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Husky Altanium Delta3 User Manual

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Altanium Delta3
User Guide
Original Instructions

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Summary of Contents for Husky Altanium Delta3

  • Page 1 Altanium Delta3 User Guide Original Instructions...
  • Page 2 Husky® product or service names or logos referenced in these materials are trademarks of Husky Injection Molding Systems Ltd. and may be used by certain of its affiliated companies under license.

  • Page 3: General Information

    Husky Regional Service and Sales Office. Ordering Spare Parts All spare parts for Husky equipment can be ordered through the nearest Husky Parts Distribution Center or online at www.husky.co. Ordering Additional Manuals Additional copies of this manual and other documentation can be purchased through the nearest Husky Regional Service and Sales office.

  • Page 4: Ordering Additional Manuals

    2.3 — September 2015 Altanium Delta3 Ordering Additional Manuals...

  • Page 5: Table Of Contents

    Husky Regional Service and Sales Offices ........
  • Page 6 2.3 — September 2015 Altanium Delta3 4.1.3.1 Controller Function Buttons......... . 17 4.1.3.2...
  • Page 7 User Guide v 2.3 — September 2015 Table of Contents Chapter 7: Making Adjustments ........57 Zone Selection .
  • Page 8 2.3 — September 2015 Altanium Delta3 7.6.1 ART Process Screen............81 7.6.1.1...
  • Page 9 User Guide v 2.3 — September 2015 Table of Contents 10.1.4 Changing the Energy Usage and Units ........114 10.1.5 Changing the Grid Size and the Group Offset .
  • Page 10 2.3 — September 2015 Altanium Delta3 11.3.2 Configuring a Zone Information Panel ........146 11.3.2.1 Creating a Zone Information Panel .
  • Page 11 15.3.3 Replacing a Blown Fuse on an Intelligent Control Card (ICC2 or ICC3) ..183 15.4 Replacing an Altanium Delta3 Display Module ....... .184 15.4.1 Disconnecting the Display Module .
  • Page 12 2.3 — September 2015 Altanium Delta3 16.5.1 Closing Profile Graph ........... .207 16.5.2 Opening .

  • Page 13: Chapter 1 Introduction

    User Guide v 2.3 — September 2015 Introduction Chapter 1 Introduction This User Guide includes general warnings and cautions to avoid injury to personnel and damage to the system. These warnings and cautions are not intended to be, nor are they all- inclusive to every condition or application that may occur during operation.

  • Page 14: Safety Signs

    Follow all warnings and instructions marked on the system. • Unless specifically explained in this manual or directed by Husky, do not attempt to repair the system. Doing so could result in damage to the system, or serious personal injury.

  • Page 15: Purpose Of The Equipment

    Husky controllers are designed to control the process temperature for injection molding applications only. Contact your nearest Husky Regional Service and Sales office if you plan to use a Husky product for anything other than its intended use. Restrictions of Use Husky injection molding equipment must never be: •...

  • Page 16: Environmental Operating Specifications

    Ratings for the entire Altanium Controller can be found on the nameplate attached to the back of the controller. The following are the equipment ratings for the Altanium Delta3 operator interface only: • Supply Voltage: 100 to 240 VAC +/- 10%, single phase •...

  • Page 17: Technical Specifications

    2.3 — September 2015 Introduction Technical Specifications The dimensions and weight of the controller can change based on the controller configuration. The following are the technical specifications for the Altanium Delta3 operator interface only: Dimensions Weight • Width: 330 mm (13 in) •...
  • Page 18 2.3 — September 2015 Altanium Delta3 Figure 1-1 Attaching Straps to Lifting Device a. Make sure the straps are positioned between the caster wheels and the retaining brackets under the base of the controller. Figure 1-2 Positioning Straps b. Make sure the straps are not pinching or crushing any cables attached to the controller.
  • Page 19 User Guide v 2.3 — September 2015 Introduction Figure 1-3 Checking Cables Use the lifting device to apply enough upward force on the straps to remove the slack, but do not lift the controller at this time. Place the ratchet strap around top of the controller, holding the four ends of the webbed straps.
  • Page 20 2.3 — September 2015 Altanium Delta3 Controller Lifting Instructions...

  • Page 21: Chapter 2 Hot Runner Temperature Control

    User Guide v 2.3 — September 2015 Hot Runner Temperature Control Chapter 2 Hot Runner Temperature Control This guide is designed to ensure that users receive the maximum possible benefit from the use of the Altanium Hot Runner Control Systems. The Altanium controllers were designed as a processor's tool for hot runner molding.

  • Page 22: Configuring A Zone For Zero Cross Control

    2.3 — September 2015 Altanium Delta3 2.2.1 Configuring a Zone for Zero Cross Control This method defines how the power to each heater is averaged over a period of time. This is achieved by switching between complete half cycles of the heater supply voltage using a snubberless TRIAC as a switching device.

  • Page 23: Thermocouple Types And Color Codes

    User Guide v 2.3 — September 2015 Hot Runner Temperature Control The meter will now display a resistance in ohms. Note this measurement on a piece of paper. Ohm's Law says: Amps = Watts / Volts Amps = Volts / Resistance Resistance = Volts / Amps Watts = Volts x Amps Example:...
  • Page 24 2.3 — September 2015 Altanium Delta3 Thermocouple Types and Color Codes...

  • Page 25: Chapter 3 Connecting The System To The Mold

    User Guide v 2.3 — September 2015 Connecting the System to the Mold Chapter 3 Connecting the System to the Mold This chapter outlines various checks to make prior to starting up the system. Prior to Startup DANGER! Electrocution hazard– contact with hazardous voltages will cause death or serious injury.

  • Page 26: Startup Procedure Checklist

    View/Text View screen. NOTE: There are no controller to mold interconnection details included in this User Guide. If this information is required, please call the nearest Husky Regional Service and Sales office. IMPORTANT! When turning off the system, wait 30 seconds before turning the main disconnect switch back on.

  • Page 27: Chapter 4 Altanium Operator Interface

    User Guide v 2.3 — September 2015 Altanium Operator Interface Chapter 4 Altanium Operator Interface This chapter provides a brief overview of the functionality of the Altanium system and provides information about the following: • Altanium operator interface • Altanium buttons •...

  • Page 28: Altanium Buttons

    2.3 — September 2015 Altanium Delta3 Figure 4-1 Home Screen 1. Controller Function Buttons 2. System Status Field 3. Navigation Buttons 4. Alarm Buttons 5. System and User Management Buttons 4.1.3 Altanium Buttons Altanium has a system header and a footer that are visible on every screen throughout the system.

  • Page 29: Controller Function Buttons

    User Guide v 2.3 — September 2015 Altanium Operator Interface 4.1.3.1 Controller Function Buttons Button Description Touch the Stop button to switch off the power to all zones, regardless of system condition. Touch the Start button to switch on the power to the zones that have a setpoint displayed.

  • Page 30: Navigation Buttons

    2.3 — September 2015 Altanium Delta3 Button Description System Mode. For a description of each system mode, refer to Section 4.1.5. System Timer. Displays the timer value. 4.1.3.3 Navigation Buttons Button Description Touch the Back button to display the previous screen (maximum of 10 screens back).

  • Page 31: Alarm Buttons

    User Guide v 2.3 — September 2015 Altanium Operator Interface 4.1.3.4 Alarm Buttons Touch the Silence Horn button to silence the audible alarm. Touch the Alarm Status button to access the Alarm screen. The time and a description of the highest priority active alarm will be displayed. If an alarm is active, the Triangle Icon (Warning) will turn yellow and the background of the button will flash red.

  • Page 32: Dialog Box Buttons

    2.3 — September 2015 Altanium Delta3 Touch the Mold Setup Info button to display the currently loaded mold and associated mold folder. The upper word is the name of the mold folder. The lower word is the name of the mold setup file. Touch this area to display the Mold Setup screen.
  • Page 33 User Guide v 2.3 — September 2015 Altanium Operator Interface System Mode Description Stop The system is stopped and no power is being applied to the heaters. Running The system is heating up to or maintaining the normal setpoint. Manual Standby The user pressed the Manual Standby button and the system is heating to the manual standby setpoint.

  • Page 34: Views Buttons

    2.3 — September 2015 Altanium Delta3 System Mode Description Stage 4 Running The system will remain in stage 4 until the user presses the Start button Indefinitely to heat the zones to the normal setpoint. Bake Out Check The system is searching for any bake out conditions on any zone. These bake out conditions would be less severe than a earth leakage.

