Page 1 Altanium Delta5 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
2.0 — March 2023 Altanium Delta5 Ordering Additional Manuals...
Page 5: Table Of Contents
Husky Regional Service and Sales Offices ........
Page 6 2.0 — March 2023 Altanium Delta5 4.1.3.1 Controller Function Buttons......... .17 4.1.3.2...
Page 7 User Guide v 2.0 — March 2023 Table of Contents 6.1.9 Rename Files .............52 6.1.10 Transfer Data to the Network .
Page 8 2.0 — March 2023 Altanium Delta5 7.8.8 Setpoint Limits ............81 7.8.8.1...
Page 9 User Guide v 2.0 — March 2023 Table of Contents Soft Start ..............107 9.6.1 Enable Soft Start.
Page 10 2.0 — March 2023 Altanium Delta5 10.8 Part Counting............. . . 149 10.8.1 Set Part Counting .
Page 11 User Guide v 2.0 — March 2023 Table of Contents Chapter 11: Mold Picture View ............177 11.1 Mold Picture View Graphic .
Page 12 2.0 — March 2023 Altanium Delta5 12.4.6 Process Data Filter............208 12.4.7 Save Process Data Setup.
Page 13 Table of Contents Chapter 15: SPI Protocol Option ............261 15.1 SPI Command Summary.
Page 15: Introduction
User Guide v 2.0 — March 2023 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 16: 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. To do so can result in damage to the system, or serious personal injury.
Page 17: 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 18: 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 Delta5 operator interface only: • Supply Voltage: 100 to 240 VAC ±10%, single phase •...
Page 19: Controller Lifting Instructions
User Guide v 2.0 — March 2023 Introduction Controller Lifting Instructions Use the steps that follow when you lift the Altanium controller. The lift device (crane or forklift) and straps that are used vary in lifting ability and lengths, depending on whether the Altanium is a single, double, or triple stack controller.
Page 20 2.0 — March 2023 Altanium Delta5 Figure 1-2 Straps Position b. Make sure that the straps do not pinch or crush the cables attached to the controller. Refer to Figure 1-3. Figure 1-3 Check Cables Use the lift device to apply enough upward force on the straps to remove the slack, but do not lift the controller at this time.
Page 21 User Guide v 2.0 — March 2023 Introduction Figure 1-4 Protect the Controller Finish Tighten the ratchet strap. Use the lift device to slowly lift the controller off the ground a few inches. Examine the webbed straps and ratchet straps to make sure the controller will not tilt. Move the controller to the new location.
Page 22 2.0 — March 2023 Altanium Delta5 Controller Lifting Instructions...
Page 23: Chapter 2 Hot Runner Temperature Control
User Guide v 2.0 — March 2023 Hot Runner Temperature Control Chapter 2 Hot Runner Temperature Control This guide is written to make sure that users get 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 24: Configure A Zone For Zero Cross Control
2.0 — March 2023 Altanium Delta5 2.2.1 Configure a Zone for Zero Cross Control This method defines how the power to each heater is averaged over a period of time. This is done by switching between complete half cycles of the heater supply voltage with the use of a snubberless TRIAC as a switch device.
Page 25: Thermocouple Types And Color Codes
User Guide v 2.0 — March 2023 Hot Runner Temperature Control Record the measurement. Use Ohm’s Law to calculate the results. Ohm's Law says: Amps = Watts / Volts Amps = Volts / Resistance Resistance = Volts / Amps Watts = Volts x Amps Example: If the resistance is 12.5 ohms and the input voltage is 240 volts, divide 240 by 12.5 to calculate the maximum amperage draw on that heating element:...
Page 26 2.0 — March 2023 Altanium Delta5 Thermocouple Types and Color Codes...
Page 27: Chapter 3 Connect The System To The Mold
User Guide v 2.0 — March 2023 Connect the System to the Mold Chapter 3 Connect the System to the Mold This chapter gives the various checks to make before you energize the system. Before Startup DANGER! Electrocution hazard– contact with hazardous voltages will cause death or serious injury.
Page 28: Startup Procedure Checklist
Text View screens. NOTE: There are no controller-to-mold interconnection details included in this User Guide. If this information is necessary, please call the nearest Husky Regional Service and Sales office. IMPORTANT! If you turn off the system, wait 30 seconds before you turn the main disconnect switch back on.
Page 29: Chapter 4 Altanium Operator Interface
User Guide v 2.0 — March 2023 Altanium Operator Interface Chapter 4 Altanium Operator Interface This chapter gives an overview of the functionality of the Altanium system and gives information about the topics that follow: • Altanium operator interface • Altanium buttons •...
Page 30: Home Screen
2.0 — March 2023 Altanium Delta5 4.1.2 Home Screen From the Home screen you can navigate to all other screens in the system. The Home screen can be accessed from all other screens in the system when you touch the Home button in the system header.
Page 31: Altanium Buttons
User Guide v 2.0 — March 2023 Altanium Operator Interface 4.1.3 Altanium Buttons Altanium has a system header and a footer on every screen in the system. 4.1.3.1 Controller Function Buttons Refer to Figure 4-1 for the Controller Function buttons location. Table 4-1 describes the button functions.
Page 32: System Status Field
2.0 — March 2023 Altanium Delta5 4.1.3.2 System Status Field Refer to Figure 4-1 for the System Status field location. Table 4-2 describes the System Status Field information. Table 4-2 System Status Field Button Description System Ready To Mold When the system starts, this status bar shows the progress as the mold zones heat to the At Temperature setpoint.
Page 33: Alarm Buttons
User Guide v 2.0 — March 2023 Altanium Operator Interface Table 4-3 Navigation Buttons (Continued) Button Description Home To see the Home screen. Quick Navigation To see a drop-down list of view buttons for products that are configured for your system (the I/O button will always show). 4.1.3.4 Alarm Buttons Refer to Figure 4-1...
Page 34: System And User Management Buttons
2.0 — March 2023 Altanium Delta5 4.1.3.5 System and User Management Buttons Refer to Figure 4-1 for the Alarm buttons location. Table 4-5 describes the System and User Management button functions. Table 4-5 System and User Management Buttons Button...
Page 35: Dialog Window Buttons
User Guide v 2.0 — March 2023 Altanium Operator Interface 4.1.4 Dialog Window Buttons The buttons in Table 4-6 are available in the Altanium dialog windows. Table 4-6 Dialog Window Buttons Button Description Accept (green check mark icon) To accept the changes you made in a dialog window. Cancel (red X icon) To discard the changes you made in a dialog window.
Page 36 2.0 — March 2023 Altanium Delta5 Table 4-7 System Modes (Continued) System Mode Description The Active Reasoning Technology (ART) tuning process is active. Calibration Shown during thermocouple input calibration for the zones. Diagnostics The mold diagnostics process is active.
Page 37: Servo Control
User Guide v 2.0 — March 2023 Altanium Operator Interface 4.1.6 Servo Control The Servo Control panel of the Altanium Home screen gives access to installed systems, such as the UltraSync-E, the UltraShot, or the Altanium Servo Controller. Refer to the appropriate user guides for more information.
Page 38: Temperature Control
2.0 — March 2023 Altanium Delta5 Table 4-9 Temperature Control Views Buttons (Continued) View Button Description Text View Shows a textual view of zone data. Refer to Section 7.6 for more information. Mold Picture View Shows an image (picture or graphic) of the mold or hot runner system layout from an imported image file.
Page 39: Common Buttons
User Guide v 2.0 — March 2023 Altanium Operator Interface Table 4-10 Temperature Control Buttons (Continued) View Button Description Diagnostic Results Shows the results of the mold diagnostics. Refer to Section 8.2 information. Staging Used to heat or cool zones in a specified order with the use of stages. From the Staging screen a user can assign zones to stages, set stage setpoints, and enter soak timers for each stage.
Page 40: System Configuration Buttons
2.0 — March 2023 Altanium Delta5 4.1.10 System Configuration Buttons The System Configuration panel of the Altanium Home screen gives access to the system setup, mold files, and I/O screens. Table 4-12 gives a description for each of the related screens for the system configuration buttons.
Page 41 User Guide v 2.0 — March 2023 Altanium Operator Interface Figure 4-2 Typical Keyboard, Keypad, and Selection Menu Screen Keyboards, Keypads, and Selection Menus...
Page 42: Keypad Use
2.0 — March 2023 Altanium Delta5 4.2.1 Keypad Use The screen keyboards and selection menus are easy to use. You type in text or make a selection, and then select the green check mark button to accept the entry.
Page 43: Select A Language
User Guide v 2.0 — March 2023 Altanium Operator Interface Select a Language The Altanium screens are available in fourteen languages. The default language is English. All screens have a Language Selection (globe) icon that shows the available languages. To select a language, do the steps that follow: Touch the Language Selection button at the bottom of the screen.
Page 44: Print To A File
2.0 — March 2023 Altanium Delta5 Print to a File To open the Print dialog box, touch the Print button on any Altanium screen. Refer to Figure 4-7. Files are saved in System\Reports folders. Figure 4-7 Print Button To print a single file, do the steps that follow: Touch the Print button.
Page 45: Print Report Descriptions
User Guide v 2.0 — March 2023 Altanium Operator Interface Figure 4-8 Print Dialog Box 4.4.1 Print Report Descriptions This section provides a description of each print report. Print files are automatically saved to one of the paths that follow: •...
Page 46 2.0 — March 2023 Altanium Delta5 Table 4-13 Print Reports Print Report Type Description Brief Zone Information From the Text View screen, the information that follows is printed to a file: • Zone number • Setpoint and units •...
Page 47: Online Help
Saves the current user interface screen to file in an image file format (.png). Online Help The online help is a Portable Document Format (PDF) file of the Altanium Delta5 User Guide. To use the online Help, do the steps that follow: Touch the Help button on an Altanium screen.
Page 48 2.0 — March 2023 Altanium Delta5 Online Help...
Page 49: Chapter 5 Security And Administration
User Guide v 2.0 — March 2023 Security and Administration Chapter 5 Security and Administration This chapter describes user management and screen security, which are done from the System Setup screen. Use the User Management and Screen Security tabs at the bottom of the System Setup screen to set the user roles and configure the items described in this chapter.
Page 50 2.0 — March 2023 Altanium Delta5 Figure 5-1 User Management Screen Touch one of the buttons described in Table 5-2 to manage users. Table 5-2 Manage Users Roles Button Description Add User Used to add a user to the system.
Page 51 User Guide v 2.0 — March 2023 Security and Administration Enter or change the user information in the dialog window that shows. Figure 5-2 shows the dialog window to add a user. Figure 5-2 Add User Dialog Window Set User Roles...
Page 52: Set Screen Security
2.0 — March 2023 Altanium Delta5 5.1.2 Set Screen Security Use Screen Security to assign what user roles have access to specified features and operations on the Altanium screens. The sections that follow describe the screens on which user roles are assigned.
Page 53 Selects the user role that can change the Company Name. Date and Time Select the user role that can set the date and time. Troubleshooting Data Selects the user role that can export diagnostic data for Husky service personnel to troubleshoot problems. User Management Select the user role that can use the User Management screen operations.
Page 54: Screen Security - Main 2 Screen
2.0 — March 2023 Altanium Delta5 Table 5-3 Screen Security - Main 1 Screen (Continued) Item Description Interface Settings Select the user role that can set Open Platform Communication Unified (OPC UA) Architecture (OPC UA) interface configurations. Certificate Select the user role that can do the OPC UA X.509 certificate management.
Page 55: Screen Security - Heats Page 1 Screen
User Guide v 2.0 — March 2023 Security and Administration 5.1.2.3 Screen Security - Heats Page 1 Screen Touch the Screen Security tab on the System Setup screen and then touch the Heats Page 1 tab to see the Heats Page 1 screen user role items. Touch the field next to each item and then select the user role for that item in the dialog window that shows.
