HRC-215 - Interempresas

HRC-215 - Interempresas
HRC-215
MICROPROCESSOR-BASED
MODULAR HOT-RUNNER
TEMPERATURE CONTROLLER
INSTRUCTION MANUAL
** FOR DISTRIBUTION IN EUROPE **
SAFETY WARNING
CE COMPLIANCE
WARNING!
READ THIS MANUAL BEFORE
OPERATING EQUIPMENT!
The high voltage required to operate this temperature
controller and the high temperatures created by its
operation can cause serious injury or death, and
presents a potential fire hazard.
Installation and operation of this equipment should only
be performed by qualified individuals and all directions
should be carefully followed. Caution should be taken
to guarantee that only the rated voltage is applied to
this unit and appropriate limiting control devices should
be used for safe operation.
DISCONNECT THE MAIN POWER FROM
THE
CONTROL
SYSTEM
BEFORE
SERVICING!
Hazardous voltage is present on the inside of the
controller and mainframe system.
Standard safety procedures should be followed.
Additionally, the following guidelines will help prevent
personal injury and product damage:
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Do not apply a voltage greater than that
specified on the product nameplates.
Do not operate controllers or mainframe
systems without appropriate supply ground
connections.
Do not insert or remove controllers into
mainframe systems with power applied.
Do not operate any controller or mainframe
system without all covers in place and properly
secured.
Do not operate this product when wet or in a
damp environment.
Do not operate this product in an explosive
atmosphere.
HRC-215 Hot Runner Controller
User’s Manual
This controller, when properly installed as described in
a grounded mainframe enclosure, complies with the
following European Standards:
•
EN-61010-1
“Safety Requirements for Electrical Equipment
for Measurement, Control and Laboratory Use
– Part 1. General Requirements (1995)”
•
EN-61326-1
“Electrical Equipment for Measurement,
Control and Laboratory Use – EMC
Requirements (1998)”
Note on EMC compliance:
Due to the processing of small analog voltages
(thermocouple input) this controller is susceptible to
interface caused by radiated electromagnetic fields.
Although steps have been taken to reduce upsets
caused by EMI, strong signals may cause degradation
of instrument accuracy. User intervention is not
required to reset the controller under these
circumstances. The controller will automatically recover
following the removal of the interfering signal.
If continuous upsets are recognized remove the
interfering signal from the process. If this is not
possible consult the manufacturer for assistance with
solving specific EMI interference problems.
Document No.: ED-0001-MN-021-F
June 1, 2006
INTRODUCTION
The HRC family of modular hot runner injection mold
temperature controllers was developed with the
operator in mind. Ease of use, reliable performance,
rugged design and trouble free operation were the
goals of its design. Runnerless mold technology is not
new but it is continually changing. Likewise, the
controller technology must continue to evolve. The
HRC temperature controllers follow this advancement
by combining the most desirable features of the
prominent temperature controllers available today and
puts them in a package that is user friendly, highly
accurate and prepared to handle even the most difficult
control applications. Dependability, productivity,
repeatability and trouble free operation are essential
characteristics of any mold system component. The
purchase and installation of this HRC temperature
controller is sure to be a compliment to even the most
critical application.
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This manual combines graphical representation of
displays with explanatory dialogue to help the user
acquaint themselves with the controller features.
Should further clarification be required do not hesitate
to contact your nearest sales representative or
distributor for assistance.
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KEY FEATURES
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The HRC modular temperature controller offers many
user-friendly features that enable novice users to
quickly become productive. These same features are
key for veteran molders who desire fluent integration of
the HRC into applications where upgrade or
replacement is necessary.
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The HRC controllers are physically and
electrically compatible with all †D-M-E® GSeries®, Smart Series® and similar style
mainframe control systems.
Large,
highly
visible
LED
displays
simultaneously display process temperature
and setpoint temperature.
Menu and Keyboard Guide quick reference
card supplied with every controller provides
convenient descriptions of the HRC operator
interface and menu options.
Symbolic mode and condition indicators
combined
with
displayed
mnemonics
(abbreviations) clearly state operating modes
or alarm conditions.
Reliable, user-friendly 3-key tactile interface.
The sealed construction protects the keys and
circuitry from debris that typically leads to
component failure.
The front panel graphics are printed on the
underside of the polycarbonate face insuring
that controls will be recognizable even after
many years of service.
HRC-215 Hot Runner Controller
User’s Manual
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Time tested and proven electronics for reliable
performance.
Automatic (closed loop) and Manual (open
loop) modes of control.
Load current (Amps) monitor mode.
Industry standard type “J” Thermocouple input
(default) or selectable type “K” Thermocouple
input.
Fully automatic, adaptive tuning of PID (threeterm) control variables providing smooth
adaptation to any runnerless mold temperature
control application with no user intervention.
Automatic slow-start temperature ramp at
start-up to ensure wet heater bake out,
prolonging heater life.
Wet heater ground fault detection at start-up
that limits or disables power to avoid
destructive short circuits.
Momentary display of output power (%)
available when in Automatic control mode.
Momentary display of load current (amps)
available when in Automatic or Manual control
mode.
Anti-arc (high voltage) protection circuit to
prevent electrical damage if the controller is
accidentally installed or removed from the
mainframe with power applied. (Circuit may be
disabled).
User enabled (jumper selectable) Automatic
T/C Fault Hold transfer to manual control
mode. Provides for uninterrupted load power
upon loss of thermocouple signal.
Option to disable the Function Control / Menu
Key to prevent unauthorized personnel from
changing control parameters.
Full diagnostic software to inform operator of
fault conditions.
Shorted Thermocouple diagnostic allows for
user selectable (jumper) sample times, giving
the operator greater flexibility to tailor the HRC
diagnostic to the unique thermal weight and
response characteristics of a variety of control
applications. (Light or heavy loads).
Over and under temperature indication with
user enabled communications output to
activate external control intervention or audible
and/or visual alarm. Selectable output for
compatibility with †D-M-E® TAS and
‡Athena® SAM accessory alarm modules.
Compliant with CE EMC and low voltage
directives.
Compliant
with
WEEE
and
RoHS
requirements.
Document No.: ED-0001-MN-021-F
June 1, 2006
SPECIFICATIONS
CONTROLS AND INDICATORS
GENERAL
Dimensions ……..………. 2.0” Wd X 7.0” Hg X 7.8” Lg
(51mm X 178mm X 198mm)
Weight …………….……………………. 1.25lb (0.57Kg)
Operating Temp. Range …. 32° to 120°F (0° to50° C)
Control Method:
Automatic Mode ……. Full Scale Auto-Tuning
PID (3-Term)
Manual Mode ……………..…. User Selectable
0% to 99% Output Power
Temperature Reset ……….. To Within ±1°F (±0.55°C)
Of Setpoint
Power Response Time ………………………… 250mS
Control Accuracy (In Auto Mode) .… ±1°F (±0.55°C)
** Dependant On Total Thermal System **
Slow Start Mode …… From Ambient to 212°F (100°C)
Low Power Application Temperature Ramp
ELECTRICAL POWER SPECIFICATIONS
Operating / Input Voltage …………… 230 VAC ±10%
(Optional 115 VAC ± 10%)
Frequency ………………...…… 50 / 60 Hz (Automatic)
Power Consumption ……..…. < 3 Watts (N.I.C. Load)
DC Power Supplies ……………. Internally Generated,
Regulated with Temperature Compensation
Circuit Protection .. Dual Fast-Acting Fuse Type ABC
Over-Voltage Protection via MOV
Circuit Isolation …..……… Transformer, > 2500 Volts
Triac Optically Coupled
INPUT SPECIFICATIONS
Sensor Type ………………….. Type “J” Thermocouple
Selectable Type “K” (Grounded or Ungrounded)
Sampling Rate ………………………………….. 250mS
Temperature Range ……... 32° to 999°F (0° to 537°C)
Temperature Accuracy ……….… ±0.3% of Full Scale
Temperature Repeatability …..… ±0.1% of Full Scale
Cold Junction Compensation ….... Automatic Across
Operating Temperature Range
Input Impedance …………………..…… 22 Meg Ohms
Input Protection …… Diode Clamp & Fusible Resistor
Input Isolation ………...…… Via Control Circuit Power
Supply Transformer
Current (Amps) Sensor Type ……...…… Transformer
Current (Amps) Range ………...……… 0-15 Amperes
Current (Amps) Accuracy / Resolution …... 0.1 Amp
OUTPUT SPECIFICATIONS
Output Voltage ……….. 240 VAC (Optional 120 VAC)
Load Power ……… 3600 Watts; 15 Amps @ 240 VAC
1800 Watts; 15 Amps @ 120 VAC
Power Disconnect ……...….. 16A Double Pole Switch
Power Output Control Device ……………..…… Triac
(Solid State – Not Mechanical)
Overload Protection ….……… Dual Fast-Acting Fuse
Type ABC
Power Line Isolation ……...… Triac Optically Coupled
HRC-215 Hot Runner Controller
User’s Manual
Process Temperature Display ……….....
