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Start-up and Service Manual - psg

1. Coincidence factor 100 duty ratio permanently at ambient temperature lt 25 C At ambient temperatures from 25 C to 55 C the coincidence factor can reduce up to 70 depending on the average output values and their duration Information about the coincidence factor applies only to installation in released PSG Racks Integrated on card By external current transformer on pT PP PCB 0 60 mA Internal 0 1 mA 5 of final value Diede Yas The system internal self protection turns off the heaters temporarily when the heatsink tempera ture exceeds TOO C Address range CANopen norm slave based on D5401 address See configuration range 1 127 fix by DIP switch Transfer rate Adjustable by jumper on card 250k or 500k def ault jumper set Max tolerable bus length m Dependent on transfer rate Terminating resistor 120 Ohm must external be set on pI PP PCB 70 30 VDC SELV PELV Power supply for electronics U are not designed for operation on DC power supply External Per HOC 06 165 0 45 A incl fan 400 VAC Y 3 N PE or 230 VAC A 3 PE External 3 x see specification under power on type plate 3 pole breaker with characteristic B Operation 0 55 C transport storage 20 70 C Operation O 90 relative atmospheric humidity no condensation Transport storage 0 95 relative atmospheric humidity no condensation Plug in into pT Rack 280 x 210 x 60 with heat sink 1 4 Com
2. 55 C transport storage 20 70 C Atmospheric humidity limit Operation 0 90 relative atmospheric humidity no condensation Transport storage 0 95 relative atmospheric humidity no condensation Standards cTUVus Certificate CU 72142541 01 based on UL 61010 1 2012 CAN CSA C22 2 NO 61010 1 12 Power supply for electronics U Cable length lt 30m Sensor cables Cable length lt 30 m Connecting cables use shielded connecting cables VO cables connecting cables for external refe Cable length lt 30 m rence junction on pT CUR Accessories Order number profiTEMP Power Plane Board pT PP PCB 025 320 profiT EMP connecting cable pT PP PCB 025 320 01 profiTEMP Rack dummy board metal sheet pT BPB12TE 025 331 10 profiTEMP Rack dummy board metal sheet pT BPBO6TE 025 331 00 dpl Rack W F Swing Mini_1502gb 3 Rev 2 00 02 Subject to technical changes 14 Chapter 4 Technical Data Technical Data pT CUR Number of zones In foutputs Digital input X4 and or X5 Alarm output X9 OPTION Measurement input X12 OPTION Digital inputs for Hot Runner mold identification X12 Digital output X4 and or AS Data interfaces CAN network X8 CAN Ethernet Optional Data interfaces RS232 R5422 configuration interface X4 and or XS Power supply for electronics Up Current cansumptian Ambient temperature limit Atmospheric humidity limit Mounting Dimensions H x W x Din mm Weight kg Connecting
3. The cable lengths and the strain relief shall be designed such that terminals of the low voltage side e g sensors etc after loosening can not touch terminals contacts of the power section and vice versa A Strain relief The connecting cables of the mains volt age must be tied together with a cable tie and be fastened to the cable fastening bar of the pT Rack O D x O O gt a X S TEN gt o z U DY gt L 3 o Y v jan D Q Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH Start up and Service manual System profiTEMP 5 5 3 Protective earthing The pT Rack must be grounded A To use Not part of delivery Connect the protective earthing based on valid national standards of the installation location The cable cross sections of all connecting cables must be installed based on valid national standards of the installation location and according to the appropriate type of installation Con sider the maximum ambient temperature at selection of cables The connection of the protective earthing shall be placed near the connection of the mains volt age Installation Protective earthing Connect the protective earthing on the pT Rack frame and the movable part on the with the earth symbol Rear Side pT Rack marked bolt Installation Protective earthing ON Ground pT Rack frame and movable part by bolt Detailed view Protective Earthing p T R
4. Pin Function and or signal 1 U X4 17 X5 14 or X8 1 2 OV X8 6 or X8 2 3 1 i 4 1 External reference junction 1 5 1 6 2 7 2 External reference junction 2 8 2 9 15 Digital input 5 10 I6 Digital input 6 ECE I7 Digital input 7 12 I8 Digital input 8 o 19 Digital input 9 14 110 Digital input 10 15 111 Digital input 11 146 2 Digital input 12 X12 Resistance ther Resistance ther mometer Pt100 mometer Pt100 2 wire 3 wire External reference junction measurement input Zone parameter P040 3 5 External reference junction dependent of sensor type HCC 06 16 S Parameter Zone parameter Al 3 5 Same sensor type as for zone parameter P040 Rev 2 00 02 Technical changes reserved 50 Chapter 6 Connections Interfaces HCC 06 16 S Parameter System parameter Exter nal reference junction Component HCC 06 16 S Parameter System parameter Exter nal reference junction Input Assign component to PT_WKZ Assign Input Al1 and or Input Al 2 Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 51 Start up and Service manual System profiTEMP 7 Setup After system rebuild and or replacing adding m removing of single components a setup must be executed This means that where necessary DIP switch settings must be executed an address scan is triggered to determine the system configuration by key CONFIG or by code number from Project Setup and C
5. Ore ERR 4 5 6 Oee conric Description A sensor break is a disconnection in the sensor circuit where the sensor wire is squeezed somewhere in between sensor and controller After detection of an error an error message is immediately output and the heating of the corresponding zone is switched OFF parameter P003 Output value 0 Reason Error cause solution Sensor break Check the connected sensors m Check connecting cable of hot runner controller Check sensor input Function and or signal Sensor error Flashing OOO Sensor incorrect polarity Blink code 3 123 SP Oie ERR 4 5 6 Oee conric Description Sensor incorrect polarity means that the thermocouple is connected with the wrong polarity to the controller Due to the incorrect wiring the controller measures a faulty actual value For not yet heated tool the fault is not visible Only when the zone is heated up the error is immediately detected and an error message displayed Reason Error cause solution sensor incorrect polarity Check the connected sensors m Check sensor connection Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 67 Start up and Service manual System profiTEMP Function and or signal Sensor error OK SIO Sensor alarm O SSC oh 18 Short circuit in sensor circuit Flashing Blink code 4 Description In a sensor short circuit fault we understand the case where a the sensor wire is squeezed somewhere
6. flashing 1 Hz in Boot Mode Wait m Controller Card HCC 06 16 S flashing 2 Hz in pre operational mode Wait Slave not reacting Controller Card HCC 06 16 S LED off e g no supply other defect m Check wiring system Check whether CAN Controller defective Function and or signal HCC 06 16 S Error in project setup OK SIO slaves O i 2 3 Flashin _ aieo ol OO OK Timeout NodeGuarding eRe 4 5 6 Q ERR LO OO can Flashing 2 Hz conric Description The Control Unit pT CUR monitors the connected slaves per NodeGuarding At least one slave can not be reached Reason Error cause solution Slave does not respond Controller Card HCC 06 16 S flashing 1 Hz in Boot Mode Wait m Controller Card HCC 06 16 S flashing 2 Hz in pre operational mode Wait Slave not reacting Controller Card HCC 06 16 S LED off e g no supply other defect m Check wiring system Check whether CAN Controller defective Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 61 Start up and Service manual System profiTEMP Function and or signal Error in project setup slaves ne _ Flashing r72 0 Incorrect slave type in proj Blink code3 RR LES ect setup OOO conric Description The Control Unit pT CUR identifies a different component in the slot than in the project setup configured Reason Error cause solution Incorrect slave type Check project setup Activate setup See chapter 7Setup page 5
7. C1 L CAN1 L 3 C2 H CAN2 H 4 C2 L CAN2 L 5 TX RS422 6 TX RS422 7 RX RS422 8 RX RS422 9 TXD RS485 10 RXD RS485 11 OVsio RS485 12 n a 13 U1 X8 1 14 U2 Power supply O 15 OV1 X8 2 16 OV2 Ground power supply X8 6 17 11 Digital input 1 X8 5 18 2 Digital input 2 19 I3 Digital input 3 20 14 Digital input 4 21 01 Digital output 1 22 O2 Digital output 2 23 O3 Digital output 3 24 04 Digital output 4 Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 45 Start up and Service manual System profiTEMP Digital input When external auxiliary voltage Up on X5 14 System parameter Inputs IP01 1 Standby high Standard setting System parameter Inputs IP02 3 Boost high Standard setting System parameter Inputs IP03 5 Zone passive high Standard setting System parameter Inputs IP04 9 Input block high Standard setting X5 PIN 21 22 23 24 Digital output System parameter Outputs OP01 0x0423F0FD Standard setting System parameter Outputs OP02 0x0423F0FD Standard setting System parameter Outputs OP03 0x0423F0FC Standard setting System parameter Outputs OP04 Ox00000000 Standard setting Rev 2 00 02 Technical changes reserved 46 Chapter 6 Connections Interfaces 6 7 4 OPTION Communication X5 Ordered variant IOK X5 Communication Digital inputs 1 4 Digital outputs 1 4 2 12 pole spring force terminal Pin Oi NI OIOI AI OINI gt INO TNS NOT
8. S Swing Mini in end position In Control Cabinet Rev 2 00 02 Technical changes reserved 28 Chapter 5 System Configuration 5 5 Connect power supply 5 5 1 Power supply electronics Connect power supply for electronics UEL on the rear side of pT Rack The power supply at least 20 30 VDC SELV PELV 6 3 A 150 W is to build in near the pT Rack m Power supply for electronics are not designed for operation on DC power supply A m The connecting cable must be lt 30 m long m The cable cross sections of all connecting cables must be installed based on valid national To use standards of the installation location and according to the appropriate type of installation Con Not part of delivery sider the maximum ambient temperature at selection of cables L J The power supply for electronics may only be connected in de energized status of System pro fiTEMP Connecting cable for power supply for electronics on the rear side of pT Rack on one of the central Power Plane here pT PP PCB 3 X6 1 U1 and X6 3 0V1 m on pT CUR X8 1 U and X8 2 OV i anschliessen Installation Power supply for electronics K U X6 1 pT PP PCB U X8 1 pT CUR e OV X6 3 pT PP PCB Pa OV X8 2 pT CUR 24 VDC Strain relief The cable lengths and the strain relief shall be designed such that terminals of the low voltage side e g s
