Husky Altanium Neo5 User Manual
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Husky Altanium Neo5 User Manual

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Original Instructions

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Summary of Contents for Husky Altanium Neo5

  • Page 1 Altanium Neo5 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 1.0 — August 2018 Altanium Neo5 Page iv...

  • Page 5: Table Of Contents

    Husky Regional Service and Sales Offices ........
  • Page 6 1.0 — August 2018 Altanium Neo5 4.2.1 Dialog Box — Accept/Cancel Buttons ........16 4.2.2...
  • Page 7 1.0 — August 2018 Altanium Neo5 Text View Screen Overview ........... . 51 7.4.1...
  • Page 8 1.0 — August 2018 Altanium Neo5 9.4.1 Opening the Alarm Screen..........102 9.4.2...
  • Page 9 1.0 — August 2018 Altanium Neo5 15.4.3 Replacing the Touch Monitor — Freestanding Configuration ... . .152 15.4.4 Replacing the MCU — Freestanding Configuration ..... . .156 15.4.5 Replacing the Operator Interface —...
  • Page 10 1.0 — August 2018 Altanium Neo5 Page x...

  • Page 11: Chapter 1 Introduction

    1.0 — August 2018 Altanium Neo5 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 12: 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 13: 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 14: Environmental Operating Specifications

    Only qualified personnel should connect the electrical power supply. All work must conform to applicable local electrical codes. Environmental Operating Specifications The following are the environmental operating specifications for the Altanium Neo5 operator interface: CAUTION! Mechanical hazard –...

  • Page 15: Weights And Dimensions

    133.36 kg (294 lb) • Height: 1512 mm (59.5 in) Controller Lifting Instructions The recommended lifting method varies depending on whether the Altanium Neo5 is a C6- 1, C6-2, or single stack (freestanding) controller. 1.8.1 C6-1 and C6-2 Lifting Instructions Use the steps that follow to correctly lift a Neo5 C6-1 or C6-2.

  • Page 16: Single Stack Lifting Instructions

    1.0 — August 2018 Altanium Neo5 1.8.2 Single Stack Lifting Instructions: Do the steps that follow to lift the single stack Neo5. Lifting devices (crane or forklift) and straps vary in lifting ability and lengths. See the table that follows for the correct lifting ability and lengths.
  • Page 17 User Guide v 1.0 — August 2018 Altanium Neo5 b. Make sure the straps are not pinching or crushing any cables attached to the Neo5. Use the lifting device to apply enough upward force on the straps to remove the slack, but do not lift the Neo5 at this time.
  • Page 18 1.0 — August 2018 Altanium Neo5 Tighten the ratchet strap. Use the lifting device to slowly lift the Neo5 off the ground a few inches. Check the webbed and ratchet straps to make sure that the Neo5 will not tip.

  • Page 19: Chapter 2 Hot Runner Temperature Control

    1.0 — August 2018 Altanium Neo5 Chapter 2 Hot Runner Temperature Control This guide is designed to make sure that users receive the maximum possible benefit from the use of the Neo5. The Neo5 was designed as a processor's tool for hot runner molding. The fundamental criteria required to operate a hot runner mold is controlling the process temperature so that it is consistent and repeatable with respect to the process setpoint.

  • Page 20: Configuring Zones

    1.0 — August 2018 Altanium Neo5 Configuring Zones In an effort to match the energy input requirements of differing types of loads, it is necessary for the output power delivered to the heaters to be adjusted over a range of 0 to 100%. The Neo5 can be set up to achieve this by using either Zero Cross Control or Phase Angle Control.
  • Page 21 User Guide v 1.0 — August 2018 Altanium Neo5 WARNING! Electrical hazard– risk of death or serious injury. Disconnect all electrical power from the mold and controller prior to performing this test. Using a multimeter, set the selector to measure resistance.

  • Page 22: Thermocouple Types And Color Codes

    1.0 — August 2018 Altanium Neo5 Thermocouple Types and Color Codes The Neo5 uses the ANSI color code for all thermocouples. The following table is provided as reference for hot runners and cables that follow other color code standards.

  • Page 23: Chapter 3 Connecting The System To The Mold

    1.0 — August 2018 Altanium Neo5 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 24: Startup Procedure Checklist

    Text View screens. 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 25: Chapter 4 Altanium Operator Interface

    1.0 — August 2018 Altanium Neo5 Chapter 4 Altanium Operator Interface This chapter gives a brief overview of the functionality of the Neo5 operator interface. General The operator interface consists of a touch-sensitive display screen. The Neo5 operator interface is a high-resolution color LCD display covered by a transparent touch screen.

  • Page 26: Operator Interface - Screens And Buttons

    1.0 — August 2018 Altanium Neo5 Operator Interface — Screens and Buttons 4.2.1 Dialog Box — Accept/Cancel Buttons At the bottom of each screen, where you have entered new data, touch to save new or changed data. If you want to close the dialog box (no changes) touch 4.2.2...

  • Page 27: Header And Footer

    User Guide v 1.0 — August 2018 Altanium Neo5 4.2.3 Header and Footer The home screen has a header and a footer. The same header and footer appears on each screen. 4.2.3.1 Header — Controller Function Buttons Button Description Stop - Removes the power from all the zones, regardless of system condition.

  • Page 28: Header - System Status Indicators

    1.0 — August 2018 Altanium Neo5 4.2.3.2 Header — System Status Indicators Indicator Description At Temperature: • Flashes when the zones are heating up to the setpoint temperature. • Solid when all automatic zones are ‘At temperature’. • Off when the controller is stopped.

  • Page 29: Footer - Alarm Buttons

    User Guide v 1.0 — August 2018 Altanium Neo5 4.2.3.4 Footer — Alarm Buttons Silence Horn - Stops the audible alarm. Alarm Reset - Changes an alarm from active to inactive. Alarm Status - The time and a description of the highest priority active alarm is displayed.