  • Page 35: Temperature Control Shortcuts Buttons

    User Guide v 2.3 — September 2015 Altanium Operator Interface Table 4-2 Views Buttons (Continued) View Button Description Touch the Text View button to display the Text View screen, which contains a textual representation of zone data. Touch the Mold Picture View button to display the Mold Picture View screen, which provides a visualization of the mold or hot runner system layout using an imported image file.

  • Page 36: Screen Buttons

    2.3 — September 2015 Altanium Delta3 4.1.8 Screen Buttons The Home screen provides a single area for a user to navigate to all other screens in the system. The Home screen can be accessed from any other screen in the system by touching the Home button in the System Header.
  • Page 37 User Guide v 2.3 — September 2015 Altanium Operator Interface Table 4-4 Screen Buttons (Continued) Screen Description ART Process Zone Calibration Zone Slot Card Layout Mold Diagnostics Diagnostics Results Energy Display Screen Buttons...
  • Page 38 2.3 — September 2015 Altanium Delta3 Table 4-4 Screen Buttons (Continued) Screen Description Supply Voltage Staging System Configuration Screens System Setup Network Setup Mold Setup Digital I/O User Management Screen Buttons...

  • Page 39: Multi Group View Screen

    User Guide v 2.3 — September 2015 Altanium Operator Interface Table 4-4 Screen Buttons (Continued) Screen Description Servo I/O This functionality is optional and the button appears on the Home screen if the system is equipped with UltraSync-E control. UltraSync-E Screens (If Equipped) Main Profile Setup...
  • Page 40 2.3 — September 2015 Altanium Delta3 Touch the column heading to sort the information in that column. A red line at the top of the column header indicates the information is in ascending order. A red line at the bottom of the column header indicates the information is in descending order.
  • Page 41 User Guide v 2.3 — September 2015 Altanium Operator Interface Table 4-5 Buttons (Continued) Button Description Expands the related group information list. If this button is green, the actual temperature for all zones is within the lower alarm limit. If this button is black, the actual temperature for all zones is not within the lower alarm limit.

  • Page 42: Changing The Header Color

    2.3 — September 2015 Altanium Delta3 Table 4-5 Buttons (Continued) Button Description Opens the Quick Set screen. Opening the Quick Set screen automatically selects all zones in the group. Opens the Color dialog box. 4.2.1 Changing the Header Color Users can assign a header color to a group displayed on the Multi Group View screen.
  • Page 43 User Guide v 2.3 — September 2015 Altanium Operator Interface Touch the desired color. Figure 4-4 Color Change Dialog Box Touch the Accept button. Changing the Header Color...

  • Page 44: Selecting A Language

    2.3 — September 2015 Altanium Delta3 Selecting a Language Altanium screens are available in several languages. The default language is English. Each screen contains a globe icon which displays the available languages. To select a language, do the following: Touch the Language Selection button.

  • Page 45: Printing To A File

    User Guide v 2.3 — September 2015 Altanium Operator Interface Figure 4-6 Language Selection Dialog Box Touch the Close button. Printing to a File To open the Print dialog box, touch the Print button on any Altanium screen. For more information, refer to Section 4.1.3.4.
  • Page 46 2.3 — September 2015 Altanium Delta3 Touch the Start button to initiate the continuous printing. Copy the content saved to a USB drive or Network as desired. Figure 4-7 Print Dialog Box Table 4-6 Print Dialog Box Item Descriptions...

  • Page 47: Print Report Descriptions

    User Guide v 2.3 — September 2015 Altanium Operator Interface 4.4.1 Print Report Descriptions This section provides a description of each print report. Generated files will automatically be saved to one of the following paths: • System\Reports\Zones • System\Reports\Diagnostics • System\Reports\Setups •...

  • Page 48: Network Settings

    2.3 — September 2015 Altanium Delta3 Print Report Type Description Mold Setup Configuration • Zone Number • Zone Name • Setpoint • Minimum Setpoint Limit • Maximum Setpoint Limit • Power Limit • Alarm • Abort • • •...

  • Page 49: Supply Voltage Screen

    User Guide v 2.3 — September 2015 Altanium Operator Interface Figure 4-8 Network Setup Supply Voltage Screen The Supply Voltage screen displays a graphical view of the phase pairs based on the Supply Configuration parameter selected in the System Setup screen: •...
  • Page 50 2.3 — September 2015 Altanium Delta3 Figure 4-9 Wye 3PH+N Supply Voltage Screen Item Description Schematic The image is a visual representation of the supply configuration Zone # Zone number of all the zones associated with a phase pair...
  • Page 51 User Guide v 2.3 — September 2015 Altanium Operator Interface Figure 4-10 Delta 3PH Supply Voltage Screen Figure 4-11 Single Phase Supply Voltage Screen Viewing the Supply Voltage...

  • Page 52: Configuring The Supply Voltage

    2.3 — September 2015 Altanium Delta3 Figure 4-12 Integrated TX Supply Voltage Screen 4.6.2 Configuring the Supply Voltage The Altanium system is configured at the factory for the supply configuration. If the system is shipped to another location where the power configuration is different (for example: another country), the setting may need to be changed.
  • Page 53 User Guide v 2.3 — September 2015 Altanium Operator Interface Figure 4-13 System Setup Screen 1. Supply Configuration Field Select the correct supply configuration. Figure 4-14 Supply Configuration Dialog Box Configuring the Supply Voltage...

  • Page 54: Using Online Help

    2.3 — September 2015 Altanium Delta3 Using Online Help The online help consists of a pdf file of the Altanium Delta3 User Guide. To use the online Help, do the following: Touch the Help button on any Altanium screen.

  • Page 55: Chapter 5 Security And Administration

    User Guide v 2.3 — September 2015 Security and Administration Chapter 5 Security and Administration This chapter describes user management functions. User Management and Security Screens Roles are assigned to allow users access to different features by limiting certain screens to each role level.
  • Page 56 2.3 — September 2015 Altanium Delta3 Touch the Screen Security button. Figure 5-1 User Management Screen 1. Screen Security Button User Management and Security Screens...
  • Page 57 User Guide v 2.3 — September 2015 Security and Administration On the Security screen, select a user type (Administrator, Supervisor, Operator, or Default User) for each of the following settings. Figure 5-2 Security Screen User Management and Security Screens...
  • Page 58 2.3 — September 2015 Altanium Delta3 Table 5-2 Security Screen Item Description Enable User Security Permission to enable/disable the user security feature. Basic Controller Permissions to operate the major controller function buttons: Start, Operation Standby, and Boost. Stop is always available. This setting also grants permission to operate the UltraSync-E Control mode buttons.
  • Page 59 User Guide v 2.3 — September 2015 Security and Administration Table 5-2 Security Screen (Continued) Item Description Monitor Zone Permission to configure the parameters in the Monitor Zone Settings area Settings of the System Setup screen. Part Counting Setup Permission to setup part counting on the System Setup screen. Temperature Permission to use the parameters in the Calibration screen to calibrate Calibration...

  • Page 60: Manage Users

    2.3 — September 2015 Altanium Delta3 Table 5-2 Security Screen (Continued) Item Description Thermocouple Permission to select and clear the Display Thermocouple Reading for Reading Manual Zones check box on the System Setup screen. Power Deviation Permission to select the Setup Alarm button in the Power Deviation section on the System Setup screen.

  • Page 61: User Preferences

    User Guide v 2.3 — September 2015 Security and Administration Figure 5-3 Manage Users 1. Add User 2. Change User Settings 3. Delete User 5.1.2 User Preferences If a user is logged into the system and makes changes to the unit of measurement or language selection, these values will be saved to that user’s profile after logout and will be recalled the next time the same user logs in again.

  • Page 62: Auto Logout

    2.3 — September 2015 Altanium Delta3 5.1.3 Auto Logout A system-wide timer will log the user off if there is no touch screen activity within a specified timeout period. The default setting is five minutes. The minimum value is 10 seconds.

  • Page 63: Chapter 6 Mold Setups

    User Guide v 2.3 — September 2015 Mold Setups Chapter 6 Mold Setups A mold setup contains the process parameters required by Altanium to operate the hot runner system for that particular mold. On the Home screen, touch the Mold Setup button to open the Mold Setup screen.
  • Page 64 2.3 — September 2015 Altanium Delta3 Table 6-1 Mold Setup Screen Item Descriptions Item Description File Tree The local drive holds all stored data contained within the Mold Setup screen. To assist in better organizing and storing files, there are three root directories included by default.