9. S and or Mini Type Wall mounting Front mounting Swing and or Mini costumer specific designation profi EMP Control Unit Rack pT CUR with insulating board made of polystyrene 48 250 VARAN without with VARAN interface X10 amp X11 HUB Ethernet interface X2 X1 amp X2 WKZ without without Hot Runner mold identification amp Exter nal reference junction IOF IOK Digital in outputs by ribbon cable X4 terminals X5 USB without with Data export import X3 profi EMP Controller Card HCC 06 16 S EU US and HCC 06 16 S EU 6 Zones max 15 A front panel metal sheet two pole protection and one pole discon nection Rev 2 00 02 Technical changes reserved 9 10 Chapter 3 System profiTEMP Hot Runner Controllers which match and adapt profi EMP pT Rack types see above Rack system containing Control Unit pT CUR and Controller Cards HCC 06 16 S i For 12 24 36 and 48 zones expandable by concatenating several pT Racks profi EMP Control Unit Rack pt CUR types see above Coordination of functions between controllers Interface between control visualization and the controllers IO Module for digital and analog inputs ci Up to maximum 250 zones profi EMP Controller Card HCC 06 16 S types see above Autarkic temperature control Sensor inputs heating outputs monitoring a 6 zones per Controller Card HCC 06 16 S Further parts profi EMP Rac
10. Service GmbH Pirnaer Strasse 12 16 68309 Mannheim Germany Tel 49 621 7162 0 Fax 49 621 7162 162 www psg online de info psg online de
11. X1 40 OPTION USB X3 40 OPTION Communication Digital in outputs X4 X5 41 OPTION Digital in outputs X4 41 Rev 2 00 02 Technical changes reserved 1 Table of contents OPTION Communication X4 OPTION Digital in outputs X5 OPTION Communication X5 OPTION Hot Runner mold identification amp External reference junction X12 OPTION Hot Runner mold identification X12 Output voltage X12 at Hot Runner mold identification OPTION External reference junction X12 Chapter 7 Setup at system rebuild at replacement of Controller Card HCC 06 16 S DIP switch lt gt 0 at replacement of Controller Unit pT CUR at adding of Controller Card HCC 06 16 S higher DIP switch setting at removing of Controller Card HCC 06 16 S highest DIP switch setting Chapter 8 Status display Trouble Shooting Status display overview Trouble Shooting Status display OK LED Status display SIO LED Status display CONFIG LED Status display ERR1 LED Error in project setup slaves Status display ERR2 LED Error heating Status display ERR3 LED Error sensor Status display ERR4 LED Data error Status display ERR5 LED other errors Status display ERR6 LED actuator deactivated Chapter 9 Replacement of single components Hot Runner Controller Card HCC 06 16 S Replace fuses Replace Hot Runner Controller Card HCC 06 16 S Replace Control Unit Rack pT CUR Chapter 10 Appendix Consumable and Spare Parts Version His
12. cables Electrical security Protection type Standards CE marking Rev 2 00 02 Subject to technical changes 4 2 profiTEMP Control Unit Rack pT CUR Maximum 250 zones By spring force terminal Number 4 Q 30 VDC Low level 0 1 VDC High level 4 30 VDC 12 mA at 30 VDC Number 1 Potential free relay contact 2 pole spring force terminal 250 VAC 1 A Number 2 external reference junction resistance thermometer Pt 00 3 wire Measurement range 10 70 Internal resolution 0 1 K Number amp 0 30 VDC Low level 0 1 VDC High level 4 30 VDC uae 2 MA at 30 WDC Number 4 10 30 VDC 100 mA at Ta 25 C Connection of control system with superior PLC or control Spring force terminal Address range Address range 1 127 78 8 100 125 250 500 800 1000 KByte configurable by flexotempMANAGER 600 500 450 2750 100 50 30 Transfer rate Max tolerable bus length m Device internal terminating resistor 10 100 Base T RJ45 connection Can be activated by jumper Address range 1 254 Available connections TCP IP Ethernet Interface OPTION Ethernet Interface OPTION VARAN BJ45 Connection OPTION USB Data ex import Indirect coupled RS232 R5422 4 wire separately outputs Available operation as R542 4 wire and or R5485 wire Ribbon cable Spring force terminal 0 255 PSG 1 255 Modbus RTU 1200 2400 4800 9600 19200 Baud 2 Stop bits NO parity Modbus RT
13. in between sensor and controller and a short circuit exists b the sensor is not in the intended position removed or is swapped with another Through the defect in the cable to the controller a low temperature value is forecast The actual temperature is much higher than the measured temperature If there is no rise in temperature measured in a zone type considered nozzles and manifold in a dependent time a sensor alarm is displayed to the operator To pre vent damage to the appropriate zone the heating is turned OFF parameter P003 Output value 0 A sensor alarm can be faulty and that is when the heat output of the zone is too small It shows an identical error image Reason Error cause solution Short circuit in sensor cir Check the connected sensors cuit m Check connecting cable of hot runner controller sensor position Check position Rev 2 00 02 Technical changes reserved 68 Chapter 8 Status display Trouble Shooting 8 2 7 Status display ERR4 LED Data error Function and or signal Data fault Flashing Blink code 1 Channel data error pT CUR Description A check sum is determined for the channel parameters of the Control Unit pT CUR Is for some reason for one of these parameters an error detected that can not be corrected the Controller Unit generates a channel data error Reason Error cause solution Check sum error in EE Check parameters PROM EEPROM OK Edit any channel parameter P Error sh
14. included Width in mm 174 1 294 6 Height in mm 400 0 400 0 Depth in mm 266 5 266 5 Mounting drilling distance dimensions A in mm 146 7 268 6 Bin mm 360 0 360 0 Weight Inclusive wall mounting set in kg 4 6 6 3 Front panel 1 HCC card 12 TE 1 TE 5 08 mm Front frame profiTEMP pT Rack F pT Rack slots 2 4 Outside dimensions Bracket included Width in mm 216 7 338 6 Height in mm 327 4 327 4 Depth in mm 264 5 264 5 Mounting drilling distance dimensions Ain mm 200 1 322 0 Binmm 234 1 234 1 Weight Front frame inclusive inkg 5 1 6 9 Front panel 1 HCC card 12 TE 1 TE 5 08 mm dpl Rack W F Swing Mini_1502gb 2 Rev 2 00 02 Subject to technical changes PSG Plastic Service GmbH 13 Start up and Service manual System profiTEMP Installation position profiTEMP pT Rack Type W profiTEMP pT Rack Type F profiTEMP pT Rack Type 5 swung out EF PEF ee ee ee ee ee ee Re ee Pe ee ee ee ERR ee PR Re RA ate RR RREO AERE ARR EARR ER ERRE RAR ERR RRR te ee a E RRR RRA a ERRAR RRA ERRERA a PRRP R EAR ERRER TAEAE RAAR R A RERA T a a a Observe the here stated and marked distances during installation s 240 mm For completely foldable provide adequate space Technical Data Power supply Heating 400 VAC Y 3 N PE or 230 VAC A 3 PE Fuse protection load circuit External 3 x see specification under power on type plate 3 pole breaker with characteristic B Sound pressure level lt 50dB Ambient temperature limit Operation 0
15. originate from the manufacturer supplier If you wish to use services within the framework of this guarantee please refer to the manufacturer supplier 2 5 Transport and Storage 2 5 1 Transport The System profiTEMP all single components together is packed fully mounted in a robust carton cushioned with foamed material This assures sufficient protection in normal case 2 5 2 Unpacking Check the packaging and then System profiTEMP for identifiable damage incurred during transit If damage is identified then please get in touch with the transportation company T In the case of damage System profi EMP may not be brought into operation 2 5 3 Storage If you should not put the System profi TEMP into operation immediately store it protected against dirt and moisture Permissible temperature 20 70 C average permissible humidity lt 95 per year no condensation 2 6 Lift and carry A fully constructed profi EMP pT rack weighs under circumstances more than 18 kg For this reason the system profi TEMP is supplied in individual components These must be individually transported When setting up the sys tem make sure that the profi EMP pT Rack first is installed in accordance with chapter ASystem profi EMP pT Rack Installation in cabinet page 18 Then it can be assembled with the individual components A fully construct ed rack must be disassembled before transport into individual components 2 7 Disposal PSG Plastic Se
16. parameter description Parameters barameter Hot Runner Controller profiTEMP Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 5 7 Start up and Service manual System profiTEMP 8 2 Trouble Shooting 4 This symbol indicates that everything is in OK 8 2 1 Status display OK LED pT CUR HCC 06 16 S Flashing 4 Hz e In monitor mode ERR O can Flashing 2 Hz OO 60 30K dO Function and or signal HCC 06 16 S pT CUR runs or pT CUR with out firmware HCC 06 16 S in pre operation al mode OK SI Continuous light 3 ok 2 ERR O can 1 ves OK Project setup run ERR 4 ning Project setup OK All Sla r O O Or Or O conric Function and or signal HCC 06 16 S Blink code 2 e Project setup stopped ERR 3 pon 0K 6 D O can Flashing 2 Hz No processing no communi cation no control etc by pT CUR HCC 06 16 S after a certain time in pre operational mode Rev 2 00 02 Technical changes reserved 58 Chapter 8 Status display Trouble Shooting Function and or signal HCC 06 16 S Flashing 2 Hz Slave missing slave does not respond Description Reason Slave does not respond Slave not reacting Rev 2 00 02 Technical changes reserved QK SIO OO sess ioe 0K 666 Orne ERAL 4 56 O can Indicates problem with slave ddd Do conric Err O can The Control Unit pT CUR can not reach
17. power max 3 X 63A Oo gt O a amp O Q Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 19 Start up and Service manual System profiTEMP Outside dimensions and installation position pT Rack see specifications chapter 7profiTEMP pT Rack Rack system amp Dummy boards page 12 The ventilation and or air conditioning of the control cabinet is set up so that the ambient condi tions of the components see chapter 7Technical Data page 11 must be maintained in contin uous Operation The type plate of pT Rack is located on the right side of the pT Rack frame top left Rev 2 00 02 Technical changes reserved 20 Chapter 5 System Configuration 5 3 Install cards dummy boards 5 3 1 Card pT CUR Installation and wiring of card pT CUR Delivered card pT CUR and insulating board Wiring of the delivered card pT CUR according to the device specification see order Wiring of pT CUR see chapter 7Connections Interfaces page 38 A Insulating board must be screwed with card pT CUR The cable cross sections of all connecting cables must be installed based on valid national To use standards of the installation location and according to the appropriate type of installation Con Not part of delivery Sider the maximum ambient temperature at selection of cables The card pT CUR may only be plugged removed in de energized status of System profi TEMP A The insulating board su
18. project are represented in this way Not applicable not existing In all cases where the adjacent symbol is to see the start up and service man ual must be consulted Rev 2 00 02 Technical changes reserved 3 4 Chapter 1 Typographical Conventions 1 1 Additional and continuative documents Protocol PSG Il Protocol PSG II Ethernet Protocol Modbus Protocol Modbus TCP Protocol CANopen Protocol VARAN Data sheets and op erating manuals Information on this topic are in the protocol description PSG II and the corre sponding object lists Information on this topic are in the protocol description PSG II Ethernet and the corresponding object lists Information on this topic are in the protocol description Modbus and the cor responding object lists Information on this topic are in the protocol description Modbus TCP and the corresponding object lists Information on this topic are in the protocol description CANopen and the cor responding object lists Information on this topic are in the protocol description VARAN and the corre sponding object lists Available by Internet see www psg online de 1 2 Product safety and quality certification marks A TUVRheinland Rev 2 00 02 Technical changes reserved cTUVus Certification clUVus Certificate CU 72142541 01 based on UL 61010 1 2012 CAN CSA C22 2 NO 61010 1 12 CE Marking PSG Plastic Service GmbH Star
