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Barnes thermoplay TH-M6 User Manual

24-48 zones hot runner controller
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Summary of Contents for Barnes thermoplay TH-M6

  • Page 3 1 Index Index ..........................3 Components identification ....................4 Installing specifications ....................7 Special warnings..............................7 Insulating the controller ............................. 8 Insulating by means of SSR: hoe does it work .................... 8 Specifications and technical characteristics ....................8 Working details ......................... 9 Drying ..................................

  • Page 4: Components Identification

    6.15 “logs” environment ............................52 6.16 “alarms” environment, recommended actions ..................53 6.16.1 Alarms and recommended actions ....................53 6.16.2 Historical alarms ............................53 6.16.3 Active alarms .............................. 55 6.16.4 Alarm configuration ..........................56 6.16.5 Alarm shout down ........................... 57 6.16.6 Alarm acknowledgment ........................
  • Page 5 Figure 1...
  • Page 6 Figure 2 The structure of the temperature controller is visible in figure 1. In function of the number of zones, 4 - 8 power boards are present. All the boards are connected to the HMI. This interface allows all the operator procedure as well as the temperature and alarms supervision of all the loops.

  • Page 7: Special Warnings

    3 Installing specifications The equipment was designed and built for the regulation of “hot runner systems” through the control of electrical energy supplied to the heating elements of the various parts of the system (distributors, nozzles, ….) with the aim of keeping process temperatures stable (max temperature 400°C).
  • Page 8 3.2 Insulating the controller When the main switch (miniature circuit breaker) is in the OFF position, components inside the cabinets are all isolated from power supply by means of a mechanical switch. Do not open the cabinet without first disconnecting the main supply cable from the power line.
  • Page 9 Reading scale Celsius, Farenheit. Main overload protection Miniature circuit breaker Operating temperature 0 – 50 [°C] Alarms and warnings Over temperature • Band around SP (High, Low, Ok) • Thermocouple failure • Inverted thermocouples • Heater failure • Fuse failure •...
  • Page 10 historical data as well as alarms are stored. It’s possible to select and export data based • on a specified time range synchronous preheating of all the zones, regardless to the thermal inertia • regulating outputs offset to avoid absorption high current peaks •...

  • Page 11: Soft Start

    At every successive start, heating begins with the same parameters active during the last stop. The zone parameters calculated automatically during the tuning phase are: “Pb” (Idx 14), “Int” (Idx 15), “Der” (Idx 16), “Fuzzy overshoot control” (Idx18). If the Auto tune function is enabled, after the Soft Start, the heating goes on until 75% (common parameter “% SP end Soft Start - start Auto Tuning”...

  • Page 12: "Check" Status

    4.7 “CHECK” status At the controller start, all the zones with one of the anomalies listed below: heater failure • thermocouple failure • heater and thermocouple not connected • are automatically disabled. The status of these zones is “CHECK”, the output power is 0%. These zones are not considered by digital output functions.

