MV2 SERIES Temperature Controller. Instruction Manual

Transcription

1 MV2 SERIES Temperature Controller Instruction Manual

2 TABLE OF CONTENTS 1 FIRST STARTUP pg..5 2 GENERAL PRESENTATION OF THE INTERFACE pg Status light pg Color touch screen pg Contextual help pg Locking/Unlocking the user interface pg Screen captures pg Navigation and screens pg Page distribution per screen pg Getting started with the interface pg Information on the heating zones pg Control screen pg Alarm screen pg Changing how many zones are displayed pg Zoom in or out by swiping pg Using the navigation button to change level of zoom pg Selection pg USING THE SYSTEM pg System configuration pg Software configuration pg General configuration pg Regional settings pg Privilege level access pg Network pg Temperature control configuration pg Temperature control configuration settings pg Heating zone configuration pg Groups of zones pg Zone configuration table pg Electrical analysis of the mold pg Readings pg Mold monitoring pg Configuration files pg Creating a configuration file pg Displaying a configuration file pg Loading a configuration file pg Updating a configuration file pg Deleting a configuration file pg Duplicating a configuration file pg Exporting and importing configuration files with a USB device pg INCOE 1/17 Page 1

3 3.2 Customary use pg Heating zone management pg 'Quick change' action bar pg First and second setpoints pg Alarms pg Viewing alarms pg Alarm log pg Advanced features pg Remote log-in pg System information pg Restoring factory settings pg Loading a company logo pg MAINTENANCE INSTRUCTIONS pg Troubleshooting pg PARTIAL SUMMARY OF EXPRESS WARRANTY pg CONTACT US pg. 52 Page INCOE 1/17

4 1 FIRST STARTUP Connect the power supply cord to the appropriate input power supply. Check all the connections including power supply and mold control cables. Turn on the system using the switch located on the front. After a few seconds, the presentation screen appears. Type of cabinet/ Model number/ Software version 2 GENERAL INTERFACE DISPLAY 2.1 STATUS LIGHT The status light is on the front of the unit. This indicator has two functions: Indicates the set-point instruction (SP1/SP2): the status light shows green if the control system is at Set-point 1 (SP1) and blue when the control system is at Set-point 2 (SP2) (see for further information on these two Set-points). The status light blinks red indicating a defect had been detected. 2.2 C OLOR TOUCH SCREEN The user interface always includes these 3 elements: Status Bar - bottom of screen Action Bar - right side Navigation Bar - top of screen INCOE 1/17 Page 3

5 Navigation tabs Action bar Name of configuration file loaded Status bar Date and time Contextual help Interface locking Screen capture Information on the screen in progress Name of the screen Current Setpoint The status bar gives general system status information such as date and time, current confi guration fi le, current screen name (and other information relevant to the screen such as the number of zones displayed out of the total number of zones, the zone number selected and the number of alarm-status zones as well as the current instruction (SP1/SP2). On the left, three icons control the graphic user interface. Status bar blinks red if alarms are triggered. The contents of the action bar depend on the screen currently in view and include control icons which directly fi ne tune the system Contextual help The question mark icon activates or deactivates the contextual help system by posting a description over the icons. It is useful during the phase of study of the user interface or when in doubt about the meaning of an icon. Page INCOE 1/17

6 2.2.2 L ocking/unlocking the user interface There are 3 access levels which allow access to all or some of the interface functions. The current access level is displayed at the bottom of the page: Current access level The functions available for the 3 access levels are listed below: Access Level Accessible Functions Interface is "Read-Only", no modifi cations can be made to the system Possible modifi cations: Change set-point Turn On/Off zones Auto/Manual mode 1st/2nd Set-point Load a file Interface is entirely open, any modifi cations are possible. On start-up, the user interface is not locked (level 2 access), all functions are accessible. When the open or closed padlock icon is pressed, a numeric keypad appears allowing changes to the access level by entering the appropriate password: To change to Level 1 access, type «654321», to confirm press To change to Level 2 access, type «123456», to confirm press To change to Level 0 access, type the password of the current Level, to confirm press To change the passwords for access levels, see INCOE 1/17 Page 5

7 2.2.3 Screen captures The camera icon is visible when a USB flash drive or a hard disk is connected. This icon enables the user to capture screens and save them to the USB device. Note: Please wait a few seconds before withdrawing a USB device to make sure that your screen capture is completely saved on the device Navigation bar and screens The four navigation tabs at the top of the screen represent the four different views provided in the user interface: System view, Control view, Alarm view and Configuration view. The current view depends on which tab is selected. Each tab gives access to a set of screens. For example, to change or view the setting of one zone or more, press "Control view". The 5 thumbnails appear in this view. Touch the tab to return to this display Select the appropriate thumbnail Press the "Zone confi guration table" thumbnail to go to that screen. The user can now check the status of the control zones by clicking on the Control view thumbnail. tab and by selecting the Control 2.3 PAGE DISTRIBUTION PER SCREEN Screens are distributed to different views according to their function: The SYSTEM view pertains to the whole system used The CONTROL view pertains to the mold temperature control The ALARM view pertains to the alarm management The CONFIGURATION view pertains to the software configuration options Page INCOE 1/17

