M SERIES I Temperature Controller Instruction Manual
M SERIES INSTRUCTION MANUAL TABLE OF CONTENTS 1 INTRODUCTION 1.1 1.2 MAIN FUNCTION MAIN FEATURES OF VARIOUS CABINET CONFIGURATIONS 1.3 Power Output 1.4 Tolerance on Supply Power 1.5 Maximum Power Consumed Depending on Cabinet Configuration 1.6 Maximum Allowable Current Depending on Cabinet Configuration 1.7 Cabinet Classes Pg. 3 Pg. 4 Pg. 5 Pg. 5 Pg. 5 Pg. 5 Pg. 5 1.8 MAIN FEATURES OF POWER CONTROL CARDS 1.9 Plant Power Supply 1.10 Tolerance on Plant Power Supply 1.
M SERIES INSTRUCTION MANUAL TABLE OF CONTENTS 2.25 Connecting Diagram 2.26 Activation of Mold Scan 28 to 29 2.27 Start Mold Analysis 2.28 Display Results 2.29 Power Percentage Monitoring 2.30 Display Alarms 2.31 Display Curves 2.32 Operating Mode for Replacing a 16A Control Card 2.33 Operating Mode for Replacing a 5A Control Card 2.34 Operating Mode for Replacing a Thermocouple Input Card 2.35 List of Spare Parts Pg. 25 Pg. 26 Pg. 27 Pg. 28 Pg. 29 Pg. 31 Pg. 31 Pg. 32 Pg. 32 Pg.
M SERIES INSTRUCTION MANUAL INTRODUCTION 1 1 INTRODUCTION The M Series of temperature controllers are designed for precision control of the hot runner system at constant temperature for optimized efficiency. This new generation of hot runner control systems uses one single microprocessor for controlling up to 24 zones, making all configurations compact. M Series controllers are ideally suited for mid to high volume molding requiring 16 to 128 zones.
1 M SERIES INSTRUCTION MANUAL INTRODUCTION 1.2 CABINET CONFIGURATIONS Cabinets are submitted to EC 73/23 Directive known as “Low Voltage” and conform to EN 61010-1 Standards. Each cabinet is equipped with a supply cable sized according to the maximum admissible current. • Voltage in three phases either in 230V or 400V with Neutral. • Maximum allowable current: depends on diameter and length of supply cable.
M SERIES INSTRUCTION MANUAL INTRODUCTION 1.3 Power Output 230V 3 Phases 60 Hz or 400V 3 Phases + Neutral 50 Hz when required. The choice is made when ordering the cabinet (see below). 2 1.6 Maximum admissible current per cabinet configuration Cabinet M4U-16.00: 63A Cabinet M4U-08.08: 63A Cabinet M4U-00.16: 40A 1.4 Tolerances on supply voltage Cabinet M4U-00.24: 40A 207V to 253V, or 360V to 440V when applied. Cabinet M9U-00.32: 40A 1.5 Maximum consumed power per cabinet configuration Cabinet M9U-00.
1 M SERIES INSTRUCTION MANUAL INTRODUCTION 1.8 MAIN FEATURES OF POWER CONTROL CARDS 1.14 Power supply 12V DC. Power control cards are submitted to the EC 73/23 Directive known as “Low Voltage” and conform to EN 61010-1 standards. Depending on cabinet configuration, two types of power control cards that can be integrated in M Series cabinets: 16A power control card (3600W) and 5A power control card (1000W). 1.15 CONNECTION TO PLANT POWER Controllers should be grounded to a suitable ground.
M SERIES INSTRUCTION MANUAL OPERATION 2 2 OPERATION 2.1 Overall diagram www.incoe.com ©INCOE® CORPORATION 8/2010 Pg.
2 M SERIES INSTRUCTION MANUAL OPERATION 2.2 Electronic diagram of power control card 16A Pg. 8 © INCOE® CORPORATION 8/2010 www.incoe.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.3 Electronic diagram of power control card 5A www.incoe.com ©INCOE® CORPORATION 8/2010 Pg.
2 M SERIES INSTRUCTION MANUAL OPERATION 2.4 Electrical diagram for power on cabinet M4U-16.00 Pg. 10 © INCOE® CORPORATION 8/2010 www.incoe.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.5 Electrical diagram for commands on cabinet M4U-16.00 www.incoe.com ©INCOE® CORPORATION 8/2010 Pg.