  • Page 13: System Start-Up

    System start-up 1. Connect the power supply cable, paying attention to the correspondence between the network voltage and what is specified in the identification plate. 2. Plug power and thermocouples cable both in the mould and controller side. 3. Turn ON the controller. 4.
  • Page 14 As soon as the supervisory software start is compete, Figure 5 page will be displayed. Particularly, upper bar allows to navigate between all the environments. Table 3: upper bar main Main page, refer to paragraph 6.3 table Table page, refer to paragraph 6.4 synoptic Allows to identify each zone on the real mould Refer to paragraph 6.10...
  • Page 15 Table 5: lower bar Date and Last alarm (red background if still active) User time 6.2 LOGIN – LOGOUT – users management At software start-up, page of Figure 5 is displayed. All the functions are blocked until login is made. Push button on the right side bar: Figure 6: login Select the user and enter the numerical password (Table 6).
  • Page 16 Figure 7: users management page In this page a list of the available users and the corresponding access levels are displayed. If one user is selected, button deletes it. button allows to create a new user and to specify what will be the relative access level: Figure 8: new user creation After login was made, the active user is displayed in the lower bar (Table 5).
  • Page 17 6.3 “main” environment and selection options Figure 9: “main” page In “main” page, each zone appears as in Figure 9 with a virtual instrument. If the controller is equipped with a number of zones bigger than 50, scrolling buttons on the right side bar are enabled.
  • Page 18 Press the button to display the heating start options (Figure 11). Refer to paragraph 4.1and 4.2 for all the details dealing with “Drying” and “Mould change” functions. Press the button. Figure 11: heating start options If the “Drying” option was selected, the page of Figure 12 is showed. The button allows to stop the routine.
  • Page 19 Figure 13: “main” after the heating start Press the button and confirm (Figure 14): the whole controller go back in “STOP” mode. Figure 14 6.3.2 TH-M6 supervisory software exit Referring to Figure 10, select option to get access to the normal Windows environment.
  • Page 20 6.3.3 Terminal and controller shut-off Referring to the Figure 10, select the option if you want to close the supervisory software and shut-off the terminal. Confirm (Figure 16). Figure 16 Now you can turn OFF the whole controller (main switch “3”) 6.3.4 Technical service through remote access Referring to Fig.10, select the option to start the remote control and give access...
  • Page 21 6.3.5 Zone status Figure 18: virtual instrument, “main” page Table 7: virtual instrument, “main” page Zone identification label. The label and the background colour can be changed, refer to paragraph 6.18 Current temperature (present value) Break or not connected thermocouple Set Point temperature Unit of measure: Celsius degree Unit of measure: Farenheit degree...
  • Page 22 Figure 19 6.3.6 How to make a selection of some zones and change regulating parameters It’s possible to change regulating parameters of one or more zones contemporary, even if the controller is in “STOP” mode. Click anywhere in the virtual instrument to select the zone. When selected, it become yellow rimmed.
  • Page 23 It’s possible to select all the zones between two of them if the button was pressed before (Figure 222). Figure 22: range between Nozzle1 and Nozzle 16 If you need to select all the zones of the controller, use the button that alternately make the function of “clean the current selection”...
  • Page 24 Figure 24: zone “Nozzle 5” is selected It’ possible to change “operative mode” (status), Set Point and the heating percentage power that is active if the zone is in manual mode. If one of the two blanks is selected, a touch screen keyboard will appear.
  • Page 25 Figure 26: MASTER zone in SLAVE mode 6.4 Table environment “table” page is an alternative, more compact, to “main” page. Selection of one ore more zones and parameters change is possible in the same way explained for the “main” environment (paragraph 6.3).
  • Page 26 6.5 “details” function This function is enabled if only one zone is selected in “main” or “table” environment and allow to know all the available information. Select the zone, than press the button : the page of Figure 28 will appear. Figure 28: details about zone “Nozzle 29”...
  • Page 27 Zone It’s the number (from 1 to 6) of the selected zone on it’s power board (e.g. the 7 zone is the 1 of the 2 board) Channel It’s the network where the power board is connected. Until 14 boards (84 zones), there will be just one channel Address It’s the serial address of the power board, corresponding to the dipswitch “U43”...
  • Page 28 Figure 31 Buttons open the pages relative to the historical alarms and historical process data of the selected zone. 6.6 SP1 - SP2 switch Two indipendent Set Point are available. There is not a fixed rule: e.g. “SP1” can be used as working Set Point and SP2 as standby Set Point.
  • Page 29 Figure 34: test page Press button. All the controller zone are switched in “OFF” mode. Referring to Figure 34, the first zone of the list will be switched in “MANUAL” mode and the heating power set to the value . If after a time of current temperature is increased of at least , test result is positive.
  • Page 30 Figure 36 It’s possible to change test parameters relative to only one zone: just select this zone in the list of Figure 3, then press the button. Advised values are: Table 8: advised values Nozzle zone Hot runner – heater band zones 6.9 “boost”...
  • Page 31 Figure 38: boost enabled Active Set Point is increased of the value stored in the zone parameter “BOOST delta” Idx 7. Press the button to switch back to normal Set Point. Alternatively BOOST will switched off after a maximum time (common parameter “BOOST max. duration” Idx 36). 6.10 “synoptic”...
  • Page 32 The “Synoptic” page uses a picture of the moulding tool as page background. Each zone virtual instrument is immediately seen in relation to its physical position. It’s possible to load a picture directly from a USB memory stick. All picture formats (e.g. .bmp, .jpg, .gif) are allowed. Picture dimension must have a ratio between base and height of 4/3.
  • Page 33 6.10.1 Synoptic configuration Press button: Figure 41: all the virtual instrument are deleted from the main area Referring to Figure 41, press the button (yellow arrow) to delete all the virtual instruments from the main area. Figure 42: background picture selection...
  • Page 34 Click on the area specified by the red arrow, then select a new image from the available ones or import it from a USB memory stick with the button. Figure 43: background picture Select the image that you want, then press the button.
  • Page 35 Referring to Figure 45, the zoom buttons (red arrows) allows to zoom in and out the background picture. Figure 45: zoom in and out of the selected background picture Figure 46: how to place an instrument Referring to Figure 46, e.g. you can easily place the virtual instrument of zone “Nozzle 1”. Press the button specified by the red arrow.
  • Page 36 The synoptic configuration (background picture and virtual instrument positions) is stored inside the recipe. 6.11 “recipes” environment Figure 47: recipes Press the button to get access to the menu of Figure 47. In the top area is reported the name of the active recipe and the measure unit. If any setting was modified after the recipe was saved last time, a warning “Active recipe was modified”...
  • Page 37 Figure 48: recipe saving Click in the blank pointed by the red and blue arrow: a touch screen keyboard appears and a new name and description can be input. Click on an existing recipe (in the below list) if you want to overwrite it. Confirmation is required: click on button.
  • Page 38 6.11.2 Recipe loading In the menu of Figure 47, the button allows to load a stored recipe (controller must be in “STOP” mode). All the settings (zone and common parameters and synoptic configuration) will be restored at the values saved in the recipe. Figure 50: recipe loading Select the recipe you want to load in the below list.
  • Page 39 Click on button to import a recipe from an external USB memory. Then select the recipe from the available ones (Figure 52). Complete the operation with button. Now the imported recipe will be displayed in the list of Figure 52. The name of the recipe includes the import date and time.
  • Page 40 Figure 53 6.11.4 Celsius – Farenheit conversion In the menu of Figure 47, if controller is in “STOP” mode, the button allows to convert all the values of the regulating parameters to the corresponding value in °F. Confirmation is required. Figure 54 6.12 “graph”...
  • Page 41 Figure 55 The buttons on the lower area of Figure 55 allows to change the displayed time range (10 minutes, 1 hour, 1 day) and to go back and forward. Click on the button to enable the multiple viewing then select up to a maximum of 10 zones in the left side list.

