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PDF - Günther Heisskanaltechnik

1. DIN 1 61 ai CIO M OO Rl OO bis Va 10 sa 10 LIO MJ OO m OG pl 81 96 De en Tox Renderung E Name Positionsplan DAVIDSMEYER amp PAUL GmbH Revision 10 96 DPIS E P2 8 User Manual Hot Runner Systems 15 Z G NTHER Hot Runner Systems Appendix H Addresses HEADQUARTER G NTHER Heisskanaltechnik GmbH Industriegebiet Nord Sachsenberger Stra e 1 D 35066 Frankenberg Eder Germany Phone Fax Modem E mail Internet Germany G NTHER Heisskanaltechnik GmbH Mr Spork Sachsenberger Str 1 D 35066 Frankenberg G NTHER Heisskanaltechnik GmbH Mr Stamm Sachsenberger Str 1 D 35066 Frankenberg WESCHU Mr Grajer Edisonstr 81 D 90431 Niirnberg Industrievertretungen Mr R mhild Thomas Mann Str 4 D 98597 Breitungen Verkaufsbiiro Mr Renz Kreuzweg 26 D 72172 Sulz Neckar Verkaufsbiiro Nord Mr Ilmer Wolkenweher Weg 24 D 23843 Bad Oldesloe 49 64 51 50 08 0 49 64 51 50 08 50 49 64 51 50 08 61 62 info guenther heisskanal de http www guenther hotrunner com Phone Fax E mail Phone 49 01 61 3 60 36 08 Fax 49 64 51 50 08 59 E mail spork guenther heisskanal de Phone 49 01 729 41 12 26 Fax 49 64 51 50 08 59 E mail stamm guenther heisskanal de Phone 49
2. 4 S m 5 witch from 0 to 1 Starting ramp 0 OFF 1 P part I part D part P part I part D part N e D lt 2 e lt D ES lt D Q reserved ramp in minutes duration in minutes d ua lt lt 5 9 2 5 5 o gt E 5 aE P 2 FT T Z N in Z Z itching off parameter 28 unit number reserved reserved g in C Fahrenheit F ising in reserved reserved 5 A a a 6 Im Iu ja G le G 2 313 lt 2 212 Is le a elele e lausibility check 0 OFF 1 ON G tage function 0 1 4 5 sec Check time sensor polarity in Sek Fig 3 1 Table of parameters gt 6 8 Lo JE gt elr e 1 4 cio d 13 5 o o EIS Tilalla o leg lels gt
3. 3 Lei Ga 5 30 3 6 Revision DP15 E P2 8 Z G NTHER HOT RUNNER SYSTEMS User Manual Hot Runner System DP15 E No Description Herewith you can adjust the temperature window in Fahrenheit from set value for all hot runners If all hot runners reaches this temperature window the appliance spray nozzle is ready A potential free relay contact close contact switched caused by a collektive OK information and the user take advantage of this relay contact see 4 7 number 5 10 or 15 hot runners The display remain indicated for a period of 1 5 seconds by a basic adjustment of 5 and 0 3 seconds per scanning 4 The lowering is adjust on 50 C If you activate the lowering function the nominal set temperature will decrease around 50 C 100 C Fahrenheit The parameters 5 6 and 7 are used for the diagnostic function After installing new tool the diagnostic function can be used to detect mixed or incorrect connected electrical connections The parameter 5 set the heat output of the diagnostic running see 4 6 The parameter 6 set the maximum heattime of the diagnostic running The parameter 7 set the maximum temperature of the operating zone The diagnostic running will be closed when the maximum heattime or the maximum temperature raise has been reached With this parameter you can choose the display between Celsius or Fahrenheit It is
4. than an error OCCUTS 5 2 5 Lowering The temperature lowering possibility of the DP15 E isn t used by the Arburg machine Lowering is achieved by corresponding set values The lowering can be activated by hand The information of the DP15 E s status is sent to the Arburg machine but this information will not be displayed 5 2 6 The alarms If faults occur during machine operation then these faults will be displayed in the second display line The following alarms of the 15 are possible Current loop disconnected Unit doesn t respond Temperature out of tolerance Power unit fails Internal unit fault Input of wrong values too small too large Input of C and Ampere at the same time only one value possible Revision 10 96 DPIS E P2 8 5 3 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS 5 2 7 Fault reports For more detailed information see 4 8 Fault reports 4 6 Diagnostic program 6 2 Intial start up Hints For faults that are not associated with the interface connection the DP15 E should be disconnected from the injection moulding machine for fault location The interface specific faults are explained in the following text For fault location the DP15 E LEDs can be used These LED s are visible if the unit cover is removed If the current loop is closed then the both and TXD LED 5 must be on e green gt input DPIS E if the LED flashes t
5. Z G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E 5 3 6 The alarms If a fault occurs during machine operation then the fault will be displayed in column in image B13 With regard to the DP15 E the following error codes are possible Thermocouple failure Timeout data transfer error Actual value error Memory error Analogue part error Temperature too high Temperature too low Set value error p eres Note If the DP15 E detects an error then the loads are isolated from the supply This error status is indicated by an LED on the DPIS E If the affected hot runner is switched off then the fault is acknowledged The hot runners without a fault will be reconnected to the supply 5 3 7 Fault reports For more detailed information see 4 8 Fault reports 4 6 Diagnostic program 6 2 Initial start up Note For faults that are not associated with the interface connection the DP15 E should be disconnected from the injection moulding machine for fault location The interface specific faults are explained in the following text For fault location the DP15 E LEDs can be used These LED s are visible if the unit cover is removed During adjustment all LEDs are switched on When the adjustment is finished the RTS LED starts flashing The flashing of the RXD and TXD LEDs is difficult to see green RXD Input DP15 E Flashing indicates that signals from the injection moulding machine are being re
6. 4 TXD 6 RXD 4 9 TXD 4 TXD pas DSUB 9 DsuB 9 8 DSUB 9 9 RXD pas Stecker Stecker 9 TXD H Stecker Stecker TYP RS 232 TYP RS 422 TYP RS 485 Fig 6 1 Connector assignment 15 Sub 9 40 Picture 6 2 Sealant material on the unit cover of the DP15 E ooh LI 20 1 DSUB 9 AMP DIN 5 Stecker Stecker Picture 6 3 Cable connection ARBURG 000000000000 x Li gt DSUB 9 DSUB 25 Stecker Stecker Picture 6 4 Cable connection KRAUSS MAFFEI DSUB 9 Weidmiiller Stecker Buchse Picture 6 5 Cable connection ENGEL Revision 10 96 DP15 E P2 8 6 5 Z G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E Hints If an EPROM update is necessary because of the interface then please disconnect communication cable to the injection moulding machine before switching on The update procedure is indicated by a U in the display do not terminate this operation until it is completed For further information please refer to your update instruction manual Please specify the interfacetype before ordering an interface board Technical data Option interface board Signaltypes RS232 level RS485 level or RS422 level optional TTY level 20mA current loop Data format 2x asyncronous full duplex operation Baudrate maximum 19 2 kBd Transmitting length max 15m for RS232 max 300m for TTY Level
7. ON 100 OFF OFF ON 150 OFF OFF ON 200 OFF OFF ON 100 OFF OFF ON 100 OFF OFF ON 150 OFF OFF 43 ON 200 OFF OFF 65 ON 100 OFF OFF 32 ON 100 OFF OFF 31 ON 150 OFF OFF 45 ON 200 OFF OFF 50 N SOON NER IN 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 HYDR SCHLIESSICHER 8 H A N D Fig 5 7 The hot runner image Revision 10 96 DPIS E P2 8 5 11 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS 5 4 5 Lowering The possibility of the DP15 E for lowering isn t used by the Engel machine the lowering is enabled by setting the corresponding set value 5 4 6 Alarms If faults occur during machine operation then these faults are displayed in the image for the alarms For the DP15 E the following faults are possible TG SOLLW A BEREICH Set value out of range TG F HLERBRUCH Thermocouple is disconnected TG HEIZUNG DEFEKT Heater unit failed TG KOMMUN TIMEOUT Communication timeout TG TEMP ZU HOCH Temperature is to high TG TEMP ZU TIEF Temperature is to low Hint If the DPIS E detects a fault the loads are isolated from the supply These faults are displayed on the DP15 E via If the affected hot runner is switched off then the fault is acknowledged The hot runners without a fault will be reconnected to the supply 5 4 7 Fault Reports For more detailed informations see chapter 4 8 Fault Reports chapter 4 6 Diagnostics and chapter 6 2 Initial Start
8. Output Control range Set range Temperature window Start up operation Starting ramp Lowering Liftup Security turnoff Other details Data storage protection Indicators Keyboard Storage temperature Operating temperature Protection type Dimensions Weight Colour of unit Z G NTHER HOT RUNNER SYSTEM S 4 5m 32A CEE plug standard Load connection 40 pin Amphenol Thermocouple connection 32 pin Amphenol a Triac unit FF 10 5 x 20 mm Type Schurter SA superfast for Triacs 5 pieces per modul LR15 MT 50mA 5 x 20 mm middle slow for electronic 1 piece per modul LR15 FF 16A 6 3 x 32 mm Type Schurter SA 1 piece per modul separate on the backplane b Operating unit and bus board LR11 MT 200mA 5 x 20 mm RS232 TTY RS422 RS485 At the moment interface protocols are available for Arburg Krauss Maffei and Mannesman Further protocols are planed SPI CAN BUS etc PID adjustable from front face of the board Control parameters are programable and can be locked in automatic recognition of 230 V and low voltage loads with automatic adjustment of the control parameters Uniform automatic parameter match by means of phase control mechanism to 500 C O to 932 F 0 to 100 2 Cto 99 3 Phases 1 adjustable ramp on 50 set value 2 heat up to 105 C 3 adjustable hold time on 105 C Equal heating of each nozzle depending o
9. Phone Fax E mail Phone 34 93 47 37 713 Fax 34 93 49 90 43 8 E mail centerplast airtel net Revision 10 96 DP15 E P2 8
10. key pressed the old set point will remain operative This will also be the case if no key has been pressed during the 10 second active setting time interval If after confirming entered values you hit enter key again the controller returns to the scan mode The controller operation works independently It is therefore not necessary to return to the scan mode Scan mode makes exact surveillance of critical regulation positions possible Value limits The temperatures are adjustable within a range from to 500 C to 932 F The percentage control mode is adjustable from 0 to 100 3 3 2 Switching hot runners on and off If a hot runner is not be used it is possible to switch this off This can be accomplished in two ways 1 Use the key to reduce the set value until the display shows If the key is pressed now the runner is switched off The last operation setting is saved This means if the runner is turned on again the state of this zone is the same as before switching off thermocouple or percentage control mode The operation mode is also indicated by the LEDs even if the runner is turned off 2 By pressing the keys at the same time the set value display shows After pressing the key the runner is switched off Additional to the procedure 1 the set value is also saved so that after turning on again pressing the keys and D the old set value i
11. Holdschmidt Rua Joao de Barro 52 BR 83326 470 Pinhais PR Battenfeld Hong Kong Ltd Mr Pechtl 2F1 No 18 Dai Fat Street Tai Po Industrial Estate Hong Kong N T Tai Po DUMIS Mlaka Mr Urana Oretnekova pot 9 SL 4000 Kranj Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail 43 1 86 94 76 4 43 1 86 94 76 47 guenther kabvsi at 31 75 68 18 00 0 31 75 68 18 00 I t b backer wxs nl 33 139 32 03 04 33 139 32 03 05 m_demicheli gunther france com 39 02 29 40 43 90 39 02 20 46 67 7 millut tin it 358 93 44 55 44 358 93 43 40 52 0 jukka traderingman fi 1 84 72 15 78 74 1 84 72 15 78 05 info ghrsi com 44 14 74 87 97 74 44 14 74 87 30 63 info gunther co uk 55 41 86 82 59 5 55 41 86 82 59 5 brale brale com br 852 26 66 91 40 852 26 65 25 26 bathk hk super net 386 64 24 81 00 386 64 24 8101 dumis siol net Revision 10 96 DP15 E P2 8 User Manual Hot Runner Systems DP15 E Worldwide Center Plast Mr Gonzalez Palacio C San Gabriel 17 L3 E 08950 Esplugues de Liob Z G NTHER Hot Runner Systems
