MV2 SERIES Temperature Controller. Instruction Manual

Transcription

1 MV2 SERIES Temperature Controller Instruction Manual

2 1 INTRODUCTION pg. 3 2 PRINCIPLE OF OPERATION pg. 3 3 GENERAL CHARACTERISTICS OF THE DEVICE pg. 4 4 GENERAL CHARACTERISTICS OF THE POWER CARDS pg. 5 5 GENERAL CHARACTERISTICS OF THE THERMOCOUPLE CARDS pg. 5 6 CONNECTIONS WITH THE ELECTRICAL SUPPLY NETWORK pg. 5 7 OPERATION AND INSTALLATION REQUIREMENTS pg. 6 8 DEFINITION OF APPLICABLE EC STANDARDS pg. 6 9 INSTRUCTIONS FOR INSTALLATION pg INSTRUCTIONS OF USE pg Diagrams pg Conditions of Safety pg Thermocouples pg Power Control pg Alarms and change of set point pg Communication Link pg FIRST START UP pg GENERAL PRESENTATION OF THE INTERFACE pg Status Light pg Color touch screen pg Contextual assistance pg Locking/Unlocking of the user interface pg Screen captures pg Navigation and screens pg CONTROL OF HEATING ZONES pg Details of the heating zones pg Changing the number of zones displayed pg Selection pg Groups of zones pg Creating a group of zones pg Viewing a zone group pg Deleting a zone group pg Configuration pg Naming of zones and assignment to groups pg On/Off pg Mode and set-points pg Temperature alarm trigger points pg Configuring the boost value pg INCOE 11/14 Page 1

3 Power monitoring pg Back-up probe pg Quick configuration changes pg Raising/Lowering the set-point pg First and second set-points pg Electrical analysis of the mold pg Readings pg Comparing new and saved reading pg Results pg ALARM LOG pg GENERAL CONFIGURATION pg Temperature units pg Changeover to manual if a thermocouple fails pg Automatic current monitoring pg Boost duration pg Maximum and minimum set-points pg Alarm output pg Restore factory settings pg START UP RAMPS pg CONFIGURATION FILES pg Before creating a configuration file (commissioning a mold) pg Loading a configuration file pg Updating a configuration file pg Deleting a configuration file pg Copying a configuration file pg Exporting and importing configuration files with a USB stick pg Export a file pg Import a file pg REGIONAL PARAMETERS pg MAINTENANCE INSTRUCTIONS pg Table of defects pg Procedure to be followed for injection controls pg. 40 Procedure to be followed by maintenance personnel pg Procedure to replace a power control card pg Procedure to replace a thermocouple card pg List of spare parts pg PARTIAL SUMMARY OF EXPRESS WARRANTY pg GLOBAL OFFICES AND SERVICE CONTACTS pg. 44 Page INCOE 11/14

4 1 INTRODUCTION A temperature controller to heat and maintain at temperature the hot runner system located in a mold. 2 PRINCIPLE OF OPERATION The MV2 range of regulators is dedicated to applications comprising a high number of zones to be controlled.. CPU Microprocessor runs max. 24 zones of regulation CPU Microprocessor runs max. 24 zones of regulation CPU Microprocessor runs max. 24 zones of regulation The control of 24 zones is managed by a single microprocessor which interacts with modular charts dedicated to the following functions: Acquisition card for a temperture zone. Power control card for a zone of regulation INCOE 11/14 Page 3

5 3 GENERAL CHARACTERISTICS OF THE DEVICE The controllers are subject to directive EC 73/23 known as Low voltage and respect EN standard Each machine is equipped with an electric feed cable dimensioned according to the maximum acceptable intensity. NOTE: During operation, during the phase of rise in temperature of the regulators and according to the percentage of power used by each regulator, it may be that the intensity of the neutral is higher than the intensity on one of the three phases. This overcurrent is controlled by the principal circuit breaker located at the back of the box. Power consumption depends on the nominal power output of heated elements and the number of regulators used. At the back of the device there is a label indicating: The job number: indicates when the machine was manufactured (Ex: 01220B for 20/12/00, B is an indicator). The standard: machine reference (MV2-L-S32: : L-size cabinet, 32 zones 15A type). The frequency used: the boxes are designed to function indifferently at 50 or 60 Hz. The three-phase voltage is either 230V or 400 V with required grounding. Acceptable useful maximum intensity: depends on the section and length of the electric cable. There are other labels indicating: The diagram of thermocouple connections. The diagram of heating resistance connections. It is imperative to respect the connection instructions, or run the risk of damaging the equipment. The general characteristics of the machine are as follows: Nominal feed voltage 230 V three-phase current To specify with the order 400 V three-phase current To specify with the order Nominal range of feed voltag e + ground V 230 V three-phase current V If 400 V three-phase current + ground Frequency of feed 50/60 Hz Class III according to standard EN Dimensions of the machine are summarized below: Model Height Width Depth Weight (example) Size L 1152 mm 347 mm 762 mm MV2-L-S48: 95 kg Page INCOE 11/14

