AHC Controller Operation Manual

AHC Controller Operation Manual
Important Safety Instructions
Name and role of each part
Elements of LCD touch panel
PROCEDURE UP TO MOLDING
AHC Controller
Operation Manual
Installation of controller/ Inputting set values/
Procedure for starting molding/
Flow Chart for Molding Start-UP
ADVANCED USAGE
Heat retention and monitoring temperature/
Timer/ Status monitoring function/ Key lock/
Storage function
MAINTENANCE
Air filter cleaning/Fuse change
Please thoroughly read this manual before use.
Please retain this manual in an easily accessible place
for future reference.
TROUBLESHOOTING
APPENDIX
Controller Specification/ Standard for Heater out put/
External interface table / Drawing list
V1.00
Types of controllers and symbols
The marks shown below are used in this manual to explain the respective types of controllers.
ˬ‒
˰!
˲!
ˬ‒
The TP type controllers are explained.
The TP type controls molds with built-in spears. The type D, G, ESP, and B spears can be used.
The controller comes in four types – AHC2TP2S, AHC2TP2T, AHC4TP4S, and AHC4TP2T.
The VP type controllers are explained.
The VP type controls molds with built-in valves, etc. In addition to valves SVP, SVY, SV32, and
SV25, other companies’ valves (200-240 V heater) can be used. The type of controller is
AHC2VP2
Other marks
The other marks used in this manual are explained. The marks shown below are used in this manual to
indicate important matters. Be sure to follow these instructions.
≆
WARNING
Mishandling can cause death or serious injury. Be sure to observe these warnings
to use the machine safely.
≆
CAUTION
Mishandling can cause injury or property damage.
cautions to use the machine safely.
IMPORTANT
Be sure to observe these
Important matters that should be observed during operation are described. Be sure
to read the explanation to prevent failure of the product, damage, and mishandling.
REFERENCE
Matters that serve as references and supplementary explanations are shown.
ɡTable of Contents
Important Safety Instructions㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
2
Name and role of each part㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
4
PROCEDURE UP TO MOLDING
Installation of controller㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 8
Inputting set values㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 9
Initial screen㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 9
Initial setting㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 9
Main setting㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 11
Set value inputting and numeric keypad㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 13
Operation㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
Procedure for starting molding㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
Other operations㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
Flow Chart for Molding Start-UP㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
14
14
16
17
Timing Chart for the Tip Timer㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 17
ADVANCED USAGE
Other settings㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
Sub setting㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
Status monitoring function㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
Special functions㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
Storage function㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
18
21
24
27
MAINTENANCE
Periodical maintenance㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
Air filter cleaning㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
Replacement of backlight of LCD touch panel㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
Fuse change㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯
18
29
29
30
30
TROUBLESHOOTING
Troubleshooting for Warning Messages㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 32
Warning Code List㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 32
When no message appears㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 38
APPENDIX
Specification㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 41
Drawing List㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 45
1
Important Safety Instructions
Following the safety tips mentioned bellow should assure safe operation.䎃 䎃
Handling the system with the way which is not described in this manual may occur an unexpected
accident, fire or electric shock.
≆
WARNING
Installation
㪝㫆㫃㫃㫆㫎㩷 㫋㪿㪼㩷 㫊㪸㪽㪼㫋㫐㩷 㫋㫀㫇㫊㩷 㫄㪼㫅㫋㫀㫆㫅㪼㪻㩷 㪹㪼㫃㫃㫆㫎㪅㩷 㪦㫋㪿㪼㫉㫎㫀㫊㪼㩷 㫋㪿㪼㫉㪼㩷 㫄㪸㫐㩷 㫆㪺㪺㫌㫉㩷 㪸㫅㩷 㪽㪸㫋㪸㫃㩷 㪸㪺㪺㫀㪻㪼㫅㫋㩷 㫆㫉㩷 㪸㩷
㫊㪼㫍㪼㫉㪼㩷㫀㫅㫁㫌㫉㫐㪅
Only matched heaters can be connected to the respective controller.
Spears can be connected to TP type controller while Valves (200V rated heater) can be
connected to VP type controller.
Otherwise there may occur an electric shock caused by a short circuit, also fire, probe burn
out, controller failure caused by abnormally high heat generation.
Do not set up the controller where it is exposed to water, oil, or some kind of liquid.
Failure to follow these instructions may result in fire or electrical shock.
Follow the specification on voltage, capacity, frequency, and phase for power supply.
Failure to follow this instruction may result in fire, electrical shock, or damaging the controller.
Electric
Power supply
The cord must be adequately grounded.
Inadequate grounding could result in electrical shock or operation error.
Properly and securely tighten screws when you connect power cord to the electrical
terminal.
Failure to follow this instruction could result in electrical shock.
Do not damage the power cord and the wire.
Do not put heavy objects on the power cord and the cable.
Do not force bending, twisting or pulling on the power cord and the cable.
Keep the power cord and the cable away from heat such as a heating cylinder of the molding
machine.
Failure to follow these instructions could result in fire or electrical shock.
Replace the power cord and the cable when damaged or frayed.
Be sure to insert the connector thoroughly and lock it.
Failure to follow these instructions could result in fire or electrical shock.
Immediately turn the power off by turning the circuit breaker off if smoke, extreme heat,
or unfamiliar noise or smell is detected, and contact our service office.
It could result in fire or electrical shock.
Connection
Molding
Do not insert any foreign objects through any openings of the controller such as a vent.
Failure to follow this instruction could result in fire, electrical shock or damaging the controller.!
Do not touch the liquid when the liquid crystal display is damaged.
It may contain harmful and irritant substance. If in eyes or contact with skin, flush thoroughly
with water immediately for 15 minutes and call a physician. If in mouth, flush with water
immediately and call a physician.
Do not repair or remodel without consulting this manual.
Use only specified parts when repairing the controller.
Failure to follow this instruction could result in fire, electrical shock, or damaging the controller.
Cut the power off by turning the circuit breaker off when it is struck by disaster such as
power failure or earthquake.
Failure to follow this instruction could result in fire or electrical shock by unexpected system
operation.
Turn the power off by turning the circuit breaker off when you need to check inside of
the controller for repair or service purpose.
Failure to follow this instruction could result in electrical shock.
Maintenance
The molding must be adequately grounded when it is being heated without the molding
machine.
Inadequate grounding could result in electrical shock.
2
≆
CAUTION
Follow the safety tips mentioned bellow. Otherwise there may occur a injury or a physical
damage.
Installation
The controller should be placed on a level and stable surface.
Failure to follow these instructions may result in personal injury or damaging the controller and
adjacent machines.
Follow this manual for environmental specification.
Do not store or operate the controller where it will be exposed to excess moisture, heat or
dust.
Failure to follow this instruction may result in fire, damage to the controller or operation error.
Do not block the vent.
Failure to follow this instruction may result in fire by overheating the unit.
Connection
Do not connect/disconnect the connector when power is on.
Failure to follow this instruction may result in electrical shock or personal injury
Make sure to follow the specification when connecting the signal cable.
Failure to follow this instruction may result in electrical shock, fire, or damaging the molding
machine or controller.
Molding
When molding with the B-Spears is finished, make sure to turn off the Manifold heater
before the spear heater.
Failure to do so will damage the B-spear.
Do not touch the circuit breaker and the switches with wet hands.
Failure to follow this instruction may result in electrical shock or damaging the controller
Do not sit, stand on or put heavy objects on the air controller.
Failure to follow this instruction may result in electrical shock, damaging the controller or
personal injury.
Do not remove a cover when power is ON.
