cover of temperature regulating gauge NOTE Do not remove the cover ON TYPE MOLD TUNING SETROCK - SELECT OFF MEDIUM CONTROL LOCKCANSEL - CONTINUE Dip switch of temperature controller Switch section 8 pieces (This figure indicates OFF state.) O N Parts names are standard type. [WO ;MC 16]

21 Chapter 5 Installation This chapter describes the method of installing the product step by step. Step Item Description 1 Installation of the Install the main unit on a stable level floor. main unit At the installation location, secure space to perform maintenance inspection as shown in Fig Figure mm 600mm Main unit 600mm 600mm 2 Connection of piping hoses Connection of the attached hoses (each hose in the corrugated cardboard case) Fully close each valve of the medium feed port and medium return port, and connect as shown in Fig Apply sealing agent to the thread part of each hose connecting nipple, mount it to the medium feed port and the medium return port of the main unit and the mold, and then securely tighten the hose fittings. Figure 5.2 Main unit Medium Medium feed return port port Hose Nipples Nipples OUT side Nipples Mold of the molding machine IN side Hose CAUTION Do not connect the hoses as they are bent at a bending radius smaller than the minimum, folded or twisted. Do not allow the hoses to interfere with other sections. Provide safety covers such as shielding plates to prevent the hoses from being trampled or crushed by an object [WO ;MC 17]

22 Chapter 5 Installation Step Item Description Connection of piping Connection of water supply and water discharge hoses Connect the water supply port of the main unit with a rubber hose 14 hose hoses to the water supply source of your facility. Connect the water discharge port of the main unit to the water 30LL(φ nipple)2 discharge destination of your facility with a heat-resistant rubber hose or SUS flexible hose. Figure 5.3 O.D. φ10.5 hose nipple (thread part Rc3/8) 30LL(φ14 hose nipple) 60LL(φ16 hose nipple) Water supply source Water supply port Water discharge port O.D. φ10.5 hose nipple (thread part Rc3/8) 30LL(φ14 hose nipple) 60LL(φ16 hose nipple) Water discharge destination CAUTION Do not connect the hoses as they are bent at a bending radius smaller than the minimum, folded or twisted. Do not allow the hoses to interfere with other sections. Provide safety covers such as shielding plates to prevent the hoses from being trampled or crushed by an object. In the case of using H model or A model at high temperature, steam may shoot from the water discharge port upon cooling, therefore fix the water discharge hose to the water discharge destination to prevent accidents. NOTE Installation of drain pan Temperature control unit using water Install a drain pan if condensation occurs. Temperature control unit using oil Installation of drain pan is recommended because of small oil leakage from the mechanical seal. Reference The mechanical seal can not seal completely, about 5 drops of oil may leak per hour. In the case of roll jacket Install the unit on higher position than the roll jacket to prevent backflow of medium. [WO ;MC 18]

23 Chapter 5 Installation Step Item Operation contents 3 Connection of power cord Turn ON/OFF switch to OFF on device control panel and cut off power breaker. Connect 4m power cord from device to the primary source of equipment. Power cord R phase Red D phase White Primary source T phase Black E Green For grounding Figure 5.4 Device Distribution equipment breaker (primary source) Power cord Ground connection Do not fail to make ground connection. WARNING Do not fail to cut off device power breaker before connecting power cord. Connection must be carried out by personnel qualified for electric works. Do not fail to make ground connection. [WO ;MC 19]

24 Chapter 5 Installation Step Item Operation contents 4 Check of positive or negative phase Turn ON the primary source of distribution equipment. Turn ON power breaker at the front of control panel. MODE=STOP Check if MONITOR display alarm PUMP Reverse on temperature controller control panel. monitor appears No indication of PUMP Reverse means positive phase, or the completion of power cord connection. If PUMP Reverse appears, turn OFF primary source and exchange the R phase (red) and T phase (black) power cords of the three with each other. Turn ON primary source again to ensure PUMP Reverse is not shown [WO ;MC 20]