12. Version Rm s e 7 TT Conductor AT AP p 5r 92 9e _ AT puo per poo er ee TT Revision 10 96 DP15 E P2 8 1 Z G NTHER Fig A4 DP15 10 E Connector assignment load plug 40 poles from DP15 US Version and DPISE CE Version mer E 7 1 1111 1 1 11 puma Condor X D Ar pA 9 87 E rane _ Neutral Conducto AS AS A6 26 A6 1 Fig A5 DP15 5 E Connector assignment load plug 40 poles from DP15 US Version and DP15E CE Version Hints In star circuit the return cable A5 A6 B5 B6 C5 and C6 only bandage with the neutral conductor In the case of the delta connection one does not mean a neutral conductor but another external conductor The connection position for special appliance does not valid for revision S L u Nozzle B6 N a Changer 9 09 Fig Connection example Controller runner A7 from the DP15 10 E Hints The load plug differ from the DP15 E correspond to the appliance look into Fig A3 A5 A 2 Revision 10 96 DPIS E P2 8 Z G NTHER HOTRUNNER SY
13. Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS On each machine an additional user block is provided for manual control After the system test of the machine the user must press the start button to the right of the emergency button After this the machine is operational To use the hotrunners the machine heater must be switched on via the hand control user block Fig 5 1 Machine heater on key 5 2 2 Image selection Seeing as there are so many possible operations a selection of different visualisation imagemasks is necessary The different imagemasks further called images contain tables and much more The selection of these images is possible by pressing the corresponding button in the key block 1 or 2 If more than one image is available these images are selected by pressing the image selection button repeatedly Note For current set value it is important to know that for the Arburg injection moulding machine the current values are in ampere and are displayed in ampere However the display of the DP15 E hotrunner regulation unit displays this in percent 100 120 ampere 5 2 3 Input of set values If you want to change a set value or a setting of the machine use the following procedure By using the cursor keys the cursor must be placed to the position that has to be changed When the position is reached inverse display of the code new adjustment values can be set using the numeric
14. all set values and parameters 4 12 Variable safety disconnection 4 13 Temperature measurement 1 Ch Ch PS P ta Fa ka ra E E SS SS EES 1 5 Serial interface 5 1 General information 5 2 Operation with Arburg 470V injection moulding machine 5 2 1 General controls 5 2 2 Image selection 5 2 3 Input of set values 5 2 4 The image MOULD HEATING UNITS 1 3 67 5 2 5 Lowering 5 2 6 The alarms 5 2 7 Fault reports 1 ra ra m WM 1 Copyright by DAVIDSMEYER amp PAUL GmbH Elektronik 111 User Manual Hot Runner System DP15 E 5 3 54 Operation with Krauss Maffei MC3 injection moulding machine 5 3 1 General controls 5 3 2 Image selection 5 3 3 Input of set values 5 3 4 The images and B17 hot runner system 401 416 5 3 5 Lowering 5 3 6 The alarms 5 3 7 Fault reports Operation with Engel 90 injection moulding machine 5 4 1 General controls 5 4 2 Image selection 5 4 3 Input of set values 5 4 4 The image Heisskan le Hot runner 5 4 5 Lowering 5 4 6 The alarms 5 4 7 Fault reports 6 Installation and start Up 6 1 6 2 6 3 Installation 6 1 1 System setup 6 1 2 Electrical connections 6 1 3 Serial interface Initial start up 6 2 1 Testing thermocouple connections 6 2 2 Test to locate disconnections in the heater circuit 6 2 3 Checking for crosswiring between thermocouple and heater circ
15. and preassembled prewired thermocable systems will be supplied directly from the manufacturer Power cables The power cable requires a 40 pin connector plug with a suitable housing Because of the large number of possible arrangements and the required special crimping tools preassembled power cables manufactured by the GUNTHER HOT RUNNER SYSTEMS should be used Revision 10 96 DPIS E P2 8 6 1 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E In order to maintain a standard and for compatibility reasons the following procedures should be followed If a combination of low voltage and 230V runners is employed the low voltage runners should be connected in a sequential arrangement of increasing voltages beginning with runner 1 After all low voltage runners have been connected the 230V runners should then be connected to the system For example in a 10 runner system runners 1 to 4 are low voltage types and runners 5 to 10 are operated at 230V The length of the power cable should not exceed 3 meters The following standard plug connections are available Low voltage e 20 pin for power components DL 4 39 pin for power components DL 6 and DL 8 40 pin for power components LS 4 LS 12 40 pin for power components LR 4 LR 12 e For the 160 T12 respectively DL 12 one 20 pin and one 39 pin plug must be used 230 V 10 pin connector socket with cable for max 5 runners AG 5 16 pin connector soc
16. first be obtained To obtain input authorisation Press the key marked KEY The status line of the display will show Please enter code number Using the numeric keypad type in the following number 8899 and then press enter e The cursor will blink and an will appear at the bottom right Input authorisation has now been granted Switch on machine heater e Press the On off key repeatedly until the following symbol appears with a red backlighting and then press enter Fig 5 2 Machine heater on key Now the set values of the injection moulding machine will be transmitted to the DP15 E Revision 10 96 DPIS E P2 8 5 5 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS 5 3 2 Image selection The high number of the possible operations means that a selection of different visualisation imagemasks is required The single imagemasks further called images contain tables and much more Single images can be selected by use of the function keys or using key Image selection Press key and enter the number of the desired image Confirm the input by pressing Enter The selected image will be displayed Note Please note that for set values of current when using the Krauss Maffei injection moulding machine the current should be entered in amperes and will be displayed in amperes The display of the DP15 E hot runner control unit shows
17. from the nominal data in C Rising regulated quantify in the rising mode in By the plausibility check the DP 15 E testet the configuration of the connected loads and check whether a low voltage or 230 volt load is connected in doing so the 230 volt load is following after the low voltage loads beginning from channel 1 After channel has been switched on the stage function start gradual the power The adjustment 25 50 75 und 100 from end of the nominal data are possible You can change the holdtime of the steps with the equation n x 4 5 sec in doing so is the setting parameter value adjustable Holdtime The registration time of 130 sec in parameter 45 is the time from the unit to adjust a low voltage thermocouple is connected with the wrong polarity Fig 3 2 descpiption of parameters 3 8 Revision DP15 E P2 8 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E 4 OTHER FUNCTIONS 4 1 Display of the serial number If during the programming phase display of the program number the key is operated the serial number of the control unit is displayed 4 2 Start Up procedure Softstart When 230 voltage nozzles are used it is necessary to employ the Softstart start up procedure to dry out the moisture that has collected in the heating elements In order to do this in the first phase of the Softstart the set time value of parameter 22 is increased from 0 to 50 Th
18. have reached the preset temperatures the output Ready to start moulding operation is switched on Additionally a potential free relay contact OK is switched on A corresponding plug with 2 5m cable can be ordered from the GUNTHER HOT RUNNER SYSTEMS company Input Lowering Abs By using potential free external contact the DP15 E can be set to lowering Hint Attention Disconnect mains before opening system Serial interface If this optional device is implemented then a 9 pin D Sub connector is located above the fault output trapezoidal connection Depending upon the ordered type of injection moulding machine protocol the connection will either be RS232 TTY current loop RS422 or RS485 For further details please refer to the GUNHER HOT RUNNERS SYSTEMS company or read the serial interface instruction manual 6 1 3 Serial interface Contents of the interface kit I interface LR19 e 1 pre assembled flatribbon cable 5m interface cable 2x0 5 qmm shielded with AMP DIN plugs to connect to Arburg interface 2 spacer bolts including nut 5m sealant material installation instructions 1 EPROM I update information I new user manual DP15 E Assembly Hint Attention Disconnect mains before opening system e Set the interface modul as shown in figure 6 1 and 6 2 below Tx and Rx passive Default setting is TTY passive remove the cover of the unit by removing the four 4 screws on the side of the u
19. or gt for runners zones parameters amp program selection lowering Key gt display of set values in percent current in Amperes amp serial number Key C or D gt for changing amp adjusting set values and parameters Key E gt ENTER KEY to confirm inputs to quit program levels and to switch scan mode on off Hint For further details concerning keys and their functions see chapter 3 3 Operation quick overview of the control keys is available in appendix F Revision 10 96 DP15 E P2 8 User Manual Hot Runner System DP15 E L 9 RUNNER SYSTEMS 2 2 Parallel display The parallel display is a 15 3 digit seven segment display for set temperature actual temperature temperature difference or actual adjustable variables in op Three 3 additional LEDs are located beside each indicator to display the status of the zone Between the operating controls and parallel display a key and 4 LED s are placed The key is used to display the set value actual value temperature difference or the display of current in LEDs above the key shows which display type is selected SOLL SET IST EXIST DIFF ok 49 000 000 49 49 o o o o o o 0 ON O 000 000 49 42 49 000 000 000 49 49 49 000 000 000 49 42 49 Fig 2 1 Parallel display DP15 E 2 2 Revisi
20. phase control mechanism to 500 C 0 to 932 F 0 to 10096 2 Cto 99 3 Phases 1 adjustable ramp on 50 set value 2 heat up to 105 C 3 adjustable hold time on 105 C Revision 10 96 DPIS E P2 8 User Manual Hot Runner System DP15 E Starting ramp Lowering Liftup Other details Data storage protection Indicators Keyboard Storage temperature Operating temperature Protection type Dimensions Weight Colour of unit Z G NTHER HOT RUNNER SYSTEM 5 even heat on of every nozzle depend of the slowest nozzle adjustable 0 255 C 0 255 F adjustable 0 255 C 0 255 F Data recovery after current failure Secure for at least ten years without battery Operating section seven segment 13mm display and LEDs Parallel read out seven segment 8mm display and LEDs Front panel with integrated mechanical keys and key foils 0 to 70 0 to 35 C IP 20 w h d 360mm x 142mm x 345mm 22 01 Ibs 10 0 Kg grey and blue RAL 9018 und RAL 5015 Revision 10 96 DPIS E P2 8 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E Appendix D Technical Data for DP15E CE Version Connection specifications Terminal voltages 200 to 250V for each phase typical 230 400V for star circuit 50 to 60Hz Star circuit 3 Phase System with neutral lead 200 250V between phase and neutral lead delta circuit 3 Phase System without neutral l
21. plug The cover of the unit may then be removed by unscrewing 4 screws both on the left and the right sides Hint Please only use fuses that correspond to specification in the bottom drawing A package of original reserve fuses is included inside the DP15E look at the positioning plan The following diagrams show the fuse positions in the various versions of the DP15E unit Fuse Positions DP15E Runnernumber 87 DP15 10E 43 Runnernumber 43 21 DP15 5E FFIOA Modul Fuse T50 mA backwall Runner 13 FI Runner 14 F2 Runner 15 backwall IN Runner 9 Fl Runner 10 2 backwall Runner 5 ES FI F1 3 FF16A 250V Schurter SA or TR5 160 mA solder Fuse for the bus board LR 11 MT 200 mA Picture B2 Fuse positions Revision 10 96 DP15 E P2 8 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS Jumper settings LR15 5 Runner 10 Runner 15 Runner Jumper settings LR17 5 Runner 10 Runner 15 Runner B 4 Revision 10 96 DP15 E P2 8 Z G NTHER User Manual Hot Runner System DP15 E HOTRUNNER SYSTEMS Appen