Do not operate with a cover removed.
Failure to follow these instructions could result in distraction to the temperature control, and it
cause unstable operation or damaging the controller.
Also could result in the destructive noise to the control unit, and it cause in unstable operation
or damaging the controller.
Maintenance
Clean or replace the filter semi-annually.
The clogged filter may cause the higher temperature and it may result in operation error, fire or
damaging the controller.
3
Name and role of each part
Front
Power breaker
Used to turn ON/OFF the power.
Air filter
Prevents dust from entering the controller.
LCD touch panel
A display with a touch panel for operation of the controller
Back
Cooling fan
Cools the inside of the controller.
Input/output connector
Used to connect the controller and mold by
a junction cable.
4
Tip timing signal input cable
Used to connect the controller and molding
machine by a tip timing signal cable.
Valve timing signal input connector
Used to connect the controller and
molding machine by a valve timing signal
cable. ( ˲ˬ only)
External interface connector
Used to connect the controller and molding
machine, etc. by a digital I/O signal cable.
Inner part
SSR
Control PCB
Quick-blow fuse
Transformer voltage㩷
changeover terminal
5
Elements of LCD touch panel
̪㧝
ˬ‒ shows up on the “Valve” screen.
̪1㧚Only ˲!
6
7
Installation of controller
Controllers are precision machines. Take the environmental condition into consideration when
installing a controller in order to use it under the best condition.
Operating environment
Install the controller on a flat horizontal place, and keep the exhaust port open.
The range of the ambient temperature and humidity should be as follows:
Temperature:
Humidity:
0-40°C
Up to 90%RH (Dew condensation not allowed)
Avoid installation in places with excess steam, oil vapor, smoke, corrosive gas, or inflammable gas.
Connection of power and ground
The range of supply voltage and frequency should be as follows:
Voltage:
Frequency:
Within ±10% of the voltage shown on the rating plate of the controller
50 or 60 Hz
Be sure to connect the ground wire to the grounding terminal for Type D Grounding (former Type 3
Grounding).
Connection of respective cables
Connect one end of the junction cable to the connector at the back of the controller and the other
end to the connector box of the mold.
Connect the end of the tip timing signal cable with a connector to the TIP TIMING connector of the
controller. Connect the other end to the [Mold opening start signal] or [Mold opening completion
signal] of the molding machine.
Connect the end of the valve timing signal cable ( ˲ˬ only) with a connector to the VALVE
TIMING connector of the controller. Connect the other end to the [Mold closing start signal] or
[Mold closing completion signal] of the molding machine.
IMPORTANT
The timing signal input cable comes in two types – one for contact input and the other for voltage input.
Check the specifications.
REFERENCE
The tip timing signal cable is the same as the valve timing signal cable.
8
Inputting set values
Set values only for [Initial setting] and [Main setting] of the AHC controller, and the basic molding
operation is possible with other settings remaining unchanged.
Initial screen
PROCEDURE UP TO MOLDING
Turn on the power to the controller, and [Initialize] blinks for several seconds in the lower left section of
the screen, and the screen shown at left will appear.
The number of controlling points of the
controller is displayed.
Select a language to be used on the screen.
REFERENCE
: The language can be changed on the
basic setting screen as well.
→ Initial setting: Basic setting (p.10)
Initial setting
Setting the zones to use
This function permits setting of the zones to use for molding.
Individually set the zones of the manifold to use.
:
Set this for zones for output and error
detection.
Set this for zones that are not used.
:
Individually set the zones of the body to use.
:
:
IMPORTANT
Set this for zones for output and error
detection.
Set this for zones that are not used.
Unconnected zones
When
is selected for unconnected zones, a heater disconnection error will be detected. Be sure to select
unconnected zones.
for
REFERENCE
For the zones for which
is selected,
will be indicated in the box of the zone number on the main setting screen.
9
Basic setting
Set the unit of temperature.
:
:
Celsius (°C) will be selected.
Fahrenheit (°F) will be selected.
REFERENCE
: The set value is automatically
converted when the unit is changed.
Set the delay off function.
:
The delay off key is displayed on the
main setting and sub setting screens.
: The delay off key is not displayed on
the main setting and sub setting
screens.
→ Other operations (p.16)
REFERENCE
:
Keys can be selected in the T P type only.
Select the language on the screen.
: Display in Japanese
: Display in English
: Display in Chinese
REFERENCE
: The screen configuration is almost the
same in any language.
IMPORTANT
Delay off function
Because of the structural nature of the B type, the temperature around the spear lowers earlier than that of the manifold when
the manifold and body heaters are stopped simultaneously, possibly causing breakage of the spear (tip bending).
Therefore, it is necessary to lower the manifold temperature first and then lower the body temperature. The delay off function
automatically conducts that operation.
(1) The manifold output is stopped and the body temperature remains at the heat-retention temperature.
(2) The temperature of all the manifold lowers below 100°C, or all heaters stop output when 30 minutes pass.
[Temperature]
Set temperature
of body
Set temperature
of manifold
Stand-by temperature of body
100°C
100°C
Heat-up
10
Delay off
Stop
[Time]
Main setting
Manifold setting
Set the manifold temperature.
The setting range is [0-450°C].
REFERENCE
PROCEDURE UP TO MOLDING
The present measured temperature is displayed.
: [999] is displayed when the sensor is not
connected.
The present output value is displayed.
The main setting screen is scrolled.
REFERENCE
:
㨂㧼 alone permits shift to the valve
screen.
REFERENCE
Standard setting
When D type spear is used: The molding machine cylinder temperature ±0°C to +20°C
When B type spear is used: The molding machine cylinder temperature - 20°C to +0°C
Body setting
Set the body temperature.
The setting range is [0-450°C].
The present measured temperature is displayed.
REFERENCE
: [999] is displayed when the sensor is not
connected.
The present output value is displayed.
˰ˬ :
˲ˬ :
The current value [A] is displayed.
The output value [%] is displayed.
REFERENCE
The standard temperature setting is the molding machine cylinder temperature ±0°C to 50°C.
11
Tip setting
Set the pre-heating current.
: The setting range is [0.0-14.0 A].
: The setting range is [0-100%].
Set the main heating current.
˰ˬ : The setting range is [0.0-14.0 A].
˲ˬ : The setting range is [0-100%].
Set the delay time.
Set how many seconds later the main heater should
be turned on after the tip timing signal is input.
The setting range is [0.0-99.9 sec.].
Set the on time.
Set the heating time of the main heating current.
The setting range is [0.0-99.9 sec.].
The present output value is displayed.
˰ˬ : The current value [A] is displayed.
˲ˬ : The output value [%] is displayed.
REFERENCE
Standard setting
ˬ‒:
˰!
˲!
ˬ‒:
12
In general, set the timer so that the main heating will be started three seconds before injection starts and that it
will be stopped approximately when injection is completed.
Refer to the timing chart of the tip timer for the detailed method of setting.
→ Example of timing chart of tip timer (p.17)
In general, start main heating three seconds before injection starts.
Adjust the value set in the timer so that the main heating will stop when pressure holding stops.
Valve setting
Set the delay time.
Set how many seconds later the valve should be
opened after the valve timing signal is input.
The setting range is [0.0-99.99 sec.].
Set the opening time.
PROCEDURE UP TO MOLDING
Set the time during which the valve should be open.
The setting range is [0.0-99.99 sec.].
The valve is opened manually.
:
:
Open
Close
REFERENCE
: Operation is possible only when
heat-up has been completed.
The condition of the valve is displayed.
: The valve is open.
: The valve is closed.