2 M SERIES INSTRUCTION MANUAL OPERATION 2.6 Safety conditions M Series cabinets are fitted with: - American standard: Iron: White / Constantan: Red - circuit breaker for tool protection. - electronic circuit for monitoring of voltage for device protection against faulty and overvoltage (10% of extra power is admissible). - Venting, filter (must be cleaned frequently to prevent damage). ‘’+’’ is Iron and can easily be identified with a magnet.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.8 Power output For 16A and 5A power control cards, heaters are connected to a female HARTING HAN E 24 pins 16A connector. Wiring diagram according to INCOE standard: A sticker is affixed on the upper cover of the cabinet (version 4U) or on backside of cabinet (version 9U and superior): 2.10 Communication according to EUROMAP 17 protocol Base Power 48 pins 16A Type HARTING HAN E WITH FEMALE INSERT. Each zone Nbr.
2 M SERIES INSTRUCTION MANUAL OPERATION 2.11 OPERATOR INTERFACE LCD Display Direction arrows and Enter key Explanation of program icons These keys are for accessing functions as defined on the LCD screen. Enter key and key for zone selection. Keep it pressed for 2 seconds for selecting all zones or a group of zones. In case zone groups have been defined, press this key to apply a new function to all zones in this group. Escape key. Key to delete an input completely or partially.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.12 START UP Connect power supply cable to an appropriate power supply (See sticker on the backside). Check thoroughly the wiring going to and from the cabinet. Switch on the cabinet with the circuit breaker on backside. After 10 seconds, the following page is displayed: Serial No. of cabinet Program release No. inside CPU Serial No.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.13 Temperature page A A: B: C: D: E: I B H F: G: H: C D E G F I: Actual temperature value in °C or °F. Setpoint in °C or °F. Decrease setpoint value. Increase setpoint value. To access the page for configuring control parameters. To access page for parameters of control zones.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.15 Mode page A I B C D E F G H A: 1st setpoint. B: Control zone in automatic mode. C: Control zone in manual mode. D: To switch a zone on or off. E: To switch a zone from automatic to manual mode. F: To switch from 1st setpoint to 2nd setpoint. G: To activate the BOOST function. H: To access next page (Temperature page). I: Indicates the zone is in BOOST mode. www.incoe.com ©INCOE® CORPORATION 8/2010 Pg.
2 M SERIES INSTRUCTION MANUAL OPERATION 2.16 EXPLANATION OF THE VARIOUS DISPLAY PAGES (From the mode page) Press CONFIG to access the following page: A: To modify system date (with the alphanumeric keyboard). A B C D E F B: To modify system time (with the alphanumeric keyboard). C: To read ambient temperature inside cabinet via a sensor on CPU card. G H I J D: To modify language. You may select among 5 languages : French, English, German, Italian and Spanish (see screen below).
M SERIES INSTRUCTION MANUAL OPERATION 2 Press CGF2 to access the following page: A B C D E F A: To select the temperature unit (°C or °F). B: To define a minimum setpoint. C: To define a maximum setpoint. D: To select a type of sensor (type J or type K). E: To allow the automatic switch to manual mode in case of thermocouple breakage. If so, the last percentage of power calculated by the CPU is applied to the zones with broken sensors. If not, the power is cut and the zone remains in automatic mode.
2 M SERIES INSTRUCTION MANUAL OPERATION 2.17 CONFIGURATION OF CONTROL PARAMETERS Keys to scroll in parameters in both directions 2.
M SERIES INSTRUCTION MANUAL OPERATION 2 Example : Label of zone 1. Zone 1 is selected : it is displayed with white background Window for parameter modification www.incoe.com ©INCOE® CORPORATION 8/2010 Pg.
2 M SERIES INSTRUCTION MANUAL OPERATION 2.19 Locking keyboard Still in the status page, press to access the following page: Display mode 2 zones on screen Access to the parameters can be locked by using the password. The factory setting is 123456. 2.20 Zooming on zones Pressing the ZOOM key enables the selection to the zoom level on display. You may display 1 zone, 2 zones or 4 zones on the screen: Display mode 4 zones on screen To change this password, please see page 18, part G.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.21 File Management From the status page, press the FILE key to access the page for file management: The arrow shows the selected file from the list File with the white background: the settings in this file are currently in use Miscellaneous information about the selected file A B C D E This page is for file management. Each file may contain the author, mold and part number as well as free comments. A: To create a new file.
