Page 1 Altanium Neo5 User Guide Original Instructions...
Page 2 Husky® product or service names or logos referenced in these materials are trademarks of Husky Injection Molding Systems Ltd. and may be used by certain of its affiliated companies under license.
Page 3: General Information
Husky Regional Service and Sales Office. Ordering Spare Parts All spare parts for Husky equipment can be ordered through the nearest Husky Parts Distribution Center or online at www.husky.co. Ordering Additional Manuals Additional copies of this manual and other documentation can be purchased through the nearest Husky Regional Service and Sales office.
Page 4 2.0 — January 2023 Altanium Neo5 Page iv...
Page 5: Table Of Contents
Husky Regional Service and Sales Offices ........
Page 6 2.0 — January 2023 Altanium Neo5 Chapter 4: Altanium Operator Interface ..........19 General .
Page 7 2.0 — January 2023 Altanium Neo5 6.2.2 Import/Export Customize Screen Settings ....... . .75 6.2.2.1...
Page 8 2.0 — January 2023 Altanium Neo5 Quick Set Screen ............110 8.7.1...
Page 9 2.0 — January 2023 Altanium Neo5 Chapter 10: Heat the Mold ............151 10.1 Neo5 Startup .
Page 10 2.0 — January 2023 Altanium Neo5 Chapter 15: Digital I/O ............. . . 191 15.1 Digital I/O Connector Pin-Out Description .
Page 11: Chapter 1 Introduction
2.0 — January 2023 Altanium Neo5 Chapter 1 Introduction This user guide includes general warnings and cautions to avoid injury to personnel and damage to the system. These warnings and cautions are not intended to be, nor are they all- inclusive to every condition or application that may occur during operation.
Page 12: Safety Signs
Follow all warnings and instructions marked on the system. • Unless specifically explained in this manual or directed by Husky, do not attempt to repair the system. Doing so could result in damage to the system, or serious personal injury.
Page 13: Purpose Of The Equipment
Husky controllers are designed to control the process temperature for injection molding applications only. Contact your nearest Husky Regional Service and Sales office if you plan to use a Husky product for anything other than its intended use. Restrictions of Use Husky injection molding equipment must never be: •...
Page 14: Environmental Operating Specifications
2.0 — January 2023 Altanium Neo5 Environmental Operating Specifications The environmental operating specifications that follow for the Altanium Neo5 operator interface: CAUTION! Mechanical hazard – risk of equipment damage. Falling or spraying liquid, including oil or water, could damage the equipment. Do not spray wash.
Page 15: Weights And Dimensions
User Guide v 2.0 — January 2023 Altanium Neo5 Weights and Dimensions The technical specifications (weights and dimensions) for the most common Altanium Neo5 configurations are shown in Table 1-2. Table 1-2 Neo5 Configuration Weights and Dimensions Configuration Dimensions Weight Neo5 Operator Interface •...
Page 16: Controller Lifting Instructions
2.0 — January 2023 Altanium Neo5 Controller Lifting Instructions The recommended lifting method varies depending on whether the Altanium Neo5 is a C6- 1, C6-2, or single stack (freestanding) controller. 1.8.1 C6-1 and C6-2 Lifting Instructions Use the steps that follow to correctly lift a Neo5 C6-1 or C6-2: 1.8.2...
Page 17 User Guide v 2.0 — January 2023 Altanium Neo5 a. Make sure the straps are positioned between the caster wheels and the retaining brackets under the base of the controller. b. Make sure the straps are not pinching or crushing any cables attached to the Neo5.
Page 18 2.0 — January 2023 Altanium Neo5 Place cloth or other cushioning material between the ratchet strap and the Neo5 to keep the finish free from rubs and scratches. Tighten the ratchet strap. Use the lifting device to slowly lift the Neo5 off the ground a few inches.
Page 19: Chapter 2 Hot Runner Temperature Control
2.0 — January 2023 Altanium Neo5 Chapter 2 Hot Runner Temperature Control This guide is designed to make sure that users receive the maximum possible benefit from the use of the Neo5. The Neo5 was designed as a processor's tool for hot runner molding. The fundamental criteria required to operate a hot runner mold is controlling the process temperature so that it is consistent and repeatable with respect to the process setpoint.