REFERENCE
The standard number of valve control circuit is one. (A maximum of four circuits can be supported on the setting screen.)
The valve solenoid driving circuit (24 DVC) is provided as standard equipment.
In general, make adjustment so that the valve will open right before injection starts and that it will close when holding pressure
is completed.
Turn tip heater ON when opening or closing the valve.
Set value inputting and numeric keypad
The method to input a set value and operate the numeric keypad is explained using the manifold
screen.
Touch the set value key to input.
ˍ
• The cursor of the set value will be shown in reverse
video, and the numeric keypad will appear.
• Press some other set value key while the numeric
keypad is being displayed, and the position of the set
value will shift.
Input a set value from the numeric keypad.
ˎ
:
The input value is entered.
:
The input value is set for all zones.
:
The numeric keypad disappears.
REFERENCE
When a value beyond the input range is input and
is touched, the value will be changed to a maximum value and
entered.
13
Operation
The operation key to operate the controller can be operated on the [Initial setting] and [Main setting]
screens.
Procedure for starting molding
1. Touch the Heat Up key.
The power will be supplied to the heater and the
temperature will rise up to the set temperature.
:
Heater power ON.
:
Heater power OFF.
2. Completion of heat-up (Ready For Molding)
Heat-up is completed when the actually measured temperatures in all zones enter the temperature
monitoring range.
ˍ
The light of Ready icon comes on.
ˎ
The Ready dialog appears.
ˏ
Touch the Confirm key and close the Ready dialog.
REFERENCE
When the heat-up standby timer is set, the heat-up will be completed after the timer operation is completed.
→ Sub setting: Heat retention and monitoring temperature (p.18)
14
3. Tip heating
Tip heating is conducted.
:
Tip heating ON
:
Tip heating OFF
PROCEDURE UP TO MOLDING
The set main heating current is supplied manually to
the tip heater.
IMPORTANT
The standard tip heating time for starting molding is 10 seconds.
When the tip timing signal is taken from the mold opening signal, it is necessary to conduct initial tip heating manually.
Conduct a valve opening/closing test. ( ˲ˬ only)
When heat-up is completed, open and close the valve manually to confirm the operation.
The valve is opened manually.
:
All valves are opened.
:
All valves are closed.
REFERENCE
For protection of molds, the valve can be opened or closed only when heat-up has been completed.
IMPORTANT
When a valve with a tip is used, be sure to heat the tip before opening or closing the valve.
15
4. Icon
Error icon
It blinks when some error occurs.
The screen will change from [Status menu] to [Self
diagnosis] automatically.
Tip timing signal icon
:
:
The tip timing has been input.
There is no signal.
REFERENCE
: In general, input the mold opening start
signal or mold opening completion signal
of the molding machine.
Valve timing signal icon ( ˲!
ˬ‒ only)
:
:
The valve timing has been input.
There is no signal.
REFERENCE
: In general, input the mold closing start
signal of the molding machine.
Other operations
The mode shifts to the heat retention (Stand-by)
mode.
The temperature of the manifold and body is raised up to
the heat retention temperature.
: Heat retention (Stand-by) mode
: Heat-up (stop) mode
ψ Sub setting: Heat retention (Stand-by) and
monitoring temperature (p.18)
The mode shifts to the delay off mode.
(
only)
The mode shifts to the boost mode.
In order to facilitate molding start-up, the
body temperature is raised by as much as
the boost temperature.
: Boost mode
: Delay off mode
: Heat-up (stop) mode
→ Initial setting: Basic setting (p.10)
: Heat-up (stop) mode
→ Sub setting: Heat retention and
monitoring temperature (p.18)
The manifold temperature is lowered, and then the
body temperature is lowered.
REFERENCE
: The key will appear only when [ON] is
selected for the delay off function.
: The key will appear only when
the boost temperature is set.
REFERENCE
The display of the operation key in each status is shown below.
Stop
Heat-upᲢmolding)
Heat retention
(Stand-by)
16
Flow Chart for Molding Start-up (TP type)
ˍ
Prepare the molding machine for molding.
(Mold open)
ː
Select [Automatic] or [Semi-Automatic] and
close the safety door.
Injection
Controller
ˎ
Prepare the controller for molding.
ˏ
Start Manual Tip Heating. ψ
PROCEDURE UP TO MOLDING
Molding Machine
Injection begins 5䌾10 sec.
after Manual Tip Heat starts.
Open Mold
Start the timing timer ψ
Tip Signal[Enable ]
Ejection Item
Start the timing timer
Close
࡮Stop the timing timer
࡮Start Tip Heat Timer on
Injection
࡮Timer on
Open Mold
Timer off. Finish Tip Heat
Tip Signal[Enable]
REFERENCE
Generally the timer is set to turn the main heater on 3 sec. before the injection starts, and turn the main heater off when the
injection is completed. Set the main heater on 3 sec. before injection, and off when the injection is completed.
Timing Chart for the Tip Timer
Open
Remove
1.5sec.
2sec.
Close
Injec
1.5sec.
Stand
Open
Remove
Close
1.5sec.
2sec.
1.5sec.
Timing
timer
Tip Heat Timer
Timing
timer
2.5sec.
4.5sec.
2.5sec.
Tip Heat
Tip Signal[Enable]
Injec
Stand
Tip Heat Timer
4.5sec.
Tip Heat
Tip Signal[Enable]
REFERENCE
A desirable tolerance for Mold Open + Remove Item + Mold Close time is under 0.1sec.
17
Other settings
Sub setting
Heat retention and monitoring temperature
The setting temperature for operation of the operation key and the monitoring temperature during
molding are set. Set the heat retention (Stand-by) temperature.
The setting range is [0-450°C].
REFERENCE
: This temperature is set so that the resin
will not be burned when molding is
stopped temporarily.
Set the temperature monitoring width.
The setting range is [0-999°C].
ˍ
ˎ
When the actually measured temperature of all
zones enter the temperature monitoring range
during heat-up, the soak timer begins operation.
When the soak timer stops operation, the
heat-up completion is displayed. ψ
When the temperature changes beyond the
temperature monitoring range during molding,
the temperature error is displayed, and the
machine conducts operation according to the
procedure selected to cope with the error.
Set the boost temperature.
Set a relative temperature with respect to the set
temperature.
The setting range is [0-100°C].
When the boost temperature is set, the boost key will
appear.
18
REFERENCE
: This function is provided to facilitate
gate opening when starting molding.
Timer
Set various timers.
Set the heating up delay time.
Turn on the heater power, and the timer begins operation,
starting heat-up when the operation is completed.
REFERENCE
: Touch the heater power key, and the
heating up delay timer operates. When
the operation of the heating up delay timer
is completed (time-up), heating-up
operation starts.
ADVANCED USAGE
The actual values set in
respective timers are displayed.
Set the watching heat-up time.
The heat-up time is monitored, and an error is displayed
when heat-up is not completed even if the preset time
comes. REFERENCE
: Detection of heater and sensor
disconnection is possible.
Set the soak time.
Input the tip heat on over time.
This timer automatically stops tip
heating.
When the temperatures of all zones enter the
temperature monitoring range during heat-up, the timer
begins operation, preventing heat-up completion until the
operation is completed.
REFERENCE
→
: The function is the same as the cold
start-up prevention timer of the molding
machine.
Set the suspend time.
The timer operates at all times during heat-up completion.
The timer is reset by the operation of the controller or input
of a timing signal. The operation shifts to heat retention
(Stand-by) when the timer operation is completed.
: The operation delay timer is used.
: The operation delay timer is not used.
When the molding machine stops due to an
REFERENCE :
error, the timer shifts the operation to heat
retention (Stand-by).