19. 06 16 S A Unused slots must be covered with ap propriate dummy boards that must be locked to the frame Front Side pT Rack Rev 2 00 02 Technical changes reserved 26 Chapter 5 System Configuration 5 4 Preliminaries for wiring of profiT EMP pT Rack Type S Swing Mini After installation and fastening of all necessary cards and if applicable dummy boards see chapter 1Card pT CUR page 20 7Controller card HCC 06 16 S page 24 ADummy board page 25 wiring starts Remove the locking screws from the pT Rack Type S Swing Mini and swing the pT Rack out Solve and remove and save the 4 locking screws for the moveable part of the pT Rack Type S Swing Mini In Control Cabinet Before lowering the movable part of the pT rack Type S Swing Mini ensure that all cards dummy boards are locked in the frame The pT Rack Type S Swing Mini may only be swung out in de energized status of System profi TEMP Risk by moving parts Moving parts can pinch fingers Keep fingers away from the side walls and the side frame or wear gloves when moving the pT rack Type S Swing Mini Move the pT rack Type S Swing Mini slowly and carefully in out Swing out moveable part of the pT Rack Type S Swing Mini In Control Cabinet Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 27 Start up and Service manual System profiTEMP Bring moveable part of the pT Rack Type
20. 1 Rev 2 00 02 Technical changes reserved 62 Chapter 8 Status display Trouble Shooting 8 2 5 Status display ERR2 LED Error heating Function and or signal HCC 06 16 S Error heating OOO Ook 1 2 3 ERR Flashi m z0 k he O can Phase fuse error code 1 ERR L AQ Continuous light Continuous light on conFic FUSE LED of the zone concerned Description The hot runner controller controls the status of fuses in the heating circuit Each zone has a FUSE LED which shows the failure of the fuse in the heating circuit A phase failure is also detected and signalized Reason Error cause solution Fuse defective Check fuse on Controller Card replace if necessary Phase missing m Check mains voltage before fuses m Check circuit breaker Check control fuse Function and or signal HCC 06 16 S Error heating DOO 1 ww 3 Flashing OO Ox Residual current Blink code2 ERR ERR rSC 4 5 6 900 Den 4 fold blinking cycle short conric pause Description The residual current see parameter SP05 Max residual current set was exceed ed for the Controller Card HCC 06 16 S and the Heatings were de energized relay on Controller Card OFF On the Controller Card the residual current for all 6 zones is determined Reason Error cause solution Tool humid Check tool on humidity Current to ground due to humidity Limit value wrong Check settings for limit value and adjust it if necessary Rev 2 00 0
21. 11 Digital input 11 112 Digital input 12 X12 Pin 9 10 11 12 13 14 15 16 digital input Connect external auxiliary voltage Ug to X4 17 X5 14 when jumper J5 J6 is NOT in standard setting Hot Runner mold identification seks eae see System parameter Inputs IP05 11 Tool coding high Standard setting System parameter Inputs IP06 11 Tool coding high Standard setting System parameter Inputs IP07 11 Tool coding high Standard setting m A M System parameter Inputs IP08 11 Tool coding high Standard setting System parameter Inputs IP09 11 Tool coding high Standard setting Am System parameter Inputs IP10 11 Tool coding high Standard setting System parameter Inputs IP11 11 Tool coding high Standard setting System parameter Inputs IP12 11 Tool coding high Standard setting _ Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 49 Start up and Service manual System profiTEMP 6 8 2 OPTION External reference junction X12 Ordered variant WKZ When using thermocouples for temperature measurement great care is required in order to achieve accurate re sults Is it necessary for design or safety reasons to arrange the reference junction in a greater distance from the measuring point an external reference junction is used X12 Hot Runner mold identification External reference junction 2 8 pole spring force terminal
22. 2 Technical changes reserved PSG Plastic Service GmbH 63 Start up and Service manual System profiTEMP Function and or signal HCC 06 16 S Error heating PA CO Current Alarm 1 2 3 Flashing O9 ox IOL Blink code 3 ERR 456 ERR CAN Heater with too high power Q OO short circuit in heating circuit 3 fold blinking cycle short ConNrFIG pause Description On the Heating output a short circuit was detected At switch on of the zone the heating current is controlled Is a defined limit exceed ed there may be a short circuit The Heating circuit is de energized relay on Con troller Card OFF Reason Error cause solution Heating overloaded Check Heating Check wiring system Function and or signal Error heating Flashing HO Thyristor alarm Blink code 4 ERR 5 tHY conric Description A thyristor alarm indicates a defect of the thyristor on the Controller Card HCC 06 16 S in the hot runner controller Since this is a critical error case which can damage the heating circuit due to over heating the heating circuit is immediately switched off relay on Controller Card OFF Reason Error cause solution Defective component Replace Controller Card or send hot runner controller in for repair Rev 2 00 02 Technical changes reserved 64 Chapter 8 Status display Trouble Shooting Function and or signal pT CUR Error heating akso 1 2 3 Total breakdown of heater Flashing O9 Hb Blink code 5 ER
23. At ambient temperatures from 25 C to 45 C the coincidence factor can re duce up to 70 depending on the average output values and their duration m Check connector connecting cable Replace if necessary Check fan and clean if necessary PSG Plastic Service GmbH 71 Start up and Service manual System profiTEMP 8 2 9 Status display ERR6 LED actuator deactivated Function and or signal Actuator deactivated pt CUR on OUT O a Flashing Blink code 1 All heating outputs are switched off Alarms are no longer processed O gt S gt O W iex ta a o os Qe Or O5 conric Function and or signal pT CUR Actuator deactivated Actuator deactivated OK SIO Flashing Triggered by a digital input all Blink code 2 429 3 heating outputs are switched r O OO off Alarms are no longer pro ERR 4 5 cessed OOs conric Rev 2 00 02 Technical changes reserved 72 Chapter 9 Replacement of single components 9 Replacement of single components According to the messages on PC with installed PSG own PC software project setup and configuration tool flexotempMANAGER or oper ation software TEMPSoft2 and or via bus connection to machine control as Status display by status LED s on the profi EMP Controller Card HCC 06 16 S and the suggested measures for Status display Trouble Shooting page 55 trouble shooting the components are replaced where nec
24. CAN Bus in pT Rack 052 264 20 Flat round cable shielded 10 pole with connector on both sides 2m CAN Bus for several p T Rack 025 320 01 profi EMP connecting cable pT PP PCB Power Plane Dummy board 025 331 00 profi EMP Rack dummy board metal sheet pT BPBO6TE 025 331 10 profi EMP Rack dummy board metal sheet pT BPB12TE Article number of different types on request Rev 2 00 02 Technical changes reserved 76 Chapter 10 Appendix 10 2 Version History Version Date 2 00 02 02 02 2015 2 00 01 01 21 2015 2 00 00 11 19 2014 1 00 03 1 14 2014 1 00 02 11 8 2013 1 00 01 8 12 2013 1 00 00 7 26 2013 Manufacturer Suppli er Rev 2 00 02 Technical changes reserved Changes In detail the following amendments corrections were made clUVus In detail the following amendments corrections were made Order numbers Technical data version 1501 In detail the following amendments corrections were made CAN termination 3 pins Reference to operation of flexotempMANAGER at creation of pT CUR Activation of address scan by key CONFIG specified Modifications for UL In detail the following amendments corrections were made Status display ERR5S LED other errors overload specified In detail the following amendments corrections were made PSG specific document variant created In detail the following amendments corrections were made PSG customer specific Doc Variant First publication PSG Plastic
25. E NOH St SS es a e O W N oO OO DAN OA A O N O 24 Rev 2 00 02 Function and or signal C1 H CAN1 H C1 L CAN1 L C2 H CAN2 H C2 L CAN2 L TX RS422 TX RS422 RX RS422 RX RS422 TXD RS485 RXD RS485 OVsio RS485 n a U1 X8 1 U2 Power supply O OV1 X8 2 OV2 Ground power supply 11 Digital input 1 2 Digital input 2 I3 Digital input 3 14 Digital input 4 01 Digital output 1 O2 Digital output 2 O3 Digital output 3 O4 Digital output 4 X5 n a ne Galvanically isolated Ug n a n a Only for purpose of configu TxD V24 ration RxD V24 OVsio Technical changes reserved X8 6 X8 5 RS422 PIN X5 5 TX 6 TX 7 RX 8 RX 9 n a 10 n a 11 n a Galvanically isolated 2 4 wire In the case of 2 wire opera tion Connect Pin 5 and 7 as well as Pin 6 and 8 PSG Plastic Service GmbH Start up and Service manual System profiTEMP 6 8 OPTION Hot Runner mold identification amp External reference junction X12 6 8 1 OPTION Hot Runner mold identification X12 Ordered variant WKZ Prerequisite By the Ethernet interface X1 a PC with installed PSG own PC software project setup and configu ration tool flexotempMANAGER or operation software TEMPSoft2 is connected via Ethernet TCP IP RJ45 sock et Information on this topic are in the Operating Instructions TEMPSoft2 A Hot Runner mold identification is available for TEMPSoft2 An e g injection mold with Hot Runner mold identi ficat
26. P switch setting Take the DIP switch setting 1 127 jec of the removed Controller Card HCC 06 16 S for the spare Controller Card HCC 06 16 S Activate address scan determi nation of system configuration Set parameters NOT required The Control Unit pT CUR has stored the specified parameters and loads them into the spare Controller Card HCC 06 16 S NOT required 7 3 at replacement of Controller Unit pT CUR Here a Control Unit pT CUR is replaced by a equivalent spare Control Unit pT CUR DIP switch setting Take the DIP switch setting of the removed pT CUR for the spare pT CUR Activate address scan determi A setup on the Controller Unit pT CUR see 7Activate setup page 51 reads nation of system configuration the addresses set for the Controller Cards HCC 06 16 S and determines the system configuration Set parameters Set parameters by project planning and configuration tool flexotempMANA GER or by own control system 7 4 at adding of Controller Card HCC 06 16 S higher DIP switch setting Here a Controller Card HCC 06 16 S is added after the already existing Controller Cards HCC 06 16 S i e a higher DIP switch setting must be set than already used DIP switch settings DIP switch setting Execute DIP switch setting 1 127 gec for Controller Card HCC 06 16 S DIP switch setting higher as already used DIP switch settings Activate address scan determi A setup on the Controller Unit pT CUR see 7Activa