Page 56 2.0 — March 2023 Altanium Delta5 Table 5-5 Screen Security - Heats Page 1 Screen (Continued) Item Description Part Counting Setup Select the user role that can use the Part Counting Setup function on the Heats Setup tab of the System Setup screen.
Page 57: Screen Security - Heats Page 2 Screen
User Guide v 2.0 — March 2023 Security and Administration Table 5-5 Screen Security - Heats Page 1 Screen (Continued) Item Description Bake Out Enable Select the user role that can enable or disable the bake out function on the Heats Setup tab of the System Setup screen.
Page 58: Screen Security - Servo Screen
2.0 — March 2023 Altanium Delta5 Table 5-6 Screen Security - Heats Page 2 Screen (Continued) Item Description Quick Set Advanced Select the user role that can change the fields in the Frequently Used, Zone Options Edit, Advanced Settings, and Control Settings drop-down lists on the Quick Set screen.
Page 59: User Preferences
User Guide v 2.0 — March 2023 Security and Administration Table 5-7 describes the Servo screen user role items. Table 5-7 Screen Security - Servo Screen Item Description Operation - Basic Select the user role that can change basic operation fields when servo equipment is installed on the Altanium controller.
Page 60 2.0 — March 2023 Altanium Delta5 Touch the Auto Logout Time field and enter the desired time value in the dialog window. Refer to Figure 5-8. Touch the Accept (check mark) button. Figure 5-8 Auto Logout Time Auto Logout...
Page 61: Mold Setups
User Guide v 2.0 — March 2023 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 Files button to open the Files screen for mold setup.
Page 62 2.0 — March 2023 Altanium Delta5 Table 6-1 Files Screen Item Descriptions Item Description File Tree The local drive holds all stored data contained in the Files screen. To help better organize and store files, there are three root directories included by default.
Page 63: Make A New Mold Setup Folder
User Guide v 2.0 — March 2023 Mold Setups Table 6-2 Files Screen Button Descriptions (Continued) Button Description Discard Changes Used to set the loaded mold setup file back to the state after it was last saved (with the Save Mold Setup button). All unsaved changes are discarded.
Page 64: Make A New Mold Setup File
2.0 — March 2023 Altanium Delta5 6.1.2 Make a New Mold Setup File When a mold setup folder has been created, a new mold setup file can be added to it. When a new mold setup file is created, and the Default folder contains only the Default mold setup file, the factory default setup file is copied and used as a template to build the new mold setup file.
Page 65: Save The Current Mold Setup File As A New File
User Guide v 2.0 — March 2023 Mold Setups 6.1.5 Save the Current Mold Setup File as a New File When a Mold Setup file has been loaded, it can be saved as a new file. To save the loaded Mold Setup file as a new file, do the steps that follow: On the Files screen, touch the Save As button.
Page 66: Rename Files
2.0 — March 2023 Altanium Delta5 Navigate to the destination folder, and then touch the Paste button to paste a copy of the file. A Files - Paste dialog window shows. Touch the Accept button. 6.1.9 Rename Files To rename a file or folder, do the steps that follow: On the Files screen, touch the file or folder to be renamed.
Page 67: Chapter 7 Making Adjustments
User Guide v 2.0 — March 2023 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 describes how to use the Altanium system to monitor and modify the system.
Page 68: Make A Zone Group
2.0 — March 2023 Altanium Delta5 Figure 7-1 Quick Set Screen - Zone Selection 1. Blocked Zone 2. Select All Button 3. Clear All Button Make a Zone Group Use the Quick Set screen to select two or more zones to form a group. Refer to Figure 7-2.
Page 69: Multi Group View Screen
User Guide v 2.0 — March 2023 Making Adjustments Figure 7-2 Quick Set Screen - Make Zone Groups 1. Zone Edit 2. Group Name 3. Group Shortcut Buttons Multi Group View Screen Use the Multi Group View screen to see all user-configured zone groups. Refer to Figure 7-3.
Page 70 2.0 — March 2023 Altanium Delta5 Figure 7-3 Multi Group View Screen The buttons on the Multi Group View screen are described in Table 7-1. Table 7-1 Multi Group View Screen Buttons Button Description Expand All Group Information Lists Used to expand all group information lists.
Page 71: Changing The Header Color
User Guide v 2.0 — March 2023 Making Adjustments Table 7-1 Multi Group View Screen Buttons (Continued) Button Description De-energize De-energizes the zones in that group if they are energized. Energize Energizes the zones in that group if they are not energized. Manual Standby Sets the zones in this group to Manual Standby.
Page 72: Graphical View Screen
2.0 — March 2023 Altanium Delta5 Figure 7-4 Color Change Dialog Box Touch the Accept button. Graphical View Screen The Graphical View screen shows zones in a graphical format. This screen makes it easy to see the full status of the mold and not have to sort through detailed data.
Page 73 User Guide v 2.0 — March 2023 Making Adjustments Table 7-2 gives the descriptions for the bars shown on the Graphical View screen. Table 7-2 Bar Descriptions Item Description Temperature Bars Each bar on the screen graphically shows the temperature control for one zone.
Page 74 2.0 — March 2023 Altanium Delta5 Table 7-3 gives the descriptions for the buttons on the screen. Table 7-3 Graphical View Screen Button Descriptions Button Description Plus/Minus (Split/Full and Detailed Screens) Toggles the zone view between split- or full-screen mode. In split-screen...
Page 75: Neo View Screen
User Guide v 2.0 — March 2023 Making Adjustments The Graphical View screen shows a maximum of 24 zones of information in full-screen mode (Figure 7-5) and 48 zones in split-screen mode (Figure 7-6). Touch and drag the scroll bar to bring additional zones into view.
Page 76: Detailed Screen Mode
2.0 — March 2023 Altanium Delta5 Figure 7-7 Neo View Screen - Simple Screen Mode 7.5.2 Detailed Screen mode If you would like to see more detailed data for the zones, touch the Plus/Minus button at the top right corner of the screen.
Page 77 User Guide v 2.0 — March 2023 Making Adjustments Figure 7-8 shows the Neo View screen in detailed screen mode. Figure 7-8 Neo View Screen - Detailed Screen Mode In each zone block of the Neo View detailed screen, nine items of information are shown for the zone (refer to Figure 7-9).
Page 78: Zone Block Background Color
2.0 — March 2023 Altanium Delta5 7.5.3 Zone Block Background Color The background color of a zone block will change to show the zone is at or near the temperature setpoint, or when the zone’s mode has changed (refer to Table 7-4).
Page 79: Follower Zone Block
User Guide v 2.0 — March 2023 Making Adjustments 7.5.4 Follower Zone Block When a zone is assigned to be a follower to a different zone (leader), the follower zone block will show the leader’s zone number and name. Every second, the follower zone block’s number and name flash blue text to show the leader’s zone number and name.
Page 80: Text View Screen
2.0 — March 2023 Altanium Delta5 Text View Screen The Text View screen shows zone information in a textual format. Refer to Figure 7-12. The screen is used to access detailed data for each zone and gives the most complete view of the process.
Page 81 User Guide v 2.0 — March 2023 Making Adjustments Table 7-6 gives descriptions of the items and buttons on the Text View screen. Table 7-6 Text View Screen Item and Button Descriptions Item/Button Description Zone Row Each row in the Text view is a heat zone in the system. Touch a zone row and the Quick Adjustment panel (if enabled) will show on the right side of the screen.
Page 82: Zone Selection In The Text View Screen
2.0 — March 2023 Altanium Delta5 Table 7-6 Text View Screen Item and Button Descriptions (Continued) Item/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 deselect all zone.
Page 83: Quick Adjustment Panel
User Guide v 2.0 — March 2023 Making Adjustments Quick Adjustment Panel When you select a zone, a block of zones, or touch the ‘Select All Zones’ button on the Neo View or Text View screens, the Quick Adjustment panel will show on the right side of the screen.
Page 84: Quick Set Screen
2.0 — March 2023 Altanium Delta5 Quick Set Screen Use the Quick Set screen to change the available zone settings and to put zones into groups. Refer to Figure 7-14. On the Home screen, touch the Quick Set button to see the Quick Set screen.
Page 85: Zone Edit
User Guide v 2.0 — March 2023 Making Adjustments Table 7-7 Frequently Used Fields (Continued) Item Description Zone On/Off Touch this field to set the selected zone(s) ON or OFF. A dialog window shows that lets you select the status. The default is ON. Regulation Mode Use this field to set the regulation mode for the selected zone(s): •...
Page 86: Setpoint Limits
2.0 — March 2023 Altanium Delta5 7.8.1.3 Setpoint Limits The Setpoint Limits fields are described in Table 7-9. Table 7-9 Setpoint Limits Fields Item Description Temperature Minimum These values are the range limits in which the Temperature Setpoint field can be set.
Page 87: Manual Boost
User Guide v 2.0 — March 2023 Making Adjustments 7.8.1.5 Manual Boost The Manual Boost fields are described in Table 7-11. Table 7-11 Manual Boost Fields Item Description Temperature Setpoint The temperature to which all zones are set when the Boost button is touched.
Page 88: Remote Boost
2.0 — March 2023 Altanium Delta5 7.8.1.7 Remote Boost The Remote Boost fields are described in Table 7-13. Table 7-13 Remote Boost Fields Item Description Temperature Setpoint Remote boost is started by a digital input signal from the IMM. This setting raises all zones to their remote boost setpoint until the timer completes or the input signal is off.
Page 89: Control Settings
User Guide v 2.0 — March 2023 Making Adjustments Table 7-14 Advanced Settings Fields (Continued) Item Description PCM - Priority Control The Priority Control Mode (PCM) controls what the controller will do in an Mode abort condition. Earth Leakage Check This lets you set the earth leakage checking feature for each zone to ON or OFF.
Page 90: Zone Name
2.0 — March 2023 Altanium Delta5 Table 7-15 Control Settings Fields (Continued) Item Description I-Integral This is the integral term value used by the control algorithm. Possible values are: 0 – 250. Refer to Section 7.10. D-Derivative This is the derivative term value used by the control algorithm. Possible values are: 0 –...
Page 91: Multiple Zones Names
User Guide v 2.0 — March 2023 Making Adjustments Figure 7-15 Zone Name Dialog Window Touch the Accept button. 7.8.2.1 Multiple Zones Names Use the Auto+ button to give names and numbers to two or more zones. The Auto+ button will give numbers to the selected zones from 001 to n, where n is the number of zones selected.
Page 92: Temperature Setpoints
2.0 — March 2023 Altanium Delta5 7.8.3 Temperature Setpoints The Temperatures Setpoints for each of the heaters in the mold must be specified. The default setting is 177 °C (350 °F). To change a setpoint of a zone, do the steps that follow: Touch the zone to be changed.
Page 93: Output Mode
User Guide v 2.0 — March 2023 Making Adjustments 7.8.6 Output Mode In hot runner temperature control systems, there are two different methods used to switch the power output to the heaters: Zero Cross Control or Phase Angle Control. Each method has its own set of advantages, but usually they have almost the same results.
Page 94: Manually Assign One Zone (Follower) To A Another Zone (Leader)
2.0 — March 2023 Altanium Delta5 After the error is cleared and reset, the follow value is written to the database. The defective zone shows its leader zone on the Quick Set screen. The automatic follow function can be disabled on the System Setup screen in the Heats Setup and Control Page 2 tabs.
Page 95: Setpoint Limits
User Guide v 2.0 — March 2023 Making Adjustments To change the zone regulation, do the step that follow: On the Quick Set screen, touch the zone to be changed. CAUTION! If a zone is changed to Monitor mode, the system will not apply power output to that heater.