  • Page 65: Creating A New Mold Setup Folder

    User Guide v 2.3 — September 2015 Mold Setups Table 6-2 Mold Setup Screen Button Descriptions (Continued) Button Description Touch the Discard Changes button to revert the currently loaded mold setup file to the state after it was last saved (using the Save Mold Setup button).

  • Page 66: Saving Changes To A Mold Setup File

    2.3 — September 2015 Altanium Delta3 If the Default folder contains a user supplied setup file named “New Setup”, the new setup file is a copy of the 'new setup' file. The user can create this 'New Setup' file by first copying an existing setup file, renaming the file to 'New Setup' then copying the file to the Default folder.

  • Page 67: Loading An Existing Mold Setup File

    User Guide v 2.3 — September 2015 Mold Setups 6.1.6 Loading an Existing Mold Setup File After a Mold Setup file has been created it is automatically loaded as the current Mold Setup in the system. To load a different Mold Setup, do the following: On the Mold Setup screen, select the Mold Setup folder that contains the Mold Setup file to be loaded.

  • Page 68: Transferring Data To The Network

    2.3 — September 2015 Altanium Delta3 6.1.10 Transferring Data to the Network Use the Mold Setup screen to transfer Altanium data to the network. When Altanium is connected to the network, the network folder structure appears by default on the Mold Setup screen.

  • Page 69: Chapter 7 Making Adjustments

    User Guide v 2.3 — September 2015 Making Adjustments Chapter 7 Making Adjustments Adjustments can be made to the process settings for a mold setup before starting the mold, or while the mold is running. This chapter explains how to use Altanium to monitor and modify the system.

  • Page 70: Creating A Group

    2.3 — September 2015 Altanium Delta3 Figure 7-1 Zone Selection 1. Blocked Zone 2. Select All Button 3. Clear All Button Creating a Group Use the Quick Set screen to select multiple zones to form a group. To create a group, do the following: On the Quick Set screen, touch and hold the first zone to select for one second.

  • Page 71: Graphical View Screen Overview

    User Guide v 2.3 — September 2015 Making Adjustments A shortcut to the newly created group appears on the Home screen and is displayed with the selected zones highlighted. Figure 7-2 Quick Set Screen 1. Zone Edit 2. Group Name Graphical View Screen Overview The Graphical View displays zones in a graphical format.
  • Page 72 2.3 — September 2015 Altanium Delta3 Figure 7-3 Graphical View Screen - Split Screen Mode 1. Config Button 2. Zone Bars 3. Amperage Bars 4. Power Bars Graphical View Screen Overview...
  • Page 73 User Guide v 2.3 — September 2015 Making Adjustments Item Description Temperature Bars Each individual bar on the screen represents a single zone of temperature control. Each bar is labeled above with the zone number. The text shown at the base of each bar is the actual temperature for that zone. The different colors in each bar have a different meaning.
  • Page 74 2.3 — September 2015 Altanium Delta3 Table 7-1 Graphical View Screen Button Descriptions Button Description Config Button Touch this button to toggle between displaying zones in split or full screen mode. In split screen mode, zone graphs are displayed in two groups, one on the top and one on the bottom.

  • Page 75: Text View Screen Overview

    User Guide v 2.3 — September 2015 Making Adjustments Text View Screen Overview The Text View screen displays zone information in a textual format. It is used to access detailed data for each zone and provides the most comprehensive view of the process. This screen can be accessed by touching the Text View button on the Home screen.
  • Page 76 2.3 — September 2015 Altanium Delta3 Table 7-2 Text View Screen Button Descriptions Button Description Zone Row Each row in the Text view represents a heating zone in the system. Touching anywhere within the row will navigate to the Quick Set screen...

  • Page 77: Zone Selection In The Text View Screen

    User Guide v 2.3 — September 2015 Making Adjustments Table 7-2 Text View Screen Button Descriptions (Continued) Button Description Select All Touch this button to select all zones in the system. This will navigate to the Quick Set screen Clear All Touch this button to clear all zone selections Figure 7-6 Text View Screen - Full Screen Mode 7.4.1 Zone Selection in the Text View Screen...

  • Page 78: Quick Set Screen

    2.3 — September 2015 Altanium Delta3 Information can be sorted according to the dynamic columns (for example, current (Amps), voltage (VAC), etc.). This can be helpful when trying to figure out which zone is drawing the most current at any moment. The ability to select column headings in order to sort information is used throughout Altanium.

  • Page 79: Frequently Used Fields

    User Guide v 2.3 — September 2015 Making Adjustments 7.5.1 Frequently Used Fields Item Description Temperature Setpoint Touch this field to display a keypad for adjusting a zone(s) setpoint in Auto or Monitor regulation. Power Setpoint Touch this field to display a keypad for adjusting the percentage of power output when a zone(s) is in Manual regulation.

  • Page 80: Setpoint Limits

    2.3 — September 2015 Altanium Delta3 7.5.3 Setpoint Limits Item Description Temperature Minimum The minimum and maximum values limit what temperature the temperature setpoint can be changed to. Temperature Maximum Power Minimum The minimum and maximum values limit what temperature the power setpoint can be changed to.

  • Page 81: Remote Standby Fields

    User Guide v 2.3 — September 2015 Making Adjustments Item Description Power The power values all zones are set to when the Boost button is touched. This setting raises all zones to their manual boost setpoint until the timer expires or the user touches the Boost button again. Possible values are 0% –...

  • Page 82: Advanced Settings Fields

    2.3 — September 2015 Altanium Delta3 Item Description Power Minimum Limits the range that can be entered for Remote Boost Power. Power Maximum 7.5.8 Advanced Settings Fields Item Description Output Power Limit Touch this field to display a keypad for adjusting the maximum percentage of power output that the system will be allowed to deliver to a zone(s).

  • Page 83: Changing A Zone Name

    User Guide v 2.3 — September 2015 Making Adjustments Item Description I-Integral This is the integral term value used by the control algorithm. Possible values are: 0 – 250. D-Derivative This is the derivative term value used by the control algorithm. Possible values are: 0 –...

  • Page 84: Changing Multiple Zones Names

    2.3 — September 2015 Altanium Delta3 7.5.10.1 Changing Multiple Zones Names Use the Auto+ button to rename and number multiple zones. The Auto+ button will number the selected zones from 001 to n, where n is the number of zones selected. For example, if renaming 7 zones, the Auto+ button will rename the zones sequentially from 001 to 007.

  • Page 85: Changing The Abort Window

    User Guide v 2.3 — September 2015 Making Adjustments 7.5.13 Changing the Abort Window Specify how many degrees above or below the setpoint to initiate the abort and shut down. The default setting is 11 °C (20 °F). Abort Example: Setpoint = 300°F, Abort = 20°F.

  • Page 86: Using The Automatic Slave Function

    2.3 — September 2015 Altanium Delta3 7.5.15.1 Using the Automatic Slave Function If a thermocouple malfunctions during operation of the mold, the Altanium Auto-Slave function will take over. Altanium constantly monitors the heaters in the mold and stores comparative data. This data is used to select an almost identical Master/Slave relationship for every zone in the mold.

  • Page 87: Setpoint Limits

    User Guide v 2.3 — September 2015 Making Adjustments Regulation Description Mode Auto In Automatic (closed loop) mode, the system will use a thermocouple to control the temperature. In Manual (open loop) mode, the system will only apply power (0 to 100%) to the heater and not look for sensor feedback.

  • Page 88: Changing The Manual Standby And Remote Standby Setpoint Limits

    2.3 — September 2015 Altanium Delta3 7.5.16.2 Changing the Manual Standby and Remote Standby Setpoint Limits It may be necessary to lower the temperatures in the mold for a period of time. This can be done on the system header by selecting the Manual Standby button (or Remote Standby from a remote location as an option) without needing to change the normal setpoint.

  • Page 89: Changing The Manual Boost Setpoints And Limits

    User Guide v 2.3 — September 2015 Making Adjustments 12. Touch the Power Maximum field and enter a setpoint value. 13. Touch the Accept button. 7.5.16.3 Changing the Manual Boost Setpoints and Limits It may be necessary to raise the temperatures in the mold for a period of time. This can be done on the system header by selecting the Manual Boost button (or Remote Boost from a remote location as an option) without needing to change the normal setpoint.

  • Page 90: Changing The Sensor Assignment (Thermocouple)

    2.3 — September 2015 Altanium Delta3 12. Touch the Power Maximum field and enter a setpoint value. 13. Touch the Accept button. 7.5.17 Changing the Sensor Assignment (Thermocouple) The Sensor setting allows the operator to assign any thermocouple to control any heater.