8 The following tables give a summary of the screens available under the various tabs. Tab Screen System Configuration files Control Zone settings table Control Heat control settings Group management Mold monitoring + Moldscan analysis INCOE 1/17 Page 7

9 Tab Screen Alarms Alarms Alarm log General configuration Regional settings Confi guration Access levels Network settings Page INCOE 1/17

10 Tab Screen System information 2.4 GETTING STARTED WITH THE INTERFACE The screens Control and Alarms all show information on the heating zones. On each of these screens the zones are represented on a grid: zoom in or out to re-size this grid. Control screen Alarms screen Information on heating zones The information displayed for each zone also depends on how much it has been zoomed Control screen 8, 12, 16 or 24-zone displays: Zone without alarm Zone switched off Zone name + Group identification icon Group Temperature % of power or current Confi guration Set-point INCOE 1/17 Page 9

11 Zone with high temperature alarm or other alarms Zone with low temperature alarm Zone name + Group identification icon Group Temperature Status % of power or current Set-point 48-zone display: Zone without alarm Zone switched off Zone name + Group identification icon Temperature Zone with high temperature alarm or other alarms Zone with low temperature alarm Zone name + Group identifi cation icon Temperature Status The meaning of the various status icons is described below: Icon Description Low temperature alarm: Temperature of the zone is below setpoint High temperature alarm: Temperature of the zone is above setpoint Zone has an alarm triggered which is not High or Low temperature A ramp has been applied to the zone so its setpoint can be gradually reached Zone is in Boost mode ( Configuring Boost value) Zone uses temperature sensor from another zone ( Zone Slaving) Page INCOE 1/17

12 Alarm screen 8, 12, 16 or 24-zone displays: Zone with high temperature alarm or other alarms Zone name + Group identifi cation icon Group Temperature Temperature alarm % of power or current Zone with low temperature alarm Power alarm 48-zone display: Zone with high temperature alarm or other alarms Zone name + Group identifi cation icon Power alarm Temperature alarm Zone with low temperature alarm The meaning of the various alarm and temperature icons is described below: Icon Problem Low temperature alarm: Temperature of the zone is below setpoint High temperature alarm: Temperature of the zone is above setpoint Open thermocouple Reversed thermocouple INCOE 1/17 Page 11

13 The meaning of the power alarm icons is described below: Icon Problem Load fault Power monitoring fault Triac fault Difference between actual current measured and last recorded current measurement Inconsistency between power value and temperature reading Page INCOE 1/17

14 2.4.2 Changing how many zones are displayed The user may zoom in or out so as to display more or fewer zones. This allows an overall view of the system showing fewer details for each zone, or alternatively to view the complete status of a smaller number of zones. The various zoom levels depend on the screen set up on the unit: 7.5 screen: 48, 24, 16, 12 or 8 zones can be displayed at once 15 screens: 16, 24, 48, 72 or 96 zones can be displayed at once Zoom level can be changed in either of two ways. Either swipe diagonally upwards to zoom in (displaying fewer zones) and diagonally downwards to zoom out (displaying more zones), or use the navigation icon on the Action bar Zoom in or out by swiping Zoom in Zoom out The number of zones currently displayed is shown in the status bar. If the unit is capable of managing more zones than the number currently displayed, the user can navigate around the zones present by swiping upwards or downwards. There is a position indicator on the right-hand side of the window giving further information on the scrolling of the zones. Towards zone 40 Position indicator Towards zone 1 Number of zones which can be displayed and number of zones currently displayed INCOE 1/17 Page 13

15 Using the navigation icon to change zoom level Pressing the navigation icon Icon on the Action bar brings up a double icon bar with the following actions: Action Scroll up, equivalent to moving towards the fi rst zone Scroll down, equivalent to moving towards the last zone Zoom in, display fewer zones but with more detail Zoom out, display more zones but with less detail Selection The user may carry out certain operations on the specifi cally selected control zones only. These zones can be selected by pressing a zone, which is then highlighted in orange: Selected zone Pressing an already-selected zone deselects it. The user may also select or deselect several zones at the same time by using the selection menu in the Action bar actions:. Once this menu has been activated, a double Action bar offers the following Page INCOE 1/17

16 Icon Action Exit selection menu Select zones group by group Select all the cabinet s zones Deselect all zones The user may select a range of zones by pressing the fi rst zone desired (e.g. Zone 3) and then holding down the last zone desired (e.g. Zone 7). All zones between these two will then be selected (Zone 3 to Zone 7) INCOE 1/17 Page 15

17 3 USING THE SYSTEM In order for the system to be used correctly, the general configuration must be set up before being used for the fi rst time. The software also has advanced features, particularly for remote operation and customizing company information. 3.1 System configuration Software configuration Software confi guration is done during its first use, or occasionally if the user wants to change a global software setting General confi guration The global settings of the software can be configured in the "General configuration" screen, accessible in the "Confi guration" tab. Applied power display mode Temperature units External alarm input disabled Alarm output Temperature units : The preferred temperature units ( C or F) will be used throughout the interface. External alarm input disabled : This option allows the EXTERNAL ALARM input to be ignored. Applied power display mode : The power applied mode is shown (% of power or Amperes). The mode selected will be displayed in all zones on the control and alarm pages. Page INCOE 1/17