REFERENCE
Timer operation
Timer
Start
Heating up
delay timer
Heater power ON
Watching
heat-up
timer
Soak timer
Suspend
timer
Tip heat on
over timer
Heat-up start
All zones enter
temperature monitoring
range.
Heat-up completion
Tip heating ON
Operation when time is over
Resetting condition
Heat-up start
0-99 min.
• Heater power OFF
• Heat-up time monitor error
Heat-up completion
Heat retention ON
Tip heating OFF
Setting
range
Heat-up completion
Error
At least one zone is out
of the temperature
monitoring range.
• Controller operation
• Timing signal input
1-99 min.
0-30 min.
1-99 min.
1-120 sec.
19
Option
Set various values for molding.
Set the 2-step heat up.
The body is on standby at the heat retention
temperature until the manifold heat-up is completed.
:
:
REFERENCE
The 2-step heat-up function is used.
The 2-step heat-up function is not used.
: This
function
raises
the
probe
temperature when the manifold heat-up is
completed, which is slower than general
heat-up speed, in order to prevent resin
burning in the body.
Set the auto heat up.
When the controller power is turned on, the system
automatically enters the heat-up state.
:
:
REFERENCE
The auto heat-up function is used.
The auto heat-up function is not used.
: Used together with the calendar timer, etc.
of the molding machine.
Set the manifold soft heat up.
The temperature will rise according to a certain heat-up
curve pattern (30°C/min.) when stress should not be
applied to the heater.
REFERENCE
:
The manifold soft heat-up function is used.
:
The manifold soft heat-up function is not
used.
REFERENCE
: This function is also effective when the
heater absorbs moisture and the earth
leakage breaker trips.
2-step heat up function
[Temperature]
Set temperature of
body
Set temperature of
manifold
Manifold temperature monitoring range
Stand-by temperature
of body
Completion of
manifold
20
[Time]
Status monitoring function
Self-diagnosis function
The status of the system is monitored at all times during operation.
When an error occurs, the screen will automatically change to the self-diagnosis screen, entering the
state selected for troubleshooting in advance.
The error signal of the digital I/O connector is output as well
Display of system error
ADVANCED USAGE
The system error that occurred in the controller is
displayed.
Error reset key
The error state is cancelled.
REFERENCE
: When the cause of the error has not
been removed, the error code and error
message appear again.
Display of PW1
Error zone
Error message
When an error occurs primarily in the mold and
junction cable, “Error code, “Error message,” and
“Error zone” are displayed.
Error code
REFERENCE
Kinds of errors to monitor
Sensor disconnection ··············································· This error is detected when the sensor is disconnected.
Crossed sensor error ················································ The response error between the sensor and heater is detected.
Sensor reverse connection error ······························ The erroneous connection of the + and – terminals of the sensor is
detected.
Temperature error ····················································· The temperature out of the temperature monitoring range during molding
is detected.
Heater burned out····················································· This error is detected when the heater is disconnected.
Overcurrent protection circuit operation···················· This error is detected when the overcurrent protection circuit (OCP)
operates.
Heat-up time watching error ····································· This error is detected when the heat-up time exceeds the value set in the
timer.
Air pressure drop error·············································· The air pressure drop signal is monitored.
External error ···························································· The contact input is monitored.
Kinds of system errors
Output device breakage error··································· Breakage of the output device in the state of short circuit is detected.
Watchdog timer error ················································ The error of the control board program is detected.
M24C64 communication error ·································· The error of the control board program is detected.
Gain non-adjusted error············································ The error of the control board program is detected.
21
ɡConditions to Detect Abnormality
Abnormality
Sensor Burned Out
Crossed Sensor
Sensor Reverse
Start
Finish
Observation Observation
Heat Up
Heat Up
Heat Up
Ready
Heat Up
Ready
Set Action
Manifold
Body
Emergency
action setup
٤
٤
Heat Off
٤
٤
Heat Off
٤
٤
Emergency
action setup
٤
٤
Tip
Heat Up
Temp. Monitoring
Ready
or
5
Heater Burned Out
Over Current
Protection
Watching Heat-Up
Time
External
Out Put Device
Burned Out
22
Heat Up
Heat Up
Emergency
action setup
˜
˰!
ˬ‒
٤
Heat Up
Heat Up
Emergency
action setup
˜
˰!
ˬ‒
٤
Heat Off
٤
٤
˜
˰!
ˬ‒
Heat Up
Ready
Heat Up
Heat Up
Action On
External Alarm
Controller On
Power Off
Heat Off ̪㧝
̪1. In case output device breaks down during short mode,output power cannot be turned off.
˰ˬ
Troubleshooting
Set the troubleshooting method.
Select the action on alarm.
:
:
The heat-up state is maintained.
Shifting to the heat retention (Stand-by)
state.
:
Shifting to the stop state.
→ Status monitoring function (p.21)
Select the action from ext. interlock.
The heat-up state is maintained.
Shifting to the heat retention (Stand-by)
state.
:
Shifting to the stop state.
→ Status monitoring function (p.21)
ADVANCED USAGE
:
:
: The external error signal is input through
the EXT. INTERFACE connector.
REFERENCE
Set the external error alarm output.
:
:
REFERENCE
An error signal is output when an
external error signal is input.
No error signal is output.
: This function does not loop the error
signal from the molding machine.
System operation history
The number of total shots of the controller and the number of operation shots after resetting are
displayed.
Total counter running hours
The running hours after shipment from the factory are
displayed.
Total counter shot
The number of shots after shipment from the factory is
displayed.
Resettable counter shot
The number of shots after resetting is displayed.
Used to reset the resettable counter.
23
Special functions
Selection of sensor
Set the sensor type.
Set the sensor type for the manifold.
:
:
The K type is set.
The J type is set.
Set the sensor type for the body.
:
:
The K type is set.
The J type is set.
IMPORTANT
Be sure to use a junction cable suitable for the selected sensor type.
Output fixed control (Regulated Control)
In order to continue molding even if the sensor is disconnected and temperature control is impossible,
fix the output value to tentatively continue molding.
Set the manifold output fixed control value.
The setting range is [0-100%].
Set the zone subject to manifold output fixed
control.
: Output fixed control is conducted.
: Temperature control is conducted.
Set the zone subject to body output fixed control.
: Output fixed control is conducted.
: Temperature control is conducted.
Set the body output fixed control value.
˰ˬ : The setting range is [0.0-4.0 A].
˲ˬ : The setting range is [0-100%].
IMPORTANT
Make a note of the output value during normal operation to provide for sensor disconnection.
Excessively high output will cause resin burning and mold breakage.
REFERENCE
Set
24
, and
will appear in the box of zone number on the main setting screen.
Key lock and password lock functions
The key lock function and password lock function are provided to prevent operation errors.
Set (Disable).
The lock function is not used in this state.
REFERENCE
:
is invalid.
ADVANCED USAGE
Set the key lock function.
All the keys including the operation key are locked.
Set the password lock function.
Unless the password is input, set values cannot be
changed. This function is used to protect all set
values.
Locking and unlocking procedure
ˍ
Touch
ˎ
Key lock function
.
Keep touching
for more than two seconds,
and Lock and Unlock will change alternately.
ˎ
Password lock function
Input a correct password on the screen that
appears when
is touched, and Lock and
Unlock will change alternately.
The input value is
entered.
The screen returns
to the original
screen.
IMPORTANT
The password is shown on the last page.
The status of the lock key changes.
3
:
:
Locked state
Unlocked state
25
Temperature control setting
For prevention of operation errors, the screen will change to the temperature control setting screen after
the password is input.