Setpoint Temperature Display ………….
Automatic (Closed Loop) Control Mode
Power Output (%) Display …………….…
Manual (Open Loop) Control Mode
Amps (Load Current) Display ……..……
Setpoint / Power / Mode Control ………
3-Key Tactile Keyboard
Display Output Power (%)
SEL
Momentary …...…..
Display Load Current (Amps) Momentary …..
SEL
Automatic Mode Indication …….….
Closed Loop LED Indicator
Manual Mode Indication …….……..
Open Loop LED Indicator
Slow Start Mode Indication ….…….
LED Indicator
Load Power Indicator ………..………
LED Indicator
DIAGNOSTICS
Diagnostics are fully automatic and require no operator
intervention.
Over Temperature Indication (+30°F/+17°C)
LED Display with Accessory Alarm Output
Under Temperature Indication (-30°F/-17°C)
LED Display with Accessory Alarm Output
Open T/C Indication ……………………
LED Display with Accessory Alarm Output
Reverse T/C Indication …………..……
LED Display with Accessory Alarm Output
Shorted T/C Indication ………………..
LED Display with Accessory Alarm Output
Shorted Output Indication ……………
LED Display with Accessory Alarm Output
Open Output Indication ……………….
LED Display with Accessory Alarm Output
Ground Fault Indication ……………..
LED Display with Accessory Alarm Output
Document No.: ED-0001-MN-021-F
June 1, 2006
CONTROLS
1. Power Switch (ON / OFF)
2. Process Temperature Display
Also Displays Diagnostic / Fault Mnemonics
3. Setpoint Temperature Display (Shown at Right)
In Automatic (Closed Loop) Control Mode
3. Load Power (%) Output Display
In Manual (Open Loop) Control Mode
MOMENTARY
DISPLAYS
USING THE KEY PAD:
SEL
SEL
+
=
Power Output (%)
Display - Momentary
+
=
Amps (Load Power)
Display - Momentary
9
MANUAL (%)
HRC 215
3. Amps (Load Current) Display
In Amps Monitor / Display Mode
PROCESS TEMP
2
4. Increment / Function Select Key
Increment Setpoint in Automatic Mode
Increment Power Output in Manual Mode
5. Function (Menu Execute) Key
6. Decrement Key
Decrement Setpoint in Automatic Mode
Decrement Power Output in Manual Mode
7. CE Caution Symbol
8. Plastic Retention / Locking Device
9. Retention / Locking Screw (Req’d for CE)
10. Back-Lit LED Operating Mode / Condition Display
10
SETPOINT
3
INDICATORS
MANUAL (%)
11. Automatic (Closed Loop) Control Mode Indicator
12. Start-Up Power Ramp Indicator
13. Load Power Indicator
14. Manual (Open Loop) Control Mode Indicator
15. Thermocouple Fault Indicator
16. Output Fault Indicator
17. Fahrenheit Temperature Mode Indicator
18. Celsius Temperature Mode Indicator
SEL
4
5
6
11
14
°F
12
15
°C
13
18
1
16
7
17
240 VAC
15 AMP
8
HRC-215 Hot Runner Controller
User’s Manual
Figure 1
Controls & Indicator Placement
Document No.: ED-0001-MN-021
Revision B - June 3, 2003
INSPECTION
After removing the HRC temperature controller from
the shipping container immediately inspect the unit for
damage resulting from mishandling in shipping. Inspect
for loose components and mechanical damage such as
bent sheet metal, marred front panel screen, etc.
Remove the spare ABC15 fuses, locking screw and
mainframe zone edge connector contact (required for
anti-arc circuit) and save them for later use.
Note: If the unit appears damaged or the container
is missing components, contact your sales
representative immediately! Use or modification of
the controller or its packaging will decrease the
likelihood of freight claim reimbursement.
INSTALLATION
Note that the contact itself completes the triac gate
(drive) circuit. No wiring, or wire connection, is required
to the #3 edge connector contact.
The anti-arc circuit can be disabled by installing a
#22-28 AWG wire jumper into the printed circuit board
jumper position P5. (Soldering is required. See Fig. 2,
Component Layout.)
It is highly recommended that the anti-arc circuit
not be disabled in this manner! If the controller is
inadvertently installed or removed from the mainframe
under power it will suffer severe damage, and possibly
be destroyed. The user is encouraged to take
advantage of this protective feature.
WARNING!
THE CONTROL SYSTEM MAINFRAME MAIN
POWER DISCONNECT MUST BE IN THE “OFF”
POSITION BEFORE INSERTING OR REMOVING
CONTROL MODULES TO PREVENT OPERATOR
INJURY AND DAMAGE TO CONTROL SYSTEM
COMPONENTS!
THIS HRC-215 IS EQUIPPED WITH A
HIGH VOLTAGE ANTI-ARC CIRCUIT!
AND IS ENABLED – TO PREVENT
ELECTRICAL
DAMAGE
TO
THE
CONTROLLER
IF
ACCIDENTALLY
REMOVED FROM THE MAINFRAME WITH
POWER APPLIED.
The controller WILL NOT apply power to
the load unless mainframe zone edge
connector contact #3 is installed.
Inspect each mainframe zone edge connector for the
required contact. If the contact is not already installed
remove the mainframe rear cover (refer to
manufacturer instructions) and install the contact
supplied with the HRC. (Insure contact is locked in the
connector by gently pushing on it from the front.)
Check the controller red power switch (Fig. 1 Item #1)
insuring that it is in the “Off” (O) position. Pull the
plunger of the black locking device (Fig. 1 Item #8)
back into the “out” position.
Align the controller PC board top and bottom rear
corners with the respective card guide rails in a
mainframe control zone. Slide the controller into the
frame, keeping it parallel with the frame surfaces, until
it meets resistance of the edge card connector. Place
thumbs on the upper and lower right corners of the
controller faceplate and firmly press it into the
mainframe until the backside of the faceplate meets
the frame.
Gently push the plunger of the black locking device into
its locked position.
Note: For CE compliance it is necessary to install the
supplied retention / locking screw (Fig. 1 Item #9)
through the controller into the mainframe. This is to
prevent inadvertent controller removal while the
mainframe system is under power.
OPERATION
Refer to Figure 1 to become oriented with the
controller displays, indicators and user controls.
Step 1: Verify installation
of contact.
HRC-215 Hot Runner Controller
User’s Manual
Step 2: If not, install
provided contact
The following control events are listed in
order of priority.
