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User Manual for TS/KTS Console together with M2 - Mold

Contents

1. Console Machine sees that no tool The Console Process cannot find change has occurred It displays an skips 2 any may flag an error to await error message step 2 Version 2 2 User Manual for TS KTS Console yy Miold Miaste es Oct 2012 Page 94 Not Under documentation control if printed May be revised without notice gt d Maintaining your controller TempMaster 1 Maintaining your controller Maintaining your controller is all about keeping it in order checking records and settings and running self diagnostic checks There are no user serviceable parts inside the Touch Screen controller and in the unlikely event of equipment failure you should return the unit for attention What is included in this section Print Out Facility Export Facility Self Diagnostic Tests System diagnosis results Upgrading Servicing and Repairing your controller Mold Not Under documentation control if printed May be revised without notice Page 95 Oct2012 Masters i User Manual for TS KTS Console Version 2 2 _ d eg TempMaster IO Maintaining your controller Print Out Facility to Printer Touch Print for a page record gives either te ke A Screen Picture if you print from DISPLAY page including Zoom view GRAPH page Or A Table Print out if you print from SETUP page TOOLSTORE page TESTING page FIT IETETTTS TITTEN ttt ee ett lee PIRI EI EITIBIELEILIWTE Eit WR WIR
2. When Staged Startup is selected then the shutdown automatically follows a staged shutdown Note however that there is a separate allocation for shutdown groups so a shutdown pattern need not be the same as the startup sequence AUTO FOLLOW measures the heat gain of every zone and automatically holds back the faster probe zones to the same rise rate as the slowest rising zone This is very similar to Master Follow but without the need to nominate any one Master Set a delay period to hold on successive groups during a Staged Shutdown It sets in minutes the time that Successive zone groups must wait before each switches off Setting this option to zero makes the timer ineffective so that Staged shutdown is reliable solely on Shutdown temperature Sets the temperature to which each Shutdown group must fall before the next group is switched off Raising the shutdown Temperature means that zones do not have to cool down so much until subsequent stages are switched off which shortens the overall shutdown time Lowering the Shutdown Temperature has the opposite effect and lengthens the shutdown time TempMaster Mig The maximum period for Shutdown Timer is 99 minutes The Shutdown Temperature setting defaults to 0 which represents an extremely long shutdown interval The highest shutdown temperature permitted is 260 C or 500 F and if this set value is equal to or higher than the normal temperature
3. 5 Set the Value Selecting zones Setting Operating Parameters User Manual for TS KTS Console Oct 2012 Page 39 Not Under documentation control if printed May be revised without notice TempMaster K Setting Operating Parameters To set Probe and Manifold temperatures 1 Select Set 2 Select Auto 3 Set the Temperature Value Touch Delete to undo any last entered figure 4 Touch Enter to confirm your settings or Esc to return to the main page without accepting the new choice and values gt ersion 2 User Manual for TS KTS Console Mold ez _ Masters Oct 2012 Page 40 Not Under documentation control if printed May be revised without notice Setting Operating Parameters FrempMaster jj To set Spear Body and Tip temperatures 1 Start with body temperature select Auto 2 Set the body temperature 3 Touch Synch for Tip Control 4 This changes the keyboard for the tip settings 5 Set the first value Pre heat User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 41 Oct 2012 Mokle ers TempMaster IO Setting Operating Parameters ee coe eee aie E 6 Touch Enter BBB 7 Set the remaining three values keypad automatically cycles through all four
4. Delete Save Restore and Backup may be accessible to level 1 operatives by selecting User or only to higher level 2 operatives by selecting System However if this is set to User when User Password is set to Disabled it leaves these operations accessible to any with no password needed at all If this is set to Enabled then all password protected functions need either a User Level 1 or System Level 2 authorisation as shown by the Password Application table on page 38 If User Password is set to Disabled then all the lower functions become available without the need for any password Only those higher functions that require a System Level 2 password retain their Password protection Finished System Settings Once you have completed all the necessary System settings and want to save them as they have been set touch the OK button If you do not wish to accept the changes made touch Cancel The configure menu disappears and the system reverts back to any previous selections that may have been made Version 2 2 Mold Miasters 0ct 2012 User Manual for TS KTS Console Page 38 Not Under documentation control if printed May be revised without notice Setting Operating Parameters FrempMaster Di GR TEEN E i 7 iat a Ba le Ks E Version 2 2 Los d JESS ae Si ef Lg La 1 Select the First zone 2 Select the Last Zone 3 Touch Range 4 Touch Set
5. The cables that connect the water manifold to the controller are marked for identification and should be connected to the appropriately marked sockets on the sensors and the controller The cables should be adequately supported using suitable cable tray or individual cable cleats in accordance with the current IEEE Regulations for Electrical Installations Coolant Monitoring User Manual for TS KTS Console Version 2 2 It is possible to monitor up to three different coolant properties using the following apparatus Temperature there is a choice of two main cards to monitor water temperature the WT4 card has 12 T C Inputs the 12RTD has 12 Resistive Temperature Device inputs and is often the preferred device for this application Flow there are many analogue devices which give a standard 0 20ma output that is proportional to the measured water flow any one of these devices may be connected to one or more of the eight channels available on the Al8 Analogue card Pressure like coolant flow above there are a choice of sensors that give a 0 20 ma output These can also be connected independently to an AIS card b ia e im Mold gt Not Under documentation control if printed May be revised without notice Page 125 Oct2012 Masters TempMaster VP Appendix D Water Manifolds Basic Detection and Configuring Once the manifold has been installed the controller may be switched on and setup The individual st
6. Server Message Block a communication protocol favoured by Windows networks 3 Click on the Printer Address Edit button and key in the Local Area address for a known network printer Alternatively supply a resource name if your system uses a name server 4 If your network uses the Windows SMB option then you must provide a printer name click on the Share Name Edit button and key in the printer name which identifies the remote network printer 5 Select standard European A4 or American Letter size 6 Touch Accept to confirm your printer selection Should you have any difficulties then contact your own IT department for help with LAN printer configuration Printing to a USB Memory Stick A fifth option in Connection is Print to File which allows you to print out a file in either a raster or pdf format to a USB Memory Stick 1 Click on the Connection Edit button and select Print to a file Note that the Make option greys out and the Mode option changes to File 2 Click on the File Edit button and select JPEG PNG or PDF 3 Use the USB port and a USB Memory Stick as a transfer media for making prints from any other pages see page 97 for details User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 51 Oct2012 Masters TempMaster j 5 Event Log and Export Pages Event Log is used to store and retrieve
7. amp Off EasyView Change Display options Set Alter temperatures or modes Picture Load Save Delete Attach Detach pictures to Modify EasyView Tools layouts ToolStore Load Save Backup Restore Delete Detect See Tool Password on page 38 U Change Network Names Address Mask Set Alter temperatures or Zoom Set Alter temperatures or modes tilities System Set Change Time Change Passwords and Password Timer Any Export function Backup auto archived history Data Log Utilities Enable Disable Obtain Network IP address Utilities Export Page Screen No Password required Level 1 User password Level 2 System password 7 modes Graph All functions including TimeLine are basically read only Utilities Printer Select Printer type and paper sizes Utilities Remote View VNC at Full or Configure VNC Settings Part Window Utilities Quad Configure any Input or Output lO channel Test Page Select zones to be Start Test Configure Test tested Password Security Every machine leaves our factory with two levels of password protection these are provided on a detachable page at the front of the Manual We recommend that you change these as soon as possible to establish your own security User Manual for TS KTS Console Version 2 2 b we Mold Not Under documentation control if printed May be revised without notice Page 49 Oct2012 Mlasters TempMaster IO Setting up othe
8. the failed zone to another similar zone Nominated Zone Slaving allows you to specify a zone to act as a master to this zone if it were to fail at any time Standby Sets the Standby Temperature for any The maximum Standby temperature zone s temperature is 250 C or 450 F Boost Sets the boost value for any zone s The maximum Boost value is temperature 250 C or 450 F above the normal set temperature Boost Time Set the duration of the Boost The maximum period for Boost Temperature Time is 9999 seconds Master Zone Select a Master Zone for any groups of Do not select until all Zones have sub zones been appropriately configured to Probes and Manifolds etc Warning and Set the first Warning and second Alarm The maximum Warning or Alarm Alarm Levels stage alarms value is 99 C or 178 F Probe or Manifold Warning and Set the first Warning and second Alarm The maximum Warning or Alarm Alarm Levels stage alarms any temperatures reaching value is 99 C or 178 F Monitor Zone the higher Alarm level will generate an automatic Mould STOP signal like the Quad IO TC card Will generate an Alarm if any average This defaults to 100 or Off so power level which is measured over the maximum power can be preceding 8 minutes exceeds this setting sustained without generating any Alarm Power Power Alarm User Manual for TS KTS Console Version 2 2 Not Under documentati
9. 10 2010pm cay 3 AE ECG 10 2010am csv es 26 10 20 10pm cav 26 10 2010am csv Set the First and Last of the zones that you mmm elen wish to examine tt e Dm CSV 1 10 2010am esy 21 10 2010pm cayv i Aute Archbend I sieer Bata Start Dane 2F 10 2010am csv aT ee 26 10 20 10pm cav oho Il gg Gal 26 10 2010am csv T h TE t Praze Lee 25 10 2010pm csv J OUC xpor np Tel inne aia di geg i 22 10 2010pm csv 21 10 2010am cev 21 10 2010pm cav d AE y l BH Wait about 10 seconds then remove storage media LI Tt E 4 H Download both files to PC Email files On receipt of your mail and attachment files we can load your files into one of our own controllers and will try to analyse the problem Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 114 Not Under documentation control if printed May be revised without notice Troubleshooting TrempMaster IO M2 Series Fuses There is an Miniature Circuit Breaker that offers general over current protection for the complete unit Supplementary Fuses All the supplementary circuits Console supply Power Supply fans are protected a pair of fuses which are fed from the upper and lower supply busbars These are Din rail mounted and can be found inside the front door at the top of the cabinet 20mm Glass Fuse Antisurge Controller Cards The current controller card has
10. Mg Introduction Screen Layout and Navigation Common to all pages Navigation Top tabs to move from page to page Control Side command buttons that change from page to page Monitor amp Information Bottom row shows Current Run Mode Current health status miscellaneous information Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 12 Not Under documentation control if printed May be revised without notice Co emp Master E The Display page Can be used for e Monitor observe zone condition e Control Start Stop amp Boost Standby immediately available All other Standby Shutdown Stop available from Mode button e Set select any one or more zones to get Set function to set or alter zone setpoint or run modes Monitor This Healthy Zone shows SETAE Zone Name user configurable Y 250 Actual Temperature may be Coarse at whole degree steps or Fine at tenth of a degree steps x9 250 Scale and Set Temperature Applied Power Applied Current Amps Deviation between Actual amp Set Temperature Green text on Black background Warning Zone Black Text on Yellow Deviation exceeds 1st stage Warning EI 7 Background Alarm Zone White text on Red Deviation exceeds 2nd stage Alarm o IR Background Fatal Zone White text on Red Problem detected see page 107 for details E d Background Zone Off Individual zone switched off Probe 14 Different header colours Us
11. Tel 353 1 201 5088 Fax 353 1 201 5099 info BrayEngineeringServices com RUMANIA International Mold Trade Co SRL Str Constantin Aricescu Nr 21 BI 20 Sc 2 Apt 20 Bucharest Sector 1 Romania Tel 4 021 230 60 51 Fax 4 021 231 78 43 contact matritehightech ro DENMARK NORWAY SWEDEN Englmayer A S Skenkelsoevej 9 Postbox 35 DK 3650 Oelstykke Denmark Tel 45 46 733847 Fax 45 46 733859 support englmayer dk ISRAEL ASAF INDUSTRIES Ltd 29 Habanai Street PO Box 5598 Holon 58154 Israel Tel 972 3 5581290 Fax 972 3 5581293 sales asaf com TURKEY MMG Consulting amp Engineering Yesil Gesme Sok No 30 3 Ciftehavuzlar 81060 Istanbul Turkey Tel 90 216 357 0783 Fax 90 216 385 0656 turkey moldmasters com www moldmasters com Version July 31 2012
12. TempMaster Mg International Representatives ARGENTINA Sollwert S R L La Pampa 2849 2 B C1428EAY Buenos Aires Argentinia Tel 54 11 4786 5978 Fax 54 11 4786 5978 Ext 35 sollwert fiberTel com ar FINLAND Oy Scalar Ltd Viertolantie 12 11120 Riihimaki Finland Tel 358 10 387 2955 Fax 358 10 387 2950 info scalar fi ITALY Commerciale Isola SPA Via G B Tiepolo 3 35010 Cadoneghe Padova Italy Tel 39 49 706600 Fax 39 49 8874231 info com isola it VIETNAM Lotus Chemical Technology 393 Dien Bien Phu St Ward 4 Dist 3 HoChiMinh City Vietnam Tel 84 8 832 7605 Fax 84 8 832 7730 dieuphuoc nguyen lotusfirma com AUSTRALIA Comtec P E 1084 South Road Edwardstown South Australia 5039 PO Box 338 Magill South Australia 5072 Tel 61 8 8374 4633 Fax 61 8 8299 0892 bparrington comtecipe com GREECE lonian Chemicals S A 21 PentTelis Ave 15235 Vrilissia Athens Greece Tel 30 210 6836918 9 Fax 30 210 6828881 m pavlou ionianchemicals gr PORTUGAL Gecim LDA Rua Fonte Dos Ingleses No 2 Engenho 2430 130 Marinha Grande Portugal Tel 351 244 575600 Fax 351 244 575601 gecim gecim pt BULGARIA Mold Trade OOD 62 Aleksandrovska St Ruse City Bulgaria Tel 359 82 821 054 Fax 359 82 821 054 contact mold trade com IRELAND Bray Engineering Services Mr Liam Shortt Unit F3 Network Enterprise Business Park Kilcoole Co Wicklow Ireland
13. about 10 seconds then remove storage media User Manual for TS KTS Console Version 2 2 b ram Mold Not Under documentation control if printed May be revised without notice Page 83 Oct 2012 Masters TempMaster IO Customising your controller Restoring tool settings lf there is any information stored in a selected tool bank or slot then this process over writes new information into that position There is an option within this sequence to restore either all of the stored tools or just one selected tool 1 To Restore all the Tools me A Pee bore em Bane Beni et AL eher Pras Aa Bama akz Open the ToolStore page D Mins _ a v gt o N Insert the storage media with the data then wait about 10 seconds until the USB Memory is ready to use Touch Restore d ti Wait about 10 seconds then remove storage media i D 3 OC d i a Di aH 1 4 SV 9 ti L La Version 2 2 User Manual for TS KTS Console b Cont Mold Maste SS Oct 2012 Page 84 Not Under documentation control if printed May be revised without notice Customising your controller TrempMaster dc Restoring tool settings 2 To Restore a single Tool Insert the storage media then wait about 10 seconds until the USB Memory is ready to use Select the tool tab Touch Restore TTET z6 16cards Joel dat Z4 12 Cards Tool dat z4 24 cards If the console sees
14. active the wait period that you wish for the operator to hold the purge material in the barrel and mould Factory Settings the default settings that you can re select at any time Version 2 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 64 Not Under documentation control if printed May be revised without notice Running your controller TempMaster Oo Check zone past performance graph Your controller can record and display the temperature history for any zone over a period of time Inspecting the last 5 or 30 minutes Select any zone Touch Zoom The Zoom page shows Touch Range Touch Up or Down User Manual for TS KTS Console Version 2 2 z i f fala e ifei P Be H siptcid 8 l 7 e ay kd RB bk A d DIN E CH e Fee gt il e Be De Hin fie Pal P is Pat wd Be Dez e The table on the left shows the main settings for the zone and the current temperature value b The upper graph on the right shows how measured samples of the actual temperatures have varied above red and below blue the set point over a period of time If the two lines are running close together then you have precise temperature control If however any zone shows a noticeably wider deviation than its neighbours it could indicate potential problems It could be a noisy thermocouple input that may be due to poor connections or a faulty thermocoupl
15. and increasing as the period counts up z ersion 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 132 Not Under documentation control if printed May be revised without notice Appendix E Sequence Valve Gate Eee 12 13 14 If you manually turn on or open valve for testing User Manual for TS KTS Console Version 2 2 After you have set all the gate open and close values touch Preview to see a graphical representation of the gate operating sequence Each gate is shown as a separate line on the graph At the bottom a red line shows whenever there is no gate open In most typical sequences you need to see at least one gate open at any time the appearance of a red line along your sequent shows that you might have a gate setting incorrect Inspect the settings more closely and adjust if necessary Touch Exit to leave the graph and return to the Display page if you wish to test the run sequence then touch Run Once Return to the main display page where you can select each zone and then go to the Graph page to get a real time view of the gate operation The Sequencing should now be ready for live use purpose You may select Manual button on the right Select valve gate and select Open Pin or Close Pin to manually open or close valve gate After manual operation is done press Auto to return automatic sequencing mode SVG card will
16. bar If the Remote application is running at full screen size then there is no immediate control available to Stop VNC Instead a timer offers a Stop VNC option 10 seconds your last button push on the remote application You can accept the Stop VNC option to return to the Utilities page or Cancel it to remain with the remote application for a while longer Multiple Consoles using Master IP Address This is used to connect one TS Console to another such that two or more consoles may work together to control one single device provided they are all interconnected via a Local Area Network To start enter the IP Address of a remote Master Console which is already linked to a controller cabinet The local console will search the LAN for that console and establish a connection Once this has been done then both consoles command and monitor a single controller cabinet Any commands such as Start of Stop may be entered on either console that command will be carried out and both consoles will see the appropriate changes The two consoles are then in effect working in parallel User Manual for TS KTS Console Version 2 2 b de mm im Mold gt Not Under documentation control if printed May be revised without notice Page 123 Oct2012 Masters TempMaster 72 A E Appendix C Extra Cards Extra facilities that can be fitted to the M2 series Controller B1 16DLI 16 channel DL Input Card The Digital Logic Inp
17. but only 32 actual zones it is best to set the last 4 zones to Not Used so they do not display false alarms such as T C Fail Such configuration is detailed in the following steps 1 Touch first zone to be re configured 2 Touch last zone to be re configured 3 Touch Range to include all those in between 4 Touch Set to see the Configure Card Slot menu 5 Select Zone Type which could be a Not Used is used to switch off unwanted card zones b Manifold which sets the zone to a slower response curve which suits that sized heater c Spear is only available when the 4SMODC card is fitted This card has two twin channels that are designed to work as a twin Spear Zone card with one triac used for the body and the second used for the tip d Monitor allows you to use any control zone from a 6MOD or similar card as a monitor zone only with no control function e Special There are a number of different cards that are not used for temperature control for instance RTD Zone suits 12RTD twelve channel temperature with Cards and Zone types and measuring cards for cooling water as part of this setting up IO Zone suits QCIO four in out channels Input Output populated with standard default HoresA Hermal Hamm Haramai Mermal Marmal li The Setup page is now complete cards values These Tool Parameters Water suits Al8 8 channel analogue or 16DLI 16 may be accepted or changed channel wa