6 4 GENERAL CHARACTERISTICS OF THE POWER CARDS The controllers are subject to EC directive 73/23 known as Low voltage and respect EN standard The power cards (according to the configuration of the controller in the order) which equip control machines of the MV2 Series are described below: Card 16A Card 15A Nominal feed voltage 230 V 230 V Nominal range of feed V V voltage Frequency of feed 50/60 Hz 50/60 Hz voltage Maximum power 3600 W 3400 W provided Protection fuse 16 A type Gg 10x38 15 A type FA 6.3x32 Length 95 mm 75 mm Width 55 mm 53 mm Weight 640 g 260 g 5 GENERAL CHARACTERISTICS OF THE THERMOCOUPLE CARDS The controllers are subject to directive EC 73/23 known as Low voltage and respect EN standard The characteristics of the thermocouple cards are as follows: Nominal feed voltage Type of thermocouple Length Width Weight 12 V continuous J or K 80 mm 42 mm 22 g 6 CONNECTIONS WITH THE ELECTRICAL SUPPLY NETWORK Connection of the ground conductor is required. It is imperative to respect the connection diagrams under penalty of serious damage to equipment. WARNING: The ground must obligatorily be connected, - if not any operation is impossible. The safety circuit on the synchronization card, reference RSYNC, will activate the circuit breaker located on the bottom of the controller INCOE 11/14 Page 5

7 7 OPERATION AND INSTALLATION REQUIREMENTS Installation in an industrial and non-wet environment. Range of operating temperatures: from -10 C to +60 C. Handling: while rolling the case. Unpacking: avoid shocks at all costs. 8 DEFINITION OF APPLICABLE EC STANDARDS Generic emission standard for industrial environment: EN Generic immunity standard for industrial environment: EN INSTRUCTIONS FOR INSTALLATION If the environment and installation requirements differ from the C.E.M test conditions, it is up to the fitter to lay out one or more filters, and possibly, a transformer device between the network and the feed, as well as the essential shieldings and complementary protections required for the C.E.M. Page INCOE 11/14

8 10 INSTRUCTIONS OF USE 10.1 DIAGRAMS The overall diagrams are in appendix. The electrical diagrams could be provided on request CONDITIONS OF SAFETY The MV2 series controllers are equipped with: A principal breaker for the protection of the tools. An electronic circuit for monitoring voltage for the protection of the machines against ground defects and surges (10% of additional acceptable voltage). Ventilation, filter with frequency of cleaning to be planned. Each power card is protected by: A surge protector (GEMOV) which is used as protection if the power supply of the device exceeds 275 V. A HIGH-SPEED fuse on the phase and the ground which protects the TRIAC against surges (16A or 15A maximum acceptable) THERMOCOUPLES The bodies of temperature measurement are connected via specified connectors fixed at the back of the controller. It can be a question of type J thermocouples (Iron-Constantan), or K (Ni.Cr/NiAL), or of auxiliary entries. For thermocouples, it is absolutely necessary to respect the poles indicated on the connection diagram. There are standards which define the color of thermocouple wires, for example: Couple J (+ = Fer, - = Constantan): French Standard: Iron: Yellow / Constantan: Black German Standard: Iron: Red / Constantan: Blue English Standard: Iron: Yellow / Constantan: Blue European Standard: Iron: Black / Constantan: White American Standard: Iron: White / Constantan: Red The + is the wire which can be easily identified thanks to a magnet. K couples (+ = Chromel or Nickel-chromium, - = Alumel or Nickel-aluminium) French Standard: Chromel: Yellow / Alumel: Blue German Standard: Chromel: Red / Alumel: Green English Standard: Chromel: Red / Alumel: Blue European Standard:Chromel: Green / Alumel: White American Standard: Chromel: Yellow / Alumel: Red The connecting cables between thermocouples J or K and the plugs at the back of the controller must at all costs be of the same metal as the thermocouple (compensation cable) so as not to introduce parasitic thermocouples INCOE 11/14 Page 7

9 10.3 THERMOCOUPLES (CONT D) Example connections diagram. Connections specified and configured on order. 1) BASE PLATE THERMOCOUPLE 32 BR. 10A MALE HARTING HAN A Type ) BASE PLATE THERMOCOUPLE 16 BR. 16A MALE HARTING HAN E Type POWER CONTROL For 15A regulators, the heated elements are connected to the female plug HARTING HAN E 16 Pins 16A located at the back of the controller. Example connections diagram. Connections specified and configured on order BASE PLATE POWER 16BR. 16A FEMALE HARTING HAN E Type Example connections diagram. Connections specified and configured on order. BASE PLATE POWER 32BR. 10A FEMALE HARTING HAN A Type WARNING: Each zone N (or module) must indeed correspond to the same N of the thermocouple and heated element. INCOE cables for thermocouples (ref. 3CJ6 or 3CJ4) and power (ref. 3CP6 and 3CP4 ) are equipped with locating pins to avoid inversions. Page INCOE 11/14

10 10.5 ALARMS AND CHANGE OF SET POINT It is possible to remotely modify the work specification in the instructions of day before and vice versa via a switch connected between terminals 1 and 4 of the 2nd plug SET POINT AND ALARMS. Closed contact = 2nd set point. Open contact = 1st set point. It is possible to activate an alarm (siren, indicator light ) from the 2nd plug SET POINT AND ALARMS. There are 2 alarm exits programmable among the system requirement screens: (see the parameter list in the paragraph 15.6) For alarm 1: contact between markers 5 and 2. For alarm 2: contact between markers 6 and 3. Label stuck on the upper lid of the controller (version 4U) or at the back of the controller (version 10U or more): nd set point Alarm Alarm COMMUNICATION LINK A digital communication link with a computer or Ethernet network is possible. 11 FIRST START UP Connect the controller power supply cord to the appropriate network. Check all the connections arriving in and departing from the controller. Turn on the controller with the breaker switch located on the front face. After a few seconds, the presentation screen appears. Type of box Model number Software version INCOE 11/14 Page 9