Document No.: ED-0001-MN-021-F
June 1, 2006
POWER ON
NO THERMOCOUPLE AT START-UP
FIRST TIME USE
If in Auto Control mode, and a thermocouple fault is
determined due to a lack of an acceptable T/C signal
the controller will continue to disable the output and
display the appropriate T/C diagnostic code. See
Diagnostic modes listed below.
When the controller is turned on for the first time it will
start with the following factory preset parameters:
United States: ……...…….…. Automatic Control Mode
Setpoint = 200°F
Degree Mode = Fahrenheit
Export Models: ……….…….. Automatic Control Mode
Setpoint = 100°C
Degree Mode = Celsius
The user is free to change these parameters at any
time after start-up. Refer to the Function Control
instructions below.
If the controller is set to Manual Control mode and
no T/C signal is applied the wet heater ground fault
diagnostic will still be active.
Note: The alarm output, if enabled (see instructions
below), will not be active in this condition unless the
controller is switched into Auto Control mode. Upon
start-up in Manual Control mode with no T/C signal
present, the HRC controller assumes that the operator
has intentionally not provided T/C input, therefore
disabling the alarm output.
REPEAT USE
FAULT DETERMINED
When power is reapplied the controller will operate
using the same modes that it was using at the previous
power off. For example, if the controller was in Auto
Control mode when it was turned off it will return in
Auto mode. Likewise if the controller was shut off in
Manual Control mode it will return in Manual mode.
WET HEATER GROUND FAULT
If the controller senses current flow greater than or
equal to 200 milliamperes (0.20 amps), it deduces that
current is leaking to ground by a conductive path
caused by moisture. In this event the following
diagnostic code is displayed in the Process
Temperature display window accompanied by the
associated condition code LED:
This diagnostic routine is bypassed if the process
temperature is greater than 212°F (> 100°C).
When the controller is first turned on output power
is disabled for 15 seconds. During this time period
the controller monitors load current (amps). If the
controller, with its output power off, monitors no current
flow, or current (amps) less than 200 milliamperes
(0.20 amps), it determines that there is no recognizable
ground fault and continues in Slow Start Control mode
as detailed below.
THIS DIAGNOSTIC ROUTINE IS PERFORMED AT
START-UP IF THE CONTROLLER IS IN AUTO
CONTROL MODE OR MANUAL CONTROL MODE!
If in Manual Control mode the controller will display
0% power output (disabled) until the 15-second time
has elapsed. Upon completion of the test, without a
ground fault, the controller will retrieve the saved (at
power-off) manual power setting from memory and
continue in Manual Control mode with that percentage
of power output.
The user may increase output power during this
test. However, doing so will abort the wet heater
ground fault diagnostic routine and also prevent the
controller from restoring the previously saved power
setting!
HRC-215 Hot Runner Controller
User’s Manual
DISPLAY SHOWN WITH FAULT INDICATOR
In this event the HRC controller will also apply a signal
on the mainframe communications bus (optional) that
can be used to activate an audible and/or visual alarm
accessory. (The operator must enable the
communications output. See the Alarm Output
Selection instructions below).
In the event of this fault the operator may continue in
one of the following three ways, listed in order of
precautionary weight:
1. The operator can turn the control system off
and investigate the severity of the probable
fault.
2. The operator can wait for controller response.
The HRC will continue to monitor the current
(amps). If the current (amps) is reduced to less
than 200 milliamperes (0.20 amps), or the
Process Temperature exceeds 225°F (107°C),
the controller will continue with normal
operation.
Document No.: ED-0001-MN-021-F
June 1, 2006
If in Auto Control mode and current flow
(amps) is decreased, and the temperature is
lower than 225°F (107°C), it enters the Slow
Start Control mode.
If in Manual Control mode the controller will
stay at 0% output power (inhibited) until the
current is reduced or the temperature exceeds
225°F (107°C). In either case the fault will be
cleared and the previous power setting will be
restored, and the module will operate normally.
If in Manual Control mode and no
thermocouple signal is present the wet
heater fault will continue until current flow
(amps) stops, regardless of the load
temperature. (Without T/C feedback the HRC
has no way to determine load temperature.)
3. The operator can override the diagnostic
routine. The controller must be set in Manual
Control mode and power must be manually
increased from 0%. (See Function Control
instructions below to change control modes).
SLOW START CONTROL
For Wet Heater Bake-Out
Disabled If In Manual Control Mode
2. The operator can switch the controller into
Manual Control mode and adjust the output
power to drive the temperature above 212°F
(100°C), and then switch the controller back
into Auto Control mode to continue normal
operation.
The Function Control sequences required for
the above action are detailed in a section
below.
AUTOMATIC CONTROL MODE
Refer to the Function Control instructions below to
select Auto Control mode.
In Automatic (Auto) Control mode the HRC controller
uses a PID algorithm to determine the required output
power to hold the Process Temperature equal to the
Setpoint Temperature.
This type of control is a “closed loop” system and
requires a thermocouple feedback signal. The Closed
Loop mode indicator indicates this control mode:
CLOSED LOOP MODE INDICATOR
The Setpoint Temperature is determined by the
operator and indicated on the lower LED display:
SLOW START MODE INDICATOR
Upon start-up, the controller always enters Slow Start
Control mode when all of the following conditions have
been met:
1. The controller is set for Auto Control operation.
2. The process temperature is less than 212°F (<
100°C).
3. The wet heater diagnostic is completed without
a fault condition.
Slow Start control utilizes a special power control
routine designed to avoid heater destruction due to
conductive paths to ground caused by moisture. While
maintaining a low power setting, the HRC controller
ramps the load temperature to 212°F (100°C) at a 1degree per second rate of rise. When 212°F (100°C)
has been achieved the controller quickly reduces
power to slow the temperature rise for a period of 1
minute. Upon completion the controller will continue to
drive the process temperature to the setpoint.
To disable Slow Start Control the operator may
perform one of the following tasks:
1. Using the Function Control selector key, the
Slow Start function can be called from the
menu and disabled by depressing the Select
key.
HRC-215 Hot Runner Controller
User’s Manual
SETPOINT DISPLAY
The Setpoint can be easily adjusted up or down at any
time during Auto Control mode operation by
depressing the Increment / Decrement keys of the key
pad:
The keys can be pressed and released one unit digit at
a time, or for larger changes, the key can be held down
for continuous change. In this mode the speed at which
the setting is changed is ramped from slow to very fast.
For example, the longer the key is held in the faster the
numbers change.
AUTOMATIC PID TUNING
The HRC controller uses a PID (three term) control
algorithm to determine the required load power needed
to reach and maintain the Setpoint Temperature. Every
thermal system has different characteristics. To
accurately control each dynamic system the HRC must
“learn” each load’s characteristics individually. In
addition, every system’s variables change with
Document No.: ED-0001-MN-021-F
June 1, 2006
temperature changes. For example, a load’s set of
control variables may be different at 200° than at 350°.
For example, the longer the key is held in, the faster
the numbers change.
To accomplish “learning” each load’s variables and to
eliminate complex operator intervention the HRC
controller automatically enters a “tuning” routine when
the Process Temperature reaches a point less than or
equal to 80°F (45°C) below Setpoint Temperature. The
controller will go through a sequence of applying
different levels of power to monitor load response. The
HRC takes the information it “learned” and adjusts the
PID control variables accordingly.
POWER TRANSFER FROM AUTO MODE
Note: The HRC automatically calls this tuning routine
at power-on regardless of the current Process
Temperature. The controller also repeats this tuning
process when the operator makes a Setpoint
Temperature change greater than or equal to 100°F
(55°C). The controller will not tune if it is turned on
with a process temperature greater than the
setpoint.
This output power level will most likely not be able to
hold the former setpoint but it will bring the load to a
constant temperature that may or may not be close to
the former setpoint value. As the controller is working
in Auto Control mode it is continually changing output
power to maintain Setpoint Temperature. The
continuous changes are required to keep up with
process upsets to the thermal system.
