XL-2-Series - Mold
Contents
1. Revision 1 1 Mold Masters Page 5 Welcome XL 2 Manual Welcome Mold Masters welcomes you to their XL 2 temperature controllers for hot runner injection moulding tools This particular member of the proven family of Mold Masters Hot Runner Controllers is user friendly and retains the standard control facilities associated with other Mold Masters controllers How to use this manual The purpose of this manual is to give you a complete understanding of how best to use the controller and to assist where there are problems or faults The Navigation section contains a brief technical description of the system components and a portrayal of the Mold Masters operating philosophy that facilitates precision temperature control The following chapters then take you carefully through the stages of setting up and running a new control system After considering system maintenance the final sections look at trouble shooting to assist in the unlikely occurrence of a system fault Page 6 Mold Masters Revision 1 1 XL 2 Manual Installation Installation Where to use this equipment WARNING Mold Masters Hot Runner temperature controllers are designed for use in the plastic injection moulding industry as temperature controllers for hot runner systems as commonly used in mould tools The controllers must not be used in residential commercial or light industrial environments Furthermore they must not be used in an explosive at2. 4609138 4705473 4740151 4747770 4771164 4777348 4786246 4793795 4795338 4818217 4820147 4836766 4837925 4865535 4891001 4911636 4917593 4917594 4919606 4921708 4923387 4932858 4938681 4941249 4945630 4979892 4981431 5000675 5002480 5007821 5015170 5022846 5028227 5030084 5046942 5049062 5061174 5094603 5106291 5118279 5118280 5122050 5125827 5135377 5142126 5148594 5206040 5217730 5223275 5227596 5227181 5235737 5238378 5238391 5268184 5269676 5282735 5284436 5299928 5312242 5326251 5334008 5334010 5346388 5366369 5366370 5387099 5405258 5421716 5427519 5429491 5437093 5441197 5443381 5460510 5474440 5494433 5496168 5507635 5507636 5536165 5591465 5599567 5614233 5641526 5644835 5652003 5658604 5695793 5700499 5704113 5705202 5707664 5720995 5792493 5795599 5820899 5843361 5849343 5853777 5935615 5935616 5935621 5942257 5952016 5980236 6009616 6017209 6030198 6030202 6062841 6074191 6077067 6079972 6095790 6099780 6113381 6135751 6162043 6162044 6176700 6196826 6203310 6230384 6270711 6274075 6286751 6302680 6318990 6323465 6348171 6350401 6394784 6398537 6405785 6440350 6454558 6447283 6488881 6561789 6575731 6625873 6638053 6648622 6655945 6675055 6688875 6701997 6739863 6752618 6755641 6761557 6769901 6776600 6780003 6789745 6830447 6835060 6840758 6852265 6860732 6869276 6884061 6887418 6890473
3. Control Method Operating Range Control Accuracy Earth Leakage Measurement Thermocouple input Power output Temperature scale Output Overload protection Card Diagnostics LED s Alarm Output Interface Case Details Page 4 380v 3 phase 50Hz with neutral others available 220 60Hz Delta PIDD self optimising 0 450 C 1 C Earth leakage measurement on individual cards set at 100KQ Iron Constantan Fe Con type J type kK or type L 16A 3600W Centigrade Celsius or Fahrenheit 16A super quick acting FF fuse Zone1 Zone2 Ground Fault T C Fault Temperature Alarm and Current Overload Double pole change over volt free contacts 1A max burden Optional Heavy duty metal cabinet Mold Masters Revision 1 1 XL 2 Manual Safety Instructions Safety Instructions DO NOT enter the cabinet without first ISOLATING the supplies there are unguarded terminals inside the cabinet which may have a dangerous potential across them Where a three phase supply is used then this potential may be at WARNING 380 volts or higher Safety Notices an explanation Within this manual safety instructions are marked as follows A WARNING symbol and message shown here identifies where there may be a hazardous situation which if not avoided may result in death or injury to personnel WARNING Most warnings pertain to electrical aspects and you must comply with them to minimise any personal danger
4. Viewing 26 Run Mode 20 Safety Instructions 5 Sensor Type Selecting 16 Set Temperature Changing 22 Special Operating Mode 25 Special Operating Modes 9 Specific faults 28 Specifications 4 Standby level setting 17 Standby Mode 20 Starting before switching on 7 Switching the whole system On and Off 8 Temperature Display Screen 9 Temperature limits setting 18 Temperature Scale changing 16 Three Phase Designation 31 Toggle Zones 9 Toggling Zone Automatically 22 Toggling Zone Manually 22 Troubleshooting 27 Wiring Standards Delta Star 31 Zone Temperature setting 16 Zones Switching 9 Mold Masters global support facilities Canada Mold Masters Limited 233 Armstrong Avenue Georgetown Ontario Canada L7G 4X5 tel 1 905 877 0185 fax 1 905 873 2818 email info 9 moldmasters com Germany Mold Masters Europa GmbH Postfach 19 01 45 76503 Baden Baden Germany Neumattring 1 76532 Baden Baden Germany tel 49 0 7221 5099 0 fax 49 0 7221 53093 email info 9 moldmasters de China Mold Masters Kun Shan Co Ltd Zhao Tian Rd Lu Jia Town Kun Shan City Jiang Su Province People s Republic of China tel 86 512 86162882 fax 0512 86162883 email MMC Sales moldmasters com regional offices United Kingdom Mold Masters UK Limited Unit 28 The Gateway Birmingham Airport Birmingham B26 30D United Kingdom tel 44 0 121 781 7800 fax 44 0 1
