User Manual For HRS-Series of Hot Runner - DMS
Contents
1. 12 Introduction Watchdog feature Watchdog feature The Controller card CPU has a watchdog timer that has to be reset by the system every 3 milli seconds If for any reason the software fails to reset the timer the program is reset to the start position which initialises the controller so protecting the tool against over heating The card resumes control of the zone from the start position Safety Memory Check CAUTION This controller uses RAM with a battery back up to store all your settings such as temperatures limits and alarms There is an extremely low small risk that an interruption may cause any of these settings to alter and if such an event should occur then there must be no risk to the equipment If a zone that had previously been set to say 260 deg should become corrupted to perhaps 520 deg then the controller must not attempt to establish the incorrect temperature upon the next start up command To ensure that this cannot happen there is a safety memory check facility This checks to see that no value has been changed since the last time that the controller was used If this facility detects that any setting is different then it protects your system by automatically erasing every single stored setting within its memory If such a rare occurrence happens to your controller then you will be met by the following screen message when you switch on CAUTION SYSTEM RAM ERROR Stored values HAVE been ERASED2. Whenever the controller is set to start the system goes into a self calibration routine This is illustrated in the following diagram and explained below Set Point Temperature a Load Test Load Test Delay T T T T T T Time e The zone controller slowly ramps up the heater power and simultaneously looks for a positive temperature change at the thermocouple input The controller verifies the actual rate of rise against a predetermined value Power is slowly increased until the correct rate of rise is achieved e The controller now increases the zone temperature at a constant rate of rise until the temperature reaches about 110 C 230 e At 110 C the controller performs a Load Test on the zone heater to check its thermal characteristics The output power is reduced to zero for a test period and the temperature monitored for a response From all this information the controller has built mathematical model of the heater characteristics and so it can automatically select a Fast Medium or Slow response heating program that suits the tool This allows more efficient control of the zones e The controller continues to ramp up the temperature to the set point which should be achieved with minimum over shoot e Having built a virtual model to map the tool and heater characteristics the controller can maintain the temperature at an accurate point with virtually no deviation Issue 2 2 HRS Users Manual
3. If you read this then you will need to go through all the various screens and input all appropriate settings This basic task is described in the next chapter of this manual The task is easier if you have all the correct settings written down in a safe place DMS recommends that a hard copy of all the controller and tool settings are saved in a safe place Introduction 13 The HRS Console The HRS Console Screen The 4 x 20 LCD Screen displays all the necessary information on one screen The information is divided into four rows to show Set temperature Actual temperature Power level and Operating Mode This last row is also used to display setting up information and error messages Set Dy BXST S l2 Inlil s NAM 246 115 L10 LIGA 15 23 0 25 NN Auto Man Off Lim cua The screen contrast may be adjusted using a small flat blade screwdriver inserted through an aperture just above the AN arrow This gives access to a trim pot which may be turned to alter the screen appearance Zone Limits Keypad The standard keypad has 7 keys including 4 arrow keys up down left and right an ENTER key a cancel or CLEAR key and a HELP key Arrow Keys These are used to move about the display and select features Enter Key This key enters the command selected on the screen E g to enter a value or select a menu option Clear Key If an entry is started the clear key erases the who
4. CNegative 30 8 T C Negative 15 4 Supply 31 8 Supply 16 4 Return 32 8 Return Index 25 Index Alarm Limts setting 16 Closed Loop Working 15 Controller Cabinet 10 Controller Cards 10 Erased Values 13 Error Messages 18 Front Panel Alarm LEDs 9 How the DMS Controller Works 12 HRS Functions 14 Keypad 9 LEDS Front Panel 9 Manual Mode Working 15 Memory Check 13 On Screen Help 17 Open Loop Working 15 Power Level Setting 15 RAM Error 13 Response Speeds changing 16 Safety Instructions 6 Service and Repairs 19 Specification 5 Switching On and Off 15 Troubleshooting 18 Turning odd zones off 17 Using your HRS Controller 14 Watchdog Feature 13 Welcome 7 Zone Temperature Alarms 16 Zone Temperature setting 15 Zones switching off unwanted zones 17 Issue 2 2 HRS Users Manual