18. disconnect units while in this mode Reduces the temperature of all zones that have any Standby Temperature configured on the Setup page Temperature remains reduced until RUN command is given STARTUP Initiates a starting sequence that is configured on the Setup Page MASTER FOLLOW Applies power to Master zones then adjusts other zones Set Temp to follow Master Zones Actual Temperature produces a homogenous heat rise MASTER ONLY applies power to Master Zones but waits until they are at full temperature before switching on all others STAGED applies power to nominated stage zones and then waits until they reach normal temperature before switching on next stage zones This cascades the startup sequence through several stages SECOND STARTUP When all the zones have reached their set temperatures the system then goes into SECOND STARTUP mode which may be configured to either RUN maintain their Set Temperature BOOST temporarily raise the temperature and then settle back to normal Set Temperature STANDBY lower zone temperatures until Run command is given Initiates a switch off sequence that is determined by the startup mode With the Startup Mode set to Master Follow or Master Only Shutdown switches off the nominated master zones then adjusts all other zones Set temperatures to the manifold Actual temperatures The whole tool then cools in a homogeneous manner With the Startup Mode se
19. immediately starts sequence after Cycle Start trigger comes in Mold Not Under documentation control if printed May be revised without notice Page 133 Oct2012 Masters TempMaster IO Appendix E Sequence Valve Gate Setting up examples Each valve gate can have up to 4 steps The valve will act according to these step settings A step consists of opening and closing the valve gate The following are various scenarios for operating a valve during a sequence Opening and closing the gate on time values alone Open the valve on an absolute time relative to i step 1 step 1 step 1 step 1 the start of the cycle and close it on an Open Trigger Open Yalue Close Trigger Close Value absolute time value relative to the start of the wette 0 00 secs Time abs Time fabs 0 00 secs Time abs 0 00 secs cycle Open the valve on an absolute time relative to Step 1 ee Step 1 Step 1 the start of cycle and close it on at Open Trigger Open Yalue Close Trigger Close Value incremental time relative to the when the a valve was opened Opening and closing the gate on screw position alone Open the valve on screw position and close it Step 1 Step 1 Step 1 Step 1 Gap Open Trigger Open Value Close Trigger Close Value Opening and closing the gate on a combination of both time and position e Step 1 step 1 tep 1 step 1 Open the valve on an absolute time relative to Open Trigger Open Value Close Trigger C1
20. large finger print and hold it there for 3 4 seconds When you remove your pointer it will reposition the target for you to touch again After a few target points it will finish and recalibrate the screen and re align its response to where you touched the screen You then need to restart the console Export the Communication Data for analysis Console Startup Select the operating mode that is assumed after initial switch on Factory settings This opens a third tab which allows engineer to get maintenance access for system calibration This is not designed for general use and it is protected by a unique password Ground Fault If this is set to Enable the ground fault detection is operative such that the card will reduce output current and so limit the ground fault current If this is set to Disabled then fault current can flow to ground If output is too high then the main output fuse will rupture Language You may select a preferred language for the screen and online help It is safe to select a different language while the system is running Although the Console does shutdown and reopen it does leave the system running safely during the changeover Limit Exceeded Disabled means that an attempt to set the temperature above the limit is non effective and the Set temperature stays the same Enabled means that an attempt to raise the Set temperature above the limit will increase the set temperature
21. more than one tool setting on Pame ies aii the memory card it displays a Select Tool eg tool06 dat Z6 10crds882 i i i i Tool dat z6 15 cards option for you to choose which particular tool you Lea dat 5 cards z4 require i SW i Wait about 10 seconds then remove storage media i D a il L Ly A User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 85 Oct2012 Masters TempMaster IS Mold Mast Customising your controller Sequencing Tools and Settings Effective startup sequence from this example b demm d ez e S Oct 2012 Page 86 The combination of Sequence and Time columns gives you the flexibility to run a preset sequence of events that you may require for special tool runs One possible use shown here would be to copy the same tool into a few slots and then make separate adjustment for each occurrence and run them in sequence For instance it may be desirable to first heat up the manifolds only to a lower start temperature Once that has been allowed to settle you could then pick a second sequence which would bring them up to normal temperature and then maybe a third and fourth which would switch on all the zones at normal temperature and put them into Run mode Sequence 1 The Tool with manifold set at just below run tem
22. or Slave to another zone ag D i et Be Bez H Si Value bar to Set Raise or Lower temperatures User Manual for TS KTS Console Version 2 2 b e Mold Not Under documentation control if printed May be revised without notice Page 19 Oct2012 Masters TempMaster M More Pages EasyView Shows zone temperature and their position in the tool Shows Zone Status Can be used to Set zone temperatures Graph Page Shows graphs of temperature versus time for up to twenty zones at a time The ToolStore page This is a tool bank in which you can store up to 200 tool configurations The Picture page Save and display up to 20 drawings or pictures Demoergirsbieen of the Lage Wie function Version 2 2 User Manual for TS KTS Console b e Mold Masters Oct 2012 Page 20 Not Under documentation control if printed May be revised without notice ee empViaster 07 More Pages The Utilities page Contains several sub pages System change the passwords and the system clock Printer select a driver for your printer Sten rn rest pret pon Remete pes Event Log to find changes that have been made to the ea aon controller settings elle ww Network set up the Controller to communicate over a EE DU network Eae Export obtain historical performance data for any zones over the last 24 hours Remote view any other networked computer via a Virtual Networ
23. recent events and is explained more fully on page 67 Export is used to collate running data and is explained more fully on page 98 Networking Remote and Quad IO pages These three pages may be used to connect your controller into a wider system that allows remote interfacing They should only be configured by competent IT staff who are familiar with networking protocol or machine interface Should you need further information please contact your supplier Version 2 2 Oct 2012 Page 52 Setting up other Utilities 27 10 2010am csv 2610 2010 pm cav 26 10 2010am cav p el 25 10 2010pm csv Aen fen TTT iesst 25 10 2010am csv VD _ 2 10 2010pm csv Cole e 21 10 2010am csv d o ls o laangem cen Sms ug baratas nn rent meme gem Machine Mame D gemet Lei o then Oban an adresa touchy gc ee 1 LL age 255 0 0 0 datem SSC EZI Guad IO Cond garaiion teas an ia ore oee Let weg Stoney tw owas Tonpowe ca E SL el GE User Manual for TS KTS Console Not Under documentation control if printed May be revised without notice Running your controller TrempMaster Li Running your controller This section of the manual is divided into four main areas that are concerned with e the basic Starting and Stopping along with Boost and Pause controls e changing temperature settings while the controller is running e inspecting historical graph
24. sales moldmasters com UNITED KINGDOM Mold Masters UK Ltd Netherwood Road Rotherwas Ind Est Hereford HR2 6JU United Kingdom tel 44 1432 265768 fax 44 1432 263782 uk moldmasters com FRANCE Mold Masters France Z la Marini re 2 Rue Bernard Palissy 91070 Bondoufle tel 33 1 82 05 00 80 fax 33 1 82 05 00 83 fr moldmasters com SINGAPORE MALAYSIA INDONESIA THAILAND Mold Masters Singapore PTE Ltd No 48 Toh Guan Road East 06 140 Enterprise Hub Singapore 608586 Republic of Singapore tel 65 6261 7793 fax 65 6261 8378 mmsinfo moldmasters com TempMaster K Global Support SOUTH AMERICAN HEADQUARTERS BRAZIL Mold Masters do Brasil Ltda Rua Hum 1106 e 1126 Jd Manchester Nova Veneza Sumare Sao Paulo Brasil CEP 13178 440 tel 55 19 3922 4265 fax 55 19 3922 4266 vendas moldmasters com br U S A Mold Masters Injectioneering LLC 103 Peyerk Court Romeo MI 48065 USA tel 1 800 450 2270 USA only tel 1 586 752 6551 fax 1 586 752 6552 mmi ing moldmasters com KOREA Mold Masters Korea Ltd 708 Byucksan Digital Valley 5 Cha 60 73 Gasan dong Geumcheon gu Seoul 153 788 South Korea Tel 82 2 2082 4755 Fax 82 2 2082 4756 mmkr sales moldmasters com SPAIN Mold Masters Espana Serennia Business Center Buenos Aires 37 29 08902 Hospitalet de Llobregat Barcelona Spain tel 34 93 802 36 01 fax 34 93 802 49 08 es moldmasters com Global Support
25. set here as a 10 Zone tool with two manifolds It needs an alternative tool setting for twelve zones with manifolds bridge and a sprue The first step is to save the current settings to a blank tool slot And then name the new tool Next open the Setup Page Select the spare un used zones and reallocate them User Manual for TS KTS Console ersion 2 2 SG i Mold ez Not Under documentation control if printed May be revised without notice Page 75 Oct2012 Miasters TempMaster IO Customising your controller You can allocate function probe or manifold and you can also use the colour picker to show a different zone type Use Alias to provide different names to identify the new Bridge and Sprue zones fol gt EI Abee Teel Ad FEIT Im EA While on the Setup page scroll along and check whether you need to adjust any other settings For instance this part of the table shows the default for probe alarms does not match the existing settings you can set them to match while still on this screen Return to the Display page to see the new tool layout It shows the new zones that need their set temperatures adjusted Select one or more of the new zones and touch set Use the key pad to set the zone temperature Finally see the new tool setting ready to use Dimri Hote EE Version 2 2 User Manual for TS KTS Console b oo Mold Masters Oct 2012 Page CP Not Under documentation contro
26. temperature until it is switched off This means that once you have switched the system on and it has reached a steady state the console could be removed without affecting the cabinet However without the console you have no means of monitoring the system changing any set temperatures or shutting down in a controlled fashion This generally means that if an accident or major fault causes the console to fail the controllers in the cabinet can if necessary maintain production until another console could be provided There is however one configuration that cannot lose the console and still maintain normal running Thermal gate control probes use cycle synchronisation for their operation and they depend on the console for their gate timing If your tool uses these particular probes then a console failure or disconnection does stop normal production If you should need to remove and or reconnect your console during production then refer to Removing a Console on page 111 for advice Console and Controller variations TS and KTS only There are more variations from the normal one to one situation described on the previous page One Console to many Controllers If HRC NET cards are installed in two or more controller cabinets it allows a networked console to switch its focus between the controllers Once you have started a controller cabinet and set the operating temperature each control card can function autonomously using its own m
27. that you must alter to change between Star and Delta supply Do not change the supply wiring until the controller has been disconnected from all electrical supplies At the upper connection blocks change the Star Delta cross links using a single 3 way link for Star supplies or three 2 way links for Delta supplies The connector strip shows the appropriate cross links to use and looks similar to this Three 2 way links for Delta Supply One 3 way link for Star Supply diagram At the base of the cabinet is the mains connector strip that will accept a Star or Delta supply cable Use only 4 core supply cable for Delta connection and 5 core supply cable for Star connection Wire this cable into the lower terminal ER blocks to match the particular supply as shown in the adjacent diagram 1 1b Current limiting fuse option wm O Where the 3 phase supply may have a high prospective sort circu
28. to activate a valve gate and two digital inputs to accept feedback signals one to confirm that the associated gate is closed and another to confirm it iS Open The card also has further inputs that affect the overall control There are four digital inputs which comprise e The Cycle Start input e An Enable input which is closed while all systems are ready to continue moulding e Two user definable inputs for other functions There are three analogue inputs that are primarily used to receive a signal which is proportional to the physical position of up to two screw feeds There are three analogue inputs two of which are primarily used to receive a signal which is proportional to the physical position of two different screw feeds The third is reserved for future development A sVersion 2 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 130 Not Under documentation control if printed May be revised without notice Appendix E Sequence Valve Gate TempMaster D Setting Up Part One Inputs and Outputs 1 Check electrical interface connections with regards to the SVG Connections Diagram will there be one provided anywhere 2 Where gating events are triggered by the screw position of the main barrel then it must first be correctly configured Got to Display page and touch Inputs 3 Under Analog Inputs and Sensor Setup touch Setup 4 Follow the Calibration procedure
29. to the limit and no more Limit N Z Alarm Disabled leaves N Z in its normal condition which does not raise a system alarm if it occurs Enabled allows N Z condition to initiate a System alarm notification in the lower status Window At the same time it energises the Alarm Relay for remote signalling Power Display Select Power Display as Peak Amps or Derive a relation between Peak and power Slave Address This is where you can input the Slave address for the console when it needs to communicate via an external protocol User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 37 Oct2012 Masters TempMaster V Configuring the Tool amp System Settings Supply Voltage Temp erature Precision Tool Password User Password Enter the System Supply Voltage It is used to Maximum supplied calculate the Watts display This is normally Voltage is 400V the phase neutral voltage on a star supply and the phase phase voltage on a delta supply Allows you to set the resolution for the Actual temperature seen on the Display Page to a floating point scale which displays temperature to within one tenth of a degree or an integer scale which rounds the displayed temperature to the nearest whole degree Select Float or Integer as appropriate Allows you to set the security level on the Tool page so that the operations of
30. values then clears after the last value is set 8 The console view returns to just the Display page About the Spear Tip Cycle Time The following shows how a spear tip temperature cycle relates to the mould cycle i External Signal Trace 1 triggers at rising edge Mould Cycle Varies in length Boost signal Trace 2 Spear Tip Power Cycle Trace 3 Spear Tip Temperature Cycle Gate open period closed Version 2 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 42 Not Under documentation control if printed May be revised without notice Setting Operating Parameters rempMiaster do To set Cavities Water Flows and Chillers 1 Select the Cavity zones Pe ze 2 Touch Set 2 Set the Values 3 Touch Enter User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 43 Oct2012 Masters TempMaster Ou Setting Operating Parameters Saving everything to a Tool Bank 1 Select the Tool store page 2 Select the new tool named earlier see page 24 3 Touch Save eleleleieieieiele Version 2 2 User Manual for TS KTS Console b a Mold Masters Oct 2012 Page 44 Not Under documentation control if printed May be revised without notice ESS emp aster E Setting up EasyView Pages Process Select a picture or
31. 39 Setting up EasyView Pages ccccceccsecceeeceeceeeceeeseeeeeeseeeaeeeeeeeeeeees 45 Setting up other Ultltes ec ccecceecseec cece eeseeeseeeseeeseeseesaees 48 RUNNING your copntroller ccc ceccecceecceeceeceeceeeceeceeceeceeesueceeseeeceeseesaneaeees 53 Customising your Contfroller eeaeeceeeeeeseeeseeeseeeaeeeeeeees 13 Maintaining your Controller ccc cccc cee ecceee sees ees eeeeeeeeseeseeseeeeeeseeseegeeas 95 TROUD ISS MO OWING E 107 Appendix A HRC Wiring Details ccccccccecceeceeeeeeeeeeeeeseeseeeeeeaeeees 116 Appendix B Networking Information ccccecceecseeeeeeeeeeeeseeeeeeeeenes 120 Appendix C Extra Garde 124 Appendix D Water Manifolds cccccccecceeceeeeeceeteeeeeteeseeeeeeeeeaeeeeaes 125 Appendix E Sequence Valve Gate 130 gle Gane ee ee ee ee S 135 Global Gupport 136 User Manual for TS KTS Console Version 2 2 Viold A Not Under documentation control if printed May be revised without notice Page 7 Oct2012 Masters TempMaster j 5 Introduction Specification The following are general specifications The actual controller console supplied may have contractual variations and differ in some specified options Supply Voltage Voltage Bandwidth Supply earth leakage trip Overload protection Mains Voltage output pattern Low Voltage output pattern Output overload protection Temperature control method Control range Temperature Scale Pr
32. 66 Not Under documentation control if printed May be revised without notice Running your controller TrempMaster Li The Event Log Page This page enables you to look up what operational changes have been made to the controller or its configuration and when they were done It is a permanent on line diary and it logs the last 40 events or changes that have happened 1 Open the Utilities page and Event Log 2 Open the Event Log sub page and touch Start Search 3 Select a search pattern Last Action shows all past actions chronologically Zone searches for past actions that have occurred within a specified zone Event searches the past actions for occurrence of a specified event type Zone amp Event searches past actions for a particular combination of specified zone and specified event System Action searches for occurrences of a specified global action All Alarms searches and returns all alarms that have occurred on any zone Zone Alarms allows you to first select a zone then searches and returns all alarms that have occurred on that particular zone All search results are displayed in the Events Log page window and the Next button shows more results if they are available User Manual for TS KTS Console ersion 2 2 o Mold A Not Under documentation control if printed May be revised without notice Page 67 Oct2012 Masters i TempMaster io Running your controller Alarms Whichever p
33. 7 j ii r L bh 5 r F d ie fa j A 1 We d user manual for TS KTS console together with M2 series of hot runners controller f im ne ee ee fam 1 Hm BH E o i a fe ms em W iy sem Lena 1 Ge Te II TLL a Mold Masters performance delivered KEEP THIS SHEET SOMEWHERE SAFE Every machine leaves our factory with two levels of password protection We recommend that you change these as soon as possible to establish your own security System Password linux User Password unix User Manual for TS KTS Console TempMaster Oo User Manual for TS KTS Console Copyright c Mold Masters 2010 This manual is intended for use with the KTS TS Console and M2 Series Controller SORA Te ME 1 with which it was supplied This manual is written and prepared for Software Version 8 October 2012 Our policy is one of continuous improvement and we reserve the right to alter product specifications at any time without giving notice User Manual for TS KTS Console Version 2 2 i b oom Not Under documentation control if printed May be revised without notice Page 5 Oct2012 Masters TempMaster io User Manual for TS KTS Console Publications Issue Date Changes Author Authorised 102 Jan 2044 Additional Console switch and power connector a SC instructions QuadlO Reset Time function added 1 1 Feb 2011 DH IE Setting Up section revised KE D Correction to passwo
34. EE 38 Setting up System Utilities cece e eee eee en ees 49 Coolant Monitoring 126 Setting Up your controller cc cece eee eeee cece eeeeeaaees 23 Creating a new Froo 76 SRUTDOW N EE 55 Deleting a tool eee 82 STOW ee cee screenees cee eases we meee ead see nee 31 Demonstration Mode 72 Shutdown Temperature 36 Display VOU EE 31 Shutdown Tmer cece cece ee eeeeeeeeseeeeeeeaaes 35 Display Mode ena 33 Spear Tip Cycle Time 43 Display page 13 Kielech ge EE 8 Display Page SyMbOIS ccccceceee ee eeee ee eeeeeeeeeeeeeees 14 RL NEE 30 Dynamic Remote Tool Load Process ees 95 STANDBY eege ere eco ean AE AE Ee NEE 55 EASY VIEW page ed ZE Ee NNN EEN Nee gege Ne d Ree 61 Standby temperature cece eecceeeeeeeeeeeeeeeeeeeeaaes 29 Event Log Page cette nneeeeneeees 68 Standby Temp nee ee ee ee naee eas 35 EXOD FACIE eher ee 99 Star J Delia ODOM ebe deree le Eed dees 117 Factory settings cccccceeee eee eee ene 38 RN TE 55 Fault and warning messages eens 108 Startup Mode 35 First TOO EEN 24 StartUp e EN left EE 33 34 Eege 55 ef nn ER KEE 101 System Settings EE 37 FUSOS EE 116 System Time and Date 51 I nput SIH AN ge Stegen deele ee 34 TC OMS E 30 I nput TUNE EE 33 TC CIN e 29 Isolate the Controller 10 Temerature Difference ssssssssrrrrsrrrrresrrrrresrrrreee 129 Language cere cheek ses ee nase ee antes cence 38 Temp erature Scale 36 39 Limit EXCGCOCG EE 38 The Tool Parametere 29 L