11 12 GENERAL PRESENTATION OF THE INTERFACE 12.1 STATUS LIGHT The Status Light is a light in the front of the cabinet. This indicator has two functions: Indicate the current set point (C1/C2) : Status light is blue if the system of control is the first set point (C1) and green when the system of control is the second set point (C2) (cf. 13.7) to have more information on these two set points). Indicate if a defect has been detected: in this case the status light flickers red COLOR TOUCH SCREEN The user interface always presents the 3 following elements: At the bottom of the screen, the status bar. On the right side, the action bar. At the top of the screen, 5 navigation tabs. Navigation tabs Action bar Name of the configuration file loaded Status bar Contextual assistance Interface e locking Screen capture Name of the screen Indicator of activated power monitoring Information on the screen in progress Alarm indicator Date and time Set point in progress indicator The status bar contains general information on the status of the system such as the date and time, the current configuration file, the name of the current screen (and other contextual information in connection with the screen), the current set point (C1/C2), alarm status and power monitoring status. On the left-hand side, three buttons which act on the graphic user interface are also present. The contents of the action bar depends on the screen currently in view and presents buttons which act directly to adjust the control box. Page INCOE 11/14

12 CONTEXTUAL ASSISTANCE The question mark button allows to activate or deactivate the contextual assistance by posting a description over the icons. It is useful during the phase of study of the user interface or at a time of doubt about the meaning of an icon LOCKING / UNLOCKING OF THE USER INTERFACE At the start, the user interface is not locked. When the open padlock button is pressed, a numeric keypad appears. password Enter to lock the interface and confirm. The interface can be unlocked while pressing the padlock button (which is now closed ) and entering once again the code before confirming INCOE 11/14 Page 11

13 SCREEN CAPTURES The camera button is present when a USB key or hard disk is connected. This button enables you to capture screens and safeguard them at the stem of your USB device. NOTE: Please wait a few seconds before withdrawing a USB device to be assured that your screen capture is completely written on the device NAVIGATION AND SCREENS The five navigation tabs at the top of the screen are for the five different views provided in the user interface: control view, alarm view, MoldScan view, file view and configuration view. The current view depends on which tab is selected. Each tab gives access to a set of screens. For instance, if you want to check the power used by the system, you need to touch the MoldScan view tab. This view s three screens are represented by thumbnails. Touch the tab to return to this display To go to a screen touch its thumbnail Measures MoldScan MoldScan Power Results MoldScan Current Results Touch the Moldscan Power Results thumbnail to go to that screen. If you then want to check current use, click once more on the MoldScan view tab and selecting the Moldscan Current Results thumbnail. The table below gives a summary of the screens available under the various tabs. Tab Screen Regulation Regulation Page INCOE 11/14

14 NAVIGATION AND SCREENS (CONT D) Tab Screen Alarms Alarms Alarm log Moldscan readings MoldScan Moldscan Power Results Moldscan Current Results Files Configuration files INCOE 11/14 Page 13

15 NAVIGATION AND SCREENS (CONT D) Tab Screen General configuration Ramp configuration Configuration Regional Parameters System information Page INCOE 11/14

16 13 CONTROL OF HEATING ZONES The three screens Regulation, Alarms and Moldscan readings 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. The Regulation and Alarms screens The Moldscan readings screen 13.1 DETAILS OF THE HEATING ZONES The information displayed for each zone also depends on the selected degree of zoom. Zoom 8, 12, 16 zones 24 zones 48 zones The Regulation and Alarms screens Temperature Status % power Current Set-point Configuration Name of zone Group The Moldscan readings screen Temperature gradient Installed power Resistance Maximum current Name of zone Group Temperature Temperature Status gradient % power Installed power Current Set-point Configuration Resistance Name of zone Group Temperature Status Gradient/Installed power Configuration Maximum Resistance / current INCOE 11/14 Page 15

17 13.1 DETAILS OF THE HEATING ZONES (CONT D) The meaning of the various status icons is described below:, and : the temperature of the zone is correct, the temperature is below the set-point (Low Temperature alarm) or the temperature is above the set-point (High Temperature alarm). : if this symbol is displayed, a ramp is applied to the zone to raise its temperature gradually to its set-point. The meanings of the configuration icons are given below: : when this icon is displayed the zone is On, if not the zone is Off. or : the zone is in automatic or in manual mode. : when this icon is displayed the zone is in Boost mode. : when this icon is displayed power monitoring is active (see 13.5). : when this icon is displayed a back-up probe is in place (see 13.5) CHANGING THE NUMBER OF ZONES DISPLAYED It is possible to zoom in or out so as to display more or fewer zones. This means it is possible to have 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. 48, 24, 16, 12 or 8 zones can be displayed at once. Zoom in or out by swiping a finger from the middle of the grid towards one of the corners (to zoom in, displaying fewer zones) or from one of the corners towards the middle (to zoom out, displaying more zones). 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, you can navigate around the zones present by swiping upwards or downwards: Towards zone 1 Towards zone 40 Number of zones which can be displayed and number of zones currently displayed Page INCOE 11/14