Page 96: Change The Manual Standby Setpoint Limits
2.0 — March 2023 Altanium Delta5 7.8.8.2.1 Change the Manual Standby Setpoint Limits To change a Manual Standby setpoint and limits for a zone, do the steps that follow: Touch the zone to be changed on the Quick Set screen.
Page 97: Change The Remote Boost Setpoints And Limits
User Guide v 2.0 — March 2023 Making Adjustments setpoint. Set the temperatures to heat the heaters in the mold to when the system is in Boost. The default setpoint is No Chg (No Change). The No Change setpoint tells the system to make no changes to the heaters during Manual or Remote Boost.
Page 98: Change The Sensor Assignment (Thermocouple)
2.0 — March 2023 Altanium Delta5 7.8.9 Change the Sensor Assignment (Thermocouple) The Thermocouple Assignment lets the operator assign a thermocouple from a different zone to control the heater of the selected zone. This is important in a condition when there could be mis-wired thermocouples or heaters in the mold.
Page 99: Change The Earth Leakage Check
You would have the Earth Leakage Check set to OFF only in special conditions. To change the Earth Leakage Check to OFF globally for the full system, please contact the nearest Husky Regional Service and Sales office. 7.8.12 Change the Automatic Manual Control...
Page 100: Change The Zone Control From Art To Pid
2.0 — March 2023 Altanium Delta5 7.8.14 Change the Zone Control from ART to PID The Altanium system can automatically adjust the control algorithm to work with different heater requirements. This control method is Active Reasoning Technology (ART). In some conditions, it may be necessary to switch from the automatically adjusted ART algorithm to an algorithm that can be manually adjusted.
Page 101: Active Reasoning Technology
User Guide v 2.0 — March 2023 Making Adjustments Active Reasoning Technology Active Reasoning Technology (ART) is the science that applies microprocessor-based control systems to automatic system decisions. It is a control method directed at an active or continuous learning process, which is tolerant to faulty functions and incorrect operation by intentionally preventing the incorrect operation or failure.
Page 102 2.0 — March 2023 Altanium Delta5 Figure 7-16 ART Process Screen Table 7-17 ART Process Screen Item Descriptions Item Description Status Text The ART status is shown at the top of the screen. Zone Selection Grid The selection grid shows the status of each zone.
Page 103: Manual Art Function
User Guide v 2.0 — March 2023 Making Adjustments Table 7-18 ART Process Screen Button Descriptions (Continued) Button Description Reset ART Process Resets the ART parameters for the selected zones. The next time the system is started, it will do the ART process on those zones again. Edit ART Values Opens the Edit ART Values dialog window to see or change the ART parameters.
Page 104: Art 2.0
2.0 — March 2023 Altanium Delta5 To manually use ART on a zone, do the steps that follow: NOTE: The system must be in RUN mode before the ART process can start. On the ART Process screen, select the zone or zones on which the ART process will manually be run.
Page 105 User Guide v 2.0 — March 2023 Making Adjustments Figure 7-17 Automatic Zone Classification A dialog window is shown after the tuning is complete for a new mold setup or if one or more zones have been re-tuned on a different mold. This is only if the heater types have changed. NOTE: This dialog will not show if the system cannot find a gap between zones wider than the Heater Classification Gap setting in System Setup.
Page 106: Pid Control
2.0 — March 2023 Altanium Delta5 7.10 PID Control The sections that follow give typical PID values and possible causes of oscillation. 7.10.1 Typical PID Values A list of some typical PID values is given in Table 7-20. Table 7-20...
Page 107: Chapter 8: Mold Diagnostics
User Guide v 2.0 — March 2023 Mold Diagnostics Chapter 8 Mold Diagnostics Mold diagnostics is used to troubleshoot problems with a mold and to make sure that the wiring integrity of a mold after maintenance has been done. Diagnostics can also be used to analyze the thermal isolation between all the cavities in the mold.
Page 108 2.0 — March 2023 Altanium Delta5 The Mold Diagnostic screen fields, selections, and buttons are described in Table 8-1. 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 start temperature to pass a test.
Page 109: Run A Mold Diagnostics Test
User Guide v 2.0 — March 2023 Mold Diagnostics 8.1.1 Run a Mold Diagnostics Test To do a mold diagnostic test, do the steps that follow: Before power is connected to the controller or the mold, clean the mold and area around it.
Page 110: Set The Maximum Test Time
2.0 — March 2023 Altanium Delta5 8.1.3 Set the Maximum Test Time On some molds, if there is a thermocouple wiring problem, a heater could be damaged during test. Heaters in some configurations may not support the peak temperatures in the default test time when full power is applied.
Page 111: Test Results Screen Values
User Guide v 2.0 — March 2023 Mold Diagnostics The buttons and fields on the Test Results screen are described in Table 8-2. Table 8-2 Test Results Screen Buttons and Fields Item Description Mold Diagnostics Opens the Mold Diagnostics screen. Rewire Automatically reassigns all the sensors to their correct location with the use of the test results.
Page 112 2.0 — March 2023 Altanium Delta5 Table 8-3 Test Result Columns (Continued) Item Description Watt Power for each zone that was calculated from the line voltage and current readings measured during the test. Resistance for each zone that was calculated from the line voltage and current readings measured during the test.
Page 113: Automatic Thermocouple Rewiring
User Guide v 2.0 — March 2023 Mold Diagnostics 8.2.2 Automatic Thermocouple Rewiring Thermocouples can be accidentally cross-wired in the mold, where the thermocouple for one heater becomes connected with a different heater. The Altanium wiring test does a check of the thermocouple/heater wiring and shows if the wiring is correct.
Page 114: Temperature Graphs Screen
2.0 — March 2023 Altanium Delta5 The column information of the Cross Talk screen is described in Table 8-4. Table 8-4 Cross Talk Screen Column Information Item Description Zone Shows the zone number. Name Shows the name of the zone.
Page 115 User Guide v 2.0 — March 2023 Mold Diagnostics The Temperature Graphs screen buttons are described in Table 8-5. Table 8-5 Temperature Graphs Screen Button Descriptions Button Description Previous Arrow Shows the results of the previous zone if multiple zones are selected.
Page 116 2.0 — March 2023 Altanium Delta5 Temperature Graphs Screen...
Page 117: Chapter 9 Heat The Mold
WARNING! Please read this entire manual before you start the system. Call the nearest Husky Regional Service and Sales office with any questions. With all of the Altanium-to-mold connections completed and the mold cooling is ON, touch the Start button to start the system.
Page 118: Earth Leakage/Wet Heater Bake Out System
2.0 — March 2023 Altanium Delta5 Earth Leakage/Wet Heater Bake Out System The Altanium is equipped with an Earth Leakage/Wet Heater Bake Out system. When the system is started, the Altanium continuously does checks for earth leakage conditions on all heaters in the mold at the same time.
Page 119: Configure The Length And Number Of Bake Out Cycles
User Guide v 2.0 — March 2023 Heat the Mold 9.2.2 Configure the Length and Number of Bake Out Cycles The low-voltage bake out operation will run up to five cycles, if necessary. The time for each cycle can be set from one to 30 minutes. The system mode and system timer shows each bake out cycle that is in progress.
Page 120: Unistart
2.0 — March 2023 Altanium Delta5 UniStart The UniStart function provides the shortest start-up time while ensuring that all temperatures track to their setpoint. NOTE: If AltaStart is enabled, only non-tip zones will be included in the UniStart process. If AltaStart is not enabled, then all zones will be included in the UniStart process.
Page 121: Soft Start
User Guide v 2.0 — March 2023 Heat the Mold Soft Start During the soft start operation, all of the Altanium zones increase in temperature at the same time and at the same rate. The soft start operation causes an even thermal expansion and identical residence time on the material.
Page 122: Adjust The Soft Start Minimum Limit
2.0 — March 2023 Altanium Delta5 9.6.3 Adjust the Soft Start Minimum Limit The Soft Start limit is used to calculate the window between the lowest temperature zone and the highest temperature zone in the system. This window is used during the Soft Start process and controls the gap between the coldest and hottest zones.
Page 123: Open The Alarms Screen
User Guide v 2.0 — March 2023 Heat the Mold The Alarms screen buttons are described in Table 9-2. The Alarms screen information columns are described in Table 9-3. Table 9-2 Alarms Screen Buttons Button Description Silence Horn Stops the alarm tone. Reset Alarms Resets the alarm light and error message.
Page 124: Clear Alarms
2.0 — March 2023 Altanium Delta5 9.7.3 Clear Alarms If an error occurs, the Altanium starts an audible and visual alarm, and shows the alarm condition on the Alarms screen. To clear an alarm, do what follows: NOTE: Before resetting an alarm, correct the source of the alarm.
Page 125: Filter Events
User Guide v 2.0 — March 2023 Heat the Mold The information on the Event History screen is described in Table 9-5. Table 9-5 Event History Screen Information Item Description Filter Lets you select the type of events shown on the Event History screen. The event types include: •...
Page 126: Alarm And Event Icons
2.0 — March 2023 Altanium Delta5 Figure 9-3 Event History Filter Window Alarm and Event Icons Table 9-6 identifies the icons that show on the Alarms and the Event History screens. Table 9-6 Icons Icon Description The warning is inactive.
Page 127: Alarm Conditions - Warning Errors
User Guide v 2.0 — March 2023 Heat the Mold Table 9-6 Icons (Continued) Icon Description The alarm or zone alarm is inactive. A user did an operation (pressed Start, pressed Stop, copied a file, pasted a file, deleted a file, and so on). A setpoint change was made.
Page 128: Abort Conditions - Shutdown Errors
2.0 — March 2023 Altanium Delta5 Table 9-7 Warning Errors (Continued) Warning Description AMC Active A zone’s thermocouple has become defective as the system operates in automatic control mode. There was no match found for this zone in the mold by the auto-follow feature or the auto- follow feature is OFF.
Page 129 User Guide v 2.0 — March 2023 Heat the Mold Table 9-8 Shutdown Errors (Continued) Shut Down Error Description Earth Leakage Limit : If the earth leakage is more than the calculated limit or default value, the earth leakage error is triggered. : If the measured leakage level is more than the Earth Leakage Fault Limit value, the earth leakage error is triggered.
Page 130 2.0 — March 2023 Altanium Delta5 Abort Conditions — Shutdown Errors...
Page 131: Chapter 10 System Setup
User Guide v 2.0 — March 2023 System Setup Chapter 10 System Setup This chapter contains the information necessary to setup the Altanium controller for operation. Many of the configurations are set in the System Setup screen, which are in tabbed groups.
Page 132: System Setup - Main 1 And Main 2 Settings
Description Serial Number The serial number is for information only. It is a number given to the system when it is manufactured. Husky support may ask for this number when they need to troubleshoot or upgrade the Altanium. Model The controller model name.
Page 133 The complete log is transferred, or a time range can be set. Diagnostics Export Used to export diagnostics files to a USB drive. This is for Husky Technical Support use only. Contact Husky for help, if necessary. Air Filter Used to set a reminder interval for the air filter replacement.
Page 134: System Setup - Network Settings
A network path can be entered for the shared network folder to upload or download files to and from the controller, in the format \\server\shared folder. For help with your controller, Husky can give assistance with a remote connection to your system with the Remote Service Assistance application.
Page 135: Wired Network
User Guide v 2.0 — March 2023 System Setup Figure 10-3 Network Setup Screen 10.2.1 Wired Network To change the network settings for a wired network, do the steps that follow: On the System Setup screen, touch the Network tab. Touch the Setup button in the WIRED NETWORK section of the screen.
Page 136: Wireless Network
2.0 — March 2023 Altanium Delta5 Enter the necessary information in the fields to configure the network connection. Touch the Update button. The Connected indicator will show when the network connection has been made. 10.2.2 Wireless Network To change the network settings for a wireless network, do the steps that follow: NOTE: The controller does not have a built-in wireless adapter.