25 Chapter 6 How to operate the temperature controller(mr980) 1. Names of Control Panel Parts Figure 6.1 Temperature controller control panel 1 2 PV SV 3 ALARM RESET 4 5 MONITOR ON/OFF 6 8 FOR SETTING PV SV SFT DWN UP ENT 7 No. Name Function 1 PV display Shows actual control temperature and timer elapsed time by a decrease. 2 SV display Shows temperature and timer set values. 3 ALARM indicator lamp Lights up when alarm occurs. 4 RESET key Resets alarm and buzzer. 5 MONITOR display Shows modes. 6 ON/OFF key Starts and stops device. 7 ON/OFF indicator lamp Lights up when ON/OFF key is ON. 8 SETTING keys PV key Switches between mode & monitor indications on MONITOR display. SV key Changes setting mode on MONITOR display. SFT key Moves cursor when setting on SV display. DWN key Decreases set value when setting on SV display. UP key Increases set value when setting on SV display. ENT key Writes set value when setting on SV display. [WO ;MC 21]

26 Chapter 6 How to operate the temperature controller(mr980) 2. Name and function of Dip switch Figure 6.2 Dip switch of temperature regulating Switch section 8 pieces This figure indicates OFF state. Pull up the switch to be ON O N ON TYPE MOLD TUNING SETROCK - SELECT OFF MEDIUM CONTROL LOCKCANSEL - CONTINUE Name of Dip switch Model switching 1~3 Functional description /Operating procedure Function Used for switching according to the model of the unit. NOTE Do not touch absolutely. Control sensor selecting 4 Function Used for selecting whether the temperature control is performed by the medium sensor or the mold sensor. NOTE Be sure to set to "Transporting medium control" side if the unit has no mold sensor (option). The switch is set to "Transporting medium control" side on delivery. [WO ;MC 22]

27 Chapter 6 How to operate the temperature controller(mr980) Name of Dip switch Setting lock 6 Functional description /Operating procedure Function Used for selecting whether all setting data is locked or canceled. Operation Cancel the setting lock. When set the switch to "OFF" side, the lock will be canceled and the setting (change) will be possible. When set the switch to "ON" side, all setting value will be locked and the setting (change) will be impossible. However, Display mode will change. The switch is set to "lock cancel" side on delivery. NOTE Perform this operation with your recognized person. LCD initialization 7 Function Used for changing the PID parameters or the engineering level setting. Operation Set to "Regular use" side under normal condition. This is set to "Regular use" side on delivery. It becomes possible to change the setting when set to "LCD initialization" side. NOTE Do not perform this operation without our service man or your recognized person. Do not change absolutely the setting because the PID parameters have already set at the time of shipment. 5 8 Function Nothing NOTE Do not touch absolutely. Setting lock 6 Set to "Setting lock" side after completing all setting [WO ;MC 23]

28 Chapter 6 How to operate the temperature controller(mr980) 3. Monitor Items on Monitor Display 3-1. Sequence Mode (monitoring) A running mode is shown on the upper side of the MONITOR display. Sequence mode MONITOR display PV display SV display Remarks Stop MODE=STOP Actual temp. When at stop Start timer MODE=TIMER Timer elapsed value Timer set value When start timer actuated Medium supply MODE= Med. Supply Actual temp. Set temp. When medium supplied Medium blow MODE= Medium Blow Actual temp. Set temp. When medium blown Heater delay MODE= Heat.Delay Actual temp. Set temp. When heater delayed Temp. control MODE= Temp Actual temp. Set temp. When temp. controlled 1 Stop preparation MODE= STOP Ready Actual temp. Set temp. When stop in preparation Air purge in preparation MODE= Purge Ready Actual temp. Set temp. When air purge in preparation Air purge MODE= Exchange Actual temp. Set temp. When air purging Auto tuning MODE=Auto Tuning Actual temp. Set temp. When auto tuning 1 or appears at the right end of MONITOR display, indicating the use of set value S SV1/SV2. shows the output of SUB heater Monitor Mode While a sequence mode is on display, a running state is shown at the lower side of MONITOR display: Alarm, Output, T, PV2(1), or Stop Timer. Upon the occurrence of an alarm, the display turns to Alarm Monitor unconditionally. Monitor mode MONITOR display Remarks Alarm Adj.Data Error Error in adjustment data RAM Error Input Error Sensor Error PUMP Reverse PUMP Overload Over Heat Heater Break Medium Low Level High Alarm Low Alarm Error in RAM Error in input value Temperature sensor abnormality Negative phase input Pump overloaded Overheat alarm Heater disconnected Medium reduced Temperature increased Temperature reduced [WO ;MC 24]