  • Page 42: Zone Parameters

    Figure 57 Click on the button to go back to the previous view. 6.13 Zone parameters In “main” page, select at least 1 zone then click on button. Figure 58 Select one zone in the left side list: the value of the parameters for this zone will be displayed. Arrows allow to navigate among the pages.
  • Page 43 Figure 59: zone parameters, page 1 Figure 60: zone parameters, page 2...
  • Page 44 Figure 61: zone parameters, page 3 Click on button, then select the parameter that you want to modify (e.g. parameter “SP MAX” in Figure 622, red arrow). Use the touch screen keyboard to input the new value, then click on enter button. Figure 62 Click on button to complete the operation.
  • Page 45 If you need to change only one parameter value, input the desired value directly in the page of Figure 58, selecting the field that you want to change. Page of Figure 63 shows that the process is in progress. Figure 63 Table 9: zone parameters, highlighted in grey if read-only even with “Administrator”...
  • Page 46 Auto Tuning enabled 0=Off,1=On (The tuning of PID parameters will be performed if selected at the heating start) Pb (Proportional band, calculated during TUNE °C 199.9 16.4 phase) Int (Integral Time, calculated during TUNE phase) Der (Derivative time, calculated during TUNE phase) 0 Integral preload Fuzzy overshoot control (calculated during TUNE 10.0...