27. PTION Interface Ethernet X1 page 40 See ZOPTION USB X3 page 40 x10 VARAN OUT see ZOPTION Interface VARAN X10 X11 page 40 VARAN IN see ZOPTION Interface VARAN X10 X11 page 40 See ZOPTION Communication Digital in outputs X4 X5 page 41 gt Awe X4 X5 See AOPTION Hot Runner mold identification amp External refer J5 J6 ence junction X12 page 47 J1 J2 X7 Connection pT PP PCB see 7 CAN Bus page 23 Ug see 7Power supply electronics page 28 CAN DI1 J3 X8 ADigital input X8 5 amp 6 page 39 X9 See Alarm output X9 page 40 pT CUR PCB Connection overview Control Unit pT CUR ASecurity References page 5 For notes pay attention to chapter ASystem Configuration page 16 Appropriate power supply cord see chapter AprofiT EMP Control Unit Rack pT CUR page 14 Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 39 Start up and Service manual System profiTEMP 6 1 Ethernet interface X2 The Ethernet interface establishes a connection between Control Unit pT CUR and a remote PC in one network by Ethernet TCP IP RJ45 socket Are the networks not compatible with each other remote maintenance can be done by VPN A routing IP must be specified All configuration can be done by the project planning and configuration tool flexotempMANAGER installed on the remote PC with which the Control Unit pT CUR can also be r
28. R Di 4 5 6 OO Heater not connected conric Description Total breakdown of heater is an alarm message in hot runner controllers It is output additional with the current alarm when a break is detected in the heating circuit i e no heating current is measured Reason Error cause solution Wiring Check wiring system Heating Check heating measure resistance Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 65 Start up and Service manual System profiTEMP 8 2 6 Status display ERR3 LED Error sensor Function and or signal HCC 06 16 S Sensor error sag OKSIO ERR Flashing 1010 can Potential error Blink code 1 E N fold blinking cycle short mO Ore pause ERR 4 5 6 on Controller Card that has O detected the potential error hat 2 fold blinking cycle short conric pause on Controller Card that is switched off due to a potential error on another Controller Card Description On the sensor input a too high voltage is detected For protection all zones get de energized relay on Controller Card OFF also the zones on the other Controller Cards due to the voltage may come from any zone Reason Error cause solution Error on tool Check sensor input Check grounding sensor Rev 2 00 02 Technical changes reserved 66 Chapter 8 Status display Trouble Shooting Function and or signal pT CUR Sensor error OKSIO Flashing T Sensor break Blink code 2 12 3 Sb m
29. Start up and Service Manual rofiTEMP having your hot runner under control P 0 Translation of original Start up and Service Manual PSG Plastic Service GmbH Start up and Service manual System profiTEMP Chapter 1 Typographical Conventions 3 Additional and continuative documents 4 Product safety and quality certification marks 4 Chapter 2 Security References 5 Security References for User 5 Intended use 6 Maintenance 6 Warranty Conditions 7 Transport and Storage 7 Transport T Unpacking T Storage T Lift and carry T Disposal T Chapter 3 System profiTEMP Hot Runner Controllers which match and adapt 8 Scope of supply 9 Chapter 4 Technical Data 11 profi EMP pT Rack Rack system amp Dummy boards 12 profi EMP Control Unit Rack pT CUR 14 profi EMP Controller Card HCC 06 16 S 15 Chapter 5 System Configuration 16 Schematic presentation 17 System profi EMP pT Rack Installation in cabinet 18 Install cards dummy boards 20 Card pT CUR 20 CAN Bus 23 Controller card HCC 06 16 S 24 Dummy board 25 Preliminaries for wiring of profi EMP pT Rack Type S Swing Mini 26 Connect power supply 28 Power supply electronics 28 Mains voltage 29 Protective earthing 31 Connection sensors heating 33 Connecting cable sensor 34 Connecting cable Heating 36 Chapter 6 Connections Interfaces 38 Ethernet interface X2 39 Digital input X8 5 amp 6 39 Alarm output X9 40 OPTION Interface VARAN X10 X11 40 OPTION Interface Ethernet
30. U PSGI 20 30 VDC SELV PELV Power supply for electronics U are not designed for operation on DC power supply 500 mA Operation 0 55 C transport storage 20 7O C Address range Transfer rate Stop and parity bit Protocol Operation 0 90 relative atmospheric humidity no condensation Transport storage 0 95 relative atmospheric humidity no condensation Slide in card in pT Rack insulating board made of polystyrene 306 x 34x 120 Ca 0 4 Power supply for electronics U Cable length lt 30 m ei Sensor cables Cable length 30 m use shielded connecting cables VO cables connecting cables for external reference junction on pi CUR Cable length lt 30 m Complies with EN 51010 1 VDE 0411 1 protection class over voltage category Ill contami nation class operating voltage 500 V Housing and terminal IP 00 incorporate in frame IP20 Complies with EN61326 1 cTUVus Certificate CU 72142541 01 based on UL 61010 1 2012 CAN CSA 22 2 NO 51010 1 12 The device complies with the European Directives for electromagnetic compatibility d pT CUR_1S02qb 2 PSG Plastic Service GmbH 15 Start up and Service manual System profiTEMP 4 3 profiT EMP Controller Card HCC 06 16 S Technical Data Installation Sensor input Thermocouple TC Accuracy of measuring Protection equipment Power output Power rating Output signal Fuse protection Per power controller card Coincidence factor No
31. V 3P N PE TEE Connect power supply electronics L1 L2 L3 N from externally see chapter 7Con nect power supply page 28 E Reference designation based on IEC 81346 2 profi EMP Control Unit Rack pt CUR profi TEMP Controller Card HCC 06 16 S profi EMP Power Plane pT PP PCB Fan G1 G2 Transformer B1 B2 Line bars X110 X120 Rev 2 00 02 Technical changes reserved 18 Chapter 5 System Configuration 5 2 System profiTEMP pT Rack Installation in cabinet pT Rack containing Control Unit pT CUR and Controller Cards HCC 06 16 S Screws e g M6 cylindric screws with hexagon socket based on DIN EN ISO 4762 4 screws A or M5 lens screws with cross recessed 4 washers based on DIN EN ISO 7045 or M5 hexagon screws based on DIN EN ISO 4017 To use Not part of delivery control cabinet stallation Fastening of pT Rack here type S Swing and or Mini with parts described under To use in For installation of pT Rack in control cabinet these requirements DIN EN 61439 1 2012 06 VDE 0660 600 1 2012 06 DIN EN 50274 VDE 0660 514 must be observed by the installer of the system Type plate is located on this side For example x O a a H a 3 PSG Plastic Service GmbH X F ISG D 68309 Mannheim a Tel 00 49 6217162 0 Typ type T Rack 08S Artikelnr article no 025330 08S Seriennr serial no 1438209063 Spannung voltageAC 400VAC Y 3 N PE Anschluss
32. achine control to check that the System profi TEMP is running correct after exchange of the component 9 3 Replace Control Unit Rack pT CUR If it is necessary to replace a Control Unit pT CUR you should first contact the manufacturer supplier for advice Rev 2 00 02 Subject to technical changes PSG Plastic Service GmbH 75 Start up and Service manual System profiT EMP 10 Appendix 10 1 Consumable and Spare Parts Order number Article description pT Rack 025 330 02W profi EMP pT Rack 02 Wall 025 330 04W profi EMP pT Rack 04 Wall 025 330 08W profi EMP pT Rack 08 Wall 025 330 02F profi EMP pT Rack 02 Front 025 330 04F profi EMP pT Rack 04 Front 025 330 08F profi EMP pT Rack 08 Front 025 330 025 profi EMP pT Rack 02 Swing 025 330 048 profi EMP pT Rack 04 Swing 025 330 06S profi EMP pT Rack 06 Swing 025 330 088 profi EMP pT Rack 08 Swing Control Unit Rack 025 343 profi EMP pT CUR 250 HUB IOF USB 250 zones 025 344 02 profi EMP pT CUR 250 VARAN HUB WKZ IOK USB 250 zones 025 344 03 profi EMP pT CUR 250 HUB WKZ IOK USB 250 zones 025 344 04 profi EMP pT CUR 250 VARAN HUB WKZ IOK USB 250 zones 025 344 05 profi EMP pT CUR 250 HUB IOK USB 250 zones Hot Runner Controller Card 025 316 00 profi EMP Controller Card HCC 06 16 S EU US 6 zones Fuses 030 612 Fuse 6x32 mm To protect electronics use ONLY fuses of type SIBA FF 16A Art No 7012540 16 Connecting Cable 052 262 01 1 Ribbon cable pT CUR to pT PP 10 pole connector 400mm
33. ack Rev 2 00 02 Technical changes reserved 31 32 Chapter 5 System Configuration Installation Protective earthing Cable lug Bolt Nut Spring washer Torque for installa Flat washer tion of protective earthing 2 Nm Protective conductor Nut Serrated washer Strain relief The protective conductor connection exists permanently In case of damage the protective con ductor connection must interrupt last of all The strain relief must be designed so that the protec tive conductor connection interrupts last under mechanical stress The cable lengths and the strain relief shall be designed such that terminals of the low voltage side e g sensors etc after loosening can not touch terminals contacts of the power section and vice versa Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 33 Start up and Service manual System profiTEMP 5 6 Connection sensors heating In the pT Racks so called Power Planes pT PP PCB are already installed The Power Planes have the following connections the following function Slot for 2 Controller Cards HCC 06 16 S m Connection mains voltage by bus line bar pre assembled Connection for electronics CAN Bus distribution and termination Connection sensor inputs Connections heating outputs m Connection of fan pre assembled etc sensor Heating Inputs Outputs HCC 06 16 S HCC 06 16 S installati
34. al inputs 1 4 Digital outputs 1 4 26 pole ribbon cable socket Pin Function and or signal 1 OVext X8 2 2 OVext X8 2 3 VEL ext X8 1 4 ADRoyt2 ADR OUT2 5 C2 L CAN2 L 6 C2 H CAN2 H 7 ADRoyt ADR OUT1 8 C1 L CAN1 L 9 C1 H CAN1 H 10 OVsio RS485 11 RXD RS485 12 TXD RS485 13 RX RS422 14 RX RS422 15 TX RS422 16 TX RS422 17 Ue jo Power supply O 18 O4 Digital output 4 19 O3 Digital output 3 20 O2 Digital output 2 21 O1 Digital output 1 22 OVi Ground power supply X8 6 23 14 Digital input 4 24 I3 Digital input 3 25 12 Digital input 2 26 11 Digital input 1 X8 5 Rev 2 00 02 Technical changes reserved 42 Chapter 6 Connections Interfaces Pin 26 25 24 Digital input When external auxiliary voltage Ug on X4 17 System parameter Inputs IP01 1 Standby high Standard setting l System parameter Inputs IP02 3 Boost high Standard setting System parameter Inputs IP03 5 Zone passive high Standard setting System parameter Inputs IP04 9 Input block high Standard setting X4 PIN 21 20 19 1 Digital output When external auxiliary voltage OV on X4 22 System parameter Outputs OP01 0x0423F0FD Standard setting System parameter Outputs OP02 0x0423F0FD Standard setting System parameter Outputs OP03 0x0423F0FC Standard setting System parameter Outputs OP04 0x00000000 Standard setting Rev 2 00 02 Technical changes reserved 6 7 2 OPTION Commun