5. card The two blue LEDs on the right indicate which zone s information is currently shown Zones can be switched anytime in Temperature Display Current Display or Power Output Display to show reading accordingly e Use to switch between two zones to view display Function Menu Revision 1 1 In this menu you can put the controller into particular working mode However Program Menu is used for changing controller set up Manual and boost mode can be set independently in each zone however standby mode always activate in both zones when the mould tool is paused Manual Mode Hnd Standby Mode tdn Boost Mode tUP Program Mode Prog e From any of the main screens press and hold for at least 2 seconds to get into Function Menu e Use A or amp to scroll through the menu e Press LC to enter into your desire mode or press Eto get back to Temperature Display Screen without changing to other mode Mold Masters Page 9 Navigation XL 2 Manual Program Menu Within this menu there are a number of controls that are provided for you to customize your controller You can select this menu from the Function Menu only Each zone has its own program menu items to meet its own needs however there are some items shared by two zones Refer to Customize your controller section for detailed explanation on each parameter in the menu e n Function Menu use A to scroll to Prog and then press C to ente
6. menu changes Press and hold it for 2 seconds to get out from special working mode Selector Toggle between two zones Press and hold it for 2 seconds to get into function menu Escape from function or program menu IO Turn controller card ON OFF Mold Masters Page 11 XL 2 Operation Diagram XL 2 Manual XL 2 Operation Diagram Main Screens 200 H Press E Press 3 Temperature Display Current Display Power Output Display Top actual temperature Top actual temperature Top actual temperature Bottom set temperature in 9C Bottom current reading Bottom power output 96 It shows F if temperature is in Fahrenheit Decimal point besides top right digit indicates the power output percentage Zone Switching 200 S 225 a n L Press Press and hold e for 200C 225C at least 2 seconds Zone 1 Display Zone 2 Display Top LED lit up Bottom LED lit up Function Menu i o AJ o Al o Al o Hnd 2 tan tUP Prog i Manual Mode Standby Mode Boost Mode Program Mode Press Program Menu DA Emi i j i _ _ Z lt z 2 gt Over Temp Limit Under Temp Thermocouple Alternating Limit Type Zone Display Mold Masters Revision 1 1 XL 2 Manual The Controller Cabinet The Controller Cabinet The power supply to the control cabinetis via a strain relief mounted cable gland plug wired in star or delta configuration Please check your spec
7. 21 782 4604 email bdavison moldmasters co uk Canada Mold Masters Technology Center 41 Todd Road Georgetown Ontario Canada L7G 4R8 tel 1 905 877 0185 fax 1 905 873 2818 email info moldmasters com Brazil Mold Masters do Brasil Ltda Rua Hum 1106 e 1126 Jd Manchester Nova Veneza Sumar Sao Paulo Brasil CEP 13178 440 tel 55 19 3922 4265 fax 55 19 3922 4266 email moldmasters moldmasters com br Austria Mold Masters Handelsges m b H Kirchenplatz 6 A 4552 Wartberg an der Krems Austria tel 43 0 7587 7297 0 fax 43 0 7587 7297 77 email office moldmasters at also Switzerland U S A Mold Masters Injectioneering LLC 2751 New Cut Road Spartanburg South Carolina 29303 USA tel 1 800 450 2270 fax 1 905 873 2818 email info moldmasters com Japan Mold Masters K K 1 4 17 Kurikidai Asaoku Kawasaki Kanagawa Japan 215 0032 tel 481 0 44 986 2101 fax 81 0 44 986 3145 email ookamoto mmkk co jp Singapore Mold Masters Singapore PTE Ltd 2 Corporation Road 3106 13 Corporation Place Singapore 618494 Republic of Singapore tel 65 6261 7793 fax 65 6261 8378 email agtan 9 moldmasters com sg also Malaysia Indonesia Thailand Mold Masters global support worldwide representatives Argentina Sollwert S R L La Pampa 2849 2 B C1428EAY Buenos Aires Argentina tel 54 11 4786 5978 fax 54 11 4786 5978 ext 35 email sollwertfi
8. 6893249 6921257 6921259 6936199 6945767 6945768 6955534 RE 38265 RE 38396 Pending Theinformation contained herein is to our best knowledge true and accurate but all recommendations or suggestions are made without guarantee Since the conditions of use are beyond our control Mold Mastersedisclaims any liability incurred in connection with the information contained herein All rights reserved No part ofthis publication may be reproduced ortransmitted in any form or by any means without permission in writing from the publisher COPYRIGHT 2005 MOLD MASTERS LIMITED ALL RIGHTS RESERVED Copyright 2005 Mold Masters Limited Printed in CANADA November 10 2005 DURAS DURA FEMTO SHOT DURA PICO SHOT DURA CENTI SHOT DURA DECI SHOT DURA HECTO SHOT DURA MEGA SHOT FLEX DURA HOT EDGE INJECTIONEERING MASTER PROBE MASTER SHOT MOLD MASTERS MOLD MASTERS ACADEMY MOLD MASTERS SYSTEM SCAN MASTER TEMP MASTER MERLIN are the registered trademarks of MOLD MASTERS LIMITED Copyright 2005 Mold Masters Limited Rev 1 1 TM XL 2 UM v1 1 X Printed in CANADA November 23 2005
9. ASE NEUTRAL J4 Use 3 stand offs to install Interconnected Jumper J4 Do not install J1 J2 J3 Connect Neutral Bue conductor to Mp2 Use black brown black for 3 phasesand Green for GND WYE SIAR 5 wires System s Revision 1 1 Mold Masters Page 33 Appendix A XL 2 Manual Plugs Configuration MOLD END Mae 12 amp 18 ZONES PART MPLUG 12 Female 9 4 5 i 8 94 Bi 19 h Thermocouples E MOLD END 4 ZONES Heater 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 1 4 1 2 3 4 Thermocouples PART MPLUG 04 Male Page 34 Mold Masters Revision 1 1 XL 2 Manual Index Alarm Messages 27 Alarm Output External 31 Alarm Settings 25 Boost Mode 21 Boost up level setting 17 Card LEDs 27 Controller Card Fuses 29 Controller Cards 13 Controller Output Fuses 29 Current Display Screen 9 Display Screens 9 Fan Fuses 29 Front Panel Status Indication 11 Function Menu 9 Fuses 28 How the Controller Works 14 Introduction 6 Keys Description 11 Manual Mode 21 Off Mode 20 Operation Diagram 12 Plugs Configuration 34 Power Output Screen 9 Revision 1 1 Mold Masters Page 35 Program Menu 10 Program Menu Items Changing 26 Program Menu Items Description 25 Program Menu Items Restoring 26 Program Menu Items Table 24 Program Menu Items