29 Chapter 6 How to operate the temperature controller(mr980) Monitor mode MONITOR display Remarks Before Maintenance Change OIL Replace oil. Change HOSE Replace hose. Check Float SW Check float switch. Change C Relay Replace cooling solenoid valve. Control Output MVH = % H Heating output 2 MVC = % H Cooling output 2 T T = 10.0 C Option 4 PV2 (1) PV2 = 28.0 PV2 monitor 3 PV1 = 28.0 PV1 monitor 3 2 MVH = % is shown when output is on the heating side, while MVC = % is given when output is on the cooling side. 3 PV2 = is shown when controlled by PV1, and PV1 = appears when under PV2 control. 4 T monitor is not available when external (die) sensor is in use. [WO ;MC 25]

30 Chapter 6 How to operate the temperature controller(mr980) 4. Set Item and Range of Temperature Controller 4-1. Set Range and Initial Set Value at Level 0 Pressing SV key on the control panel turns MONITOR display and PV display to character display, enabling settings at level 0. Setting contents Character Set range Initial value Remarks Main temp. setting 1 SV1 SLL~SLH 50.0 Main temp. setting 2 SV2 SLL~SLH 30.0 Timer time setting Timer 00:00 ~ :00 h:min 4-2. Set Range and Initial Set Value at Level 1 Depressing SV enabling settings at level 1. key for 5 sec on the control panel turns MONITOR display to character display, Setting contents Character Set range Initial value Remarks High alarm temp. High Alarm 0.0~ : Function OFF (deviation) Low alarm temp. Low Alarm 0.0~ : Function OFF (deviation) T select T Indication Un use or Use Un use T OK criterion T OK Level 0.0~ : Function OFF (deviation) Temp. OK criterion TEMP OK Level 0.0~ : Function OFF (deviation) Starting select ON/OFF Operation Key or DI-1 Key 5 SV1/SV2 select SV1/2 Operation Key DI-6 AUTO Key Timer function select TIMER Function START TIMER START 5 or END TIMER TIMER Action upon high alarm Hi-Alarm Action Continue or STOP Continue Limiter upper limit SV Limiter High SLL~SSL 95.0 SLH Limiter lower limit SV Limiter Low 0.0~SLH 0.0 SLL H/L switching temp. H/L Switch Level 10.0~ LS HL HX 6 H/L switching Hys H/L Switch Hys 1.0~ LS HL HX NOTE 5 Setting is available only while the device is at rest. 6 HL switching point temperature: HL switching point temperature initial value of LS model is [WO ;MC 26]

31 Chapter 6 How to operate the temperature controller(mr980) Setting contents Character Set range Initial value Remarks PV bias medium PV Bias CH1-10.0~ PV bias die PV Bias CH2-10.0~ Medium blowing time Medium Blow TMR 0~600 Sec 15 Sec Heater delay time Heater Delay TMR 0~180 Sec 10 Sec Stop delay time Stop Delay TMR 0~1000 Sec 0 Sec SV change gradient time SV Change TIMER 0~100 Min 0 Min Oil replacement time OIL Exchange **** 10H H Not settable Rubber hose replacing Hose Exchange **** 10H H Not settable time Float SW checking time Float SW Check **** 10H H Not settable Heating relay counter Heat Relay **** 10³ 0 10³ Not settable Cooling relay counter Cool Relay **** 10³ ³ Not settable [WO ;MC 27]

32 Chapter 6 How to operate the temperature controller(mr980) 5. Modes on MONITOR Display 5-1. Indication when Powering ON [Type & function setting: 1 sec] Control CH1 Float Switch 2 PV display:c HL SV display: [Starting status] RESET PV display:c HL SV display: 5-2. Indicated Modes [When at rest] MODE=STOP PV display: SV display: [When timer in use] MODE=TIMER PV display:remaining time SV display:set time [When water being fed] MODE=Med. Supply Medium Low Level PV display: SV display: [When medium being blown] MODE=Medium Blow [When heater delayed] MODE=Heat.Delay [When temperature controlled] MODE=TEMP 1 PV display: SV display: PV display: SV display: PV display: SV display: [When stop in preparation] [When air purge in preparation] [When air purging] MODE=STOP Ready MODE=Purge Ready MODE=Air Purge PV display: SV display: PV display: SV display: PV display: SV display: [When auto tuning] MODE=AutoTuning PV display: SV display: [WO ;MC 28]