  • Page 30: System Screen Selections - Zone Views

    1.0 — August 2018 Altanium Neo5 4.2.4 System Screen Selections — Zone Views 4.2.5 System Screen Selections — Temperature Management 4.2.6 System Screen Selections — Data Collection and Monitoring 4.2.7 System Screen Selections — System Configuration Page 20...

  • Page 31: Supply Voltage Screen

    User Guide v 1.0 — August 2018 Altanium Neo5 Supply Voltage Screen The Supply Voltage screen displays a graphical view of how the input supply voltage is wired. A table shows how the zones are connected to the input power.
  • Page 32 1.0 — August 2018 Altanium Neo5 System Modes Table 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...
  • Page 33 User Guide v 1.0 — August 2018 Altanium Neo5 System Modes Table (Continued) System Mode Description Stage x Active (Cooling) All zones assigned to stage x are cooling to the stage setpoint. Stage x Soaking After cooling down, the system will maintain the stage x setpoint until (Cooling) the soak timer expires.
  • Page 34 1.0 — August 2018 Altanium Neo5 Page 24...

  • Page 35: Chapter 5 Security And Administration

    1.0 — August 2018 Altanium Neo5 Chapter 5 Security and Administration This chapter describes the user management functions. Login/Logout 5.1.1 Login In the footer, touch the Log off/Log on button If logging in: a. Use the keyboard to type in your user name, then...

  • Page 36: User Management And Security Screens

    1.0 — August 2018 Altanium Neo5 b. Type in your password, then If logging out: On the logout dialog box , touch User Management and Security Screens All users are assigned a role. There are three different roles. Each role is customized by the administrator.

  • Page 37: Manage Users

    User Guide v 1.0 — August 2018 Altanium Neo5 5.2.1 Manage Users To create/delete a user or change a user’s password, do the steps that follow: On the Home screen, in the systems configuration row, select On the top of the User screen, if necessary, select 5.2.1.1 Add a User...
  • Page 38 1.0 — August 2018 Altanium Neo5 • Full Name: • User Role: • Password: • Language: Page 28...
  • Page 39 User Guide v 1.0 — August 2018 Altanium Neo5 • Units: • Functionality: • Auto Logout Time: When there is no activity for the time entered in the Auto Logout Time dialog box, the Neo5 will automatically logout the user. The default time is 5 minutes. The minimum is 10 seconds.

  • Page 40: Delete A User

    1.0 — August 2018 Altanium Neo5 5.2.1.2 Delete a User Select the user in the User Name column. Select in the left hand column. Select on the Delete User screen. The user is deleted. Page 30...

  • Page 41: Change A User Password

    User Guide v 1.0 — August 2018 Altanium Neo5 5.2.1.3 Change a User Password Select the user in the User Name column. Select In the Password screen, use the keyboard to enter the new password. After you select , the confirm password screen will show.

  • Page 42: Set The Security Settings

    1.0 — August 2018 Altanium Neo5 5.2.2 Set the Security Settings On the Home screen, in the systems configuration row, select On top of the User screen, if necessary, select On the Screen Security screen, assign a role (operator, supervisor or administrator) to each function.

  • Page 43: Enable Security

    User Guide v 1.0 — August 2018 Altanium Neo5 Touch the box to the right of the function/screen name to show the dialog box. Select a user role, then The Users tab is greyed out because only the administrator can manage users. Refer to Section 5.2.1.
  • Page 44 1.0 — August 2018 Altanium Neo5 Page 34...

  • Page 45: Chapter 6 Mold Setups

    1.0 — August 2018 Altanium Neo5 Chapter 6 Mold Setups The mold setup has the process parameters necessary to operate the hot runner system. Mold Setup Screen The Mold Setup screen stores and manages files such as mold setups, images, documents and reports.
  • Page 46 1.0 — August 2018 Altanium Neo5 If molds is selected, all the mold folders will be shown in the left hand pane. If system is selected, the Reports folder, containing all system files will be shown. Touch, , Details to expand display files in a tabular layout with file name, file size, and the date and time last modified.

  • Page 47: Saving Changes To A Mold Setup File

    User Guide v 1.0 — August 2018 Altanium Neo5 6.1.1 Saving Changes to a Mold Setup File Once a Mold Setup file has been loaded, you can permanently save changes made to it. On the Mold Setup screen, touch the Save Changes button. This will display the Mold Setup - Save dialog box for confirming the mold and name of the file that the changes are to be saved to.

  • Page 48: Deleting Files

    1.0 — August 2018 Altanium Neo5 6.1.4 Deleting Files When a file or folder is no longer required on the internal hard drive, you can delete it. On the Mold Setup screen, touch the file or folder to be deleted.

  • Page 49: Chapter 7 Making Adjustments

    1.0 — August 2018 Altanium Neo5 Chapter 7 Making Adjustments You can make adjustments to the process settings for a mold setup before starting the mold, or while the mold is running. This chapter explains how to use, monitor and modify the system.

  • Page 50: Creating A Group

    1.0 — August 2018 Altanium Neo5 Creating a Group On the Home screen, select On the Groups button, touch to open the drop down menu. Assign names to one or more of the Group (1 thru 10) Name holders.
  • Page 51 User Guide v 1.0 — August 2018 Altanium Neo5 Select the zones that you want to be in a group. Touch the field to the right of Group. From the list in the Group dialog box, touch the Group Name that you want to give to the selected zones, then A Group selector button for that group will be displayed at the bottom of the screen.
  • Page 52 1.0 — August 2018 Altanium Neo5 As necessary, do steps 3 thru 6 again to assign zones to the remaining groups. To delete a group, touch the box to the right of the Group X Name. 10. On the Group Name Keyboard screen, touch to delete the name, then The group name will be at the bottom of all the quick set screens.
  • Page 53 User Guide v 1.0 — August 2018 Altanium Neo5 On the home screen, in the zone views row, select All the groups that were set up in the Quick Set groups screen will be shown. Page 43...