Touch the temperature
control setting menu.
Input the password to shift to the temperature control
setting screen.
The input value is entered.
ˍ
ˎ
The screen returns to the
original screen.
Self-tuning
The password is shown
on the last page.
IMPORTANT
Touch the menu.
operation
The temperature control constants of the manifold and body can be set manually. Do not change them
unless there is a problem with temperature control.
Set the manifold temperature control constant (PID).
REFERENCE
: Setting is possible when the self-tuning
function is off.
Set
for self-tuning.
Set the body temperature control constant (P.I.D).
REFERENCE
: Setting is possible when the self-tuning
function is off.
Self-tuning
operation
The controller automatically selects the temperature control constants of the manifold and body.
Set
for self-tuning.
Since constant setting is conducted automatically, the
respective P.I.D setting keys in reverse video will
disappear.
REFERENCE
: ˰ˬ conducts self-tuning of the manifold
only.
㧝㧜㧜
㧝 㧞 㧟 㧠
REFERENCE
The automatically set
constant is displayed.
: The numbers
REFERENCE
correspond to board
1-4 sequentially
from the left.
Temperature control constant (P.I.D)
P is the size of the proportional band. (400 = 40°C) Make P smaller, and the response will be better. However, excessively
small P may cause instability. When P is larger, the response will be deteriorated but the stability will improve.
I is the integration constant. Make I larger, and the continuous followingness will improve (offset removal is faster), but hunting
will result easily. It is recommended not to make I larger unnecessarily.
D is the differential constant. Make D larger, and the foresighted followingness will improve, stabilizing the temperature when a
6D spear is used. However, excessively large D may cause temperature fluctuation.
26
Storage function
Set value storage for each mold
Name the molding condition, and a maximum of 16 cases can be stored and called up.
The stored names are displayed.
The present value is stored.
of the mold No. to store.
ADVANCED USAGE
Touch
The stored set value is called up.
Touch
of the mold No. to call up.
Mold No.
Storing procedure
ˍ
Touch
of the mold No. to store.
Input an alphanumeric name, and touch
.
ˎ
:
Enter the input name to store the molding condition.
:
The screen changes to the name input (number) screen.
:
The screen changes to the name input (alphabet) screen.
:
Storing operation is stopped, retuning to the previous screen.
REFERENCE
A maximum of 12 characters can be input as a name to store.
27
Calling-up procedure
ˍ
Touch
of the mold No. to call up.
The set value dialog for each mold appears.
ˎ
:
The set value for each mold, which is displayed in the
dialog, is called up.
: Calling up is stopped, and the dialog is closed.
Mold No. display
The [Mold No.] is displayed when the stored set value for each mold is displayed.
The present mold No. is displayed.
The present mold No. is displayed.
REFERENCE
The [Mold No.] display will disappear when the set value is changed.
28
Periodical maintenance
≆ WARNING
Before maintenance
When inspecting the inside of the controller or changing parts, turn off the power breaker to stop power
supply to the controller, and then remove the cover from the controller, otherwise an electric shock or
fire will result.
REFERENCE
MAINTENANCE
It is recommended to make a note of the connection destination and installation position in order to prevent incorrect wiring or
installation.
Air filter cleaning
The filter can be removed for cleaning.
≆ WARNING
When the controller with a clogged filter is used, the temperature inside the controller will rise, not only preventing the controller
from delivering its performance sufficiently but also causing breakage of the controller or fire.
Washing air filter with water
When the filter cannot be cleaned by a vacuum cleaner, it is possible to remove it and wash it with water. When the filter is
washed with water, drain the water sufficiently and dry the filter before installing it again.
Water remaining on the filter will cause trouble.
IMPORTANT
Clean the filter frequently when used in a dusty environment.
It is necessary to clean the air filter at the suction port at least every year.
ˍ
Apply a vacuum cleaner to the slit
and suck the dust.
Screw
1
ˎ
When removing the air
filter, remove the screws in
four places and then
remove the cover.
Screw
2
Screw
4
Screw
3
ˏ
Clean the air filter on the
opposite side in the same
manner.
29
Replacement of backlight of LCD touch panel
When the LCD touch panel blacks out and the LED in the lower left section of the LCD touch panel
comes on in orange (green when normal), the backlight has burned out.
When the LED comes on in
orange, the backlight has burned
out.
IMPORTANT
When the backlight burns out, the screen blacks out and the display becomes invisible. Since input on the touch panel is valid,
however, improper touch panel operation may result when the touch panel is touched confusing the situation with the backlight
off state.
REFERENCE
When the LED is lit in green while the backlight is off, the function that protects the display element of the LCD touch panel is
activated.
The backlight will go out automatically when the touch panel is not operated for five minutes.
The life of the backlight is approx. five years when used normally.
When the backlight burns out, it must be replaced with a new one. The type is PS300-BU00 (digital).
You can contact our company also for replacement of the backlight.
Fuse change
1. Remove the side panel.
The fuse is on the right side when viewed from the front of the controller.
Screw
1
ˍ
Remove the screws
in four places.
ˎ
Remove the side panel.
30
Screw
4
Screw
2
Screw
3
2. Replacement of blown fuse
AHC2VP2
Manifold 1
Manifold 1
Manifold
Manifold 2
Manifold 2
ˍ
The manifold fuse cannot be confirmed
visually. Use a tester for confirmation.
Select the resistance range of the tester and
apply the probes to both ends of the fuse.
Unless the resistance is approx. “0ǡ,” the fuse
has been blown.
When the manifold fuse is blown
ˎ
Replace it with a reserve fuse (fast-blow fuse
20A for semiconductor protection).
Type of fuse: 314020 (Little fuse)
MAINTENANCE
Valve
ˍ
Valve 1
Valve 2
Valve 1
Valve 2
Visually check the fuse.
When the valve fuse is blown
ˎ
Replace it with a reserve fuse (fast-blow fuse
10A for semiconductor protection).
Type of fuse: 312010 (Little fuse)
AHC4TP4S
Manifold 1
Manifold 2
Manifold 1
Manifold 2
Manifold
ˍ
The manifold fuse cannot be confirmed
visually. Use a tester for confirmation.
Select the resistance range of the tester and
apply the probes to both ends of the fuse.
Unless the resistance is approx. “0Ω,” the fuse
has been blown.
When the manifold fuse is blown
ˎ
Manifold 3
Manifold 4
Manifold 3
Manifold 4
Replace it with a reserve fuse (fast-blow fuse
20A for semiconductor protection).
Type of fuse: 314020 (Little fuse)
≆ WARNING
Be sure to substitute a specified fuse. Any fuse other than the specified one may cause trouble.
IMPORTANT
Check the cause of the fuse blowing. When the blown fuse is replaced with a new one without removing the cause, the new
fuse will be blown repeatedly.
Do not apply excessive force when putting in and out the fuse, otherwise the glass tube may be broken.
31
Troubleshooting for Warning Messages
This section explains about troubleshootings when error message displays on the screen of AHC
controller.
Other errors
Failed Output Device ٟ ਄૏ㅢାࠛ࡜࡯㧔::㧕
Watched Timer Error
higher-level communication
M24C64 Error
error (02:XX)
Calibration Error
Japanese characters
Status monitor error
System error
ٟ
ٟ
ٟ
ٟ
ٟ
ٟ
ٟ
ٟ
ٟ
ٟ
ٟ
Sensor Burned Out
Heater Burned Out
Crossed Sensor Sensor Reverse
Temp. Too Low
Temp. Too High
Over Current Protection Circuit Action
show up even on English
language display.