22. possible to switch on the starting mechanism to ensures an even set value based heat on all of the different nozzles see 4 3 The parameters 10 11 12 and 13 14 15 are adjustment parameters for the PID regulator which influence the characteristic features of the regulator KP is the proportional data of the P regulator for SV 24V KP describes the relation from regulated quantity to the regulated variation TN is the readjustment time of the integrating circuit for SV 24V TV is the suspension time of the differential circuit for SV 24V is the proportional data of the P regulator for 230V TN is the readjustment time of the integrating circuit for 230V TV is the suspension time of the differential circuit for 230V The representation of the delivery year be caused by double figures example 1996 will be shown as 06 The representation of the delivery month be caused by double figures The serial number be caused by six figures of the control unit will be shown see 4 3 If the runner channnel temperature exceeds 500 C the load circuit is disconnected for safety reasons If a safety disconnection occurs the loads are disconnected and the fault is displayed on the panel of the 15 If you want do set the value of the temperature threshold below 500 C you have the possibility to set the parameter 21 between 0 500 The set value is be subtracted from 500 C and this new value will be used as the new safety t
23. unit isn t necessary and for security reasons is not possible The input of parameters and set values is not possible during use of the serial interface depending upon communication protocol type An exception is the parallel display the display modes of this can be changed as before Note If for example the parameters need to be changed then the connection between DP15 E hot runner control unit and the injection moulding machine must be opened disconnect cable or switch off the machine so that no information can be sent to the DP15 E The DP15 E then detects that no interface is in use and enables the keypad after a few seconds The DP15 E works as stand alone system without connection to the injection moulding machine For operation hints about the use of the parallel display of the injection moulding machine please refer to machine manual 5 2 Operation with Arburg 470V injection moulding machine 5 2 1 General controls For detailed informations please see the ARBURG manual The unit address of the DP15 E must be set in the parameter level parameter 30 Default is 1 for address 1 At the injection moulding machine a keyboard dialogic is provided This keyboard is separated in three square user blocks These blocks are placed below the display The user blocks 1 and 2 are used to select the different images The user block 3 is used for numerical inputs and cursor controls Revision 10 96 DP15 E P2 8 5 1
24. 3 902 972 3 90 23 903 supad td netvision net il 351 2 44 58 99 00 351 2 44 58 99 12 equimoldes mail telepac pt 47 22 44 95 64 47 22 55 11 06 plastkompaniet os telia no 42 0 1 84 72 39 66 42 0 1 84 72 39 66 guenther trysky sochor iol cz 36 12 39 05 17 36 12 39 05 17 zastrow westel900 net 886 2 22 99 03 16 886 2 22 99 05 35 industra ms29 hinet net 52 55 66 47 32 52 55 46 40 14 zoica dfl telmex net mx 48 22 62 25 22 8 48 22 62 97 774 45 48 79 98 88 45 48 79 80 16 mail hh plastkombi dk Revision 10 96 DP15 E P2 8 User Manual Hot Runner Systems 15 Z G NTHER Hot Runner Systems Worldwide Dipl Ing H G nther Ges m b H Mr Feik Speichm hlgasse 1 A 2380 Perchtoldsdorf Technisches B ro B cker Mr B cker Pieter Lieftinckweg 20 NL 1505 HX Zaandam G NTHER France S A Mr Demicheli 6 rue Jules Verne F 95320 Saint Leu La Foret Millutensil SRL Mrs Just Oselieri Corso Buenos Aires 92 1 20124 Milano Trader Ingman Oy Mr Ingman Str msintie 23 A 1 FIN 00930 Helsinki G NTHER Hot Runner Systems Inc Mr Vander Noot 725 Hastings Lane USA Mexico Canada Buffalo Grove Illinois 60089 G NTHER U K Mr Heendeniya 52 Lambardes New Ash Green GB Longfield Kent DA3 SHU Brale Ltda Mr
25. 34aa ya zy suoz suoz suoz auoz suoz Age BEE EL J038uu0J ITZTET N 11 uaLTI 4 IN ZN EN Board Terminal 2 N KEN A SZ ZZ 28 10 94 De len Marquardt 15 01 96 DAVIDSMEYER amp P UL GmbH E Name Revision 10 96 DPIS E P2 8 Z G NTHER User Manual Hot Runner System DP15 E HOTRUNNER SYSTEMS Appendix H Layout schematics DP15 US Version LR 17 3 F2 Fl DAMDSMEYER amp PAUL GMBH STAND DAUM DAUM I 1 1750894 1 jPostionsplan BAUGRUPPE py Geh use 5 1 1 Revision 10 96 DP15 E P2 8 1 User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS L G NTHER ics DP15E CE Version Layout schemat ped 0744 9 EZ EA 6 4 SX TZ TA dn gad IZ TA 62 12 ZL al ee 8141 OLAT 1 61 ai ZIEL 41 el a1 vial Van
26. 911 96 12 30 0 Fax 49 911 96 12 30 50 E mail thomas grajer weschu de Phone 49 36 84 88 68 0 Fax 49 36 84 88 68 22 E mail roemhild TV gmx de Phone 49 74 54 66 81 Fax 49 74 54 16 67 E mail k h renz t online de Phone 49 45 31 80 07 39 Fax 4 49 45 31 80 07 63 Revision 10 96 DP15 E P2 8 User Manual Hot Runner Systems DP15 E Worldwide Su Pad Ltd Mr Sadeh 2 Hamelacha Street New Industrial Zone IL Rosh Ha Ayn 48091 EQUIMOLDES Lda Mr Rodrigues Rua Pinhal do Rei 14 P 2445 Martinganca Plastmaskiner A S Mr Schr er Frederik Stangs gate 2a N 0272 Oslo Dipl Ing Petr Sochor Ve Vilk ch 1849 CZ 347 01 Tachov Basler Trade KFT Mr Zastrow Postbox 25 H 1581 Budapest Industrade Corporation Room No 202 No 5 Wu Chuan 1 Road Hsin Chuang Taipei Hsien Taiwan Eduardo Campos Madrigal Grupo Zoica S A de C V Sadi Cornot No 77 Col San Rafael C P 06470 Deleg Cuauhtemoc Mexico D F G NTHER S C Mr Olszowski ul Poznanska 14 m 33 PL 00 680 Warszawa HH Plastkombi aps Mr Hansen stergade 24 D DK 3200 Helsinge Z G NTHER HotRunner Systems Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax bla a Phone Fax E mail Phone Fax E mail Phone Fax E mail Phone Fax Phone Fax E mail 972 3 90 2
27. CS schemat Ion DP15 US Versi WOW ju1 naye vaa 2507 4892 83027 m D 29902 BIOEIE H meez n 8uoz auoz 2 suoz 2 JE1UOASP I N 9Nnu3015 r Fordi ted 9v Sv 0 eS ry 2 4 zy V I Ic 0 4 V 48 4307 nao soNnis131 Age DEE Sa TNODASINNISI 37 A SZ ZT ssn yasuezjaN ET N E 1 KALEEI TE 5 51 37 i Kuhr 30 05 95 Bratt 1 5 7 G NTHER MACH EH ssn Jsa pueh EE 1521 Revision 10 96 DPIS E P2 8 GUNTHER HOT RUNNER SYSTEMS User Manual Hot Runner System DP15 E ICS schemat lon DP15 E CE Versi Appendix G SNIB3MQ 1 9NDDIN3S8V E 187 TUNGON 38NLYYISAEIL E 187 NOON 1 1 EI NaON 81 eod 5 KSS amp ze 5555 vnaaz n asya Aasz aBz N DU Nav 1v L3
28. Cable cross section 0 4 qmm max 1000m for RS422 and RS485 Isolation voltage 5 Input output 6 2 Initial start up 6 2 1 Testing thermocouple connections e Install unit as described in chapter 6 1 As a saftey precaution please DISCONNECT the power cable plug e Switch the unit on The control unit DP15 E displays the program version e g P2 70 and then it checks the heater circuits displays for adjustment After these displays a fault alarm must show up indicating a disconnection to the heater circuits Use the far right key to set the parallel display to set values Make sure that all runners are set for automatic temperature control Manual operation is indicated by a horizontal line in the first digit of the display e Set parallel indicator to display actual values e At this point all connected runners must show a temperature value if not it is necessary to check the thermocouple connections for those runners that show a fault 6 6 Revision 10 96 DPIS E P2 8 Z G NTHER User Manual Hot Runner System DP15 E HOTRUNNER SYSTEMS 6 2 2 Test to locate disconnections in the heater circuit e Switch off runners which are not being used After the power plug has been DISCONNECTED set all runners to 0 C or 0 Reconnect power cable After cycling power off on no fault indication for the heater circuits should occur fault LED 18 switched off e Ifa fault occurs the runner num
29. DP15 E unit instructions GUNTHER Heisskanaltechnik IST EXIST SOLL SET v A F AJ E ABFCDE Fig Operator control panel DP15 E usermode program level parameter level diagnosis key pressed scanmode on poweron runner number program number parameter number runner count down zone count down count down Look at the test result count down runner number program number parameter number runner count up count up count up count up Look at the testresult Thermocouple activity display delivery date gt Display current serialnumber in Percentage activity gt Display current in A count down of counting down the set count down of set values values for all zones parameter value count up ofthe counting up the set count up of the set values values for all zones parameter values scanmode on off the program accept take over of zone displayed is parameter the changed activated set value A amp B lowering on off start of the diagnosis start of the A amp F loweringon off P runner switched turn off all runners IL load on off separated adjust F amp E selection on selection on quit the parameter quit the diagnosis mode lifting up on off GJ A amp E load of the default values of the DP15 E set values and parameters Fig F2 Brief operating instructions Revision 10 96 DPIS E P2 8 F 1 User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS I
30. GUNTHER HOT RUNNER SYSTEMS DP15 and DP15E User Manual for Softwareversion P2 8 G NTHER Heisskanaltechnik DP1 5 SCH ISTIEXIST 5 Be 25 soLuser 1 lt se 2 UMS 208 DIFF NIB UB 4 WB V a F V a E 5 sm Revision 10 06 15 P2 8 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E Contents Page 1 Safety precautions 1 1 2 Operating and display controls 2 1 2 Operation 2 1 2 2 Parallel display 2 2 3 Operating instructions 3 1 Switching nn General information 3 2 Scan mode 3 3 Operation mode 3 3 1 Changing set values 3 3 2 Switching hot runners on and off 3 3 3 Changing the operating modes Thermocouple and Percentage 3 3 4 Lowering or rising the temperature 3 3 5 Parallel display 3 4 Use of the set value programs 3 5 Changing the parameters 3 5 1 Meaning amp interpretation of the parameters WWW WW W La 1 AAA ra Lu 1 4 Other functions 4 1 Display of the serial number 4 2 Start up procedure Softstart 4 3 Starting ramp 4 4 Display of current value 4 5 Display of the setting 4 6 Diagnostic program 4 7 Ready to start moulding operation 4 8 Fault reports 4 9 Load separated adjustment mode 4 10 Integrated help programs 4 11 Automatic setting for
31. PROM To activate the new software switch the unit completely off and then on again Now the unit should operate as before Revision 10 96 DPIS E P2 8 6 9 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E Appendix A Cable and connector assignment DP15 US Version 1 Netz O _ Thermo Last Load m ei Fig Al 1 Connector positions on rear panel DP15 Ser Serial interface Ready for injection Def Collective fault Abs External lowering DP15E CE Version Fehler Keine g ltige Verkn pfung Fig Al 2 Connector positions on rear panel 15 Ser Serial interface Ready for injection Def Collective fault Abs External lowering Raw Metal 1 red 1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 Casan 9 6 3 1 7 5 5 9 Fig A2 Connector assignment of thermo socket 32 poles from DP15 US Version and DP15E CE Version Rome TS LS os bo bio br ps pio pr ps ps io pr ps Neutral Condor as AG AG es es es 66 Fig DP15 15 E Connector assignment load plug 40 poles from DP15 US Version and DP15E CE
32. R HOT RUNNER SYSTEMS User Manual Hot Runner System DP15 E by pressing or keys Now the points in the set value indicator are flashing By pressing the key the new temperature will be saved for all runners in program displayed in runner number indicator To activated the program you have to press the key again During the change of the set values programs you can activated the last active program by pressing the and keys ATTENTION If the temperature is changed for all runners the percentage control mode or thermocouple mode is active for all runners For guidance purposes the set value for the first zone will be shown by the LED indicator The last adjustment is saved under the first displayed program number By pressing the E key the user is able to leave the program mode changes carried out now will be saved in the actual program 3 5 Changing the parameters The term is used to identify settings which affect the function of the control unit and which are directly adjustable by the operator Each parameter or setting is assigned with a specific number and has a clearly defined function If during the program mode press and simultaneously the keys and are pressed at the same time again the parameter level is entered The zone display will show The actual value display will show the n