  • Page 91: Changing The Earth Leakage Check

    “On” for all zones. Turning Earth Leakage Check off is only necessary under very special circumstances. To turn the Earth Leakage Check off globally for the entire system, please call the nearest Husky Regional Service and Sales office. 7.5.20 Changing the Automatic Manual Control (AMC) Setting...

  • Page 92: Changing P, I Or D Parameter Values

    2.3 — September 2015 Altanium Delta3 Proportional, Integral and Derivative parameters. The default control mode for all zones is ART. To toggle the zone control between ART and PID: Touch the zone to be changed. Under Control Settings, touch the Control Mode field.

  • Page 93: Art Process Screen

    User Guide v 2.3 — September 2015 Making Adjustments 7.6.1 ART Process Screen The ART Process screen is used to initiate the Active Reasoning Technology self tuning process and monitor its progress. This screen will appear automatically after touching START if any zone in the currently loaded mold setup has not completed the ART process.

  • Page 94: Using The Manual Art Function

    2.3 — September 2015 Altanium Delta3 Table 7-4 ART Process Screen Button Descriptions Button Description Start ART Process Touch the Start ART Process button to start the ART process. Cancel ART Process Touch the Cancel ART Process button to stop the ART process.

  • Page 95: Pid Control

    User Guide v 2.3 — September 2015 Making Adjustments When all selected zones complete the ART process, a checkmark will appear for each zone. To cancel the ART process at any time, touch the Cancel ART Process button. PID Control Altanium offers the choice of using ART (automatic tuning), or PID (manual tuning).
  • Page 96 2.3 — September 2015 Altanium Delta3 Table 7-7 Possible Causes of Oscillation (Continued) Cause Description "D" too large Stepped power change too large for the rate of change of temperature. Shear An important issue often overlooked is the effect of shear in the material as it passes through the gating area.

  • Page 97: Chapter 8 Mold Diagnostics

    User Guide v 2.3 — September 2015 Mold Diagnostics Chapter 8 Mold Diagnostics Diagnostics is a useful tool for troubleshooting problems with a mold or for verifying the wiring integrity of a mold after maintenance has been performed. Diagnostics can also be used to analyze the thermal isolation between all the cavities in the mold.
  • Page 98 2.3 — September 2015 Altanium Delta3 Table 8-1 Mold Diagnostics Screen Field and Button Descriptions Field/Button Description Validate Zone After The number of degrees that a zone must heat above its starting temperature to pass a test. Zone Cooling Time The amount of time to wait after completing a previous test before starting the next test.

  • Page 99: Running A Mold Diagnostics Test

    User Guide v 2.3 — September 2015 Mold Diagnostics 8.1.1 Running a Mold Diagnostics Test Before beginning the automated mold diagnostics test, do the following: Before connecting any power to the controller or the mold, clean the mold and its surroundings.

  • Page 100: Setting The Maximum Test Time

    2.3 — September 2015 Altanium Delta3 8.1.3 Setting the Maximum Test Time On some molds, if there is a thermocouple wiring problem, a heater could be damaged during test. Specifically, some heaters in some configurations may not support the peak temperatures reached when full power is applied for the default test time.

  • Page 101: Test Results Screen Values

    User Guide v 2.3 — September 2015 Mold Diagnostics Item Description Mold Diagnostics Opens the Mold Diagnostics screen. Rewire Automatically reassigns all the sensors to their proper location based on the results of the test. Cross-Talk Opens the Cross-Talk screen. Temperature Graphs Opens the Temperature Graphs screen.

  • Page 102: Automatic Thermocouple Rewiring

    2.3 — September 2015 Altanium Delta3 Item Description Wiring The wiring test tests for correct zone sensor assignment. This test determines whether sensor assignments match. If a sensor assignment does not match, the cross-talk findings test will fail. Wiring values are displayed as follows: •...

  • Page 103: Cross-Talk Screen

    User Guide v 2.3 — September 2015 Mold Diagnostics Cross-Talk Screen On the Diagnostics Results screen, touch the Cross-Talk button to open the Cross-Talk screen. Use this screen to view how much heat transfer is occurring between zones in the mold.

  • Page 104: Temperature Graphs Screen

    2.3 — September 2015 Altanium Delta3 Temperature Graphs Screen On the Diagnostics Results screen, touch the Temperature Graphs button to open the Temperature Graphs screen. The Temperature Graphs screen displays a trace for each zone tested that represents the temperature rise over the duration of the test.
  • Page 105 User Guide v 2.3 — September 2015 Mold Diagnostics Table 8-2 Temperature Graphs Screen Item Descriptions (Continued) Item Description Heat Up Starting Temperature The temperature of the zone when the zone started the heat up stage of the test. Ending Temperature The temperature of the zone when the zone finished the heat up stage of the test.
  • Page 106 2.3 — September 2015 Altanium Delta3 Temperature Graphs Screen...

  • Page 107: Chapter 9 Heating The Mold

    User Guide v 2.3 — September 2015 Heating the Mold Chapter 9 Heating the Mold This chapter describes how to start the Altanium system and check for any errors, and alarm conditions if they occur. With all Altanium-to-mold connections made and mold cooling switched on, touch the Start button to start the system.

  • Page 108: Earth Leakage/Wet Heater Bake Out System

    2.3 — September 2015 Altanium Delta3 Earth Leakage/Wet Heater Bake Out System Altanium is equipped with an advanced Earth Leakage/Wet Heater Bake Out system. From the moment the system is started, Altanium will constantly check for earth leakage conditions on every heater in the mold simultaneously. When necessary, it will initiate a low voltage bake out on the faulty zone(s) to try to bake the moisture out of the heater(s).

  • Page 109: Soft Start Routine

    User Guide v 2.3 — September 2015 Heating the Mold bake out cycle, the system will automatically shut down and trigger a bake out alarm. If there is no more moisture in the system after the selected number of bake out cycles have finished, the soft start process will begin.

  • Page 110: Disabling Soft Start

    2.3 — September 2015 Altanium Delta3 To enable soft start, do the following: On the System Setup screen, select the Soft Start Enable check box. 9.3.2 Disabling Soft Start Once soft start is disabled, it will not be applied until the next time the mold heats are turned To disable soft start, do the following: On the System Setup screen, clear the Soft Start Enable check box.

  • Page 111: Opening The Alarm Screen

    User Guide v 2.3 — September 2015 Heating the Mold Figure 9-1 Alarm Screen 1. Silence Horn Button 2. Reset Alarms Button 3. Clear Inactive Alarms Button Table 9-1 Alarm Screen Button Descriptions Button Description Silence Horn Clears the audible alarm. Reset Alarms Resets the alarm light and error message.

  • Page 112: Alarm States

    2.3 — September 2015 Altanium Delta3 9.4.2 Alarm States Alarm states are as follows: Alarm State Description Active When an alarm first occurs it is assigned the active state. Inactive Not Press the Reset Alarms button and the alarm will be assigned the inactive Acknowledged not acknowledged state.

  • Page 113: Event History Screen

    User Guide v 2.3 — September 2015 Heating the Mold Event History Screen The Event History screen lists the zone alarms, alarms, warnings, setpoint changes, setup changes, HMI startup and out of specification events that have occurred previously. On the Home screen, touch Event History.

  • Page 114: Filtering Events

    2.3 — September 2015 Altanium Delta3 Table 9-3 Event History Screen Item Descriptions (Continued) Item Description Date/Time Date and time that the event was triggered. Source Cause of the event. Description Description of the event. Mold Indicates the mold that is associated with the mold setup that was loaded when the event occurred.

  • Page 115: Alarm Conditions - Warning Errors

    User Guide v 2.3 — September 2015 Heating the Mold Alarm Conditions — Warning Errors Alarm conditions are displayed on the Alarm screen and the Event History screen. The following conditions cause the audible and visual alarms to initiate. Since they are warnings, they will not shut any part of the system down.

  • Page 116: Abort Conditions - Shutdown Errors

    2.3 — September 2015 Altanium Delta3 Abort Conditions — Shutdown Errors Abort conditions are displayed on the Alarm screen and the Event History screen. The following conditions initiate the audible and visual alarms. Since they are shut down errors, they will cause a zone or system shut down situation based on the PCM setting.
  • Page 117 User Guide v 2.3 — September 2015 Heating the Mold Table 9-6 Shutdown Errors (Continued) Shut Down Error Description Rev. Thermocouple The positive and negative leads from the thermocouple have been switched or the connections are reversed. As power is applied, the temperature goes down instead of up.
  • Page 118 2.3 — September 2015 Altanium Delta3 Abort Conditions — Shutdown Errors...