  • Page 54: Color Code

    1.0 — August 2018 Altanium Neo5 If you touch the screen will go to the full screen view. Touch to go back to the half screen view. 7.2.1 Color Code You can color code the groups. On the header bar...

  • Page 55: Layout Order

    User Guide v 1.0 — August 2018 Altanium Neo5 7.2.2 Layout Order You can also choose a layout order for the groups. Select Touch the clear previous button or clear all button to clear the numbers. Touch the box for the group that you want to be at the top (1st position) on the multi- group view.

  • Page 56: Show Group Details

    1.0 — August 2018 Altanium Neo5 7.2.3 Show Group Details Touch in the header of the group to show the group details. Page 46...

  • Page 57: Neo2 View Screen Overview

    User Guide v 1.0 — August 2018 Altanium Neo5 Touch to show the details of all the groups. Touch to collapse all the group details or touch to collapse only that group’s details. Touch to go to the Quick Set screen.
  • Page 58 1.0 — August 2018 Altanium Neo5 NOTE: Heat OFF. NOTE: Heat OFF/zones cooling/zones 1 and 2 are switched OFF. Page 48...
  • Page 59 User Guide v 1.0 — August 2018 Altanium Neo5 NOTE: Heat ON/zones (green) at temperature/zones (white) are not at temperature/zone 1 is slaved to zone 24/zones 9, 17, and 25 - switched OFF. Item Description Temperature Bar The bar in each zone shows the temperature of the zone.
  • Page 60 1.0 — August 2018 Altanium Neo5 Touch the button and the screen will toggle to the screen below. This screen only shows the temperature of the zone. Touch the button again to toggle back to the graphical view. Page 50...

  • Page 61: Text View Screen Overview

    User Guide v 1.0 — August 2018 Altanium Neo5 Text View Screen Overview The Text View screen displays zone information in a tabular format. Detailed data for each zone is shown in each row of the table. This provides the most comprehensive view of the process.
  • Page 62 1.0 — August 2018 Altanium Neo5 Column Header 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. Refer to 7.5.

  • Page 63: Zone Selection In The Text View Screen

    User Guide v 1.0 — August 2018 Altanium Neo5 7.4.1 Zone Selection in the Text View Screen Use the Text View screen to select one or multiple zones. To view one zone, touch anywhere in the row of that zone.

  • Page 64: Frequently Used Fields

    1.0 — August 2018 Altanium Neo5 Select the zone, zones, or groups that you want to change or enter data. To expand each tab, touch 7.5.1 Frequently Used Fields Page 54...
  • Page 65 User Guide v 1.0 — August 2018 Altanium Neo5 Touch the box to the right of the parameter to display a keyboard or menu. Temperature Setpoint — Use the keypad to enter the zone(s) temperature setpoint in Auto or Monitor regulation.
  • Page 66 1.0 — August 2018 Altanium Neo5 Power Setpoint — Use the keypad to adjust the percentage of power applied when the zone(s) is in Manual regulation. Zone On/Off — Turns the selected zone(s) ON or OFF. The default is ON.
  • Page 67 User Guide v 1.0 — August 2018 Altanium Neo5 Regulation — Sets the regulation mode for the selected zone(s). AUTO or Automatic (closed loop) uses the thermocouple feedback to control the temperature. Manual (open loop) means the system will only apply power (0 to 100%), user selected, to the heater and not look for thermocouple feedback.

  • Page 68: Zone Edit Fields

    Touch the common name tab to assign that name to the zone(s). All the zones in group husky #1 have been assigned the zone name, valve gate. After you name all the zones, touch Auto+. Auto+ assigns a number, in sequential order, to all the zones.
  • Page 69 User Guide v 1.0 — August 2018 Altanium Neo5 Touch the box to the right of the locked/unlocked button. In the dialog box select lock or unlock, then . If a zone(s) is locked, you cannot make changes from the Quick Set screen.

  • Page 70: Groups

    1.0 — August 2018 Altanium Neo5 7.5.3 Groups Refer to Section 7.2. 7.5.4 Setpoint Limits Page 60...
  • Page 71 User Guide v 1.0 — August 2018 Altanium Neo5 Setpoint Range — Use the minimum and maximum dialog boxes to set the range for the temperature setpoint. Example: If the Minimum is set to 100°F and the Maximum to 600°F, you will not be able to enter a setpoint that is less than 100°F or more than 600°F.

  • Page 72: Manual Standby

    1.0 — August 2018 Altanium Neo5 7.5.5 Manual Standby Manual Standby Temperature Setpoint — The temperature all zones are set to when you select . Manual Standby lowers the temperatures of all the zones to the setpoint until the timer expires or you touch again.
  • Page 73 User Guide v 1.0 — August 2018 Altanium Neo5 Manual Standby Temperature Range — Use the minimum and maximum dialog boxes to set the manual standby temperature range. Manual Standby Power Setpoint — The power level that all zones are set to when you select .
  • Page 74 1.0 — August 2018 Altanium Neo5 Manual Standby Power Range — Use the minimum and maximum dialog boxes to set the manual standby power range. Duration Timer — In the dialog box, set the time that the zones will stay in the manual standby mode.

  • Page 75: Manual Boost

    User Guide v 1.0 — August 2018 Altanium Neo5 7.5.6 Manual Boost Manual Boost Temperature Setpoint — The temperature all zones are set to when you select Manual boost increases the temperature of all the zones to the manual boost temperature setpoint until the timer expires or you touch again.
  • Page 76 1.0 — August 2018 Altanium Neo5 Manual Boost Temperature Range — Use the minimum and maximum dialog boxes to set the manual boost temperature range. Manual Boost Power Setpoint — The power level that all zones are set to when you select .
  • Page 77 User Guide v 1.0 — August 2018 Altanium Neo5 Manual Boost Power Range — In the dialog boxes, set the minimum and maximum manual standby power range. Manual Boost Duration Timer — In the dialog box, set the time that the zones will stay in the manual boost mode.