MANUAL CONTROL MODE
CURRENT (AMPS) MONITOR MODE
Refer to the Function Control instructions below to
select Manual Control mode.
Refer to the Function Control instructions below to
select Current (Amps) Monitor mode.
In Manual Control mode the HRC controller regulates
load power determined by the user selected Power
Output setting. The power delivered is constant and
will only change with user input.
Whether operating in Auto Control mode or Manual
Control mode the HRC allows the operator to
continuously monitor load current (amps). The
monitored value is the average current (amps) being
delivered to the load. Because the HRC applies power
to the load using a pattern of voltage pulses, true
instantaneous current would be rapidly changing from
second to second and would be difficult for the
operator to interpret. The displayed average value is a
much more useful quantity to the user.
This type of control is an “open loop” system and
requires no thermocouple feedback signal. The Open
Loop mode indicator indicates this control mode:
When the HRC controller is operating in Auto Control
mode it records the average power setting required to
maintain Setpoint Temperature. When the operator
switches from Auto Control mode to Manual Control
mode this power setting is automatically set for use.
The operator is free to change the power setting at any
time following the control mode transition.
OPEN LOOP MODE INDICATOR
The Power Output setting is determined by the
operator and indicated on the lower LED display:
POWER OUT DISPLAY
The Power Output setting can be easily adjusted up or
down at any time during Manual Control mode
operation by depressing the Increment / Decrement
keys of the key pad:
CURRENT (AMPS) DISPLAY
Additionally, the operator may momentarily view load
current (amps) by pressing and holding the Increment
Key and the Decrement Key at the same time. (Refer
to the User Interface section below).
LOAD POWER INDICATION
In either Auto Control mode or Manual Control mode
power being delivered to the load is indicated:
LOAD POWER INDICATOR
The keys can be pressed and released one unit digit at
a time, or for larger changes, the key can be held down
for continuous change. In this mode the speed at which
the setting is changed is ramped from slow to very fast.
HRC-215 Hot Runner Controller
User’s Manual
The indicator flashes concurrently with the firing
(closing) of the load power output device (triac). Power
is delivered by time proportioned preset patterns. The
time interval between pulses is proportional to the
power requirement. The lower the power, the slower
Document No.: ED-0001-MN-021-F
June 1, 2006
the flash. Conversely, the higher the power the faster
the flash. For example, at maximum power output
(99%) the LED indicator will be on continuously. With
power off (0%) the indicator will never turn on.
The INCREMENT function is automatically active
(Select inactive) during normal Auto and Manual
Control modes and is used to increase the Setpoint
Temperature and Power Output level respectively.
WARNING! The Load Power Indicator lights
The SELECT function is automatically active
(Increment inactive) during Function Control mode and
is used by the operator to Select, or activate, different
control, display and operating modes. Function Control
operations are detailed below.
when the triac is turned on by the controller’s MCU
and is independent of voltage applied to the load!
The indicator not being illuminated is not a guarantee
that the control device (triac) is open. The HRC
controller will recognize a shorted triac fault (See
Diagnostic instructions below) and will notify the
operator. But, in this situation, the HRC controller can
not open or control the failed triac.
For this reason it is imperative that under a load fault
condition that the operator switch the controller power
disconnect switch (Fig. 1 Item #1) and also the
mainframe system disconnect to the “OFF” positions
before removing a controller or interconnect cabling.
USER INTERFACE
The user makes various control mode and setting
changes using the three momentary switch keypad on
the controller front panel (Fig. 1 Item #4, 5 & 6).
The operator simply pushes and holds the desired key
until the variable change is recognized on the
appropriate display. For multiple keystrokes of the
same key the user can hold the key in the closed
position rather than entering several individual
closures. In this event the controller continuously
repeats the function and the input becomes more rapid
the longer the key is held in.
It may be noticed that the HRC controller does not
accept quick individual key entries. The operating
program has a switch closure delay time requirement
that must be met before the controller will accept input
as a good key and react accordingly. This
precautionary measure is included to prevent the
controller from reacting to environmental noise.
CAUTION: The operator should not use anything other
than their finger to actuate a keypad key! The use of
pens, pencils, screwdrivers or other tools will damage
the keyboard assembly. Such damage is considered
abuse and is not included under warranty coverage.
The individual keys are described as follows:
INCREMENT / MODE SELECT KEY
This is a dual function key.
HRC-215 Hot Runner Controller
User’s Manual
DECREMENT KEY
The Decrement key is only active during normal Auto
and Manual Control modes and is used to decrease
the Setpoint Temperature and Power Output level
respectively.
MOMENTARY POWER (%) DISPLAY
SEL
Pressing and holding the Increment key and Function
key together will instantly display the load power (%)
being applied to the load. This feature is useful when
operating in Auto Control mode as it allows the user to
monitor changes of the required power being supplied
to the load.
Note that this value is an instantaneous value. Recall
that when operating in Auto Control mode the HRC is
constantly changing output power to maintain the
Setpoint Temperature. When the operator switches to
Manual Control mode, or the Automatic T/C Fault Hold
Control Mode Transfer is invoked, the HRC uses an
average power that is calculated over a longer period
of time. Therefore, the momentary power (%) value
may not match the average power (%) value.
MOMENTARY CURRENT (AMPS) DISPLAY
SEL
Pressing and holding the Increment key and
Decrement key together will instantly display the load
current (amps) being delivered to the load. This feature
is available whether operating in Auto Control mode or
Manual Control mode.
The monitored value is the average current (amps)
being delivered to the load. Because the HRC applies
power to the load using a pattern of voltage pulses,
true instantaneous current would be rapidly changing
from second to second and would be difficult for the
operator to interpret. The displayed average value is a
much more useful quantity to the user.
Document No.: ED-0001-MN-021-F
June 1, 2006
CURRENT (AMPS) MONITOR MODE SELECT
FUNCTION CONTROL KEY
The Function Control key is used during normal modes
of operation to call the Control and Operating Modes
menu. This menu is the operator’s way of selecting
different control modes (Auto or Manual), Current
(Amps) Monitor mode, temperature scale (°F or °C)
and to turn off Slow Start Control.
FUNCTION CONTROL MODE
As the operator activates the Function Control Key a
scrolling style menu displays control and mode function
mnemonics (abbreviations) on the lower LED display
(Fig. 1 Item #3). The controller simultaneously flashes
the associated Mode LED to assist the operator in
identifying the selection.
As stated above when the HRC is in Function Control
mode the SELECT function of the Increment/Select
key is automatically active (Increment inactive). As
shown in the following examples, pressing the Select
key will activate the Mode Function that is
currently displayed.
Repeatedly pressing the key toggles the user through
the menu in the following order:
AUTOMATIC CONTROL MODE
while the “current” menu
Pressing the Select key
option is displayed puts the HRC into Load Current
(Amps) Monitor mode.
The average load current (amps) will be continuously
displayed on the lower display (See Fig. 1).
When Current (Amps) is being displayed there is no
interruption to any of the control functions of the HRC.
TEMPERATURE SCALE SELECT (°F/°C)
while the Degree Mode
Pressing the Select key
menu option is displayed alternates the HRC
temperature scale from Degrees Fahrenheit to
Degrees Celsius (°F to °C) or from Degrees Celsius to
Degrees Fahrenheit (°C to °F).
Either the °F or °C LED Mode Indicator will be
continuously illuminated to indicate the selected mode
of operation.
SLOW START CONTROL DEACTIVATE
Pressing the Select key
while the “closed loop”
menu option is displayed puts the HRC into Auto
Control mode and immediately returns the controller to
“closed loop” control with the associated process
displays.
MANUAL CONTROL MODE
Pressing the Select key
while the “open loop”
menu option is displayed puts the HRC into Manual
Control mode and immediately returns the controller to
“open loop” control with the associated process
displays.