18 Alarm output : The unit has two Alarm output settings. When and how these outputs are set can be set in this screen. The options are: High Temperature Alarm: the output is activated if a zone is in the High Temperature alarm state Low Temperature Alarm: the output is activated if a zone is in the Low Temperature alarm state High or Low Temperature Alarm: the output is implemented if a zone is in either the High or Low Temperature alarm state High or Low Temperature Alarm (except on initial warm-up): the output is activated if a zone is in either the High or Low Temperature alarm state, unless the system is carrying out its initial warm-up. MoldScan: the output is activated if a fault is detected by a rapid MoldScan analysis or by the power monitoring system ( All: the output is activated if one of the conditions above occurs Regional settings The regional settings of the software can be confi gured in the General configuration screen, accessible in the Confi guration tab. To adjust these settings, go to "Regional Settings", then "Confi guration" view. Choice of language Adjust date and time Time zone To modify the date, press one of the fi elds (day, month, year) then scroll with the up and down arrows to increase/decrease this fi eld. To change the language of the interface, click on the corresponding flag. The Time Zone setting must be specifi ed when a time server is used. The modifi cations are confi rmed when the icon is pressed. With a change of language, the interface is reloaded and the Control screen is displayed INCOE 1/17 Page 17

19 Privilege level access The privilege level access screen is accessible in the Confi guration tab. The user may change passwords for each access level (1 & 2). The user will be asked for both the current and new passwords Network settings The network settings are accessible in the Confi guration tab. The network settings enable an IP address to be assigned to a screen automatically or manually, and network settings such as Network Mask or Gateway to be confi gured. The icon indicates that the unit is connected to the network. The icon indicates that the unit is not connected. Page INCOE 1/17

20 3.1.2 Temperature control configuration The Temperature Control screen is accessible in the Temperature Control tab. It must be carried out during the fi rst time the mold is used Temperature control configuration settings The "Temperature control settings" screen is accessible in the "Control" type of start-up mode (type of ramp) press one of the following icons. Start-up ramp selection Power restriction Action if a thermocouple fails tab. To select the Ramp-specific variable Maximum and minimum setpoints Automatic current monitoring Boost duration Power Restriction : Power restriction can be confi gured to the type of ramp selected (default 15%). Depending on the type of ramp selected, another setting will be displayed: Ramp duration, for the Duration ramp Ramp gradient, for the Gradient ramp Stabilization period, for the Staggered ramp The Synchronized ramp has no specifi c variable. Action if a thermocouple fails : When switched to manual mode, the zone concerned automatically changes to manual mode if a particular thermocouple fails. Automatic current monitoring : If this option is activated, the control mode of the zone carries out MoldScan rapid analyses at intervals to detect any faults. For further details, see Power monitoring. Boost duration : The duration of the Boost function can be set in this fi eld. For further details on this function, see Confi guring Boost value INCOE 1/17 Page 19

21 Maximum and minimum set-points : Maximum and minimum set-points can be specifi ed for automatic mode. Start-up ramps: On start-up, the zones in automatic mode are heated gradually until they reach their operating set-point. There are four possible types of start-up ramps: Duration: the system keeps the temperature at 100 C or 212 F for a programmable length of time (default 5 minutes). Gradient: the system applies a number of programmable set-point degree per minute increments (default 20 C or 68 F/min) until the operating set-point is reached. When power is turned on the fi rst staging-post is set at 50 C or 122 F. When the temperature reaches the set-point, the ramp is terminated. Synchronized: the system automatically selects the zones which are working properly (no failed thermocouples or heating elements), and then starts heating these zones. An algorithm makes the quickest zones copy the temperature changes of the slowest. Staggered: this ramp uses the grouping of zones in manifold or nozzle groups (. Initially all the zones in manifold type groups are heated in a synchronized ramp, while the zones in nozzle type groups are kept at 100 C or 212 F. When all the zones in the manifold groups have reached their particular set-points, the system stabilizes their heating by means of a programmable waiting time (default 1 minute) and then executes a synchronized ramp on the zones in the nozzle groups. The staggered ramp is terminated when all zones have reached their operating set-points. Power restriction : Power can be restricted at the start of the ramp in all four start-up modes. The default level to which power is restricted is 15%. Page INCOE 1/17

22 Heating zone confi guration The Control screen is accessible in the Control" tab. To configure a heating zone, press it twice ( double-click on it) or use the Action bar to bring up the confi guration menu and press the Zone configuration icon. To confi gure more than one heating zone simultaneously, select a number of zones ( and press one of them twice ( double-click ). This zone then becomes the reference zone. This brings up the Zone confi guration screen: Selected zones Action Bar Name and number of reference zone Group The values which appear on the screen are those common to the zones selected. For values which are not identical for all selected zones, the following symbol will appear: ---. Only the changed values will be applied to the selected zones upon validation. The modified values appear in red. To confi rm changes, press the. This screen is made up of three subscreens: One for naming zones and group assignment One for working mode setting One for tolerance setting Naming zones and Group assignment : The user can change the name of the selected zone(s) by pressing the icon. If more than one zone is selected, the selection number is appended to the name entered. For example, if zones 2, 5 and 7 are selected and the name Manifold is entered, the zones will be named Manifold 1, Manifold 2 and "Manifold 3". Zones can be assigned to a group by pressing the < and > icons. It is, however, easier to use the Group management window ( INCOE 1/17 Page 21