  • Page 78: Remote Standby

    1.0 — August 2018 Altanium Neo5 7.5.7 Remote Standby Remote Standby is activated with a digital input to the Neo5 from a remote location on the IMM. Remote Standby Temperature Setpoint — The temperature all the zones are set to when a remote standby signal is received.
  • Page 79 User Guide v 1.0 — August 2018 Altanium Neo5 Remote Standby Temperature Range — Use the minimum and maximum dialog boxes to set the remote standby temperature range. Remote Standby Power Setpoint — The power level all zones are set to when a remote standby signal is received.
  • Page 80 1.0 — August 2018 Altanium Neo5 Duration Timer — In the dialog box, enter the time that the zones will stay in the remote standby mode. NOTE: The Duration Timer, Remote Standby Delay, and Input Mode are system settings that apply to all the zones.
  • Page 81 User Guide v 1.0 — August 2018 Altanium Neo5 Remote Standby Operational Description Manual Remote Delay Time Input Mode Operation - STANDBY Button Select Time Time ---- 0:00:00 0:00:00 Trigger System will not enter Standby since no timers are set.

  • Page 82: Remote Boost

    1.0 — August 2018 Altanium Neo5 7.5.8 Remote Boost Remote boost is activated with a digital input to the Neo5 from a remote location on the IMM. Remote Boost Temperature Setpoint — The temperature all zones are set to when a remote boost signal is received.
  • Page 83 User Guide v 1.0 — August 2018 Altanium Neo5 Remote Boost Temperature Range — Use the minimum and maximum dialog boxes to set the remote boost temperature range. Remote Boost Power Setpoint — The power level that all zones are set to when a remote boost signal is received.
  • Page 84 1.0 — August 2018 Altanium Neo5 Duration Timer — In the dialog box, enter the time that the zones will stay in the remote boost mode. NOTE: The Duration Timer, Remote Boost Delay, and Remote Boost Input Mode are system settings that apply to all zones.
  • Page 85 User Guide v 1.0 — August 2018 Altanium Neo5 Remote Boost Operational Description (Continued) Manual Delay Remote Input Operation - Boost Button Select Time Time Time Mode ---- X:XX:XX X:XX:XX Trigger System delays for specified time and then enters Boost until the timer expires.

  • Page 86: Heater Types

    1.0 — August 2018 Altanium Neo5 7.5.9 Heater Types Assign names to one or more of the Custom Heater Types (1 thru 8). a. Touch the field to the right of the Custom Type 1. The Custom Heater Type Name keyboard screen will be displayed.

  • Page 87: Advanced Settings

    User Guide v 1.0 — August 2018 Altanium Neo5 Select the zones that you want assigned to a specific heater type. Touch the field to the right of Heater Type. From the drop down list, in the Heater Type dialog box, touch the heater type that you want to assign to the selected zones, then As necessary, do steps 2.
  • Page 88 1.0 — August 2018 Altanium Neo5 Output Power Limit — In the dialog box, enter the maximum percentage of output power that will be supplied to heat the zones. Slaved to Zone — In the dialog box, enter the zone number that the selected zone will be slaved to.
  • Page 89 User Guide v 1.0 — August 2018 Altanium Neo5 Output Mode — In the dialog box, you can choose what type of output mode that will be used to control the zones. Choose zero cross or phase angle. PCM - Priority Control — In the dialog box, select zone or system. In an abort condition Neo5 will remove power from the zone if the malfunctioning zone is set to Zone or go into stop mode if the malfunctioning zone is set to system.
  • Page 90 1.0 — August 2018 Altanium Neo5 Earth Leakage Limit — In the dialog box, enter the limit, in Amps. The limit is the threshold where Neo5 will give an Earth Leakage Alarm. No Response Limit — This is a global setting that determines how long the system should apply 96% power or more without a 5 degree rise in the temperature before it is declared an alarm condition.

  • Page 91: Control Settings Fields

    User Guide v 1.0 — August 2018 Altanium Neo5 No Heater Limit — This limit is used by the system to determine if a heater is still connected to the zone. If the current measurement of the zone is below the limit for more than 10 seconds, the No Heater Alarm will be activated.

  • Page 92: Art Settings

    1.0 — August 2018 Altanium Neo5 Control Mode — ART automatically adjusts the control algorithm to suit different heater requirements. If a zone is not controlling properly the system allows users to switch from the automatically adjusted ART algorithm to an algorithm that can be manually adjusted (PID).
  • Page 93 User Guide v 1.0 — August 2018 Altanium Neo5 • Reset — Resets the ART parameters for the zones. At the next start operation, the zones will go through the ART process. NOTE: Reset can be selected regardless of the system mode.
  • Page 94 1.0 — August 2018 Altanium Neo5 Minimum P — In the dialog box, enter the minimum Proportional (P) value. Minimum I — In the dialog box, enter the minimum Integral (I) value. Minimum D — In the dialog box, enter the minimum Derivative (D) value.
  • Page 95 User Guide v 1.0 — August 2018 Altanium Neo5 Default P — In the dialog box, enter the default P value. Default I — In the dialog box, enter the default I value. Default D — In the dialog box, enter the default D value.

  • Page 96: Zone Slave

    1.0 — August 2018 Altanium Neo5 ART Offset — The ART Offset is the number of degrees that the actual temperature has to be below the normal setpoint for all the zones before the system starts the ART process.