35. and vice versa A Strain relief All cables of one plug of the pT CUR must be tied to gether for each plug as close to the plug as possible lt 15 mm with a cable tie and to be fastened to the cable fastening bar of the pT Rack Detailed view pT CUR Sprofitemp 2 Detail view Rear Side pT Rack The type plate is located on the board Procedure for service and or maintenance please refer to the chapter 7Replace Control Unit Rack pT CUR page 74 Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 23 Start up and Service manual System profiTEMP 5 3 2 CAN Bus Connect CAN Bus between pT CUR and following Power Plane pt PP PCB 1 on the rear side of pT Rack A 10 pole ribbon cable To use Not part of delivery Installation of ribbon cable is only allowed in de energized status of System profiTEMP CAN Bus by 10 pole ribbon cable on the first Power Plane following pT CUR here pT PP PCB 1 X4 on pT CUR X7 should be connected Installation pT PP PCB 4 pT PP PCB 3 pT PP PCB 2 pT PP PCB 1 TEEI ton or eon wa Leet Lien eer 5 O CAN Bus R X4 pT PP PCB 1 flx Ax ike xa x7 X7 pT CUR Card pT CUR is terminated by internal terminating resistor 120 Ohm CAN Bus is terminated pole ETTA Each pT Rack is terminated on the last Power Plane here pT PP PCB 4 The CAN Bus connection between the Control ler Cards
36. as described in chapter 7System profiTEMP pT Rack Installation in cabinet page 18 Protect device against moisture Do not use in areas with high humidity Check that the specified voltage on the type plate is identical with the mains voltage on site Ensure that the power cord and the connecting cables are not damaged by overrun squeezing tearing or suchlike Protect the cords cables against oil sharp edges and temperatures above 70 C Connect the connecting cable only in de energized status Place the connecting cable to prevent stumbling Assure yourself that the e g connected injection mold is linked to the protective conductor Do not place any tanks filled with liquid on the top of the device otherwise a dangerous situation may emerge The area around the fan must be kept open Do not insert any objects Work like e g maintenance and repair may be carried out by authorized and skilled qualified personnel only Only qualified personnel skilled and on the risks trained may use the device The relevant accidental regulations as well as other general approved safety relevant occupational medical norms have to be obeyed Unauthorized modifications of the device exclude liability of the manufacturer supplier for resultant damages Rev 2 00 02 Technical changes reserved 5 6 Chapter 2 Security References Before working on this device always switch off the mains switch and make sure that the device is de energized Prote
37. at least one slave in the project setup be cause he does not respond or react Error cause solution Controller Card HCC 06 16 S flashing 1 Hz in Boot Mode Wait m Controller Card HCC 06 16 S flashing 2 Hz in pre operational mode Wait Controller Card HCC 06 16 S LED off e g no supply other defect m Check wiring system Check whether CAN Controller defective PSG Plastic Service GmbH 59 Start up and Service manual System profiTEMP 8 2 2 Status display SIO LED 110 OK gt Flashing 0 1 2 3 OK Communication CAN R 000 4 5 LO SIO O ERR CAN Flashing conric Synchronous flashing pT CUR and HCC 06 16 S and or continuous light at high bus load 8 2 3 Status display CONFIG LED Function and or signal OK SIO Flashing O 0 1 2 3 OOO Address scan running ERR 4 sg OOO conric Rev 2 00 02 Technical changes reserved 60 Chapter 8 Status display Trouble Shooting 8 2 4 Status display ERR1 LED Error in project setup slaves Function and or signal HCC 06 16 S Error in project setup OK SIO et OOO 0K 1 6 O ERR Flashing 00 Time out error slave does Blink code 1 ERR PEPS Ocan not respond 00 ox C ERR conric CAN Description The Control Unit pT CUR can not reach at least one slave in the project setup be cause he does not respond or react Reason Error cause solution Slave does not respond Controller Card HCC 06 16 S
38. concerning the handling of ESD devices must be observed Electrostatic sensitive devices Rev 2 00 02 Subject to technical changes PSG Plastic Service GmbH 73 Start up and Service manual System profiTEMP 9 1 Hot Runner Controller Card HCC 06 16 S Replace fuses 1 Pay attention to 7Security References Component identification according to Status display page 5 ERR2 LED Error heating page 62 Working on the System profi T EMP are only allowed in de energized status of System profiTEMP Pay attention to 7Security References page 5 Working on the System profi EMP may be carried a out by authorized and skilled qualified personnel only Fuse Use ONLY fuses of type SIBA FF 16A Art No 7012540 16 see chapter 7Consumable and Spare Parts page 75 The action concerning the handling of ESD devices must be observed Electrostatic sensitive devices Cards count at System profiTEMP from left to right 1 Open locking for card Lift the card out of the slot carefully 2 Replace fuses F1 6 F7 F12 Look for right fit Insert card carefully into the slot into the guide brackets top bottom and regard the latching of the connectors 3 Tighten locking for card After reconnection of the power supply and the waiting for the start up time of all components are either LED displays see chapter 7Status display Trouble Shooting page 55 or the PSG own operating and display unit or the visualizat
39. ct the supply voltage against unintentional reclosing Components may only be brought into operation when they were implemented safe of contact before If this device is integrated in a system the system producer is responsible for the security of the system A In all cases where the adjacent symbol is to see on the device note the safety instructions necessarily on the System profiT EMP identified by this symbol sign label Warning Possibility of General warming n all cases this start up and service manual must be consulted electric shock sign 2 2 Intended use The System profi TEMP is exclusively designed for temperature dependent control of electric heaters It is intended solely for installation in a cabinet which can only be opened with a tool or key from qualified person nel The cabinet must be build up in a way that protection against electric shock and fire protection based on UL 61010 and CSA C22 2 No 61010 is guaranteed Project setup and start up can be carried out by the PSG own project setup and configuration tool flexotempMA NAGER For the parameterization of customer desired functions the installer of the system is responsible The System profi TEMP provides extensive error messages see chapter 7Status display Trouble Shooting page 55 and security functions that can and must be used by the installer of the system in individual responsibility Operation by PC with installed PSG own PC software pro
40. e OK All Slaves stopped slave does OK Project not respond setup running Communication CAN SIO Flashing during ad dress scan Explanation blink code Highest Blink code 1 Blink code 2 Decreasing Priority Priority etc LED switch on 1 LED switch on 2 BO time thereafter mE mE _ time thereafter pause repeat pause repeat Blink code 1 Blink code 2 Blink code 3 Blink code 4 Blink code 5 ee BE EEE oF Uk i Of U6 Ul Ut ATime out er 7Timeout Alncorrect ror slave NodeGuar slave type in does not re ding page 60 project setup page Error in project set Error heating AResidual ACurrent fuse error page page page 62 Sensor error APotential er ror page 65 correct polarity page 66 Data fault AChannel AChannel ASystem data 7ASystem data data error pIT data error error pT Cur error slave Other errors CUR page page page 69 page 69 68 Actuator deactivat ed AHeater alarm page 70 Apt CUR on A7Actuator de OUT page activated 71 In Project Setup and Configuration Tool flexotempMANAGER the status is shown too Rev 2 00 02 Technical changes reserved 56 Chapter 8 Status display Trouble Shooting Information on this topic are in the operating instructions Operation Project Setup and Configuration Tool flexotempMANAGER Operation Information on this topic are in the
41. emote controlled Operation Information on this topic are in the operating instructions Project Setup and Configuration Tool flexotempMANAGER Operation 6 2 Digital input X8 5 amp 6 Digital input 1 0 30 VDC Low level 0 1 VDC High level 4 30 VDC Imax 12 mA at 30 VDC X4 26 X5 17 same signal as X8 5 X8 Power supply electronics Interface CANopen Digital input 1 6 pole spring force terminal Pin Function and or signal 1 U Power supply See APower supply electronics page 28 2 OV i Ground power supply 3 C H CAN H_ 4 C L CAN L 5 D1 Digital input 1 X4 26 X5 17 6 OVD Ground digital input 1 X4 22 X5 16 X8 Pin U 5 1 Q O X8 A PIN D1 System parameter Inputs IP01 1 Standby high Standard setting Rev 2 00 02 Technical changes reserved 40 Chapter 6 Connections Interfaces 6 3 Alarm output X9 Alarm output potential free relay contact 2 pole spring force terminal 250 VAC 1A X9 Alarm output 2 pole spring force terminal Pin Function and or signal 1 13 ge 2 14 b 6 4 OPTION Interface VARAN X10 X11 Ordered variant VARAN The VARAN implementation in the Control Unit pT CUR RJ45 socket provides users with a real time Ethernet bus system with all its advantages for machine automation To build a VARAN bus line structure the interface VARAN OUT X10 is used 6 5 OPTION Interface Ethernet X1 Ordered va
42. ensors etc after loosening can not touch terminals contacts of the power section and vice versa a O a amp Qo 5 o Strain relief poa O amp Oo _ i The connecting cables of the power sup ply for the electronics must be tied to gether with a cable tie and be fastened to the cable fastening bar of the pT Rack Dac Ec Detail view Electronic The power supply for electronics by Power Plane is sufficient for a complete with Controller Cards equipped pT Rack0O8 Per pT Rack a power supply for electronics has to be used Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 29 Start up and Service manual System profiTEMP 5 5 2 Mains voltage Connect mains voltage on the rear side of pT Rack When installing the system profi T EMP pT Rack into a control cabinet a separator for the mains voltage in the form of a switch or circuit breaker must be provided This separator must be arranged suitable and must be easily accessible for the user This separator must be marked so that it can be clearly identified belonging to the System profi TEMP pT Rack and can be uniquely identified by the user Install an external fuse 3 pole breaker with characteristic B see specification under power on A Type plate page 18 e g 63 A The external fuse maximal 3 x See specification under power o