ٟ Timed Up Watching Heat Up Timer
ٟ Air Pressure Too Low
ٟ External Alarm
Warning Code List
Code
32
Description
Component to be checked
≔≔
Manifold Temp. Too Low
≔≕
Body Temp. Too Low
≕≔
Manifold Temp Too High
≕≕
Body Temp Too High
≖≛
External Alarm
≖≜
Air Pressure Is Too Low
≗≔
Opened Manifold Sensor
≗≕
Opened Body Sensor
Spear Body‫ޔ‬Valve Body
≘≕
Body Heater Burned Out
Spear Body
≘≖
Tip Heater Burned Out
Spear Tip‫ޔ‬Valve Tip
≚≕
Body O.C.P
Spear Body
≚≖
Tip O.C.P
Spear Tip‫ޔ‬Valve Tip
≛≛
Timed Up Watching Timer
≤≔
Manifold Sensor Reverse
≤≕
Body Sensor Reverse
≥≔
Crossed Manifold Sensor
≥≕
Crossed Body Sensor
≩≤
Watched Timer Error
≩≥
M24C64 Error
≩≦
Failed Output Device
≩≨
Calibration Error
Spear Body‫ޔ‬Valve Body
Spear Body‫ޔ‬Valve Body
Spear Body‫ޔ‬Valve Body
Spear Body‫ޔ‬Valve Body
Status monitor error
[Sensor disconnection error]
Spear
Valve
Manifold
Cause
Correction
Imperfect contact of sensor connector
㨂㧼‒
Remove the junction cable from the controller, and check to see if the
connector pin has receded, causing imperfect contact.
Disconnection of sensor
Disconnection of junction cable
Measure the resistance on the junction cable side (mold side) with an
ohmmeter of a tester. When the needle points at infinity, the sensor,
junction cable, or connector box is out of order. Check it. (The
normal resistance is from several tens of Ω to several kΩ.)
Imperfect contact of spear sensor
When the condition is normal after inspection for “imperfect contact”
and “disconnection of sensor and junction cable,” it is possible that
disconnection sometimes occurs depending on the body temperature.
Spear
Imperfect contact of valve sensor
[Heater disconnection error]
Spear
Valve tip
Imperfect contact of output connector
㨂㧼‒
Check to see if the connector pin has receded, causing imperfect
contact.
Disconnection of heater
Disconnection of junction cable
Measure the resistance on the heater and junction cable side with an
ohmmeter of a tester. When the needle points at infinity, the heater or
wiring is disconnected. Check it. (The normal resistance is from
several tens of Ω to several kΩ.)
Failure of output board
Touch the error reset button to see if disconnection recurs. If it surely
recurs, the output board may have failed.
㧔Spear
Valve tip
㧕
Imperfect contact of spear heater
[Sensor response error]
When the error occurs occasionally or at the rate of several times per
month, disconnection may be caused by thermal expansion when the
temperature is raised
Spear
Valve
Manifold
The sensor and heater are not
responding correctly.
Check the wiring and make adjustment so that the sensor and heater
will response correctly.
The set temperature is more than 50°C
lower than the actual temperature.
Wait until the actually measured temperature lowers, and then raise
the temperature again.
TROUBLESHOOTING
Valve
REFERENCE
A response error is displayed when the actually measured temperature exceeds the set value + 50°C during heat-up.
33
Spear
[Sensor reverse connection error]
The ± terminals of the sensor are
connected reversely.
Valve
Manifold
Check and correct the wiring.
REFERENCE
An error is displayed when the actually measured temperature rises on the minus side and lowers up to the room
temperature – 50°C.
Spear
[Temperature error (lower limit)]
The monitoring temperature range is
too small.
Valve
Manifold
Displayed when the actually measured temperature drops below “Set
temperature – Temperature setting range] during molding because of
some trouble.
→ Sub setting: Heat retention and monitoring temperature (p.18)
REFERENCE
:
When a spear is used, the body temperature changes
periodically by intermittent heating of the tip heater.
The set temperature was changed
beyond the temperature monitoring
range during molding.
Change the setting temperature little by little, or turn off the heater
power once and then raise the temperature again.
→ Main setting (p.11)
The manifold heater was disconnected.
Measure the resistance on the heater and junction cable side with an
ohmmeter of a tester. When the needle points at infinity, the heater or
wiring is disconnected. Check it. The normal resistance is from
several tens of Ω to several kΩ.
Manifold heater
The valve body heater was
disconnected.
Valve body 㩷
The fuse was blown.
Manifold
→ Periodical maintenance: Fuse change (p.30)
Valve body The power has an open phase.
Check to see if the three phases of the controller power is supplied
normally.
[Temperature error (upper limit)]
Spear
Valve
Manifold
The temperature monitoring range is
too small.
Displayed when the actually measured temperature exceeds “Set
temperature + Temperature setting range] during molding because of
some trouble.
→ Sub setting: Heat retention and monitoring temperature (p.18)
When a spear is used, the body temperature changes
REFERENCE :
periodically by intermittent heating of the tip heater.
The set temperature was changed to
out of the temperature monitoring range
during molding.
Wait until the actually measured temperature lowers.
0
The pre-heating is excessive.
Excessive pre-heating does not permit body temperature control.
The sensor wiring does not match the
heater wiring.
Check and correct the wiring.
Spear
34
[Overcurrent Protection (OCP) Circuit operation]
Short circuit due to breakage of heater
Short-circuiting of heater wiring
Short-circuiting of wiring inside
connector box
Spear
Valve tip
Remove the junction cable from the connector box, and measure the
resistance with a tester. The normal value is 0.1-1.0Ω for the spear
tip and several Ω for the spear body and valve tip When the
resistance is smaller than the normal value, check for a short-circuited
section.
The sensor has come off and cannot
detect the temperature.
Check and correct the wiring.
The heater is disconnected.
Check the heater.
The timer setting is not correct.
Correct the heat-up time monitoring timer.
→ Sub setting: Timer (p.19)
TROUBLESHOOTING
[Heat-up time monitoring error]
[Air pressure drop error]
The air pressure drop signal was input.
Check the air circuit to find the cause of air pressure drop.
[External error]
The external error signal was input.
Check the external equipment for failure and correct it.
35
System error
[Output device breakage error]
Spear
Valve
The output device (FET) on the control
board was short-circuited and broken.
This error occurs in cases where the OCP circuit fails to protect the
output device when the heater is short-circuited and overcurrent flows
or in cases where the device is deteriorated due to aging.
IMPORTANT :
Turn off the main breaker because the power is
supplied to the heater even if the heater power switch
is not pressed.
The output device on the control board
is broken. Change the board.
Contact our sales division shown on the back cover.
[Watchdog timer error]
The control program has detected an
error.
Contact our sales division shown on the back cover.
[M24C64 error]
The control program has detected an
error.
Contact our sales division shown on the back cover.
[Calibration Error]
The control program has detected an
error.
36
Contact our sales division shown on the back cover.
Other errors
‫ ޟ‬਄ ૏ ㅢ ା ࠛ ࡜ ࡯ 㧔 㧜 㧞 㧦 ˜ ˜ 㧕‫ ޠ‬displayed in Japanese means “High-order
communication error (02:XX)”.
The communication data is garbled
under the influence of strong noise
The influence of noise is conceivable when the error occurs several
times a day and the system operates normally after recovery. The
AHC controller is designed to sufficiently withstand the electromagnetic
noise within the industrial standard. When there is some equipment
generating noise in excess of the standard, measures are necessary to
cope with the noise of the equipment.
Breakage of the communication cable,
etc.