33. STEMS User Manual Hot Runner System DP15 E Coding of the regulation unit The coding applies only for units using a delta net supply lt p SO OG Es gt p ND c gt 1O0 p ND c lt OG u gt e e 290 DP15 5 DP15 10 DP15 15 Codingbolts Coding the power component Type LS until revision B 1 56 LS 12 10 9 OO y 9 12 Revision 10 96 DPIS E P2 8 A 3 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS Connector assignment of the power unit typ LS since revision C 154 1 lt zone pBvowwx 6 7 19 1 Fig LS4 Connector assignment output plug 10 poles LS6 6 5 4 3 2 1 lt zone TT 1 2 T5 Woaw ojoje Fig A7 LS6 Connector assignment output plug 16 poles A 4 Revision 10 96 DP15 E P2 8 G N
34. THER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E 1 58 oM 8 7 6 5 4 3 2 1 zone mme TT avsatt 2 13 123 o 19 13 Fig 8 1 58 Connector assignment output plug 16 poles 1510 O O 10 9 8 7 65 4 3 2 1 lt zone zone 1 10 I peer ES s Wow oja Fig A9 1510 Connector assignment output plug 24 poles Revision 10 96 DPIS E P2 8 A 5 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS 1 512 24V output 1 1 24 2 13 14 15 16 17 18 19 20 21 22 23 24 gt Tof rn 2 3 4 5 6 7 8 9 10 11 12 Fig 10 1512 Connector assignment output plug 24 poles A 6 Revision 10 96 DP15 E P2 8 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E Appendix B FUSE POSITIONS of the DP15 US Version The outputs for a maximum of 15 zones are separate fused with superfast fuses These fuses are located on the triacmodul and also on the ground inside of the DP15 The fuses from the last 3 runners are within easy reach on the backplane In order t
35. Use the key on the left of the parallel display to select values The LED s above the key identify the values shown Additionly an individual temperature reading is provided for each runner If the green LED lights up the programmed temperature window for the runner has been reached while the red LED will indicate that the temperature is either above or below the programmed window setting The temperature window can be set with the parameter values 3 4 Use of set value programs A set value program is a preprogrammed series of set values and their corresponding operating methods which a user can change and enter into the system They can be entered and activated solely by the simple operation of a single key If the tools or the moulding compounds are changed it is advisable to also change the program accordingly There are 4 set values programs P1 P2 P3 and P4 available When the control unit is turned on the last one of the previously used programs will be automatically reactivated By pressing the and keys simultaneously the program mode is activated The set value program in operation will be shown In this level another set value program can be selected by pressing the A or B keys The point in the runner number indicator is then flashing By using the key the new program will be activated Additionally the temperature may be changed for all runners 3 4 Revision DP15 E P2 8 G NTHE
36. al keyboard The input will be displayed in the lowest line of the display To accept the value press the key Yes If you need to delete a value press the key No and one after the other 5 2 Revision 10 96 DP15 E P2 8 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E 5 2 4 The Image 3 6 TOOL HEATING UNIT 1 For more detailed information please refer to the ARBURG manual TOOL HEATING UNITS I 4 selected zones Device status regulate 5 available zones f833 preheat to norminal temp Temperature sinkage f834 preheat to preheat temp Temp sinkage manual op f835 preheat w manual operat Deg lowered temperature T834 deg preheating temper Ampere lowered value 8345 ampere preheating value nominal actual temperature tolerance 275 deg 184 deg C T835T 30 deg zone I T835S Ampere adjustment T836 275 deg C 184 deg C T836T 30 deg zone2 T836S Ampere adjustment T837 275 deg 184 deg C T837T 30 deg zone3 T837S Ampere adjustment T838 275 deg 184 deg C T838T 30 deg zone4 T838S Ampere adjustment Fig 5 2 The Image 3 6 Tool heating unit 1 Hints e 1830 input of used zones e Unit status regulate this means the heater is on and the hotrunner is enabled off this means the heater is off and the hotrunner disabled 18301 number of available zones on the DP15 E if this value is
37. al value will be shown in the column IST The tolerance is surveilled by the moulding machine The tolerance limit is set in the column and The temperature lowering is also controlled by the moulding machine and is entered in the column Abs Wert lowering value The entered value is the absolute value to which the runner will be lowered The lowering is activated in the column Abs BIN EIN for on and AUS for off 5 10 Revision 10 96 DPIS E P2 8 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E In the column emergency operation you can decide if an automatic selection to the percentage mode to the runner is necessary when the thermocouple to this runner has failed If this option is active the last set value before the thermocouple fails is activated In the column Stellerbetr percentage mode you can select between the thermocouple and percentage mode AUS thermocouple mode EIN percentage mode The column shows the actual set value of the runners and the last column tol shows if the runner is within the tolerance or not if the runner is within the tolerance the square is paint black otherwise the the square is white runner out of tolerance hot runners SM2 94 08 13 00 59 communication G nther ON Kom Soll Not Steller P betr betr ON 100 OFF OFF ON 150 OFF OFF ON 200 OFF OFF ON 100 OFF OFF
38. at the rear of the unit heat sink Furthermore it is important to ensure that the air circulation for the fan in the bottom of the DP15 E is not blocked The system must be setup on a stable and level area The DP15 E must be preserved from physical shock or vibration Look into appendix D for maximum operating temperatures Avoid a to high or to low air humidity as well as the possibility of condensation Protect the DP15 E from dust or dirt When the unit is assembled for example installed in a service cabinet a cable inlet of 120x90 mm must be provided 6 1 2 Electrical connections The following electrical connections are required for installation DP 15 US Version Three phase CEE 32 A plug Phasedistribution DP15 5 11 fuse 32 L2 L3 not used 3 DP15 10 11 12 fuse 32A DP15 15 L1 L2 L3 f ue 32A DP 15E CE Version Three phase CEE 32 A plug Phasedistribution DP15E 5 fuse 25 1 2 L3 not used DP15E 10 11 12 fuse 25 DP15E 15 11 12 13 fue 25A TI Hints Please check mains voltage star delta prior to installation Star is the standard configuration of the delivered unit Delta is possible if the voltage between two phases is not hiher than 200 250V Please read appendix Thermocouple cables The thermocouple cable requires a 32 pin 2 x 16 pins socket with a suitable socket housing The cable assignment is listed in appendix A Cable connector assignment Parts
39. ber for the faulty runner is indicated by the LED on the operating section on the left part of the front panel If in doubt switch off failed runners for easier fault location Note Four set value programs and four fixed programmed auxiliary programs are provided as an installation help These programs are available by simultaneously pressing the keys and when the unit is switched on These set value programs are programmed as follows Program I All runners on manual operation at 0 runners off Program 2 All runners at operating temperature with set value 0 C runners off Program 3 runners at operating temperature with set value 100 C runners off Program 4 All runners at operating temperature with set value 200 C runners on These programs are accessed by simultaneously pressing the keys function and enter Selected the desired program by using the and keys and confirm with the key The auxiliary programs are exclusively intended for test purposes and therefore prevent an unintended overwriting of the 4 set value progams during testing Any changes and alterations of the set values and operating conditions made in the auxiliary program will NOT be stored Revision 10 96 DPIS E P2 8 6 7 Z G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E 6 2 3 Check for crosswiring between thermocouple and heater circuit e All runners with
40. ce Control Automatic control system Load matching Output Range of control Set Range Temperature window Start up operation 200 to 250V for each phase typical 230 400V for star circuit 50 to 60Hz For 230V 10A per runner Fuse 10A superfast FF 10A See the maximum current for each phase each phase maximum 32 5 runners per phase 5 120 per runner in connection with our powerparts 24V 25A per runner in connection with our powerparts Ohmic and inductive ohmic loads are allowed Thermoelectric couple Type L Fe CuNi Electric compensation Normally open contact w o voltage potential max 230 not secured by fuse 230V 1A optional Clamp normally open contact 4 5m 32A CEE plug standard Load connection 40 pin Amphenol Thermocouple connection 32 pin Amphenol a Triacteil FF 10A superfast for Triacs 5 units per modul MT 50mA for electronic 1 unit per modul 16 Wickmann Typ LCT16 b Operating unit and bus board 200mA between the connecting clamps RS232 TTY RS422 RS485 At time interface protocols are available for Arburg Kraus Maffei and Mannesman Further protocols are planed SPI EUROMAP17 CAN BUS etc P PI PID adjustable from front face of the board Control parameters are programable and can be locked in Automatic recognition of 230 V and low voltage loads with automatic adjustment of the control parameters Uniform automatic parameter match by means of
41. cieved red TXD Output DP15 E Flashing indicates that the 15 is sending information red RTS Output DP15 E Flashing indicates that the 15 is sending information this inhibits information transfer from the Krauss Maffei machine Revision 10 96 DPIS E P2 8 5 7 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS F Thermocouple failure If the DPIS E detects disconnection of a thermocouple then the thermocouple failure is displayed in the corresponding control zone by an e Please check the thermocouple e In principal the hot runner can still be used in the control mode T Timeout data transfer error e The communication between the DP15 E and MC3 has failed Check the cable connection Check the 24V supply of the 50200 I Actual value error e f actual value cannot be displayed in the display field of the computer screen then an I will be displayed to indicate fault M Memory error e Memory error in control system checksum error A Analogue part error heater circuit open A load disconnection has been detected Check the cable connection and the load Temperature too high e Upper temperature limit Temperature too low Lower temperature limit The set tolerances have been exceeded This error message always occurs during preheating of the hot runners If the tolerance limits are exceeded during machine operation then the tolerance values ma
42. ditionally the unit will check the heater circuits Do not terminate the update procedure shown in the display by During the check out the identification JU and the number of tested zones will show in the indicator window After this the unit start the parameter mode and displays the parameter 76 Software version Also the LED for collective fault is on With the keys or you can select the parameters 76 77 78 and 79 The unit shows the following values software version delivery year refer to parameter 16 78 delivery month refer to parameter 17 serial number refer to parameter 18 Parameter number 76 To activate the new software you have to enter four values to the parameters 76 to 79 With the help of the softwareversion you can ask for these four values at your next G nther Hot Runner salesoffice These four values are defined as hardware licence 0 255 software licence 0 255 78 user licence 0 255 checksum 0 255 With the keys and you can select the parameter number and with the keys and D you can enter the new values The entered value is confirmed by pressing the key Only if all entered values are correct you can quit the parameter mode by pressing the keys F and E at the same time Then the LED for collective fault is still on These changes must only be performed once after inserting a new E