43. essary You should first contact the manufacturer supplier for advice In all other here not explicitly described cases send the System profiTEMP in for repair In all cases where the adjacent symbol is to be seen on the device note the safety instructions necessarily on the System profiTEMP identified by this symbol sign label In all cases this start up and service manual must be consulted In case of replacement of single components for maintenance note 7Security References page 5 necessarily Work like e g maintenance and repair for System profi EMP may be carried out by authorized and skilled qualified personnel only Only qualified personnel skilled and on the risks trained may use the System profi EMP The relevant accidental regulations as well as other general approved safety relevant occupational medical norms have to be obeyed Before working on the System profi EMP always switch off the mains switch and make sure that the System profiTEMP is de energized Protect the supply voltage against unintentional reclosing Single components must be replaced by components of the same type see type plate Take care to transfer the same settings e g parameterization Before switch on of the zones it is to be ensured that the System profiTEMP is configured for the application see chapter Intended use page 6 An incorrect configuration can lead to damage to the control section or to injuries to persons The action
44. ication X4 Ordered variant IOF X4 Communication Digital inputs 1 4 Digital outputs 1 4 26 pole ribbon cable socket Pin oO ON O oF FB WwW N gt NINI NI NINININI gt a O O A ON a O O O0 N 0O OIA CW NM RS485 PIN 10 11 12 13 14 15 16 Function and or signal OVext X8 2 OV oxt X8 2 VEL ext x8 1 ADRoyt2 ADR OUT2 C2 L CAN2 L C2 H CAN2 H ADRoyt ADR OUT1 C1 L CAN1 L C1 H CAN1 H OVsio RS485 RXD RS485 TXD RS485 RX RS422 RX RS422 TX RS422 TX RS422 UEL o Power supply O 04 Digital output 4 O3 Digital output 3 O2 Digital output 2 01 Digital output 1 OV Ground power supply 14 Digital input 4 I3 Digital input 3 2 Digital input 2 11 Digital input 1 X4 OVsio RxD Vi24 Galvanically isolated Ug TxD V24 n a Only for purpose of configu n a ration n a n a PSG Plastic Service GmbH Start up and Service manual System profiT EMP X8 6 X8 5 RS422 PIN 10 11 12 13 14 15 16 X4 n a n a n a RX TX TX Galvanically isolated 2 4 wire In the case of 2 wire opera tion Connect Pin 13 and 15 as well as Pin 14 and 16 Rev 2 00 02 Technical changes reserved 43 44 Chapter 6 Connections Interfaces 6 7 3 OPTION Digital in outputs X5 Ordered variant IOK X5 Communication Digital inputs 1 4 Digital outputs 1 4 2 12 pole spring force terminal Pin Function and or signal 1 C1 H CAN1 H 2
45. in the pT Rack is done by plug X3 X9 on each Power Plane pT PP PCB Rev 2 00 02 Technical changes reserved 24 Chapter 5 System Configuration 5 3 3 Controller card HCC 06 16 S Install Controller Card HCC 06 16 S Install delivered Controller Card HCC 06 16 S The card HCC 06 16 S may only be plugged removed in de energized status of System profi TEMP Installation HCC 06 16 S Plug Controller Card HCC 06 16 S fol lowing pI CUR into the guide brackets top bottom Ensure that the connectors are latched in Front Side pT Rack Installation HCC 06 16 S Lock card HCC 06 16 S top bottom Plug in and lock further Controller Cards HCC 06 16 S following right Front Side pT Rack The type plate is located on the board Procedure for service and or maintenance please refer to the chapter 7Hot Runner Controller Card HCC 06 16 S Replace fuses page 73 7Replace Hot Runner Controller Card HCC 06 16 S page 74 Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 25 Start up and Service manual System profiTEMP 5 3 4 Dummy board If one or more slots in the pT Rack remain unused these are to cover each with a suitable dummy board see chapter Consumable and Spare Parts page 75 which must be locked to the frame The pT Rack should be on the front completely closed Unused slots must be covered with appropriate dummy boards that must be locked to the frame Installation HCC
46. ion of the machine control to check that the System profi TEMP is running correct after exchange of fuses on the components Rev 2 00 02 Subject to technical changes 74 Chapter 9 Replacement of single components 9 2 Replace Hot Runner Controller Card HCC 06 16 S 1 Pay attention to ASecurity References Component identification according to Status display page 5 ERR2 LED Error heating page 62 Working on the System profi TEMP are only allowed A in de energized status of System profi EMP Pay attention to 7Security References page 5 Working on the System profiT EMP may be carried A out by authorized and skilled qualified personnel only The action concerning the handling of ESD devices must be observed Electrostatic sensitive devices Cards count at System profi TEMP from left to right 1 Open locking for card Lift the card out of the slot carefully Insert spare card carefully into the slot into the guide brackets top bottom and regard the latching of the con nectors 2 Tighten locking for card Make the HCC 06 16 S card known to the System profi TEMP see chapter 7Setup page 51 and Aat replace ment of Controller Unit pT CUR page 53 After reconnection of the power supply and the waiting for the start up time of all components are either LED displays see chapter 7Status display Trouble Shooting page 55 or the PSG own operating and display unit or the visualization of the m
47. ion shares encoding information with TEMPSoft2 via the digital inputs of Control Unit pT CUR In the tool data in TEMPSoft2 the tool coding is specified A program and a view can be assigned which are used after identification of the tool The Hot Runner mold identification in TEMPSoft2 handles 16 Bits As digital inputs 11 14 of X4 X5 changes in standard configuration necessary and I5 112 of X12 standard set ting can be used Should 16 bits be used for Hot Runner mold identification further modules have to be connect ed Output voltage X12 at Hot Runner mold identification As standard setting the output voltage of Hot Runner mold identification is identical with the power supply on ter minal X8 Should the digital inputs be supplied by another power supply replug the jumpers J5 J6 and connect an auxiliary power supply PIN J5 J6 Function and or signal 1 gt 2 J5 X4 17 X5 14 o z J6 X8 6 1 gt J5 X8 1 2 J6 X8 2 3 Standard setting X12 Hot Runner mold identification External reference junction 2 8 pole spring force terminal Pin Function and or signal 1 U X4 17 X5 14 or X8 1 standard 2 OV X8 6 or X8 2ctandard 3 1 4 1 External reference junction 1 5 1 6 2 T 2 External reference junction 2 8 2 Rev 2 00 02 Technical changes reserved 47 48 Chapter 6 Connections Interfaces Digital input 5 Digital input 6 Digital input 7 Digital input 8 Digital input 9 Digital input 10 1
48. ive Function and or signal Data fault OK SIO Flashi Blink ae System data error slave OOO ERR 4 5 6 L800 conric Description A check sum is determined for the system parameters of the Controller Card HCC 06 16 S Is for some reason for one of these parameters an error detected that can not be corrected the Controller Card generates a system data error Reason Error cause solution Check sum error in EE Check parameters PROM EEPROM OK Edit system parameter SP03 Error should disappear after a short time Check sum error in EE Replace Controller Card HCC 06 16 S PROM EEPROM defective Rev 2 00 02 Technical changes reserved 70 Chapter 8 Status display Trouble Shooting 8 2 8 Status display ERR5 LED other errors Function and or signal pT CUR Other errors Flashing Blink code 1 Description Reason High temperature at instal lation location Overload Connector to fan defective Mechanical defect of fan Rev 2 00 02 Technical changes reserved OK Heater alarm z hSE O 1 2 r O ele Heat sink temperature too high 5 pia 4 6 O conric The heat sink temperature has exceeded the limit value All outputs on the Controller Card are switched off parameter P003 Output value 0 Error cause solution Check environmental conditions at installation location Check Coincidence factor 100 duty ratio permanently at ambient temperature lt 25 C
49. ively numbered 1 250ge due to the setting of the DIP switch 1 127ge on the Controller Card HCC 06 16 S See chapter 7Setup page 51 pT PP PCB 4 pT PP PCB 3 p1 PP PCB 2 pT PP PCB 1 Connecting cables sensor MISIRIS deena Miele lel eS pT CUR on terminal X1 and or X2 per Power Plane pT PP PCB L H xl i A Strain relief The cable lengths and the strain relief shall be designed such that terminals of the low voltage side e g sensors etc after loosening can not touch terminals contacts of the power section and vice versa Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 35 Start up and Service manual System profiTEMP A Strain relief The connecting cables of the Heating of one HCC 06 16 S card must be tied to gether with a cable tie and be fastened to the cable fastening bar of the pT Rack A Rear Side pT Rack Shielding The shielding of the sensor cables is tied together to the cable fastening bar of the pT Rack Detail view Connecting Cable Sensor I Oana Al Bw ow NIN A gt T e ee ee i i Lae ae 2 LaLa To shield the terminals X1 X2 pin 13 can be used Hold the cable for shielding as short as possible Rev 2 00 02 Technical changes reserved 36 Chapter 5 System Configuration 5 6 2 Connecting cable Heating Each Power Plane pT PP PCB has slots for 2 Controller Cards HCC 06 16 S Therefore 2 6 Heating inputs can be connected on
50. ject setup and configuration tool flexotempMANAGER or operation software TEMPSoft2 and or via bus connection to machine control If the System profiTEMP is not used for this intended purpose safe operation of the equipment A is not guaranteed Uses other than the above shall be improper and exclude the liability of the manufacturer supplier for any related persons property and consequential damage 2 3 Maintenance No special maintenance of the System profi TEMP is necessary Maintain a clean surface of the operating unit For cleaning use a damp cloth Avoid the use of solvents cleansers and abrasives Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH Start up and Service manual System profiTEMP 2 4 Warranty Conditions This product is subject to the legal warranty time periods for faults or deficiencies in manufacture Content of Warranty If a malfunction relatively occurs through the manufacture the manufacturer supplier repairs or replaces the non conforming product according to their own discretion The following repairs do not fall under the warranty and are liable to costs Malfunctions after the legal notice periods have expired Malfunctions caused through operating error and or incorrect parameterization of the user if the device is not operated as described in the start up and service manual Malfunctions caused through other devices Changes or damage to the device which do not
51. k dummy board metal sheet pT BPBO6TE and or pT BPB12TE cover front side pT Rack 2 sizes iW Not part of delivery Connecting cable Between pT CUR and the following Power Plane pT PP PCB in pT Rack Between pT Racks the amount of the components depends on the number of zones i Not part of delivery Various parts not part of delivery described in chapter 7 System Configuration page 16 as To use Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 11 Start up and Service manual System profiTEMP 4 Technical Data Following is the technical data for the used components for System profiTEMP gt 4 gt pT Rack here type S pT CUR HCC 06 16 S with insulating board You can find the latest technical data on all PSG products at any time on the homepage www psg online de Rev 2 00 02 Subject to technical changes 12 Chapter 4 Technical Data 4 1 profiT EMP pT Rack Rack system amp Dummy boards profiTEMP pT Rack Swing pl Rack slots 2 4 6 8 Outside dimensions Bracket included Width in mm 216 7 338 6 460 5 582 4 Height in mm 400 0 400 0 400 0 400 0 Depthinmm 267 5 2675 267 5 267 5 Mounting drilling distance dimensions Ainmm 146 7 268 6 390 5 512 4 Bin mm 360 0 360 0 360 0 360 0 Weight Swing frame inclusive inkg 77 9 6 12 3 14 1 Front panel 1 HCC card 12 TE 1 TE 5 08 mm Va Wi Wall mounting profiTEMP pT Rack W pT Rack slots 2 4 Outside dimensions Bracket