35. Master J Using EasyView to change temperatures 1 Select the desired zones 2 Touch Set 3 And then To Set a new temperature Touch Set To Raise the overall temperature Touch Add To Lower the overall temperature Touch Subtract 4 Enter the Temperature setting or change n ven eee 5 Touch Enter to make the setting or Esc to defer the action User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 61 Oct2012 Masters TempMaster IO Running your controller Using EasyView to change Modes 1 Select the desired zones 2 Touch Set 3 And then a To change to Manual Touch Manual b To Slave a zone Touch Slave c To return to Auto Touch Auto 4 a for Manual enter the Percentage power i vw ae b For Slaving select a similar master zone from the Zone list c For Auto enter the required zone temperature es ee er e 5 Touch Enter to make the setting or Esc to defer the action Version2 2 User Manual for TS KTS Console Masters Oct 2012 Page 62 Not Under documentation control if printed May be revised without notice Running your controller TempMaster R Purge sequence The purge mode is only available while the tool is in Run Mode and has two different modes Mechanical Mechanical purge is a pass
36. Master console The second console connects to the first via an Ethernet link to the first and nominates the first console as Master by using the Master IP Address setting on the Utilities Remote page y Version 2 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 120 Not Under documentation control if printed May be revised without notice Appendix B Networking Information TrempMiaster do When you have two or more console commanding a single controller then one only is connected to a Controller cabinet via its own Data Link This is the Master Console and you should note its IP Address which is printed on the console case Sub consoles must be connected to the Master over a network On those consoles you must open the Remote tab on the Utilities page and enter the first IP Address into the Master IP Address box on that page Once this has been accepted and communication established then you are able to control the one Controller cabinet from any of the linked consoles Any changes made on one console are shown on all the others User Manual for TS KTS Console Version 2 2 b Lt Te Mold Not Under documentation control if printed May be revised without notice Page 121 Oct2012 Masters gt TempMaster IO Appendix B Networking Information Configuring a Networking connection Touch Screen consoles can communicate over SS a PER P an Ethernet network in order to pass information i pe
37. Sensor Type eege Ne E RENE ENEE EEN EN Resizing for fewer ZONES cccecceeeeeeeeeeeeeeessuaaeeees 17 Backing up tool settngs eee ees 83 Restoring tool settings 85 te RE 37 Reynolds Un Ve EE 129 Beacon and SOUNGE EE 71 PUM NEE 55 Blanking DGlAY vusacsvesinesseiansadsxevedenseteepernaeinaevienees 37 Running your controller 54 ee EE 57 Safety 1 NSEPUCHIONS ic scrse cent opsctasicas ieisrecesndersrundeitceess 9 SCHEER 55 Saving everything to a Tool Bank 45 Boost temperature EE 29 Saving tool settngs cece eee nae eens 80 Boost mi vu 29 Screen Layout andNavigation 12 Button One Mode cece ee eeeee ee eeeene eens 33 Second Gtartunp cece ee eseeeeeeseeeeeeeaaes 35 Button Two Mode eee eee eeeeeneeees 33 Self Diagnostic Tests 101 Card I e e ge 71 SMSO bere Egeter ER eebe e S 30 Change Oe e 59 Sequence Valve Gate 131 Change Temperatures cccecee cece eeeeeeeeseeeeeeeaaes 58 Sequencing Tools and Gettmge 87 Check zone past performance 66 Servicing and repairing your controller 106 Configure the Control Cards 27 Setting Operating barametere ssssesrrrerrrrerrrrsrrre 40 Configuring a Networking CONNECTION cee eee es 123 Setting PaSSWOldS Ce gg ae geeg uh ebe EENEG 51 Configuring a Remote Connection 124 Setting the Tool parameters cccce cece ee ects eeeeeees 28 Configuring the Tool amp System Settings serssss 32 Setting up EasyView Pages 46 Console SlarlUp
38. Setup page displays an Analogue Input column After selecting the flow zones and the Analogue Input column touching Set displays a range of devices that are known to match the Analogue Input Version2 2 User Manual for TS KTS Console Mold Masters ooOct2012 Page 124 Not Under documentation control if printed May be revised without notice Appendix D Water Manifolds TempMaster Mg Appendix D Water Manifolds Installing and configuring a Water Manifold The M2 series controller provides a compact system for monitoring the coolant system within a mould Each controller may vary slightly in its make up but generally it comprises e a Controller Cabinet with 1 analogue input cards 2 other control cards as required e one or more water manifolds with flow sensors and Jor pressure sensors e Sufficient data cable to link the manifolds to the cabinet Installation The water manifolds should be firmly mounted in a position that will not be subjected to excess heat vibration or other undue stress The coolant system should be plumbed in by a qualified fitter ensuring that the flexible coolant pipes are not trapped by moving parts or kinked by being stretched around corners or similar obstructions There should be a main flow and return shut off valve provided so that the water manifolds may be easily isolated for repair or maintenance You should not use any liquid sealant that may contaminate the coolant circuits
39. WER WOR EN kl tlt mm Dh WON OR OO WI Version 2 2 User Manual for TS KTS Console b onl Mold Masters Oct 2012 Page 96 Not Under documentation control if printed May be revised without notice Maintaining your controller TrempMaster Wi Print out to File Rather than print to a printer either local or network connected you can print any of the normal print options to a USB Memory stick Insert storage media then wait about 10 seconds until the USB Memory is ready to use Local USB Network TCP Network LPD Windows 5MB Select Utilities and Print page Print to File At the Connection option touch Edit and select Print to File On return to the main Print page you will see that the second Printer Setting has changed from Model to File and see that this option defaults to PDF For different print options touch File Edit and select JPEG PNG or PDF Return to any page eg the Setup Page and touch the Print button on that page When done wait about 10 seconds then remove storage media and take it to a Personal Computer Plug the USB Memory stick into a PC to view the printed page Pee ae ele fifiiiiaigtitrizs User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 97 Oct2012 Masters TempMaster IO Maintaining your controller Export Facility You can extract the last 24 hours of zone
40. a Edit the actual screw travel length b Move screw to forward position and touch Forward c move screen to rear position and touch Back nr d Touch OK to save the settings and exit the Orsi oi cee GA SSS 5 Activate the digital inputs for Gate Closed and Gate manema Valve T open as required ne rps Part Two General parameters 6 External connections See Associated tool drawings Diagrams tables are required 7 Goto Setup page to see the detected Sequence card s NOTE If no SVG card is seen then check to see you have the right tool selected If the SVG card has recently been added then you may need to go to the ToolStore page to select a new blank tool slot and touch Detect so the console finds the new SVG card Touch Config and select SVG Settings tab NOTE this tab is only visible when an SVG card has been detected 8 Set the parameters as follows User Manual for TS KTS Console Version 2 2 E Mold Not Under documentation control if printed May be revised without notice Page 131 Oct2012 Masters TempMaster IO Appendix E Sequence Valve Gate Graph Mode Set the x axis to be a function time or screw position Max Cycle Time Sets the period of time that is shown on the Display Period graph Monitor Time If you have active inputs to monitor that a gate is open and closed then the system will generate an alarm if it sends an open or close signal and the gate fails to
41. abled then all functions that normally need a User Level 1 Password become Open level Higher level functions that require a System Level 2 password retain their Password protection About password active times After you key in a password access is possible while you continue to input data Each key touch resets the timer but when no more input is detected it times out and then denies unauthorised access This is the same for both User level 1 and System level 2 passwords If while the System password is active you visit a lower level page that only requires User Level 1 password level eg Display or none at all eg Graph then the System password will expire after 20 seconds but on doing so it becomes a User Level 1 password which would allow you to continue setting lower level parameters Password Application Table The Password Application shows the default level of password that is required for various functions on the different screen pages Other options including Allow Set Zone Off Tool Password and User Password may alter some levels of control Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 48 Not Under documentation control if printed May be revised without notice Setting up other Utilities FrempMaster doo Change Display options Go to Zoom page to use required to use required to use Display Run Stop Change Modes Turn zone On
42. age may be active there is a common Mode and Status window at the bottom of the page Mode RUN Status RR lf your controller is switched on and running normally then the left hand Mode window will show RUN as black text on white background and the opposite Status window will show NORMAL as green text on black background Mode Window If the controller is manually switched out of RUN mode then the Mode window shows the selected function and is seen flashing on and off The table below lists the different displays Black text in RUN White box All control zones are working normally White text in The System has been shut down and the heaters are at Blue box room temperature Black text in Any zones with Boost Temperatures configured are getest being temporarily raised machine request Status Window The right hand Status window shows NORMAL if all the zones are at their set temperature and no faults have been detected If any zone detects a fault then the Status window changes its display and colour as detailed below Green text in NORMAL Black box Controller is running normally White textin Red This shows either a Fatal Error or a zone s temperature box exceeds alarm limits Note that the status alarm is only active when in Run Mode so systems whose temperature rises slowly such as a Master follow will not raise spurious alarms Once they switch over to Run mode at their set temperature then the al
43. ages of setting up water flow and pressure have been brought together in the following steps Switch on the controller Check the Display page to see whether the unit has already been configured with the correct number of Flow and Sensor channels and other control zones as required If the Analogue Input zones are already configured then you may move on to step 8 and start by setting the alarm limits If the Analog Input cards are new and not displayed then continue from step 3 below Open the ToolStore page and select a blank tool store location Select Detect and touch Yes this should detect the Analogue Input cards and present them as a number of flow or pressure sense channels It may also reveal other cards detected at the same time Probe and Manifold heater zones need to be set up as shown in the manual on page 24 before returning here to set coolant monitoring To set the Analogue Input Function first touch the particular sensor channels which are connected to one type of sensor flow pressure temperature etc Then touch anywhere in the Sensor column Touch Set to open a Sensor pick list and choose the appropriate sensors sc FO P0S Flow sensor FD P20 Flow sensor FD PS0 Flow sensor PF2W511 Flow sensor PF2W520 Flow sensor PF2W540 Flow sensor EX 110 Gauging sensor HN 10 Pres e CSLFB1O Flow sensor To Set the Analogue channels monitoring limits stay on the SetUp page touch the analogue fl
44. ak stage is active and the controller will hold the mould at temperature for at least that preset Soak time during which the Next and Back buttons are faded and inoperable Once the timer expires the operator can touch Next and continue with the final Mould and quality checks You may exit the Purge wizard at any time by touch Exit at the lower left of the Wizard screen User Manual for TS KTS Console Version 2 2 E Not Under documentation control if printed May be revised without notice Page 63 Oct2012 Masters TempMaster Lu Running your controller Preset Purge parameters You can set the Purge Parameters at any time te Purge Wizard Settings while the Purge Wizard is on the screen This SS picture shows the Purge Wizard settings at Recommended EE 2 default value and they are as follows Saye 220 Recommended Cycles how many times Purge Cycles 250 the Wizard suggests you repeat the sequence if you do not accept the final quality MaMa 250 Purge Material the weight of purge Soak Time min material you wish to instruct the operator to actory Settings I d Factory Sett oad Purge Cycles the number of cycles you wish to instruct the operator to run to expel the first or purge material Action Normal Cycles the number of cycles you wish to instruct the operator to run to load the new colour material Soak Time Only available when Chemical Purge is
45. arm becomes active x Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 68 Not Under documentation control if printed May be revised without notice Running your controller TempMaster IO Identifying Zone alarms Normal Zone This shows a healthy zone E Green text on Black background Warning Zone Black Text on This shows a first stage warning Yellow Background Frobe 16 White text on Red ot WEE Background a fc A aa Probe 16 Alarm Zone sel 19 250 This shows a second stage alarm Fatal Error an abbreviated Error message White text on Red for a list of all Error messages see page E Background 107 User Manual for TS KTS Console ersion 2 2 z Mold A Not Under documentation control if printed May be revised without notice Page 69 Oct2012 Masters i TempMaster K Running your controller Beacon and Sounder extension A Beacon and Sounder extends any second stage temperature alarm or fatal error alarm Curing the alarm condition automatically extinguishes the beacon sounder A key switch is also provided to mute the sounder at any time Note however that no reminder is given to show that the sounder is muted when the system is healthy Re occurrence of subsequent alarm conditions will cause the beacon to light but not create an accompanying audible alarm Card Indicators Zone Control Cards also have their own LED indicators that give a state of health displa
46. arms or informing the E ee Normally Open moulding machine In order to capture A Alarm 240v contact2 Contacts fleeting alarm conditions the relay is held on for about 15 seconds after the alarm condition is cleared The contacts are rated for 5A at 240V HAN4A An optional input can be accepted through the same connector It may be used for Cycle synch spear tips Inhibit Mode remote Boost or Standby or any other user definable function For exact details consult the specification for the particular model Pin Connection 1 5 Serial Port CO EH A male 9 way D panel connector can be provided for an RS 232 serial port 2 Transmit which is used to communicate with a remote computer for data collection The pin outs are as follows C ON E User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 117 Oct2012 Miasters gt TempMaster IO Appendix A HRC Wiring Details 1 6 USB Port A USB port is standard on all Touch Screen Consoles Waly Name Description for connection to a printer or plugging in Memory Sticks for other functions such as backup and restore 2 JS me Ground Earth 432 1 USB Type A 1 7 Remote Tool Load Connector The 105 offers extra input output functions that enable remote tool loading This connects to your remote machine via an AMP 183040 circular connector in tool load signal from molding mac
47. articular tool You should also note that they are all configured on a zone by zone basis which can allow you to make precise settings Note also all the values on the setup page are stored with the tool setting which is currently selected on the tool page If you go to the tool page and load a new tool for a different purpose then the new tool may well bring its different setting into this page 3 Configure Tool and System Settings The Config button opens more settings which are grouped into e Tool Settings such as Alarm Time and Startup Mode which will be specific to this one tool e System Settings such as such as Language or Screen Blanking times which will be commonly set for whichever tool is loaded into your console 4 Set up Operating Parameters Once you have all the above set to your particular system you finally need to go back to the main Display Page and set your main operating temperatures and other values required for any monitoring zones that you may have in your console for steel temperature water flow coolant temperature or other ancillary facilities User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 23 Oct2012 Masters i TempMaster IO Setting up your controller Create a first tool 1 Select the ToolStore page 2 Selecta blank sub tab and touch Detect 3 Enter System password 4 Type in a new nam
48. ation control if printed May be revised without notice Page 103 Oct2012 Masters TempMaster Mg Maintaining your controller T C Interaction with zone NN A different zone s to the one being tested had an unacceptable rise in temperature greater than Bad Rise set in Test Values Indicates faulty T C positioning or close zone proximity Heater TC Common with zone NN Cross wiring fault between displayed zones Could be either Heater or thermocouple wiring at fault Message Overflow There is a limited amount of memory available to store test results If this message is seen too many errors have occurred to store them all ersion 2 2 User Manual for TS KTS Console Mold A R Masters Oct 201 Page 104 Not Under documentation control if printed May be revised without notice Maintaining your controller TempMaster Mig Servicing and repairing your controller unit to inspect it or replace fuses glass bodied fuses Replacement parts Always isolate your controller at source before you open the Only use Ceramic Body Fuses on Control Cards NEVER use Q 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 Inspect the fan filters at regular intervals Both the upper and lower filters covers can be
49. by any detected alarm condition It is not activated if the controller is manually put to Stop mode by the user An output is given if the controller is put locally or remotely into Boost Mode A new proposed output which will be given if any zone deviates from its setpoint enough to generate a first stage Warning User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 91 Oct2012 Masters TempMaster io Customising your controller Default Input Output Selection and connector pin table The standard interface is a Harting STA 20 pin female connector within an H A16 housing Even though input outputs channels may be individually configured to assume different functions the default options are as shown in the following table along with the connector pin configurations UO Connections 3 E Input 1 Go to RUN Mode NO Contact 1 MC Contact 1 Output 1 Injection Disable NC Contact 1 Contact 1 p an TARDY Nee T NO Contact 2 Ea MC Contact 2 po Output 2 Temperature Disturbance NC Contact 2 I i on Input3 Go to STARTUP mode NO Contact 3 MC Contact 3 Output 3 Boost NC Contact 3 6 3 16 Input4 Goto STOP Mode NO Contact 4 MC Contact 4 Output 4 Spare Inactive NC Contact 4 x Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 92 Not Under documentation control if printed May be revised without notice C
50. ch time all Zones are checked to see that none experience a significant temperature rise 2 It heats the first zone and checks a the first zone rises sufficiently to qualify as a to see that Good Rise if not it increases the applied power and looks for the Good Rise It continues to raise the power and look for a Good Rise until the configured Heat Time expires If it does not see a good rise within that time then the zone has failed b the temperature of the zone under test does not reduce further which would indicate a reversed thermocouple on that zone c no other zone raises enough to become a Bad Rise which would indicate excessive thermal conduction between adjacent zones d no other zone rises by as much as the Good Rise which would indicate cross wiring between the zone under test and another thermocouple 3 After completing the test on the first zone the routine then moves on to subsequent zones until all have been tested Why you may need to change your test parameters Normally there is no reason to alter the test parameters in your self diagnostic routine Therefore if you have any doubts or queries please contact your supplier for advice before you Change any test parameters o ersion 2 2 User Manual for TS KTS Console Mold eC i Masters Oct 2012 Page 100 Not Under documentation control if printed May be revised without notice Maintaining your controll