10. C or 842 F 100 450 C or 212 842 F Boost level tUP 75 C or 135 F 1 Max temp limit Set temp Communication address Adr 0 0 99 Temperature scale CF C C F Thermocouple type JL J J L Alternating Display dSP 0 1 Page 24 Mold Masters Revision 1 1 XL 2 Manual Customizing your controller Functions of Menu Items External Alarm Output Activation Items There is a remote alarm connector located on the side of the cabinet which has a relay to turn on audible alarms or lights or to turn off other machinery Parameters in External Alarm Output Activation are provided for the user to choose under what circumstance to trigger the alarm relay External alarm will be switched on if the specific instance happens and its menu item is set to 1 For instance if thermocouple break happens and the value in Abr is set 1 external alarm will then be triggered To disable the alarm triggering in any specific condition set its value to 0 Alarm Items In Alarm parameters you may adjust either over or under temperature alarm limits If these temperatures are exceeded the alarm relay on the card changes state and T Led will be lit up There is a remote standby connector is available on the side of the cabinet The user can use this input point to switch the XL 2 into Standby Mode remotely as long as Menu Item El is set to 1 To disable this feature simply set its value to 0 Soft Start Item
11. CI SHOTe DURA HECTO SHOTe DURA MEGA SHOTe FLEX DURA HOT EDGEe INJECTIONEERINGe MASTERPROBE e MASTER SHOTe MOLD MASTERSe MOLD MASTERS ACADEMY s MASTER SERIESe MOLD MASTERS SYSTEMe SCAN MASTERe STACK LINKe MERLINeare the registered trademarks of MOLD MASTERS LIMITED Information contained herein is to our best knowledge true and accurate but all recommendations or suggestions are made without guarantee Sincethe conditions of use are beyond our control Mold Mastersedisclaims any liability incurred in connection with the use of our products and information contained herein No person is authorized to make any statement or recommendation not contained herein and any such statement or recommendation so made shall not bind Mold Masterse Furthermore nothing contained herein shall be construed as a recommendation to use any product in conflict with existing patents covering any products or its use and no license implied or in fact granted herein under the claims of any patents All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopy recording or any information storage and retrieval system without permission in writing from the publisher All details standards and specifications may be altered in accordance with technical development without prior notification May be manufactured under one or more of the following U S Patents
12. Juan Xalpa Iztapalapa 09850 M xico City D F tel 452 55 5612 2302 tel 452 55 5614 6371 fax 52 55 5612 2312 email intecplast att net mx Spain Tein Ingiener S L C Sep lveda 32 08015 Barcelona Spain tel 34 93 289 05 10 fax 34 93 289 05 11 email sandra romero tein moldmasters com Turkey MMG Consulting amp Engineering Yesil esme Sok No 30 3 Ciftehavuzlar 81060 Istanbul Turkey tel 90 216 357 0783 fax 90 216 385 0656 email mmgevrek superonline com Denmark H amp G Englmayer A S Skenkelsoevej 9 Postbox 35 DK 3650 Oelstykke Denmark tel 445 46 733847 fax 445 46 733859 email support englmayer dk also Norway Hong Kong Nicko International Ltd Rm 1203 Chevalier Commercial Centre 8 Wang Hoi Road Kowloon Bay Hong Kong tel 4852 2755 2783 fax 4852 2798 8656 email sales nicko com hk Italy Commerciale Isola SPA Via G B Tiepolo 3 35010 Cadoneghe Padova Italy tel 39 0 49 706600 fax 39 0 49 8874231 email info com isola it Portugal Gecim LDA Avenida Da Liberdade No 155 Bloco A 2 A D P 2430 Marinha Grande Portugal tel 4351 244 575600 fax 4351 244 575601 email gecim 9 gecim pt Sweden Forvema AB Box 34 Fritslavagen 42 S 511 21 Kinna Sweden tel 46 320 16611 fax 46 320 16065 email hakan boerjesson forvema se trade marks and patents DURAe DURA FEMTO SHOTe DURA PICO SHOTe DURA CENTI SHOTe DURA DE
13. Manual Mode Hnd open loop control Boost Mode tUP how to apply a short increase Changing Set Temperature Toggling Zone Display Revision 1 1 Mold Masters Page 19 Running your controller XL 2 Manual Run Mode 1 Press I O to turn on the controller card Once the card is on it is already in Run Mode Both zones are running Off Mode Each card controls two zones at a time which can be turned off together or individually Turn both zones off at the same time 1 Press I O to turn the controller card off Display is off Turn one zone off 1 Uselz to reduce the set temperature of your desired zone Top display on the zone shows OFF Standby Mode tdn This mode is available for times when the mould tool is paused In this condition all the zones can be reduced by the certain amount temperature which helps to prevent degradation on certain materials To determine the decrement refer to Setting Standby Level Once standby mode is activated both zones would be reducing to standby temperature 1 From the Temperature Display Screen press and hold E for at least 2 seconds until you get into Function Menu 2 Use M to scroll to tdn Confirm your decision by pressing C to activate this function or to exit without changing operating mode 4 Once standby mode is enabled top display is alternating between tdn and actual temperature reading Bottom display shows the standby temperature You
14. XL 2 Series User manual revision 1 1 TempMaster Amendment Record XL 2 Manual Amendment Record XL 2 Series Manual Issue Date Amendments Author Authorised 1 0 July 04 First Issue DT JN 1 1 Nov 05 Re organized format DT JN Copyright 2004 Mold Masters Developments This manual is intended for use with the XL 2 Series Controller Our policy is one of continuous improvement and we reserve the right to alter product specifications at any time without giving notice Page 2 Mold Masters Revision 1 1 XL 2 Manual Contents Contents Amendment Record E 2 oir SENE DD IER 3 be 012101 HEIEREN 4 Safety TEE aE e len 5 WEI i tee EE D DVS Vell ATOM cs Pt AZAD ai ait th RE Wez kk z R Wez NGA NA Kna 7 Switching On ang OTT ce sues sags EDD sees os RO EB ease Ce deseo banyan seo decret 8 DN AVG AMOI eb 9 AL 2 Operation Diagram sss NA ee ette aee IERI I RI Ide 12 The Controller Gabinete cs ER 13 How the XL 2 Controller Works 14 setting up your Controller AKA AUNG 15 Running your COMUPOIGE pem 19 Customizing your Controller 23 eelere ee e EE 27 APPENdIX AN cost eom r AAA AMKA adv dU TR ooo veis den dette Lina 30 RR Mee es ta i Se cec ceci Ue SINUM DEDE 35 Revision 1 1 Mold Masters Page 3 Specifications XL 2 Manual Specifications The following are general specifications The actual controller supplied may differ in specified options Supply Voltage