52. m profi EMP is integrated in a system the system installer is responsible for the security of the system For the parameterization of customer desired functions the installer of the system is responsi ble Work like e g maintenance and repair for System profi EMP may be carried out by authorized and skilled qualified personnel only Only qualified personnel skilled and on the risks trained may use the System profi EMP The relevant accidental regulations as well as other general approved safety relevant occupational medical norms have to be obeyed Before working on the System profi EMP always switch off the mains switch and make sure that the System profi T EMP is de energized Protect the supply voltage against unintentional reclosing Single components must be replaced by components of the same type see type plate Take care to transfer the same settings e g parameterization Before switch on of the zones it is to be ensured that the System profi TEMP is configured for the application see chapter Alntended use page 6 An incorrect configuration can lead to damage to the control section or to injuries to persons The action concerning the handling of ESD devices must be observed Electrostatic sensitive devices Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 17 Start up and Service manual System profiTEMP 5 1 Schematic presentation HCC HCC 06 165 106 16S En et ez CAN 24VDC 400
53. n Type plate page 18 must A be configured based on valid national standards for used cable power The cable cross sections of all connecting cables must be installed based on valid national TONGE standards of the installation location and according to the appropriate type of installation Con Not part of delivery sider the maximum ambient temperature at selection of cables The mains voltage may only be connected in de energized status of System profi EMP Solve and remove the screws for the acrylic glass covering carefully Connecting cables for mains voltage phase L1 L2 L3 neutral conductor N on the rear side of pT Rack online bar L1 L2 L3 Installation online bar N connect central After installation of the connecting cables insert the acrylic glass covering carefully Insert and tighten the screws of the acrylic glass covering pT PP PCB 4 pT PP PCB 3 pT PP PCB 2 pT PP PCB 1 7 Connect mains voltage on m L1 L2 L3 and N should be connected BIENEN CIEMAT A DISIRI eat pT CUR A Pay attention to the safety instruction on the acrylic glass covering Installation Mains voltage Rev 2 00 02 Technical changes reserved 30 Chapter 5 System Configuration Pre assembled line bars Torque for installation of power cords bus line bar distributor 2 Nm Standard wiring 400VAC Y 3 N PE or 230 VAC A 3 PE Detailed view Mains Voltage Rear Side pT Rack Strain relief
54. nd Service manual System profiTEMP T Switching output 1 O O7N Neutral conductor 1 Switching output 2 Heating output Heating output 2 i A All phases and neu tral conductors have to be led through the corresponding differ ential current trans former on the Power Plane O aN Switching output 5 O11N Neutral conductor 5 Switching output 6 O6N 0O12N Neutral conductor 6 O O O O Bi WwW Ww NM N gt Z Z Z O O CO Z Rear Side pT Rack Detail view Connecting Cable Heating A The connecting ca bles of the Heating of one HCC 06 16 S card must be tied to gether with a cable tie above the flat ca ble plug as seen here A Rear Side pT Rack Strain relief The connecting ca bles of the Heating of one HCC 06 16 S card must be tied to gether with a cable tie and be fastened to the cable fastening bar of the pT Rack Detail view Connecting Cable Heating Rev 2 00 02 Technical changes reserved 38 Chapter 6 Connections Interfaces 6 Connections Interfaces The Control Unit pT CUR has connections and or interfaces for Coordination of functions between the controllers Interface between control visualization and the controllers O module for digital and analog inputs In some cases a configuration of the connections and or interfaces must be made what is described in the in dividual connections and or interfaces See 7Ethernet interface X2 page 39 See ZO
55. on installation Ue Uz VDC VDC X2 X1 pT PP PCB Further pT PP PCB H X5 11213 X7 11213 X6 113 Power supply for electronics Schematic presentation Power Plane pT PP PCB Further pT PP PCB or One time on pT CUR Rev 2 00 02 Technical changes reserved 34 Chapter 5 System Configuration 5 6 1 Connecting cable sensor Each Power Plane pT PP PCB has slots for 2 Controller Cards HCC 06 16 S Therefore 2 6 Sensor inputs can be connected on the rear side of the Power Plane The connecting cable Sensor must be lt 30 m long The connecting cable sensor must be shielded Cables must have a wire end ferrule for connection to screw terminal Internal reference junction When using the present reference junction Standard on the power plane pT PP PCB the con A nection of the sensor is made with an appropriate compensating cable of the corresponding ther mocouple observe polarity To use Not part of delivery External reference junction When using an external reference junction which is located at the terminal point of the compen sating cable on Controller Unit pT CUR use copper CU wires with a minimum cross section of 0 25 mm and shielding The connecting cables for sensors may only be connected in de energized status of System pro fiTEMP Sensor on Power Plane pt PP PCB X1 Installation Sensor on Power Plane pt PP PCB X2 etc installation The zones are consecut
56. onfiguration Tool flexotempMANAGER or external PLC parameters must be set when different from default setting werden muss mussen Generally applies The address is binary coded and can be set between 1 127 gec by DIP switch The address must be unique for System profi EMP Gaps in the CAN address setting by DIP switch are feasible After setup the zones are numbered consecutively without gaps The following exceptions apply when setting the CAN address Only HCC 06 16 S card DIP switch 8 set to ON in combination with any DIP switch setting is equivalent to CAN address 127 dec Only pT CUR Device ID DEFAULT all DIP switches set to ON resulting IP 192 168 0 220 When the Control Unit pT CUR is connected by interface an interface specific base part address CP01 NodelD CP06 IP CPO9 CP12 can be added to the address NodelD IP by Project Setup and Configuration Tool flexotempMANAGER Show context menu by using the secondary mouse key in the project planning and configuration tool flexotempMANAGER and select menu item lt Start ad dress scan gt Is there still no component created see Project Setup and Configuration Tool flexotempMANAGER Operation chapter Create projects Activate by code number from external PLC iH setup by key CONFIG on Controller Unit pT CUR Press the key CONFIG on the Controller Unit pT CUR as long ca 3 5 sec as the LED CONFIG starts flashing address scan i
57. ould disappear after a short time Check sum error in EE Replace Controller Unit pT CUR PROM EEPROM defective Function and or signal Data fault OOO Flashing Blink code 2 3 Channel data error slave OOO ERR 4 5 6 LOCO conric Description A check sum is determined for the channel parameters of the Controller Card HCC 06 16 S Is for some reason for one of these parameters an error detected that can not be corrected the Controller Card generates a channel data error Reason Error cause solution Check sum error in EE Check parameters PROM EEPROM OK Edit any channel parameter P Error should disappear after a short time Check sum error in EE Replace Controller Card HCC 06 16 S PROM EEPROM defective Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 69 Start up and Service manual System profiTEMP Function and or signal Data fault OK SIO Flashi Blink pete 99 System data error pT Cur OOO ERR 4 5 6 L300 conric Description A check sum is determined for the system parameters of the Controller Unit pT CU PCB Is for some reason for one of these parameters an error detected that can not be corrected the Controller Unit generates a system data error Reason Error cause solution Check sum error in EE Check parameters PROM EEPROM OK Edit system parameter SP03 Error should disappear after a short time Check sum error in EE Replace Controller Unit pT CUR PROM EEPROM defect
58. plies with EN 61010 1 VDE 0471 1 protection class over voltage category I from HW number 000010 on over voltage category Ill contamination class 2 operating voltage 300 W Housing and terminal IP OC Complies with EN61326 1 EN 61010 1 The device complies with the European Directives for electromagnetic compatibility complies with EN 61326 1 and low voltages complies with EN 61010 1 cTUVus Certificate CU 72142541 01 based on UL61010 1 2017 CAN CSA C22 2 NO 61010 1 12 By interface master component pl CUR pT DU pi DC pi Cu Power supply for electronics U Cable length lt 30m Sensor cables Cable length lt 30 m use shielded connecting cables VO cables connecting cables for external Cable length 20 m reference junction on pT CUR d_pT HOC 06165_1502qb 2 Rev 2 00 02 Subject to technical changes 16 Chapter 5 System Configuration 5 System Configuration The basic system design is explained in the Start up and Service manual using a pT Rack S Swing Mini The implementation of the number of zones can vary The following work should be performed prior to commissioning of the system A A In all cases where the adjacent symbol is to see on the device note the safety instructions necessarily on the System profiT EMP identified by this symbol sign label In all cases this start up and service manual must be consulted Warning Possibility of General warning electric shock sign If the Syste
59. pplied must be connected to the card pT CUR before plugging into the pT Rack Installation pT CUR Plug the wired card pT CUR into the left front side of pT Rack Front Side pT Rack Rev 2 00 02 Technical changes reserved 21 Start up and Service manual System profiTEMP Installation pI CUR NOTE To make the connection cables more vis ible the insulation board was removed in this view Before fixing the card pT CUR into pT Rack it is necessarily to connect it to card pT CUR again A Plug card pT CUR into guide brack ets top bottom B Lead the connecting cables of pT CUR gently through frame and Power Plane on the rear side of pT Rack Installation pI CUR NOTE In this view the insulating board is screwed with card pT CUR A Move card pT CUR into guide brack ets top bottom until the front panel fits with the frame B Always make sure that the connect ing cables of pT CUR are not stuck be tween frame and Power Plane Rev 2 00 02 Technical changes reserved 22 Chapter 5 System Configuration Installation pI CUR Lock card pT CUR top bottom Front Side pT Rack Strain relief Do the plugs of pT CUR have a screw lock the plug must be tightened with the screws of the counter plug The cable lengths and the strain relief shall be designed such that terminals of the low voltage side e g sensors etc after loosening can not touch terminals contacts of the power section