  • Page 97: Manually Slaving One Zone To Another Zone

    User Guide v 1.0 — August 2018 Altanium Neo5 If the automatic slaving function is unable to find a suitable partner, the Automatic Manual Control (AMC) function is activated. If AMC is set to On, the system automatically switches the bad zone into Manual mode applying a calculated average power output to the heater.

  • Page 98: Changing The Zone Control From Art To Pid

    1.0 — August 2018 Altanium Neo5 7.5.14.1 Changing the Zone Control from ART to PID The control algorithm is automatically adjusted to suit different heater requirements. This control method is referred to as Active Reasoning Technology (ART). In some cases, it may be necessary to switch from the automatically adjusted ART algorithm to an algorithm that can be manually adjusted.

  • Page 99: Mold Diagnostics

    1.0 — August 2018 Altanium Neo5 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. You can also use diagnostics to analyze the thermal isolation between all the cavities in the mold.
  • Page 100 1.0 — August 2018 Altanium Neo5 On the mold test screen, select settings. Touch the box to the right of the validate Zone After button. On the Validate Zone After dialog box, enter the temperature, then . This is the temperature rise in degrees that a zone must reach before it is considered an operational zone.
  • Page 101 User Guide v 1.0 — August 2018 Altanium Neo5 If the fixed setpoint is enabled, then the entered value is used as the minimum setpoint. If not enabled, the lowest normal setpoint for the zones that are selected for testing is used as the minimum setpoint.

  • Page 102: Running A Mold Diagnostics Test

    1.0 — August 2018 Altanium Neo5 11. On the maximum test time dialog box, enter the maximum test time, then . Refer to 8.2.2. Output Power Limit — This is a link to the quick set screen to allow the user to set an Output Power Limit if desired.

  • Page 103: Zone Cooling Time

    User Guide v 1.0 — August 2018 Altanium Neo5 Only zones selected will be tested. Select the desired zone(s) on the Mold Test screen. 10. Make sure that Neo5 is stopped. 11. Touch the box next to the test that you want to run on the selected zones. Refer to 8.2.3.

  • Page 104: Mold Test Results

    1.0 — August 2018 Altanium Neo5 Mold Test Results On the Home screen, select The following section describes the fields and buttons on the Mold Test Results screen. Item Description Zone Zone number Name Zone name Senor Indicates the number of the sensor being used for that zone.
  • Page 105 User Guide v 1.0 — August 2018 Altanium Neo5 Item Description The thermocouple test will determine whether the thermocouple for that zone is operating correctly. Thermocouple values are displayed as follows: • ? = indicates the thermocouple for the zone was not tested or did not complete the test.

  • Page 106: Automatic Thermocouple Wiring

    1.0 — August 2018 Altanium Neo5 Item Description The ground fault test tests for an earth leakage in each zone. Earth leakage values are displayed as follows: • ? = Test did not complete. • - - - = No current sensor for this zone.

  • Page 107: Compare Mode Test Results

    User Guide v 1.0 — August 2018 Altanium Neo5 8.3.2 Compare Mode Test Results When the compare function on the Mold Test Results screen is checked, the Diagnostics Results screen will show two tables, one above the other. The top table shows the ’baseline’...
  • Page 108 1.0 — August 2018 Altanium Neo5 Press . In the drop down menu, Select Compare, select the test that you want to compare to the baseline. Differences in amps, watts, voltage, and ohms are highlighted in red in the lower table.

  • Page 109: Chapter 9 Heating The Mold

    1.0 — August 2018 Altanium Neo5 Chapter 9 Heating the Mold This chapter describes how to start the Neo5 system and check for errors, and alarm conditions if they occur. Heater Circuit Test 9.1.1 Startup When you select in the header, a heater circuit test on all the zones is done before full power is applied.

  • Page 110: Earth Leakage/Wet Heater Bake Out System

    1.0 — August 2018 Altanium Neo5 Earth Leakage/Wet Heater Bake Out System Neo5 is equipped with an advanced Earth Leakage/Wet Heater Bake Out system. When the Neo5 is started, a check for earth leakage conditions on every heater is done simultaneously and continuously.

  • Page 111: Soft Start Routine

    User Guide v 1.0 — August 2018 Altanium Neo5 Soft Start Routine During the soft start routine, all the zones warm up simultaneously, and at the same rate. The soft start routine results in even thermal expansion and identical residence time on the material.

  • Page 112: Opening The Alarm Screen

    1.0 — August 2018 Altanium Neo5 Item Description Date/Time Date and time that the alarm was triggered. Source Cause of the alarm. Description Description of the problem that triggered the alarm. This button is a quick link to the Event History screen. The Event History screen stores all the alarms after they have been cleared from the Alarm screen.

  • Page 113: Clearing Alarms

    User Guide v 1.0 — August 2018 Altanium Neo5 9.4.2 Clearing Alarms If an error occurs, Neo5 will turn on audible and visual alarms and display the alarm condition on the Alarm screen. To clear an alarm, do the following: NOTE: Before resetting an alarm, correct the source of the alarm.

  • Page 114: Filtering Events

    1.0 — August 2018 Altanium Neo5 Item Description Date/Time Date and time that the event was triggered. Source Where the event occurred. Event Name 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 1.0 — August 2018 Altanium Neo5 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 1.0 — August 2018 Altanium Neo5 Shutdown Errors Shut Down Error Description Abort Over Temp A zone's actual temperature has exceeded its setpoint by the amount set for the abort limit. Abort Under Temp A zone's actual temperature has dropped below its setpoint by the amount set for the abort limit.