43. dix Star Delta switch over net voltage Hint ATTENTION Prior to opening the unit disconnect mains supply The unit DP15 E is prepared for a standard connection of a 400 star net supply In case 240 V delta net supply is necessary for example in the U S A this can be adapted by using four screwbridges Hint Switch the unit voltage off and secure the unit against further use Disassemble unit cover Connect bridges as shown in the diagrams below Terminal Board quomm ea m 22220222220 Star Delta switch over Close the unit cover Hint The voltage 01 02 and 03 must be within the range of 200V 250V If the unit is powered with other voltages the warranty expires and in some cases the unit can be damaged When using a Delta net supply the cable is not compatible for the different versions That means that the DP15 5 E should only be used with a cable intended for five hot runner unit The use of a cable designed for a 10 or 15 hot runner unit will lead to operations errors Revision 10 96 DPIS E P2 8 1 Z G NTHER HOT RUNNER SYSTEMS User Manual Hot Runner System DP15 E Appendix D Technical Data for DP15 US Version Connection Specifications Terminal Voltages Load connection Loads Thermocouple connection Alarm output OK output Lowering input Net cable Sockets Fuses Serial Interfa
44. e connected to the 15 The different types of thermocouples are set in parameter 24 The following table shows the possible thermocouple types and the corresponding settings for parameter 24 The standard setting for parameter 24 is 0 for metal constantan Type Material Parameter mn Fe CuNi iron constantan default RON NiCr Ni nickelchromium nickel Fig 4 2 Thermocouple type classification Revision 10 96 DPIS E P2 8 4 7 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E 5 Serial interface 5 1 General information For the 15 unit an optional serial interface for injection moulding machines is available An add on kit for delivered units is also available With this interface it is possible to remote control and display the information of the DP15 E unit via the injection moulding machine The interface enables easy quality control because of the possible production data acquisition Because each injection moulding machine producer has its own communication protocol please ask the GUNTHER HOT RUNNER SYSTEMS company if your communication protocol is available Please send the exact model and manufacturer s name of the injection moulding machine For further details on how to assembly interface please look into interface mounting manual Because the 15 unit receives all necessary information from the injection moulding machine an operation of the hotrunner regulation
45. e ramp time should be selected in such a manner that the DP15 E reaches the temperature of 105 C at the end of the ramp If the temperature is less than 105 C at the end of the ramp the DP15 E will increase the temperature to 105 C After the DP15 E has reached the 105 C the second time controlled phase of the Softstart the holdtime begins This is adjustable by the parameter 23 parameter 22 and 23 can only be changed by GUNTHER HOT RUNNER SYSTEMS company The holdtime is used to adequately dry out the nozzle with a low thermic load This start up operation will begin automatically after the control unit or runner is switched on and also after a program change The Softstart start up procedure is activated individually and automatically for each zone when the actual temperature of a 230 volt nozzle remains below 100 because the set value is programmed over 100 C The Softstart is indicated by a point beside the actual value display After the end of the the unit will switch from Softstart to normal operating procedure To prevent overheating of the moulding material in the 5 volt nozzles during combined operations employing both 5 volt and 230 volt nozzles the 5 volt nozzles are limited to temperatures not exceeding 105 C during Softstart The temperature lowering is taken into consideration during Softstart s so that the DP15 E unit can begin to operate immediately with an instant tem
46. ead 200 250V between each phase Load connection 10 runner Fuse 10 superfast FF 10A also each I runner per phase 16A See the maximum current for each phase each phase maximum 25A 5 runners per phase Maximum power DP15 SE PhaseLl zone1 4 je2 3KW 10A zone 5 3 6 KW 16 maximum overall load CE 3 6 KW 16 DP15 10E Phase L1 zonel 4 je23KW 10A zone 9 3 6 KW 16 Phase L2 zone5 8 je2 3KW 10 zone 10 3 6KW 16A maximum overall load CE 7 2 KW 2x16A DP15 15E PhaseLl zonel 4 23 KW 10 zone 13 3 6 KW 16 Phase L2 zone5 8 je2 3KW 10 zone 14 3 6 KW 16 Phase L3 zone 9 12 je2 3KW 10 zone 14 3 6 KW 16 maximale overall load CE 10 8 KW 3x16A 5 120 per runner in connection with our power units 24V 25A per runner in connection with our power units Loads Ohmic and inductive ohmic loads are allowed Thermocouple connection Thermoelectric couple type L Fe CuNi Electronic compensation Fault output Potential free contact normally open max 230 not secured by OK output Potential free contact normally open max 230 not secured by fuse Lowering input Connect a potential free contact normally open Revision 10 96 DPIS E P2 8 D 3 User Manual Hot Runner System DP15 E Net cable Sockets Fuses Serial interface Control Automatic control system Load matching
47. elay in the DP15 E 4 10 Integrated help programs As explained in chapter 3 4 Use of set value programs the user has 4 programs available These programs are normally used for special production processes The user may use these programs to test the system but changes to these programs cannot be stored These programs work like the programs but the changes made are not saved see also 6 2 2 4 11 Automatic setting for all set values and parameters If you want to set all set values and parameters to state default press both keys A and when the unit is switched on The DP15 E unit then resets all internal values to the default values This state is be shown in the IST EXIST display by an U for Update DO NOT terminate the update procedure by switching the DP15 E unit off The update mode is terminated when the U disappears from the display If a mains supply failure should occur then the process must be repeated The old values programmed by the user are destroyed If software updates for software revision to P1 53 up to 2 xx are performed the initialisation runs automatically The displayed U is followed by a code number 3 auto update from lt 1 53 to gt 2 29 U2 auto update from older software to new revision Ul performing conversion lt gt F If the DP15 E shows in the IST EXIST display a system error has occured In this case please inform the cu
48. et temperatures the OK LED is switched on Additionally a potential free relay contact is switch on This relay contact is located on the rear side of the system and is marked with OK The OK LED and the relay output will be switched off in case of e a fault e lowering 4 8 Fault reports In the event of a fault the alarm LED will flash and the protection system will shut down the power With this fault the relay contact is switched The alarm report is a common alarm signal and therefore does NOT indicate source or origin The indication of the involved runner and the type of fault is shown by the other A flashing fault signal indicates a fault in the runner which is just shown by the runner indicator In the scan mode the runner indicator will automatically switch to show where the fault exists If a scan is in progress it will automatically be terminated If several runners are detect the runner number indicator will show the number of the first runner detected with a fault The meaning of the individual LED s is as follows LED indicating a break in the heater circuit is switched on e load disconnected or an open in the heating circuit e during the operation a low voltage load has failed an internal fuse of the unit has blown LED indicating a thermocouple fault is switched on e disconnected thermocouple alow voltage thermocouple is connected with the wrong polarity e safety cutout see 4 12 has responded If a
49. ey FA and enter the number 8 Now you see display showing the transfered or received data The keys assignment for Fo or keys depend on the machine type used If the before described action does not enable o the debugger then please ask the Engel company how you can select the debugger on your machine More information on the debugger is in chapter 5 4 7 fault reports Fig 5 6 Key for debugger selection Hint Please not that for set values of current the Engel machine display the value in percent 100 equals 120A 5 4 3 Input of set values If the set value or machine settings needs to be changed use the following procedure By using the cursor keys the cursor must moved to the position to be changed When the positon is reached shown by an inverse representation of the associated symbol the new set value is entered using the numeric keypad To accept and confirm the value press enter 5 4 4 The image hot runner channels Heisskan le For more detailed information see the Engel user manual The image Heisskan le displays all runners of the DP15 E at one time The column Zone shows the runner number the DP15 E In the column you can activated the communication for each runner EIN for on and AUS for off Runners which are not used or have failed must be switched off AUS In the column Soll set the set value must be entered The display of the actu
50. fault occurs the entire power system of the control unit is shut down and deactivated for safety reasons In the event of thermocouple failure it is possible to operate the affected runner manually With other faults the fault must be located and repaired first and then the control unit has to be switched on again or the runner channel must be switched off before moulding operation can be continued The LED for collective fault is switched on and the IST EXIST display is flashing with the display indicating e A TRIAC short circuit 4 4 Revision 10 96 DP15 E P2 8 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E A TRIAC has been destroyed by an external short circuit possibly a wrong fuse type used By removing the fuses and loads nozzle and distributor step by step it is possible to find the defect runner When changing the fuse it is important that the new fuse is a super fast 10 type FF 10 250V fuse The LED for collective fault is switched on yet no fault occurs Load separated adjustment mode is active see 4 9 The LED for collective fault is switched on and the IST EXIST display is flashing with the display indicating e plausibility error A low voltage runner has been detected on a higher channel than the first 230 V runner The channel number display shows the zone number of the 230V runner which is placed directly before the detected low voltage runner This arran
51. gement isn t allowed note parameter 43 All 230V runners have to be connected to the higher zone numbers The IST EXIST display is flashing with the display indicating UUU e internal controller temperature is too high The last error messages will be saved and can be displayed by using the parameters 26 to 29 The parameter 26 contains a counter of errors which occured before the controller was switched on The counter on parameter 28 displays the number of errors which appeared since the unit was powered up The corresponding error codes are stored in parameter 27 and 29 code number error discription 11 triac short cut 19 load disconnection 13 thermocouple disconnected 14 internal error 15 security cut off 16 plausibility 17 polarity of thermocouple 18 current error ampere error 19 internal controller temperature 20 reserve Revision 10 96 DPIS E P2 8 4 5 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS 4 9 Load separated adjustment mode make adjustments during temperature critical applications it is possible to set DPIS E to a load separated adjustment mode which does not heat up the nozzles To set this mode press both and keys and switch the unit on The mode is displayed by the collective fault LED To quit the load separated adjustment mode the unit must be switched off In the load separated adjustment mode all loads are switched off by the main r