  • Page 119: Chapter 10 System Setup Screen

    User Guide v 2.3 — September 2015 System Setup Screen Chapter 10 System Setup Screen This chapter describes the functionality available within the System Setup screen, and provides instructions on setting some of the most commonly used system wide preferences. To display the System Setup screen, touch System Setup on the Home screen.
  • Page 120 2.3 — September 2015 Altanium Delta3 Figure 10-1 System Setup Screen System Setup Screen...
  • Page 121 Item Description Serial Number The Serial Number is for informational purposes only. It is a number assigned to the system when it is manufactured. Husky support may ask for this number when troubleshooting or upgrading Altanium. Model Controller model name.
  • Page 122 2.3 — September 2015 Altanium Delta3 Table 10-1 System Setup Screen Item Descriptions (Continued) Item Description Date and Time Current date and time displayed on the user interface. Time Zone Current time zone displayed on the user interface. Automatic Daylight Saving Automatic daylight savings on/off check box.
  • Page 123 User Guide v 2.3 — September 2015 System Setup Screen Table 10-1 System Setup Screen Item Descriptions (Continued) Item Description Bake Out Alert Enable If this parameter is enabled, the system stops and generates an alarm for each zone with a bake-out condition that has not been cleared during the bake out cycle.
  • Page 124 2.3 — September 2015 Altanium Delta3 Table 10-1 System Setup Screen Item Descriptions (Continued) Item Description Soft Start Enable Toggle this parameter on or off. If this parameter is on, the soft start process is applied upon startup. Soft Start Minimum Limit...

  • Page 125: Force Temperature Units To Option

    User Guide v 2.3 — September 2015 System Setup Screen 10.1.1 Force Temperature Units To Option Users can select how the available temperature units are displayed using the Force Temperature Units To option: Degrees Celsius (C), degrees Fahrenheit (F), or degrees kelvin (K).

  • Page 126: Changing The Units Of Measure

    2.3 — September 2015 Altanium Delta3 Figure 10-3 Data Collection 1. Data Collection Area 10.1.3 Changing the Units of Measure Users can configure Altanium to display the international system of units (SI) or the imperial units of measure. To change the units of measure, do the following: On the System Setup screen, under User Settings, touch the Units button.

  • Page 127: Changing The Grid Size And The Group Offset

    User Guide v 2.3 — September 2015 System Setup Screen To change the energy usage and units, do the following: On the System Setup screen, under Energy Usage and Units, touch the Energy Cost Rate (Kwh) or Currency Type button as desired. A dialog box will open. Change the desired units.

  • Page 128: Setting The Remote Standby Duration Timer

    2.3 — September 2015 Altanium Delta3 To set the manual standby duration timer, do the following: On the System Setup screen, under Manual Standby and Boost, touch the Manual Standby Duration Timer field. Enter the time required in the format HHMMSS.

  • Page 129: Standby Operation Description

    User Guide v 2.3 — September 2015 System Setup Screen To change the remote standby input mode, do the following: On the System Setup screen, under Remote Standby, touch the Remote Standby Input Mode field. Select the desired setting. NOTE: This setting will not appear if the remote standby option is not available on the system.

  • Page 130: Boost Timer Settings

    2.3 — September 2015 Altanium Delta3 Table 10-3 Remote Standby Operational Description (Continued) Manual Delay Remote Input Cycle Operation - STANDBY Button Time Time Time Mode Enabled Select ---- 0:00:00 0:00:00 ON/OFF ---- System enters Standby until the input signal is not active.

  • Page 131: Setting The Remote Boost Delay Timer

    User Guide v 2.3 — September 2015 System Setup Screen To set the remote boost duration timer, do the following: On the System Setup screen, under Remote Boost, touch the Remote Boost Duration Timer field. Enter the time required in the format HHMMSS Touch the Accept button.

  • Page 132: Power Deviation Settings

    2.3 — September 2015 Altanium Delta3 Table 10-5 Remote Boost Operational Description Manual Delay Remote Input Operation - Boost Button Select Time Time Time Mode ---- 0:00:00 0:00:00 Trigger System will not enter Boost since no timers are set.
  • Page 133 User Guide v 2.3 — September 2015 System Setup Screen Figure 10-4 Power Deviation 1. Power Deviation Figure 10-5 Power Deviation Dialog Box Power Deviation Settings...

  • Page 134: Power Limiting

    2.3 — September 2015 Altanium Delta3 Table 10-6 Power Deviation Settings Setting Description Power Deviation Enable Toggles the feature on or off. Sample Period Defines the amount of time the system will take to establish a baseline average power value (i.e.

  • Page 135: Monitor Zone Settings

    User Guide v 2.3 — September 2015 System Setup Screen Figure 10-6 Power Limiting 1. Power Limiting 10.1.11 Monitor Zone Settings Allow Monitor Regulation For Selection - This parameter allows the user to change the regulation mode to 'Monitor' for any zones in the Quick Set screen. If a zone is already in 'Monitor' regulation when this parameter is de-selected, the system will automatically change the regulation mode to 'Automatic'.

  • Page 136: Options And Licensing

    13.1. Users can purchase additional options such as 8 I/Os, All I/Os, Remote Load, Part Count, and SPI by contacting Husky for an electronic license file. To view existing licensing information, do the following: On the System Setup screen, under Options and Licensing, select View License.
  • Page 137 User Guide v 2.3 — September 2015 System Setup Screen Figure 10-8 View License Popup Users can update license files from local, USB and network drives. To update licensing information, do the following: On the System Setup screen, under Options and Licensing, select Update License. Upload the new license as applicable.

  • Page 138: Diagnostics Export

    1. Options and Licensing 10.1.13 Diagnostics Export Diagnostics Export allows users to export diagnostics files to a USB drive. This feature is intended for Husky Technical Support use only. Please contact Husky for assistance if required. 10.1.14 Part Counting Optional digital inputs and an output are available to automatically count up parts, including the ability to set a sack full limit.
  • Page 139 User Guide v 2.3 — September 2015 System Setup Screen NOTE: The Heater Type parameter must be set to Tips for all zones that pertain to a cavity in the mold. If no zones have a Heater Type parameter assigned, an error message will appear.

  • Page 140: Resetting The Part Counter

    2.3 — September 2015 Altanium Delta3 Figure 10-11 Part Counting - Setup Dialog Box 10.1.14.1.1 Resetting the Part Counter When activated, Digital Input 8 (Reset Parts Counter) will automatically reset the Parts in Sack parameter and Parts display on the system header to zero when the current part count is greater than or equal to the sack full limit.
  • Page 141 User Guide v 2.3 — September 2015 System Setup Screen To allow the system to optimize the sack full limit, do the following: On the Quick Set screen, set the PCM - Priority Control Mode to Zone. The system will automatically adjust the sack full limit when an abort condition error occurs.

  • Page 142: Remote Load

    2.3 — September 2015 Altanium Delta3 10.1.15 Remote Load Mold setups can be loaded directly from the injection molding machine. Using the Remote Load option, the injection molding machine can signal the controller on one of up to 1023 input combinations to indicate which mold setup to load.
  • Page 143 User Guide v 2.3 — September 2015 System Setup Screen Figure 10-14 Remote Load - Setup Dialog Box Select the Remote Load Enable check box. Select Configure Digital I/O if not previously done. This will bring up the Digital I/O screen.

  • Page 144: Zone Alarm Control

    2.3 — September 2015 Altanium Delta3 Figure 10-15 Remote Load - Assign Mold Setup Dialog Box Touch the Accept button to use the mold setup file selected. The new mold setup selected will be displayed. This now means that whenever the applicable remote load ID is requested this is the mold setup that will be loaded.
  • Page 145 User Guide v 2.3 — September 2015 System Setup Screen Figure 10-16 System Setup Screen - Zone Alarm Control 1. Zone Alarm Control Table 10-7 Zone Alarm Control Settings Setting Description Alarm Sensitivity Determines the duration of time the system has to stay in an error condition before it is declared an alarm.

  • Page 146: Mold Cooling Enable

    2.3 — September 2015 Altanium Delta3 Table 10-7 Zone Alarm Control Settings (Continued) Setting Description No Response Limit This is a global setting that determines how long the system should apply 96% power or greater without a 5 degree rise in temperature before it is declared an alarm condition.

  • Page 147: Staged Startup And Shutdown

    User Guide v 2.3 — September 2015 System Setup Screen Figure 10-17 System Setup Screen - Mold Cooling Enable 1. Mold Cooling Enable 10.2 Staged Startup and Shutdown This feature allows the system to heat or cool zones in a predetermined order by using stages.