18 13.3 SELECTION It is possible to carry out certain operations on the specifically selected control zones only. These zones can be selected by touching a zone, which is then highlighted in orange: Selected zones Touching an already-selected zone deselects it. It is also possible to select or deselect more than one zone together, by using the selection menu in the Actions bar. Once this menu has been activated, the Actions bar offers the following actions: Icon Exit the selection menu Action Select zones group by group Select all the unit s zones Deselect all zones Managing groups of zones (see13. 4). The interface must be unlocked for this action to be available INCOE 11/14 Page 17

19 13.4 GROUP OF ZONES Zone groups have two functions: Making it easier to configure the unit by selecting the group of zones whose configuration is to be modified. Specifying which zones are lines and which are blocks, to improve their regulation. Once the interface is unlocked (see ) touch the Manage Groups button bring up the Manage Groups screen: on the selection menu (see 13.3) to List of groups (empty in this case) Here it is possible to create a group, delete a selected group or view a selected group. It is also possible to exit the Manage Groups screen by touching the button. Page INCOE 11/14

20 CREATING A GROUP OF ZONES To create a new group of zones, touch. The screen below appears: Name of group Type of group (blocks or lines) Touch the button to name a group and assign a group type: group of blocks or group of lines. WARNING: It is very important to specifiy the right group type in order to ensure the heating of the group s zones is properly regulated. The group is created when the button is pressed in the Actions bar. Touching the button on the Actions bar will cancel its creation VIEWING A ZONE GROUP View a group by selecting it in the list of groups and touching the button. The screen below appears: Name of group Type of group (blocks or lines) Zones assigned to this group The 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 > buttons INCOE 11/14 Page 19

21 DELETING A ZONE GROUP It is possible to delete a zone group by selecting it in the list of the groups and touching the button. You will be asked to confirm the deletion. The group will be deleted if the button is pressed in the Action bar. Touching the button 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 CONFIGURATION Before you can configure the heating zones you should navigate to the Regulation screen ( Control tab) or the Alarms screen ( Alarms tab). To configure a heating zone, touch it twice ( double-click ). To configure more than one heating zone simultaneously, select a number of zones (see 13.3) and touch one of them twice ( double-click ). This zone then becomes the reference zone. This brings up the zone configuration screen: Selected zones Reference zone s name and number On/Off Group Powerm monitoring Back-up probe Mode Set-points and manual values Boost value The values shown on the screen are those for all the selected zones. Any values which are not identical for all the selected zones are shown as: ---. Only changes from these values will in fact be applied to the selected zones on validation. The modified values appear in red. Page INCOE 11/14

22 NAMING OF ZONES AND ASSIGNMENT TO GROUPS You can change the name of the selected zone(s) by touching the button. If more than one zone is selected, the selection number is appended to the name entered. For instance, if the zones 2, 5 and 7 are selected and the name Block is entered, the zones will be named Block 2, Block 2 and Block 3. Zones can be assigned to a group by touching the < and > buttons ON / OFF The selected zones can be turned on or off by touching the ON and OFF buttons MODE AND SET-POINTS The heating zones can be regulated automatically or manually. In automatic mode a set-point is specified in C or in F and the INCOE control system automatically selects the power to be applied to the zone in order to bring that zone up to the selected temperature and keep it there. Automatic mode needs the zone to be fitted with a working thermocouple probe or, failing that, a back-up probe to have been configured (cf ). Under this mode the temperature is monitored and alarms can be flashed up (see ). In manual mode a level of power to be applied can be specified manually. The temperature is not monitored at all in this case. The INCOE control system allows the user to configure two temperature set-points for automatic mode, and two levels of power to be applied in manual mode. The choice between these two set-points or these two power levels is made according to the set-point mode chosen for the unit (C1/C2). See 13.7 for further details TEMERATURE ALARM TRIGGER POINTS Zone temperature is monitored in automatic mode. If this temperature rises above or falls below the relevant set-point, a High or Low Temperature alarm is triggered. The alarm trigger levels can be configured at this screen. If these trigger levels are set at ± 5 C and the zone s set-point is 150 C, a Low Temperature alarm flashes up if the zone s measured temperature falls below 145 C, and a High Temperature alarm if the temperature rises above 155 C INCOE 11/14 Page 21

23 CONFIGURING THE BOOST VALUE In automatic mode the Boost allows the user to raise or lower a zone s temperature set-point momentarily. The current set-point is raised or lowered by the boost amount, which can be set at this screen. Old value, followed by new value For a positive boost amount For a negative boost amount NOTE: The duration of the Boost is the same for all heating zones, and can be configured at the General Configuration screen (see 15.4) POWER MONITORING How the power monitoring system works: Temperature % Power Setpoint change +5 C Setpoint -5 C Alarm Average power calculation over 5 minutes Automatic monitoring around tolerances Average power calculation over 5 minutes Automatic monitoring around tolerances The basic idea is to monitor the power applied to the load so as to notice if one of various parameters drifts from its proper value (for example: excessive power consumption, etc.): a change in the the power percentage signals an abnormal physical change in the zone under regulation. Page INCOE 11/14