Page 137: Network Share
User Guide v 2.0 — March 2023 System Setup NOTE: The SSID, Authentication method, and Signal strength for all available WiFi networks are shown. They listed in order by their signal strength. Select an SSID from the list. The SSID shows in the Network SSID field. NOTE: The HMI application supports specific types of the authentication modes (Open, and WPA-Personal) for wireless network configuration.
Page 138 2.0 — March 2023 Altanium Delta5 Figure 10-8 Network Share Configuration Dialog On the Network Share Configuration dialog, you can enter the network path for the shared network folder to upload or download files to and from the controller, in the format: \\server\shared folder.
Page 139: Dashboard Interface
User Guide v 2.0 — March 2023 System Setup Table 10-3 Network Configurations (Continued) Item Description Connection Status A status field that notifies the user of the current state of the network share connection. Possible values are: Not Connected The system is not connected to the specified network share.
Page 140: Remote Service Assistance
Dashboard Interface checkbox is enabled. 10.2.5 Remote Service Assistance If you find a problem that you cannot correct, contact the nearest Husky Regional Service and Sales office. Working with a Husky service technician, you can start a TeamViewer session that lets the technician see and operate your Delta5 controller system remotely.
Page 141: Start A Teamviewer Session
System Setup 10.2.5.2 Start a TeamViewer Session If problem cannot be corrected on the phone, the Husky service technician will give you a user name and password to start a TeamViewer session. TeamViewer lets the technician see and operate your Delta5 system remotely.
Page 142 2.0 — March 2023 Altanium Delta5 With the VNC feature installed on your Delta5 system, a VNC Server Options panel will show on your Network screen. Refer to Figure 10-11. For VNC operation, VNC client software must be installed. The controller and the IMM must be on the same network with no firewall between them.
Page 143: Vnc Client
User Guide v 2.0 — March 2023 System Setup Table 10-4 VNC Server Option Descriptions (Continued) Item Description Log VNC session activity Use this checkbox to enable VNC logging. Logging information is written to a text file and can be retrieved with the Log File Export Option. NOTE: At intervals, the VNC log is deleted, so the file does not use too much disk space.
Page 144: Opc Ua Interface
The Husky OPC UA server supports the Euromap 82.2 standard for hot runner devices. OPC UA relies on digital certificates to provide secure communication between a client and a server so that the data is confidential and cannot be modified during transmission.
Page 145: Opc Ua Interface Enable
EM82.2 OPCUA Interface R 1.00 (Euromap R 1.00) NOTE: For information or assistance on the OPC UA server and/or interface setup, contact Husky. 10.2.7.1 OPC UA Interface Enable To see the OPC UA Interface Setup window: On the System Setup screen, touch the Network tab at the bottom of the screen.
Page 146: Certificates
10.2.7.2 Certificates The Altanium Delta5 controller includes functions for creating, importing, and exporting X.509 digital certificates for the purpose of fulfilling secure communication between the client and server. It also provides the ability to create, import and export user certificates to be used in user identity authentication.
Page 147: Server Certificates
User Guide v 2.0 — March 2023 System Setup Table 10-6 give the certificate Management utility descriptions (right side of window). Table 10-6 Certificate Management Utility Descriptions Item Description Certificate Type (radio Choose the type of certificates to manage by selecting a specific radio buttons) button.
Page 148: Shotscopenx
2.0 — March 2023 Altanium Delta5 10.2.8 ShotscopeNX If your system has the optional ShotscopeNX (SSNX) feature, the interface setup panel will show on the Network tab. SSNX models intelligent devices, so that the data from subsystems, such as hot runner controllers, can be joined together with data from the IMM to give an integrated view of a cell’s data.
Page 149: Time Synchronization
User Guide v 2.0 — March 2023 System Setup Type in "ping <the IP address recorded in step 3>" and press Enter. Make sure that four replies from the controller are shown on the command prompt widow (refer to Figure 10-14).
Page 150 2.0 — March 2023 Altanium Delta5 Figure 10-15 Time Synchronization Setup Window Enter the necessary information in the fields described in Table 10-7 to configure the Time Synchronization. Table 10-7 Time Synchronization Setup Items Item Description Network Time Protocol...
Page 151: System Setup - Heats Settings
User Guide v 2.0 — March 2023 System Setup Table 10-7 Time Synchronization Setup Items (Continued) Item Description Last Successful Sync A status field that lets you know the last time a successful sync occurred. Time Time This field is updated automatically whenever the Synchronization Setup dialog is shown or whenever you update the time manually.
Page 152: Heats Setup - Control
2.0 — March 2023 Altanium Delta5 10.3.1 Heats Setup - Control Page 1 On the Control Page 1 tab of the Heats Setup screen, temperature configurations are set for the categories that follow: • Manual Standby and Boost •...
Page 153 User Guide v 2.0 — March 2023 System Setup Table 10-8 System Setup Screen - Heats Setup - Control Page 1 (Continued) Item Description Remote Standby Input Mode The standby setting is enabled by one of three settings: Trigger, On/Off, or a Direct signal. Trigger: Includes a delay timer and duration timer.
Page 154 2.0 — March 2023 Altanium Delta5 Table 10-8 System Setup Screen - Heats Setup - Control Page 1 (Continued) Item Description Number of Bake Out Cycles The number of tries to bake out the moisture in a heater. The parameter range is 1 to 5.
Page 155: Heats Setup - Control
User Guide v 2.0 — March 2023 System Setup 10.3.2 Heats Setup - Control Page 2 On the Control Page 2 tab of the Heats Setup screen, configurations are set for the categories that follow: • Part Counting • • Thermocouples •...
Page 156: Heats Setup - Control
2.0 — March 2023 Altanium Delta5 Table 10-9 System Setup Screen - Heats Setup - Control Page 2 (Continued) Item Description Auto Following Power Limit This value is the limit used by the Auto Following function to calculate if the average power output of a candidate zone is in the permitted deviation of the follower zone.
Page 157 User Guide v 2.0 — March 2023 System Setup Table 10-10 System Setup Screen - Heats Setup - Control Page 3 Item Description AltaStart Enable Used to enable AltaStart function for heat sequencing. Refer to Section 9.3. NOTE: At least one zone’s heater type must be set to ‘Tips’ or the system will not allow you to enable the function.
Page 158: Heats Setup - Monitoring 1 And Monitoring 2
2.0 — March 2023 Altanium Delta5 Table 10-10 System Setup Screen - Heats Setup - Control Page 3 (Continued) Item Description Tuning Strategy Used to select the ART Classic or ART 2.0 tuning strategy. ART 2.0 is selected by default. Refer to Section 7.9...
Page 159 User Guide v 2.0 — March 2023 System Setup Table 10-11 System Setup Screen - Heats Setup - Monitoring 1 Item Description Alarm Sensitivity The duration of time the system has to stay in an error condition before an alarm occurs. Maximum Temperature Limit The number of degrees over the setpoint that the Maximum Temperature Alarm occurs.
Page 160 2.0 — March 2023 Altanium Delta5 Table 10-11 System Setup Screen - Heats Setup - Monitoring 1 (Continued) Item Description Display Failure Data This button becomes enabled when the system has completed the circuit test and failures have been found. Touch the button to see past test results, so you do not have to run the circuit test again.
Page 161 User Guide v 2.0 — March 2023 System Setup On the Monitoring 2 tab of the Heats Setup screen, mold monitoring configurations are set for the categories that follow: • No Heater Detection • Current Deviation The Monitoring 2 tab is shown in Figure 10-20 with the configuration settings for each category.
Page 162: Force Temperature Units To
2.0 — March 2023 Altanium Delta5 10.4 Force Temperature Units To Users can select how the available temperature units are shown with the Force Temperature Units To option: Degrees Celsius (C), degrees Fahrenheit (F), or degrees kelvin (K). When C, F, or K is selected, all temperatures shown in the system are forced to that unit. This includes all stored mold setups.
Page 163: Power Conservation
User Guide v 2.0 — March 2023 System Setup Type the number of days and touch the Accept button. Touch the Change Reminder checkbox to enable the reminder. When asked, “Are you sure?”, touch the Accept button. Touch the Exit button. 10.7 Power Conservation To conserve power, the Altanium controller lets you set the display to automatically turn off (change to a dark screen) if it is not used in a set interval of time.
Page 164: Reset The Part Counter
2.0 — March 2023 Altanium Delta5 Touch the Sack Full Limit field and then enter a quantity of parts that tells the system when the sack is full. You can set the quantity from 1 to 1,000,000. Touch the Configure Digital I/O button if this was not done before.
Page 165 User Guide v 2.0 — March 2023 System Setup The system automatically adjusts the sack full limit when an abort condition error occurs. The list that follows shows abort condition errors: • Abort Over Temperature • Abort Under Temperature • Fuse 1 Blown •...
Page 166: Remote Load
2.0 — March 2023 Altanium Delta5 10.9 Remote Load Mold setups can be loaded directly from the injection molding machine. With the Remote Load option, the injection molding machine can send a signal to the controller on one of up to 1023 input combinations to identify which mold setup to load.
Page 167 User Guide v 2.0 — March 2023 System Setup NOTE: The user can select what to do with changes that were made before to the current mold setup. When a request has been started to load a different mold setup, the system uses this parameter to save or discard the changes. Touch one of the 63 rows that do not have a mold setup assigned.
Page 168: Grid Size And The Group Offset
2.0 — March 2023 Altanium Delta5 10.10 Grid Size and the Group Offset To change the layout on the Card Layout screen, you must change the grid size. To configure the linked systems, you must change the group offset setting. The default group offset setting is 96 zones.
Page 169: Monitor Zone Settings
User Guide v 2.0 — March 2023 System Setup 10.12 Monitor Zone Settings When enabled, the Allow Monitor Regulation For Selection lets the user change the regulation mode to 'Monitor' for zones in the Quick Set screen. If a zone is currently in Monitor regulation when this parameter is de-selected, the system automatically changes the regulation mode to 'Automatic'.
Page 170 2.0 — March 2023 Altanium Delta5 The Setup Alarm dialog window shows. Refer to Figure 10-25. Touch each field to enter the changes and then touch the Accept button. Refer to Table 10-14 for the field descriptions. To enable the feature, touch the Power Deviation Enable checkbox, so a check mark shows.
Page 171: Current Deviation
User Guide v 2.0 — March 2023 System Setup Table 10-14 Power Deviation Settings (Continued) Setting Description Use this button to start a new sample period in conditions where Baseline Average the initial sample time was not sufficient to make sure there are Relearn good baseline average power values.
Page 172: Energy Usage And Units
2.0 — March 2023 Altanium Delta5 10.17 Energy Usage and Units Energy accumulation data is updated every three seconds and shown in real time to the user on the Energy Display screen. Users can set the Energy Cost Rate (Kwh) and Currency Type.
Page 173: Standby Timer Settings
User Guide v 2.0 — March 2023 System Setup Touch the Enable or Disable button. Reboot the Altanium controller. Figure 10-27 Zone Slot Screen 10.19 Standby Timer Settings To decrease the temperatures in the mold for a specified period of time, set the standby timers related with each standby function.
Page 174: Set The Remote Standby Duration Timer
2.0 — March 2023 Altanium Delta5 10.19.2 Set the Remote Standby Duration Timer The zone temperature decreases for a specified time duration or until it gets to a set remote standby temperature. NOTE: If the remote standby feature is not installed on the system, only the Manual Standby Duration Timer setting is shown on the screen.
Page 175: Set The Remote Standby Input Mode
User Guide v 2.0 — March 2023 System Setup 10.19.4 Set the Remote Standby Input Mode The Remote Standby Input Mode setting is enabled by one of three settings: Trigger, On/Off, or Direct. NOTE: This setting does not show if the remote standby option is not installed on the system. To change the Remote Standby Input mode, do the steps that follow: On the System Setup screen, touch the Heats Setup tab and then touch the Control Page 1 tab.