HRC-215 Hot Runner Controller
User’s Manual
Pressing the Select key
while the Slow Start
Control mode menu option is displayed aborts the HRC
Slow Start Control mode.
Note: If this operation is performed Slow Start Control
cannot be restarted from the menu! The only means of
reinitializing Slow Start is by turning controller power
“OFF” and then back “ON”. Also, this option (SLO) will
only appear in the menu when Slow Start Control is
active.
MENU ACTION FEATURES
1. The function display, when selected, will only
be active for 3 seconds with no user input. If
the menu is selected and there are no valid
key entries (Increment/Select or Function)
during this 3-second interval, the HRC will
revert back to the current control mode
process display.
Document No.: ED-0001-MN-021-F
June 1, 2006
2. The Decrement key is totally inactive during
Function Control / Menu Action. Therefore, if
the key is pressed the HRC will not respond.
3. When in Current (Amps) Monitor mode, both
the Increment and Decrement keys are totally
inactive.
4. The temperature control process is not
interrupted during Function Control activity.
The HRC continues “back ground” control,
whether in Auto or Manual Control mode. It
does not suspend control activity while waiting
for user input.
DIAGNOSTICS
The HRC controller has the capability to diagnose a
variety of unusual operating and fault conditions and
alert the operator so appropriate adjustments can be
made.
When the Process Temperature is lower than the
setpoint by 30°F (17°C) or more the HRC alerts the
user of an under-temperature alarm condition.
In this event the HRC controller will also apply a signal
on the mainframe communications bus (optional) that
is used to activate an audible and/or visual alarm
accessory. (The operator must enable the
communications output. See the Alarm Output
Selection instructions below).
Note: This feature is only active during normal Auto
Control mode operation. It is disabled through Slow
Start Control and PID Auto Tuning modes and
initializes when the process temperature reaches
setpoint.
Thermocouple Fault
OPEN THERMOCOUPLE
These conditions are described below and presented
with the associated display mnemonic and Condition
Indicator.
OVER SETPOINT ALARM INDICATION
DISPLAY SHOWN with
THERMOCOUPLE FAULT INDICATOR
When the HRC controller senses a temperature signal
over range (> 999°F or 537°C) it will display the fault
mnemonic on the Process Temperature display.
Alarm mnemonic alternates with Process Temperature
display.
When the Process Temperature exceeds the setpoint
by 30°F (17°C) or more the HRC alerts the user of an
over-temperature alarm condition.
In this event the HRC controller will also apply a signal
on the mainframe communications bus (optional) that
is used to activate an audible and/or visual alarm
accessory. (The operator must enable the
communications output. See the Alarm Output
Selection instructions below).
UNDER SETPOINT ALARM INDICATION
THE CONTROLLER WILL AUTOMATICALLY
SWITCH TO MANUAL CONTROL MODE AND THE
OUTPUT WILL BE IMMEDIATELY DISABLED
(OUTPUT POWER = 0%) UNTIL THE OPERATOR
OVERIDES THE FAULT (Increases output power
manually) OR RESETS THE CONTROLLER. (Turning
power “OFF” and then back “ON”).
UNLESS the operator chose to enable the Automatic
T/C Fault Hold feature, in which case the HRC will
continue to output the average power required to hold
setpoint temperature prior to the fault. (See the T/C
Fault Hold instructions detailed below).
If the HRC controller is in Auto Control mode and this
fault occurs, a signal will be applied on the mainframe
communications bus (optional) that is used to trigger
an audible and/or visual alarm accessory. (The
operator must enable the communications output. See
the Alarm Output Selection instructions below).
IF THE CONTROLLER IS IN MANUAL CONTROL
MODE it will continue to supply output power even
though a T/C fault is indicated. (The feedback is not
necessary for “open loop” control).
Alarm mnemonic alternates with Process Temperature
display.
HRC-215 Hot Runner Controller
User’s Manual
Document No.: ED-0001-MN-021-F
June 1, 2006
Thermocouple Fault
BACKWARD THERMOCOUPLE
(POLARITY REVERSED)
DISPLAY SHOWN with
THERMOCOUPLE FAULT INDICATOR
When the HRC controller senses a temperature signal
under range (< 32°F or 0°C) it will display the fault
mnemonic on the Process Temperature display.
THE CONTROLLER WILL AUTOMATICALLY
SWITCH TO MANUAL CONTROL MODE AND THE
OUTPUT WILL BE IMMEDIATELY DISABLED
(OUTPUT POWER = 0%) UNTIL THE OPERATOR
OVERIDES THE FAULT (Increases output power
manually) OR RESETS THE CONTROLLER. (Turning
power “OFF” and then back “ON”).
UNLESS the operator chose to enable the Automatic
T/C Fault Hold feature, in which case the HRC will
continue to output the average power required to hold
setpoint temperature prior to the fault. (See the T/C
Fault Hold instructions detailed below).
If the HRC controller is in Auto Control mode and this
fault occurs, a signal will be applied on the mainframe
communications bus (optional) that is used to trigger
an audible and/or visual alarm accessory. (The
operator must enable the communications output. See
the Alarm Output Selection instructions below).
IF THE CONTROLLER IS IN MANUAL CONTROL
MODE it will continue to supply output power even
though a T/C fault is indicated. (The feedback is not
necessary for “open loop” control).
Thermocouple Fault
SHORTED THERMOCOUPLE
DISPLAY SHOWN with
THERMOCOUPLE FAULT INDICATOR
When the HRC controller is applying full power to the
load and senses a temperature rise no greater than
3°F (1.7°C) over the default (90 second) or the user
selected (250 second) time period the fault mnemonic
will be displayed on the Process Temperature display.
(The mnemonic will alternate with the Process
Temperature although the sensor input may not reflect
the actual temperature of the load).
HRC-215 Hot Runner Controller
User’s Manual
THE CONTROLLER WILL AUTOMATICALLY
SWITCH TO MANUAL CONTROL MODE AND THE
OUTPUT WILL BE IMMEDIATELY DISABLED
(OUTPUT POWER = 0%) UNTIL THE OPERATOR
OVERIDES THE FAULT (Increases output power
manually) OR RESETS THE CONTROLLER. (Turning
power “OFF” and then back “ON”).
UNLESS the operator chose to enable the Automatic
T/C Fault Hold feature, in which case the HRC will
continue to output the average power required to hold
setpoint temperature prior to the fault. (See the T/C
Fault Hold instructions detailed below).
UNLESS THE SHORTED THERMOCOUPLE (Sho)
DIAGNOSTIC IS DISABLED, In which case the HRC
will remain in Auto Control mode applying full power.
The fault mnemonic will continue to be displayed
alternating with the Process Temperature and an alarm
signal (if enabled) will be applied to the mainframe
communications bus.
If the HRC controller is in Auto Control mode and this
fault occurs, a signal will be applied on the mainframe
communications bus (optional) that is used to trigger
an audible and/or visual alarm accessory. (The
operator must enable the communications output. See
the Alarm Output Selection instructions below).
Accidental Fault Indication may be invoked when
trying to start very heavy, slow changing loads. If this is
suspected the operator can override the fault by
increasing the Output Power setting. This action should
be continued until the Process Temperature is driven
to or above Setpoint Temperature. Once this
temperature has been reached the HRC can be
switched back into Auto Control mode and normal
operation should commence.
If this attempt fails to increase the Process
Temperature a true fault condition may exist. The
operator may take the following course of action:
1. TURN OFF CONTROLLER AND MAINFRAME
SYSTEM POWER and disconnect the
interconnect cabling from the mold. It is now
safe to thoroughly inspect the suspected faulty
thermocouple and take appropriate action.
Service personnel should make certain that the
appropriate T/C is connected to its respective
controller and inspect all associated wiring.