24 POWER MONITORING (CONT D) When a zone under control is being monitored, the system waits for the power applied to the load to stabilize before looking for divergences from the power percentage. Divergences are detected by comparing the amounts of power applied with the safety tolerances set by the user. 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 file is loaded. When the monitoring system detects an anomaly, it flashes up an alarm symbol for the faulty zone and triggers an alarm signal at the back of the unit, allowing a visual alert (alarm indicator light) and / or deactivation of the machine cycle (alarm touched). Power monitoring can be activated at this screen, and the tolerance set. The level is expressed as a percentage of the power normally applied to the zone. For instance, if the power applied to the zone to keep it at 180 C 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% BACK-UP PROBE A back-up probe can be configured at the bottom of the screen to cope with the problem of defective thermocouple probes. For instance, if the zone 1 thermocouple malfunctions during production then the job can be finished by configuring the zone to use the thermocouple probe for zone 10, whose heating characteristics are known to be similar QUICK CONFIGURATION CHANGES Various frequent actions can be carried out directly from the Regulation or Alarms screens as well as at the zone configuration screen. To do this, select one or more zones (see 13.3), the following actions will appear in the Actions bar: Icon Action Activate/Deactivate the selected zones (see ) Toggle the selected zones between manual and automatic mode (see ) Activate boost on the selected zones Raise/lower the selected zones set-point. Touching this button brings up a numerical keypad INCOE 11/14 Page 23

25 13.7 RAISING / LOWERING THE SET-POINT Touching the button brings up the following numerical keypad: Name of the variable being changed Old value & new value Touching the button will enter an absolute value. Touching the button will enter an increment; likewise touching the button will enter a decrement FIRST AND SECOND SET-POINTS The INCOE control system accepts two set-points per mode for each of the heating zones (see ): the First Set- Point (C1) and the Second Set-Point (C2). If the system is configured to use the First Set-Point (C1), the set-point for an automatically configured zone will be Automatic Set-Point 1 (see ). If the zone is configured manually, the power applied will be Manual Value 1 (see ). If the control system is configured to use the Second Set-Point (C2), the Automatic Set-Point 2 or Manual Value 2 will be used (see ). The status bar features a C1/C2 indicator showing which set-point the system is currently configured to use, the first or the second (see 12.2). To toggle between the first and second set-points, go to the Regulation screen ( Regulation tab) or on the Alarms screen ( Alarms tab ) and touch the button in the Actions bar. Page INCOE 11/14

26 13.9 ELECTRICAL 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). Zone s temperature gradient (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 at the start of the analysis; they are then heated to 180 C. 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 failure. Current difference fault (only if the readings from an earlier analysis have been saved). These analyses can be carried out via the Moldscan readings screen, accessed from the MoldScan tab. Two kinds of reading can be viewed on this screen: The latest readings, shown only for consultation and for comparison with the saved readings. Saved readings: the values used by the INCOE control system for fault detection. The status bar indicates which readings are being displayed: Readings currently being displayed INCOE 11/14 Page 25

27 READINGS (CONT D) NOTE: The INCOE control system can carry out rapid mold analyses for its own purposes, in which case the latest readings displayed on this screen are those done by the system. Which actions can be carried out depends on which values are currently being displayed. The following actions can be carried out when Latest Readings are being displayed: Icon display Saved Readings. Action carry out full mould analysis on the selected zones. A confirmation dialogue will ask you to confirm the action. Warning: A full analysis cannot be carried out during production. rapid mould analysis on the selected zones. Save latest readings ( saved readings is updated accordingly). The following actions can be carried out when Saved Readings are being displayed: Icon Action display Latest Readings. This deactivates monitoring Reset Saved Readings (except the temperature gradient reading). Page INCOE 11/14

28 COMPARING NEW AND SAVED READINGS A zone s latest readings can be compared with its saved readings by double-clicking the zone. This brings up the detailed Moldscan readings screen: Navigating among zones Saved readings Latest readings Navigate from one zone to another by clicking on the < and > buttons at the top of the screen RESULTS The power and current Results screens provide a quick way of finding out the maximum power (or current) needed for a mold to work, and the levels currently in use. NOTE: These Results are only available once a rapid analysis has been carried out and the readings have been saved (see ). The power and current Results screens can be accessed in the MoldScan tab. Each of these screens presents a table with the zones in the first column (by group), the maximum power or current in the second and the current level of consumption in the third. These details can be viewed zone by zone, by touching the line for a particular group. The Other line gives details of those zones which have not been assigned to a group. The All line gives details of all the unit s zones, giving a view of the unit s total consumption INCOE 11/14 Page 27

29 14 ALARM LOG The log of alarms generated within the system can be consulted on the Alarm log screen in the Alarms tab. In the example shown they are sorted by descending zone number The list can contain up to 1000 alarms. Touch the bar at the top of the list to present 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 touching its line to select it and then touching the button. It is also possible to delete all alarms (for example at the start of a production run): select all lines with the button then touch the button. Page INCOE 11/14