51. clear the fault User Manual for TS KTS Console de Version 2 2 Mold Miasters Oct 2012 Page 108 Not Under documentation control if printed May be revised without notice Troubleshooting Error Message RTD T C Cause The RTD monitor cannot see an input RTD is open circuit An open circuit thermocouple has been detected and no auto response has been selected in the T C Open Error column of the Setup page If a triac fails it goes short circuit and passes full load current In such a condition you have lost control of the load and cannot switch it off from the console The TRC alarm flags up the fault state which relies on operator intervention to manually shut the system down Note the triac monitor does not function in auto mode If the triac were to fail while the zone is run in auto then the only indication will be an abnormally high zone temperature because the triac is passing high uncontrolled current The TRC alarm is only seen if a triac fails on a zone that is running in closed loop manual condition TempMaster IV Action Check the RTD and its wiring for a broken connection For immediate recovery you can either slave that control zone to an adjacent zone or change to open loop control Make a note of the above action so that when the controller is free you can check to see whether the input fuse on the control card has ruptured If the fuse is good then you may need to ch
52. ct any more pictures Version 2 2 User Manual for TS KTS Console b e Mold Masters Oct 2012 Page 88 Not Under documentation control if printed May be revised without notice Customising your controller rempMiaster do To save an image Insert storage media then wait about 10 seconds until the USB Memory is ready to use Select the required picture and touch Save Save more pictures at the same time by selecting them and touching save If any picture Mold Masters heo colour Mack mould has associated text containing a title and de GE description it will also be saved at the same S time Wait about 10 seconds then remove storage media To delete an image User Manual for TS KTS Console Version 2 2 Select the unwanted image and touch Delete as Se Le asters heo colour stac runner system for 16 pius 18 cavities Touch OK we Mold Not Under documentation control if printed May be revised without notice Page 89 Oct2012 Masters TempMaster Ve Customising your controller The 4 channel Input Output Card The following input output functions are available on 103 104 and IO5 cards Extra tool selection function is available only with the 105 card and is described on page 93 Interface This is a digital Input Output card that Sytem Print Event Log Network Ten Wem Gen offers up to four separate inputs and outputs to meom ees Sen facilitate remote interaction w
53. d May be revised without notice Page 32 Configuring the Tool amp System Settings The Tool Settings The Tool Settings are those parameters which affect only the selected tool It takes two steps to save the settings or changes made here First you must touch Accept on this screen and then go to the ToolStore page and touch Save All changes are then saved TempMaster IV within the ToolStore memory for that selected tool Function Description Button One Mode the Display page The Run option toggles between Run and Stop The Startup option toggles between Startup and Shutdown Button Two Mode Select Standby or Boost as the second mode button on the Display page Display Mode Set the display page and set up page to group the ZONES as Sorted with all Spear zones displayed first followed by Probes then Manifolds then Specials Mixed which groups the probe and manifold zones as they are positioned within the card rack Manifolds may appear out of sequence order but grouped with their corresponding probe zones Select whether to quantify the Flow Zones in Gallons or Litres Input Timer minutes If either of the above Stop or Standby options is Initiated then this timer starts as soon as the input open close signal is received Once this timer period has expired it switches the console into the selected Stop or Standby mode If however the remote signal
54. d is look for incoming signals and operate normally detected in the rack Second Select a final operating mode that the console Startup assumes once it has completed a Startup Sequence and attained normal temperature RUN is default condition BOOST will temporarily assume boost settings until it times out STANDBY will reduce to Standby Temperature until it is manually or remotely changed Standby Temp Set an overall standby temp which will override individual standby temperature settings that may be configured within the earlier Tool parameters Max standby Temp is 260 C Leave this set to 0 for individual standby values to remain valid Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 34 Not Under documentation control if printed May be revised without notice Configuring the Tool amp System Settings Startup Mode Shutdown Timer Shutdown Temp erature Select between three different Startup modes MASTER FOLLOW a default option that ties the faster acting nozzles set temperature to slower manifold s actual temperature This produces a homogenous rise with all zone temperatures coming up together MASTER ONLY heats only the nominated Master zones first it does not apply any power to the subordinate nozzles until the Master zones have reached their set temperature STAGED allows you to nominate up to eight stage groups that will heat up in successive stages
55. d load any tool Note its current Connection setting Touch Connection and then Set In the Select Item option touch Demo Mode Accept the warning that this option will disable the Console User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 71 Oct2012 Masters TempMaster IO Running your controller De selecting Demo Mode Taking the console out of Demo mode is a simple reverse of the Selection routine Select the current tool Touch Connection and Set Dam ER Select the original setting that was noted at Step 2 while selecting Demo Mode above PELL FAE Version2 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 12 Not Under documentation control if printed May be revised without notice Customising your controller TempMaster Q Customising your controller Your controller has a dedicated Tool Bank which enables you adapt it quickly to different circumstances It has two hundred available positions that can be individually configured named saved and recalled whenever the tool or job changes There is also a Picture page that can hold up to twenty various images that may be useful for operation or maintenance One image may be dedicated to EasyView while others may be reserved for photographs diagrams or even tabulated data The most common add on seen in a high proportion o
56. disappears before the Timer expires than it resets the Timer period to zero for a restart Set how the console responds to a remote input normally open pair STANDBY If Closed switches the controller into Standby mode when the remote input is closed and returns to its previous state when the signal is removed STANDBY If Opened switches the controller into Standby mode when the remote input is opened and returns to its previous state when the signal is restored BOOST if Closed this switches the controller into boost mode when the remote line is closed STOP if Closed switches the controller into Stop mode when the remote line is closed STOP if Opened switches the controller into Stop mode when the remote line is opened User Manual for TS KTS Console Not Under documentation control if printed May be revised without notice Page 33 Select Run or Startup as the first mode button on Limits If the controller has spear zones then the Standby option is greyed out and the second button option is fixed as Boost NOTE This parameter only appears if a Flow Monitor Analogue Input card is detected in the rack The maximum period for Input Timer is 25 minutes NOTE 1 The remote input is only effective when the system is in RUN mode 2 This function defaults to BOOST when the controller has Spear zones 3 Only those zones that have Boost or Standby temperatures configured in th
57. drawing of the tool and save it toa memory card 2 Import the image a EIERE See page 88 for details 1 Prepare and load an image Do this on a PC away from the Console Open ToolStore and load the 3 Select the tool l appropriate tool Open picture page and select the tab for the new picture 3 Select the picture There are 20 picture slots and a EST 200 tool slots one picture dE w ress or gan 1 cet can be used for more than one a tool 4 Attach the image Touch Attach Lald baniera hee C baur pach mouki Fanner ryrie for 18 plus 14 corvitien vay T User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 45 Oct 2012 Masters i TempMaster IO Setting up EasyView Pages 5 Configure the Open the picture EasyView Image Touch View or the picture thumbnail Touch Show Touch Place Select a zone from the list Jp Select a tem Probe 1 Probe 2 Probe 3 Probe 4 Probe 5 Probe 6 Probe 7 Probe amp Probe 9 Probe 10 Probe 11 Touch the picture to place the NOTE minipanel TO move a minipanel drag it to another Repeat these steps until you location have placed all the required To remove a minipanel touch Delete zones and select zone to remove Version 2 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 46 Not Under documentation con
58. e Temperature control could also suffer if you manually select the wrong speed setting for a zone response rather than using the automatic choice c The lower of the two graphs shows the output power levels that have been measured over the same period of time Power traces should be fairly similar for similar zones at similar temperatures To toggle the view from 5 minutes to 30 minutes To select adjacent zones Mold i 3 gm tgm Not Under documentation control if printed May be revised without notice Page 65 Oct2012 Masters TempMaster K Running your controller Inspecting the last 24 hours Select up to 20 zones and open the Graph page Use Pow Temp button to toggle the display to show a recent trace of either temperature or power Touch the Timeline to activate the slider bar at the bottom of the page Scroll to select time and date which is displayed in Message bar frt hii 10 15 o BS Pe Fri Nov 19 15 17 43 2010 Fri Nov 19 15 12 43 2010 HAH Fri Nov 19 15 12 43 2010 S Thu Nov 18 20 01 45 2010 i z Thu Now 18 13 37 19 2010 Touch Set to select a listed time period ob Thu Nov 18 13 32 19 2010 tt 8 Thu Now 18 13 32 19 2010 i Thu Now 18 13 27 19 2010 Thu Mow 18 13 27 19 2010 Thu Now 18 13 22 19 2010 Thu Mow 18 13 22 19 2010 Touch Scale to toggle the view from 5 minutes to 30 minutes Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page
59. e 128 Not Under documentation control if printed May be revised without notice Appendix D Water Manifolds TempMaster IO Display This shows an example Display page which has cavity temperature Flow temperature and Flow pressure zones Most of the zones are cross referenced to show 1 Delta T temperature difference in the cavity temperature zones 2 Delta P pressure difference in the coolant pressure zones 3 Reynolds Factor flow analysis in the coolant flow zones The zone page below shows the details for a typical coolant pressure monitoring zone e miasta Te T Out E EE E 1 14 ERED BER ERED EI EZ age EI EI User Manual for TS KTS Console Not Under documentation control if printed May be revised without notice E F Page 129 Fare So amt Oct 2012 i ell E i Be Version 2 2 b r gt ers TempMaster co Appendix E Sequence Valve Gate Appendix E Sequence Valve Gate The SVG or Sequence Valve Gate card operates in a cyclic manner where it can open and close any of 12 remote gates up to four times during each cycle Each zone is individually configurable to open and close in response to e Time to the nearest 1 100 sec from receiving a cycle start signal e Position of the main barrel screw feed e Pressure from a remote sensor located within the mould cavity e Acombination of the these three triggers Each zone has one digital output
60. e Boost mode is determined by two quantities that determine boost the boost temperature and it s time e Boost Time that takes precedence over boost temperature Once the boost period expires then the extra heating power is removed regardless of whether the zones actually reach the configured Boost temperature e Boost raises the temperatures of only zones that have any boost temperature configured e Boost mode is only available while the system is in Run mode e The Boost Command may be received locally through the console interface or remotely via the remote console interface or the Quad I O Card Manual Boost display When a Manual Boost command is given the Mode window shows BOOST in black letters on a yellow background The BOOST message displays until Boost Time period expires after which the zones returns to normal set temperature and the Mode Window shows RUN Remote Boost display When a boost Command is received from an external source the Mode window shows M C BOOST as black letters on a white background The time that the message displays for is dependent on the external signal Brief Signal If the external signal is brief for example it lasts 1 second and the Boost Time is set to something longer perhaps 3 seconds then the nozzles are boosted for 3 seconds after which they return to normal level The M C BOOST signal is also displayed for 3 seconds after which it returns to RUN Long Signal If the Boost Time is set
61. e for the tool and press Enter 5 If the tool is connected via a Network to any other cabinet the next step presents an option to select the local controller labelled Serial Port or a remote controller labelled hrcnetx If no network connected controllers are detected then it automatically passes this option and goes straight on to step 6 Serial Port dee i hrenetS 6 The console runs an automatic Card Detect routine to find out what type and how many cards are fitted in the selected controller Once it has gathered this information then the console opens the Setup page for you to start configuring the new tool If the system has any problem running the detect sequence it may report an Auto Detect Failed and ask if you want to repeat the Detect routine If the reason for failure is obvious such as a loose network cable or a mains glitch during the Detect routine then you may touch OK to re try card detection If the detection routine continues to fail then contact your supplier for advice o ersion 2 2 User Manual for TS KTS Console Mold GG Masters Oct 2012 Page 24 Not Under documentation control if printed May be revised without notice Setting up your controller TempMaster Mg SetUp Page cards that may be detected Cards initially detected by the New Tool process are shown in the second column and will assume their default values The following is a list and descrip
62. eck the wiring for faults or even replace the thermocouple If the triac has failed return to your supplier for repair User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 109 Oct2012 Mlasters TempMaster Mg Troubleshooting Warning Message Abnormal Condition The control zone is in manual mode The zone is slaved to another control zone where represents the number of that zone i e S 2 means the zone is slaved to Zone 2 The same power is being sent to both zones In the Display page the set point displayed on the selected zone is the same as that on the slave zone Displayed when the zone is in diagnostic test mode WARN If during the test procedure a temperature interaction is found between zones this message is displayed FAIL The zone under test has failed Individual Controller Card Diagnostics If a fault on a control card is suspected check the LED card status lamps From top to bottom they are SCAN this LED flashes briefly as the controller interrogates each card in sequence FUSE Should normally be extinguished It lights to show that an output fuse has failed TC Should be normally extinguished It lights to show that the card has detected an open circuit fault on the thermocouple circuit GF Should be normally extinguished It lights to show that the card has detected a ground fault on one of the zone
63. ee em p Master Lo Display Page Monitoring TSA2 wide screen The TSA2 has a wide screen format which offers more zones on the display page Other pages appear similar to the standard format KTS which are used throughout the rest of the manual Pip Pin Ba Das E e Ba Da Be Delt iw Be Ba Da Ba mGa aad EA Use Page Up or Page Down to scroll up and down to see more zones Or Use Display button to show 80 zones each zone shows Title Actual Set Power Current and deviations EW eh be Ge a a Be F E mia a A Pap ell Be Bei Bei e Ba Be Wa Be Pap Bel Be Be Be e Be Ba Bell e Ba im Ba e 7 Ae 144 Zones each zone shows Title Actual and Set Bt Hes a el Hol Hl Ul G EESESEKEI Ce eis EEEE EEE 2 ll RI 224 Zones each zone shows Title and Actual 240 Zones each zone shows Actual Temperature f f Data page which shows the setup and data for all the console zones EEIEIE IE EEIEIEE IIIInIIIIIIIIR HAHAHAH User Manual for TS KTS Console Version 2 2 p e Mold Not Under documentation control if printed May be revised without notice Page 15 Oct2012 Masters TempMaster P3 A se Display Page Monitoring KTS standard width Use Page Up or Page Down to scroll up and Ce down to see more zones er ETETEN Use Display button to show 40 zones each zone shows Title Actual Set Power Curr
64. eel cet cat Baie Bick Bic Bec ep ap ap att User Manual for TS KTS Console Not Under documentation control if printed May be revised without notice 5 5 SS el i Kn 5 B D e L I N OO O O v E ry SS ae e 2 ei E es el o E Oo E Se c D o O 5 a le 5 lt a 8 2s o E dk o a o dE o n EG gt o c8 c 8 gt ob 5 0 O Z O me qe awry g Mold Mast ee emp Master EZ Display Page Setting Temperature eee Touch one zone ebe Beki e Be Be Be le e be Ge Be w j i 1 e i d A f I E T re G Sai F e S EX oF s E z5 WI Ji re re j i i ir watts A Rb Si att TE i D D D Ip i li d i d e Hes d x D D 7 E E e wb Touch another eee ass e e D e E e a D DN sata a e r i a a D i D D sg bs ei L V a e A EL D D EE See D R m D a b MA ES i i Ka p E n J Sege i A e 7 E lr e li A e HN JE i e ze S S WW Wel t Touch Range SEENEN E ii Dan bas VEH ME i z em a a ls RK BEER Ty cs a a Ce a 7 D Ce a sl emm o nae 1 LE g e ECH eee E IE all d IW SCC fi vase u zl ma marn i CR o ZS KL F k d L t 7 T AAE EA any KH Cire L vs H H e A A H Touch Set Ech eT ET i if G li E Ce oaan ie deg ad E A Cance d IRCH WH WH SES 4 a a a D mad ke kr Al Led Ee gt l erst mee Srieclion E d Mode bar to set zone as Closed Auto Temperature Open Manual Power
65. eir SetUp will respond to the remote input signal Version 2 2 Mold Oct2012 Masters TempMaster Wey Configuring the Tool amp System Settings Power Mode Selects how power levels are shown on the Display Page Percentage power is constantly displayed while you have an option on what is seen in the lower window If you have control cards with current measuring coils this option allows the lower window of each zone to show three possible parameters Amperes shows the zone current Watts provided the supply voltage has been set shows the power in the zone If there are no current measuring coils then the lower window display will be blank Ohms provided the supply voltage has been set shows the calculated resistance value for that zone Power Alarm Allows you to pause the Power Alarm by this many Defaults to Zero minutes delay Delay minutes so it does not instantly cause an alarm effect Pressure Select whether to quantify the Pressure Zones in Units Bar or PSI Purge Mode Choose to use a Mechanical which uses heat steps only or Chemical to work with special purge compounds Quad IO Reset This is a timer within the IO Card The timer will set Maximum Reset time is 90 Time all relay outputs to off de energised if it fails to see seconds communication with the Console within this set time NOTE This parameter only The default setting is 0 in which case it will not appears if an IO car
66. ent and deviations 70 Zones each zone shows Title Actual and Set 110 Zones each zone shows Title and Actual 160 Zones each zone shows Actual Temperature Data page which shows the setup and data for all the console zones ETTETETEJE i User Manual for TS KTS Console Version 2 2 Masters Oct 2012 Page 16 Not Under documentation control if printed May be revised without notice ee Emp aster EZ Display Page Resizing for fewer zones Both the TSA Wide and the KTS can resize individual zone panels if there are not enough zones within the tool to fill the first page Big Panels 30 zones or less in TSA wide 12 zones or less in KTS Medium Panels 48 zones or less in TSA Wide 24 zones or less in KTS Normal Panels 80 zones or less in TSA Wide 40 zones or less in KTS Display Page Monitor Zoom Hi i Touch any zone and Zoom a St Sat Sal e be Se We le Zoom page shows Zone Settings Recent Temperature Deviation Zone Power Levels Historical A Fag BEZ CH gp Fo ees User Manual for TS KTS Console Version 2 2 4 ef Not Under documentation control if printed May be revised without notice Page 17 Oct2012 Masters TempMaster P A se Display Page Start Stop and more IER EI T e e ei FEEF Parer en BERORRI eg e e e IN e Wei el Isi el Be ali sl Mi Wel Mel WS Fe Bei Belt See reit dg Bel el Bali pai ee Bcc A 2 och W
67. entation control if printed May be revised without notice Maintaining your controller TempMaster IV System diagnosis results The Test page retains information about any test that is run You can scroll the screen to view all the results or touch Print for a hard copy You may also Save the test results as a reference set Future tests will then show any difference between the current test and the saved reference Interpreting the test results A result is given for each zone tested as a table form which shows five columns that are 1 Zone tested shows which zone number for which the results are applicable 2 Test results Zone Test OK tells you there were no problems detected Alternatively it displays one of the messages listed below to explain why the zone test was not good 3 Measured Amps shows how much current was measured as a result of applying a set voltage 4 Measured Watts and Ohms are derived from measured current and the given system voltage 5 Deviation shows the difference between the current readings and those that have been saved 6 Leakage shows if any earth leakage current was measured Unsatisfactory Test User Manual for TS KTS Console Version 2 2 Below is a complete list of the various messages along with further detail and possible causes User skipped Test You skipped the test for this zone by pressing Skip while it was being tested User Aborted Test You abor