2. If the operator allowed the controller to run at
99% power and realized no temperature
increase, and trouble shooting the control
system power and T/C circuits determined no
error, there could be a design problem with the
mold. If the tool is being run for the first time
and will not come up to temperature, the watt
density of the problematic zone heater may be
too low. A thorough review of the mold design
by a qualified engineer may be necessary.
Document No.: ED-0001-MN-021-F
June 1, 2006
Additionally, low line voltage can lead to poor
response from the heaters. Again, if no
thermocouple errors are discovered, a full
system analysis may need to be done by
qualified personnel.
IF THE CONTROLLER IS IN MANUAL CONTROL
MODE it will continue to supply output power even
though a T/C fault is indicated. (The feedback is not
necessary for “open loop” control).
USER SELECTABLE SHORTED
SAMPLE TIME or DISABLE
T/C
As stated above, accidental fault indication may be
invoked when trying to start very heavy, slow changing
loads. If this is suspected the operator can change the
Shorted T/C diagnostic test sample time. As stated
above, the HRC requires a temperature rise of 3°F
(1.7°C) over a preset time period to not call a Sho fault.
The factory default time is 90 seconds, but heavy
thermal loads often require more time than this to
register changes in temperature. If the user suspects
such a load is being controlled the test time period may
be changed to 250 seconds by activating the “Sho T/C
LONG DELAY” DIP switch of SW4. (See Fig. 2). The
switch bank SW4 must be set to the user’s
requirements as detailed in Figure 2.
If the user continues to experience errant fault
recognition the Shorted T/C diagnostic can be
disabled. In the same manner as enabling the Sho T/C
long delay, the “Sho T/C *OFF*” DIP switch of SW4
must be activated as detailed in Figure 2.
CAUTION: IT IS STRONGLY RECOMMENDED
THAT SHORTED T/C DIAGNOSTIC NOT BE
DISABLED! Under this condition the HRC will continue
to apply full (99%) output power to a load that may
have
a
faulty
thermocouple.
Under
these
circumstances THE PROCESS TEMPERATURE
DISPLAY IS NOT REPRESENTATIVE OF THE TRUE
TEMPERATURE OF THE LOAD. The heater may be
creating an extremely high temperature that could
create dangerous and volatile conditions.
To change the printed circuit board SW4 Sho DIP
switches it will be necessary to turn the HRC controller
and mainframe power **OFF** and remove the
controller from the mainframe.
WARNING!
THE CONTROL SYSTEM MAINFRAME MAIN
POWER DISCONNECT MUST BE IN THE “OFF”
POSITION BEFORE INSERTING OR REMOVING
CONTROL MODULES TO PREVENT OPERATOR
INJURY AND DAMAGE TO CONTROL SYSTEM
COMPONENTS!
HRC-215 Hot Runner Controller
User’s Manual
Switch SW4 is located near the top of the printed
circuit board and is easily accessible without removing
the HRC side panel.
Note that if both the “Sho LONG” and “Sho OFF” DIP
switches are accidentally selected the HRC will
recognize the errant switch selection and respond to
the Shorted T/C diagnostic in the default 90 second
time period. Having both Sho DIP switches activated
will be interpreted as an error by the HRC.
Load Fault
OPEN OUTPUT (LOAD OR TRIAC)
DISPLAY SHOWN with
LOAD FAULT INDICATOR
When the HRC senses load current (amps) less than
or equal to 100 milliamperes (0.10 amps) while it has
output power set greater than 25% this fault mnemonic
will be displayed on the Process Temperature display.
There is either a failed open condition with the output
control device (triac) or an open in the load power
circuit, such as the interconnect cabling, mold
connector or heater wiring.
THE HRC ANTI-ARC CIRCUIT MUST BE
COMPLETED! (Refer to the voltage anti-arc feature
section above). If the Anti-Arc circuit is not closed by
either the mainframe edge connector contact #3
(preferred, anti-arc enabled) or by installation of PC
board jumper P5 (anti-arc disabled), the HRC MCU will
not be able to turn the power output control device
(triac) on!!
The HRC controller in the faulty zone may be swapped
with another working controller to verify proper
operation of the output control device (triac). If the triac
fails open the controller MCU will not be able to apply
power to the load.
This Load Diagnostic is active in either Auto or
Manual Control modes.
The controller will remain in Auto Control mode with
output power on until the load current (amps) exceeds
100 milliamperes (0.10 amps). If this occurs the HRC
will then continue in normal Auto Control mode.
In this event the HRC controller will also apply a signal
on the mainframe communications bus (optional) that
is used to activate an audible and/or visual alarm
accessory. (The operator must enable the
communications output. See the Alarm Output
Selection instructions below).
Document No.: ED-0001-MN-021-F
June 1, 2006
Load Fault
SHORTED OUTPUT (LOAD OR TRIAC)
DISPLAY SHOWN with
LOAD FAULT INDICATOR
When the HRC senses load current (amps) greater
than 100 milliamperes (0.10 amps) while it has output
power turned off (0% output power) it will display this
fault mnemonic on the Process Temperature display.
The controller will remain in Auto Control mode with
output power off (0%) until the load current (amps)
returns to less than or equal to 100 milliamperes (0.10
amps) If this occurs the HRC will then continue in
normal Auto Control mode.
WARNING!! The HRC is not in control of the load
and corrective measures should be taken
immediately!
There is either a failed closed (shorted) condition with
the output control device (triac) or an uncontrolled
closure of the load power circuit beyond the control
module that is causing the load to heat out of control.
The operator should turn HRC controller power and the
mainframe control system power “OFF” and determine
the cause of the problem.
The HRC controller in the faulty zone may be swapped
with another working controller to verify proper
operation of the output control device (triac). If the triac
fails closed the controller MCU will not be able to turn
off power to the load.
It is critical that the HRC controller power switch
be turned “OFF” before removing the HRC
controller! If the triac has failed shorted, there may be
current flow through the module. Removing the
controller under these circumstances can result in
operator injury and controller / control system damage.
THE ENABLED VOLTAGE ANTI-ARC FEATURE
WILL NOT ELLIMINATE THIS DANGER!
of indication was selected to notify the operator that a
short fault might have driven the temperature over
range, rather than defaulting to only the open
thermocouple indication. If these two fault conditions
occur the HRC will be forced into Manual Control mode
with output power turned off (0%).
In this event the HRC controller will also apply a signal
on the mainframe communications bus (optional) that
is used to activate an audible and/or visual alarm
accessory. (The operator must enable the
communications output. See the Alarm Output
Selection instructions below).
ALARM OUTPUT SELECTION
If enabled, the HRC controller has the capability to
activate an alarm signal on the mainframe
communications bus (optional). The alarm signal will
be automatically activated in the event of any of the
above listed operating fault conditions and is used to
trigger audible and/or visual alarm accessories, such
as the GMFTA-205 mainframe alarm accessory.
Prior to applying power the operator must select and
enable the appropriate accessory circuit using
hardware jumper P4 on the PC board. (See the
Component Layout of Figure 2). The jumper must be
moved from the factory default setting (open circuits) to
a position that will complete the appropriate alarm
circuit required by the type of accessories being used.
The labeling on the PC board will assist the operator in
selecting the required circuit for either the standard
HRC accessory (GMFTA-205) and common †D-M-E®
TAS (labeled “EQUIV”) or ‡Athena® SAM (labeled
“ALTERNATE”) alarm accessories.
CAUTION! The alarm output circuit of the HRC is
similar to others on the market. In an alarm condition
communications pins #4 or #6 (selectable) are
connected to pins #11 and #12. The MAXIMUM
allowable current through this completed circuit is
100mA and it is the accessory component’s
responsibility to limit this current. If the user is not
sure of accessory compatibility the local sales
representative or distributor should be contacted
for clarification before one of the selectable
circuits is chosen.
This Load Diagnostic is active in either Auto or
Manual Control modes.