30 15 GENERAL CONFIGURATION The unit s general configuration can be accessed via the General Configuration screen under the Configuration Tab. Temperature units Automatic current monitoring Boostd uration Action if a thermocouple fails Alarm output Maximum and minimum set-points 15.1 TEMPERATURE UNITS The preferred temperature units ( C or F) will be used throughout the interface CHANGEOVER TO MANUAL IF A THERMOCOUPLE FAILS It is possible to have the configuration of the zone concerned automatically changed to manual mode if a particular thermocouple fails INCOE 11/14 Page 29

31 15.3 AUTOMATIC CURRENT MONITORING If this option is activated, the control system carries out MoldScan rapid analyses at intervals to detect any faults. For further details (see ) BOOST DURATION The duration of the Boost function can be set in this field. For further details on this function (see ) MAXIMUM AND MINIMUM SET-POINTS Maximum and minimum set-points can be specified for automatic mode ALARM OUTPUT The unit has two Alarm outputs which can be used to control a button or an indicator light (see 10.5). When and how these outputs are controlled can be configured on this screen. The options possible are: High Temperature Alarm: the output is implemented if a zone is in the High Temperature alarm state. Low Temperature Alarm: the output is implemented 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 Temperature or the Low Temperature alarm state. High or Low Temperature Alarm (except on initial warm-up): the output is implemented if a zone is in either the High Temperature or the Low Temperature alarm state, unless the system is carrying out its initial warm-up. MoldScan: the output is implemented if a fault is detected by a MoldScan rapid analysis (see 13.9) or by power monitoring (see ). All: the output is implemented if one of the conditions above occurs RESTORE FACTORY SETTINGS Press the button to restore factory settings on the device. All control settings will be reset. Page INCOE 11/14

32 16 START-UP RAMPS On start-up, the zones under automatic mode are heated gradually until they reach their operating set-point. There are four possible types of start-up ramp: Duration: the system keeps the temperature at 100 C for a programmable length of time (default 5 minutes). Gradient: the system applies a number of programmable set-point staging-posts (default 20 C/min) until the operating set-point is reached. When power is turned on the first staging-post is set at 50 C. When the temperature reaches the set-point, the ramp is terminated. Synchronized: the system automatically selects those 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 block or line groups (see 13.4). Initially all the zones in block type groups are heated in a synchronized ramp, while those zones in line type groups are kept at 100 C. When all the zones in the block 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 lines groups. The staggered ramp is terminated when all zones have reached their operating set-points. Power can be restricted at the start of the ramp in all four modes. The default level to which power is restricted is 15%. The Ramps screen, which can be accessed from the Configuration ramp) to be selected and its associated variables configured. tab, allows the start-up mode (type of Start-up ramp selection Power restriction Ramp-specific variable Power restriction can be configured whatever the type of ramp selected (default 15%). Depending on the type of ramp selected, another variable 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 specific variable INCOE 11/14 Page 31

33 17 CONFIGURATION FILES 17.1 BEFORE CREATING A CONFIGURATION FILE (COMMISSIONING A MOLD) Configuration files enable you to store the whole configuration of the heating system for a given mold and manufacture. It includes the configuration of the control zones and any 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 configuration file, therefore, you should: 1. Switch off heating in the zones: in the Regulation tab, Regulation 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 confirm. 3. Choose the type of start-up ramp: in the Configuration tab, Ramps screen, select the ramp type, configure power restriction and the ramp s specific variable, then confirm. 4. Configure the zone groups (see ). 5. Configure the heating zones (see 13.5). 6. Turn zone heating On: in the Regulation tab, Regulation screen, select all zones (selection menu then Select All ) and start. 7. Carry out a rapid or full analysis of the mold: in the MoldScan tab, Moldscan readings screen, select all the zones (selection menu then Select All ) and do a rapid analysis or full analysis (not during production). 8. Save the readings obtained. Once these operations have been completed a file can be created in the File Configuration screen ( Files tab). Page INCOE 11/14

34 17.1 BEFORE CREATING A CONFIGURATION FILE (COMMISSIONING A MOLD (CONT D) List of files (empty in this case) Details of the selected file Touching the brings up the file creation screen: Here the fields below can be edited by clicking on the button for each line: File name (mandatory): the file s name as it will appear in the list of files. Created by (optional): the name of the person who created the file. Mold reference number (optional): the number of the mold concerned. Product reference number (optional): the number of the product concerned. Notes (optional): notes on the configuration file. Finally, you need to give confirmation. Many hundreds of files can be created INCOE 11/14 Page 33

35 17.2 LOADING A CONFIGURATION FILE Configuration files are loaded using the File Configuration screen ( Files tab), selecting a file in the left-hand list (the file s name is highlighted and its details appear in the fields on the right of the list) and clicking on the Load button. 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 CONFIGURATION FILE A file s contents can be updated: 1. Go to the File Configuration screen ( Files tab). 2. Load the file to be changed. 3. Make the desired configuration changes. 4. Go to the File Configuration screen ( Files tab). 5. In the left-hand list select the file to be changed (the file s name is highlighted and its details appear in the fields on the right of the list). 6. Touch the button. Since changing a file involves irretrievably deleting the old configuration, a confirmation dialogue will appear each time a file is saved DELETING A CONFIGURATION FILE To delete a configuration file: 1. Go to the File Configuration screen ( Files tab). 2. In the left-hand list, select the file to be deleted (the file s name is highlighted and its details appear in the fields on the right of the list). 3. Touch the button. Since deleted files are irretrievable, a confirmation dialogue will appear each time a file is saved COPYING A CONFIGURATION FILE To copy a configuration file: 1. Go to the File Configuration screen ( Files tab). 2. Load the file to be copied. 3. Touch the button. 4. Complete the form with a different filename 5. Confirm. Page INCOE 11/14