23 Working mode setting : On/Off Setpoints and manual values Zone Slaving Boost value Working mode On/Off : The selected zones can be turned on or off by pressing the ON and OFF icons. W orking mode and set-points : Heating zones can be regulated automatically or manually. In automatic mode a set-point is specified in C or in F and the control system automatically selects the power to be applied to the zone in order to bring that zone up to the selected temperature. Automatic mode needs the zone to be fi tted with a working thermocouple probe. If there isn t one, a back-up probe will have to be confi gured using the Zone Slaving function. Under this mode the temperature is monitored and alarms are active (. In manual mode, the operator applies a power level manually. The temperature is not monitored at all in this case. The control system allows the user to configure two temperature set-points for the automatic mode, and two percentage-based power levels to be applied in manual mode. The choice between these two set-points or these two percentage-based power levels is made according to the set-point mode chosen for the unit (SP1/SP2). See for more information. Page INCOE 1/17

24 Zon e Slaving : A slave zone can be confi gured at the bottom of the screen. For example, if zone 1 thermocouple malfunctions during production then the job can be fi nished by configuring the zone to use the thermocouple probe for zone 10, whose heating characteristics are known to be similar. This allows zone 1 to return to automatic control mode. No back-up zone Zone list Gives access to the list of zones for specifying a back-up probe. C onfiguring Boost value : In automatic mode the Boost allows the user to raise or lower the temperature set-point of a zone momentarily. The current set-point is raised or lowered by the boost amount, which can be set in this screen. New value For a positive boost value For a negative boost value Note: Boost Duration is the same for all heating zones, and can be confi gured in the General Confi guration screen ( ) INCOE 1/17 Page 23

25 Tolerance setting : Power monitoring PTI Temperature tolerances Power monitoring : How the power monitoring system works: Temperature % Power Setpoint change +5C Setpoint -5C Alarm Average power calculation over 5 minutes Automatically placed under surveillance if outside tolerances Average power calculation over 5 minutes Automatically placed under surveillance if outside tolerances The basic idea is to monitor the power applied to the load so if one of various parameters drifts from its proper value (for example: excessive power consumption, etc.): a change in the power percentage signals an abnormal physical change in the zone under regulation. When a zone is being monitored, the system waits for the power applied to the load to stabilize before looking for variances from the power percentage. Variances are detected by comparing the amounts of power applied with the safety tolerances set by the user. Page INCOE 1/17

26 The monitoring system is completely independent, automatically recalculating these parameters when circumstances change and events occur, such as: The set-point is changed The zone is switched on or off The zone is changed from Auto mode to Manual, or vice versa A mold adjustment fi le is loaded When the monitoring system detects an anomaly it fl ashes up an alarm symbol for the faulty zone and triggers an alarm signal at the back of the unit (electrical contact), allowing a visual alert (alarm indicator light) and / or deactivation of the machine cycle (set off). The power monitoring function can be activated in this screen, and the desired tolerance set. The level is expressed as a percentage of the power normally applied to the zone. For example, if the percentage of power applied to keep the zone at 400 F is 35% and the tolerance has been set at 10%, the system will generate an alarm if the power applied to maintain the temperature exceeds 45% or falls below 25%. PT I : The PTI detection mechanism allows: The temperature reading to be checked for consistency with the power applied The power applied to be limited until the reading has been verified Heating to be switched off at the end of a set period (configurable) if the temperature does not change consistently with power applied These precautions can prevent overheating of elements, protecting the personnel working around the mold. Note: PTI detection takes place on cool zones, those whose temperature reading is below 50 C or 122 F. PTI detection takes place when a zone is started. It involves a phase of diagnosis of the corresponding thermocouple probe, during which the power applied to the zone is limited. This phase is displayed by means of an icon and continues until: The zone s temperature reading has risen by 10 C or 50 F The temperature reading is below 50 C or 122 F When the icon disappears, the probe is regarded as functional and the power restriction is removed. Periodic PTI detection also continues for as long as the temperature reading is below 50 C or 122 F. If the temperature reading fails to progress during 300 seconds (confi gurable) despite the power applied, a PTI fault is detected. This will be shown by the icon and furthermore the heating of the zone is cut off INCOE 1/17 Page 25

27 PTI faults can be caused by: Pinched thermocouple (TC) Mis-wiring of a thermocouple to a different heater Power fault A PTI fault may be cleared if: The zone has been stopped The zone has been changed to manual mode The TC has been slaved (TC slaving function) The PTI detection settings for the zone concerned were met PTI activation and entry of its detection period can be done from this screen. The default setting is ON. The user can stop the detection system zone by zone if necessary. This may be needed in very rare circumstances if the power restriction prevents a zone rising above the 10 C or 50 F temperature increase threshold. If the detection system is stopped no PTI fault can be detected. The PTI Detection Period is the time after which a PTI fault is declared; from then on, the heating zone will be power-restricted. This power restriction may be the one connected with the detection system itself (see above) or the power restriction connected with the functioning of the ramps. This setting may be increased for a heating zone which is slow to heat (great thermal inertia, large manifold). It may be reduced for a heating zone with a very large heat gain (low thermal inertia, very rapid nozzle). Temperature alarm trigger points : Zone temperature is monitored in automatic mode. If this temperature rises above or falls below the actual operating set-point, a High or Low Temperature Alarm is triggered. The alarm temperature settings can be confi gured in the tolerance screen. For example, when the high/low alarm settings are set at 5 C or 41 F and the zone s set-point is 150 C or 302 F, a Low Temperature alarm flashes up if the zone s measured temperature falls below 145 C or 293 F and a High Temperature alarm, if the temperature rises above 155 C or 311 F. Page INCOE 1/17