Page 176 2.0 — March 2023 Altanium Delta5 Table 10-16 Remote Standby Operational Description (Continued) Manual Delay Remote Input Cycle Operation - STANDBY Button Select Time Time Time Mode Enabled ---- X:XX:XX X:XX:XX Trigger System delays for a specified time and then enters Standby until the timer completes.
Page 177: Boost Timer Settings
User Guide v 2.0 — March 2023 System Setup 10.20 Boost Timer Settings To increase the temperatures in the mold for a specified period of time, set the boost timers related with each boost function. When the system enters Boost, the timer starts. When the timer completes, the temperatures decrease back to the setpoint.
Page 178: Change The Remote Boost Input Mode
2.0 — March 2023 Altanium Delta5 Enter the time requirement in this format: HHMMSS. Touch the Accept button. 10.20.4 Change the Remote Boost Input Mode The Remote Boost Input Mode setting is enabled by one of three settings: Trigger, On/Off, or Direct.
Page 179: Resin Protection Timer
User Guide v 2.0 — March 2023 System Setup Table 10-18 Remote Boost Operational Description (Continued) Manual Delay Remote Input Operation - Boost Button Select Time Time Time Mode ---- 0:00:00 0:00:00 ON/OFF System enters Boost until the input signal is not active.
Page 180: Set The Resin Degradation Limit
2.0 — March 2023 Altanium Delta5 10.21.1 Set the Resin Degradation Limit The Resin Degradation Limit is the temperature used to make the decision when to start the timer. The default value is 121 °C (250 °F). To set the Resin Degradation Limit, do the steps that follow: On the System Setup screen, touch the Heats Setup tab and then touch the Control Page 1 tab.
Page 181: Auto Power Limiting
14.1. Users can purchase additional options such as 8 I/Os, All I/Os, Remote Load, Part Counting and SPI interface by contacting Husky for an electronic license file. To view your system’s licensing information, do the steps that follow: From the Home screen, touch the System Setup button.
Page 182 2.0 — March 2023 Altanium Delta5 Figure 10-29 View License Dialog Users can update license files from local, USB, and network drives. To update licensing information, do the steps that follow: From the Home screen, touch the System Setup button.
Page 183: Diagnostics Export
2.0 — March 2023 System Setup 10.24 Diagnostics Export Diagnostics Export is used to export diagnostics files to a USB drive. This feature is for Husky Technical Support use only. Please contact Husky for assistance if necessary. 10.25 Mold Cooling Enable The Mold Cooling Enable Limit sets the threshold that the system uses to make the decision when to activate or deactivate the Mold Cooling Enable output.
Page 184: Staging Screen
2.0 — March 2023 Altanium Delta5 10.26.1 Staging Screen Use the Staging screen to assign zones to stages, set stage setpoints, and enter soak timers for each stage. Figure 10-30 Figure 10-31 show the Startup and Shutdown panels of the Staging screen.
Page 185: Enable/Disable Staged Startup
User Guide v 2.0 — March 2023 System Setup Table 10-19 Staging Screen Settings Item Description Staged Startup Enable Enables or disables the staged startup sequence. Run Last Stage Indefinitely When enabled, all zones in the last assigned stage will not change to their normal setpoint when all zones have achieved the stage setpoint and the soak timer has completed.
Page 186: Enable Or Disable Staged Shutdown
2.0 — March 2023 Altanium Delta5 10.26.3 Enable or Disable Staged Shutdown Users can enable or disable the Staged Shutdown feature on the Staging screen. The Staged Shutdown process is used to control how the temperature decreases (cools) in the system.
Page 187: Set The Soak Timers
User Guide v 2.0 — March 2023 System Setup 10.26.6 Set the Soak Timers At the end of each stage during staged startup or shutdown, when all zones are at their stage setpoints, they can “soak” for a specified time before the next stage starts. Use the Staging screen to change the soak time durations.
Page 188 2.0 — March 2023 Altanium Delta5 The Supply Voltage screen shows a graphic image of the type of configuration that has been selected. The four supply configurations are shown in Figure 10-32, Figure 10-33, Figure 10-34, and Figure 10-35. The areas of the Supply Voltage screen are described in Table 10-20.
Page 189 User Guide v 2.0 — March 2023 System Setup Figure 10-34 Single Phase Supply Voltage Screen Figure 10-35 Integrated TX Supply Voltage Screen Supply Voltage Screen...
Page 190: Configure The Supply Voltage
2.0 — March 2023 Altanium Delta5 Table 10-20 Supply Voltage Screen Areas Item Description Schematic The image is a graphic that shows the supply configuration. Zone # The zone number of all the zones related to a phase pair.
Page 191: Chapter 11 Mold Picture View
User Guide v 2.0 — March 2023 Mold Picture View Chapter 11 Mold Picture View This chapter describes how to use the mold picture view. 11.1 Mold Picture View Graphic You can load a mold picture view graphic from one of the sources that follow: •...
Page 192: Load A Mold Picture View Graphic
2.0 — March 2023 Altanium Delta5 11.1.2 Load a Mold Picture View Graphic The Altanium can show up to five different images in the mold picture view. To load a mold picture view graphic, do the steps that follow: On the Home screen, touch the Mold Picture View button.
Page 193 User Guide v 2.0 — March 2023 Mold Picture View Figure 11-2 Change View Settings Dialog Window 1. Select File Name Button 2. Image File Name Field 3. Auto Fit Image Checkbox 4. First Selection Field 5. Second Selection Field 6. Zone Number Touch the Select File Name button.
Page 194: Mold Picture View Toolbar
2.0 — March 2023 Altanium Delta5 11.2 Mold Picture View Toolbar Use the Mold Picture View toolbar to change the view of the mold picture view graphic. To hide or show the Mold Picture View toolbar, touch the screen.
Page 195: Configure A Mold Picture View
User Guide v 2.0 — March 2023 Mold Picture View 11.3 Configure a Mold Picture View Configure a Mold Picture View to add zone information panels and leader lines to the loaded mold picture view graphic. 11.3.1 Edit Mode To configure the Mold Picture View, touch the Edit button (refer to Figure 11-3) to enter Edit mode.
Page 196: Make A Zone Information Panel
2.0 — March 2023 Altanium Delta5 11.3.2.1 Make a Zone Information Panel To make a zone information panel, do the steps that follow: Make sure that the Mold Picture View is in Edit mode. Touch the Choose Heat Zone button. Refer to Figure 11-4.
Page 197: Edit A Zone Information Panel
User Guide v 2.0 — March 2023 Mold Picture View 11.3.2.3 Edit a Zone Information Panel In addition to the zone number, a zone information panel also contains two items of information from the list that follows: • Zone Name •...
Page 198: Make A Leader Line
2.0 — March 2023 Altanium Delta5 To configure the content of the zone information panel, do the steps that follow: • To change the first selection displayed on the zone information panel, touch the First Selection field, and then select an item.
Page 199: Delete A Leader Line
User Guide v 2.0 — March 2023 Mold Picture View 11.3.2.7 Delete a Leader Line To delete a leader line, do the steps that follow: Make sure that the Mold Picture View is in Edit mode. Touch and drag the leader line to be deleted onto the related zone information panel or off the mold picture view graphic.
Page 200 2.0 — March 2023 Altanium Delta5 Exit Edit Mode...
Page 201: Chapter 12 Data Recording
User Guide v 2.0 — March 2023 Data Recording Chapter 12 Data Recording Data recording is used to track the operation of a mold. This tool helps analyze the system to make the molding process better, track errors, find the source of an error, or predict where future errors could occur.
Page 202 2.0 — March 2023 Altanium Delta5 Figure 12-1 Trend Plot Screen 1. Variable Selection Button Touch the Variable Selection button. The Statistical Process Control Details Variable Selector dialog window shows. Refer to Figure 12-2. Figure 12-2 Statistical Process Control Details Variable Selector Dialog Window 1.
Page 203: History Plot Screen
User Guide v 2.0 — March 2023 Data Recording Touch the Minimize/Maximize buttons to navigate to the selection you want. Touch the process variable you want to see. Touch the Accept button. 12.2 History Plot Screen The History Plot screen gives a visual summary of the recorded operation that shows power usage, temperature fluctuations, setpoint values, pressures, positions, and times.
Page 204: Curve Data Point
2.0 — March 2023 Altanium Delta5 Available process variables for heat zones are: • Actual Current • Actual Earth Leakage (shown only when configured in System Setup) • Actual Power • Actual Temperature • Actual Temperature Setpoint • Actual Voltage Available process variables for UltraSync-E (if installed) are: •...
Page 205: Set The Timeframe
User Guide v 2.0 — March 2023 Data Recording Table 12-2 Plot Screen Curve Data Descriptions (Continued) Screen Element Description Midline The midline is the middle value of the curve. For example, (540 + (-90)) / 2 = 225). Variable Selection Touch the button next to the process variable name to select a process Button parameter to see.
Page 206: Change The Zone Shown On The History Plot Screen
2.0 — March 2023 Altanium Delta5 12.2.4 Change the Zone Shown on the History Plot Screen To change a zone shown on the History Plot screen, do the steps that follow: On the History Plot screen, touch the Variable Selection button of the zone or process to be changed.
Page 207: Process Limits Screen
User Guide v 2.0 — March 2023 Data Recording 12.3 Process Limits Screen Use the process Limits 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 208 2.0 — March 2023 Altanium Delta5 Figure 12-7 Target and Global Settings The process Limits screen settings and information fields are described in Table 12-3. Table 12-3 Process Limits Screen Fields Limit Definition Use Limits Select the Use Limits checkbox and the Altanium controller will trigger an alarm if the process variable is not in the lower and upper limits.
Page 209: Target Settings
User Guide v 2.0 — March 2023 Data Recording Table 12-3 Process Limits Screen Fields (Continued) Limit Definition Process Outside When enabled, this activates the Process Outside Limit (Digital Output 6) Limit signal when one or more of the process variables goes out of specification limits.
Page 210: Global Settings
2.0 — March 2023 Altanium Delta5 If you want to set these Target Settings critical, touch the Critical field and select Yes. If you want to activate the Process Outside Limit (Digital Output 6) signal during an out of limit condition, touch the Process Outside Limits checkbox, so the check mark shows.
Page 211 User Guide v 2.0 — March 2023 Data Recording Figure 12-8 Process Variable Selector Dialog Window Touch the checkboxes of the items you want to see on the process Limits screen, so check marks are shown for those items. Touch the Accept button. Process Variable Selector...
Page 212: Process Monitoring Setup
2.0 — March 2023 Altanium Delta5 12.4 Process Monitoring Setup On the process monitoring Setup screen, you can set the system to record data in a time mode interval or with a cycle mode start configuration. Cool down data collection can also be enabled from this screen.
Page 213: Cool Down Data Collection
User Guide v 2.0 — March 2023 Data Recording 12.4.2 Cool Down Data Collection You can continue data collection for an interval of time after the controller has stopped. In the Cooldown Data Collection panel of the process Limits screen, you can set a time value from 1 to 180 minutes.
Page 214: Data Collection Start Conditions
2.0 — March 2023 Altanium Delta5 Touch the Cycle Start Trigger gear button. The Configure Signal dialog window shows (refer to Figure 12-10). Figure 12-10 Configure Cycle Start Trigger Window Select the signal type and related source, condition, and value to configure a start signal.
Page 215: Data Collection Stop Conditions
User Guide v 2.0 — March 2023 Data Recording Table 12-4 Cycle Mode - Conditions to Start (UltraSync-E or Altanium Servo Control Installed) (Continued) Mold Servo Cycle Mode Heats UltraSync-E Controller Conditions Running Engaged Engaged Selection Conditions to Start Condition Condition Condition Shown on...