15. agnostic status indication The card requires no analogue calibration and is ready for use once set up from the display console Output Triacs The controller card has an on board triac that is capable of controlling heating loads of up to 16 Amps peak Revision 1 1 Mold Masters Page 13 How the XL 2 Controller Works XL 2 Manual How the XL 2 Controller Works Mold Masters controllers are designed to perform in closed and open loop configurations However we consider that the normal operating mode is closed loop This is illustrated in the following diagram and explained below Set Point rt lt gt Za Temperature 1 E Time 1 The zone controller slowly ramps up the heater power and simultaneously looks for a positive temperature change at the thermocouple input The controller verifies the actual rate of rise against a predetermined value in program parameter r1 Power is slowly increased until the correct rate of rise is achieved 2 Atramp temperature rE the dwell time rt is activated 2minutes this permits any residual moisture in the heating elements to be eliminated After a zones reached to ramp temperature they will start heating up together again 3 The controller continues to ramp up the temperature to the set point with the speed set in program parameter r2 which should be achieved with minimum over shoot 4 Having built a virtual model to map the tool and heater charact
16. atus lamps on the controller card From left to right they are Z LEDis lit if heater has more than 100KQ leaking to chassis ground Message Gnd shows in faulty zone lt li LED is lit when the thermocouple is open or flashing reversed Message shows in faulty zone Revision 1 1 Mold Masters Page 27 Troubleshooting XL 2 Manual LED is lit when temperature reading exceeds over under temperature limit w LED is lit if the zone contains low resistance in the heater circuit or current reading exceeded maximum current limit Cur in Program Menu Message Cur shows in faulty zone To remove a card from its slot unscrew four corner screws first There is no need to switch off the main supply However if WARNING operational requirements allow the cabinet may be isolated The shrouded terminals on the euroback board are live unless the power supply is switched to OFF Specific Faults Rapid Temperature Fluctuations The most likely cause of temperature fluctuations is extraneous voltages being picked up by the thermocouple cable i e common mode This may be due to poor earthing of the tool or a faulty shielded thermocouple wire or alternatively a faulty heater We recommend that all earth connections be tested Not able to set a Higher Temperature This problem can occur if you try to set the temperature above the limits Check the Max Temp setting tLi in Program Menu and revise it if necessary Groun
17. bertel com ar Finland Oy Scalar Ltd Mestarintie 5 SF 12100 Oitti Finland tel 4358 19 787 690 fax 358 19 787 6921 email timo makinen scalar fi India Unimark 201 Vikrant Industrial Estate Govandi Mumbai 400 088 India tel 491 22 2550 6712 fax 91 22 2550 6713 email unimark vsnl com Korea Kyung in System J 502 Kuro Distribution Business Center 636 62 Kuro Dong Kuro Ku Seoul Korea tel 82 0 2 2634 9453 4 fax 82 0 2 2634 9608 email kyungins 9 hanmir com Romania International Mold Trade Co SRL Str Constantin Aricescu Nr 21 Bl 20 Sc 2 Apt 20 Bucharest Sector 1 Romania tel fax 40 21 231 7843 email roman dial kappa ro Taiwan Credit amp Finder International Corp No 756 Chung Cheng Road Chung Ho City Taipei Hsien Taiwan ROC tel 886 2 22224993 fax 886 2 22224705 email cfic ms19 hinet net Australia Comtec IPE 1084 South Road Edwardstown South Australia 5039 PO Box 338 Magill South Australia 5072 tel 61 0 8 8374 4633 fax 61 0 8 8299 0892 email bparrington comtecipe com France MAP BP 2001 F 91071 Bondoufle Cedex France tel 33 01 69 11 81 50 fax 33 01 60 86 69 33 email maud francigny supratec fr Israel ASAF Industries Ltd 29 Habanai Street PO Box 5598 Holon 58154 Israel tel 972 3 5581290 fax 4972 3 5581293 email info 9 asaf com Mexico Intec Plast S A de C V 185 Av Once Bod 8 Col San
18. boost temperature Boost up level is to determine the increment for the zone during boost function activated Please note that on a slow responding manifold if you set a high boost temperature the zone is unlikely to reach your set boost temperature before the boost time limit expires Boost up level from factory setting is 75 C or 135 F which means if your controller is set at 200 C temperature will raise to 275 C On the other hand if controller is set in Fahrenheit set temperature is at 400 F temperature will boost up to 535 F 1 From the Temperature Display Screen press and hold e button for at least 2 seconds until you get into Function Menu 2 Use AI to scroll to Prog then press C button to enter 3 Use to scroll to parameter tUP You will see the bottom display flashing 4 Press C to get access to change parameter setting The bottom display should stay 5 Use Lor S change to your desire setting 6 Press to store the change The bottom display should be flashing again 7 Toreturn to Temperature Display Screen by pressing Setting Standby Level Before you activate Standby function you must first configure the amount When standby is activated the controller will reduce to standby temperature Standby level is to determine the decrement for the zone during standby function activated Standby level from factory setting is 100 C or 180 F which means if your controller is set a