5. W arrows to increase or decrease the temperature Each depress alters the current value by one and while in the mode you can also use the and gt arrows to shift the cursor up and down the units from tens to hundreds and back again This makes it easier for you to make large changes 3 When the set value is correct press the Enter button to confirm the new settings and the cursor moves back to the Mode row leaving the new Set temperature as you require Setting Zone power levels manual working Where you wish to set fixed power settings using Open Loop mode the controller will hold the power output to your set level 1 Use the Left and Right arrow keys to select the particular zone then use the Up AN and Down V keys to display MAN in the Mode Row and press Enter The Cursor now highlights the third Power row 2 Next set the power level by using the AN or W arrows to increase or decrease the displayed power setting Each depress alters the current value by one 3 When the set value is correct press the Enter button to conform the new settings and the cursor moves back to the Mode row leaving the new power output as you require Using your controller 17 Changing Speed settings Changing Speed settings On page 11 we described how the DMS controller can automatically select the correct operating speed for you particular load However you can override this au
6. in the plastic injection moulding industry as temperature controllers for third party hot runner systems as commonly used in mould tools The controllers must not be used in residential commercial or light industrial environments Furthermore they must not be used in an explosive atmosphere or where there is a possibility of such an atmosphere developing They should be installed in a clean dry environment where the ambient conditions do not exceed the following limits e Temperature 0 to 35 C e Relative Humidity 90 non condensing When in use this equipment does not emit audible noise in excess of 10dbA Controller Tool Connections The various connections to the system using the cables supplied with the equipment are specified in the loom or cable data sheet and Appendix A Equipment failure through mis 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 mold 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 DMS Standard connections In such cases wiring errors have caused equipment failure DMS cannot be responsible for damage caused to the controller by customer wiring and or connection errors Controller Power Supplies The control cabinet can be manufa
7. D P gt User Manual For HRS Series of Hot Runner Controllers MiNI O DMS Ltd Unit 11 Blenheim Road Cressex Industrial Estate High Wycombe Bucks HP12 3RS Tel 44 0 1494 523811 Fax 44 0 1494 452898 HRS Users Manual 3 Amendment Record HRS Users Manual Amendment Record Issue Date Amendments Author Authorised 1 0 11 3 99 Initial Issue DH AR 2 0 22 06 99 Manual Revision DH AR 2 1 11 02 02 Cable mis wiring disclaimer DH AR added 2 2 28 08 02 Zero Power note added DH 9 Copyright c DMS Developments 1999 This manual is intended for use with the HRS Series controller Serial Morais with which it was supplied Our policy is one of continuous improvement and we reserve the right to alter product specifications at any time without giving notice Issue 2 2 HRS Users Manual 4 HRS Users Manual Contents Contents HRS Users Manta iii 3 Introduccion dad da td 6 Using your controllerne rashidi nonini inaisha ier ainai 14 Troubleshooting ai RESAS aK ii 19 APPENDIX As 21 HRS Users Manual 5 Specification Specification The following are general specifications The actual controller console supplied may have contractual variations and differ in some specified options Supply Voltage HRS Single phase with 13A or 16A connector Plug Supply Voltage HRS4HP 415v 3 phase 50 60Hz with neutral others available 240 480
8. MS standard Other specifications may have been stated when the controller was ordered Please refer to the supplied specification details 1 CONNECTION INFORMATION 1 1 Mains supply cable termination Please take extreme care when connecting the controller to the mains supply especially if it is a three phase supply Incorrect connection may appear to work but can result in damage to the controller The controller is normally supplied with the mains supply cable suitably terminated into an appropriate plug However if the unit is requested without any mains plug then the conductors will be labelled as shown below Cable Marking Single phase 3 phase star A 3 phase delta A supply supply supply L1 Live Phase 1 Phase 1 L2 No Connection Phase 2 Phase 2 L3 No Connection Phase 3 Phase 3 N Neutral Neutral No Connection Earth Symbol Earth Earth Earth 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 2 Loom Thermocouple cables Thermocouple cable colours and number may vary Refer to controller documentation for details Normally J Type are the only thermocouples catered for although K type may be accommodated as a special Type Positive Negative 1 3 Loom Power cables The colour of the power cables will depend on whether the controller is supplied for single phase or three phase star or delta supply Supply Li