The HRC has set the output power to 0% (off) and if in
Manual Control mode the Increment Key will be
inactive! The HRC will not allow the operator to
increase power in this uncontrolled situation.
If the probable fault drives the Process
Temperature out of range (exceeds 999°F / 537°C)
the shorted output mnemonic (ShO) will alternate with
the open thermocouple mnemonic (oPE). This manner
HRC-215 Hot Runner Controller
User’s Manual
Document No.: ED-0001-MN-021-F
June 1, 2006
AUTOMATIC T/C FAULT HOLD
CONTROL MODE TRANSFER
ALTERNATING MNEMONICS
If enabled, the HRC controller has the ability to
automatically switch from Auto Control mode to Manual
Control mode and maintain output power in the event
of T/C loss (closed loop break). When this transition is
made the HRC will continue with ouput power set to
the average power required to maintain setpoint prior
to the T/C fault.
When the HRC enters this mode of operation the
above detailed mnemonics will alternate on the
Process Temperature display at 3-second intervals.
The power setting being used will also be continuously
displayed on the Setpoint / Power display.
The alternating mnemonics alarm the user of a fault
condition, indicate the type of fault (reversed T/C used
in the example above) and inform the operator that the
HRC automatically changed to Manual Control mode.
Note: This output power level will most likely not be
able to hold the former setpoint but it will bring the load
to a constant temperature that may be close to the
former setpoint value. As the controller is working in
Auto Control mode it is continually changing output
power to maintain Setpoint Temperature. These
continuous changes are required to keep up with
process upsets to the thermal system.
ENABLING AUTO T/C FAULT HOLD
Prior to applying power the operator must enable this
automatic function. The “AUTO T/C HOLD” DIP switch
of SW4 must be changed from the factory default
setting (T/C Fault Hold disabled) to the closed circuit
position. (See the Component Layout of Figure 2.)
A DIP switch on the PC board was selected for this
feature to insure that the user’s desire to take
advantage of Automatic Fault Hold was deliberate. In
some situations it may not be desirable for the
controller to take over before an appropriate evaluation
of the fault can be made.
TYPE “K” THERMOCOUPLE
SELECTION
The HRC can be changed to operate with type “K”
Thermocouple feedback. Prior to applying power the
operator must change the T/C input to type “K.” The
“TYPE ‘K’ T/C” DIP switch of SW4 must be changed
from the factory default setting (“J” type) to the closed
circuit position (“K” type). (See the Component Layout
of Figure 2.)
The thermocouple amplifier and conditioning circuitry
of the HRC was designed to operate specifically with
the industry standard type “J” thermocouple. By
selecting the type “K” option, the software of the
controller mathematically compensates for the
difference between the type “J” and type “K”
thermocouple signals and is accurate enough for most
control applications. Recalibration of the HRC in type
“K” mode is not necessary.
FUNCTION CONTROL / MENU KEY
DISABLE
To prevent unauthorized personnel from changing
control parameters the FUNCTION CONTROL / MENU
KEY of the HRC can be disabled. This should only be
done once HRC set-up to a particular mold zone
(heater) has been completed and is operating
satisfactorily without user intervention. (Once the
FUNTION CONTROL KEY is disabled it will be
inconvenient for the operator to change operating
modes because the controller will have to be removed
from the mainframe to reactivate the FUNCTION
CONTROL KEY.)
To change the printed circuit board SW4 FUNCTION
CONTROL KEY ENABLE switch it will be necessary to
turn the HRC controller and mainframe power **OFF**
and remove the controller from the mainframe.
First time use: To prevent unauthorized use of this
feature the factory installs resistor R56 across the DIP
switch to make the switch inoperable. (See the
Component Layout of Figure 2.) This resistor must be
removed from the printed circuit board. (It will be
necessary to desolder the component using a
soldering iron. This should only be done by qualified
personnel to prevent damage to the printed circuit
board and / or surrounding components.)
Once enabled the HRC will always change to Manual
Control mode with output power in the event of a T/C
fault. To again disable the feature the operator must
switch the DIP switch to the inactive, or open, position.
HRC-215 Hot Runner Controller
User’s Manual
Document No.: ED-0001-MN-021-F
June 1, 2006
Once the resistor has been removed, the “FUNCTION
KEY ENABLE” DIP switch of SW4 will be operational.
To disable the FUNCTION CONTROL KEY, the DIP
switch should be down, or in the open position.
To enable, or reactivate, the FUNTION CONTROL
KEY, the DIP switch should be up, or in the closed
position.
MAINTENANCE
The HRC controller requires very little maintenance for
continuous,
reliable
and
accurate
operation.
Depending on the atmosphere of the facility it may be
appropriate to periodically clean the main printed circuit
board assembly. This should only require blowing off
dust and debris using clean and dry compressed air.
If the printed circuit board has been soiled and the air
is not sufficient it is acceptable to clean the board,
components and component leads using ISOPROPYL
ALCHOHOL only. Be sure that the board and
components are completely dry before reapplying
power to prevent unsafe and damaging short circuits.
If the faceplate / keyboard assembly needs to be
cleaned use only a DAMP RAG AND MILD
DETERGENT. Gently rub the polycarbonate overlay to
remove any oil and debris. Be sure that all components
are completely dry before reapplying power to prevent
unsafe and damaging short circuits.
TYPE “J” T/C TEMPERATURE CALIBRATION
STEP 1: With the thermocouple input set to 200°F
(93°C). Slowly turn Pot R27 (Low Cal) as required until
the HRC Process Temperature display reads the same
as the simulator (200°F / 93°C).
STEP 2: Change the calibrator input to 800°F (427°C).
Slowly turn Pot R19 (High Cal) as required until the
HRC Process Temperature display reads the same as
the simulator (800°F / 427°C).
Turn the potentiometers slowly and STOP when
resistance is met to avoid unintentional physical
damage to the components!
STEP 3: Repeat steps 1-2 as many times as
necessary until the low end and high end displays
consistently match the simulator.
Note: It should only be necessary to repeat these steps
2-3 times to calibrate the HRC. If calibration has not
been achieved after several attempts there may be
component malfunctions that need serviced. Contact
your local sales representative or distributor to make
arrangements to return the controller for repair by an
authorized technician.
TYPE “K” T/C TEMPERATURE CALIBRATION
It is not necessary to recalibrate the HRC using a type
“K” T/C input to operate properly in type “K”
Thermocouple input mode. Insure that the controller is
in calibration using the standard type “J” T/C input.
CALIBRATION
The manufacturer recommends that the HRC controller
be calibrated every 12 months to maintain accuracy
and to perform within the operating specifications.
Arrangements can be made with a sales representative
to have the HRC controllers calibrated using standards
and equipment traceable to each region’s respective
governing agencies.
TEMPERATURE CALIBRATION
There are two temperature calibration potentiometers
on the main printed circuit board (See Fig. 2). Pot R27
is used to set the low end of the temperature scale and
pot R19 is used to set the high end of the scale.
For the highest accuracy it is recommended to
calibrate the HRC controller in the degrees
Fahrenheit (°F) temperature scale.
A “J” type thermocouple calibrator (millivolt source) is
required to calibrate the HRC. The simulated T/C
signal must be applied directly to the controller edge
card “finger” contacts. (Fig. 2; T/C polarity is critical).
HRC-215 Hot Runner Controller
User’s Manual
Document No.: ED-0001-MN-021-F
June 1, 2006
CURRENT (AMPS) CALIBRATION
REPLACEMENT PARTS
There is a current (amps) calibration potentiometer on
the main printed circuit board (See Fig. 2). Pot R46 is
used to set the load current scale.
It is recommended that the HRC controller be returned
to an authorized representative for repair and
calibration service.