Page 216 2.0 — March 2023 Altanium Delta5 Table 12-5 Cycle Mode - Conditions to Stop (UltraSync-E or Altanium Servo Control Installed) Mold Servo Cycle Mode UltraSync-E Heats Running Controller Conditions Engaged Condition Engaged Selection Conditions to Stop Condition Enabled Condition...
Page 217 User Guide v 2.0 — March 2023 Data Recording Table 12-5 Cycle Mode - Conditions to Stop (UltraSync-E or Altanium Servo Control Installed) (Continued) Mold Servo Cycle Mode UltraSync-E Heats Running Controller Conditions Engaged Condition Engaged Selection Conditions to Stop Condition Enabled Condition...
Page 218 2.0 — March 2023 Altanium Delta5 Table 12-5 Cycle Mode - Conditions to Stop (UltraSync-E or Altanium Servo Control Installed) (Continued) Mold Servo Cycle Mode UltraSync-E Heats Running Controller Conditions Engaged Condition Engaged Selection Conditions to Stop Condition Enabled...
Page 219 User Guide v 2.0 — March 2023 Data Recording Table 12-5 Cycle Mode - Conditions to Stop (UltraSync-E or Altanium Servo Control Installed) (Continued) Mold Servo Cycle Mode UltraSync-E Heats Running Controller Conditions Engaged Condition Engaged Selection Conditions to Stop Condition Enabled Condition...
Page 220 2.0 — March 2023 Altanium Delta5 Table 12-5 Cycle Mode - Conditions to Stop (UltraSync-E or Altanium Servo Control Installed) (Continued) Mold Servo Cycle Mode UltraSync-E Heats Running Controller Conditions Engaged Condition Engaged Selection Conditions to Stop Condition Enabled...
Page 221 User Guide v 2.0 — March 2023 Data Recording Table 12-5 Cycle Mode - Conditions to Stop (UltraSync-E or Altanium Servo Control Installed) (Continued) Mold Servo Cycle Mode UltraSync-E Heats Running Controller Conditions Engaged Condition Engaged Selection Conditions to Stop Condition Enabled Condition...
Page 222: Cycle Input (Heat Control Only)
2.0 — March 2023 Altanium Delta5 12.4.3.3 Cycle Input (Heat Control Only) Cycle Input supplies a start or end of cycle signal from the injection molding machine. This input can be configured as the trigger to log process data on Altanium systems configured for heats control only.
Page 223: Save Process Data Setup
User Guide v 2.0 — March 2023 Data Recording 12.4.7 Save Process Data Setup With the use of the Save Process Data Setup panel on the Setup tab of the Process Monitoring screen, you can configure the Delta5 to save a process data file to a shared network directory. Refer to Figure 12-11.
Page 224 2.0 — March 2023 Altanium Delta5 To limit the size of the file, touch the field that is next to the Maximum Data File Size. On the keypad that opens, enter the maximum size of the data file. Touch the green check mark to accept your entry.
Page 225: Chapter 13 Color Change
This has an impact on injection mold production where fast color change is important. Husky and Chem-Trend have worked together to create a process using Chem-Trend’s Ultra Purge purging compounds that is designed specifically to reduce color-change time and carbon formation in hot runners.
Page 226: Color Change Screen
2.0 — March 2023 Altanium Delta5 13.1 Color Change Screen With the Color Change feature installed on the Delta5 controller, the Color Change button shows in the Temperature Control panel of the Home screen (refer to Figure 13-1). Figure 13-1...
Page 227: Ultra Purge Settings Panel
User Guide v 2.0 — March 2023 Color Change 13.1.1 Ultra Purge Settings Panel The Ultra Purge Settings panel has the user-configurable settings based on the specific needs of the process with Ultra Purge recommendations. Table 13-1 gives the descriptions for the items in the panel.
Page 228: Ultra Purge Mode Buttons And Status
2.0 — March 2023 Altanium Delta5 13.1.3 Ultra Purge Mode Buttons and Status The buttons are used to start or cancel the Color Change process, and a status field that indicates the state of the process as it progresses (refer to Table 13-2).
Page 229: Cycle Input Connection
User Guide v 2.0 — March 2023 Color Change 13.2 Cycle Input Connection A digital connection between the Altanium controller and the injection molding machine maximizes the effectiveness of the color change feature by establishing an input to the controller to count the number of injection cycles. This connection is optional and is made using a discrete digital input (dry contact closure) to the Altanium controller from the injection molding machine.
Page 230: Ultra Purge Process Sequences
2.0 — March 2023 Altanium Delta5 Figure 13-4 Start the Ultra Purge Process 1. Configure the Ultra Purge resin settings. 2. Touch the Start button to heat the hot runners. 3. Wait for Running mode. 4. Touch the Ultra Purge Sequence panel Start button.
Page 231: Color Change And Non-Thermal Sensitive Resin Example
As you start each sequence in Figure 13-5, look through the sequence steps to see if the "Husky Machine Connection" or "Ultra Purge Booster" settings should be enabled or not enabled. Set them, as necessary, before you touch the Ultra Purge Sequence panel Start button.
Page 232 2.0 — March 2023 Altanium Delta5 When asked if you are performing a color change, touch the Yes button (refer to Figure 13-6). Figure 13-6 Performing a color change? Yes When asked if you have thermal sensitive resin, touch the No button (refer to Figure 13-7).
Page 233 User Guide v 2.0 — March 2023 Color Change Increase the tips and manifolds offset temperatures, as necessary (refer to Figure 13-8). Touch the Start Color Change button and then the green check mark button to continue. Figure 13-8 Increase Tips and Manifolds Offset Temperatures Add the recommended amount of Ultra Purge compound to the IMM (refer to Figure 13-9).
Page 234 2.0 — March 2023 Altanium Delta5 11. Make sure that the Husky Machine Connection checkbox is not checked (refer to Figure 13-10). 12. When asked if "You are molding parts out of Ultra Purge?", touch the No button. Figure 13-10 Molding Parts from Ultra Purge? 13.
Page 235 User Guide v 2.0 — March 2023 Color Change 15. Reduce the shot size to 15% of the maximum shot size allowed (refer to Figure 13-12). 16. With the mold open, do two short injection shots through the mold. 17. Touch the check mark button to continue (Figure 13-12).
Page 236 2.0 — March 2023 Altanium Delta5 19. When the soak timer has completed, touch the check mark button to continue (Figure 13-14). NOTE: The check mark button becomes enabled when the soak time completes. Figure 13-14 Ultra Purge Soak Time Completes 20.
Page 237 Figure 13-16 Continue to Do Short Injection Shots with Ultra Purge 22. Make sure that the Husky Machine Connection checkbox does not have a check mark (not enabled) and then do four to five injection shots with the new production resin (Figure 13-17).
Page 238 2.0 — March 2023 Altanium Delta5 24. Touch the green check mark button to confirm that the purging has completed (Figure 13-18). Figure 13-18 Confirm Purging is Complete 25. Make sure that the Use Purge Booster checkbox does not have a check mark (not...
Page 239: Color Change And Thermal Sensitive Resin
User Guide v 2.0 — March 2023 Color Change 28. Touch the green check mark button to complete the Ultra Purge process (Figure 13-20). Figure 13-20 Ultra Purge Process Completed 13.4.2 Color Change and Thermal Sensitive Resin This process is followed for thermally sensitive resins and increases the tip and manifold temperatures before adding the Ultra-Purge compound to the IMM.
Page 240: Color Change And Thermal Sensitive Resin Example
As you start each sequence in Figure 13-21, look through the sequence steps to see if the "Husky Machine Connection" or "Ultra Purge Booster" settings should be enabled or not enabled. Set them, as necessary, before you touch the Ultra Purge Sequence panel Start button.
Page 241 User Guide v 2.0 — March 2023 Color Change When asked if you are performing a color change, touch the Yes button (refer to Figure 13-23). Figure 13-23 Performing a color change? Yes When asked if you have thermal sensitive resin, touch the Yes button (refer to Figure 13-24).
Page 242 13-25). When the compound had been added, touch the green check mark button to continue. Figure 13-25 Add Ultra Purge to Press 10. Make sure that the Husky Machine Connection checkbox is not checked (refer to Figure 13-26). 11. When asked if "You are molding parts out of Ultra Purge?", touch the Yes button.
Page 243 User Guide v 2.0 — March 2023 Color Change 13. Touch the green check mark to continue (Figure 13-27). Figure 13-27 Mold Part until Ultra Purge is 100% in Molded Parts 14. Touch the Start Soak Timer button and let the soak timer complete (Figure 13-28).
Page 244 2.0 — March 2023 Altanium Delta5 15. When the soak time has completed, touch the check mark button to continue (Figure 13-29). NOTE: The check mark button becomes enabled when the soak time completes. Figure 13-29 Ultra Purge Soak Time Completes 16.
Page 245 User Guide v 2.0 — March 2023 Color Change 17. Continue to do short injection shots with the Ultra Purge (Figure 13-31). NOTE: This helps flush the Ultra Purge and bring the new color resin to the hot runners. Figure 13-31 Continue to Do Short Injection Shots with Ultra Purge 18.
Page 246 2.0 — March 2023 Altanium Delta5 20. Touch the green check mark button to confirm that the purging has completed (Figure 13-33). Figure 13-33 Confirm Purging is Complete 21. Adjust the hot runner temperature to x F (x C) below the normal setpoint (refer to °...
Page 247 User Guide v 2.0 — March 2023 Color Change 23. When the Purge Booster Time completes, touch the green check mark button to continue (refer to Figure 13-35.) Figure 13-35 Purge Booster Time Completes 24. Adjust the hot runners’ temperatures to their operational parameters. 25.
Page 248: No Color Change
As you start each sequence in Figure 13-38, look through the sequence steps to see if the "Husky Machine Connection" or "Ultra Purge Booster" settings should be enabled or not enabled. Set them, as necessary, before you touch the Ultra Purge Sequence panel Start button.
Page 249 2.0 — March 2023 Color Change Configure the settings in the Ultra Purge Settings panel for the resin that you will use. Touch the Husky Machine Connection and Use Purge Booster checkboxes, so the check marks show (refer to Figure 13-39).
Page 250 2.0 — March 2023 Altanium Delta5 When asked if you are performing a color change, touch the No button (refer to Figure 13-40). Figure 13-40 Performing a color change? Yes Add the recommended amount of Ultra Purge compound to the IMM (refer to Figure 13-41).
Page 251 13-42). Figure 13-42 Molding Parts from Ultra Purge? With the Husky Machine Connection enabled, the controller will count the shots and calculate when the Ultra Purge Usage Amount is achieved. 10. Touch the green check mark button when the controller gets to the Ultra Purge Usage...
Page 252 2.0 — March 2023 Altanium Delta5 11. Touch the Start Soak Timer button and let the soak timer complete (Figure 13-44). NOTE: The elapse time is shown on the screen above the Start Soak Timer button. Figure 13-44 Allow for Soak Time 12.
Page 253 User Guide v 2.0 — March 2023 Color Change 13. Load the new production resin into the IMM (Figure 13-46). Figure 13-46 Load New Color or Production Resin 14. Continue to do short injection shots with the Ultra Purge. NOTE: This helps flush the Ultra Purge and bring the new production resin to the hot runners.
Page 254 2.0 — March 2023 Altanium Delta5 16. Let the controller count parts until it gets to twice the Ultra Purge amount, and then touch the green check mark button (Figure 13-48). Figure 13-48 Count Parts until Twice the Ultra Purge Amount 17.
Page 255 User Guide v 2.0 — March 2023 Color Change 18. Adjust the hot runner temperature to x F (x C) below the normal setpoint (refer to ° ° Figure 13-50). 19. Touch the Start Purge Booster button. Figure 13-50 Adjust Hot Runner Temperature and Start Purge Booster 20.