36 17.6 EXPORTING AND IMPORTING CONFIGURATION FILES WITH A USB STICK A configuration file can only be exported to or imported from a USB stick once the USB stick (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 and buttons will appear in the Actions bar of the File Configuration screen ( Files tab) EXPORT A FILE To export a configuration file: 1. Go to the File Configuration screen ( Files tab). 2. Choose the file to be exported in the list on the left (the name of the file appears in bright and the data relating to it appears in the fields to the right of the list). 3. Touch the button. 4. The navigation screen of the USB device appears. Only the directories are presented: 5. Choose the directory in which to export the file. 6. Touch the button INCOE 11/14 Page 35

37 IMPORT A FILE To import a configuration file: 1. Go to the File Configuration screen ( Files tab). 2. Touch the button. 3. The navigation screen of the USB device appears. Only the directories and configuration files (which ends in.mv2) are presented: 4. Navigate the file list to choose the file to be imported. 5. Touch the button. The imported file is then present in the list of files. Page INCOE 11/14

38 18 REGIONAL PARAMETERS The regional parameters correspond to adjustments of the date, time and language used by the interface. Regional Parameters screen, Configuration view allows to carry out these adjustments. Adjust date and time Choice of language To modify the date, press one of the fields (day, month, year) then scroll with the higher and lower buttons to increase/decrease this field. To modify the date, press one of the fields (hour, minutes) then scroll with the higher and lower buttons to increase/decrease this field. To change the language of the interface, click on the corresponding flag. The modifications are taken into account when the button is selected. In the event of change of language, the interface is reloaded and the Regulation screen is then visible INCOE 11/14 Page 37

39 19 MAINTENANCE INSTRUCTIONS 19.1 TABLE OF DEFECTS Defect Effects Visible on the screen Protections Solutions Cut thermocouple. Drop in temperature. and Status Light flickering red Activated alarm. Cutting of TRIAC commands and cessation of heating. low-level - Remedy the cut by testing the thermocouple with the ohmmeter. - Move into manual mode if you do not have time to repair or activate the breakdown probe allowing you to regulate with the probe of a nearby zone. Thermocouple pinched. Overheating The temperature is constant and lower than the desired set point. Being in low-level alarm, the following symbol appears for the zone in Activated low-level alarm. The following symbol appears to indicate that you are using a breakdown service probe. - To cure the pinching. - Move into manual mode if you do not have time to repair or activate the breakdown probe allowing you to regulate with the probe of a nearby zone. question: and Status Light flickering red The following symbol appears to indicate that you are using a breakdown service probe. Reversed thermocouple. Drop in temperature. Activated low-level alarm. - Reverse the polarities. Completely cut cartridge. Partially cut cartridge. Cartridge grounded. Oscillations of temperature. and Status Light flickering red Drop in Activated low-level temperature. The symbol appears alarm. on the screen at the level of the zone in question and Status Light flickering red Drop in temperature. Drop in temperature. The real temperature is unstable. Fall in posting of the real temperature and indication of power different from expected. The symbol appears on the screen at the level of the zone in question and Status Light flickering red Cut in regulator dealing with the defective zone. The symbol appears on the screen and Status Light flickers red Applied power increases. The posting of the real temperature is unstable and possibly the symbols or appear on the screen and Status Light flickers red. Activated low-level alarm. The percentage of control power increases. Activated low-level alarm. Fuse fusion High and low-level alarms activated. - Check the connections. - Change the cartridge. - Check the connections. - Change the cartridge. -Too much humidity: dry the cartridge and if necessary change it. - Box switched on, check using fusion indicators of the defective fuses. Box not switched on, replace fuses where the indicator has remained lit. Replace with same type of fuse. - Material Problem. - Moldl Problem. Page INCOE 11/14