  • Page 117: Chapter 10 System Setup Screen

    1.0 — August 2018 Altanium Neo5 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. Items in this screen depend on the access rights of the user and the current state of the system.
  • Page 118 System Setup Screen Item Descriptions 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. Model Controller model name.
  • Page 119 User Guide v 1.0 — August 2018 Altanium Neo5 System Setup Screen Item Descriptions (Continued) Item Description Global Output Power Limit Controls the maximum output power delivered to each zone. Overrides the individual zone setting in the Quick Set screen.
  • Page 120 1.0 — August 2018 Altanium Neo5 System Setup Screen Item Descriptions (Continued) Item Description Auto Power Limiting Enable If checked, the Auto Power Limiting feature is enabled. Circuit Test State 4 Power Determines the power percentage applied during circuit test state...

  • Page 121: Changing The Number Of Zones In The System

    User Guide v 1.0 — August 2018 Altanium Neo5 10.2 Changing the Number of Zones in the System You may need to add or remove zones to an existing mold setup. If the mold running has fewer control zones than listed on the screen, you can remove the unused zones to make sure they are not displayed.
  • Page 122 1.0 — August 2018 Altanium Neo5 Page 112...

  • Page 123: Chapter 11 Staged Startup And Shutdown

    1.0 — August 2018 Altanium Neo5 Chapter 11 Staged Startup and Shutdown This feature allows the Neo5 to heat or cool zones in a predetermined order by using stages. Zones can be assigned to any of the 4 stages and can be configured with a separate set point for each stage.

  • Page 124: Setting Soak Timers

    1.0 — August 2018 Altanium Neo5 Item Description 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 125: Set The Stage Temperature And Power

    1.0 — August 2018 Altanium Neo5 11.2 Set the Stage Temperature and Power Select Stage (1, 2, 3, or 4) (Startup) and touch to show the drop down menu. Touch the button to the right of the Stage X Temperature bar.
  • Page 126 1.0 — August 2018 Altanium Neo5 Page 116...

  • Page 127: Chapter 12 Data Recording

    1.0 — August 2018 Altanium Neo5 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 128: Viewing The Process

    1.0 — August 2018 Altanium Neo5 12.1.1 Viewing the Process Change the zone: Touch the box to the right of the Zone box. Use the keypad and enter the new Zone number. Touch Change the parameter: Touch the #1 parameter box.

  • Page 129: Chapter 13 Data Exchange

    1.0 — August 2018 Altanium Neo5 Chapter 13 Data Exchange You can store reports and images to the Neo5 hard drive. From the file management screen you can move the reports/images to a network or USB device for sharing, storing or printing.
  • Page 130 1.0 — August 2018 Altanium Neo5 Item Description Save Process Data Setup Check the save data to File box to save the process data to the Neo5 hard drive. Touch the Frequency button and enter in the time intervals that you want Neo5 to save the current process data.

  • Page 131: Report Descriptions

    User Guide v 1.0 — August 2018 Altanium Neo5 13.2 Report Descriptions This section provides a description of each print report. Reports will be saved to one of the locations that follow: • System/Reports folder in the Neo5 hard drive, •...
  • Page 132 1.0 — August 2018 Altanium Neo5 Print Report Type Description Diagnostics From the Test Results screen, print the following to file: • Zone Number • Zone Name • Sensor • Fuses • • Amperage • Volts AC • Watts •...
  • Page 133 User Guide v 1.0 — August 2018 Altanium Neo5 Print Report Type Description Zone Calibration • Date and Time • Mold Folder and Mold Setup • System Status • Low Test Value • High Test Value • Zone Number: — Low Value Before Calibration —...
  • Page 134 1.0 — August 2018 Altanium Neo5 Page 124...

  • Page 135: Chapter 14 Digital I/O

    • Run Light The input and output connectors are located on the back of the Neo5 (see Section 15.2). If you need help to connect the Neo5 inputs and outputs, contact your Husky Regional Service and Sales Office. Page 125...

  • Page 136: Configure The Digital I/O

    1.0 — August 2018 Altanium Neo5 14.1 Configure the Digital I/O On the Home screen, in the System Configuration row, select Digital I/O. Item Description Active Indicates the logical state of the I/O signal. This displays the final state of the signal after the optional invert is applied.

  • Page 137: Digital I/O Connector Pin-Out Description

    User Guide v 1.0 — August 2018 Altanium Neo5 14.2 Digital I/O Connector Pin-Out Description The tables that follow include the connection descriptions for all of the optional Inputs and Outputs available for the Neo5. 14.2.1 Digital Input Descriptions Digital Inputs...

  • Page 138: Input Connector Pin-Out

    1.0 — August 2018 Altanium Neo5 14.2.3 Input Connector Pin-Out The table that follows shows the connection detail for all the inputs wired for dry contacts (No voltage). CAUTION! Electrical hazard - risk of damage to the equipment. DO NOT apply a voltage to any of the Inputs.

  • Page 139: Output Connector Pin-Out

    User Guide v 1.0 — August 2018 Altanium Neo5 The table that follows shows the connection detail for all the inputs wired to accept voltage from an external source. CAUTION! Electrical hazard - risk of damage to the equipment. DO NOT apply a voltage greater than 30VDC to any of the inputs.
  • Page 140 1.0 — August 2018 Altanium Neo5 Digital Outputs Connector/Pin Field Cable Wire Color Signal Function Input / 7 Brown Run Light Input / 8 Yellow Page 130...

  • Page 141: Chapter 15 Maintenance

    1.0 — August 2018 Altanium Neo5 Chapter 15 Maintenance This chapter describes the maintenance tasks required to maintain the Neo5. Do the maintenance tasks only when necessary. Periodically, and before starting the equipment, check that all cables and cable connections are free from wear or damage.

  • Page 142: Servicing The System

    1.0 — August 2018 Altanium Neo5 15.1 Servicing the System The Neo5 systems are based on two user serviceable components: • X-Series or H-Series Intelligent Control Cards • Neo5 Operator Interface Neo5 Integrated Configuration (C6-2 Configuration shown) Page 132...
  • Page 143 User Guide v 1.0 — August 2018 Altanium Neo5 Neo5 Freestanding System Configuration (Single Stack) WARNING! Hazardous voltages - risk of death or serious injury. Before servicing the Altanium Neo5 lock out and tag the Main Power switch in accordance with local codes.