Page 20: Configuring Zones
2.0 — January 2023 Altanium Neo5 Configuring Zones In an effort to match the energy input requirements of differing types of loads, it is necessary for the output power delivered to the heaters to be adjusted over a range of 0 to 100%. The Neo5 can be set up to achieve this by using either Zero Cross Control or Phase Angle Control.
Page 21 User Guide v 2.0 — January 2023 Altanium Neo5 The Neo5 will provide wattage, resistance, or amperage information for heaters, if equipped with intelligent control cards: X ICC or H ICC . Alternatively, this information can be determined using Ohm’s Law. The steps and formulas that follow demonstrate how: WARNING! Electrical hazard–...
Page 22: Thermocouple Types And Color Codes
2.0 — January 2023 Altanium Neo5 Thermocouple Types and Color Codes The Neo5 uses the ANSI color code for all thermocouples. The following table is provided as reference for hot runners and cables that follow other color code standards.
Page 23: Chapter 3 Connecting The System To The Mold
2.0 — January 2023 Altanium Neo5 Chapter 3 Connecting the System to the Mold This chapter describes the connection to a power source and the checks to make before you start the system. Prior to Startup DANGER! Electrocution hazard – contact with hazardous voltages will cause death or serious injury.
Page 24: Startup Procedure Checklist
Text View screens. NOTE: There are no controller-to-mold interconnection details included in this user guide. If this information is required, please contact the nearest Husky Regional Service and Sales office. IMPORTANT! When turning off the system, wait 30 seconds before turning the main disconnect switch back on.
Page 25: Supply Voltage Screen
User Guide v 2.0 — January 2023 Altanium Neo5 Supply Voltage Screen The Supply Voltage screen shows a graphical view of the phase pairs from the Supply Configuration parameter selected in the System Setup screen (in the Voltage Settings area).
Page 26 2.0 — January 2023 Altanium Neo5 Figure 3-2 Wye 3PH+N Supply Voltage Screen Figure 3-3 Single Phase Supply Voltage Screen Page 16...
Page 27 User Guide v 2.0 — January 2023 Altanium Neo5 Figure 3-4 Integrated TX Supply Voltage Screen Table 3-1 shows how the zones are connected to the input power. Table 3-1 Input Power Information Item Description Schematic The image is a visual representation of the supply configuration.
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Page 29: Chapter 4 Altanium Operator Interface
2.0 — January 2023 Altanium Neo5 Chapter 4 Altanium Operator Interface This chapter gives a brief overview of the functionality of the Neo5 operator interface. General The operator interface consists of a touch-sensitive display screen. The Neo5 operator interface is a high-resolution color LCD covered by a transparent touch screen.
Page 30: Operator Interface - Screens And Buttons
Zone Views, Temperature Management, Data Collection and Monitoring, and System Configuration. Figure 4-1 Altanium Neo5 Controller Home Screen 1. Controller Function Buttons 2. System Status Field 3. Navigation Buttons 4. System Screen Selections 5. Alarm Buttons 6. System and User Management Buttons 7. Screen Header 8.
Page 31: Basic/Advanced Mode
Altanium Neo5 4.2.2.1 Basic/Advanced Mode The Altanium Neo5 has Basic and Advanced Operating mode functionality. The controller is normally delivered in Basic Operating mode. Basic Operating mode hides many familiar buttons and functionality on the controller screens when compared to the previous Neo model.
Page 32: Header And Footer
2.0 — January 2023 Altanium Neo5 Figure 4-3 System Setup Screen in Basic Operating Mode Touch the Use Advanced Functionality checkbox (shown in Figure 4-3), so the check mark shows. The hidden buttons and functionality will now show on the System Setup screen.
Page 33: Header - Controller Function Buttons
User Guide v 2.0 — January 2023 Altanium Neo5 4.2.3.1 Header — Controller Function Buttons Table 4-1 describes the controller function buttons. Table 4-1 Controller Function Buttons Button Description Stop Removes the power from all the zones, regardless of system condition.
Page 34: Header - Navigation Buttons
2.0 — January 2023 Altanium Neo5 Table 4-2 System Status Indicators (Continued) Indicator Description Company Name Your company name is displayed. System Mode This field shows the Neo5’s current system mode. For a description of each system mode, refer to Section 4.3.