19. d fault detection The Ground fault detection detects any fault caused by earth leakage current Earth faults can be caused if a tool has been idle for some time and damp has got into one heater It may be possible to identify the heater and repair the faulty zone by using the adjacent heaters to heat it up and dry it out so curing the original problem Fuses There are supply fuses for four separate functions for the whole unit In the unlikely event of a fuse failure always isolate the incoming main supply before opening the cabinet door or removing any panels Replacement Fuses If you find that any fuse has ruptured then please make sure that you replace the faulty fuse for a new one with identical characteristics All the fuse types are listed in the attached tables WARNING Page 28 Mold Masters Revision 1 1 XL 2 Manual Troubleshooting Fans Every Cabinet has auxiliary fans to ensure adequate cooling If any fan has stopped working then first inspect the unit to see if there are any blockages or objects fouling the impellors Once you are certain that the fan is free to rotate then proceed to check its supply fuse that is located on the main termination rail 1 1 4 Glass Fuse Antisurge Controller Cards There is a protection fuse for power input on the controller card Fuse Rating 500mA Output Overload Protection Fuse On the back of 4 12 18 zones cabinet there are fuses for protecting the heating l
20. een press RZ to decrease set temperature Toggling Zone Display View Zone Display Manually 1 From the Temperature Display Screen press Eto toggle between two zones display The blue zone LED lights up accordingly View Zone Display Automatically The controller card is able to display two zones temperature reading alternatively every 10seconds automatically in Temperature Display Screen 1 From the Temperature Display Screen press and hold E for at least 2 seconds until you get into Function Menu 2 Use A to scroll to Prog Press C to choose Program Menu Use to scroll to ASP You will see the bottom display flashing 4 Press C to get access to change parameter setting The bottom display should stay Use A button to change to setting to 1 to enable this feature Press C to store the change The bottom display should be flashing again 7 Press Cio get back to Temperature Display Screen The controller card alternates two zones display reading automatically in every 10seconds The blue zone LED lights up accordingly Note This feature will only kick off provided dSP is set as 1 and both zones are in Temperature Display Screen Page 22 Mold Masters Revision 1 1 XL 2 Manual Customizing your controller Customizing your controller Program Menu is where you may set controller to different output alarm temperature alarm limits heating characteristics and other special operat
21. eristics the controller can maintain the temperature at an accurate point with virtually no deviation Page 14 Mold Masters Revision 1 1 XL 2 Manual Setting up your controller Setting up your controller New XL 2 series controllers are correctly configured at the factory and you should not need this section for a new system However if you are reconfiguring your controller to a new tool or environment then you may need this chapter of the manual This initial set up is detailed here in easy to follow steps that help you to become familiar with your new equipment What is covered in this section Setting your preferred Temperature Unit Matching Sensor Types Setting the Required Temperatures Setting Boost Level Setting Standby Level Monitoring Temperature Limits Revision 1 1 Mold Masters Page 15 Setting up your controller XL 2 Manual Page 16 Setting the Temperature Scale Whether your display shows temperature in Fahrenheit or Centigrade changes in this parameter apply to both zones of the controller card 1 j From the Temperature Display Screen press and hold button for at least 2 seconds until you get into Function Menu Use A to scroll to Prog Press to choose Program Menu Use to scroll to temperature unit parameter C F You will see the bottom display flashing Press C to get access to change parameter setting Bottom display should stay Use A or button to change
22. g to the Cable Markings 1 2 Alarm Output A cabinet connector provides an alarm output from an internal set of relay contacts Using an external power source the cabinet can initiate a number of warning devices whenever any zone goes into an alarm state This is commonly used for beacons audible alarms or informing the moulding machine The contacts are rated for 1A at 220V Revision 1 1 Mold Masters Page 31 Appendix A XL 2 Manual An input can be accepted through the same connector It may be used for Remote Standby Mode or any other user definable function For exact details consult the specification for the particular model Input Output Auxiliary Input signal Standby Port Auxiliary Input Gnd DY Por Input Output Alarm 220v contact 1 100mA N Bas Alarm 220v contact 2 PRU n 100mA 1 5 Serial Port A male 9 way D panel connector is provided for an RS 485 serial port It can communicate with a remote computer for data collection The pin outs are as follows Mold Masters Revision 1 1 XL 2 Manual Appendix A INSTRUC TION HOW TO CONVERT DELIA WYE FOR SNGLE BREAKER SYSIEM AMERICAN DELIA 220V PHASE PHASE Install jumpers J1 J2 J3 Do not connect Neutral Hue conductor Use black brown black conductor for 3 phases Green for GND Delta 4 wires System EUROPEAN SIAR 380v PHASE PHASE 220v PH
23. ifications for details of which configuration has been configured Connections to the tool are by looms terminating type Contact 24pole connectors with 48pole housing or their equivalents There are normally two types of cables supplied a thermocouple connection using type H BE24BS and typical connector and wiring details are shown in Appendix A An alarm output option is available for extending the alarm or perhaps inhibiting the injection process Controller Cards The controller card is dual zone modular that provides real time temperature control Each card has three main components e thermocouple amplifiers e CPU e multi voltage output triacs Thermocouple Amplifiers The thermocouple amplifiers have preset responses for both J and L type thermocouples The selection of sensor type can be done in Program Menu this in turn sets the differential amplifier to match the selected thermocouple type Central Processor Unit CPU The CPU provides the following facilities e closed and open loop control of the zones e processes thermocouple and current readings to show on display e checks for alarm conditions including excess current incorrect thermocouple wiring Zone over temperature condition low impedance between heater and ground and generates alarm information for the display screen and alarm relay e controls the output power to the on board triac using a number of self tuning algorithms e controls a row of di