52. hen the injection moulding machine is sending information red TXD gt output DP15 E if the LED flashes then the DP15 E is sending information Current loop disconnected Please check the unit address If the address is ok then check the cable connection Unit doesn t respond e The same as above Current loop disconnected Power unit fails e Anerror in the power unit of the DP15 E has been detected Check the cable connection and the load Internal unit fault A broken thermocouple has been detected Thes faults are displayed on the 15 for each runner Check the thermocouple In principle the hot runner can still be operated in the control mode Temperature out of tolerance A user error on the Arburg machine Input of wrong values too small too large A user error on the Arburg machine 5 4 Revision 10 96 DPIS E P2 8 Z G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E Input of C at the same time only one value possible A user error on the Arburg machine 5 3 Operation with Krauss Maffei MC3 injection moulding machine 5 3 1 General controls For more detailed information please refer to the Krauss Maffei manual Communication between the DP15 E and the injection molding machine does not need to be enabled and begins as soon as the unit has finished the self test routine To enable the transfer of set values to the DP15 E authorisation must
53. hreshold example you choose 100 for parameter 21 and the new safety disconnection is by 400 C The ramp time standard 5 min set time value of parameter 22 is increased from 0 to 50 The ramp time should be selected in such a manner that the DP15 E reaches the temperature of 105 C at the end of the ramp 23 After the start up procedure softstart the temperature of 105 C should be hold for the adjusted time The holdtime is used to adequately dry out the nozzles with a low thermic load see 4 2 N 6 7 WW Revision 10 96 DP15 E P2 8 3 7 Z G NTHER User Manual Hot Runner System DP15 E HOTRUNNER SYSTEMS No Description You have the possibilty to choose the thermocouple types parameter The standard setting is 0 for iron constantan see 4 13 25 The parameter lowering in per cent be caused by one channel which is using without sensor in per cent from the regulated quantity The parameter 26 27 28 and 29 serve for the errorlocation from software hardware 30 systemerrors Arburg unit number standard value 1 for address I The interface protocol must be identical with the using interface parameter 3T seton 0 without Interface support In parameter 31 you could choose the interface after that the DP15 E choose in parameter 32 automatical the baudrate 2400 baud Bose Rising temperature
54. icator In addition to this the temperature rise will be shown on the set value display By using the keys A and B simultaneously one can now obtain a reading of the test results for each of the runners put through the diagnostic program The following example will illustrate and explain the evaluation procedure 4 2 Revision 10 96 DP15 E P2 8 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E Set value Actual value 15040 45 2 Runner number reading number of the testchannel Set value reading number of the channel with the highest temperature difference Actual value reading temperature increase in C from the channel with in set value is shown Fig 4 1 Diagnosis results The results of the data should be interpreted as follows When runner 1 is heated the temperature rise in runner 2 is greatest The same applies in reverse The conclusion which can be drawn is that the thermocouple or heating circuit connections of the runners 1 and 2 have been swapped by mistake However while runners 3 and 4 have been properly connected the temperature increase in runner 4 is inadequate when compared to the temperature rise in the other runners This might indicate a defect in the thermocouple short circuit exists The temperature reading for runner 5 shows no increase in the temperature for this runner The thermocouple 5 is not connected Hints In order to obtain clear a
55. ket with cable for max 8 runners AG 8 e 32 pin connector socket with cable for max 15 runners AG 16 If you order a power cable the following information is required e Number of low voltage runners e Number of 230V runners e Type of low voltage connection such as 720 pin or 39 pin or for DLA for or DL12 e of connections for 230 V 10 pin 16 pin or 32 pin AG 5 AG 8 AGI6 Hints To prevent connection errors between the temperature controller DP15 E and the power unit the load connector of the DP15 E is mechanically coded The power cables should be equiped with the same encoder system as the DP15 E This applies only for units using a star net supply see appendix C You can also order cable for connecting several low power units to DP15 E e g connection for 2 x DL8 or 3 x DLA etc Signal inputs and outputs of the DP15 E Output Fault Def If a thermocouple or heating circuit failure is detected it will be reported here The output Defect fault is a potential free normaly open contact for 230V max or a protected extra low potential as specified by VDE VDE union of german electrical engineering The contact must be fused externally A corresponding plug with 2 5m cable can be ordered from the GUNTHER HOT RUNNER SYSTEMS company 6 2 Revision 10 96 DPIS E P2 8 Z G NTHER Output Ready to start moulding operation OK As soon as the adjusted runners
56. ll loads have completed their Softstart see 4 2 The Softstart is indicated by a point beside the actual value display The scan mode can be cancelled by pressing any key and restarted by pressing the E key in the operation mode Hint If a fault occurs the scan mode will be terminated and channel number causing a fault will be shown on the display If several faults occur at the same time the zone where the first fault occured is displayed This display also appears during a fault condition when you switch from the operating mode to the scan mode The user is able to set the speed for scanning the runners see parameter No 3 Additionally the user is also able to set the maximum number of zones to be scanned see parameter No 2 Revision 10 96 15 P2 8 3 1 Z G NTHER User Manual Hot Runner System DP15 E HOTRUNNER SYSTEMS 3 3 Operation mode 3 3 1 Changing set values After the scanning operation is terminated by pressing any key a zone is selected by pressing or key The desired set value is entered by pressing the or key Their function is dynamic i e the longer the key is pressed the quicker the set point value changes The flashing dots below the set point numbers indicates that the new set point has not been entered into the system By pressing the key the new set point can be confirmed and entered If the zone number is changed or the F
57. ls nozzles distributor and control unit to ensure trouble free operation Incorrectly connected circuits are located before start of operation Low installation cost due to combined thermal and power connections The DP15 E has numerous special functions for optimal system utilization Advantages for the user Power output surveillance is possible during operation Decrease temperature for all control points by simply pressing a key Reading of the effective current at low voltage Several set value programs simplify material or tool change If desired a serial interface is available as connection to the injection moulding machines Revision 10 96 DPIS E P2 8 Z G NTHER HOT RUNNER SYSTEMS User Manual Hot Runner System DP15 E 2 Operating and display controls The operating and display controls of the DP15 E are located on the operation control panel and the parallel display Great emphasis has been placed upon ease of use and good layout 2 1 Operation Heisskanaltechnik LED Indicator Exit Value Indicator SOLL SET SET Value Indicator Runner Number Wa 90 Keys Fig 2 0 Operation control panel DP15 E Key functions Function of the LED Indicator 9 Percentage mode Sensor is broken A Current in Ampere Headcircuit Is broken F Degree Fahrenheit Collective fault C Degree Celsius OK Ready to Inject Keys A
58. n the slowest nozzle adjustable 0 255 C 0 255 F adjustable 0 255 C 0 255 F adjustable 0 500 C 0 500 F Data recovery after current failure Data storage lifetime at least ten years without battery Operating section seven segment 13mm display and LEDs Parallel display seven segment 8mm display and LEDs Front panel with integrated mechanical keys and key foils 0 to 70 C to 35 C IP 20 w h d 468mm x 142mm x 345mm 28 61 Ibs 13 0 Kg grey and blue RAL 9018 and RAL 5015 Revision 10 96 DPIS E P2 8 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E Appendix E Service form Addresses see appendix I FA To From Company Company Phone Phone FAX Fax City City Date Date Response partner Please call back Ask for customer service Ask for repair other Service Form for control units from the GUNTHER HOT RUNNER SYSTEMS company Type of unit Serial number Program version Used connecting cable Net voltage Net kind star triangular other Connected loads a SV runners b 24V runners c 230V runners If power units 5V 24V are used are collective rails connected Description of previous history Initial startup prior operation etc Problem description Revision 10 96 DP15 E P2 8 E 1 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS Appendix F Quick reference of
59. nd straightforward information from the diagnostic program the following recommendations should be followed e Only runners that are connected are tested By switching off unused runners channels the diagnostic testing time is reduced e The obtained temperature increases depend upon several factors such as the set value the time interval the temperature rise and the load nozzle e The tool should be at a relatively low temperature This means it is necessary to cool down the tool before the diagnostic test e The duration of a diagnostic test should preferably not be less than 30 seconds and the temperature increase should be at least more than 30 C This should avoid incorrect temperature data due to already heated channels e With a 230 voltage load a longer test duration leads to correct results if average set values are used e The adjustable variable for diagnostic tests should not be less than 40 e With complicated wiring mistakes it will be necessary and advisable to proceed slowly and cautiously step by step This means that only some and not all of the thermocouple should be connected for each diagnostic test phase By simultaneously pressing the keys and it is possible to lave the diagnostic program 4 7 Ready to start moulding operation Revision 10 96 DP15 E P2 8 4 3 Z GUNTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEM S As soon as the adjusted runners have reached the pres
60. nit e Plug the interface modul into the 20 pin connector so that both transformers are placed vertically one over the other Remove the filler panel at rear of the unit Revision 10 96 DPIS E P2 8 6 3 Z G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E e Pull the pole connector with its flatribbon cable through the opening of the unit and connect the D Sub 9 pin connector by using the spacer bolts and nuts from the outside of the unit Plug the flatribbon cable onto the interface modul Interface typ TTY RS232 Hint ATTENTION check the polarity Pin 1 of the PCD must correspond to pin 1 of the socket e Fix the sealant material to the unit so that the interface modul is secured by the unit cover See picture 2 Replace the unit cover and refasten the screws ay the cable to the injection moulding machine and fix up the connectors on both sides Interface protocol and baudrate adjust Parameter 31 and 32 Parameter 31 protocol typ 0 without Interface support 1 Engel protocol 2 ARBURG protocol 3 Krauss Maffei protocol 10 test protocol actual value temperature of the hot runners Parameter 32 Baudrate 1 1200 baud 2 2400 baud 3 4800 baud standard for ARBURG protocol and Engel protocol 4 9600 baud standard for Krauss Maffei MC3 5 19200 baud 6 4 Revision 10 96 DPIS E P2 8 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS I RXD
61. o be changed the runner has to be initially switched off see above Switching off does not have to be confirmed If the key is now pressed the operating mode is changed from Thermocouple to Percentage as indicated by the flashing of the relevant LEDs If the key is pressed again the operating mode will also change The set value is set at and can be changed with the key The new set values must then be confirmed with the key 3 3 4 Lowering or rising the temperature If production stops for a longer period of time it is advisable to lower the set temperatures without turning the unit off By pressing the keys and B at the same time lowering temperature is activated The runner number indicator shows the label for decreasing if you use F then the indicator shows an 17 An external activation of the temperature lowering is possible by connecting a closing contact at the rear side of DP15 E It is possible to connect a potential free contact to the unit with a cable which is available from GUNTHER HOT RUNNER SYSTEMS specially for relay output of injection moulding machines If temperature lowering is active the zone number display shows the value for Absenkung lowering in German and Fahrenheit for lowering Simultaneously the actual value of the last shown runner is displayed In this state no other user control is possible Re