68. er TempMaster IO Running a Self Diagnosis test The diagnostic routine may be performed at any time that the controller is connected to the tool provided that it is not in use for production The other panels on the page give feedback about how the test is progressing To select some zones for testing E Probe 1 F Probe 2 Probe 3 d Probe 4 lear Probe 5 SR Probe 6 Touch Edit in the First Zone box Cl Probe 7 Probe Probe 9 Probe 10 Probe 11 Probe 12 cerry Frobe 1 JL Probe 2 i CT Probe 3 Select the first zone nord Probe 4 E Probe 5 Probe 6 d Probe 7 Probe amp Probe 9 Repeat for the Last Zone Probe 10 Probe 11 Probe 12 To select every zone for testing Touch the First Last reset For a full Self diagnosis Check that the Test Pattern is set to Full For the reduced Power Test select Power User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 101 Oct2012 Masters TempMaster IO Maintaining your controller Touch Start Test progress for any one zone is shown in the upper right panel Test history fall all zones is shown in the lower panel To pass by or skip any zones touch the Skip To stop the test and omit remaining zones touch Cancel Version 2 2 User Manual for TS KTS Console pS es Mold Masters Oct 2012 Page 102 Not Under docum
69. er configurable colours User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 13 Oct2012 Masters i TempMaster P3 A se Display Page other Symbols and what they mean The previous page shows the more common parameters that you expect to see on a temperature controller however there are more Some of which may be immediately obvious and others which may be less so Parameters that are Set Temperature Degree C c Degree F Flow monitoring coolant flow with analogue or digital devices Gallons per minute c Litres per minute c Pressure monitoring coolant pressure with analogue devices Other Percentage a set percentage power output for a zone with KA no thermocouple or closed loop Parameters that are Measured and displayed seen in lower half of panel Percentage power output for that zone E Ampere Current measured in a zone a S Ohms Resistance value Delta a difference symbol of a zone calculated from used when comparing flow or SEA pressure between two points stated voltage and measured current Reynolds Number an indication of the quality of coolant flow in a circuit Blank no quantity currently on display Version 2 2 User Manual for TS KTS Console Mold Mast jy SS COct2012 Page 14 Not Under documentation control if printed May be revised without notice
70. es and it flags up a HELP message if such a condition arises The water flow sensor has detected a high flow rate The water flow sensor has detected a low flow rate No mains supply synchronisation pulses being received The three phase supply is used in a cross over detection circuit to generate timing pulses for accurate phase control and firing the triac If the phase detection fails on one or two phases then there is no pulse to use to measure phase angle and the LINE error message is generated Meanwhile all circuits on the healthy phases will continue to work normally This will occur if the console is switched to a remote controller with a network link but it cannot establish any communication with the remote unit The console can display the appropriate zones for the particular tool but it cannot relay any temperature information It shows a LINK fatal error in place of the actual temperature No load on that zone Only occurs when in manual closed loop mode where the current is pre set The current sensing circuit has not detected a current flow therefore the zone is flagged as not having a load The RTD zone has detected a temperature in excess of 99 C This is an abnormal alarm because RTD circuits can only read from 0 99 deg so a fault must be suspected and investigated Meanwhile no control zones are affected All the control cards are interrogated in sequence on a working controller you can see the SCAN LEDs
71. f If set to Enable then you can switch the console into Standby Mode from any other operating mode If set to Disable you cannot switch from Stop mode into Standby Instead you must first put the console into a run or start mode before Standby Mode is available Set how long the screen remains visible The maximum period for Blanking Delay is 98 minutes You can override the Blanking Delay so that it remains permanently visible by setting this time to 99 minutes Set the communication rate between the Console and the control cards Newer control cards can work at faster speeds 38400 and units are always matched at the factory However if you swap a new card for an older one you may need to select a lower baud rate 19200 or 9600 to make it work correctly If the baud rate is too high for an older card then you will see N Z because it cannot communicate at that speed User Manual for TS KTS Console Page 36 Not Under documentation control if printed May be revised without notice Cie MUS e mpMaster dc Calibrate Touch If Enabled this starts a routine to check the alignment between where you actually touch the screen and where the interface perceives that you touch the screen The process stops the controller so be careful not to do this while the system is in use It then places cross hairs at certain points on the screen respond by touching the screen with a fine pointer rather than a
72. f our controllers is the 4 channel Input Output card which provides an effective means of communicating your controller with other mould related equipment What is included in this section Using the ToolStore Page Creating a new Tool Renaming an Existing Tool Loading Tool settings Locally amp Remotely Saving Tool settings Deleting a Tool Backing up Tool Settings Restoring tool settings The Picture Page The Quad IO Card User Manual for TS KTS Console ersion 2 2 o j Mold Ka pn d em Not Under documentation control if printed May be revised without notice Page 73 Oct2012 Masters i TempMaster IO Customising your controller Using the Tool Store page Two rows of Tool Bank buttons allow you select 10 different tool banks each of which contains twenty tool slots this gives a capacity for up to 200 different tool settings Note that the tools are numbered from 1 200 sequentially through the pages This ensures that individual tools can be identified when called for remote loading This is detailed in the IO5 card description on page 93 The lower window shows the following details for the tools Tool the tool number not user configurable Name a user configurable text field for tool name The colour of the name is a key that shows the state of tool black a tool store that has been named but holds no settings blue a tool that has been saved and named but is not in current use purple
73. flashing in a sequence as each card is briefly checked for satisfactory communication If any card fails to respond to the console then an N Z error message is displayed for the offending zone Unlike other alarms in this list N Z does not normally initiate a System alarm However there is an option within the setup Configuration which gives the option of making N Z a system alarm if so desired See page 37 The console has detected a control card that has no settings The card has detected an abnormal input at the T C termination that indicates a shorted or Reversed thermocouple Action Please make a note of the serial numbers for both the controller and console Also note the console software date on the Utilities page Contact your supplier with this information to hand These are only monitored conditions and neither will cause any shutdown or pause action However you should check that the coolant water system is not blocked or leaking to ensure that no overheating occurs There is a phase detection circuit on each M2 series card and a common phase detection circuit on all other controller types Although a fault in such circuits may cause the LINE error message such fault is very rarely seen The most common error is either the absence of one phase or if a plug has been re wired incorrectly a swapped phase and neutral If a LINE error message occurs then switch off and isolate the contro
74. gineers are making continual improvements to our control system It may be possible to apply system upgrades to your own controller however this would depend on the type and age of your equipment Contact your supplier with the serial number of your console and he can tell you about whether your console will accommodate and upgrade and what may be available There is usually no need to return your control system to your supplier for any upgrades They may be downloaded via the internet These following instructions will guide you through the upgrade procedure Preparation 1 Download the upgrade from the internet onto your PC 2 Copy the upgrade program data onto suitable storage media USB Flash 3 Before you start any upgrade shutdown your machine to leave your console free Procedure 1 Select the Utilities page 2 Insert the USB Flash Memory 3 Touch the Upgrade button 4 When the upgrade is complete remove the USB stick and restore the console User Manual for TS KTS Console b m Version 2 2 Mold Masters Oct 2012 Page 106 Not Under documentation control if printed May be revised without notice BCS Ee mp Master d Troubleshooting The control system has several features which provide an early diagnosis of faults in the control system the tool heaters and thermocouple sensors If the system detects any malfunctions in one or more of the control zones then it displays an error message on the Main Displa
75. h Slave c To return to Auto Touch Auto 4 a for Manual enter the Percentage power b For Slaving select a similar master zone from the Zone list c For Auto enter the required zone temperature EIS EECH ea 5 Touch Enter to make the setting or Esc to defer the action Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 58 Not Under documentation control if printed May be revised without notice Running your controller TempMaster Oo More about Slaving Zones There are several points that you should remember when using zone slaving User Manual for TS KTS Console Version 2 2 1 You can only slave like zones for like zones You cannot slave a probe zone to a manifold zone 2 You cannot nominate another zone that is already slaved to another If for example zone 2 is currently slaved to zone 3 you cannot slave zone 1 to zone 2 The leading zone must already be a healthy zone 3 You cannot nominate a zone that creates a loop If for example zone 2 is slaved to zone 3 then you cannot slave zone 3 back to zone 2 4 When selecting a lead zone to slave to you should find a similar zone type that is currently operating at the same temperature and at the same power level If you nominate a lead zone that is working at the same temperature but outputting a noticeably different power level then the slaved zone may not regulate efficiently Mold i b e gm i es No
76. hine which the pins are configured according to the table 1 to ask console to load tool Pin Function e fams o AMP 183040 1 Connector 8 address 64 EN address 128 11 Tool loaded Normally Open console to molding machine Normally Closed 5 Version 2 2 User Manual for TS KTS Console Mold a Masters Oct 2012 Page 118 Not Under documentation control if printed May be revised without notice Appendix A HRC Wiring Details TempMaster Oo 1 8 Touch Screen Schematic HRC Touch Screen Console System Memory Integrated PC Motherboard Opto Isolator COM USB Ethernet not for TSA Used for Exchange E i Protocols Network Keyboard Mouse Printer Flash Card Control Cabinet Opto Isolator HRC HRC HRC HRC Mains Power Control Control Control Control Card Card Card Card Distribution dE Voltage Free alarm See Wm e Heater Thermocouple Supply Outputs Inputs from to Tool Tool User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 119 Oct2012 Masters TempMaster LAJ Appendix B Networking Information Appendix B Networking Information How the Console and Controller work together Because each individual controller card has its own central processor then once it has received a signal to start and knows its set temperature it can function independently and hold the zone
77. icroprocessor This allows you to switch the console s communication away from one cabinet to startup or monitor other remote controller cabinets While the console is focused on any one controller cabinet then it is not monitoring the others in its group However the alarm beacon on a remote cabinet shows if any remote cabinet needs particular attention To switch between different controller cabinets use the ToolStore page this switching process is detailed in the Connection paragraph on page 74 Linked Controllers Multiple controller cabinets can be linked in such a way that they behave like a single controller A data link is used between the controller cabinets and the DIL switch on the back plane board is configured sequentially through the multiple controller cabinets For instance where a 60 zone cabinet and 30 zone cabinet work together they could be configured together to appear as one 90 zone controller A single console could be connected to either controller and it would display all 90 zones as a single controller Also if each of the cabinets had a console then the two consoles would work in parallel as a many to one configuration and this is described below Many Consoles to one Controller If in the above example two linked controllers each had consoles fitted then they would act as Many consoles to one controller The first would be directly connected to the cabinet via its data link and be the
78. inked eege EE 121 The User Interface steiere EENEG 22 Load a new Image erennere 89 To set Probe and Manifold temperatures 068 41 Loading tool settings eeen 79 To set Spear Body and Tip temperatures 42 Maintaining your controller 96 elo n gi e CN ER Master P ee EE 124 ToolStore RS ee ee eege See 75 Master EEN e 29 TouchScreen removal and reconnection 112 Maximum POWER EE 30 TROUBDIESHOO UNG norconia d 108 Maximum Setpoint Setting 30 Uira SPEC E 30 More about Slaving Zones 60 Upgrading i ce een Senne mer eee ene 107 One Console to many Controllers cceeceeeeeeaees 121 User PaSSWOlG BEE 39 Password Application Table 49 Using the 105 card for Remote Tool Selection 94 Password Override ccccccce ee eeee ee eeeeeeeeeeaeeeeeeaneeeeas 51 dr GE 124 Passwords Options cess eeeeeeeeeeees 49 Warning and Alarm Levels 29 Picture Pae EE 88 Water Manifolds EE 126 Power LE 34 User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 135 Oct2012 Masters Global Support Manufacturing Facilities GLOBAL HEADQUARTERS CANADA Mold Masters Limited 233 Armstrong Avenue Georgetown Ontario Canada L7G 4X5 tel 1 905 877 0185 fax 1 905 873 2818 info moldmasters com INDIA Mold Masters Technologies Private Limited 247 Alagesan Road Shiv Building Saibaba C
79. inter Output Connector Data Communications Alarm Output T C Tool Connector 415 Volts 3 phase 50 60 Hz with neutral Other available include 240 380 400 and 480 volts in Star or Delta configuration Stable within 20 supply voltage swing 300mA note this is for tool protection Miniature Circuit Breaker Burst fired with zero voltage crossover Typically 24 volts AC User configurable between burst fired or phase angle High speed semiconductor fuse links Closed loop Auto or open loop Manual with HR Software 0 472 Centigrade Celsius 32 881 Fahrenheit Centigrade Celsius or Fahrenheit USB Port RS 232 serial DB9 male connector Closing Contact Relay 5 Amp max Harting type Han A or equivalent Heater Tool Harting type Han E or equivalent Connector i 5 Version 2 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 8 Not Under documentation control if printed May be revised without notice Introduction TempMaster Me Safety Instructions DO NOT open the controller cabinet without first ISOLATING the electrical 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 415 volts or higher Safety Notices an explanation WA A WARNING symbol and message shown here identifies where there may be a hazardous situation which if not avoided may resul
80. ion NES 40 24 a May 2004 1 Enter the Set time area by touching Set Time the System tab 2 Inthe Set Time box touch the time element that you wish to change 3 Use the up and down buttons to set the required value 4 Select OK to save the new setting to the system J Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 50 Not Under documentation control if printed May be revised without notice Setting up other Utilities Print Page Using a locally connected Printer 1 Use the Printers list to select the printer Em Event Log hemort ren nemete Gwasa that you intend to use If a precise match is nan De ss a not available then select something similar lt a since most similar printers share drivers boss can 2 Click on the Connection Edit button and pesme l select the Local USB option NOTE The Local Remote option is not available on the TS console 3 Select standard European A4 or American Letter size 4 Touch Accept to confirm your printer selection Using a remote Network Printer 1 Use the Printers list to select the printer that you intend to use 2 Click on the Connection Edit button and select a network descriptor for your network Network TCP Transmission Control Protocol a Standard Network communication protocol Network LPD Line Printer Daemon for a UNIX Linux Network Protocol Windows SMB
81. ion control if printed May be revised without notice Page 81 Oct2012 Masters TempMiaster Idi Customising your controller Backing up tool settings Backing up tools is a means of saving tool settings to an external media which may be kept in a safe place for secure recovery or transferred to another controller for use elsewhere NOTE If the particular tool has an EasyView image and EasyView page associated with it then the Minipanel configuration is saved within this Backup procedure However you should save the same picture and keep the Picture and Tool files together if you wish to reuse them at a later date 1 To save backup all the tools Baha Beni Bi KH Open the ToolStore page PEGG GE El P d Insert storage media then wait about 10 seconds until the USB Memory is ready to use Touch Backup The tool is saved to the memory stick along with Tool Name and Tool Notes Wait about 10 seconds then remove storage media KA Version 2 2 User Manual for TS KTS Console Mold Miasters Oct 2012 Page 82 Not Under documentation control if printed May be revised without notice Customising your controller FrempMaster J Backing up tool settings 2 To save backup one selected tool setting Insert storage media then wait about 10 seconds until the USB Memory is ready to use Select the tool to Backup Touch Backup o o o o o M H o o Wait
82. it AN EN current then Current Limiting Fuses may be required These will be HERR Earth located in the base of the cabinet You may find inline fuse holders in place of the bottom connectors where the incoming flex cable is normally terminated Version 2 2 User Manual for TS KTS Console d ez tem ers Oct 2012 Page 116 Not Under documentation control if printed May be revised without notice Appendix A HRC Wiring Details FrempMaster doo 1 2 Loom Thermocouple cables Where a thermocouple cable uses conduit with individual Type Positive Negative conductors rather than multi core cable then the colour of the l thermocouple conductors are as shown below RTD thermocouple cable colours and number may vary Refer K to controller documentation for details K 1 3 Loom Power cables Where a power cable uses conduit with individual S phase type Supply Return conductors rather than multi core cable then the colour of Star or Delta the power cable conductors are as shown below 1 4 Alarm Output Auxiliary Input An option cabinet connector provides an l alarm output from an internal set of relay Pin Connection Input output contacts Using an external power source the 1 Auxiliary Input signal cabinet can initiate a number of warning Dependent on Spec devices whenever any zone goes into an 3 Auxiliary Input Ground alarm state This is commonly used for ra beacons audible al
83. ith the controller aC Cc nea Sau Ire Gupta Boon Les neta Stop ran outputs inactive eae Setup is available on the Utilities page where you can pick Quad I O to see the four input and output options Display The card has its own main page panel which show 1 That it has healthy communications with the Console shows N Z is communications fail If the IO card TC input is being used to monitor a temperature then it will be displayed here 2 The set temperature is used as a monitor point rather than a control point In this example the IO Input expects to see something at 22deg Warning and alarm settings as above and below this set temperature 3 The two digital numbers represent the state of inputs and outputs They are read from right to left with Input above and output below The example shown here shows an input seen on Imput1 and outputs generated on Outputs 1 amp 2 S Configure Controller Tool Settings System Settings Factory Settings QUAD watchdog timer The Quad IO Card has Power Mode an internal reset mechanism which de energises feani we Detay in seconds reng all output relays if it loses communication with the Quadio Reset Time console An option within the Config Tool Settings Second Startup 8 allows you to set that timer to respond according to StandPy Temp Seel Ia your operating needs Flom Version 2 2 User Manual for TS KTS Conso