60. riant HUB The other Ethernet interface enables beside 7Ethernet interface X2 page 39 a simultaneous connection e g of a Touch panel by Ethernet TCP IP RJ45 socket As Touch panel TEMP Touch can be used with the hot runner controller operation software TEMPSoft2 6 6 OPTION USB X3 Ordered variant USB Data im export can be done by the USB port The USB stick can be controlled by code numbers send by a superior control system 10 programs can be stored on loaded from USB stick A program means a data set with all parameters of all zones of a hot runner controller Export of a service file is planned In the service file are important characteristics and data of the hot runner con troller saved which help in error analysis In the case of service export service file from the hot runner controller on USB stick and transfer it to manufacturer supplier Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 41 Start up and Service manual System profiTEMP 6 7 OPTION Communication Digital in outputs X4 X5 By X4 X5 are 4 digital inputs and 4 digital outputs are available and for communication exists a serial data inter face RS232 RS485 Digital input 1 4 0 30 VDC Low level 0 1 VDC High level 4 30 VDC Imax 12 mA at 30 VDC Digital output 1 4 10 30 VDC 100 mA at Ta 25 C X4 26 X5 17 same signal as X8 5 6 7 1 OPTION Digital in outputs X4 Ordered variant IOF X4 Communication Digit
61. rvice GmbH as a manufacturer within the meaning of ElektroG Electrical and Electronic Equip ment which implements the European WEEE directive 2002 96 EC in German law is registered under number WEEE registration number DE 66448978 In this case the components of the System profi TEMP are considered Rev 2 00 02 Technical changes reserved 7 8 Chapter 3 System profiTEMP Hot Runner Controllers which match and adapt 3 System profiTEMP Hot Runner Controllers which match and adapt Your advantages are obvious Seamless integration in the operation logic of the injection molding machine Robust and field proven control algorithms Space saving gain in ease of use and consistent product quality by Connecting Diagnostics Each time at switch on the electric system is checked Prevents overmolding Mold check Complete diagnosis of electric systems including wiring Heat n Dry For a longer lifetime of your heating elements Easy maintenance LED s assist in diagnosing Heater control Control of cable break short circuit of heating coil heater breakdowns and insulation defects a oon Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH Start up and Service manual System profiTEMP 3 1 Scope of supply Generally System profiTEMP consists of the following components pT Rack here type S pT CUR HCC 06 16 S profi EMP pT Rack 02 04 06 08 Slots for controller cards W F
62. s running The LED CONFIG flashes as long as an address scan is running The LED CONFIG stops flashing when the address scan is completed which can last up to several minutes Rev 2 00 02 Technical changes reserved 52 Chapter 7 Setup Information on this topic are in the operating instructions Operation Project Setup and Configuration Tool flexotempMANAGER Operation Information on this topic are in the parameter description Parameters barameter Hot Runner Controller profiTEMP Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 53 Start up and Service manual System profiTEMP 7 1 at system rebuild See chapter 7System Configuration page 16 DIP switch setting Execute and or check DIP switch setting 1 127g for single Controller Cards HCC 06 16 S Activate address scan determi A setup on the Controller Unit pT CUR see 7Activate setup page 51 reads nation of system configuration the addresses set for the Controller Cards HCC 06 16 S and determines the system configuration Set parameters Set parameters by project planning and configuration tool flexotempMANA GER or by own control system 7 2 at replacement of Controller Card HCC 06 16 S DIP switch lt gt 0 Here a Controller Card HCC 06 16 S is replaced by a equivalent spare Controller Card HCC 06 16 S The CAN address set for the original Controller Card HCC 06 16 S must be set for the spare Controller Card HCC 06 16 S DI
63. t up and Service manual System profiTEMP 2 Security References For the System profiTEMP hereinafter referred to as device consisting of see 7Scope of supply page 9 the following safety instructions must be observed Before installation handling or operation of the device please read through this start up and A service manual completely and carefully 2 1 Security References for User All persons responsible for the mounting start up operation maintenance servicing of the device have to be skilled appropriately consider this start up and service manual exactly regard this start up and service manual as part of the product m maintain this start up and service manual during lifetime of the product pass this start up and service manual to all successive owners or operators of the product make sure that every obtained amendment is integrated in this start up and service manual Please note the following safety instructions necessarily for protection against electric shock risks of injuries and fire Before start up adhere strictly to the local safety regulations as well as the safety instruction Consider the regulations for prevention of industrial accidents for electrical installations and equipment by govern ment safety organization in industrial facilities Do not throw packaging material careless away thermoplastic foil styrofoam parts etc may get dangerous for persons The device must be installed
64. te Temperature control Measurement input leakage current mea surement Measurement range Resolution Accuracy of measuring Protection equipment Reversed polarity of power supply Overload protection Disconnection of power outputs in case of excess temperature Data interface CAN field bus Power supply for electronics U Fuse protection for electronics Current consumption at 24 VDC Power supply Heating Fuse protection load circuit Ambient temperature limit Atmospheric humidity limit Mounting Dimensions H x W x D in mm Weight in kg Electrical security Protection type Electro Magnetic Compatibility EMC CE marking Standards General Software update Connecting cables In pre assembled pT Rack pT PP PCB line bar fan Number 6 screwed terminal Combicon 3 81 Fe CuNi type L 35 500 Fe CUNI type J 35 5009C Ni CrNi type K 35 900 C lt 1K Reversed polarity of power supply diode over voltage temperature input electronic detection and signaling Number 6 Faston flat cable plug 6 3 2730 VAC 15 4 per zone dissipation loss per zone at 15 A max 20 W At ambient temperatures gt 50 C max output power 20 KW per HCC card Phase angle or pulse group output zero crossing switching Fuse protection on card 2 pole 6 3 x 32 mm Lise ONLY fuses of type SIBA FF 164 Art No 7012540 16 Fuse protection current registration leakage current measurement current transformer on pT PP PCB
65. te setup page 51 reads nation of system configuration the addresses set for the Controller Cards HCC 06 16 S and determines the system configuration Set parameters Check specification of parameters for the new zones by project planning and configuration tool flexotempMANAGER or adjust the number of zones by own control system Rev 2 00 02 Technical changes reserved 54 Chapter 7 Setup 7 5 atremoving of Controller Card HCC 06 16 S highest DIP switch setting Here the Controller Card HCC 06 16 S with the highest DIP switch setting is removed DIP switch setting Activate address scan determi nation of system configuration Set parameters Rev 2 00 02 Technical changes reserved Remove the Controller Card HCC with the highest DIP switch setting A setup on the Controller Unit pT CUR see 7Activate setup page 51 reads the addresses set for the Controller Cards HCC 06 16 S and determines the system configuration The zones for the removed Controller Card HCC 06 16 S were omitted by proj ect planning and configuration tool flexotempMANAGER or adjust the number of zones by own control system PSG Plastic Service GmbH 55 Start up and Service manual System profiTEMP 8 Status display Trouble Shooting 8 1 Status display overview On the card pT CUR are 9 LED s available The status of System profiT EMP can be identified by the blink code light In monitor Project setup Project setup Slave missing mod
66. the Power Plane The cable cross sections of all connecting cables must be installed based on valid national standards of the installation location and according to the appropriate type of installation Con A sider the maximum ambient temperature at selection of cables Cable with quick connect receptacle 6 3 0 8 fully insulated for connection to Faston flat cable To use plug Not part of delivery The connecting cables for Heating may only be connected in de energized status of System pro fiTEMP Connecting cable Heating on Power Plane pt PP PCB 01 06 O1N O6N Installation Connecting cable Heating on Power Plane pt PP PCB 07 012 O7N O12N etc installation The zones are consecutively numbered 1 250qge due to the setting of the DIP switch 1 127 dec on the Controller Card HCC 06 16 S See chapter 7Setup page 51 pT PP PCB 4 pT PP PCB 3 pT PP PCB 2 pT PP PCB 1 x Connecting cables Heating z z z D cas zza a on Faston flat cable plug 01 06 O1N z559 0550 O6N and or 07 012 O7N O12N per I I 42 N g Power Plane pT PP PCB Strain relief The cable lengths and the strain relief shall be designed such that terminals of the low voltage side e g sensors etc after loosening can not touch terminals contacts of the power section and vice versa Pay attention to the safety instruction on circuit board Rev 2 00 02 Technical changes reserved PSG Plastic Service GmbH 37 Start up a
67. tory Rev 2 00 02 Technical changes reserved 43 46 47 47 47 49 51 73 74 15 19 76 PSG Plastic Service GmbH Start up and Service manual System profiTEMP 1 Typographical Conventions symbols and conventions are used in this document for faster orientation for you Symbols A Caution p Note Example Reference FAQ To use Installation Equations lt View gt Project A A Warning Possibility of General warning n a electric shock sign With this symbol references and information are displayed which are decisive for the operation of the device In case of non compliance with or inaccurate compliance there can result damage to the device or injuries to persons The symbol refers to additional information and declarations which serve for improved understanding With the symbol a function is explained by means of an example With this symbol information in another document is referred to Here FAQ Frequently Asked Questions are answered specifies which materials components etc are to be used Indicates how the installation should take place for example order arrange ment etc Cross references are marked with this character In the pdf version of the doc ument the objective of the cross reference is reached via the link Calculation specifications and examples are represented in this way Menu points e g view are represented in this way Windows e g

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