2 M SERIES INSTRUCTION MANUAL OPERATION 2.22 Modification of zone status A: To switch on and off one or more zones. A message OFF is displayed when switched off. B: To switch from automatic to manual mode and vice-versa. C: To switch from 2nd setpoint to 1st setpoint and vice-versa. D: To activate the BOOST function to be configured in the PARAM page. The BOOST function is stopped after a predefined time or by pushing the BOOST key a second time. (see page 23 part E and part 13.2).
M SERIES INSTRUCTION MANUAL OPERATION 2 2.24 MOLDSCAN OPTION 2.25 Connecting diagram The aim of this option is to analyze the electric heaters inside the tool by measuring the current zone by zone in order to define: - installed electrical power (in Watts). - the temperature increase (in Degrees/Minute). It shows all alarms (thermocouple broken or reversed, open load ...) in a dated logbook. It also shows in real time a diagram about the temperature changes and the setpoint for a selected zone.
2 M SERIES INSTRUCTION MANUAL OPERATION 2.26 Activation of MoldScan Turn to on the line ”Activate MoldScan option” with the left and right arrows, then validate; this is done from the System page (CFG1) or in the MODIF menu. Line “Automatic Analysis “: when this feature is selected, a diagnostic on the zone(s) in automatic mode and currently under temperature low or high alarms is performed. A new Scan is carried out on these zones until the alarm disappears.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.27 Start mold Analysis The following page is displayed when pressing the SCAN menu: Select YES for “Advanced Data Analysis” and validate. This starts a detailed Analysis of control zones and to define all parameters described in 14.2. If you select NO, a shorter Analysis will be carried out. All parameters described in 14.2 except the response time (in degree /minute). With the direction arrows, select YES and enter to start a MoldScan Analysis.
2 M SERIES INSTRUCTION MANUAL OPERATION 2.28 Display results The following page is displayed when the diagnostic is over: A message asking if saving is required is shown. Press MEAS to display results when the Analysis of the control zones is over. The page below is displayed: Tip: It is recommended to save values of the Analysis by selecting YES with the left and right arrows, then enter. The first parameter displayed is the reference current value saved during the Scan process.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.29 Power percentage monitoring This function allows to obtain an alarm signal when the percentage of power sent to the heaters in the mold is considered as out of the normal values. You have to give the system a reference value on each zone. This value is a percentage of power in reference to the average percentage of power on the zone. The average value is refreshed every second so that an alarm could be declared every second.
2 M SERIES INSTRUCTION MANUAL OPERATION By selecting REF, you can memorize the actual Average power output values (PCA) as Reference values (PCR), as shown below: Reference power (PCR) (defined by the user) Then, you have to set a monitoring tolerance value (PCS) Monitoring tolerance between 0 and 100%. If this value is 0, the monitoring is switched off. In the main screen of the MOLDSCAN feature, when an alarm on the percent output shows up, an icon as shown on zone 4 will be displayed: Pg.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.30 Display alarms 2.31 Display curves Press the ALARM key to display all alarms as shown below: Press menu MEAS to display actual temperature and setpoint as a matter of time. As shown below: Displayed zone Setpoint value Actual temperature value A: to move to the oldest or to the latest alarm message 500 messages are stored. Alarm 501 erases alarm 1 automatically, and so on. B: to sort alarm messages by zone number or date and time.
2 M SERIES INSTRUCTION MANUAL OPERATION 2.32 Remove and replace a 16A control card 1) 1) Remove back cover and unscrew the 2 screws holding the TRIAC BTA40A/700B. Then you may pull the control card in your direction in order to remove it from the black 6 pins connector. DO NOT REMOVE CARD IF TRIAC HAS NOT BEEN UNSCREWED. Screw driver 2) 2) Hold control card in hand and remove the 2 connectors as shown. Place new card and replace with. 2.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.34 Remove and replace a thermocouple input card 1) Cabinet is switched off, remove front plate to access the faulty card. Without using any tool pull the card upwards to remove it from the 20 pins and 6 pins Black connectors. 1) 2) Replace with new card make sure that gold plated contacts are well located inside the 4 pins and 20 pins Black connectors. 2) NOTE: CHECK THAT ALL CONTACTS ARE SECURE www.incoe.com ©INCOE® CORPORATION 8/2010 Pg.