28 Groups of zones Zone groups have two functions: Making it easier to confi gure the unit by selecting the group of zones whose configuration is to be modifi ed Specifying which zones are nozzles and which are manifold, to improve control Zone groups can be managed in the "Group management" screen, accessible in the "Control" tab. List of groups The user may create a group, delete a selected group or view a selected group. Creating a zone group: To create a new group of zones, touch. The screen below appears: Group Name Group Type (manifolds or nozzles) Press the icon to name a group, and assign a group type: group of manifolds or group of nozzles. Warning: It is very important to specify the right group type in order to ensure the heating of the group zones is properly controlled INCOE 1/17 Page 27

29 The group is created when the icon is pressed in the Action bar. Pressing the icon on the Action bar will cancel its creation. Deleting a zone group: Delete a zone group by selecting it in the list of groups and pressing. The user will be asked to confi rm the deletion. The group will be deleted if the icon in the Action bar is pressed. Pressing the icon on the Action bar will cancel the deletion of the group. Once a group has been deleted its zones no longer belong to any group. Viewing a zone group: View a group by selecting it in the list of groups and pressing. The screen below appears: Group Name Group type icon (manifolds or nozzles) Zones assigned to this group Zones out of the group and current groups This screen shows which zones are assigned to each of the various groups. The composition of the various groups can be seen by touching the < and > icons. Group type is represented by an icon: = manifold ; = nozzle. The user can choose the desired zones to assign to the group by selecting them in the right-hand list (Zones OUT of the group) and clicking on. To remove a zone from the list of the group, the user can simply select it in the left-hand list (Zones IN the group) and click on. Use the and icons to select the left-hand list (Zones IN the group) and the right-hand list (Zones OUT of the group). Use the and icons to deselect all the zones in the list. Page INCOE 1/17

30 When a zone is removed from a group, it is not assigned to any group any more Zone confi guration table Press the Control tab twice («double-click») and select the «Zone confi guration table» screen. Changes the setting of the group of zones Changes the setting of all the zones in a group Changes the setting of the zone This screen allows all the settings of all zones to be viewed and changed. Press a group arrow to view the settings zone by zone. The setting for an individual zone can be changed (by pressing the setting for that zone), as well as the setting for a group of zones (by pressing the setting for the fi rst member of that group), or the setting for all zones (by pressing the setting for the fi rst member of the All group). Three categories of settings can be displayed from this screen: Screen Settings General settings (On/Off, Auto/Manual, &c.) INCOE 1/17 Page 29

31 Set-point settings (SP1 auto, SP2 auto, SP1 manu, ) Tolerance settings (High and low temperature alarm thresholds, ) These settings are accessible from the Action bar. Page INCOE 1/17

32 3.1.3 Elec trical analysis of the mold Readings The electrical analysis of the mold (MoldScan) provides readings for the mold s various zones: Power of the zone s heating element (in Watts) Resistance of the zone s heating element (in Ohms) Maximum current in the zone s heating element (in Amperes) Temperature gradient of the zone (in C/Minute or F/Minute) There are two alternative levels of analysis. Rapid mold analysis provides readouts of the power, resistance and maximum current of the heating element in some or all zones. This analysis takes a few seconds, and can be carried out during production. Full analysis is identical to rapid analysis but includes a readout of the temperature gradient in some or all zones. It needs the selected zones to be below 80 C or 176 F at the start of the analysis; they are then heated to 180 C or 356 F. This analysis can take some minutes, and cannot be carried out during production. The following faults can be detected at the end of a rapid analysis: Load interruption fault Triac short-circuit Current difference fault (Only if readings from an earlier analysis have been previously saved). These analyses can be carried out through the "Moldscan" menu of the "Control" screen, accessible in the "Control" tab INCOE 1/17 Page 31

33 The following actions can be performed in the "Moldscan" menu: Icon Action Perform full mold analysis on selected zones and a confi rmation dialogue will ask to confirm the action Warning: A full analysis cannot be performed out during production Rapid mold analysis on selected zones After any analysis, full or rapid, the user must save the calculated values as reference values in order to keep them ( Mold monitoring Through the mold monitoring screen the user can quickly assess the operation and consumption of the control system. The mold monitoring screen is accessible in the "Control" tab. 'Electrical diagnosis' feature 'Power monitoring' feature 'Consumption' feature 'Reference values' feature The mold monitoring offers 4 features. Each of these features are displayed in a table containing the following 4 columns: 1. Zones by groups 2. Reference value 3. Measured value 4. Current value in % These details can be viewed zone by zone, by pressing ' ' on the row of a particular group. The Other row gives details of zones which have not been assigned to a group. The All row gives details of all the cabinet s zones, giving a view of the unit s total consumption. Note: The user can only have valid reference values if a mold analysis has been completed and the result has been saved The control system can perform rapid mold analyses for its own purposes, in which case the latest readings displayed in this screen are those done by the system Page INCOE 1/17