24. in this mode use to switch to another zone repeat the above steps again Note This feature cannot be disabled completely by setting EHd in program menu to 0 for preventing accidental change of mode Boost Mode tUP This mode provides a means of temporarily boosting the zone temperature for 2 minutes To determine the increment refer to Setting Boost Up Level 1 From the Temperature Display Screen press and hold amp 2 for at least 2 seconds until you get into Function Menu 2 Use ito scroll to UP 3 Confirm your decision by pressing C or press to exit without changing operating mode 4 Once boost mode is enabled top display is alternating between tUP and actual temperature reading Bottom display shows the boost temperature You may adjust the boost temperature by using or Rz 5 To exit from boost mode simply press Eto get back to normal operating mode Boost mode in each zone activates independently If both zones need to be running in this mode use to switch to another zone repeat the above steps again Note This feature cannot be disabled completely by setting EtU in program menu to 0 for preventing accidental change of mode Revision 1 1 Mold Masters Page 21 Running your controller XL 2 Manual Changing Set Temperature Increase Setting 1 From the Temperature Display Screen press Alto bring the setting up Decrease Setting 1 From the Temperature Display Scr
25. ing mode What is included in this section Functions of Menu Items Viewing current item parameters Changing menu item parameters Recalling factory settings Revision 1 1 Mold Masters Page 23 Customizing your controller XL 2 Manual The following table shows all menu items factory setting and their adjusting range Menu items Symbol Factory Setting Adjusting Range EXTERNAL ALARM OUTPUT ACTIVATION Excess temperature AOt 1 0 1 Low temperature AUt Current overload ACU Thermocouple breakage Abr Reversed thermocouple APo Earth leakage AEL Standby mode Atd 0 Manual mode AHd ALARM Input from moulding EI 1 0 1 machine Over temperature range Ot 10 C or 18 F 0 25 C or 0 45 F Under temperature range Ut SOFT START Ramp1 end temperature rE 120 C or 248 F 120 160 C or 248 320 F Ramp1 temperature r1 1 C 6s or 1 F 4s 1 C 10s 1 C 6s or 1 F 6s 1 F 4s Ramp2 temperature r2 1 C 3s or 1 F 2s 1 C 10s 1 C 1s or 1 F 6s 1 F 1s Dwell time at Ramp1 end rt 2min 1 10min temperature SPECIAL OPERATING MODE Control mode at not 1 0 1 thermocouple leakage Manual mode enable EHd 1 0 1 Standby mode enable Etd 1 0 1 Boost mode enable EtU 1 0 1 OTHERS Over current shut off Cur 18 0A 18 0A Standby level tdn 100 C or 180 F 1 set temperature Max temperature limit tli 450
26. m values 1 From the Temperature Display Screen press and hold e button for at least 2 seconds until you get into Function Menu 2 Use sto scroll to Prog then press C button to enter Program Menu 3 Use Al or scroll the menu Top display shows Menu Item symbol bottom shows value Changing menu item parameters 1 From the Temperature Display Screen press and hold e button for at least 2 seconds until you get into Function Menu 2 Use fA to scroll to Prog then press C button to enter Program Menu 3 Use A or RZ scroll to your desire item You will see the bottom display flashing 4 Press to get access to change parameter setting The bottom display should stay Use Alor S change to your desire setting Press C to save the change The bottom display should be blinking again To exit from Program Menu without changing setting press to return to Temperature Display Screen 7 You may repeat step 3 6 to change other parameter settings Restoring all Parameters to factory settings In order to restore the parameters back to their original factory setting 1 From the Temperature Display Screen press and hold both Al and S together for at least 2 seconds until Std is shown on the top display 2 Press to restore the factory settings the display should go back to Temperature Display Screen Or press OI to escape without loading settings Mold Masters Revision 1 1 XL 2 Manual Tr
27. may adjust the standby temperature by using ES or EI 5 To exit from Standby Mode simply press CJ to get back to normal operating mode Note This feature cannot be disabled completely by setting Etd in program menu to 0 for preventing accidental change of mode However this feature can also be initiated by the moulding machine via the rear panel connector In this case the standby enable or disable is controller by the signal injected by the moulding machine Page 20 Mold Masters Revision 1 1 XL 2 Manual Running your Controller Manual Mode Hnd When Closed Loop Auto mode is not your preferred or the controller detects thermocouple failure in the system this mode helps to continue the operation with constant power output 1 From the Temperature Display Screen press and hold DI for at least 2 seconds until you get into Function Menu Manual mode Hnd is the first item in the Function Menu 2 Confirm your decision by pressing C to activate this function or to exit without changing operating mode 3 When Manual Mode is enabled it goes to Power Display Screen Top display is alternating between Hnd and actual temperature reading bottom shows power percentage 4 Use E or M to adjust to desire power output percentage 5 To exit from Manual Mode simply press Eto get back to normal operating mode Manual mode in each zone activates independently If both zones need to be running