Breakage of the communication cable is conceivable when the normal
status is not restored. Contact our sales division shown on the back
cover.
REFERENCE TROUBLESHOOTING
This message is displayed by the LCD touch panel itself. (Other messages are displayed by the AHC controller.) It is
displayed when the communication data differs from the format.
37
When no message appears
The method to cope with the trouble when no message appears during use of the AHC controller is shown below.
The display on the LCD touch panel disappears.
The earth leakage breaker of the power supply trips.
The temperature will not rise even if the heater power is turned on, or the temperature rises slowly.
The temperature drops during heat-up or molding.
Resin will not come out from a mold in which a spear is used.
The tip (valve) timer will not operate.
The display on the LCD touch panel disappears.
Cause
Correction
The display on the LCD touch panel
disappears.
Lower-left LCD → Green
On the LCD touch panel, the backlight goes out and the panel enters
the screen saver mode when it is not operated for more than five
minutes. Touch the screen, and the backlight will come on and the
original display will return.㩷
The display on the LCD touch panel
disappears.
Lower-left LCD → Orange
When the LCD touch panel blacks out and the LED in the lower left
section of the LCD touch panel comes on in orange (green when
normal), the backlight has burned out.
→ Periodical maintenance: Replacement of backlight of LCD
touch panel (p.30)
The earth leakage breaker of the power supply trips.
The heater may be short-circuited by
moisture.
Manifold
Valve
38
(1) If the manifold is short-circuited, select Manifold soft start to supply
power to the heater. When Manifold soft start is selected, power
is supplied at first with small output, and the situation will improve
in some cases.
(2) If the earth leakage breaker still trips after the procedure (1),
measure the insulation resistance of the heater, set (Disable) for
the manifold and probe with small resistance, and heat up the
damp heater.
(3) If the earth leakage breaker still trips after the procedure (2),
remove the fuse from the manifold and probe circuits with small
resistance, and heat up the damp heater, because the earth
leakage breaker may be tripped by the leakage current of the
SSR.
(4) If the problem is not solved after the procedure (3), dry the heater
with a dryer and then supply power to the heater.
The temperature will not rise even if the heater power is turned on, or the temperature rises slowly.
Manifold
Valve body The manifold heater is disconnected.
Manifold heater
The valve body heater is disconnected.
Valve body 㩷
→ Periodical maintenance; Fuse change (p.30)
Measure the resistance on the heater and junction cable side with an
ohmmeter of a tester. When the needle points at infinity, the heater or
wiring is disconnected. Check it. The normal resistance is from
several tens of Ω to several kΩ.
The heat-up delay timer has been
selected.
Wait until the heat-up timer completes operation, or cancel the timer.
→ Sub setting: Timer (p.19)
2-step heat-up has been selected.
Keep the body on standby at the heat retention temperature until the
manifold temperature rises up to the temperature monitoring range.
→ Sub setting: Option (p.20)
When the temperature of only one
probe rises slowly or it rises only
halfway, the sensor wiring is
short-circuited.
The sensor may have been short-circuited in the connector box or near
the flange of the probe. When the sensor is short-circuited halfway, a
temperature lower than the actual temperature will be displayed.
The sensor type (J/K) is wrong.
When the sensor type is K and the setting on the screen is J, the
temperature shown on the screen will be below the set temperature
although the actual temperature has exceeded the set temperature.
→ Special function: Selection of sensor (p.24)
The sensor is about to come off.
In the case of a manifold, a lower temperature may be displayed when
the sensor is about to come off.
Manifold
Manifold soft start has been set.
TROUBLESHOOTING
The fuse is blown.
When Manifold soft start is set, the output is increased gradually from
the low level, taking longer time for heat-up than usual.
→ Sub setting: Option (p.20)
The temperature drops during heat-up or molding.
The operation delay timer is used.
Unless the tip timing signal or valve timing signal is input, the timer will
be activated, and when it finishes counting, the system will
automatically shifts to the heat retention status.
→ Sub setting: Timer (p.19)
The heat-up delay timer is set.
Stop power supply to the heater when heat-up is not completed within
the preset time.
→ Sub setting: Option (p.20)
39
Resin will not come out from a mold in which a spear is used.
Manual tip heating is not conducted
during start-up.
Tip heating for 5-10 seconds is necessary when molding with a spear
is to be started.
→ Operation: Procedure for starting molding (p.14) The tip timing signal cable has not been
connected.
Tip heating is necessary before injection when the mold has a spear.
Connect the tip timing signal cable to the mold opening start signal or
mold opening completion signal of the molding machine.
㩷
Tip timing signal
㩷
When the tip timing signal is
㩷
input, this section is shown in
㩷
reverse video.
㩷
㩷
㩷
㩷
The tip (valve) timer will not operate.
Heat-up has not been completed.
Unless heat-up has been completed, the tip (valve) timer will not
operate. Wait until heat-up is completed.
A wrong timing cable is used.
The signal cable comes in two types – one for the contact and the
other for voltage. Use them correctly according to the output of the
molding machine side.
There is no output from the molding
machine.
When the timing signal is input,
and
in the upper right corner
of the screen are shown in reverse video. If they are not displayed,
check the output of the molding machine with a tester. Use the
“Voltage range” in the case of voltage output and the “Resistance
range” in the case of the relay output (contact output).
Valve timing signal
When the valve timing signal is
input, this section is shown in
reverse video.
40
Tip timing signal
When the tip timing signal is
input, this section is shown in
reverse video.
Specification
Controller Specification
Item‒
Power supply voltage
Description‒
AC200V
AC200Vr
*\*\
AC220V
AC220Vr
*\*\
AC240V
AC240Vr
*\*\
Environment (temperature)
0㨪40°C㧔Storage temperature: -20°C㨪60°C㧕
Environment (Humidity)‒
㨪90% (Avoid Condensation)
Controlled object
ˬ‒
˰!
Spear (D, G, ESP, B [max.controllable size is STT22B220])
˲!
ˬ‒
Valve (SVP, SVY, SV32, SV25) , ESN,
Other probes with 200-240V heater
2VP2
Main breaker
Temperature Input range
Temperature Input
Resolution‒
Temperature Unit‒
Timing Signal Input‒
Ext. Interface‒
2TP2S, 2TP2T
30A (Ground-fault circuit breaker is selectable)
4TP4S, 4TP2T
50A (Ground-fault circuit breaker is selectable)
Sensor (J)
0㨪500°C
Sensor (K)
0㨪600°C
0.1°C / LSB
Celsius (°C)/ Fahrenheit (°F) (Transformable on the screen)
Contact Input
Dry contact input
Voltage Input
DC24V, AC100㨪240V
Contact Input
Dry contact input
Contact Output
DC24V/ 0.5A
24V Voltage Output
DC24V/ 300mA
Entry Unit
5.7inch LCD (with a touch panel)
Number of Files‒
16
Line noise
Noise Immunity
Static electricity
Dimension‒
Weight‒
APPENDIX
Common-mode voltage 2kV (100ns/1us)
Normal mode voltage 2kV (100ns/1us)
Up to 15KV for air discharge
Up to 8KV for contact discharge
390(w) x 330(D) x 200(H)
2VP2
18Kg 䋨 Including Main unit and Power wire. Excluding
Junction cable.䋩
2TP2S, 2TP2T
21Kg 䋨 Including Main unit and Power wire. Excluding
Junction cable.䋩
4TP4S, 4TP2T
30Kg 䋨 Including Main unit and Power wire. Excluding
Junction cable.䋩
41
Standard for Heater Output (Power Supply Voltage AC200V)
Output
Voltage
Capacity
AC200V
3KW
AC32V
4.5A
Manifold
Protected
Circuit
Quick-blow fuse Time Proportioning Control
Output (Control Cycle 1sec)
(20A)
Spear Body
Output method
㧻㧯㧼
Closed-loop effective current
Phase control
Control Method
PID Temperature
Control
(With self-tuning)
PID Temperature
Control
Spear Tip
AC11V
㧻㧯㧼
14A
Closed-loop effective current
Phase control
Valve Body
AC200V
1.5KW
AC11V
5A
Quick-blow fuse Time Proportioning Control
Output (Control Cycle 1sec)
(20A)
Valve Tip
㧻㧯㧼
With self-tuning
Intermittent heat
control
PID Temperature
Control
(With self-tuning)
Intermittent heat
control
IMPORTANT
Total capacity is restricted to the capacity of main breaker.