34 'Electrical diagnosis' feature: This feature displays the maximum power, the rated current, or the resistance measured on the mold during the last analysis completed and saved. Current diagnosis Resistance Power diagnosis The user can access the power diagnosis display by pressing on the icon, the current diagnosis by pressing on the icon, and the resistance display by press on the icon. 'Power monitoring' feature: This feature displays the average power percentage applied to maintain the mold's temperature. The reference value is calculated once the temperature has been stabilized INCOE 1/17 Page 33

35 'Consumption' feature: This feature displays the instantaneous and maximum consumption of the mold zones. 'References' feature: This feature displays the saved reference values. The following actions can be performed: Icon Action Save latest readings (saved readings are updated accordingly) Reset saved readings (except the temperature gradient reading) Page INCOE 1/17

36 3.1.4 Configuration files Configuration files enable the user to store the whole configuration of the Hot Runner system for a given mold and production. It includes the configuration of the control zones, all groups, the unit s general configuration, the type of ramp and its configuration, and the electrical analysis of the mold (saved readings). Before creating a confi guration fi le, the user should: 1. Switch off heating in the zones in the Control tab, Control screen, select all zones (selection menu then Select All ) and switch them off 2. Configure the unit: in the Configuration tab, General configuration screen, configure the various options and confi rm 3. Confi gure the zone groups: 4. Confi gure the temperature control: Switch zone heating on in the Control tab, Control screen, select all zones (selection menu then Select All ) and start 6. To perform a rapid or full analysis of the mold in the Control tab, Control screen, select all zones (selection menu then Select All ) and do a rapid or full analysis (not during production). 8. Save the readings obtained in the "Control" tab, "Mold monitoring" screen, 'Reference values' mode, press Once these operations have been completed a fi le can be created in the Configuration files screen ( System tab ). List of fi les Details of the selected fi le INCOE 1/17 Page 35

37 Creating a configuration file Pressing brings up the fi le creation screen: The fi elds below can be edited by clicking on the icon for each line: File name Created by (mandatory): the file s name as it will appear in the list of files (optional): the name of the person who created the fi le Mold reference number Product reference number (optional): the number of the mold concerned (optional): the number of the product concerned Notes (optional): notes on the confi guration file Finally, press to confi rm. Hundreds of fi les can be created. Page INCOE 1/17

38 Displaying a confi guration file A fi le s contents can be viewed. 1. Go to the Confi guration fi les screen ( System tab ) 2. Choose the fi le to be displayed in the list on the left (the name of the file is highlighted and data relating to it appear in the fi elds to the right of the list). 3. Press. A new window appears with General configuration (of the cabinet) at the top. Below is a table showing all the zones in the fi le, with their settings Loading a confi guration file Load confi guration fi les using the Configuration files screen ( System tab ): select a file in the left-hand list (the fi le s name is highlighted and data relating to it appear in the fields to the right of the list), then press on the Load icon. Note: Loading a file will delete and replace the unit s current configuration. A confirmation dialogue will appear as a precaution when a file is loaded Updating a confi guration file The contents of a fi le can be updated: 1. Go to the Confi guration fi les screen ( System tab ) 2. Load the fi le to be changed 3. Make the desired configuration changes 4. Go to the Confi guration fi les screen ( System tab ) 5. Select the fi le to be changed in the list on the left (the file s name is highlighted and data relating to it appears in the fi elds to the right of the list). 6. Press Since changing a fi le involves irretrievably deleting the old configuration, a confirmation dialogue will appear each time a fi le is saved INCOE 1/17 Page 37

39 Deleting a confi guration file To delete a confi guration fi le: 1. Go to the Confi guration fi les screen ( System tab ) 2. Select the fi le to be deleted in the list on the left (the file s name is highlighted and its details appear in the fi elds to the right of the list) 3. Press Note: Deleted fi les are irretrievable, a confirmation dialogue box will appear each time a file is saved. To copy a confi guration fi le: Duplicating a confi guration file 1. Go to the Confi guration fi les screen ( System tab ) 2. Load the fi le to be copied 3. Press 4. Complete the form with a different fi le name 5. To confi rm entry press Exporting and importing confi guration files with a USB device A confi guration fi le can only be exported to or imported from a USB flashdrive once the USB fl ashdrive (or a USB hard disk) has been connected to the unit using the USB port on the front. Once the peripheral has been connected, the icon will appear in the Action bar of the Confi guration fi les screen ( File tab ). Press this icon to bring up the double bar of icons and give access to, and. Export a file: To export a confi guration fi le: 1. Go to the Confi guration fi les screen ( System tab ) 2. Choose the fi le to be exported in the list on the left (the name of the file is highlighted and data relating to it appears in the fi elds to the right of the list) Page INCOE 1/17

40 3. Press 4. The navigation screen of the USB device appears. Only directories are displayed 5. Choose the directory in which to export the fi le 6. Press Import a file: To import a confi guration fi le: 1. Go to the Confi guration fi les screen ( System tab ) 2. Press 3. The navigation screen of the USB device appears. Only directories and confi guration files (which end in.mv2) are displayed 4. Navigate the fi le list to choose the file to be imported 5. Press The imported fi le is then present in the list of files INCOE 1/17 Page 39