  • Page 148: Enabling Or Disabling Staged Shutdown

    2.3 — September 2015 Altanium Delta3 To enable or disable staged startup, do the following: On the Staging screen, do the following: • To enable staged startup, select the Staged Startup Enable check box. • To disable staged startup, clear the Staged Startup Enable check box.
  • Page 149 User Guide v 2.3 — September 2015 System Setup Screen Figure 10-18 Staging Screens - Startup and Shutdown Item Description Staged Startup Enable Enables or disables the staged startup sequence. Run Last Stage Indefinitely If this setting is enabled, all zones in the last assigned stage will not change to their normal setpoint once all zones have achieved the stage setpoint and the soak timer has expired.

  • Page 150: Setting The Staged Temperature And Power Setpoints

    2.3 — September 2015 Altanium Delta3 Item Description Stage x Power The setpoint that is used when zones are in manual regulation during stage x. Staged Shutdown Enable Enables or disables the staged shutdown sequence. Staged Shutdown Override The staged shutdown override limit is used during staged Limit shutdown.
  • Page 151 User Guide v 2.3 — September 2015 System Setup Screen NOTE: It is not necessary to select zones to set the soak timer. On the Staging screen, touch the desired Soak Timer field. Enter the time required in the format HHMMSS. Soak timers have a range of 00:00:00 to 23:59:59.
  • Page 152 2.3 — September 2015 Altanium Delta3 Setting Soak Timers...

  • Page 153: Chapter 11 Mold Picture View

    User Guide v 2.3 — September 2015 Mold Picture View Chapter 11 Mold Picture View This chapter describes how to use the mold picture view. 11.1 Loading a Mold Picture View Graphic Load a mold picture view graphic from one of the following locations: •...
  • Page 154 2.3 — September 2015 Altanium Delta3 Touch the name of the view to upload the new mold picture view graphic. Figure 11-1 Mold Picture View Screen 1. Edit Button 2. Views Touch the Edit button. Touch the Change View Settings button.
  • Page 155 User Guide v 2.3 — September 2015 Mold Picture View Touch the Select File Name button. Figure 11-3 Change View Settings Dialog Box 1. Select File Name Button 2. Image File Name Field 3. Auto Fit Image Check Box 4. First Selection Field 5.

  • Page 156: Using The Mold Picture View Toolbar

    2.3 — September 2015 Altanium Delta3 11.2 Using the Mold Picture View Toolbar Use the Mold Picture View toolbar to change the view of the mold picture view graphic. To hide/show the Mold Picture View toolbar, touch the screen.

  • Page 157: Configuring A Mold Picture View

    User Guide v 2.3 — September 2015 Mold Picture View 11.3 Configuring a Mold Picture View Configure a Mold Picture View to add zone information panels and leader lines to the uploaded mold picture view graphic. To configure the Mold Picture View, make sure Altanium is in Edit mode. To hide/show the Edit toolbar, touch the screen.

  • Page 158: Edit Mode

    2.3 — September 2015 Altanium Delta3 11.3.1 Edit Mode To put Mold Picture View into Edit mode, do the following: On the Mold Picture View screen, touch the Edit button. Figure 11-6 Mold Picture View Screen 1. Edit Button 2. Views 11.3.2 Configuring a Zone Information Panel...

  • Page 159: Moving A Zone Information Panel

    User Guide v 2.3 — September 2015 Mold Picture View To create a Zone Information Panel, do the following: Make sure Mold Picture View is in Edit mode. Touch the Choose Heat Zone button. Figure 11-7 Mold Picture View Screen in Edit Mode 1.

  • Page 160: Editing A Zone Information Panel

    2.3 — September 2015 Altanium Delta3 11.3.2.3 Editing a Zone Information Panel In addition to the zone number, a zone information panel also contains two of the following pieces of information: • Zone Name • Current Temperature Setpoint •...

  • Page 161: Creating A Leader Line

    User Guide v 2.3 — September 2015 Mold Picture View To configure the content of the Zone Information Panel, do the following: • To change the first selection displayed on the Zone Information Panel, touch the First Selection field and select one of the following: Current Setpoint, Actual Temperature, Actual Power, Actual Current, Zone Name, or Actual Earth Leakage.

  • Page 162: Changing The Color Of A Leader Line

    2.3 — September 2015 Altanium Delta3 11.3.3 Changing the Color of a Leader Line To change the color of a Leader Line, do the following: Make sure Mold Picture View is in Edit mode. Touch the Zone Information Panel associated with the Leader Line to be changed.

  • Page 163: Deleting A Zone Information Panel

    User Guide v 2.3 — September 2015 Mold Picture View 11.3.5 Deleting a Zone Information Panel To delete a Zone Information Panel, do one of the following: Make sure Mold Picture View is in Edit mode. Touch and drag the Zone Information Panel to be deleted onto the Delete button or off the mold picture view graphic, or: Select the Zone Information Panel and touch the Delete button.
  • Page 164 2.3 — September 2015 Altanium Delta3 Exiting Edit Mode...

  • Page 165: Chapter 12 Data Recording

    User Guide v 2.3 — September 2015 Data Recording Chapter 12 Data Recording Data Recording is a useful tool to track the operation of a mold. This tool helps analyze the system to optimize the molding process, track errors, find the source of a recent error or predict where future errors may occur.
  • Page 166 2.3 — September 2015 Altanium Delta3 Figure 12-1 Process Trend Screen 1. Variable Selection Button Touch the Minimize/Maximize button. Figure 12-2 Statistical Process Control Details Variable Selector Dialog Box 1. Minimize/Maximize Button Select the desired process variable. Viewing the Process Trend...

  • Page 167: Process History Screen

    User Guide v 2.3 — September 2015 Data Recording 12.2 Process History Screen On the Process History screen, the data is presented zone by zone. The Process History screen provides a visual summary of the recorded operation, noting power usage, temperature fluctuations, setpoint values, pressures, positions and times.

  • Page 168: Curve Data Point

    2.3 — September 2015 Altanium Delta3 Figure 12-3 Process History Screen 1. Process Variable 2. Graph Section 3. Timeframe Table 12-1 Process History Screen Item Descriptions Item Description Process Variable The process variable shown in the process history. Graph Section The operating history of one zone.

  • Page 169: Setting The Timeframe

    User Guide v 2.3 — September 2015 Data Recording Figure 12-4 Process History Screen 1. Curve 2. Curve Data Point 3. Midline 4. Description of Data Table 12-3 Process History Screen Curve Data Descriptions Screen Element Description Curve Graphical representation of data values. Curve Data Point Currently selected data value.

  • Page 170: Setting The Date And Time Range

    2.3 — September 2015 Altanium Delta3 Figure 12-5 Process History Screen 1. Timeframe Field Touch the desired timeframe. 12.2.3 Setting the Date and Time Range Select the desired date range for the curves. The default old date is the New Date value minus the Timeframe value.

  • Page 171: Changing The Zone Displayed On The Process History Screen

    User Guide v 2.3 — September 2015 Data Recording 12.2.4 Changing the Zone Displayed on the Process History Screen To change a zone displayed on the Process History screen, do the following: On the Process History screen, touch the Variable Selection button of the zone or process to be changed.
  • Page 172 2.3 — September 2015 Altanium Delta3 Touch the Minimize/Maximize button. Figure 12-7 Process History Variable Selector Dialog Box 1. Minimize/Maximize Button Select the desired heat zone or process. Changing the Zone Displayed on the Process History Screen...

  • Page 173: Process Targets Screen

    User Guide v 2.3 — September 2015 Data Recording 12.3 Process Targets Screen Use the Process Targets screen to set up the specification limits for each variable. When a variable value is outside the lower or upper limits, the variable is considered out of specification and triggers an alarm, a digital output and/or the controller may stop.

  • Page 174: Filtering By Units

    2.3 — September 2015 Altanium Delta3 Limit Definition Stop Controller If selected, the controller will stop if any critical process variable is not within the lower and upper limits. Digital Output On If selected, a digital output will trigger if any process variable is not within the lower and upper limits.

  • Page 175: Chapter 13 System Options

    User Guide v 2.3 — September 2015 System Options Chapter 13 System Options Altanium has many additional optional features available to assist in the molding process. There are hardware, software and a combination of hardware and software options that can be used to complement the system.
  • Page 176 2.3 — September 2015 Altanium Delta3 Figure 13-1 Digital I/O Screen Table 13-1 Digital I/O Screen Item Descriptions Item Description Input/Output Corresponds to the input or output number assigned to the option. Name The names of the input and output options.