33 Chapter 6 How to operate the temperature controller(mr980) Mode display changes in the following order each time PV key is pressed: [Mode & alarm monitor] [Mode & PV monitor] [Mode & T monitor] MODE=STOP Over Heat MODE=STOP PV2 =123 MODE=STOP T =123 [Mode & MV monitor] MODE=TEMP 1 MVH =100.0 % SH Level 0 setting display changes in the following order each time PV Pressing key returns it to mode & alarm monitor. SV key is pressed. [Mode & alarm monitor] [Setting of control temp. SV1] MODE=STOP Over Heat SV1 = 50 PV display: SV display: [Setting of control temp. SV2 = 30 PV display: SV display: [Timer setting] TIMER = 0:00 PV display: SV display: [WO ;MC 29]

34 Chapter 6 How to operate the temperature controller(mr980) Depressing SV key for 5 sec switches mode & alarm monitor to level 1 setting display (High Alarm). The setting display changes in the following order each time key is pressed. Pressing key returns it to mode & alarm monitor. SV PV [Mode & alarm monitor] MODE=STOP Over Heat [High alarm temp.] High Alarm = 10.0 [Low alarm temp.] Low Alarm = 10.0 [ T indication select] T Indication = Unuse [ T OK criterion] T OK Level = 10.0 [SV1/SV2 select] SV1/2 Operation = Key [Starting select] ON/OFF Operation = Key [Temp. OK criterion] TEMP OK Level = 10.0 [Timer function select] TIMER Function = START Timer [Action at high alarm] Hi-Alarm Action = Continue [Limiter upper limit] SV Limiter high = 90.0 [H/L switching hys] H/L Switch Hys = 2.0 [H/L switching temp.] H/L Switch Level = 85.0 [Limiter lower limit] SV Limiter Low = 0.0 [PV bias medium] PV Bias CH1 = 0.0 [PV bias die] PV Bias CH2 = 0.0 [Medium blowing time] Medium Blow TMR = 15 Sec [SV switching gradient time] SV Change TIMER = 0 Min [Stop delay time] STOP Delay TIMER = 0 Sec [Heater delay time] Heater Delay TMR = 10 Sec [Oil replacement time] OIL Exchange = 0 10H [Rubber hose replacement time] Hose Exchange = 0 10H [Float SW check] Float SW Check = 0 10H [Cooling solenoid valve replace] C Relay Counter = 0 10³ [Heating relay replace] H Relay Counter = 0 10³ [WO ;MC 30]

35 Chapter 6 How to operate the temperature controller(mr980) 6. Functions and Operation of MONITOR Display 6-1. Mode Display Mode display changes each time PV key is pressed. MONITOR display MODE=STOP Indicates device is at a stop. Indication MODE=STOP PV2 =123 MODE=STOP T =2 MODE=TEMP 1 MVH =100.0 % SH Indicates temperature of medium return sensor when medium feed is controlled. (option) Indicates temperature of medium feed sensor when die is controlled. (option) Shows temperature difference between sensors TC2 and TC1. Shows output state when temperature is controlled Level 0 Setting Mode Level 0 setting mode changes each time key is pressed. Pressing key returns to mode & alarm monitor. SV PV MONITOR display SV1 = 50 Indication/function Mode for setting (changing) control temperature SV1 The numeral shown is current set value. SV2 = 30 Mode for setting (changing) control temperature SV2 The numeral shown is current set value. TIMER = 0:00 Mode for setting (changing) start timer The numeral shown is current set value. [WO ;MC 31]