62. o exchange the fuses first pull OUT the power plug The cover of the unit may then be removed by unscrewing 4 screws both on the left and the right sides Hint Please only use fuses that correspond to specification in the bottom drawing A package of original reserve fuses is included inside the DP15 look at the positioning plan The following diagrams show the fuse positions in the various versions of the DP15 unit Fuse Positions DP15 ee 1909 ee Runnernumber 12 11 10 9 DP15 15 8 7 6 5 4 3 2 1 Runnernumber 8 DP15 10 4 Runnemumber 4 3 2 1 Fl DP15 5 Fuss T50 mA FF16A ann Typ FFIOA or Wickm Typ 16LCT TR5 160 mA solder Fuse for the bus board LR 11 MT 200 mA Picture Fuse positions Revision 10 96 DPIS E P2 8 B 1 User Manual Hot Runner System DP15 E FUSE POSITIONS of the DP15E CE Version Z GUNTHER HOT RUNNER SYSTEMS The outputs for a maximum of 15 zones are separate fused with superfast fuses These fuses are located on the triacmodul inside of the DPISE and also on the backplane of the DPISE The fuses from the last 3 runners are within easy reach on the backplane In order to exchange the fuses first pull OUT the power
63. of thermocouple failure e Existing power units from the 160 series can continue to be used as the DP15 E control unit is compatible with all existing GUNTHER power units Because of the module construction system upgrades are possible The DP15 E is reliable and safe due to continuous checking and monitoring functions Advantages for the user Continuous self monitoring function Protects low voltage nozzles from current overload Identifies thermocouple failures heat circuit disconnections and short circuits Turns off the power supply in case of a malfunction and signals the alarm via a potential free contact Revision 10 96 DPIS E P2 8 1 1 Z G NTHER User Manual Hot Runner System DP15 E HOTRUNNER SYSTEMS Parameters and programs are saved in an EEPROM and are therefore not lost in the case of a power supply failure The DP15 E is designed for easy use this makes installation and tool change simple Advantages for the user The DP15 E is especially designed for simple and easy operation The multi function keypad has an easy to use layout and because of its dust and water proof key pad it daily withstands tough environments The simple operator entry levels prevents wrong operation hot runners are simultaneously displayed and for each hot runner the set and actual values The control parameters are adjustable according to the application The diagnose function tests the complete system consisting of too
64. ol mode the present setting will be displayed briefly in the indicator At the same time the LED indicator will display the value This percentage reading equals the flow of current amps in percent The adjustable variable for the actual setting makes it possible to observe the course and progress of the operation in the thermocouple control mode and to determine the suitable adjustable variable for the current after the predetermined temperature has been reached 4 6 Diagnostic program Occasionally when new tool is connected to the system the electrical connections can be mixed up and or incorrectly connected This type of error may not always be detected during normal operation of the control unit The diagnostic program provides an easy tool for quick detection and localisation of this type of error The diagnostic program tests the combined function of the tool and the control unit and checks for wiring faults It can identify and locate incorrect connections particularly those between the thermocouple and the heating circuits It can also be used to detect short circuits in the thermocouple All operating zones are tested in sequence For a specific testing period one preset heating temperature is used Simultaneously the temperature conditions of all of the other runners are recorded Should specific rise in temperature be recorded inside the maximium testing period the unit will automatically switch over to check the next
65. on 10 96 DPIS E P2 8 G NTHER HOT RUNNER SYSTEMS User Manual Hot Runner System DP15 E 3 Operating instructions 3 1 Switching on General information After the unit has been switched on the program revision number will be shown on the display identified by the letter Then the unit automatically performs system check which includes the heating circuits whether a low voltage or 230 volt load is connected During the hot runner channel test JU and the channel number is displayed If faults are detected on the system or the loads nozzles distributor or cables the fault is displayed and the loads are switched off When low voltage nozzles are used the current pick up will be shown in the set value indicator With 230 volt nozzles the indicator will show 0 3 2 Scan mode After the end of the calibration the controller is in the scan mode The scan mode is indicated by decimal point at the end of the channel number display Zone In this mode the zones with set and actual values will be displayed in the left display section one after another Runners which are switched off will be skipped The unit F for each zone number will be displayed at the same time Loads for 230V for set values above 105 C 221 F will activate Softstart If the Softstart is active for a nozzle the temperatures for each load will be regulated to 105 C The regulation to 105 C ends if a
66. perature lowering 4 3 Starting ramp In hot runner systems you will often find loads with different thermic time constants If the time constants differ widely then a fast nozzle reaches its set value earlier than the slow manifold This physically based heat up delay can generate plastic defects in the nozzle because it reaches the set value much earlier then the other nozzles This is the reason why it is possible to switch on the starting mechanism with parameter 9 The starting mechanism ensures an even set value based heat on all of the different nozzles The individual nozzle will be decoupled from the leading mechanism 50 C before reaching the set value If the starting mechanism isn t required the parameter 9 must be set to zero 4 4 Display of the current value By pressing the F key in adjustment mode when using low voltage nozzles the actual current value will be displayed It should be taken into account however that if the adjustable variable for the current is changed several seconds are required before the change can take effect and the new current value is measured and displayed With this function it is possible to establish a relationship between the adjusted variable and the current intensity Revision 10 96 DPIS E P2 8 4 1 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS 4 5 Display of the setting By pressing the key while in the thermocouple contr
67. r current a clamp ampmeter with a true RMS reading can be used Current range 0 150A for low voltage or 0 10A for 230V types In case you encounter any unexpected problems we offer customer service via telephone fax or personal visits Before getting in contact with us please fill out the service form sheet see appendix so that a maximum of detailed information is available 6 8 Revision 10 96 DPIS E P2 8 Z G NTHER User Manual Hot Runner System DP15 E HOTRUNNER SYSTEMS 6 3 Installation of a new software EPROM Hints Attention Before opening the DP15 E switch the unit off and disconnect the mains plug Check that the DP15 E is properly disconnected For a softwareupdate all loads and thermocouple connector must be disconnected and if installed the interface connector to another unit must also be disconnected After this remove the cover of the unit by removing the four screws on the side of the unit and pull the board with the name LR10 See positionplan appendix out of the carrier Before this unlock the PCB slides The EPROM can now be changed During replacement please make sure that the new EPROM is positioned correctly on the socket and that all pins are inserted into the socket Reinsert the LR10 board into the same slot with same orientation and close the slide locks on both side of the carrier Then place the cover on the unit and screw them together After power on the DP15 E unit performs an update and ad
68. runner The adjustable variables the maximum duration for the test and also the desired rise in temperature can be set by using the parameter values Therefore it is recommended that prior to the start up the respective parameter settings are checked and if necessary adjusted to meet changes The diagnostic program is initiated by simultaneously pressing the keys and B in the program mode The diagnosis can only be stopped by switching off the unit The number of the zone which is being tested will be shown on the zone display The actual value indicator will show the temperature of this zone The set value display shows an incrementing second counter which counts up to preset time All of the LED s are flashing At the same time the parallel indicator will indicate the temperature differences so that an individual evaluation is possible During the testing phase initial information about the wiring can be made available If the recorded temperatures clearly indicate an effective rise in temperature this confirms that the runner has been properly wired into the system After the diagnostic tests are completed the flashing of the LED s stops and the test protocol can be displayed The actual value display shows the assigned number for each runner in which the temperature rise has been the highest during the test run Usually it will be identical with the number assigned to the tested runner displayed by the runner number ind
69. s shown There are also two different procedures to turn on runners set and existing value display which have been switched off 1 Using the key the set value is set and confirmed by pressing the key It is important to check the actual operation mode by using the 3 2 Revision DPIS E P2 8 G NTHER HOT RUNNER SYSTEMS User Manual Hot Runner System DP15 E 2 By pressing the keys C and D at the same time the display shows the last valid set value before switching off This can be confirmed with the keys and or after changing use the same keys to confirm If this runner was not switched off in the same way the set value occurs The old set values are available after switching on even if the unit was switched off Runners which are switched off will not be displayed in the scan mode and are not checked for faults anymore 3 3 3 Changing the operating modes Thermocouple Percentage In the event that a thermocouple fails to function or for any other reason the percentage control mode can be carried out to continue the control operation manually The current will then be displayed in percent 96 For low voltage nozzles it will be 100 equals approximately 120 amps on 5V loads 10096 equals approximately 25 amps on 24V loads The valid operating mode will be displayed by the LED s or or F If this valid operating mode has t
70. stomer service 4 6 Revision 10 96 DP15 E P2 8 Z G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E 4 12 Variable safety disconnection If the runner channel temperature exceeds 500 C the load circuit is disconnected for saftey reasons If you want do set the value of the temperature threshold below 500 C you have the possibility to set the parameter 21 between 0 and 500 The set value is be subtracted from 500 C and this new value will be used as the new safety threshold If a safety disconnection occurs the loads are disconnected and the fault is displayed on the panel The fault is displayed by the flashing thermocouple disconnection LED To avoid confusion with a thermocouple fault the thermocouple failure identifier ll will not be displayed The fault can be acknowledged by cycling the hot runner power If temperature is displayed in Fahrenheit the set value is doubled and then subtracted Example at 300 C the safety cutout should be happened 500 C 200 C 300 C gt Parameter 21 200 C 4 13 Temperature measurement The temperature of the hot runners are measured by thermocouples The thermocouple generates a temperature dependant thermo electric voltage This thermo electric voltage is measured by the DP15 E compared with the characteristic curve of the thermocouple converted and then displayed as an actual EXIST temperature From software version 2 50 onwards different thermocouples can b