M SERIES INSTRUCTION MANUAL OPERATION 2 2.35 List of spare parts INCOE item Description Quantity 5034 16A Control card 2 4779 5A Control card 2 5095 Thermocouple input card 2 649 Fuse 16A type GRB (10 x 38 mm) 4 4472 Fuse 5FA 6.
M SERIES INSTRUCTION MANUAL TROUBLESHOOTING 3 3.1 Table of possible faults Fault Effects / tool Thermocouple broken Decreasing temperature. Display Safeguards Solutions - Alarm for deviation low activated. - Command of TRIAC is cut and there is no power to the heater -Repair break after testing thermocouple with ohm-meter. - Switch to manual mode if repair is too long or if you did not activate sensor slaving for operating with the sensor of another similar zone (see p21 confirm).
M SERIES INSTRUCTION MANUAL TROUBLESHOOTING 3 Fault Effects / tool Display Safeguards Solutions Temperature variation. Display of actual Actual temperature is temperature is unstable, symbols unstable. or - Deviation low and high are activated. - Problem with material to hot or to cold. - Problem with mold. - Deviation low is activated. - Fuse GRB 16A for 16A control cards or fuse FA 6,3A for 5A control cards is blown - Too high moisture : dry out heater and replace if necessary.
M SERIES INSTRUCTION MANUAL TROUBLESHOOTING 3 PROCEDURE FOR MOLD SETTERS Example of trouble: a control zone does not reach setpoint value. Locate faulty zone. Go to temperature page. Press on menu PARAM. Scroll in parameters with the + key until « applied power (%)» is shown. Or press menu ZOOM and select the faulty zone on the wide display. Check if the bar graph shows maximum power.
3 M SERIES INSTRUCTION MANUAL TROUBLESHOOTING PROCEDURE FOR MAINTENANCE PERSONNEL Example of trouble : a control zone does not reach setpoint value. - Remove the holding bar and move the control card upwards to remove both 20 pins and 4 pins black connectors. - Re-mount the holding bar. Read page 16 to locate the faulty zone. Then switch off the M Series cabinet with the main circuit breaker. Unscrew top cover and backplate (from 9U versions). Locate faulty control card for that zone.
M SERIES INSTRUCTION MANUAL WARRANTY 4 4.1 GENERAL TERMS & CONDITIONS OF SALE 1 Applicable Law and Jurisdiction These general terms and conditions apply to all proposals and quotations submitted by Seller, to all purchase orders received by Seller, and to all goods and services sold by Seller, except as other-wise specifically provided in a document signed by Seller.
M SERIES INSTRUCTION MANUAL WARRANTY 4 4 C.
M SERIES INSTRUCTION MANUAL GLOBAL SERVICE 5 5.1 GLOBAL SERVICE In case of problem or for any further information, please use the contact information below, or visit www.incoe.com. INCOE® North America INCOE® China | Shanghai Support: Sales & Support: T: + 86 (21) 5818-6300 F: + 86 (21) 5818-6303 E: info@incoe.cn T: + 1 (248) 556-7790 F: + 1 (248) 556-7799 E: tech.support@incoe.
M SERIES INSTRUCTION MANUAL GLOBAL OFFICES 5 5.2 GLOBAL OFFICES INCOE® North America INCOE® China | shanghai INCOE® Corporation 1740 East Maple Road Troy, Michigan 48083 USA INCOE® Hotrunners (Shanghai) Co., Ltd. 399 Xuanzhong Road, Building 16 Pudong New Area Shanghai 201314 China Main: T: + 1 (248) 616-0220 F: + 1 (248) 616-0225 E: info@incoe.com Sales: T: + 1 (248) 556-7770 F: + 1 (248) 616-0227 E: customer.support@incoe.com Support: T: + 1 (248) 556-7790 F: + 1 (248) 556-7799 E: tech.
M SERIES INSTRUCTION MANUAL NOTES www.incoe.com ©INCOE® CORPORATION 8/2010 Pg.
M SERIES INSTRUCTION MANUAL NOTES Pg. 44 © INCOE® CORPORATION 8/2010 www.incoe.
www.incoe.com © INCOE® CORPORATION 8/2010 printed 04/11 ...