Page 35: Footer - Alarm Buttons
User Guide v 2.0 — January 2023 Altanium Neo5 4.2.3.4 Footer — Alarm Buttons Table 4-4 describes the alarm buttons. Table 4-4 Alarm Buttons Silence Horn Stops the audible alarm. Alarm Reset Changes an alarm from active to inactive. Alarm Status The time and a description of the highest priority active alarm is displayed.
Page 36: System Screen Selections - Zone Views
2.0 — January 2023 Altanium Neo5 Table 4-5 System and User Management Buttons (Continued) Save Now Opens a dialog window that lets you save a screen shot, report, or process data on the internal hard drive. The saved file can be transferred to a USB drive or network with the use of the Mold Setup Info screen.
Page 37: System Screen Selections - Temperature Management
User Guide v 2.0 — January 2023 Altanium Neo5 4.2.5 System Screen Selections — Temperature Management Table 4-7 describes the Temperature Management buttons. Table 4-7 Temperature Management Buttons Button Description Quick Set The Quick Set screen is used to create and name groups of zones, set temperatures and limits by zone, and many other configurations.
Page 38 2.0 — January 2023 Altanium Neo5 Table 4-8 Data Collection and Monitoring Buttons Button Description Alarms Use the Alarms screen to see all errors that occur. Event History Use the Event History screen to see past alarms, warnings, setpoint changes, setup changes, HMI startup, and operational events that do not agree with specified conditions.
Page 39: System Screen Selections - System Configuration
User Guide v 2.0 — January 2023 Altanium Neo5 4.2.7 System Screen Selections — System Configuration Table 4-9 describes the System Configuration buttons. Table 4-9 System Configuration Buttons Button Description System Setup Use the System Setup screen to set some of the most commonly used system wide preferences.
Page 40: System Modes
2.0 — January 2023 Altanium Neo5 System Modes Table 4-10 gives the complete list and descriptions of the system modes that are shown in the System Mode field of the screen header. Table 4-10 System Modes System Mode Description Stop The system is stopped, and no power is being applied to the heaters.
Page 41: Screen Keyboards, Keypads, And Selection Menus
User Guide v 2.0 — January 2023 Altanium Neo5 Table 4-10 System Modes (Continued) System Mode Description Stage x Active (ART) The ART process is running on only the zones assigned to stage x. Stage x Soaking After heating up, the system will maintain the stage x setpoint until the (Heating) soak timer expires.
Page 42: Keypad Use
2.0 — January 2023 Altanium Neo5 Figure 4-4 Typical Keyboard, Keypad, and Selection Menu 4.4.1 Keypad Use The screen keyboards and selection menus are easy to use. You type in text, or make a selection, and then select the button to accept the entry.
Page 43: Enter A Specified Setpoint Value
User Guide v 2.0 — January 2023 Altanium Neo5 Figure 4-5 Temperature Setpoint Keypad Example 4.4.1.1 Enter a Specified Setpoint Value You can enter a specific value for a setpoint. To do this, type the numbered value on the screen keypad, and then select the button to accept the change.
Page 44: Save Now
2.0 — January 2023 Altanium Neo5 Example To add or subtract a specified value from the existing zone temperature setpoint, do the steps that follow: Touch the box to the right of the Temperature Setpoint field. The Normal Temperature Setpoint keypad shows.
Page 45 User Guide v 2.0 — January 2023 Altanium Neo5 Figure 4-6 Save Now Dialog Touch the button next to the file(s) that you want saved. The Save Files Result dialog shows. Figure 4-7 Save Files Result Dialog Touch the button to close the result dialog.
Page 46: Save A Dialog Window
2.0 — January 2023 Altanium Neo5 Save a Dialog Window You may find it necessary to save a screen shot of a dialog window. To do this, select the camera button that is at the top right corner of all dialog windows.
Page 47: Chapter 5 Security And Administration
2.0 — January 2023 Altanium Neo5 Chapter 5 Security and Administration This chapter describes the user management functions. Log In/Log Out Users of the Neo5 controller must log into the system. Each user must have their own user name and password. Do the steps that follow to log into the system: To log in: In the footer, touch the Log In/Log Out button.
Page 48 2.0 — January 2023 Altanium Neo5 Type in your password, then touch the button to complete the login (refer to Figure 5-2). Figure 5-2 Password Dialog Screen To log out: In the footer, touch the Log In/Log Out button.