9. We recommend that all earth connections are tested Issue 2 2 HRS Users Manual 20 Troubleshooting Servicing and repairing Servicing and repairing Always isolate your controller at source before you replace fuses or open the unit for inspection When it comes to machine maintenance there is very little that you need WARNING todo to look after it Replacement parts DMS does 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 Regular Inspection The aperture for the rear mounted fan should be checked periodically to see that it has not become clogged and that the fan is free to rotate Failure to do this can allow lint and dust to collect and reduce the flow of cooling air This in turn may incur more expensive repairs if internal components subsequently overheat 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 APPENDIX A 21 APPENDIX A HRC Wiring Standards Issue 2 2 HRS Users Manual 22 APPENDIX A HRC Wiring Standards HRC Wiring Standards The following standards only apply to HRS controllers wired to D
10. ctured to accept a wide range of supplies and sequence of phases Refer to the serial plate in the controller cabinet for confirmation of the supply requirements If the local supply is outside the specified range please contact DMS for advice Tel 0 44 494 523811 Fax 0 44 1494 452898 Introduction 9 The Controller Cabinet The Controller Cabinet The HRS is a two part case with the input and output cables rear mounted along with the main switch Load fuses are panel mounted on all models so that changing a fuse does not require operator access to the inside of the case There are no user serviceable parts inside the case Controller Cards There are two boards mounted inside the HRS cabinet The main motherboard which controls the zone temperatures and the display board for the visual display and interface processing The motherboard card has three main components e thermocouple amplifier e CPU e multi voltage output triacs Thermocouple Amplifiers HRS Controllers are normally configured for use with J type thermocouples Central Processor Unit CPU The CPU provides the following facilities e closed and open loop control of the zones e communicates settings and thermocouple readings over the data link to the display micro processor e checks for alarm conditions including blown fuse incorrect thermocouple wiring zone over temperature condition heater not responding to controller output and genera
11. itched Off The heat of a nozzle is proportional to the applied current Setting any zone to zero degrees temperature or 0 power means that only the current is reduced to zero However the current control is not a breaking contact switch but a semi conductor device known as a Triac This means that at zero current there may still be some voltage at the nozzles WARNING 97 de y On a single phase or 3 phase star supply with a neutral the triac is on the live side of the supply this keeps residual voltage to a low value However on a 3 phase delta wired supply there will be phase voltage on the nozzle while the controller s main isolator is On even when the heating is set to zero degrees 0 or Off ALWAYS isolate the controller before you open up a controller to examine any wiring or change fuses Remember that with respect to the mains supply 0 power is NOT Off Issue 2 2 HRS Users Manual 16 Using your controller Setting the zone temperatures Setting the zone temperatures Where you wish to set a fixed temperature using Closed Loop mode the controller will hold the required output to maintain that temperature 1 Use the Left and Right arrow keys to select the particular zone Use the Up Jand Down V keys to display AUTO in the upper Mode Row and press Enter The Cursor now highlights the top Set row 2 Set the temperature point by using the AN or
12. l features which provide an early diagnosis of faults in the control system the tool heaters and thermocouple sensors Error Messages If the system detects any malfunctions in one or more of the control zones then it may display any of four error messages in Mode row Error Cause Action Message ERR No temperature rise has Check thermocouple wiring it been detected in that zone may be reversed Heater wiring may be faulty or element may be open circuit FUSE The fuse for that zone has Replace the fuse with one of failed the same rating and type i e High Rupture Current load Please Note A fuse can fuse dto a fault The fuses are panel mounted only q on the back of the unit external to the controller Identify and rectify the fault before replacing the fuse OVER The particular Zone There could be an interaction temperature is exceeding between the zones or the the limits wrong thermocouple may be connected to the zone input Check the thermocouple wiring T C An open circuit Check the thermocouple thermocouple has been wiring for a loose connection detected If OK then replace the thermocouple as soon as convenient Specific Faults Rapid Temperature Fluctuations The most likely cause of temperature fluctuations is extraneous voltages being picked up by the thermocouple cable i e common mode This may be due to poor earthing of the tool or alternatively a faulty heater