External interface table
Pin #‒
Description‒
Description‒
Ძ
Air pressure Too Low (Contact Input) ˲ˬ
ᲫᲭ
Წ
External Alarm (Contact Input)
ᲫᲮ
Ჭ
Spare (Contact Input)
ᲫᲯ
Ხ
Spare (Contact Input)
ᲫᲰ
Ჯ
Contact Input Common (Contact Input)
ᲫᲱ
Ჰ
Voltage Output Common (24V Voltage Output)
ᲫᲲ
Ჱ
Reserved
ᲫᲳ
Ჲ
Reserved
ᲬᲪ
Ჳ
Reserved
ᲬᲫ
Open Valve (24V Voltage Output) ˲ˬ
ᲬᲬ
ᲬᲭ
ᲬᲮ
ᲫᲪ
ᲫᲫ
ᲫᲬ
Ready (Contact Output)
IMPORTANT
Rating for the contact output is less or equal to DC24V/ 0.5A
Rating for the contact input is less or equal to DC24V
Rating for the Valve Open (DC24V voltage output) is 300mA.
REFERENCE
Digital I/O cable (SH-S10013) is optional parts.
Air unit connection cable (SH-S10009) is optional parts.
42
Pin #‒
Trouble (Contact Output)
Trouble (Contact Output)
Reserved
Security setup
Password is [5414].
Please keep this paper in safe place by cutting along a perforation at right.
Cut off
Cut off
APPENDIX
43
44
AHC 2VP2 Appearance Drawing
45
46
AHC 2TP2S, 2TP2T Appearance Drawing
AHC 4TP4S, 4TP2T Appearance Drawing
47
48
AHC 2VP2 Circuit Drawing
AHC 2TP2S Circuit Drawing
49
50
AHC 4TP4S Circuit Drawing
Seiki Network
AGENTS
Head Office
4364 Katako,Bansei-Cho,Yonezawa-City,
Yamagata 992-1125
TEL: 81-(0)238-28-5411 FAX: 81-(0)238-28-1363
URL http://www.seiki-hot.com/
E-mail seiki@seiki-hot.com
Business Office
(Japan)
Tokyo Office
4F.Kawamura Bldg., 5-10-6 Shinbashi,Minato-ku,
Tokyo 105-0004
TEL: 81-(0)3-5777-0601 FAX: 81-(0)3-5777-0651
Osaka Office
6F. Shin-osakamaru Bldg., 1-18-5 Higashinakajima,
Higashiyodogawa-Ku,Osaka-City,Osaka 533-0033
TEL: 81-(0)6-6323-6072 FAX: 81-(0)6-6325-4056
Thailand
KISHIMOTO SANGYO (THAILAND) LTD.
159 Sermmit Tower, 11th. Floor, Sukhumvit 21 Rd. (Asoke),
North Klongtoey, Watana, Bangkok 10110, Thailand
TEL: 66-(0)2-260-8624 FAX: 66-(0)2-260-8631
Singapore
KISHIMOTO SANGYO (ASIA) PTE.,LTD.
101 Thomson Road, #30-02/04 United Square,
Singapore 307591, Singapore
TEL: 65-6255-3188 FAX: 65-6255-3867
Malaysia
KISHIMOTO SANGYO (MALAYSIA) SDN.,BHD.
6th. Floor, Wisma Genting Jalan Sultan
Ismail, 50250, Kuala Lumpur, Malaysia
TEL: 60-(0)3-2162-4011 FAX: 60-(0)3-2162-4078
U.S.A.
Nagoya Office
6F.Office-Kurond Bldg., 3-108 Issha,Meitou-Ku,
Nagoya-City, Aichi 465-0093
TEL: 81-(0)52-704-5692 FAX: 81-(0)52-704-5708
Mitsui Plastics Inc
100 High Grove Blvd. Glendale heights, IL 60139
TEL: 1-630-924-8800 FAX: 1-630-924-8879
Korea
Touhoku Office / Overseas Group
4364 Katako, Bansei-Cho,Yonezawa-City,
Yamagata 992-1125
TEL: 81-(0)238-28-1250 FAX: 81-(0)238-28-1222
Song Won Industrial Co., Ltd.
2F,22-3,Maesanro-1ga, Kwunsun-ku, Suwon-Si,
Kyung-Ki-Do,Korea
TEL: 82-(0)31-253-8030 FAX: 82-(0)31-253-8031
Taiwan
Supiya Enterprise Co.,Ltd.
2F. No.380 Sec.1, Fu Hsing S.Rd.,
Taipei, Taiwan
TEL: 886-(0)2-2701-1158 FAX: 886-(0)2-2754-9118
U.K.
Eastern Plastics Machinery Ltd.
Eastern House, Coggeshall Ind. Park,
Coggeshall, Essex, CO61TW, England
TEL: 44-(0)1376-562288 FAX: 44-(0)1376-561385
Germany
Franz Sax Konstruktionsbuero
Fruehlingstrasse19,
90431 Nuernberg, Germany
TEL: 49-(0)911-302184 FAX: 49-(0)911-301480
Austraria
J.H.MACHINERY PTY LTD.
2-48 Reserve Road, Beaumaris,
Victoria, 3193, Australia
TEL: 61-(0)3-9589-0187 FAX: 61-(0)3-9589-6450
SEIKI SCIENCE &
Unit 2608,The Metropolis Tower,10 Metropolis Drive
TECHNOLOGY(HK)CO., LTD. Hunghom, Kowloon, Hong Kong
TEL: 852-2364-6800
FAX: 852-2366-0651
SEIKI SCIENCE &
Guanlan Techno Centre,
TECHNOLOGY(HK)CO., LTD. B District 5F, Miaoxi Industrial Zone, Guihua Baoan,
SHENZHEN OFFICE
Shenzhen, China 518110
TEL: 86-(0)755-2798-8107 FAX: 86-(0)755-2798-8124
AGENTS
Hong Kong
KISHIMOTO SANGYO (HONGKONG) CO.,LTD.
Unit 2608, The Metropolis Tower, 10 Metropolis Drive
Hunghom, Kowloon, Hong Kong
TEL: 852-2311-8377 FAX: 852-2366-0651
Mitsui Plastics Trading(HongKong) Co., Ltd.
Unit 1702-4, Lippo Centre Tower 2,
89 Queensway, Hong Kong
TEL: 852-2511-0123 FAX: 852-2802-2822
Shanghai
KISHIMOTO TRADING (SHANGHAI) CO.,LTD.
15th Floor, HSBC TOWER 101 Yin Cheng East Road,
Pudong New Area, Shanghai, China 200120
TEL: 86-(0)21-6841-2957 FAX: 86-(0)21-6841-5904
000.0.000
2007.2.100
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