84. ive sequence that gives the operator four programmed steps to expel one colour and then introduce a new different colour Add Purging Material After you select Purge from the S Mode drop down the screen changes Je a and guides you through the four steps Each step tells you to perform a preset Action l action after which you can touch aC em L sense cre or Recommend Ea Es Next to move on to the next stage geg a Wag Eventually it asks whether the quality i of the new colour is acceptable Answering No takes you back to the beginning to run the sequence again Answering Yes closes the purge screen and returns you to the main Display page You may exit the Purge wizard at any time by touch Exit at the lower left of the Wizard screen Chemical Chemical purge is a combination of active and passive sequence It is a preferred sequence to use a proprietary purge agent Boost Temp rature E Toh After you select Purge from the Mode drop down the screen changes and guides you through the seven steps It goes to Boost temperature as soon as the purge sequence is started and overrides the normal Boost Time and Mode ES Toot D 23 MM Jig 18 Oct 2012 09 07 Status Dram d holds the Boost temperature until you press Next The next two steps or Add and Mould are passive and wait until the operator completes each action and touches Next The So
85. ked Computer VNC protocol and set up a remote Master IP address Quad IO set up Quad IO card Inputs and relay outputs The Testing page Check the condition of a mould tool after commissioning or maintenance The Set up page For setting up the system User Manual for TS KTS Console Version 2 2 E Not Under documentation control if printed May be revised without notice Page 21 Oct2012 Masters TempMaster Mg Introduction The User Interface Where the configuration of parameters requires a user interface then either a keyboard or a keypad is displayed Keyboard for Alpha numeric input Keypad 1 Basic numeric Keypad 2 Basic keypad PLUS Value Set Temp Add and Subtract and Mode Auto Manual and Slave Keypads 3 amp 4 More buttons to select and configure synchro tips b de Version 2 2 Mold Masters Oct 2012 Page 22 we woe me omen wn ow Jes sm I ee ren Te P Keis Je Pm oe gopog User Manual for TS KTS Console Not Under documentation control if printed May be revised without notice ES emp Master E Setting up your controller New Touch Screen consoles and controllers are provisionally configured at the factory and you may not need this section for a new system However if you need to match a Touch Screen console to a new tool or e
86. l if printed May be revised without notice Customising your controller TempMaster Di Renaming an existing tool Touch the relevant tool tab Touch the Set button Edit the name Touch Enter User Manual for TS KTS Console Version 2 2 b e Mold Not Under documentation control if printed May be revised without notice Page Cf Oct 2012 Masters TempMaster g Customising your controller Loading tool settings locally Note that the operating mode for the controller cabinet remains unchanged by loading a tool So if your controller is in Run mode and another tool setting with different temperatures is selected and loaded then the tool will immediately change to run at the different temperature settings Select the desired tool Touch Load If the Load button is greyed out then swapping Tools on the fly has been Disabled See Allow ToolLoad page 36 Touch OK or Cancel to exit Loading tool settings remotely If the controller is fitted with an 105 card then it is possible to remotely select different tools See page 93 in Customising you controller for information about how this works Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 78 Not Under documentation control if printed May be revised without notice Customising your controller TrempMaster dc Saving tool settings If you change tool settings and want t
87. le Masters Oct 2012 Page 90 Not Under documentation control if printed May be revised without notice Customising your controller Inputs Each Input circuit requires an incoming pair that is volt free and normally open The incoming pair must go to short circuit or close to trigger the required command Optional inputs Option Inactive Run Startup Standby Shutdown Stop Machine OK Passkey Inj Confirm Outputs that may be selected are as follows Description Puts the Controller into BOOST mode When closed it allows console to go to Run or Startup Mode If opened the console is put into Stop mode with resultant Mould Protect Responds to an external Card Key reader which is used to simulate User level authentication A Passkey input then allows any operation which would normally require a low level User password This input is used to confirm that Inj Disable is functioning correctly If Input is seen when no Inj Disable signal is given out then the system fails safe until the fault is fixed A manual reset is then needed to unlock the controller Each Output group is a single pole changeover relay element that is rated at 240 volts 1Amp maximum It comprises a common or moving contact MC that is connected to a normally closed NC contact when de energised When the controller activates any Output channel the normally closed NC and moving contact MC go to open circuit while the normally
88. ll provide the required flow rate Within the Extended Options box you can provide the water temperature by referencing an appropriate Temperature sensor By Reference touch Edit and from the next option box select an appropriate Temperature sensor zone Finally you can set the third parameter Pipe Size Note The last setting within Extended Option allows you to set an alarm level for Reynolds number so that any value of Reynolds Number that deviates beyond an expected level will raise an alarm on the main Display Page Setup Delta difference Display Delta Difference in pressure is simply calculated as the difference in pressure levels between two associated Pressure Sensors On the Setup Page and select any one pressure zone the touch Set to display the Configure Card panel note it is similar to a flow zone except that the Pie size and Reynolds alarm are greyed out Within the Extended Option you can select another Pressure zone to compare the difference between the two By Reference touch Edit and from the next option box select an appropriate Pressure sensor zone Note when setting a differential comparison between zones A and B you must first go to Zone A and reference B then you must go to Zone B and reference A They must be mutually set as a complimentary pair Niold Version2 2 User Manual for TS KTS Console Masters Oct 2012 Pag
89. ller then check supply wiring for presence of all three phases Check that the network link is good and or the remote controller is still switched on and available Isolate the system supply and check the connections between the controller and the tool heaters Also check the heater for continuity Check that a different RTD has not been fitted If every zone shows N Z and no cards show or flash their SCAN LEDs then check the communication lead between the console and the controller cabinet If only one or two zones are displaying N Z then check the card for faults If you have recently changed any cards and put any older discrete component cards into a new controller that has surface mount cards then it is possible that the console s modern scan speed is too fast for the older control cards In such a condition check the console baud rate and try setting it to Low If this cures the problem and you later replace the older card for a newer surface mount version then remember to reset the Baud rate back to high for optimum working This Error message may be seen fleetingly during switch on it should disappear after the initial card scan If the message persists then you may need to re apply the correct card settings on the Setup page If the REV alarm persists then you should switch off the controller and investigate the offending zone Alternatively you could slave the offending zone to a good zone until you have time to
90. mage Open Pictures page Select a picture tab Touch either the picture or View View picture User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 87 Oct2012 Masters TempMaster IO Customising your controller To load a new image 1 Save one or more pictures onto a USB Memory Stick The Console can recognise most common raster image files such as jpg gif tif or png 2 Create associated text for each picture with a title then a blank line and then up to 150 words as extra descriptive text Save them to the same memory stick as a txt doc or odt files with the Same name as used for each picture The console will automatically associate same named picture and text files 3 Insert Media then wait about 10 seconds until the USB Memory is ready to use 4 Select an empty tab and touch Load geschier 5 Select one image from the list presented The rakit ipa mould jpg console will load the new picture and the Poia associated text provided it sees a text file of the Pose same name If no text file is detected with the same OF icturesoipa pictures jpg name then it uses the name of the picture file as a picturet4 ipg title for the picture tab and in its description gf Picturets ipg pictures jpg 6 View new picture 7 To load more pictures go back to step 4 touch another blank tab and Load then sele
91. n separate Display Pages By default all zones are in group 1 but selected zones can be allocated to subsequent groups Zones that need not be shown on the Display page can be allocated to Display Group Zero Setting the Tool parameters Option for alarm actions are Console which displays the alarm condition in that one panel and Status Panel Beacon extends the alarm to activate and attached Alarm Beacon and Sounder Mould Protect puts the console to Stop mode All zone heaters will as a result cool down Injection Disable sends out a shut down signal from the IO card which may be externally configured to stop the moulding machine The maximum setting for Alarm Time is 999 seconds The highest Maximum Setpoint temperature that you can set is 450 C or 850 F The lowest Minimum Setpoint temperature that you can set is 0 C or O F The highest Maximum Power Setting that you can set is 100 power The highest T C Offset temperature is 75 C or 135 F Note The Ultra settings force the controller to stay in burst fired all the time These settings are used when a very small controller could show temperature instability in Burst fired mode There is a limit of 6 Display Groups User Manual for TS KTS Console Page 30 Not Under documentation control if printed May be revised without notice Setting the Tool parameters TempMaster RA Startup Stage Configure grou
92. nd Manifold Other Monitoring Synchro Cards Cards Spear Rack Address slot address slot address slot address TCOpenMode TCOpenMode Mode Normal ban Normal Cem pwwo ho ooo pe Startup Stage Shutdown Stage Reading Avg Pre heat These Columns do not appear on the set up Bact page unless a control card is configured to be a Synchro Tip type If these preset figures are not suitable for the tool in question then you can simply change them to your preferred values by following the next pages b gt Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 26 Not Under documentation control if printed May be revised without notice Setting up your controller FrempMaster j How to Configure the Control Cards The Setup Grid displays Icons in the first column to show what cards have been detected Because none of the cards know their function all temperature control cards initially default to Probe zones along with the Probe default values as seen in the first picture Auxiliary cards such as Analogue Input RTD Cards and other similar will also default to values suggested in the table on the previous page Pre configures Set up Values Although the tool may run on this basic setting it is best that you configure any larger slower zones such as manifolds etc Surplus zones should also be set to Not Used this time for instance if you have six cards offering 36 control zones
93. nnections In such cases wiring errors have caused equipment failure Mold Masters cannot be responsible for damage caused to the controller by customer wiring and or connection errors User Manual for TS KTS Console Version 2 2 m Mold a F E Not Under documentation control if printed May be revised without notice Page 9 Oct 2012 Masters TempMaster IO Isolate the Controller The main power switch is sufficiently rated to disconnect the total load current during switch On and switch Off To prevent its operation during maintenance you can use a suitably sized padlock or similar device to lock the switch in the Off position Larger Controllers may have multiple supplies with multiple isolators For such controllers then all Isolators must be turned off for safe access into the cabinet Switching On Main Cabinet Switch ON the Main Isolator to energise the main cabinet KTS Console TSA2 Console The KTS Console has a main On Off switch at the rear right hand side of the console case which is normally left switched on If left on then the console will start its boot up sequence as the cabinet is powered up If the cabinet is switched on and the console does not start then check this switch has not been turned off The TSA2 Console has a non latching push button at the bottom right hand side of the screen After switching on the main cabinet on you then need to briefly press the start butt
94. nvironment then you should use this section of the manual and work through the four main stages which are briefly described below Subsequent pages within Setting Up section give a more detailed explanation of each 1 Create a first tool This starts at the Tool Page where a Detect command interrogates the cabinet to see what various cards are available and then puts that information into the Setup page 2 Set up Tool parameters Once the card information has been written into the Setup page you then need to look at the displayed cards and allocate a duty to those cards It may be that your cabinet is fitted throughout with four zone 15 Amp cards but it takes local knowledge to know which zones are nozzles which are manifolds or bridges and which are sprue bushes A screen that simply reads Zones 1 60 is not as instructive as one that reads Nozzles 1 40 Manifolds 1 8 etc Setting your zones to reflect the tool not only makes it easier to use but it will also pre program control card characteristics so they are more likely to match the heat load Even though automatic first time start can do this for you it helps if the cards have some idea of their duty before they are first used Once card duty has been allocated then the various tool parameters will take up default values these may be fine for your general use but there are many tool parameters such as warning and alarm levels which you may wish to fine tune to your p
95. o save them then you have two choices 1 Over writing the last settings with new saved settings If you know that the new settings are satisfactory then you can save them back into the same tool store Select the tool Touch Save and OK User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 79 Oct2012 Masters TempMaster IO Customising your controller Saving tool settings 2 Saving modified settings without losing existing ones If you have changed some tool settings and want to keep them but at the same time you wish to retain the old unmodified settings then you must create and save into a new store as follows Select a spare blank tool tab Touch Save and OK Enter a new tool name and touch Enter Version 2 2 User Manual for TS KTS Console D Ke Mold Masters Oct 2012 Page 80 Not Under documentation control if printed May be revised without notice Customising your controller FrempMaster Di Deleting a tool Once you have deleted a tool there is no way to recover its previous settings Take care that you are deleting the correct tool Rame mamy Rma pi 1 ep a 1 pes Select the unwanted tool o o o KH o o o o o Touch Delete ele G G 8 e e e Touch OK User Manual for TS KTS Console Version 2 2 b oom Mold Not Under documentat
96. olony Coimbatore T N India 641 011 tel 91 422 423 4888 fax 91 422 423 4800 mmtplinfo moldmasters com Regional Offices AUSTRIA East and South East Europe Mold Masters Handelsges m b H Pyhrnstrasse 16 A 4553 Schlierbach Austria tel 43 7582 51877 fax 43 7582 51877 18 at moldmasters com MEXICO MM Hot Runner Injection Mexico S A de C V Av San Carlos No 4 Nave 2 Parque Industrial Lerma Lerma Estado de Mexico 52000 M xico tel 52 728 282 48 33 fax 52 728 282 47 77 mexico moldmasters com EUROPEAN HEADQUARTERS GERMANY SWITZERLAND Mold Masters Europa GmbH Postfach P O Box 19 01 45 76503 Baden Baden Germany Neumattring 1 76532 Baden Baden Germany tel 49 7221 50990 fax 49 7221 53093 europe moldmasters com JAPAN Mold Masters K K 1 4 17 Kurikidai Asaoku Kawasaki Kanagawa Japan 215 0032 tel 81 44 986 2101 fax 81 44 986 3145 info mmkk co jp CZECH REPUBLIC Mold Masters Europa GmbH Hlavni 823 75654 Zubri Czech Republic tel 420 571 619 017 fax 420 571 619 018 cz moldmasters com POLAND Mold Masters Europa GmbH Skr Pocztowa 59 00 908 Warszawa Poland tel 48 0 66 91 80 888 fax 48 0 66 91 80 208 p moldmasters com ASIAN HEADQUARTERS CHINA HONG KONG TAIWAN Mold Masters KunShan Co Ltd Zhao Tian Rd Lu Jia Town KunShan City Jiang Su Province People s Republic of China tel 86 512 86162882 fax 86 512 86162883 mmc
97. on control if printed May be revised without notice Page 29 Oct2012 Mlasters TempMaster Mp Mold Mast Alarms Active Alarm Time seconds Maximum Setpoint Setting Minimum Setpoint Setting Maximum Power Setting T C Offset Value Display Group 5 Version 2 2 es i 1 ers Oct 2012 Offers a selection table which allows you to decide how any of the following alarm conditions should affect the system High Temperature Alarm Low Temperature Alarm Zone Alarm Power Alarm Reynolds Number Alarm Configure a brief delay between an alarm condition being detected and an external alarm being sent Sets the highest permitted setpoint for the zone s Sets the lowest permitted setpoint for the zone s Sets the highest permitted power level for the zone s This will work in either open loop Auto or closed loop Manual configuration However it is not effective for 4MODS cards working Seki Spear probes Sets a proportional offset between measured and displayed temperature to compensate for a probe where the T C may not be sufficiently close to the tip Select or over ride the Auto Speed setting to determine the control characteristic for the zone temperature Select temperature sensor for the zone s J or K type for xMOD cards or Analogue sensors for Al cards Analogue sensors read 0 20 mA and may be used for flow pressure or other device Select groups of zones to display o
98. on until it illuminates Release the button and the console will start its normal boot up sequence Mold Heating After the consoles have started and the main display screen is visible then the controller may or may not start to heat up the zones it depends on how the Console Startup option is configured See page 37 If Console startup is set to Stop then the tool remains at zero power and at room temperature If it set to any of the other three options Startup Standby or Run the controller applies power to the zones so that they heat up Version 2 2 User Manual for TS KTS Console Oct 2012 Page 10 Not Under documentation control if printed May be revised without notice oe emp Master Are Switching Off or Shutting Down We recommend that you use the console to shut down the heating load and only use the main isolator to switch off a dormant controller 1 Shut down the heating On the main page select the Stop mode and reduce the heating to zero 2 Shut down the Console e a a a On the Utils page touch the Exit button and 3 10 22 16 Nov 2010 this will shut down the Console Computer PNK Aa 3 Shut down the Controller Finally use the main power switch to isolate all the power to the whole system User Manual for TS KTS Console ersion 2 2 gt Mold Ze Not Under documentation control if printed May be revised without notice Page 11 Oct2012 Masters TempMaster
99. ontroller Identify and load fuse The blown fuse is located either rectify the fault before replacing the fuse on the control card or on the off board triac module If fitted Note The fuse detection circuit requires a continuous low level current through a high impedance bleed resistor to maintain the alarm condition As a result the load circuit is still connected to the mains voltage supply and it is not safe to attempt to repair or replace the fuse without first isolating the circuit If the fuse in question is mounted on a control card then it is safe to unplug the board in order to isolate the circuit and replace the fuse on the card The system has detected an earth fault Check your heater wiring for a low Note this can only be detected by impedance path to earth controllers fitted with EM Cards or MD240 diagnostics User Manual for TS KTS Console Version 2 2 E Not Under documentation control if printed May be revised without notice Page 107 Oct2012 Mlasters i TempMaster Mg Troubleshooting Bye Message Cause There is a system failure and the console does not know how to respond This alarm may occur if an older model console is connected to a later version cabinet If the early version console does not recognise an alarm that has been generated by a later generation control card then it cannot display an appropriate alarm message The console software has a routine to check incoming messag