40 19.1 TABLE OF DEFECTS (CONT D) Defect Effects Visible on the screen Protections Solutions Clean shortcircuit at the cartridge level. Triac shortcircuit. Drop in temperature. The zone in question is in low-level alarm. The symbol appears on the screen and Status Light flickers red. The percentage of power increases. Overheating The real temperature strongly increases. The following symbols appear: or and Status Light flickering red The power applied is null. Activated low-level alarm. Fuse fusion - Too much humidity: dry the cartridge and if necessary change it. - Box switched on, check using fusion indicators of the defective fuses. Box not switched on, replace fuses where the indicator has remained lit. Replace with same type of fuse. Activated high alarm. - If the power applied is equal to 100% (regulator heats at full power) and the element heats permanently, that means that the triac is in short-circuit. - Switch off the box at once - To change the triac or the control card in question. - Send the regulator to INCOE for repair. Fuse fusion. Temperature reading decreases. The zone concerned is at fault on the screen of the box. Activated low-level alarm. - Box switched on, check using fusion indicators of the defective fuses. Box not switched on, replace fuses where the indicator has remained lit. Replace with same type of fuse. The zone heats permanently. The temperature increases. The real temperature of the zone in question does not stop increasing. The symbol appears and Status Light flickering red Activated high alarm. - Check the value of the power applied in the PARAM screen. - Check all connections as well as the cartridge element. The zone does not function at startup of the box. Heating cartridge in question does not heat. No posting on the zone in question. Activated low-level alarm. - Check the thermocouple card by exchanging it with another zone which functions. - Check the fuses of the box. Circuit breaker general of the box triggers at startup. No cartridge heats within the mold. The screen does not light up. Box not on. - Check the supply voltage. - Check the presence of the ground if you are in 400V TRI. - Check total installed power. Defective load Material infiltration The temperature does not increase. Material infiltration The symbol MoldScan alarm activated appears and Status Light flickering red The symbol MoldScan alarm activated - Change the cartridge. - Dismount and check the mold. Partially deteriorated charge Drop in temperature. appears and Status Light flickering red The symbol MoldScan alarm activated appears and Status Light flickering red - Change the cartridge INCOE 11/14 Page 39

41 PROCEDURE TO BE FOLLOWED FOR INJECTION CONTROLS Example of breakdown: a mold zone does not go up to the desired set point. Look at the number of the zone at fault. Go to the Regulation screen, Regulation view and modify the level of zoom to reveal the power applied (red bar). Check if the bar is at maximum. If the power applied posted on the screen is equal to 100% and the zone is still not heating that can come from 3 causes: The element to be heated is oversized compared to what the INCOE power card can deliver and in the medium-term the fuses will roast. (Max. intensity, 16A or 15A according to versions). The power card has 2 fuses (one on the phase and the other on the ground. Perhaps both or only one is defective. There is between the exit of the power card and the connection in the mold a disconnected or badly connected wire. The element can be also defective. Beyond these observations, any intervention inside the Series M boxes must be made by a competent person. PROCEDURE TO BE FOLLOWED BY THE MAINTENANCE PERSONNEL Example of breakdown: a mold zone does not go up to the desired set point. Visualize the defect on the zone in question on the Regulation screen, Regulation view. If no indicator ignites, switch off the box using the circuit breaker. Using a tester, check if the fuses are good (if the indicators of fusion are out of service). If the fuses are good, then switch the box back on. Verify using the tester whether there is 230V AC voltage at the exit of the power card (at the level of the 2 blue or red clips depending on the versions). Note: it is necessary that the zone is in manual mode with a set point equal to 100% and that the other zones are all switched OFF. If there is 230V AC, this means that the breakdown does not come from the power card. Switch off the box. Test the continuity of wires between the exits on clips, the harting plugs at the back of the box and the wiring at mold level. IMPORTANT NOTE: During operation, during the phase of rise in temperature of the regulators and according to the percentage of power used by each regulator, it may be that the intensity of the ground is higher than the intensity on one of the three phases. This overcurrent is controlled by the principal circuit breaker located at the back of the contoller. Power consumption depends on the nominal power output of heated elements and the number of regulators used. In addition: Any intervention on the device will have to be carried out by a competent person. Any changed part must have the same characteristics. Controller must be disconnected from power source before performing maintenance inside of the enclosure. Detect the site of the power card corresponding to the zone at fault. On this one there are 2 indicators of fuse fusion which are located beneath each fuse. They indicate whether one of the two fuses is out of service. If you see one or the two indicators are on, that means that the fuse(s) should be changed. Warning: use the same type of fuse according to the power card version. Page INCOE 11/14

42 19.2 PROCEDURE TO REPLACE A POWER CONTROL CARD 1. Having opened the machine, using an adapted screwdriver, unscrew the screws being used to fix the triac. Then you can pull the card towards you to dislodge it from the 6 point connector. ATTENTION: DO NOT REMOVE THE CARD WITHOUT HAVING UNSCREWED THE TRIAC BEFORE. Example Version 16A Example Version 5A (Also Version 15A) 2. Then hold the card in your hands and remove the 2 thimbles as shown below. Then insert the new card using the reverse operations. Example Version 16A Example Version 5A (Also Version 15A) INCOE 11/14 Page 41

43 19.3 PROCEDURE TO REPLACE A THERMOCOUPLE CARD 1. Box switched off, unscrew the front plate to reach the defective card directly. After having removed the maintenance bar you can draw the card upwards in order to dislodge it from the 2 20-point connectors and 4 black points. 2. Replace and place the new card checking well that the gilded contacts are indeed in the 4-point connectors and black 20-point females. Screw back the maintenance bar. VERIFY THAT ALL THE CONTACTS ARE WELL INSERTED LIST OF SPARE PARTS Ref. Label Quantity 5034 Control card version 16A Control card version 15A Control card version 5A Thermocouple card A Fuse Type UR (10 x 38 mm) Type FA 15A Fuse (6.3 x 32 mm) Type FA 6.3A Fuse (5 x 20 mm) Triac BTA40A / 800B Triac BTA24A / 800B Triac BTA12A / 700B LCD display 240 X 128 pixels Feed 230V/12V-5V 110W Ventilator 230VAC (120 X 120 X 38 mm) CPU board Synchro card Terminal MV2 T Page INCOE 11/14