Page 256 2.0 — March 2023 Altanium Delta5 21. Adjust the hot runners’ temperatures to their operational parameters. 22. When the temperatures are at their parameter settings, touch the green check mark button to continue (refer to Figure 13-52). Figure 13-52 Ultra Purge Process Completed 23.
Page 257: Chapter 14 System Options
User Guide v 2.0 — March 2023 System Options Chapter 14 System Options The Altanium controller has many additional optional features available to help in the molding process. There are hardware, software, and a combination of hardware and software options that can be used to maximize the system. 14.1 Digital I/O Use the I/O screen to configure the digital inputs and outputs.
Page 258: Enable An I/O Option
This signal shows the Delta5 system E-Stop is in correct operation. If there was a problem with the E-Stop function, the indicator would not be illuminated. Bench Mode Plug This indicator is for Husky Technical Support only. Installed Enable an I/O Option...
Page 259: Digital Inputs
The sections that follow describe the Digital Inputs screens. 14.3.1 Servo Digital Inputs There are 10 servo digital inputs. For Delta5 systems with UlraSync-E, Husky sets the input signals that follow to digital inputs 1 through 5. These input signals can be changed to agree with customer IMM configurations and operations.
Page 260: Heats Digital Inputs
2.0 — March 2023 Altanium Delta5 A list of the usual input signals from the IMM is shown in Table 14-3. Table 14-3 Servo Digital Input Signals from the IMM Signal Description IMM In Auto This signal is TRUE when the IMM is in automatic cycle mode.
Page 261 User Guide v 2.0 — March 2023 System Options Table 14-4 describes the input signals on the Heats Page 1 screen. Table 14-4 Heats Input Signals (Heats Page 1) Signal Description Remote Standby Puts all zones that have a Remote Standby setpoint into Standby mode (Lower setpoint) when this input signal is activated.
Page 262: Digital Outputs
• Heats (Page 1 and 2) If your Delta5 system operates an UltraSync-E, Valve Gate Sequencer, or some other Husky injection product, one or more tabs will show to configure the outputs to those products. Refer to the user guide for that product for information about the digital output signals.
Page 263 A list of the usual output signals to the IMM is shown in Table 14-6. For Delta5 with UltraSync- E systems, Husky sets these output signals to digital outputs 1-4. These output signals can be changed to agree with customer IMM configurations and operations. Table 14-6...
Page 264 2.0 — March 2023 Altanium Delta5 Table 14-6 Output Signals to the IMM (with UltraSync-E) (Continued) Signal Description UltraSync-E Stems At Open This signal tells the IMM that the valve gates are at the Open position. The At-Open output signal is ON when all of the conditions that follow are TRUE: •...
Page 265: Heats Digital Outputs
User Guide v 2.0 — March 2023 System Options Table 14-7 Servo Digital Output Selections (Continued) Signal Type Signal Condition Position Controller Function • Fault Stop Immediately • Fault Stop End Of Cycle • Calibration Active • Process Outside Limit •...
Page 266 2.0 — March 2023 Altanium Delta5 Table 14-8 describes the heats output signals on the Heat Page 1 tab. Table 14-8 Heats Output Signals (Heats Page 1) Signal Description Alarm Activated when an Alarm or Abort condition occurs. This state stays until the alarm condition is CLEARED or RESET.
Page 267: Configurable Signals
User Guide v 2.0 — March 2023 System Options Table 14-9 describes the heats output signals on the Heat Page 2 tab. Table 14-9 Heats Output Signals (Heats Page 2) Signal Description Boost Active Activated when the controller is in Boost mode. This state stays high (regardless if the Boost mode has been canceled or expired) until all zones are under the Upper Alarm limit.
Page 268: Logic Function
2.0 — March 2023 Altanium Delta5 Figure 14-5 Configurable Signals Screen The three tabs at the bottom of the Configurable Signals screen give access to the signals. There are two configurable signals on each tab. 14.5.1 Logic Function When set to AND, the configurable signal is TRUE only when all conditions are TRUE. When set to OR, the configurable signal is TRUE when one or more conditions are TRUE.
Page 269: Force
• Controller Functions • Configurable Signal • A Husky control technology installed on your Altanium system, such as UltraSync-E • Safety Signal • Temperature Control With each signal type, there can be related signal sources, conditions, and values that must be set.
Page 270 2.0 — March 2023 Altanium Delta5 Figure 14-6 Delta5 Connectors, Typical Table 14-10 Delta5 Connector Identification Item Cable Connection Description 100-240 VAC In Main AC power from the Altanium mainframe. Ethernet Interface to customer networks. HDMI or VGA Video signal to touch monitor.
Page 271: Input/Output Connector Pin-Out Description
User Guide v 2.0 — March 2023 System Options 14.7 Input/Output Connector Pin-Out Description The sub-sections that follow give the connection details for all of the optional inputs and output signals. Inputs are active High (12 VDC with a maximum current rating of 1 A). All outputs are a dry contact relay type.
Page 272 2.0 — March 2023 Altanium Delta5 Table 14-12 Output Base Connector Pins (Continued) Connector/Pin Field Cable Wire Color Signal Function Output / C Abort (PCM) Output / D BLU/RED Abort (PCM) Output / E At temperature Output / F...
Page 273: Part Count Base Connector Id
User Guide v 2.0 — March 2023 System Options 14.7.3 Part Count Base Connector ID The part count base connector pins are identified in Table 14-13. Table 14-13 Part Count Base Connector Pins Connector/Pin Field Cable Wire Color Signal Function Part Count / A Reset parts counter Part Count / B...
Page 274 2.0 — March 2023 Altanium Delta5 Remote Load Base Connector ID...
Page 275: Chapter 15 Spi Protocol Option
User Guide v 2.0 — March 2023 SPI Protocol Option Chapter 15 SPI Protocol Option The Altanium controller communicates with central networks or molding machines that support the Society of Plastics Industry (SPI) standard protocol. The system takes the device ID of 26h on the SPI communications channel. This ID has been assigned to general-purpose temperature controllers with multiple zones.
Page 276: Process Setpoint
2.0 — March 2023 Altanium Delta5 15.1.2 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 277: Alarm 1 Setpoint
User Guide v 2.0 — March 2023 SPI Protocol Option 15.1.5 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 278: Controller Status
2.0 — March 2023 Altanium Delta5 15.1.8 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 279: Manual Percent Output
User Guide v 2.0 — March 2023 SPI Protocol Option 15.1.9 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 280 2.0 — March 2023 Altanium Delta5 Open/Closed Loop...
Page 281: Chapter 16 Maintenance
2.0 — March 2023 Maintenance Chapter 16 Maintenance This chapter describes the maintenance tasks necessary to maintain the Altanium Delta5 system. At intervals and before you energize the equipment, do a check of all cables and cable connections to make sure that there is no wear or damage. Do not operate equipment if the cables are damaged.
Page 282 2.0 — March 2023 Altanium Delta5 Figure 16-1 Delta5 System Configuration WARNING! Hazardous voltages– risk of death or serious injury. Before servicing the Altanium unit, lock out and tag the Altanium Main Power switch in accordance with local codes.
Page 283: Card Layout Screen
User Guide v 2.0 — March 2023 Maintenance 16.2 Card Layout Screen The Card Layout screen identifies the cards used in the mainframe, and to which zones each card controls. The Card Layout screen is accessed from the Home screen or the Event History screen.
Page 284: Troubleshooting With The Card Layout Screen
2.0 — March 2023 Altanium Delta5 16.2.1 Troubleshooting with the Card Layout Screen The Card Layout screen can be accessed from the Event History screen to identify which card or component on a card is related to an alarm error. For example, to identify an open fuse, do the steps that follow: On the Event History screen, touch the Filter button.
Page 285 User Guide v 2.0 — March 2023 Maintenance Deselect all checkboxes, and then select only the Zone Alarm Active and Zone Alarm Inactive checkboxes. Touch the Exit button. A list of active and inactive faults is shown. Select the applicable error and then touch the Card Layout button. A screen with the fault information shows.
Page 286: Intelligent Control Cards
2.0 — March 2023 Altanium Delta5 16.3 Intelligent Control Cards There are two series of intelligent control cards (ICC)s that the Delta5 is designed to work with. These are the X-Series (ICC ) and H-Series intelligent control cards (ICC ).
Page 287 User Guide v 2.0 — March 2023 Maintenance WARNING! Hazardous voltages– risk of death or serious injury. Before servicing the Altanium unit, lock out and tag the Altanium Main Power switch in accordance with local codes. Both series of cards plug into backplanes that are installed into the bays of the controller mainframe (Figure 16-9).
Page 288: Replace An Intelligent Control Card (Icc2 Or Icc3)
2.0 — March 2023 Altanium Delta5 16.3.1 Replace an Intelligent Control Card (ICC or ICC 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 289 User Guide v 2.0 — March 2023 Maintenance Slide a screwdriver between the silver post and the ledge on the cabinet and gently pry the board out. Refer to number 3 in Figure 16-10. 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 290: Replace An Open Fuse On An Intelligent Control Card
2.0 — March 2023 Altanium Delta5 16.3.2 Replace an Open Fuse on an Intelligent Control Card 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 291 Remove and replace the faulty fuse with one of identical type and rating. Refer to Figure 16-11. Husky recommends SIBA 712540 Series or equivalent fuses. Make sure the fuse is fully seated. Poor seating will cause a hot spot, which can cause problems for the system. NOTE: 20- and 30-Amp cards will only have two fuses.
Page 292: Delta5 Operator Interface
2.0 — March 2023 Altanium Delta5 16.4 Delta5 Operator Interface The Delta5 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). Refer to Figure 16-12.
Page 293 User Guide v 2.0 — March 2023 Maintenance The operator interface does not contain user-serviceable parts. You can only replace the touch monitor or master control unit as complete subassemblies. In some conditions, the Altanium will not operate if the display is defective. If the display input power is correctly connected and all three phase indicators are lit, then the display could be at fault.
Page 294: Remove And Replace The Touch Monitor
2.0 — March 2023 Altanium Delta5 16.4.1 Remove and Replace the Touch Monitor 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 295 User Guide v 2.0 — March 2023 Maintenance After the cable retaining bracket has been removed, carefully pull downward on the Touchscreen (USB Type B) connector to disconnect it from its port and follow the same step for the adjacent Power (Coaxial Jack 2.5mm) connector. Refer to callout 3 in Figure 16-13.
Page 296 2.0 — March 2023 Altanium Delta5 11. Use a 4 mm right-angle Allen key or hex wrench to remove the two bottom socket cap screws from the retaining plate that secures the touch monitor to the pedestal. Refer to...
Page 297 User Guide v 2.0 — March 2023 Maintenance 13. Securely hold the touch monitor and slide it upwards until the screws have cleared the upper mounting slots and pull forward to remove the touch monitor from the mounting bracket. Refer to Figure 16-16.
Page 298: Remove And Replace The Mcu
2.0 — March 2023 Altanium Delta5 16.4.2 Remove and Replace the MCU 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 299 User Guide v 2.0 — March 2023 Maintenance Find the two lower screws that hold the MCU to the mounting bracket and completely remove them with a 4 mm right-angle Allen key or hex wrench. Refer to Figure 16-18. IMPORTANT! Only loosen the top fasteners.
Page 300 2.0 — March 2023 Altanium Delta5 Find the two top fasteners that hold the MCU to the mounting bracket and loosen them with a 4 mm right-angle Allen key or hex wrench. Refer to Figure 16-19. Loosen the screws only; do not remove them.
Page 301 User Guide v 2.0 — March 2023 Maintenance 11. Securely hold the MCU and slide it down onto the mounting bracket, so the top MCU screws go into the bracket slots. 12. Rotate the touch monitor to the full back position. Refer to Figure 16-18.