  • Page 177: Turning An I/O Option On Or Off

    User Guide v 2.3 — September 2015 System Options To configure the digital I/O, do the following: On the Home screen, touch the Digital I/O button. Configure the settings according to requirements. 13.1.1 Turning an I/O Option On or Off The system comes standard with the ability to configure up to 4 I/O options.

  • Page 178: Input/Output Connector Pin-Out Description

    2.3 — September 2015 Altanium Delta3 Figure 13-2 Delta3 Connector Gland Plate, Typical 1. Output COMM 2. Ethernet 3. EtherCAT 4. SPI 5. 100-240VAC In 6. Part Count 7. Input 8. Remote Load 9. Output Cable Connection Description Output COMM CANBus communication to Altanium mainframe.

  • Page 179: Input Base Connector Id

    User Guide v 2.3 — September 2015 System Options 13.3.1 Input Base Connector ID Field Cable Wire Connector/Pin Signal Function Color Input / A Remote standby Input / B WHT/BLK Remote boost Input / C Remote start Input / D BLK/WHT Cooling lines not enabled Input / E...

  • Page 180: Part Count Base Connector Id

    2.3 — September 2015 Altanium Delta3 Field Cable Wire Connector/Pin Signal Function Color Output / L RED/GRN At standby temperature Output / M ORG/RED At standby temperature Output / N BLK/WHT Maximum temperature error Output / P WHT/BLK Maximum temperature error...

  • Page 181: Remote Load Base Connector Id

    User Guide v 2.3 — September 2015 System Options 13.3.4 Remote Load Base Connector ID Field Cable Wire Connector/Pin Signal Function Color Remote Load / A Load setup Remote Load / B WHT/BLK Setup B0 Remote Load / C Setup B1 Remote Load / D BLK/WHT Setup B2...
  • Page 182 2.3 — September 2015 Altanium Delta3 Remote Load Base Connector ID...

  • Page 183: Chapter 14 Spi Protocol Option

    User Guide v 2.3 — September 2015 SPI Protocol Option Chapter 14 SPI Protocol Option The system communicates with any central network or molding machine that supports the Society of Plastics Industry (SPI) standard protocol. The system assumes a device ID of 26h on the SPI communications channel. This ID has been assigned to general-purpose temperature controllers with multiple zones.

  • Page 184: Process Setpoint

    2.3 — September 2015 Altanium Delta3 14.1.2 Process Setpoint Summary This command is used to set and read the temperature setpoint for an automatically controlled zone. It is valid even if the selected zone is running in MANUAL or VIEW regulation mode.

  • Page 185: Alarm 1 Setpoint

    User Guide v 2.3 — September 2015 SPI Protocol Option 14.1.5 Alarm 1 Setpoint Summary This command is used to set and read the alarm window value for a single zone. The alarm window is used only for zones with Auto or View regulation.

  • Page 186: Controller Status

    2.3 — September 2015 Altanium Delta3 14.1.8 Controller Status Summary This command is used to read the condition of a single zone. The definition of the status bits is given below: SPI DEFINITION SYSTEM DEFINITION Heater Power Power to heater is not zero...

  • Page 187: Manual Percent Output

    User Guide v 2.3 — September 2015 SPI Protocol Option 14.1.9 Manual Percent Output Summary This command is used to set and read the manual percent output for a manually-regulated zone. It is valid even if the zone is running in the Auto or View regulation mode.
  • Page 188 2.3 — September 2015 Altanium Delta3 Open/Closed Loop...

  • Page 189: Chapter 15 Maintenance

    Maintenance Chapter 15 Maintenance This chapter describes the maintenance tasks required to maintain the Altanium Delta3 system. The following maintenance procedures are to be performed only when needed. Periodically and before starting the equipment check that all cables and cable connections are free from wear or damage.

  • Page 190: Card Layout Screen

    2.3 — September 2015 Altanium Delta3 15.2 Card Layout Screen The Card Layout screen identifies the cards contained within the mainframe, and which zones each card belongs to. The Card Layout screen can be accessed form the Home screen or the Event History screen.
  • Page 191 User Guide v 2.3 — September 2015 Maintenance Figure 15-3 Card Layout Screen 1. Filter Button 2. Card Layout Button Deselect all check boxes, then select only Zone Alarm Active and Zone Alarm Inactive. Figure 15-4 Filter Dialog Box Touch the Exit button. A list of Active and Inactive faults will be displayed. Select the applicable error, then touch the Card Layout button.

  • Page 192: Servicing The Altanium System

    2.3 — September 2015 Altanium Delta3 Figure 15-5 Card Layout Information 15.3 Servicing the Altanium System The X-Series card cage contains everything needed to run up to 12 heaters in the mold. The H-Series card cage runs up to 24 heaters in the mold. This consists of a green Passive Backplane and one to six Intelligent Control Cards which are plugged into the Passive Backplane.

  • Page 193: Altanium X/H-Series Card Cage

    User Guide v 2.3 — September 2015 Maintenance 15.3.1 Altanium X/H-Series Card Cage Figure 15-6 X/H-Series Card Cage Access all user-serviceable parts, including fuses and circuit boards, by loosening the upper and lower slotted screws on each heat sink assembly and then sliding a screwdriver between the horizontal silver post and the ledge on the cabinet and prying the board out.

  • Page 194: Replacing An Intelligent Control Card (Icc2 Or Icc3)

    2.3 — September 2015 Altanium Delta3 Figure 15-7 Altanium Main Power Switch 1. Main Power Switch 15.3.2 Replacing an Intelligent Control Card (ICC or ICC WARNING! Electrical and mechanical hazard- risk of death, serious injury and/or damage to the equipment.

  • Page 195: Replacing A Blown Fuse On An Intelligent Control Card (Icc2 Or Icc3)

    User Guide v 2.3 — September 2015 Maintenance Figure 15-8 Removing the Board 1. Screw Location CAUTION! Static electricity hazard - risk of damage to the equipment. Do not, under any circumstances, place any PCB on carpets, rugs, or other material that is likely to create a static charge.

  • Page 196: Replacing An Altanium Delta3 Display Module

    Carefully place the card on an earthed/grounded surface. Remove and replace the faulty fuse with one of identical type and rating. Husky recommends SIBA 71-25-40 Series or equivalent fuses. Make sure the fuse is fully seated.
  • Page 197 User Guide v 2.3 — September 2015 Maintenance IMPORTANT! A minimum of 2 people are required to perform this procedure. Facing the front of the controller, locate the four 1/4 inch-20 button head cap screws that hold the Delta3 interface plate to the mainframe. Figure 15-9 Disconnecting the Delta3 Interface Plate from the Mainframe 1.

  • Page 198: Connecting The Display Module

    2.3 — September 2015 Altanium Delta3 Figure 15-10 Disconnecting the Delta3 Interface Plate from the Display Module 1. Button Head Cap Screws, Bottom Hold or gently brace the display module. Remove the four screws using the 5/32 inch hex wrench provided with the controller.
  • Page 199 User Guide v 2.3 — September 2015 Maintenance Figure 15-11 Attaching the Delta3 Interface Plate to the Display Module 1. Button Head Cap Screws, Bottom Position the display module with the attached interface plate on the mainframe. Facing the front of the controller, locate the four 1/4 inch-20 button head cap screws that hold the Delta3 interface plate to the mainframe.

  • Page 200: Mounting The Display Module Remotely

    2.3 — September 2015 Altanium Delta3 15.4.3 Mounting the Display Module Remotely The display module can be mounted remotely if the Remote Mount option is ordered. To mount the display module remotely, do the following: IMPORTANT! A minimum of 2 people are required to perform this procedure.

  • Page 201: Replacing The Motherboard Battery

    User Guide v 2.3 — September 2015 Maintenance Install the 4 mounting feet into the display module. Use the threaded holes where the mounting plate screws were removed in step Figure 15-14 Installing the Delta3 Mounting Feet to the Display Module 1.
  • Page 202 2.3 — September 2015 Altanium Delta3 Disconnect power from the controller. Remove the four screws securing the controller cover to the base. Figure 15-15 Controller 1. Controller Cover 2. Screws Remove the controller cover. Remove and discard the motherboard battery.

  • Page 203: Calibrating The Thermocouple Inputs

    The system has been factory-calibrated and in most cases it is not necessary to recalibrate until Altanium has been running for one year. If calibration is necessary, please contact the nearest Husky Regional Service and Sales office for calibration instructions. 15.7 Cleaning the System 15.7.1 Cabinet...
  • Page 204 2.3 — September 2015 Altanium Delta3 Touch Screen...