  • Page 144: Cable Connections

    1.0 — August 2018 Altanium Neo5 Neo5 Main Power Switch - Freestanding Configuration (Single Stack) 15.2 Cable Connections Depending on the Neo5 configuration, there will be cable connections at the back and front of the controller. The insulation level of control cables and devices connected to the Neo5 connectors are: •...

  • Page 145: Cable Connections - Freestanding Configuration

    User Guide v 1.0 — August 2018 Altanium Neo5 Cable Connections - Rear of Neo5 Item Cable Connection Description Horn Audible alarm. LCD1 (HDMI) Video signal to touch monitor. Touch Screen Touch screen signal to the touch monitor. Ethernet User interface to customer networks.

  • Page 146: Intelligent Control Cards

    1.0 — August 2018 Altanium Neo5 Item Cable Connection Description 100-240VAC In Main AC power from the Altanium mainframe. Output COMM CANBus communication to the Altanium mainframe. Touch Screen Touch screen signal to the touch monitor. Ethernet User interface to customer networks.
  • Page 147 User Guide v 1.0 — August 2018 Altanium Neo5 X-Series Intelligent Control Card Mainframe Bay with Backplane Exposed Both series of cards plug into backplanes that are installed into the bays of the Neo5. mainframe. The cards manage the power being delivered to the heaters, the thermocouple feedback and control and circuit protection.

  • Page 148: Replacing An Intelligent Control Card

    1.0 — August 2018 Altanium Neo5 IMPORTANT! Although they look similar, X-Series and H-Series cards use different backplanes and are not compatible with each other. IMPORTANT! You must have an Intelligent Control Card present in the position labeled 1 in all backplanes for the system to function properly.
  • Page 149 User Guide v 1.0 — August 2018 Altanium Neo5 CAUTION! Mechanical failure mode - attempting to remove a card when the upper and lower heatsink mounting fasteners are not fully disengaged from the female threads on the cabinet can result in catastrophic damage to the card.

  • Page 150: Replacing A Blown Fuse On An Intelligent Control Card

    1.0 — August 2018 Altanium Neo5 CAUTION! Static electricity hazard - risk of damage to the equipment. The Intelligent Control Cards are electrostatic discharge sensitive. Do not, under any circumstances, place any Intelligent Control Card on carpets, rugs, or other material that is likely to create a static charge.
  • Page 151 Carefully put the card on an earthed/grounded surface. Remove and replace the faulty fuse with one of identical type and rating. Husky recommends SIBA 712540 Series or equivalent fuses. Make sure the fuse is fully seated.

  • Page 152: Neo5 Operator Interface

    1.0 — August 2018 Altanium Neo5 15.4 Neo5 Operator Interface The Neo5 operator interface is used to enter and display molding parameters. It consists of two main components; the touch monitor and the master control unit (MCU). It is also available in two different configurations;...

  • Page 153: Replacing The Touch Monitor - Integrated Configuration

    User Guide v 1.0 — August 2018 Altanium Neo5 15.4.1 Replacing the Touch Monitor — Integrated Configuration WARNING! Electrical and mechanical hazard - risk of damage to the equipment. Turn off all power to the system and disconnect it completely from the main input power. Follow the local Lock Out Tag Out procedures.
  • Page 154 1.0 — August 2018 Altanium Neo5 Unplug the mini USB and HDMI connectors at the back of the touch monitor. Page 144...
  • Page 155 User Guide v 1.0 — August 2018 Altanium Neo5 Loosen the two upper fasteners using a 4mm socket wrench or nut driver. IMPORTANT! Only loosen the fasteners. The mounting holes in the bracket holding the touch monitor are slotted key holes that allow the monitor to be removed without removing the fasteners completely! Rotate the touch monitor to the full back position and loosen the two lower fasteners.
  • Page 156 1.0 — August 2018 Altanium Neo5 Securely grip the touch monitor and slide it upwards until the fasteners have cleared the upper mounting slots and lower key holes. Pull forward to remove the touch monitor from the mounting bracket.

  • Page 157: Replacing The Mcu - Integrated Configuration

    User Guide v 1.0 — August 2018 Altanium Neo5 15.4.2 Replacing the MCU — Integrated Configuration WARNING! Electrical and mechanical hazard - risk of death, serious injury and/or damage to the equipment. Turn off all power to the system and disconnect it completely from the main input power.
  • Page 158 1.0 — August 2018 Altanium Neo5 Locate and remove two mounting fasteners holding the MCU in place at the back of the unit. Page 148...
  • Page 159 User Guide v 1.0 — August 2018 Altanium Neo5 Put your hand on the front of the MCU and push it backwards to disengage the hidden hooks that hold it in place on top of the mainframe. IMPORTANT! Do not pull up on the MCU because it is held into position by hooks that fit into slots in the top of the mainframe and are hidden from sight! Push back on the MCU from the front to disengage the hooks and then lift up.
  • Page 160 1.0 — August 2018 Altanium Neo5 Carefully remove the power and communication couplings from the pocket at the bottom of the MCU and continue to rotate the unit upwards until it is resting on its front face. Page 150...
  • Page 161 User Guide v 1.0 — August 2018 Altanium Neo5 Using your fingers, gently rotate the power and communication couplings to disconnect the cables from the top of the mainframe. After the power and communication cables are disconnected, carefully lift the MCU from the mainframe.