71. thermocouples are set for heating operation with a set value of 0 C Program 2 as supplied e Disconnected runners which therefore could send fault signals should be switched off Following this no fault signals should now be generated e Set parallel display to show actual values e Set the set value for the first runner to a temperature increase e g 100 and observe the parallel display See if the temperature in this runner rises or if the temperature rises in another runner If the temperature in another runner rises more quickly this will indicate a fault e Shut down the first runner again and repeat this for all runners in sequential order Continue this procedure with all runners The same procedure is performed by the diagnostic program see section 4 6 6 2 4 Additional comments Hints When working on the 230V loads it is important that the DP15 E is switched off and the mains plug is disconnected e The DPIS E unit differs from most other 230V microprocessor control units in sofar that it provides an immediate current reading of 230V loads during power on and gives a definite indication if a heater circuit is disconnected With low voltage runners it is possible to visually check for shorts in the heater circuit by pressing the key and observing the adjustable variable in amp re output With 230V the display will be in The valid standard is displayed with LEDs in or Amps To check the heate
72. this in percent 100 120A 5 3 3 Input of set values If the set value or a machine setting needs to be changed use the following procedure By using the cursor keys the cursor must be moved to the position that has to be changed When the position is reached shown by an inverse display of the associated symbol the new set value is entered using the numeric keypad The input is displayed on the bottom line of the display To accept and confirm the value press enter 5 3 4 The images B13 and B17 Hot runner system 401 416 The Hot runner system DPI5 E is visualised with images and B17 The DPIS E offers a maximum of 15 hot runners Hot runners 1 15 on the DP15 E correspond to hot runners T401 T415 on the Krauss Maffei injection moulding machine Set value input for higher numbered hot runners will be ignored The image B13 shows the hot runner number the set value the actual value the tolerances and possible faults in the DP15 E in text mode Image B17 shows the temperature in bar chart form Please take into account that when operating with an interface the DP15 E hot runner channels have specific tolerances Note If the DP15 E is operating without an interface connection then the tolerances set in parameter 1 are valid 5 3 5 Lowering The lowering feature of the DP15 E is not used by the Krauss Maffei machine lowering is achieved by corresponding set value selection 5 6 Revision 10 96 DPIS E P2 8
73. uit 6 2 4 Additional comments Installation of a new software EPROM Appendices Appendix A Cable and connection assignment Coding the regulation unit Coding the powercomponent Type LS Appendix B Fuse positions Jumper settings LR15 LR17 Appendix C Star Delta switch over Appendix D DP15 Technical data for the DP15 and DP15 E Appendix E Service form Appendix F Quick reference of the DP15 E unit instructions Appendix DP15 and DP15 E Schematics Appendix H Layout schematics of DP15 and DP15 E Appendix I Addresses Appendix J EG Declaration of conformity Z G NTHER HOT RUNNER SYSTEMS LN CA CA CA CA UA CA CA CA CA CA CA 1 1 1 1 1 1 1 1 1 1 ka M WMD M Ch 09 tA NNNO0O 1 1 Lu ka Ch Ch Ch AA ANA 1 eH E Dim Dm DO DD gt gt Fe DI Revision 10 96 DP15 E P2 8 Z G NTHER HOT RUNNER SYSTEMS User Manual Hot Runner System DP15 E Warranty conditions 1 Installation and Start must be carried out by an electrician 2 Prior to installation please refer to chapter 6 of the DP15 E user manual Installation amp Start up 3 Before connecting the unit to main power supply please check mains voltage and type of net Star Delta 1 Safety precautions The hot runner system DP15 is available in the ground s
74. umber of the parameter and the set value display shows the parameter value By operating the and keys the parameter number can be selected and with the and keys the desired value can be set These changes are then entered by pressing the key When and keys are simultaneously operated the setting operation is terminated 3 5 1 Meaning amp interpretation of the parameters The system parameters of the DP15 E can be changed in the parameter level The parameters have the following meaning Parameters which are marked by F may be only changed by the GUNTHER HOT RUNNER SYSTEMS Parameters marked with G cannot be changed The meaning of parameters which are marked with N can by inquired at GUNTHER HOT RUNNER SYSTEMS company The parameters 20 and 31 to 38 are reserved Revision 10 96 15 P2 8 3 5 Z G NTHER HOT RUNNER SYSTEMS in or F 0 equal 10 10 15 User Manual Hot Runner System DP15 E N phase in 0 3sec intervals ing in C Fahrenheit F Set point value during diagnosis in diagnosis period for each runner in sec 15 B alo g un 8 amp B m c un Bx QO e ES D lt e D ES Ta
75. up Hints For faults that are not associated with the interface connection the DP15 E should be disconnected from the injection molding machine for the purpose of fault location The interface specific faults are explained in the following text For fault location the DP15 E LEDs used These are visible if the unit cover is removed If the current loop is closed then both RXD and TXD LED s must be on green RXD input DPIS E if the LED flashes then the injection moulding machine is sending information red TXD gt output DP15 E if the LED flashes then the DP15 E is sending information 5 12 Revision 10 96 DPIS E P2 8 Z G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E The Engel injection moulding machine offers the option to use a machine integrated debugger for fault search In chapter 5 4 2 is described how you can start the debugger The debugger displays the information that is send an received by the interface The injection moulding machine sends a telegram of set values and DP15 E responds to this by sending the actual values With this tool you can quickly find out if communication is working The telegram of the moulding machine causes a current echo because the connection is wired as a current loop After this echo the answer from the moulding machine must be received by DP15 E If no characters are received Check the cable connection Check the polarit
76. vision 10 96 15 P2 8 3 3 Z G NTHER User Manual Hot Runner System DP15 E HOTRUNNER SYSTEMS Additionally it is possible to increase the temperature for all runners at the same time By pressing the keys and at the same time the temperature rise is activated The runner number is displayed and UA for rising if you use F then the indicator shows 177 The temperature lowering mode is cancelled by pressing the keys and F simultaneously once more Now the old set values are valid The lowering value may be adjusted by parameter A in C F 0 255 or by parameter 25 96 0 100 The rise temperature mode is cancelled by pressing the keys and The rising value may be adjusted by parameter 39 in C F 0 255 or by parameter 40 in 0 100 If the lowering or rising is cancelled the old set values are restored 3 3 5 Parallel display The parallel display allows simultaneous observing of all runners This display also shows the present set value the actual values the temperature deviations or the actual percentage values Switched off zones are shown For zones operating in the percentage mode the display shows all values in Zones operating in the percentage control mode can be identified by a vertical line in the space before the first digit in the LED indicator If the thermocouple is damaged the indicator will show 11
77. y If characters received are distorted Check the interface settings e 8 Bit UART 4800 baud no parity one startbit one stopbit TG SOLLW A BEREICH Set value out of range Wrong input from the user Temperature limits during input were exceeded TG F HLERBRUCH Thermocouple is disconnected e The DP15 E has detected a disconnected thermocouple Check the thermocouple You can continue to use the hotrunner in the percentage mode TG HEIZUNG DEFEKT Heater unit failed A load disconnection has been detected Please check the cable connection and the load itself TG KOMMUN TIMEOUT Communication timeout The communication between the DP15 E and injection moulding machine is disturbed e Please check the cable connection TG TEMP ZU HOCH Temperature to high TG TEMP ZU TIEF Temperature to low High temperature limit Low temperature limit The set tolerances values were exceeded These errors always occurs during preheating phase of the hot runners If the temperature exceed the tolerance limits during normal injection moulding operation then please check if the tolerances are to small Revision 10 96 DPIS E P2 8 5 13 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS 6 Installation and start up 6 1 Installation 6 1 1 System setup The absolute measures of the appliance can you see into appendix D During system setup make sure not to obstruct the air circulation
78. y be too small 5 Set value failure An operator error has occured The temperature limits were not stored after input 5 8 Revision 10 96 DP15 E P2 8 G NTHER HOTRUNNER SYSTEMS User Manual Hot Runner System DP15 E 5 4 Operation with Engel CC90 injection moulding machine 5 4 1 General controls For detail informations please see the Engel manual The communication between the 15 and the injection moulding machine starts without authorization as soon as the selftest programs have passed 5 4 2 Image selection The high number of possible operations means that a selection of different visualisation imagemasks is required The single imagemasks in the following called image contain tables and much more The selection of each image is performed by pressing the image activating key The display map for hot runners will be activated by pressing the key shown in figure 5 4 followed by pressing the F6 key Softkey re Fig 5 4 Key for mould heater The alarms can be selected by pressing the key which is shown in figure 5 5 9 9 Key for alarm image Revision 10 96 DPIS E P2 8 5 9 Z G NTHER User Manual Hot Runner System DP15 E HOT RUNNER SYSTEMS For easy error location the injection moulding machine CC90 has implemented debugger The debugger is selected by pressing the following keys press key displayed in figure 5 6 press the F6 key enter the password 222222227 press the k
79. ystems DP15E CE Version and DP15 US Version The following explain description relate to both control unit in doing so the differences always separate demonstrate This unit has been built and tested accodring to DIN 57411 part 1 and VDE 0411 part 1 Germany It has left the factory in perfect condition In order to keep your product fully operational and to guarantee safe operation please read this instruction manual carefully and follow all hints Before switching on it is important to check that the local voltage is complimentary to that allowed by the unit The plug should only be plugged into to an earthed socket Any disconnection of the earth cable e g an extension of the cable without earth connected can cause hazardous conditions on the unit Hint Disconnect mains before opening unit Refer to a qualified technician for servicing The DP15 E unit is an optimized hot runner control unit it is more efficient and reduces costs Advantages for the user Available in 5 10 15 hot runner versions according to the user s requirements The DPIS E automatically recognises low voltage nozzles and 230V hot runner elements and sets its control parameters accordingly e Only one unit is required for mixed operation e PID controller with variable parameters fast heating of 5V and 24V low voltage nozzles careful heating of 230V hot runner elements Control operation is possible at all times even in the event

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