  • Page 47: Common Parameters

    6.14 Common parameters Click on button to view and change the parameters that have the same value in all the zones of the controller. Arrows allow to navigate among the pages. Figure 64 Figure 65: common parameters, page 1...
  • Page 48 Figure 66: common parameters, page 2 Figure 67: common parameters, page 3...
  • Page 49 Figure 68: common parameters, page 4 Click on button, then select the parameter that you want to modify (e.g. parameter “Time for calculation of average power” in Figure 69). Use the touch screen keyboard to input the new value, then click on enter button. Figure 69 Complete with button.
  • Page 50 Table 10: common parameters, highlighted in grey if read-only even with “Administrator” level of access. Idx Parameter M.U. Default Value Value Value Cycle time 10.0 (if changed, the new value will be active at the next system start up) % SP end Soft Start - start Auto Tuning SP1/SP2 selection 0=SP1 1=SP2...
  • Page 51 Temperature memory limit for SSR Alarm °C 1000 WAIT function hysteresis °C 100.0 EasyMode, automatic reply at start questions 0:Off Time for calculation of average power 3600 BOOST max. duration 3600 Threshold value A/D alarm NTC sensor 1023 (heatsink overheating – only with board cnt-02) >1023 = Off Offset A/D to alarm from NTC sensor->STOP 1023...
  • Page 52 6.15 “logs” environment Click on button. Here it’s possible to view all the actions that were made by controller operators. Specify the date of interest than confirm with button. Each record consists of a description of the action, the date and time and the user that was active in that moment. It’s not possible to delete event log.

  • Page 53: Historical Alarms

    6.16 “alarms” environment, recommended actions 6.16.1 Alarms and recommended actions Table 11: alarms and recommended actions Alarm message What to do [AL.SSR] Solid state relays failure Is a serious alarm. Shut the temperature controller off and disconnect the heater connected to the zone in which the anomaly was found.
  • Page 54 Figure 71: historical alarm Table 12: information reported in the alarm list Alarm description – zone label Activation date Activation time End date End time Identification label of the fuse Zone label Zone number (1-6) inside the relative board Serial network (1-2) Serial address of the relative board...

  • Page 55: Active Alarms

    Figure 72: historical alarms, time range selection Figure 73: export to a tab-delimited file 6.16.3 Active alarms Click on button to show only the active alarms. Now, for each record are reported all the information of Table 12, except date and time of the end of alarm.

  • Page 56: Alarm Configuration

    Figure 74: active alarms 6.16.4 Alarm configuration The button in Figure 75: alarm configuration allows to enter in the alarm handling configuration. Figure 75: alarm configuration In the Alarm Configuration page (Figure 77: alarm configuration settings ) all the alarms contained in Table 11 are shown and it is possible to set them to “stand-by”...
  • Page 57 Figure 76: time before stop Figure 77: alarm configuration settings By pressing the button the user exit from configuration and the active alarm list is displayed. 6.16.5 Alarm shout down The button visible in Figure 75: alarm configuration 6 allows to quieten the siren while the alarmi s active.