28. mosphere or where there is a possibility of such an atmosphere developing They should be installed in a clean dry environment where the ambient conditions do not exceed the following limits Ambient temperature 0 to 50 C Relative Humidity 9096 non condensing When in use this equipment does not emit audible noise in excess of 10dBA Controller Tool Connections The various connections to the system using the cables supplied with the equipment are specified in Appendix A Controller Power Supplies Revision 1 1 The control cabinet can be manufactured to accept a wide range of supplies and sequence of phases Refer to the serial plate in the controller cabinet for confirmation of the supply requirements If the local supply is outside the specified range please contact our Service department for advice Tel 1 905 877 0185 1 800 450 2270 Fax 1 905 873 2818 Mold Masters Page 7 Switching On and Off XL 2 Manual Switching On and Off The main Power Switch is a rotary Switch at the back of the cabinet This Switch is sufficiently rated to disconnect the total load current during switch On and switch Off You can use a suitably sized padlock or similar device to lock the switch in the Off position to prevent operation during maintenance Although the main switch has the capacity to switch the whole system Off we recommend that you only do this in an emergency situation A se
29. oad output Fast blow Revision 1 1 Mold Masters Page 29 Appendix A XL 2 Manual Appendix A XL 2 Wiring Standards Page 30 Mold Masters Revision 1 1 XL 2 Manual Appendix A XL 2 WIRING STANDARDS The following standards only apply to controllers wired to Mold Masters standard Other specifications may have been stated when the controller was ordered Please refer to the supplied specification details 1 CONNECTION INFORMATION 1 1 Three Phase Designation Please take extreme care when connecting the controller to the three phase supply Incorrect connection may appear to work but can result in damage to the controller The controller is supplied according to your requirements in either a star or delta supply WARNING For European Star 380V Use 5 conductors Change jumper settings by joining all MP1 MP2 and MP3 to the blue N conductor at the terminal blocks Cable Marking Supply Description IR Phase 1 black Phase 2 brown Phase 3 black N Mp1 Mp2 Neutral blue Mp3 Earth Symbol Earth green yellow For American Delta 240V Use 4 conductors Change jumper settings by joining R MP3 S MP1 and T MP2 at the terminal blocks Do not link all MP1 MP2 and MP3 together Cable Marking Supply Description Phase 1 black Phase 2 brown Phase3 black Earth Symbol Earth green yellow N B The delta supply cable does not have a neutral wire Cable colours may vary therefore wire up accordin
30. oubleshooting Servicing and repairing your controller Always isolate your controller at source before you open the unit to inspect it or replace fuses When it comes to machine maintenance there is very little that you WARNING need to do to look after it Replacement parts We do not expect that you will need to repair any controller parts at board level other than fuses In the unlikely event of any board failure then we provide an excellent repair and exchange facility for all our customers Cleaning and Inspection Any excess dust that has entered into the cabinet may be removed with a light brush and vacuum cleaner Any internal cable forms that flex to accommodate opening doors should be checked to see that there is no fraying or damage to cable insulation External cables should be checked to see that there has no damage to the flexible conduit plugs or sockets If the flex has been squashed if there is visible damage or if there are any exposed conductors then for your own safety it must be replaced If the equipment is subject to vibration then we recommend that you use an insulated screwdriver to check that no terminals have become loose Troubleshooting The control system has several features which provide an early diagnosis of faults in the control system the tool heaters and thermocouple sensors Individual Card Diagnostics If a fault on a controller card is suspected check the LED card st
31. quenced method for switching On and Off protects the controller and keeps the switched load to a minimum to extend the life of the main Isolator Switching On Once the controller card is on it gets into Run mode automatically to start heating the tool Switching Off or Shutting Down We recommend that you use the controller to shut down the heating load and only use the main isolator to switch off the whole system once it is idle 1 Shut down the heating Use 1 0 switch to turn off each controller card 2 Shut down the Controller Now use the Main Rotary Switch on the cabinet to isolate all the power from the whole system Page 8 Mold Masters Revision 1 1 XL 2 Manual Navigation Navigation This part of the manual introduces you to the controller card to show what facilities are available and what information is available Main Screens Once the controller card is turned on it always shows Temperature Display Screen of the first zone in controller card There are three main screens in total they always display actual temperature on top display and bottom displays are set temperature current reading and power output percentage in that specific zone A decimal point beside the top right digit indicates the amount of output power Temperature Display Current Display Power Output Display e Use C to rotate through different screens Zones Switching There are two zones per controller
32. r into Program Menu e Scroll through the menu by using AI or to Top display shows menu item bottom shows setting You cannot change setting when bottom display is flashing e Press Cl to gain access for any changes by bottom display then stays e Use Work to change setting press C to save the change Bottom display starts flashing again If bottom display stays pressing C to escape from Program Menu without changing setting e After changes are made press to return to Temperature Display Screen Page 10 Mold Masters Revision 1 1 XL 2 Manual Navigation Revision 1 1 Front Panel Status Indication There are two blue and four red LED indicators to show the status of the controller card Zonet display 12 zone display E Em y ED MA GND earth leakage alarm indicator Thermocouple failure T C break LED stays or T C polarity LED blinks Temperature alarm Over under temperature alarm indicator Overload Excess current cut out alarm indicator Keys Description A K O Increment up Change set temperature power output 9o in manual mode or program parameter values Rotate through function and program menu Decrement down Change set temperature power output in manual mode or program parameter values Rotate through function and program menu Enter Rotate through Temperature Current and Power display Gain access and confirm program