13. le of the entry Help Key This displays the built in help menu which can give assistance Front panel Status Indication There are LED indicators below each channel to show its status Green The controller is operating normally Amber The actual temperature of the particular zone is below the lower limit of the set point Red The actual temperature of the particular zone is above the lower limit of the set point Issue 2 2 HRS Users Manual 14 Using your controller What is covered in this section Using your controller The HRS is a simple and accurate multi channel Hot Runner Controller which can easily be adapted to accommodate many different working environments Its accuracy is derived from the CPU temperature control described earlier while its simplicity comes from the single page display with its touch pad control What is covered in this section Switching On and Off Setting the required temperatures Setting zone power levels Changing Speed settings Setting Zone Limits Switching Zones off Help Feature Using your controller 15 Switching On and Off Switching On and Off For the HRS models the main Power Switch is a rocker Switch at the rear of the cabinet For the HP variation it is a three pole rotary switch Both switch types are sufficiently rated to disconnect the total load current and these are used for switching On and Off O C F or 0 Power is NOT Sw
14. o 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 Introduction 7 Welcome Welcome DMS welcomes you to their HRS range of temperature controllers for hot runner injection moulding tools This particular member of the proven family of DMS Hot Runner Controllers is user friendly and retains the standard control facilities associated with other DMS controllers How to use this manual The purpose of this manual is to give you a complete understanding of how best to use the controller and to assist where there are problems or faults The first part of this manual from here to page 12 contains a brief technical description of the system components and a portrayal of the DMS operating philosophy that facilitates precision temperature control The following chapters then take you carefully through the stages of setting up and running a new control system After considering system maintenance the final sections look at trouble shooting to assist in the unlikely occurrence of a system fault Issue 2 2 HRS Users Manual 8 Introduction Where to use this equipment Where to use this equipment DMS Hot Runner temperature controllers are designed for use
15. ress Enter when it is correct 4 The display now returns to its previous working mode and shows Man or Auto accordingly Issue 2 2 HRS Users Manual 18 Using your controller Turning a zone off Turning a zone off Any single zone can be individually switched off while leaving the other working zones unaffected 1 Use the Left and Right arrow keys to select the particular zone and then use the Up AN and Down V arrow keys to display OFF in the mode Row and press Enter 2 The message OFF will then be displayed within the Mode window All the power settings remain unchanged while the Zone is switched off To restore that zone use the keys to select Auto or Man Using On Screen Help The HRS Controller has an On screen help section which may be accessed while the controller is running To use this facility simply press the Help button on the keypad to display a list of Help topics 1 Auto 2 Man ual 3 Limits 4 Off 9 Keys 6 Faults Use the Up A and Down v arrow keys to step the cursor through the options and press Enter when you are at the required topic Each page of Help text is self contained and self explanatory To return to normal operation press the Clear key and you will return to the front display with everything set as before using the Help facility Troubleshooting 19 Troubleshooting Error Messages The control system has severa