100. open NO and moving contact MC go to short circuit Optional outputs that may be selected are as follows TempMaster IV Option Inactive Inj Disable Inj Disable Ext Controller Alarm Hot Runner Temp Dist Cavity Alarm Water Flow Pressure Alarm Stopped Boost Warn Description This output will not be used and remains inactive Output is seen if the system is idle Output is cleared once the system has started up and gone into Run mode Output is given if system has an out of limits alarm no other alarm eg Fuse of T C causes Output to be given This output mimics Injection Disable in order to provide two identical outputs Output is given if ANY alarm is generated This mimics the secondary output alarm beacon Hot Runner Output is given if any probe nozzle or manifold deviates from its set point enough to generate a second stage Alarm An output is given if any Fatal Error occurs eg Fuse or T C etc An output is given if any Cavity Zone usually and RTD sensor deviates from its Set temperature enough to generate a second stage Alarm An output is given if any Flow Sensor gives a flow reading that deviates from its nominal setpoint enough to generate a second stage Alarm An output is given if any Pressure Sensor gives a pressure reading that deviates from its setpoint enough to generate a second stage Alarm An output is given if the controller is automatically put into Stop mode
101. operate It does however take a finite time between sending the signal and seeing a response so this Monitor time allows you to set an acceptable time lag that must lapse before a failed event alarm is raised Number of Steps Select how many events for each gate you wish to provide for within one or events cycle Valve Disable Enable this option if you want the pins to open only while in Run mode and when the zones are within temperature limits Valve Type Allows you to select either Single or Dual Valve type Part Three Operating Parameters 9 Goto Display Page touch any zone and touch Set 10 Set the running parameters for absolute time or actual screw position Touch all the gates and then anywhere in the first column Step 1 Open Trigger Select Screw or Timer from the drop down list according to your required operating parameter 11 Set the opening and closing triggers for each gate Touch the first gate then touch the Open value and use the keypad enter the value at which it opens Repeat the same procedure to set close value NOTE The Screw position calibration is such that the screw position is at maximum when the barrel is at rear start of stroke and as it travels in then screw position falls to zero when at end of travel So an open value might be 290mm while its close value may be at 270mm The next gate open and close will be similarly lower Inversely Time counts up so starting a Osecs
102. ose Value the start of cycle and close it on screw position Open the valve on position of the screw and step 1 step 1 step 1 step 1 close it on an absolute time relative to the Open Trigger Open Value Close Trigger Close Value A om Degeees Open the valve on screw position and close it i i i step 1 step 1 step 1 step 1 on an incremental time relative to the when open Open value Close S Ee the valve was opened Serew Omm Time ine 0 00 sees Note time abs time absolute Time is relative to the start of cycle start input time inc time incremental Time is relative to the when the valve was opened Version2 2 User Manual for TS KTS Console Masters Oct 2012 Page 134 Not Under documentation control if printed May be revised without notice KEES T E aster 7 index Aar Re E 29 PONEN PCS E 101 Alar TIME E 30 TE 31 Alar Sooo oe ee ee ee 69 Pressure Difference s ssssrrrerrrrrrssrrrrrerrrrresrrrre 129 Alarms ACUVE E 30 Print Out Fachltv eee eeee eee eenee ees 97 PAE Sep oedee teens EE 29 Quad 70 Card lO3 4 amp B xccevices cine czcerecivscacecsiaxines 91 Allow Set Zone ERR Sek dere eps iess eg isg ege geg eege ge 37 Rack et Eege ege ge ed 29 Allow StandDy E 37 Remote Applications ccccceeeeeesseeeeeeeeeesueaeees 124 Allow TOOILOGC is d crseceausdeaddariddavianscnsiastidsahisdariedads 37 Renaming an existing Tool 78 Analog
103. our controller Static Remote Tool Load Process If you want to load a tool without receiving console feedback then you can simply short appropriate pins together Load Tool 10 connect load pin and tool id pins to ground connect pins 1 3 amp 5 to 14 Load tool 19 connect pins 1 2 3 amp 6 to 14 Dynamic Remote Tool Load Process This sequence allows a degree of control and feed back The procedure to remotely load another tool in this example it will be tool 10 is as follows Step Action Remote Machine Local Console Console checks to see that it has valid tool settings in that tool bank Connects pins 14 Selects a Tool ground to pins 3 amp 5 If no then If yes then it and Initiates address 2 8 10 and there is no disables Tool tool load pin 1 tool load change in Tool loaded Signal Loaded signal pins 11 amp 12 go Closed while pins 12 amp 13 go Open configuration for selected tool operator intervention No Tool and goes Process ends Found to step 3 Loads Tool 10 and indicates process Waits for Tool Loaded is finished by enabling Tool Loaded Signal Signal pins 11 amp 12 go Open and pins 12 amp 13 go Closed Console can find a tool and loads it Sees Tool Loaded signal from console and Console loses the disconnects Pins1 3 amp 5 Change Tool command from ground pin 14 Process Ends
104. ow zones and then touch any of the Alarms and Warning columns and then Set to setup 1st and 2nd stage alarms Repeat for all High and A Version2 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 126 Not Under documentation control if printed May be revised without notice Appendix D Water Manifolds rempMiaster dc Low levels To set the flows and pressure to normal expected values open the Display Page Select the flow zones and then touch Set in order to type ina value in litres min that meets the expected flow for those zones Select the pressure zones and then touch Set in order to type in a value in Bar or PSI that meets the expected level for those zones Set any other zones types that may be available according to the normal Setting Up procedure User Manual for TS KTS Console Version 2 2 E Mold Not Under documentation control if printed May be revised without notice Page 127 Oct 2012 Maste lt TempMaster IO Appendix D Water Manifolds To Set Reynolds Number and Difference monitoring display setup Reynolds Number Display oa Reynolds Number is calculated from a formula age e H a R that needs three actual values for Flow rate mme water temperature and Pipe size On the Setup Page and select any one flow zone 4 E Sper gem the touch Set to display the Configure Card See EH panel reynolds aen a000 eae This zone wi
105. p and all other zones turned off is loaded The Start button is displayed for you to initiate the sequence from this page The sequence timer holds this condition for 60 minutes and then steps to next sequence E ol Gik eil HIN Hik es Sequence 2 All other zones remain off while manifold rise to normal temperature The sequence timer holds this condition for 10 minutes then steps to next sequence i Gee r Ga ey Sequence 3 The Tool setting with Probe zones switched on set to normal temp loads The Probe zones start to heat up The sequence timer holds this condition for 15 minutes and then steps to next sequence Sequence 4 The tool setting with all Zones including cavity and water temp monitoring switch on once the nozzle zones have had enough time to reach normal temperature The tool assumes Run mode after last sequence has been engaged St Ball Eat Et Eat Version 2 2 User Manual for TS KTS Console Not Under documentation control if printed May be revised without notice Customising your controller TrempMaster Di The Picture Page The picture gallery has the ability to store up to 20 images that can be displayed at full screen size Explanatory notes may accompany each picture if so they are displayed alongside the thumbnail view of the image The Picture page is also used to configure Images for the EasyView page though that process is fully described on page 45 To view an i
106. performance data as a zipped spreadsheet This data is written in a CSV comma separated value form and then compressed into a zip file before exporting To extract the data Insert storage media then wait about 10 seconds until the USB Memory is ready to Eni aanas 28 a use w A ca i 2 10 2010am csy LJ 25 10 2010pm csv em 25 10 2010am csv 22 10 2010pm cav 2 1 10 2010am cav 21 10 2010pm csy Select Utilities and Export page start ate C 27 10 20i0am csv ez SS J 2 1 0 pm cav 26 10 20 10am cey e e period by touching de KZ SD 2010pmn Ce Edit in the Start and End boxes mize tae 25 10 2010am cav 22 10 2010pm csv 21 10 20 10am cav 21 10 2010pm cav Seem Print ratte Meit apart pe pap Sen Date 27 10 2010am cav e E 26 10 2010pm cev 26 10 2010am cav Select the zones by touching Pete geg Bos 10 2010pm csv Edit in the First and Last boxes a eana i 1 10 2010am cav 21 10 20 10pm cav sm ee mais en ren pen oti Lean Histery Date fan dvcheetd History Data snoa Lei 27 10 2010am csv preg e 26 10 2010pm csv oo e JS 26 10 20 10am_ csy Fitton IT e 25 10 2010pm csy er em 25 10 2010am csv 2210 201 pm csyv 21 10 2010am csv 21 10 2010pm cav Touch Export Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 98 Not Under documentation control if printed May be re
107. protection fuses for both the T C di input and for the heating load output vi Ir 4 If the Fuse LED indicator shows that the output fuse has Z ruptured then the card may be easily removed and the fuse changed Only use Ceramic Body Fuses on Control Cards NEVER use glass bodied fuses If the T C LED indicator shows an open circuit T C circuit then this may indicate that the input fuse has ruptured Output Fuse Type HRC High Speed Input Fuse Type Surface mount quick blow Part Code 62MAQBSM m User Manual for TS KTS Console ersion 2 2 Mold Ze Not Under documentation control if printed May be revised without notice Page 115 Oct2012 Masters TempMaster io Appendix A HRC Wiring Details Mold Mast Appendix A HRC Wiring Details 1 1 Three phase Designation Please take extreme care when connecting the controller to the three phase supply Incorrect connection may result in damage to the controller The controller is normally supplied according to your requirements in either a star or delta supply However some models may have a dual supply option which accepts either Star or Delta 3 phase supply Cable Marking Supply Description N B The delta supply cable does not have a neutral wire Cable colours may vary therefore wire up according to the Cable Markings 1 1a Star Delta option Where a cabinet is fitted with a dual supply option then there are two places within the rear of the cabinet
108. ps of zones into discrete There is a limit of 6 Startup Startup Groups Groups Shutdown Stage Configure groups of zones into discrete There is a limit of 6 Shutdown Shutdown Groups Groups Readings Avg for Analogue Input Cards Can be used to smooth out analog input Available setting options are O display where the sensor may send 2 4 8 16 or 32 fluctuating readings The drop down list is NOTE This parameter only the number of readings that are read to appears if an Flow Monitor generate an overall average Analogue Input card is detected in the rack The following 4 parameters appear only if a spear card is detected Pre Heat User Manual for TS KTS Console Version 2 2 Sets the power level for the spear body Sets the power level required to open the tip Sets a delay following the signal to inject until the Boost opening power is applied Sets the Gate open period for applying tip power i b e gm tpm Mold Not Under documentation control if printed May be revised without notice Page 31 Oct 2012 Masters TempMaster IS Configuring the Tool amp System Settings Configuring the Tool amp System Settings Touch Config to view the Global Console parameters Sie si si sisi sis s s The Configure Controller panel shows two tabs for Tools Settings and System Settings with a brief description for each pa Flow Units The Tool Settings are concerned with onl
109. r Utilities Setting Passwords On the Utilities gt System Page System Password 1 Inthe System box touch Edit to display VT samm the Keyboard entry window em ar je pa mm me J S sme Lel fio f22 16 Nov 2010 2 First establish your authority by entering sa 0 a a we om comet the System password 3 Next enter your new System password 4 Finally re enter your new System password to confirm it User Password 1 In the User box touch Edit to display the Keyboard entry window 2 First establish your authority by entering the System password 3 Next enter your new User password 4 Finally re enter the new User password to confirm it Setting your password timer In the Time Limit box touch Edit to display the Keyboard entry window 2 First establish your authority by entering the System password 3 Atthe Password Timer keyboard enter your preferred elapsed time in minutes and touch Enter Password Override To override the User and System Password control set the Password Timer to 99 This setting negates the need to enter a Password at any of the usual checkpoints such as Load Tool or Temperature Change However you still need a Password input in order to Change a Password Setting the System Time and Date We recommend that you set the correct time and time zone so that you may take full Hour Min Day Month Year advantage of the software features that use the time funct
110. rd deels to Correction to password deels details E trace option on Graph GES ESN Display Page Resize and New Tool default types added KI N New Print options allow Print to File USB Stick pe mr Dec 2011 Power connector Power connector changed to C13 connector to Power connector changed to C13 connector 3 connector 1 Lon Updated information about supplementary circuit a fuses we May 2012 Instructions for using the 1O5 tool load card added eg TEIE along with changes to ToolStore page New Sequence Valve Gate Card added Create First tool and New Tool revised 2 0 Aug 2012 Ground Fault Limit option introduced DH DT amp IE Amps option added to Easyview IO Card has new mini panel on Display page Extra information about Ultra Speed 2 1 Aug 2012 l e DH IE Extra information about Tool Test and deviation Version 2 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 6 Not Under documentation control if printed May be revised without notice User Manual for TS KTS Console TrempMaster 1 Contents User Manual for TS KTS CGonsole 5 OIC UON BE 8 Setting UP your controller cece ccccceccseeceeceecceeceecaueceeeeeesaeeseeeauesuseseesaes 23 Setting the Tool parameters ccccccceccsscceeceeeceeecuesaseceeeeeesaeeseeeaes 28 Configuring the Tool amp System Settings ccccccceccceeeceeeeeeeseeeeees 32 Setting Operating Parameters cece eecceeeceeeeeeeeeteeeeeeeeeeees
111. removed by the inserting a wide flat screwdriver blade and carefully twisting them off The filters are removable and a light tapping action removes loose dirt and dust Failure to do this reduces the flow of cooling air and may cause overheating If filters do become clogged they need to be replaced and these can be obtained from your supplier quoting the serial number of the cabinet 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 If the equipment is subject to vibration then we recommend that you use an insulated screwdriver to check that no terminals have become loose External cable looms should be checked to see that there has been 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 User Manual for TS KTS Console Not Under documentation control if printed May be revised without notice A Picture shows where filter cover may be taken off in order to remove filter and clean or replace it b Version 2 2 F Mold Page 105 Oct2012 Masters TempMaster co Maintaining your controller Upgrading In order to maintain our high quality our development en
112. rs User Manual for TS KTS Console Version 2 2 i TempMaster Mg Troubleshooting Reconnecting a console Connect the power cable first 540V Mains Supply Check that the correct tool is selected Touch Run Reconnect the data cable 240V Data Mains Link Supply Version2 2 User Manual for TS KTS Console Masters Oct 2012 Page 112 Not Under documentation control if printed May be revised without notice Troubleshooting FrempMaster Wi Other problems with the Tool If you find that the Controller is not running correctly and cannot resolve the problem with either the manual or on line help then it may help if we can see exactly how your system is configured Insert Media then wait about 10 seconds until the USB Memory is ready to use Open the ToolStore page Tanto Select the tool a 8 i i 8 9 i tJ Touch Backup Iesiecr 2 1 2010am cev EN 10 2010pm cayv Select Export on the Utilities page en e Co E 10 2010pm cav 1 10 2010am csv 21 10 2010pm cav User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 113 Oct2012 Masters TempMaster Mg Troubleshooting Set the Start and Finish time to cover the Km e hos 10 2010pr cav i uzae fe S 10 201 mj problem period Coco M ioco ten cov 1 10 2010am csv 21
113. s both to and from the console You can set up ES your network connection within the Utilities page cut m Domain Hame penssystenss com Edn by touching the Network tab to see this ce eee screen w dares waers em Het Man kel What facilities Networking offers nene a p Acs A Canel Provided your remote terminal has an X Win EEA server or similar application you can easily a Teo communicate with the console to return an emulation of the working program This means that you can monitor the Touch Screen Console and you also have the facility for remote control If you have network connections to multiple consoles then you can transfer files such as tool settings between the different machines How to make the connection In order to use this facility connect your console to an active network using a T base lead to the socket on the Touch Screen computer The next step is to allocate a unique name to the machine within your factory environment and set the domain name for your own system Obtaining an IP address depends on the size of your internal network For connection to a large network it may be sufficient to enable the Automatic IP facility On a smaller network you may need to disable the automatic facility and use the Edit buttons to enter your preferred IP address and Sub net mask details Networking configuration depends a lot on your system and should only be carried out by competent IT staff Sho
114. s and event logs to trace back how the controller has behaved over the last 5 or 30 minutes or even the last 24 hours e recognising what alarms may be generated what they mean and what to do about them What is included in this section Controlling Zones Starting Stopping and more Using the Display Page to control and monitor temperatures Using the Easy View page to control and monitor temperatures Using the Purge Option Looking at temperature history for the last 5 to 30 minutes Looking at temperature history for the last 24 hours Checking the log book for past events Alarms what alarms may be seen on the controller User Manual for TS KTS Console Version 2 2 i bh oa Not Under documentation control if printed May be revised without notice Page 53 Oct2012 Masters TempMaster Mp Running your controller Control Modes for all zones from the Display Page Operation Available by Button One or Mode Button STOP Button One or Mode Button STANDBY Button Two or Mode Button STARTUP Button One or Mode Button S HUTDOWN Button One or Mode Button BOOST Button Two or Mode Button Mode Button while in Run Version 2 2 en Mold Miasters 0ct 2012 Page 54 Description Switches on all zones Switches off all zones NOTE Selecting Stop does not remove voltage from the heaters it switches off by setting all the target temperatures to Zero Do NOT try to change fuses or
115. s controlled by this card LOAD L1 to L2 L6 The Load LED s should also be normally lit and a pulsing appearance shows that there is a regulated supply being delivered to the load To remove a card from its slot pull the red handles forwards and gently pull the card out There is no need to switch off the main supply NOTE The shrouded terminals on the Euro back board are live unless the power supply is switched to OFF Version 2 2 User Manual for TS KTS Console yy Miold Miaste es Oct 2012 Page 110 Not Under documentation control if printed May be revised without notice gt d Troubleshooting TrempMaster IO TouchScreen removal and reconnection Provided you are not using cycle synchronised probes the display console can be unplugged while the system is running without causing immediate problems However we recommend that you only do this to recover from an emergency situation and that you run the system without a console for as short a period as possible The task is easier if it can be done after shutting down the whole system Removing a console Unplug the data lead 240V Mains Supply Saft Thee Stop the console by touching Exit ee Unplug the power lead 240V Data Mains Link Supply Remove the console bh e Not Under documentation control if printed May be revised without notice Page 111 Oct2012 Maste
116. t Under documentation control if printed May be revised without notice Page 59 Oct 2012 Masters TempMaster K Running your controller About EasyView page The EasyView page allows you to relate zone temperatures to physical position ai Display Sau Graph ToolStore Pictures Utilities Testing Setup Gelee Mas A auan mmm CR 9 Oo bi D gt Amps q N 30 Jul 2012 15 37 Status J Apart from the zone alias name the mini panels show one other piece of information which may be either the Actual temperature the Setpoint temperature the current Applied power the deviation between Set and Actual temperatures the current or Amps consumed by that zone While no zone is selected you can change the displayed value by touching one of the Actual Setpoint Power Deviation or Amps buttons at the side of the page Touching any one mini panel within the EasyView page causes the sidebar function buttons to switch to Set and Zoom in readiness for your next input The Mini panel header is not colour coded as on the Display page However the lower half while showing Temperature or Power is colour coded to indicate the alarm status i e White on Red 2nd stage Alarm Status or Fatal Error Version2 2 User Manual for TS KTS Console Masters Oct 2012 Page 60 Not Under documentation control if printed May be revised without notice Running your controller Fremp