36 Chapter 6 How to operate the temperature controller(mr980) 6-3. Level 1 Setting Mode Pressing SV key for 5 sec changes the display to level 1 setting mode (High Alarm). Setting display changes each time SV key is pressed. Pressing each mode indicates the current set value. PV key returns to mode & alarm monitor. = in MONITOR display High Alarm = 10.0 Indication/function Mode for setting (changing) high alarm temperature for control temperatures SV1 and SV2 (deviation setting) Low Alarm = 10.0 Mode for setting (changing) low alarm temperature for control temperatures SV1 and SV2 (deviation setting) T Indication = Unuse Mode for selecting display or non-display of T Unuse does not indicate T, while Use shows it. T OK Level = 10.0 Mode for setting (changing) temperature criterion for T OK TC2 TC1= T OK criterion: OK is output if it is within set temperature. 1 TEMP OK Level = 10.0 Mode for setting (changing) OK temperature criterion to control temperatures SV1 and SV2: OK is output if it is within set temperature to controlled temperatures SV1 and SV2. 1 ON/OFF Operation = Key Mode for selecting starting/stopping method With Key, device starts or stops by panel. ON/OFF key operation on control With DI-1, device starts or stops in response to external ON/OFF signal. SV1/2 Operation = Key Mode for switching between control temperatures SV1 and SV2 With Key, switching occurs by depressing or key for 1 sec or more on control panel. AUTO causes their automatic switching in response to external contact ON/OFF pulse, while DI-6 causes switching in response to external signals. DWN UP 1 means optional. [WO ;MC 32]

37 Chapter 6 How to operate the temperature controller(mr980) MONITOR display TIMER Function = START Timer Indication/function Mode intended for switching timer function. START Timer means start timer (starting after set time), while STOP Timer means stop timer (stopping after set time). Hi-Alarm Action = Continue Mode intended for selecting action when high alarm occurs. Continue will continue running, STOP will stop operation. SV Limiter High = 90.0 Mode intended for setting the upper limit of SV temperature limiter according to type. SV Limiter Low = 0.0 Mode intended for setting the lower limit of SV temperature limiter according to type. H/L Switch Level = 85.0 Mode intended for setting temperature at which it is switched from L to H. H/L Switch Hys = 2.0 Mode intended for setting temperature range in which unnecessary output is not made to control temperature SV in switching from L to H. PV Bias CH1 = 0.0 Mode intended for setting temperature compensation when medium is controlled. PV Bias CH2 = 0.0 Mode intended for setting temperature compensation when die is controlled. Medium Blow TMR = 15 Sec Mode intended for setting medium blowing time (water supply) when powering on. (only L/H) Heater Delay TMR = 10 Sec STOP Delay TMR = 0 Sec Mode intended for setting delay time from pump start to heater operation. Mode intended for setting stop preparing time (cooling time from heater stop to pump stop) [WO ;MC 33]

38 Chapter 6 How to operate the temperature controller(mr980) MONITOR display SV Change TIMER = 0 Min Indication/function Mode intended for setting gradient time (time taken until SV1/ SV2 temperature is reached) when switching between control temperatures SV1 and SV2. Injection Cycle = Sec Mode intended for setting switching cycle time when AUTO is selected for switching between control temperatures SV1 and SV2. Exhaust TIMER = 30 Sec OIL Exchange = 0 10H Hose Exchange = 0 10H Float SW Check = 0 10H H Relay Counter = 0 10³ Mode intended for setting exhaust time. (option) Monitor for oil replacement time (measure time) Monitor for hose replacement time (measure time) Monitor for float switch check or replacement time (measure time) Monitor for replacement time of heating relay (electromagnetic contractor) in control panel C Relay Counter = 0 10³ Monitor for replacement time of cooling relay (cooling solenoid valve) [WO ;MC 34]

39 Chapter 6 How to operate the temperature controller(mr980) 7. Setting of Functions Change MONITOR display to level 1 setting mode to set the following function items: [ T indication] [ T OK criterion] T Indication T OK Level = Unuse = 10.0 [Temp. OK criterion] TEMP OK Level = 10.0 [Start select] ON/OFF Operation = Key [SV1/SV2 change select] [Timer function select] SV1/2 Operation = Key TIMER Function = START Timer [Hi-alarm action] Hi-Alarm Action = Continue Step Item Operation 1 Release of setting lock Open front cover to turn setting lock dip switch 6 to Setting lock release (OFF) side. The switch is on Setting lock release (OFF) side when shipping. 2 Switching to level 1 setting mode Depress SV key for 5 sec on control panel, and MONITOR display turns to High Alarm. = Indication of setting mode Setting mode changes each time key is pressed. Display function item to be set. SV SFT 4 Setting (changing) operation Press key on control panel to flicker mode display. Select set value by pressing and keys and define it by pressing ENT key. DWN UP 5 Setting lock At the end of setting operation, turn dip switch 6 to Setting lock (ON) side. [WO ;MC 35]