16. tes alarm information for the display screen and alarm relay if fitted e controls the output power to both the on board and off board triacs using a number of self tuning algorithms e monitors the thermocouple every 20 milliseconds e continuous monitoring of a reference voltage signal on the bus and adjusts the on board triac output to compensate for fluctuations in the supply voltage the system can accommodate up to 30 swings in the supply The card requires no analogue calibration and is ready for use once set up from the display console Issue 2 2 HRS Users Manual 10 Introduction The Controller Cabinet Display Board The display board drives the LCD display unit and communicates input from the tactile keypad to the central processor via a data link Input and Output Supplies The power supply to the cabinet is via a cable at the rear of the panel that may be single or 3 phase according to particular model and load requirements Connections to the tool are made through a single loom which carries the heater supplies and thermocouple returns End terminations are mode through a Harting type Han A female connectors or their equivalents and the wiring details are show in Appendix A Introduction 11 How the DMS Controller Works How the DMS Controller Works DMS controllers are designed to perform in closed and open loop configurations However we consider that the normal operating mode is closed loop
17. tomatic selection and force the controller into one of three preferred modes 1 Use the Left and Right arrow keys to select the particular zone then use the Up AN and Down N keys to display the Speed settings in the Mode Row and press Enter when your preferred speed is displayed The options are Fast This settings tends to be preferred where probes and Heaters have integral thermocouples Medi um Use this setting for medium reaction time heater loads such as large probes or more often small sub blocks Slow this is only required for larger heaters with slow reaction times such as manifolds or platens with a large heating mass Setting Zone Alarm limits You can set zone limits to provide a visual warning if actual temperatures go above or below the nominal set points They may be independently set within the range of 1 to 99 C To set these limits 1 Use the Left and Right arrow keys to select the particular zone Use the Up AN and Down vV arrow keys to display LIM in the lower Mode row and press Enter 2 The cursor moves to the top row where the letter H is displayed alongside the present high alarm point Use the Up AN and Down v arrow keys to set the alarm point and press Enter when it is correct 3 The cursor now moves to the second row where the letter L is displayed alongside the present low alarm point Use the Up AN and Down W arrow keys to set the alarm point and p
18. v Star Delta Supply Voltage 20 supply voltage swing Tolerance Supply Protection Miniature Circuit Breaker Overload Protection High Speed Semiconductor Fuse Links Mains Voltage Output Burst fired zero crossover Output Current HRS 10 A max Output Current 15 A max HRS4HP Control range 0 472 Centigrade Celsius Temperature scale Centigrade Celsius Control Method Open or closed loop with HR software Thermocouple input Iron Constantan Fe Con type J Front panel LED Normal running high and low temperature Alarm Indicators T C amp Heater Tool Harting type Han A or equivalent connector Keypad 7 pad tactile switch Display 4 x 20 characters LCD Case HRS Metal case 44w x 10h x 20d cm Case HRS4HP Metal case 36w x 16h x 34d cm Issue 2 2 HRS Users Manual 6 Introduction Safety Instructions Introduction Safety Instructions WARNING DO NOT enter the cabinet without first ISOLATING the supplies there are unguarded terminals inside the cabinet which may have a dangerous potential across them Where a three phase supply is used then this potential may be at 415 volts or higher Safety Notices an explanation WARNING CAUTION Within this manual safety instructions are marked as follows A WARNING symbol and message shown here identifies where there may be a hazardous situation which if not avoided may result in death or injury to personnel Most warnings pertain t
19. ve supply Neutral return Single phase Blue S phase star Red Blue Red Yellow 3 phase delta APPENDIX A 23 HRC Wiring Standards 2 LOOM TOOL END CONNECTIONS 2 1 For HRS2 models Tool Connector Harting Han 10A 1 off male insert 09 20 010 2612 1 off housing 09 20 010 0301 Connections Pin Zone Connection 1 T C Positive T C Negative 1 Supply Pp pu 2 T CPositve 2 T CNegative nU N U Not used 2 2 For HRS4 HP models Tool Connector Harting Han 16A 16E for HP version 1 off male insert 09 20 016 2612 1 off housing 09 20 016 0301 O O Connections Pin Zone Connection Pin Zone Connection 1 T C Positive 9 3 T C Positive Issue 2 2 HRS Users Manual 24 APPENDIX A HRC Wiring Standards 2 3 For HRS8 models Tool Connector Harting Han 32A 1 off male insert 09 20 016 2612 1 off male insert 09 20 016 2613 E Eo y 1 off housing 09 20 032 0301 SN NE F E Connections Pin Zone Connection Pin Zone Connection 5 2 T CPositive 21 6 T CPositive 6 2 T CNegative 22 6 T CNegative 7 2 Supply 23 6 Suppy 8 2 Retun 24 6 Return 9 3 T CPositive 25 7 T C Positive 13 4 T CPositive 29 8 T C Positive 14 4 T
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