41 Export a configuration fil e to a USB device in PDF format: To export a confi guration fi le in PDF format 1. Go to the Confi guration fi les screen ( System tab ) 2. Choose the fi le to be exported as a PDF file in the list on the left (the name of the file is highlighted and data relating to it appears in the fi elds to the right of the list) 3. Press 4. The navigation screen of the USB device appears. Only directories are presented 5. Choose the directory in which to record the fi le 6. Press Page INCOE 1/17

42 3.2 Customary use Heating zone management 'Quick change' action bar Various frequent actions can be carried out directly from the Control or Alarms screens as well as in the zone confi guration screen. To do this, select one or more zones ( the icon is then shown in the action bar. Pressing this icon brings up a double bar of icons with the following actions: Icon Action Give access to the Zone confi guration screen Activate/Deactivate selected zones ( Working mode setting) Toggle selected zones between manual and automatic mode ( Working mode setting) Raise/lower set-point of selected zones. Pressing this icon brings up a numerical keypad Activate Boost on selected zones ( Working mode setting) INCOE 1/17 Page 41

43 Increasing/decreasing set-point: Pressing the icon brings up the following numeric keypad: Name of the setting being changed Max value Minimum value Old value New value Pressing the icon will enter an absolute value. Pressing the icon will enter an increment; likewise pressing the icon will enter a decrement First and second set-points The control systems accept two set-points per mode for each of the heating zones ( Working mode and set-points), the First Set Point (SP1) and the Second Set Point (SP2). If the system is confi gured to use the first set-point (SP1), the set-point for an automatically confi gured zone will be Automatic Set-point 1. If the zone is confi gured manually, the power applied will be Manual Value 1. If the control system is confi gured to use the second set-point (SP2), Automatic Set-point 2 or Manual Value 2 will be used. The status bar features an SP1/SP2 indicator showing which set-point the system is currently confi gured to use ( 2.2). Press the It is accessible from all screens. icon to switch between the fi rst and second set-points. Page INCOE 1/17

44 3.2.2 Alarms Viewing alarms Current system alarms can be viewed in the "Alarms" screen in the "Alarms" tab (see section 2.4) Alarm log The log of alarms generated within the system can be viewed on the Alarm log screen in the Alarms tab. In the example shown the alarms are sorted by descending zone number The list can contain up to 1000 alarms. Press the bar at the top of the list to view the alarms sorted by zone number, name, date or alarm type, in increasing or decreasing order. An upturned or downturned triangle marks the sort parameter and shows the direction of sorting (in increasing or decreasing order). Any alarm may be deleted by pressing its line to select it and then pressing. To delete all alarms (for example at the start of a production run): select all lines using the icon, then press INCOE 1/17 Page 43

45 3.3 Advanced features Remote log-in The user may log in to the interface using a VNC client (available at viewer/). When the application has started, enter the interface s IP address which can be found on the Network Confi guration screen (. In the VNC client options, uncheck the setting Adapt to network speed and select Best quality. Check the changes you have made and then press Connect. The application displays the interface and is now operable System information System information gives details of the company and of the unit s configuration. Details of the software version can also be found here. The System Info. screen in the Confi guration tab displays the data. By pressing "More...", you can view detailed information about the system. Page INCOE 1/17

46 Restoring factory settings The icon will restore the cabinet to its original factory settings. All control settings will be reset Loading a company logo When connecting a USB device, the Import company logo icon appears. Logo requirements are to have a fi le named logo.jpg or logo.png on the USB device. Once loaded, the logo appears on the System Info screen, but it will also feature at the top of any PDF fi les generated ( - Export a confi guration fi le to a USB device in PDF format) The logo can be removed at any time by pressing INCOE 1/17 Page 45

47 4 MAINTENANCE INSTRUCTIONS 4.1 Troubleshooting Problem Effects Display Alarm Solutions Open thermocouple Thermocouple pinched Reversed thermocouple Completely cut heater Partially cut heater Grounded heater Drop in temperature Overheating Drop in temperature Drop in temperature Drop in temperature Drop in temperature and status light blinks red The temperature is constant and lower than the desired set-point. Being in low temperature alarm, the symbol appears for the zone in question and status light blinks red. and status light blinks red The symbol appears on the screen at the zone in question and status light blinks red. Fall in posting of real temperature and indication of power different from expected. The symbol appears on the screen at the zone in question and status light blinks red. Cut in controller dealing with the defective zone. The symbol appears on the screen and status light blinks red. Applied power increases. Activated low temperature alarm.triac commands stop and heating ceases Activated low temperature alarm. Activated low temperature alarm. Activated low temperature alarm. Activated low temperature alarm. The percentage of control power increases. Activated low temperature alarm. Fuse blown - Remedy the cut then testing the thermocouple with the ohmmeter - Switch to manual mode if you do not have time to repair or activate the zone slaving allowing you to control with the probe of a nearby zone - Remove the pinching - Switch to manual mode if you do not have time to repair or activate the zone slaving allowing you to control with the probe of a nearby zone - Reverse the polarities - Check connections - Change the heater - Check connections - Change the heater - Too much humidity: dry the heater and change it if necessary - Cabinet switched on, check defective fuses using fusion indicators Cabinet not switched on, replace fuses where the indicator has remained lit Replace with same type of fuse Page INCOE 1/17