  • Page 205: Chapter 16 Ultrasync-E, If Equipped

    IMPORTANT! Controllers for UltraSync-E hot runners are designed for use with a specific hot runner. Contact the nearest Husky Regional Service and Sales office before attempting to use the controller with any other hot runner. 16.1 Connecting the Controller...

  • Page 206: Ultrasync-E Screens

    2.3 — September 2015 Altanium Delta3 16.2 UltraSync-E Screens Use the Home screen to access the UltraSync-E Home, Profile and Setup screens. Figure 16-1 Home Screen with UltraSync-E Option 16.2.1 UltraSync-E Home Screen Buttons Use the UltraSync-E Home screen buttons to open the following UltraSync-E screens: •...

  • Page 207: Ultrasync-E Home Screen

    User Guide v 2.3 — September 2015 UltraSync-E, If Equipped Button Description Use the UltraSync-E Home button to open the UltraSync-E Home screen. Use the UltraSync-E Profile button to open the UltraSync-E Profile screen. Use the UltraSync-E Closing Profile button to open the UltraSync-E Closing Profile screen.

  • Page 208: Control Modes Buttons

    2.3 — September 2015 Altanium Delta3 Figure 16-2 UltraSync-E Home Screen 1. Control Modes Buttons Drop-Down 2. Control Bar 3. Control Bar Status Indicators 4. Command Buttons 5. UltraSync-E Home Screen Tab 6. UltraSync-E Opening Profile Tab 7. UltraSync-E Closing Profile Tab 8. UltraSync-E Setup Tab 16.3.1 Control Modes Buttons...

  • Page 209: Manual Control Buttons

    User Guide v 2.3 — September 2015 UltraSync-E, If Equipped Item Description Disengaged Button Activates Disengaged mode, where UltraSync-E is controlled by the operator using the Altanium user interface. Disabled Button The UltraSync-E servo system is disabled. 16.3.2 Manual Control Buttons Use the Manual Control buttons to indicate current position of the stems, change the position of the valve gates and to calibrate UltraSync-E.

  • Page 210: Control Bar Status Indicators

    2.3 — September 2015 Altanium Delta3 Item Description IMM E-Stop OK Displays the state of the IMM E-Stop. IMM Safety Gates Indicates the IMM safety gates are closed. Closed Controller E-Stop OK Displays the state of the UltraSync-E cabinet E-Stop At Temperature Displays the At Temperature status.

  • Page 211: Ultrasync-E Setup Screen

    User Guide v 2.3 — September 2015 UltraSync-E, If Equipped Item Description Peak Open Force Peak force during the last open motion. Peak Close Force Peak force during the last close motion. 16.4 UltraSync-E Setup Screen Configure the UltraSync-E advanced options on the UltraSync-E Setup screen. UltraSync-E can only be configured when the user level is sufficient and UltraSync-E is not engaged.

  • Page 212: Other Settings

    2.3 — September 2015 Altanium Delta3 Monitoring Description Minimum Maximum Default Position Alarm If the position of the valve stems deviates from the 0.01 mm 1.00 mm 0.05 mm Window set position by more than this amount, the alarm “Position Deviation Limit Exceeded”...

  • Page 213: Signals

    User Guide v 2.3 — September 2015 UltraSync-E, If Equipped Item Description Use the Signals button to open the Signals screen. Use this screen to configure the permit calibration and permit disengaging signals from the IMM. Use the Maintenance button to open the Maintenance screen. Use the Tool button to open the Tool screen.

  • Page 214: Permit Disengaging

    2.3 — September 2015 Altanium Delta3 • The benefit of using this input is to prevent calibration when damage may occur, such as when the mold is closed with parts in the cavities. • The signal is configured with two “anded” conditions.

  • Page 215: Maintenance

    User Guide v 2.3 — September 2015 UltraSync-E, If Equipped Open Valve Stems Close Valve Stems Input Signal Description Command Command Configuration Examples Examples One Trigger Valve stems open after the • Clamp closed — Open Command signal is • Mold close active and the stem open •...

  • Page 216: Tool

    2.3 — September 2015 Altanium Delta3 16.4.3.3 Tool Use the Tool dialog box to configure the UltraSync controller for the hot runner tool it is actuating. These settings can only be changed in Disabled mode. Each motor is associated with a parameter set. Operation of UltraSync-E is not allowed until...

  • Page 217: Pullback

    User Guide v 2.3 — September 2015 UltraSync-E, If Equipped 16.4.3.4 Pullback Figure 16-7 Pullback Dialog Box Pullback is an optional motion that occurs after the Stems Close motion. Touch the Pullback button to open the dialog box. During Pullback Opening, the Opening force limit is used. The motion profile is defined on the Pullback dialog box.

  • Page 218: Ultrasync-E Opening Profile And Closing Profile Screens

    2.3 — September 2015 Altanium Delta3 16.5 UltraSync-E Opening Profile and Closing Profile Screens Use the UltraSync-E Opening Profile and Closing Profile screens to setup and view the motion profiles used to open and close the valve stems. Figure 16-8 UltraSync-E Opening and Closing Profile Screens...

  • Page 219: Closing Profile Graph

    User Guide v 2.3 — September 2015 UltraSync-E, If Equipped Closing and Description Minimum Maximum Default Opening Profiles Number of Steps Defines the number of profile steps Opening: 2 used during the motion. Closing: 3 Position Sets the end position of the motion. Close: 0.0mm Maximum If multiple steps are used, sets the...

  • Page 220: Opening

    2.3 — September 2015 Altanium Delta3 Item Description Duration The elapsed time of the last valve stem close motion. Peak Force The peak force recorded during the last valve stem close motion. 16.5.2 Opening Use the Opening profile graph to monitor and configure the valve stem open motion profile.

  • Page 221: Inputs

    User Guide v 2.3 — September 2015 UltraSync-E, If Equipped Item Description In Use Set this to enable the signal. When enabled, the controller will read or set the signal according to the signal description in Section 16.6.1 Section 16.6.2. Active The current state of the input or output.
  • Page 222 2.3 — September 2015 Altanium Delta3 Figure 16-10 Inputs Screen Signal Name Description Pin (s) 24 VDC of Controller Reference HIGH level from the valve gate controller, for dry contacts. IMM in Auto Active when IMM is cycling in Automatic. Signal is...

  • Page 223: Outputs

    User Guide v 2.3 — September 2015 UltraSync-E, If Equipped 16.6.2 Outputs Use the Outputs screen to configure the digital output signals to the injection molding machine. Figure 16-11 Digital Outputs Screen Signal Name Description Pin (s) IMM Signal Reference Reference signal from IMM for dry contacts.

  • Page 224: Configurable Signals

    2.3 — September 2015 Altanium Delta3 16.6.3 Configurable Signals Configurable signals are outputs defined using Boolean logic. Input functions, output functions, and other configurable signals can be assigned as conditions to a given configurable signal that when all are true the signal is active.

  • Page 225: Safety Signals

    User Guide v 2.3 — September 2015 UltraSync-E, If Equipped 16.6.4 Safety Signals Safety signals are non-configurable fixed signals hardwired to the safety relay inside the UltraSync-E controller. These signals are intended to connect to the IMM safety gate and E- stop circuits to ensure user safety.

  • Page 226: Calibrating The Ultrasync-E

    UltraSync system. The problems discussed are not a definitive list. If a problem is not listed in this chapter, contact Husky Technical Support or the nearest Husky Regional Service and Sales office for assistance.
  • Page 227 Internal error. Cycle power to the drive. Invalid warning code Internal error. Cycle power to the drive. False FPGA version Contact Husky Service. Error in module A Cycle power to the drive, check wiring to module, replace module. Error in module C Cycle power to the drive, check wiring to module, replace module.
  • Page 228 2.3 — September 2015 Altanium Delta3 Fault Fault Solution Number Heat sink over temperature Check for obstruction of the drive heat sink fins (located out the back of the controller). There is a fan on the heat sink (bottom) that should come on before this fault occurs.

  • Page 229: Alarm: Position Deviation Limit Exceeded

    User Guide v 2.3 — September 2015 UltraSync-E, If Equipped Fault Fault Solution Number Motor over temperature Let motor cool down. Increase cycle time (cycle time should not be less than 3sec). Error I t > 100% Let motor cool down. Increase cycle time (cycle time should not be less than 3sec).
  • Page 230 2.3 — September 2015 Altanium Delta3 • Maintenance pin(s) not removed before operation (Gen1 tools only) • Force limit set too low to complete the motion. To troubleshoot this fault: • Review the concurrent alarms on the alarm page or in the Event log to determine when the fault occurred.

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