40 Chapter 6 How to operate the temperature controller(mr980) 8. Mode Setting of SV Display (changing) Change MONITOR display to level 0 setting mode to set the following mode items: Setting (changing) is available when either the device is in operation or at rest Mode Items to be Set and Setting Contents Setting mode item [Setting control temp. SV1] [Setting control temp. SV2] SV1 = 00 PV display: SV display: SV2 = 00 PV display: SV display: Setting contents Intended to set control temperature while in operation. Usually use SV1. [Timer setting] TIMER = 0:00 PV display: SV display: Intended to set time for automatically starting running (start timer). If not used, set it at Setting Operation Step Item Operation 1 Release of setting lock Open front cover to turn setting locking dip switch 6 to Setting lock release (OFF) side. The switch is on Setting lock release(off) side when shipping. SV 2 Switching to level 0 setting Press key on control panel, and MONITOR display turns mode to SV1. = 00 3 Indication of setting mode Setting mode changes each time key is pressed. Display mode item to be set. SFT 4 Setting (changing) operation Press key on control panel to flicker mode display. SV Input numeral by pressing and keys and define it by pressing ENT key. DWN UP 5 Setting lock At the end of setting operation, turn dip switch 6 to Setting lock (ON) side. [WO ;MC 36]

41 Chapter 6 How to operate the temperature controller(mr980) 9. Setting (Changing) of High and Low Alarm Temperatures Change MONITOR display to level 1 setting mode to set the following items of high alarm and low alarm temperature modes. Setting (changing) is available when either the device is in operation or at rest Setting contents Setting mode item [High alarm temperature] High Alarm = 10.0 Setting contents Intended for setting temperature at which temperature rise alarm occurs. (deviation) When control temperature (actual PV) rises to the upper limit set while in operation, the temperature rise alarm occurs. [Set range] Set in the range of +2 to +20 from set temperatures SV1 and SV2. It is set at +10 prior to shipping. NOTE Setting at 00.0 disengages this alarm. [Low alarm temperature] Low Alarm = 10.0 Intended for setting temperature at which temperature drop alarm occurs. (deviation) When control temperature (actual PV) drops to the lower limit set while in operation, the temperature drop alarm occurs. [Set range] Set in the range of -2 to -20 from set temperatures SV1 and SV2. It is set at -10 prior to shipping. NOTE Setting at 00.0 disengages this alarm Setting Operation As described in 7. Setting of Functions. [WO ;MC 37]

42 Chapter 6 How to operate the temperature controller(mr980) 10. Switching Operation of Control Temperature (for reference) This temperature controller stores two control temperatures (setting temperatures SV1 and SV2), which can be switched by key operation on the control panel or SV switching (DI-6) of the external contact. There are three options for external contact SV switching (DI-6): SV1 by opening the contact; SV2 by closing it; and automatic SV switching by judging molder operation or stop from cyclic contact ON/OFF operation. Set a switching way as described in 7. Setting of Functions. When SV is switched, SV1 >>> SV2 or SV2 >>> SV1 appears for 2 sec on MONITOR display. Setting contents Character Set range Initial value SV1/SV2 Select SV1/2 Operation Key DI-6 AUTO Key Switching by Key Operation on Control Panel (key) Switching occurs by depressing or key for 1 sec when MONITOR display is in the monitor state. DWN UP Switching by External Contact (DI-6) The temperature is switched to SV1 by opening SV switch input contact (DI-6), and to SV2 by closing it Switching through External Contact ON/OFF Pulse (AUTO) The temperature can be automatically switched by judging the operation or stop of the molder from the cyclic ON/OFF operation of SV switch input contact (DI-6). The molder clamping signal is used as SV switch input contact (DI-6). Molding cycle time: 0 to 3600 sec variable (initial value: 40 sec) At stop: Molding cycle time set < pulse cycle = Stop (switch to SV1) Molding: Molding cycle time set > pulse cycle = Molding (switch to SV2) Molding cycle time set Molding cycle time set DI-6 SV SV1 SV2 SV1 SV2 SV1 Switched to SV2 when DI-6 is turned ON. Switched to SV1 if no pulse is for set molding time or longer. NOTE The automatic switching (AUTO) is available only while running. The temperature is fixed at SV1 while at stop. [WO ;MC 38]