STEP 1: Drive a known resistive load with the HRC set
in Manual Control mode with output power set at
99%. Full output power will eliminate the pulsing action
of the HRC lower output power and is the only way to
accurately calibrate the current (amps) circuit.
Warning: HRC service by unauthorized personnel may
void warranty coverage!
The resistive load may be a heater less than 3600
watts. Whatever type of load is chosen must be
capable of safely dissipating the supplied power of the
HRC to prevent a hazardous condition.
STEP 2: Unless it is already known, measure and
record the resistance (ohms) of the load and the
applied voltage, and calculate the load current. For
example:
Some component failures are easily recognized and
can be quickly repaired in the field by qualified
maintenance personnel. The following list of
replacement parts identifies these components that are
readily available through local sales representatives
and distributors.
DESIG.
F1, F2
SW1
240 Volts (applied) ÷ 41 Ohms = 5.8 Amps
T1
OR
T2
If the power (watts) of the load is known, calculate the
load current using the applied voltage. For example:
1400 Watt Heater ÷ 240 Volts (applied) = 5.8 Amps
STEP 3: Switch the HRC into Current (Amps) Monitor
mode.
STEP 4: Adjust pot R46 until the Current (amps)
Display of the HRC displays the correct calculated load
current (amps). From the examples above, 5.8 amps
Turn the potentiometer slowly and STOP when
resistance is met to avoid unintentional physical
damage to the components!
Q1
R24
U2
U3
U5, U9
U8
U10
U6, U7
U4
MOV1
----
DESCRIPTION
PART NO.
FUSE – 15 AMP 250VAC
**Type ABC15 only***
POWER SWITCH
16A 250VAC
TRANSFORMER
240/120VAC PRIMARY
TRANSFORMER
CURRENT SENSING
TRIAC
40 AMP 600VAC
RESISTOR FUSE – 2.2K
**Flameproof Type Only**
IC – DISPLAY DRIVER
IC – DISPLAY DRIVER
IC – OPTOCOUPLER
IC – TRIAC DRIVER
143-004
164-500
164-501
163-500
163-502
158-001
154-001
154-011
162-100
152-504
IC - +5VDC REGULATOR
163-503
IC – AMPLIFIER
163-501
IC – EEPROM MEMORY
164-502
MOV – 275 VOLT
SURGE (OVER VOLTAGE)
PROTECTOR
KEYBOARD ASSEMBLY
Includes new front panel
159-303
158-100
Refer to the Component Layout (Fig. 2)
HRC-215 Hot Runner Controller
User’s Manual
Document No.: ED-0001-MN-021-F
June 1, 2006
ACCESSORY ALARM
OUTPUT SELECT
JUMPERS
FUNCTION KEY ENABLE
SELECTOR SWITCH
AUTOMATIC T/C FAULT HOLD
SELECTOR SWITCH
FUNCTION KEY
DISABLED
FACTORY DEFAULT
AUTO T/C HOLD DISABLED
** R56 MUST BE REMOVED FROM THE
BOARD TO ACTIVATE THIS FEATURE **
ACTIVATE SWITCH FOR
AUTO T/C FAULT HOLD ENABLED
FACTORY DEFAULT
OUTPUTS DISABLED
ACTIVATE SWITCH FOR
FUNCTION KEY
ENABLED
INSTALL JUMPER FOR
SHORTED THERMOCOUPLE
SAMPLE TIME SELECTOR SWITCH
HRC or EQUIVALENT
ALARM ACCESSORY
FACTORY DEFAULT
90 SECOND SAMPLE / DELAY TIME
TEMPERATURE and
CURRENT (AMPS)
CALIBRATION
POTENTIOMETERS
INSTALL JUMPER FOR
ALTERNATE
ALARM ACCESSORY
NOTE: TOP TWO (2) JUMPERS
RESERVED FOR FUTURE
SERIAL COMMUNICATIONS
ACTIVATE SWITCH FOR
LONG - 250 SECOND SAMPLE / DELAY TIME
ACTIVATE SWITCH FOR
SHORTED T/C (Sho) DISABLED **CAUTION**
REFER TO CALIBRATION
INSTRUCTIONS DETAILED
IN THE USER’S MANUAL
THERMOCOUPLE TYPE
(J / K) SELECTOR SWITCH
FACTORY DEFAULT
TYPE “J” THERMOCOUPLE SELECTED
ACTIVATE SWITCH FOR
TYPE “K” THERMOCOUPLE
P4
T/C WHT (+)
T/C RED (-)
ANTI-ARC
AC LOAD
AC LOAD
AC INPUT
AC INPUT
GROUND
U6
CALIBRATION TEMP
HIGH - 800°F
U5
CALIBRATION
AMPS
R27 R46 R19 1 2 3 4 5 6
U2
SW4
U1
U7
U4
R56
R24
2.2K
U3
0.0
MUST BE REMOVED TO ACTIVATE
FUNCTION KEY ENABLE /
DISABLE DIP SWITCH
*FLAMEPROOF*
FUSIBLE LINK
U8
P5
U9
P2
*ANTI-ARC PROTECTION*
TRIAC GATE DISABLE
T2
T1
U10
P1
F1
275V
TYPE “J”
THERMOCOUPLE
P3
SELECT
Sho T/C LONG DELAY
P3 FOR FACTORY USE ONLY!
Sho T/C *OFF* CAUTION! ONLY ONE!
TYPE K T/C
FUNCTION KEY ENABLED
**PROGRAMMER**
A C T I VAT E
AUTO T/C HOLD
JUMPER
TxD
RxD
HRC or EQUIV.
ALTERNATE
CALIBRATION TEMP
LOW - 200°F
COMMUNICATIONS
*** REQUIRES RECALIBRATION ***
F2
MOV1
ABC TYPE FUSE ONLY
ABC15 or LESS
WARNING!!
ANTI-ARC PROTECTION
TRIAC GATE CUT-OFF JUMPER
JP3
JP2
TRANSFORMER PIN #1
*PRIMARY SIDE - 240VAC*
FACTORY INSTALLED “JP1” SHOWN ABOVE
*** 240 VAC ***
JP1
ALTERNATE SETTING “JP2” & “JP3”
120 VAC
FACTORY DEFAULT
ANTI-ARC FEATURE ENABLED
INPUT VOLTAGE JUMPERS
INSTALL JUMPER FOR
ANTI-ARC FEATURE DISABLED
SOLDER INSTALL #22-#28 AWG WIRE JUMPER
HRC-215 Hot Runner Controller
User’s Manual
Figure 2
Component Layout
Supplement Dwg. No.: ED-0001-AS-022-D
Document No.: ED-0001-MN-021
February 21, 2006
DISCLAIMER
LIMITED WARRANTY
The information contained in this manual is proprietary
and supplied for customer use only.
The manufacturer warrants that this product will be free
from defects in materials and workmanship for a period
of one year from the date of shipment.
Any unauthorized reproduction of this document is
strictly prohibited.
All information contained in this document is deemed
accurate at the time of its publication. Every effort will
be made to insure that its contents match the hardware
supplied. Specifications, hardware and software are
subject to change without notice and the manufacturer
assumes no obligation of informing the holder of this
document of such changes.
†D-M-E®, G-Series® and Smart Series® are all
registered trademarks of D-M-E Company.
‡Athena is a registered trademark of Athena Controls,
Incorporated.
HRC-215 Hot Runner Controller
User’s Manual
The manufacturer, at its discretion, may or may not
grant warranty service if it is determined that this
product has been abused, used in a system or
application which it was not designed for, altered or
tampered with by unauthorized personnel.
If warranty service is applicable the manufacturer, at its
option, may either repair the damaged product without
charge for parts and labor or provide a replacement
product in exchange for the defective unit.
This
warranty
excludes
fuses.
Appropriate
arrangements must be made with a sales agent prior to
the return of any material.
Document No.: ED-0001-MN-021-F
June 1, 2006
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