117. t in death or injury to personnel Most warnings pertain to electrical aspects and you must comply with them to minimise any personal danger A CAUTION warning identifies where there may be a hazardous situation which if not avoided may result in damage to property Caution warnings present no personal danger but may cause the equipment to fail or lose its memory Where to use this equipment The display console and controller cabinet together are designed for use in the plastic injection moulding industry as temperature controllers for third party hot runner systems as commonly used in mould tools They must not be used in residential commercial or light industrial environments Furthermore they must not be used in an explosive atmosphere or where there is a possibility of such an atmosphere developing The HRC cabinet and Touch Screen console should be installed in a clean dry environment where the ambient conditions do not exceed the following limits e Temperature 0 to 35 C e Relative Humidity 90 non condensing Check your wiring Before you energise the system pay special attention to how the supply to your controller is wired and how it is connected to the mould Lack of attention to detail causes errors such as e incorrect wiring of mains supply phases into the controller e crossing heater supply feeds with thermocouple detection although this error can be eliminated by the adoption of Mold Masters Standard co
118. t to Staged Shutdown consecutively switches off the zone groups in timed intervals and in the order as nominated by Shutdown Stage configuration When the Shutdown sequence finishes then the system goes to STOP mode Temporarily raise the temperature of all zones that have any Boost Temperature configured on the Setup page When the boost period expires then zone temperatures return to normal Set levels This is a preset Purge sequence to help you change colour in the mould tool For details about this option read Using The Purge Sequence on page 63 User Manual for TS KTS Console Not Under documentation control if printed May be revised without notice Running your controller TempMaster IO Control for individually selected zones Operation Available by Description Value w se sa ma Add 1 Subtract 1 Select Zone GES rte sven Lise STOP 2 Touch Set fee 7 e 2 ome UUW Switches off the one zone 3 On keypad touch OFF Boost 1 1 Select Zone e om Tas Temporarily raises 2 Touch Set Ss the temperature of BOOST 3 On k CHE the selected zones N Keypad touc until Boost Time BOOST DEO expires User Manual for TS KTS Console Version 2 2 5 Not Under documentation control if printed May be revised without notice Page 55 Oct 2012 Masters TempMaster IO Running your controller More about using Boost
119. ted out of the test by pressing Cancel Open Circuit T C Thermocouple detected as being open circuit Check thermocouple wiring for displayed zone Blown Fuse Check card fuse This message is also displayed if the zone was set to use an off board triac that was not installed N B Off board triacs have their own fuse No Mains Sync Pulse This is probably due to an error in the supply wiring No Card Present No card was detected in the rack at the slot identified with the displayed zone Cooling Test Failed All zone temperatures had to be stable or falling before the heating test begins If any zones continued to rise with power set to zero within the cooling period this error is raised Heating Test Failed Temperature did not rise by the set number of degrees within the heating period This may be caused by an open circuit heater a pinched shorted or dislodged thermocouple or the zone was set to on board triac when the cabinet was wired for off board triacs Check for Reversed T C Temperature appeared to be decreasing when power was applied Below 0 or Reversed T C May be caused by a reversed thermocouple Also in the unlikely event that the test was carried out at an ambient temperature below 0 C the controller would not work with the resulting negative temperature readings Failed to React Correctly Unexpected results This message is followed by further error messages b Ge Mold Not Under document
120. ter flow measurement cards Setting or changing the parameters are described in the 6 Choose any Header colour if the default selection is not following pages required 7 Touch OK 8 Repeat steps 1 to 7 for other types of zones User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 2 Oct2012 Masters i TompMiaster M Setting the Tool parameters 1 Select the zones CEO EK OK EK OK E 3 8 8 8 8 8 8 8 8 8 8 8 2 Select the parameter 3 Touch Set 4 Set the Value gt ersion 2 User Manual for TS KTS Console Mold E e a enn Masters Oct 2012 Page 28 Not Under documentation control if printed May be revised without notice Setting the Tool parameters FrempMaster doo The Tool Parameters Function Description Setting Limits Rack Position Identifies the position of the card within the This is not user configurable rack Input for alternative zone names Has an auto increment number facility TC Open Mode Choose a response for any zone that detects a failed thermocouple Normal No action corrective taken the zone power sets down to 0 and it shows a T C fatal alarm Auto Manual The zone has sufficient data after 10 minutes steady running to switch to Manual mode at a power level that should hold the previous temperature Auto Slave The zone has sufficient data after 10 minutes steady running to slave
121. the tool that is currently in use and that has no changes to any settings red the tool that is in current use but which has been changed from its stored settings Description a user configurable text field that may be used to hold an expanded description of the tool Sequence a sequential order that allows you to run a series of tools or tool settings in a preset and set duration sequence When Tool Sequencing is not used then it defaults to 0 to be non active Time is used as part of the sequence configuration to set the time for which any sequence step is held See page 86 for more detailed information on these two parameters Connection this normally defaults to Local Serial which indicates that the tool settings are stored locally within the console memory However if the console is networked and thus connected to two or more controller cabinets this may show the name of one or more remote HRC NET cards The Connection column also provides a demo facility as described on page 71 o ersion 2 2 User Manual for TS KTS Console Mold K _ EEN Masters Oct 2017 Page 74 Not Under documentation control if printed May be revised without notice Customising your controller rempMiaster dc Creating a new tool If you need to have different tools to use for different applications then you will need to create a new tool to hold alternative settings By way of an example a tool with four QMOD cards is currently
122. then it has no effect and the shutdown interval becomes dependant on the Shutdown timer Temp erature Select Degree C or Degree F as required Scale Weight Unit Choose to use Metric Kg or Imperial Lbs as the unit for weight Finished changing Tool Settings If you have made any changes to Tool settings note that it takes two steps to save them First you must touch Accept on this screen and then go to the ToolStore page and touch Save User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 35 Oct 2012 Masters TempMaster 1 Ati tii Ruma ACSC The System Settings These are general settings which apply to the system regardless of what tool may be loaded Function Allow Global Set Allow ToolLoad Allow Set Zone Off Allow Standby Blanking Delay Baud Rate Version 2 2 Mold Miasters Oct 2012 Description Limits Select Enable if you wish to allow probe and manifold zones to be set together or Disable if they must be set as discreet and separate actions Select Enable if you want to be able to change tools while in Run mode or Disable if you wish to prevent such changes and force the operator to shut down to swap tools If set to Enable then you need no password to switch a zone to off If you set this to Disable then you need a System Level 2 password in order to switch a zone of
123. tion of the cards that may be detected by your console Symbol Card and Description 6 zone card at 5 Amp rating for Probes with optional Current sensing Card N O ey 4 zone card at 15 Amp rating with current sensing and optional Ground Fault monitoring 2 zone card at 20 Amp rating for manifolds with optional Current sensing N N 8 channel 4 20mA Analogue Input card typically AIS used with analogue flow sensors to monitor coolant e flow rates DI2 16 channel digital input card typically used accept external signals WT3 o bal 12 channel RTD card used for temperature a monitoring using Resistive Temperature Devices WT4 era ge 12 channel TC card used for temperature ener monitoring using thermocouple sensors 4 channel SE Input Output card for remote 4 channel digital Input Output card for remote signalling PLUS remote Tool Selection input 32 channel Digital output Card used to signal DO32 7 external equipment SVG SE 12 channel sequential valve gate card that can Act S I open and close valve gates at discreet preset point User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 25 Oct 2012 Masters i TempMaster io Setting up your controller Pre configured Set Up values The table below shows the whole SetUp chart and the differing values that are given to both Probe and manifold zones Parameter Probe a
124. to 3 seconds and the external signal lasts for 4 seconds then the nozzles are boosted for 3 seconds and then return to their nominal value However the M C BOOST message in the Mode window displays for 4 seconds while the external signal is present even though no boost current is being applied for the last second Version 2 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 56 Not Under documentation control if printed May be revised without notice Running your controller rempMiaster do Using Display Page to change Temperatures 1 Select the desired zones sc tine Se s r i el EK poe Hr Tange we oom Pe d fa EJ r3 2 Touch Set 3 And then To Set a new temperature Touch Set To Raise the overall temperature Touch Add To Lower the overall temperature Touch Subtract 4 Enter the Temperature setting or change Le lee E iiwan 1 Sen 5 Touch Enter to make the setting or Esc to defer Ee the action User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 57 Oct 2012 Mokle ers TempMaster IO Running your controller Using the Display page to change Modes 1 Select the desired zones this automatically changes the function keys from Global to Zone 2 Touch Set to display the keyboard 3 And then a To change to Manual Touch Manual b To Slave a zone Touc
125. trol if printed May be revised without notice Setting up EasyView Pages TempMaster 5 Configure the Touch Exit to finish EasyView Image contd Open the EasyView Page to see results User Manual for TS KTS Console Version 2 2 3 Mold Not Under documentation control if printed May be revised without notice Page 47 Oct2012 Miasters TempMaster R5 Setting up other Utilities Setting up other Utilities System Page Software Date The System page has a date to show which software version is loaded and it is automatically reconfigured if ever the software is upgraded It is helpful if you make a note of the Software version date before you contact your supplier with any technical query Passwords Options Three levels of Password control If the User Password option see page 38 is set to Enabled then there are three levels of control 1 Open Level includes some limited functions that need no password such as searching the event log or exporting performance data 2 User or Level 1 password which gives low level access to e switch the tool on and off e alter temperatures e select different tools 3 System or Level 2 password which gives high level access to e all user level functions e set the user password e re configure the settings for a new tool e store and load new tool settings to from the disc Two Levels of Password Control If the User Password option is set to Dis
126. uld you need further information please contact your supplier bh gt Version 2 2 User Manual for TS KTS Console Mold Masters Oct 2012 Page 122 Not Under documentation control if printed May be revised without notice Appendix B Networking Information TrempMiaster Oo Configuring a Remote Connection The Remote tab on the Utilities page allows you to configure two different functions Remote Applications os Lens mt test rears Mal tes A VNC application is available to connect to Se a EES monitor and control an external application ae mmm that is hosted on a remote networked VIC Password ee eet computer You can use either the whole ankinn AE EE screen or just part of it to view the remote Meer aare application Haer Addrean Mode En Loaded fost 19653 To start the remote application 1 2 3 4 6 Open the Utilities page Touch the Remote tab Enter the IP Address of the remote networked computer If the remote application is Password protected you need to enter it into the VNC password box or if it is not then the Password box may be left blank Select whether you wish to run the remote application within the existing Window or at Full Screen size Touch Start VNC to initiate the remote application To Close the remote application From the Utilities page 1 If the remote application is running within the remote window then touch Stop VNC on the side
127. ustomising your controller TrempMaster Idi Using the Ob card for Remote Tool Selection The 105 offers all the same functions of the 4 channel input output card along with some extra input output functions that enable remote tool loading These extra functions connect to the remote machine via an AMP 183040 circular connector The connector pins are configured according to the table below Pin Function tool load signal from molding machine to ask console to load tool address 1 address 2 address 4 address 8 address 16 address 32 address 64 address 128 AMP 183040 1 Connector Tool loaded Normally Open signal from console to molding machine Normally Closed Common Ce DS P Static or Dynamic Tool Loading The 105 can be used in two ways to enable remote tool loading The static method is enacted by simply connecting appropriate load and tool ID pins to ground The tool is loaded and feedback is ignored The dynamic method sends a change tool command by connecting the load and tool ID pins to ground it then watches to see that a tool has been satisfactorily loaded and then ends the tool load process It is also free to repeat the operation and load another tool should the need arise User Manual for TS KTS Console Version 2 2 Not Under documentation control if printed May be revised without notice Page 93 Oct2012 Masters i TempMaster io Customising y
128. ut card can be supplied wherever there is need to accept a digital input The input logic values are determined by software programming and are not a user available function B2 12 channel RTD Input Card This card is used for cooling water measurement and display The 12RTD is set up as a Special in the Set up page and the measured temperature is displayed on the Display page with a range of 0 to 99 C and resolution of 0 1 C The RTD card may have Alarm levels set and any deviation outside these limits may just trigger a Warning Beacon or shut down the mould according to your needs this response option can be set in the Configure Alarms choice on the Setup Page B3 WT4 12 Channel T C Card This card can accept up to 12 zones for either J or K Type thermocouples It provides channel monitoring with 1st and 2nd stage alarms Monitored zones display as a normal cavity zone with actual temperature constantly displayed while the Set temperature in the second box refers to the nominal expected temperature either side of which the lower and upper alarm levels are set B4 AIS Analogue Input Cards The analogue input card has eight inputs that are used to read analogue output devices with an output range of 4 20mA These are usually associated with coolant flow detector devices that are calibrated for particular flow rates When the auto detect procedure sees one or more of these cards within the controller cabinet then the
129. vised without notice Maintaining your controller TempMaster J When done wait about 10 seconds then remove storage media and take it to a Personal Computer Ue t D Wi 8 yil D D i1 i P a H V Decompress the exported data file into a standard CSV comma separated value format Import Data to a spreadsheet User Manual for TS KTS Console Version 2 2 Mold Not Under documentation control if printed May be revised without notice Page 99 Oct2012 Masters TempMaster RZ Maintaining your controller Self Diagnostic Tests The Controller has a diagnostic testing tool which has two main options within its test profile 1 Power Test Power Test is a facility that can only be used on Current Measuring cards 6MODC 3MODC etc It performs a quick check to see that just the heater zones are functioning correctly and that the feedback from current sense coils are consistent with tools history file It does not check for zone wiring errors or similar and it is designed as a maintenance aid only 2 Full System Test The Diagnostic test allows you to check that every zone is functioning correctly It is the correct routine that you should use e as an acceptance check e to see that a new tool is wired up correctly e asamaintenance aid to check that a working tool is functioning correctly The following describes the test sequence to show how it works 1 It cools the whole tool during whi
130. y and which can be seen through the cabinet windows SCAN this LED flashes briefly as the controller interrogates each card in sequence FUSE Should normally be extinguished It lights to show that an output fuse has failed TC Should be normally extinguished It lights to show that the card has detected an open circuit fault on the thermocouple circuit GF Should be normally extinguished It lights to show that the card has detected a ground fault on one of the zones controlled by this card LOAD L1 to L2 L6 The Load LED s should also be normally lit and a pulsing appearance shows that there is a regulated supply being delivered to the load Version 2 2 User Manual for TS KTS Console Masters Oct 2012 Page 70 Not Under documentation control if printed May be revised without notice Running your controller TempMaster IO Training and Demonstration Mode Your controller has a Demo Mode that can be used for training or demonstration purposes While this mode is engaged the controller will not communicate with the associated Controller Cabinet therefore we recommend that you ensure that the system is idle before using the Demo Mode Facility About Demo Mode Demo Mode feeds every zone within the selected tool with a stream of pre recorded temperature data The Console appears to be working and it gives a real trace when Graph page is selected Selecting Demo Mode Open the Tool Page to select an
131. y Input Timer those parameters which affect the selected ae agni il tool To keep the settings or changes made Second Startup here you must then go to the Tool page and Standby Temp touch Save so that they are saved within the ToolStore memory with the selected tool Tool Settings System Settings Alarm Theme Delay in seconds that may defer an outgoing alarm condition Time Sees ER Lem Tool Settings System Settings Options AllowToolload Allow Set Zone Off Autostop Mode Blanking Delay Baud Rate Console Startup Allas Tocallaad System Settings are Global parameters such as Language and these are applied to the whole system regardless of what tool has been selected Enable izsable loading of a tool when in fun mode Disabbe Enable Action Ve xem ow Tool Settings System Settings SVG Settings Option Currant Setting Button One Mode Run Button Two Mode Standby Display Mode Sorted You can see an overview for each of the settings if you touch View in either tab Input Timer Input Signal Power Mode ower Alarm Delay Pressure Units Second Startup Standby Temp Startup Mode Shutdown Timer 0 Mins Standby N Closed Amperes 0 Mins Bar Hun DG Master F ollow Disabled Shutdown Temp Disabled Temp Scale Degree C Version 2 2 Mold Miasters Oct 2012 User Manual for TS KTS Console Not Under documentation control if printe
132. y page in place of a temperature value If the system detects any abnormal condition it displays a warning message in the Main menu Fault and warning messages Any of the following messages may be displayed on the Fault Indication line Error Cause Action Message The controller is unable to supply the Isolate system supply check loom and current requested Note This error heater wiring continuity Also check the message is most likely to be seen if the heater resistance against other known particular zone is set as a Spear type good zones to see that it is not noticeably higher than average Little or no temperature rise has been Check thermocouple wiring it may be detected in that zone When the console reversed Heater wiring may be faulty or starts to apply power it expects to see an element may be open circuit equivalent heat rise at the thermocouple If the Thermocouple has been trapped and pinched elsewhere in the tool or cable then it cannot see the full heat rise that occurs at the tip If left uncorrected then there is a danger that the zone could overheat and damage the tip Instead the circuit maintains the output at whatever level it reached when the monitor circuit detected the fault and the error message was displayed The fuse for that zone has failed Replace the fuse with one of the same Please Note A fuse can only fail due to a rating and type i e High Rupture Current fault external to the c

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