33. s Parameters in Soft Start will define the heating profile Controller will have a virtual model built to map the tool and heater characteristics these parameters do not need to be adjusted unless there is an unusual large heating plate Special Operating Mode Items Control mode is used when a thermocouple fails the operation can still carry on The controller card holds historical power level for that specific zone after reaching set temperature and maintaining for at least 5 minutes This mode will be kicked in if not is set to 1 and thermocouple break happens The user can enable special operating mode in the Function Menu however the mode cannot be turned on if its corresponding enable setting is set as 0 in the program menu For example if EHd item is set to O manual mode cannot be activated completely which is for preventing accidental change of mode Others Items These parameters are to set over current limit standby level boost level and temperature scale Max temperature limit item is to set maximum temperature permitted fro this specific zone Item Revision 1 1 Mold Masters Page 25 Customizing your controller XL 2 Manual Page 26 Adr is only used for establishing serial communication with Graphical Interface via RS485 Item dSP can be set to alternate temperature reading between two zones automatically in every 10seconds Viewing current parameters To see Menu Ite
34. setting Press C to store the change Bottom display should be flashing again Press Gl to get back to Temperature Display Screen Matching Sensor Types There are two different types of probe sensors J type and L type with different characteristics The sensor type is normally configured to a J type before leaving the factory and should only need to be altered in rare circumstances Changes in this parameter apply to both zones of the controller card 1 From the Temperature Display Screen press and hold l for at least 2 seconds until you get into Function Menu Use A to scroll to Prog Press C to choose Program Menu Use to scroll to J L You will see the bottom display flashing Press C to get access to change parameter setting The bottom display should stay Use A or button to change to your desire setting Press to store the change The bottom display should be flashing again Press O to get back to Temperature Display Screen Setting the Required Temperatures 1 From the Temperature Display Screen of the desired zone use Alor button to change the temperature setting Press E to switch to the other zone and repeat the above step if necessary Mold Masters Revision 1 1 XL 2 Manual Setting up your controller Setting Boost up level Before you activate Boost function you must first configure the amount When boost is activated the controller will raise up to
35. t 260 C temperature will reduce to 160 C On the other hand if controller is set in Fahrenheit set temperature is at 400 F temperature will drop to 220 F 1 From the Temperature Display Screen press and hold e button for at least 2 seconds until you get into Function Menu Use A to scroll to Prog Press C to enter Program Menu 3 Use to scroll to parameter tdn You will see the bottom display flashing 4 Press to get access to change parameter setting The bottom display should stay 5 Use Al or M button to change to your desire setting Revision 1 1 Mold Masters Page 17 Setting up your controller XL 2 Manual 6 Press to store the change The bottom display starts flashing again 7 To exit from Program Menu press Monitoring Temperature Limits Your controller card looks at the actual temperature of each zone and verifies that the zone is operating within specific limits Rather than fixed points of temperature the Ot and Ut Limits are set to degrees above the and below the set point If these temperatures are exceeded the alarm relay on the XL 2 card changes state to raise a disable injection interlock or alarm Setting Over Temperature Limit Ot 1 From the Temperature Display Screen press and hold e button for at least 2 seconds until you get into Function Menu 2 Use to scroll to Prog Press C to get into Program Menu 3 The first parameter in Program Menu is Ot Yo
36. u will see the bottom display flashing 4 Press to get access to change parameter setting The bottom display should stay Use Al or Rz change to your desire setting 6 Press to store the change The bottom display should be flashing again 7 Press l to get back to Temperature Display Screen Setting Under Temperature Limit Ut 1 From the Temperature Display Screen press and hold e button for at least 2 seconds until you get into Function Menu 2 Use M to scroll to Prog Press C to enter Program Menu 3 Use to scroll to parameter Ut You will see the bottom display flashing 4 Press C to get access to change parameter setting The bottom display should stay 5 Use Al or RZ change to your desire setting 6 Press Clto store the change The bottom display starts flashing again 7 Press Cio get back to Temperature Display Screen Page 18 Mold Masters Revision 1 1 XL 2 Manual Running your Controller Running your controller Running your controller is concerned with everyday use of the controller for normal production use This is considered as selecting an appropriate run mode for the machine according to whether the tool is working or waiting It may also be necessary to make changes to the heater temperatures and using the graphical display of recent performance may help such decisions What is included in this section Run Mode Off Mode Standby Mode tdn
Download Pdf Manuals
Related Search