  • Page 162: Replacing The Touch Monitor - Freestanding Configuration

    1.0 — August 2018 Altanium Neo5 15.4.3 Replacing the Touch Monitor — Freestanding Configuration WARNING! Electrical and mechanical hazard - risk of damage to the equipment. Turn off all power to the system and disconnect it completely from the main input power. Follow the local Lock Out Tag Out procedures.
  • Page 163 User Guide v 1.0 — August 2018 Altanium Neo5 WARNING! Pinch Point Hazard - keep hands and fingers clear of the Neo5 touch monitor hinge mechanism. Unplug the mini USB and HDMI connectors at the back of the touch monitor and loosen the two upper fasteners using a 4mm socket wrench or nut driver.
  • Page 164 1.0 — August 2018 Altanium Neo5 IMPORTANT! Only loosen the top fasteners. The top mounting holes in the bracket holding the touch monitor are slotted and allow the monitor to be removed without removing the top fasteners completely! Rotate the touch monitor to the full back position and completely remove the two lower fasteners.
  • Page 165 User Guide v 1.0 — August 2018 Altanium Neo5 Securely grip the touch monitor and slide it upwards until the fasteners have cleared the upper mounting slots and pull forward to remove the touch monitor from the mounting bracket. Ensure the fasteners are preinstalled on the upper threaded studs and the fasteners are left off the lower studs on the back of the touch monitor.

  • Page 166: Replacing The Mcu - Freestanding Configuration

    1.0 — August 2018 Altanium Neo5 15.4.4 Replacing the MCU — Freestanding Configuration WARNING! Electrical and mechanical hazard - risk of death, serious injury and/or damage to the equipment. Turn off all power to the system and disconnect it completely from the main input power.
  • Page 167 User Guide v 1.0 — August 2018 Altanium Neo5 Unplug the Touch Screen and LCD1 connectors at the bottom of the MCU and decouple the Power and Communication connectors. Locate the four fasteners holding the MCU to the mounting bracket. The bracket is located between the Touch Monitor and the MCU enclosure.
  • Page 168 1.0 — August 2018 Altanium Neo5 Loosen the two top fasteners holding the MCU to the mounting bracket using a 4mm Allen key or hex wrench. Page 158...
  • Page 169 User Guide v 1.0 — August 2018 Altanium Neo5 IMPORTANT! Only loosen the top fasteners. The top mounting holes in the bracket holding the MCU are slotted and allow the unit to be removed without removing the top fasteners completely! Locate and completely remove the two lower fasteners.
  • Page 170 1.0 — August 2018 Altanium Neo5 Securely grip the MCU and slide it upwards until the fasteners have cleared the upper mounting slots and pull forward to remove the MCU from the mounting bracket. Follow steps 1 thru 6 in reverse order to install the new MCU.

  • Page 171: Replacing The Operator Interface - Freestanding Configuration

    User Guide v 1.0 — August 2018 Altanium Neo5 15.4.5 Replacing the Operator Interface — Freestanding Configuration WARNING! Electrical and mechanical hazard - risk of death, serious injury and/or damage to the equipment. Turn off all power to the system and disconnect it completely from the main input power.
  • Page 172 1.0 — August 2018 Altanium Neo5 Locate and remove the two fasteners holding the operator interface at the front of mainframe. Page 162...
  • Page 173 User Guide v 1.0 — August 2018 Altanium Neo5 Locate and remove the two fasteners holding the operator interface at the back of mainframe. This step will require a screwdriver short enough to clear the MCU located above the two back mounting screws.

  • Page 174: Neo5 Mobile Stand

    1.0 — August 2018 Altanium Neo5 15.5 Neo5 Mobile Stand The Neo5 integrated configuration is available with a mobile stand as a paid option. The mobile stand allows the touch monitor of the Neo5 integrated configuration to be raised to an optimal viewing height (1320mm –...

  • Page 175: Installing Neo5 On The Mobile Stand

    User Guide v 1.0 — August 2018 Altanium Neo5 15.5.1 Installing Neo5 on the Mobile Stand The Neo5 mobile stand and controller come as separate pieces and must be assembled. WARNING! Electrical and mechanical hazard - risk of serious injury and/or damage to the equipment.
  • Page 176 1.0 — August 2018 Altanium Neo5 Place the mobile stand in an open flat area of the floor and set the brakes (located on the front wheels). Locate the 4x mounting holes on the top plate of the mobile stand.
  • Page 177 User Guide v 1.0 — August 2018 Altanium Neo5 WARNING! Heavy object - two person lift requirement. To avoid injury ask for assistance and use proper lifting technique when lifting the Neo5. Refer to Section 1.8.1. Once the Neo5 controller has been centered on the mobile stand, put the four leveling pads through the holes and firmly tighten by hand.

  • Page 178: Cleaning The System

    1.0 — August 2018 Altanium Neo5 15.6 Cleaning the System WARNING! Electrical and mechanical hazard - risk of death, serious injury and/or damage to the equipment. Turn off all power to the system and disconnect it completely from the main input power.

  • Page 179: Basic Troubleshooting

    User Guide v 1.0 — August 2018 Altanium Neo5 15.7 Basic Troubleshooting WARNING! Electrical and mechanical hazard - risk of death, serious injury and/or damage to the equipment. Turn off all power to the system and disconnect it completely from the main input power.
  • Page 180 1.0 — August 2018 Altanium Neo5 Troubleshooting Procedures Problem Potential Cause Solution Ground Fault Bad heater. Consult the mold electrical prints and use an Short in wiring. ohmmeter or insulation resistance meter to Bad Card. inspect the cables and mold.
  • Page 181 User Guide v 1.0 — August 2018 Altanium Neo5 Troubleshooting Procedures Problem Potential Cause Solution No Connection, T/C Thermocouple circuit is broken. Shorting the thermocouple input should Bad thermocouple. display an ambient temperature on the Card is not seated. operator interface. If it does, the problem is Card is not calibrated.
  • Page 182 1.0 — August 2018 Altanium Neo5 Page 172...

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