  • Page 58: Alarm Acknowledgment

    6.16.6 Alarm acknowledgment The button in Figure 75: alarm configuration 5 allows to confirm the active alarm acknowledgment. 6.17 “export” environment Select in “main” or “table” page the zones of which you need to export historical data. Then click on the button in the upper bar.
  • Page 59 Figure 79: data loading Figure 80: requested data The buttons allows to change the time range and to export the data in a tab-delimited file, as described in paragraph 6.16.2 Referring to Figure 80, there is one record per second. In Table 13 are listed all the information reported, per each zone.
  • Page 60 Table 13: exported data, per each selected zone Date Time Measure Unit (°C / °F) Current Temperature (Present Value) Active Set Point value Average Power % Operative Mode (status) Historical data (and alarms) are stored until the free space on the disk is bigger than 300MB. Then oldest recorded data will be deleted to get fee space for the new data saving.
  • Page 61 Figure 82 Select the zones that you need to change identification label and colour with the same procedure saw in paragraph 6.3.6; e.g the first 16 zones in Figure 82. Then select Figure 83 Set the fields “Description”, “Number and “Colour” as displayed in Figure 83 to get the following configuration:...

  • Page 62: Maintenance

    Figure 84: label modification Identification label of each zone is the merge of the two fields “Description” and “Number” set in the page of Figure 84. The first zone of the active selection has exactly the set number, the other have increasing values. 7 Maintenance Periodical maintenance is limited to the clean the opening of the cooling fans.

  • Page 63: Fuse Replacement

    7.2 Fuse replacement The replacement of the “protective” fuse is an operation that can be done where the controller is used. Before opening the temperature controller it is necessary to unplug the power cable. This must be done only by qualified personnel. The interruption of a fuse is due to an anomalous absorption.
  • Page 64 The digital inputs (from the exterior to the temperature controller) are: DIN-1: automatic commutation on SP2, message in bottom area “external SP2” • The parameter for the switch no-nc is “INPUT 1 (switch to SP2) logical level” Idx 22 (refer to paragraph 6.14). Figure 86 DIN-2: automatic commutation of all the zones in OFF, message in bottom area “OFF •...
  • Page 65 It will not be possible to change the operative mode (status) of any selected zones: Figure 88 If any digital inputs is active, are reported also in the alarm pages. The digital outputs (from the temperature controller to the exterior) are: OUT-1: all the temperatures are in tolerance and there is not any alarm active.
  • Page 66 Figure 89 Figure 90 Select the update .zip file with button, set the import option as displayed in Figure 90. Then click on button. Set the new project as the default one with button. Figure 91 Close “Project Manager” and start supervisory software (refer to paragraph 5). Login as an “Administrator”...
  • Page 67 Click on button. Figure 92 In the list of Figure 92, select the previous project in order to inherit (import) controller configuration, recipes (and synoptic configurations), event log and historical data and alarm. Then click on button to proceed. Load the recipe that was active in previous project (refer to paragraph 6.11.2).

  • Page 68: Warranty

    10 Warranty The warranty covers only the failure due to manufacturing defects. The warranty for the power boards has a duration of 365 worked days (common parameter “Total worked days” Idx 49). All the other components are covered for a duration of 2 years from the delivery date. 11 Disposal of A.E.E.
  • Page 69 Network ITALY Torino, Asti, Vercelli, Cuneo, Biella: VA.BI. RAPPRESENTANZE s.a.s. -Via Dei Ronchi, 2 0-1 0091 Alpignano (TO) -T. +39 335 6959 057 - vnarduzzi@gmail.eom Aosta, Alessandria, Liguria:THERMOPLAY S.p.A. -Via Carlo Viola 74 -11 026 Pont Saint Martin (AO) T. +39 34 0 97373 03 - thermoplay@thermoplay.com Milano ovest, Novara, Verbano-Cusio-Ossola, Sondrio, Varese, Como, Pavia, Lodi, Cremona e prov.: THERMOPLAY S.p.A.
  • Page 71 THERIVIDPLAV@ 'v· A business of BARNES GROUP INC THERMOPLAY S.p.A Via C . Viola, 74- 11026 Pont S. Martin (AO) ltaly lei. +39 0125 800311 r.a. -thermoplay@thermoplay.com THERMOPLAY U.K. Ltd. Business C e ntre, 8 Madeira Avenue Leigh on Sea, Essex SS 9 3E B, U.K.

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