Page 302: Remove And Replace The Operator Interface
2.0 — March 2023 Altanium Delta5 16.4.3 Remove and Replace the Operator Interface 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 303 User Guide v 2.0 — March 2023 Maintenance Use a #4 Phillips screwdriver to remove the four screws that hold the operator interface to the top of the mainframe. Refer to Figure 16-22. NOTE: This step will require a screwdriver short enough to clear the MCU located above the two back mounting screws.
Page 304 2.0 — March 2023 Altanium Delta5 10. Connect the Power and Communication connectors that come from the controller mainframe to the bottom of the MCU enclosure. 11. Remove the lock out equipment and tag from the main power switch.
Page 305: Install The Remote Operator Interface
User Guide v 2.0 — March 2023 Maintenance 16.4.4 Install the Remote Operator Interface Figure 16-24 Remote Operator Interface Installation of the remote operator interface can be: • Permanently mounted in place with the use of the four mounting holes in the base plate.
Page 306 2.0 — March 2023 Altanium Delta5 Figure 16-25 Remote Operator Interface Mounting Holes Figure 16-26 Remote Operator Interface Rubber Leveling Pads 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 307 User Guide v 2.0 — March 2023 Maintenance To install the remote operator interface, do the steps that follow: WARNING! Make sure that the operator interface is in an area free of vibration to prevent premature failure of the electronic components in the MCU and touch monitor. Make sure that the operator interface is in an area free of debris and liquids.
Page 308 2.0 — March 2023 Altanium Delta5 Connect the male end of the 7.6 m (25 ft) power cable to the female power connector on the back of the controller mainframe. Refer to Figure 16-28. Figure 16-28 Remote Operator Interface - Mainframe Cable Connection WARNING! The cables should be routed in accordance with local codes.
Page 309 User Guide v 2.0 — March 2023 Maintenance Connect the male end of the 7.6 m (25 ft) communication cable to the female communication connector on the bottom of the operator interface MCU. Refer to Figure 16-30. Connect the female end of the 7.6 m (25 ft) power cable to the male power connector on the bottom of the operator interface MCU.
Page 310: Install The Alternative Mounted Operator Interface
2.0 — March 2023 Altanium Delta5 16.4.5 Install the Alternative Mounted Operator Interface Figure 16-31 Alternative Mounted Operator Interface 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 311 User Guide v 2.0 — March 2023 Maintenance Figure 16-32 Alternative Mounted Operator Interface - Mounting Holes Use a #4 Phillips screwdriver to install the supplied four M6 metric screws through the mounting holes on the MCU base plate into the top of the mainframe. NOTE: This step will require a screwdriver short enough to clear the MCU located above the two back mounting screws.
Page 312 2.0 — March 2023 Altanium Delta5 Connect the female Power cable connector and male Communication cable connector to the male Power connector and female Communication connector on the MCU. Refer Figure 16-34. Figure 16-34 Power and Communication Cables Connect the Touchscreen Signal cable connector, Touch Monitor Video cable connector and Touch Monitor Power cable connector to the Touch Screen connector, LCD 12 VDC connector, and VGS connector on the bottom of the MCU.
Page 313 User Guide v 2.0 — March 2023 Maintenance Use tie wraps to collect the lengths of cables between the touch monitor, controller mainframe, and MCU. Make sure that all wires are away from pinch points and that there is enough service loop to let the touch monitor and swing arm move freely. Refer to Figure 16-36.
Page 314: Install The Dual Touch Monitor
2.0 — March 2023 Altanium Delta5 16.4.6 Install the Dual Touch Monitor Figure 16-37 Dual Touch Monitor Install 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 315 User Guide v 2.0 — March 2023 Maintenance Figure 16-38 Dual Touch Monitor Install - Unpack Install the Dual Touch Monitor...
Page 316 2.0 — March 2023 Altanium Delta5 Connect the USB Extension cable (USB Type A connector end) to one of the available USB ports on the bottom of the MCU enclosure. Refer to Figure 16-39. Figure 16-39 USB Extension Cable...
Page 317 User Guide v 2.0 — March 2023 Maintenance Connect the HDMI end of the HDMI-to-DVI Extension cable to the HDMI connector end of the DisplayPort to HDMI Converter. Refer to Figure 16-41. Figure 16-41 HDMI-to-DVI Extension Route the USB and HDMI-to-DVI Extension cables from the MCU to the location of the secondary touch monitor.
Page 318 2.0 — March 2023 Altanium Delta5 Figure 16-42 Route Cables Configure the AC/DC Adapter for the extension cable plug type that is compatible with the electrical outlet where it will be connected. Refer to Figure 16-43. IMPORTANT! The AC/DC Adapter provides power to the secondary touch monitor and is required to be plugged into its own power source.
Page 319 User Guide v 2.0 — March 2023 Maintenance CAUTION! Make sure that the secondary touch monitor is in an area free of vibration to prevent premature failure of the electronic components in the unit. Make sure that the secondary touch monitor is in an area free of debris and liquids and that it is placed on a flat, level surface to prevent the unit from movement or falling when in use.
Page 320: Thermocouple Calibration
Altanium Delta5 16.5 Thermocouple Calibration To run a satisfactory injection process, temperature accuracy of the zones is important. The Altanium Delta5 lets you make sure that your temperature readings are correct with the use of zone calibration. NOTE: Amperage and voltage calibrations are only done by Husky service.
Page 321: Figure
User Guide v 2.0 — March 2023 Maintenance Make sure that the controller is in Stop mode. On the Home screen, touch the Zone Calibration button. The Zone Calibration screen shows (refer to Figure 16-45). Figure 16-45 Zone Calibration Screen When you open the Zone Calibration screen, the following actions occur: •...
Page 322 2.0 — March 2023 Altanium Delta5 Connect the wire harness pins to the selected thermocouple connector inputs located on the back of the controller. Table 16-3 Table 16-4 for reference. Table 16-3 Thermocouple Color Codes International ANSI International IEC 584-3...
Page 323: Clean The System
User Guide v 2.0 — March 2023 Maintenance 16.6 Clean the System 16.6.1 Cabinet (Mainframe) 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 324: Basic Troubleshooting
Table 16-5 lists some basic problems that could occur, along with possible causes and solutions that can help with troubleshooting the Altanium Delta5. If the problems shown continue after troubleshooting, or problems occur that are not shown in the table, please contact the nearest Husky Regional Service and Sales office.
Page 325 User Guide v 2.0 — March 2023 Maintenance Table 16-5 Troubleshooting Procedures (Continued) Problem Possible Causes Solution Ground Fault Bad heater. Read the mold electrical prints and Short in wiring. use an ohmmeter or insulation Bad Card. resistance meter to inspect the Mis-wired mold, cable, or controller.
Page 326 2.0 — March 2023 Altanium Delta5 Table 16-5 Troubleshooting Procedures (Continued) Problem Possible Causes Solution No Connection, T/C Thermocouple circuit is broken. Short the thermocouple input and it Bad thermocouple. should show an ambient Card is not seated. temperature on the operator Card is not calibrated.
Page 327: Failure Causes And Solutions
User Guide v 2.0 — March 2023 Maintenance 16.8 Failure Causes and Solutions When the controller does a circuit test, it will stop the system and alert you if failures were detected during the test. The controller shows a window of possible causes and solutions data.
Page 328: Supported Electrical Failures
2.0 — March 2023 Altanium Delta5 Figure 16-47 Electrical Fault Example - Heater Leaking Current to Earth 16.8.1 Supported Electrical Failures The controller will help detect and give possible solutions for 9 electrical failures: Wired • Heater leaking current to earth •...
Page 329 User Guide v 2.0 — March 2023 Maintenance Figure 16-48 Causes and Solutions Window - Control Card Failure Supported Electrical Failures...
Page 330 2.0 — March 2023 Altanium Delta5 Supported Electrical Failures...
Page 331: Appendix A Glossary Of Terms
User Guide v 2.0 — March 2023 Glossary of Terms Appendix A Glossary of Terms Table A-1 gives the definitions for terms and symbols used in this user guide. Table A-1 Glossary of Terms and Symbols Automatic Manual Control Amp or Amps Ampere or Amperes ANSI American National Standards Institute...
Page 332 2.0 — March 2023 Altanium Delta5 Table A-1 Glossary of Terms and Symbols (Continued) Milliampere (or milliamp) Master Control Unit Millimeter(s) Negative Acknowledge Network Time Protocol  Ohm or ohms OPC UA Open Platform Communication Unified Architecture Priority Control Mode...
Page 333: Index
Index Alarms screen Abort clear (reset) conditions (shutdown errors) open window, quick set screen states Active reasoning technology AltaStart ART 2.0 ART. See Active reasoning technology buttons Assign follower zone to leader manual function Assistance, remote service Adjustments, making Automatic Administration and security change manual control, quick set Advanced settings, quick set screen...
Page 334 Boost timer settings Color codes manual boost duration electrical wire standards operation description thermocouple types remote boost delay Common buttons remote boost duration Conditions remote boost input mode abort Buttons alarm active reasoning technology configurable signals screen Configurable signals alarm conditions commons force...
Page 335 protection Dashboard interface purpose Data ratings filter, process monitoring restrictions of use recording safety signs Date and time range, history plot technical specifications Delay limit check, process limits troubleshooting, basic Derivative control. See PID Errors Detailed screen mode, neo view shutdown Detection, no heater warning...
Page 336 part count base Heat remote load base mold digital sequencing. See AltaStart digital inputs Heater heats circuit test servo current deviation digital outputs determine size heats Heating, fast servo Heats safety signals control page 1 descriptions Integral control. See PID control page 2 descriptions Intelligent control cards control page 3 descriptions...
Page 337 Maintenance procedures delete alternative mounted operator discard changes interface installation load existing clean the system rename dual touch monitor installation save changes MCU removal and replacement save current mold file as new operator interface removal and file replacement transfer data to network remote operator interface transfer data to USB storage installation...
Page 338 Names, set zone, quick set screen Part counting Navigation buttons base connector ID Neo view screen reset detailed zone blocks sack full output optimization follower zone block modes PID control detailed screen Pin-out descriptions input base simple screen output base status abbreviations part count base zone block background color...
Page 339 Report files Quick adjustment panel Resin protection timer Quick set screen cycle idle reaction abort window cycle idle time limit advanced settings degradation limit alarm window Restrictions of use ART to PID, change automatic manual control Safety control settings equipment signs earth leakage check, change signals frequently used fields...
Page 340 security - servo Soft start staging disable supply voltage enable system setup minimum limit, adjust main 1 zones Sorting, text view screen main 2 Specifications, equipment temperature graphs SPI protocol text view command summary trend plot commands user management alarm 1 reset zone slot alarm 1 setpoint Security and administration...
Page 341 Status sensor assignment, quick set abbreviations, neo view blocks types and color codes field indicators Time mode configuration, process process monitoring monitoring Supply voltage Time range and date, history plot configure Time synchronization screen Timeframe, history plot Synchronization, time Timer System resin protection cleaning...
Page 342 Warning errors Wet heater bake out system Wired network setup Wireless network setup Zone alarm control block background color, neo view blocks, neo view control (change ART to PID), quick edit, quick set screen follow, quick set automatic follow manually assign follower to leader follow, quick set screen monitor settings...

Husky Altanium Delta5 User Manual

Chapter 2 Hot Runner Temperature Control

Chapter 3 Connect the System to the Mold

Chapter 4 Altanium Operator Interface

Chapter 5 Security and Administration

Chapter 7 Making Adjustments

Chapter 8: Mold Diagnostics

Chapter 9 Heat the Mold

Chapter 10 System Setup

Chapter 11 Mold Picture View

Chapter 12 Data Recording

Chapter 13 Color Change

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Summary of Contents for Husky Altanium Delta5