48 Oscillations of temperature Clean short-circuit at heater Triac short-circuit Real temperature is unstable Drop in temperature Overheating The posting of real temperature is unstable and possibly the symbols or appear on the screen and status light blinks red. The zone in question is in low temperature alarm. The symbol appears on the screen and status light blinks red. The percentage of power increases. Real temperature increases rapidly. The following symbols appear: or and status light blinks red. Power applied is null. High and low temperature alarms activated. Activated low temperature alarm. Fuse blown Activated high temperature alarm. - Material problem - Mold problem - Too much humidity: dry the heater and change it if necessary - Cabinet switched on, check defective fuses using fusion indicators Cabinet not switched on, replace fuses where the indicator stays lit Replace with same type of fuse. - If the power applied is equal to 100% (controller heats at full power) and the element heats permanently, that means that the triac is in short-circuit - Switch off the cabinet at once - Change the triac or the power card in question - Send the controller for repair (within 24h) Fuse blown The zone heats permanently The zone does not function at cabinet startup. Circuit breaker trips at startup Temperature reading decreases Temperature increases Heater concerned does not heat. No heaters are heating within the mold. The zone concerned is at fault on the screen of the cabinet. The real temperature of the zone in question does not stop increasing. The symbol appears and status light blinks red. No posting on the zone in question. The screen does not light up. Activated low temperature alarm. Activated high temperature alarm. Activated low temperature alarm. System will not power on - Cabinet switched on, check defective fuses using fusion indicators - Cabinet not switched on, replace fuses where the indicator stays lit Replace with same type of fuse - Check the value of the power applied in the PARAM screen - Check all connections as well as the heater element - Check thermocouple card by exchanging it with another zone which functions - Check the fuses of the cabinet - Check the supply voltage - Check the presence of the earth if you are in 400V TRI - Check total installed power INCOE 1/17 Page 47

49 Defective load Material infi ltration Partially deteriorated load Temperature does not increase Material infi ltration Drop in temperature The symbol appears and status light blinks red. The symbol appears and status light blinks red. The symbol appears and status light blinks red. MoldScan alarm activated MoldScan alarm activated MoldScan alarm activated - Change the heater - Dismantle and check the mold - Change the heater Page INCOE 1/17

50 5 PARTIAL SUMMARY OF EXPRESS WARRANTY INCOE CORPORATION warrants to buyer products (or portions thereof) it manufactures to be free from defects in material and workmanship for the periods given in the table below. The warranty term is measured from the date of shipment from INCOE to the extent provided in the INCOE General Terms and Conditions of Sale referenced below ( INCOE Warranty ). INCOE s exclusive obligation and buyer s exclusive remedy under the INCOE Warranty is limited to repair (by INCOE or INCOE s designated representative) or replacement of parts, FOB INCOE, at INCOE s discretion. INCOE will assign to buyer whatever assignable warranty INCOE receives on product sold by INCOE but not manufactured by INCOE. The INCOE Warranty and the repair or replacement remedy on INCOE manufactured product and INCOE s obligations on all product sold by INCOE are subject to further conditions, limitations and disclaimers of implied warranties contained in INCOE s General Terms and Conditions of Sale, which are located on our website These are subject to change without notice prior to any sale. Thus, this Partial Summary is not a binding document. The INCOE Warranty does not cover, for example only, the following: Repair or replacement due to normal wear, or damage caused during routine maintenance or use. Damage from failure to follow recommended maintenance and operating procedures, as outlined in any applicable INCOE manual. Damage arising from modifications not included in the procedures in any applicable INCOE manual. Damage to components due to product or mold design. Damage resulting from the use of unauthorized parts, or authorized parts which are supplied, manufactured or modifi ed by procedures not included in any applicable INCOE manual and the parts list. Consequential loss, personal injury, damage to goods and/or equipment, work stoppages, delays, or slowdowns in production. Transportation charges and local sales taxes for replaced or repaired parts. Expenses resulting from meeting local codes and standards. Normal maintenance and perishable items. Hot Runner Systems & Components Other Than Wear Components 1 Year Wear Components Including Thermocouples, Valve Gate Sleeve Seals (Pin Seals), Valve Gate Seals, Tips & Valve Pins 6 Months Threaded Nozzle Hot Runner Systems Total of 3 Years Leak Free Controllers (Temperatures/Valve Gate) 2 Years Nozzle Heaters 3 Years All other Goods (including Services) 90 days If replacement parts are to be furnished under the INCOE Warranty, the buyer must submit a purchase order for the replacement parts and return the failed part to INCOE. Replacement product will be sent promptly on receipt of purchase order. Upon return of the part and approval by INCOE, a credit memo will be issued if the part is covered under INCOE Warranty. Failure to return the failed part within 30 days of receipt of the replacement part will result in rejection of the warranty claim and the waiver of any such claims. Parts may not be returned without a return authorization number from INCOE. Returned parts must be properly identifi ed with a tag showing INCOE job number, return authorization number and date, and be packaged so as to avoid further damage in shipping, and shipped to the location specified by INCOE. The INCOE Warranty may be superseded only by a specific individual contract signed by an INCOE officer. ( ) INCOE 1/17 Page 49