Page 49: User Management And Security Screens
User Guide v 2.0 — January 2023 Altanium Neo5 User Management and Security Screens A user type is given to each person who operates the Neo5 (refer to Table 5-1). The user types control what level of operations and changes are permitted, and what screens can be viewed by the user in the Neo5 system.
Page 50: Add A User
2.0 — January 2023 Altanium Neo5 Figure 5-4 Users Screen 5.2.1.1 Add a User To add a new user, do the steps that follow: Select the Add New User button at the left side of the screen. Use the keyboard or drop-down selection dialogs to enter in the data that follows:...
Page 51 User Guide v 2.0 — January 2023 Altanium Neo5 Figure 5-5 User Name Keyboard b. Type the user’s full name and then select the button (refer to Figure 5-5). Figure 5-6 User’s Full Name Keyboard c. Select the user role and then select the...
Page 52 2.0 — January 2023 Altanium Neo5 d. Type the password that the user must use and then select the button (refer to Figure 5-8). Figure 5-8 Password Keyboard e. Type the password again to confirm it was entered correctly and then select the...
Page 53 User Guide v 2.0 — January 2023 Altanium Neo5 g. Select the units (Imperial or Metric) for the user and then select the button (refer to Figure 5-11). Figure 5-11 Units Selection h. Select the functionality (Advanced or Basic) for the user and then select the...
Page 54: Delete A User
2.0 — January 2023 Altanium Neo5 5.2.1.2 Delete a User To delete a user, do the steps that follow: Select the user in the User Name column as shown in Figure 5-14. Figure 5-14 Select User to be Delete Select the Delete User button at the left side of the screen.
Page 55: Change A User Password
User Guide v 2.0 — January 2023 Altanium Neo5 5.2.1.3 Change a User Password To change a user password, do the steps that follow: Select the user in the User Name column (refer to Figure 5-16). Figure 5-16 Select the User for a Password Change Select the Change Password button at the left side of the screen.
Page 56: Set The Security Settings
2.0 — January 2023 Altanium Neo5 Figure 5-18 Confirm Password Keyboard The password has changed. 5.2.2 Set the Security Settings Security parameters can be set for each screen that has restrictions. When you touch a screen name, it expands to show the list of parameters for that screen. Individual security levels are available for the following: •...
Page 57 User Guide v 2.0 — January 2023 Altanium Neo5 Figure 5-19 Screen Security Screen On the Screen Security screen, assign a role (Operator, Supervisor or Administrator) to each function. • When Operator is selected, the supervisor and administrator roles also have access to the function/screen.
Page 58 2.0 — January 2023 Altanium Neo5 Figure 5-20 Screen Security Drop-Down Selections b. Touch the box to the right of a function/screen name in the list to show the Operator Level selection dialog (Figure 5-21). Figure 5-21 Operator Level Selection Dialog c.
Page 59: Security Assignments Override
User Guide v 2.0 — January 2023 Altanium Neo5 5.2.3 Security Assignments Override You can set an override for some of the functions/screens that already have their user roles assigned. Touch the white box in a name tab and select the Operator Level that will override the parameters under that tab.
Page 60 2.0 — January 2023 Altanium Neo5 • System Setup (Override Capable) Monitor Zone Settings Wattage Voltage Global Output Power Limit Alarm Control Settings Show Thermocouple Readings Temperature Units At-Temperature Controls System Settings Force Phase Angle Control Earth Leakage Enable...
Page 61 User Guide v 2.0 — January 2023 Altanium Neo5 • Quick Set Frequently Used Zone Edit Setpoint Limits Advanced Settings Control Settings Standby and Boost ART Settings No Heater Detected Enable Heater Types Groups • Users (One Selection) • Mold Test Configure and Run •...
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Page 63: Chapter 6 Customize
2.0 — January 2023 Altanium Neo5 Chapter 6 Customize The Customize screen is used to configure what system functions and settings are shown when in the Advanced and Basic Modes. This screen is also where you can setup which screen the controller shows when powered ON.
Page 64: Customize Screen Buttons
2.0 — January 2023 Altanium Neo5 Customize Screen Buttons Table 6-1 describes the buttons found on the Customize screen. Table 6-1 Customize Screen Buttons Button Description Advanced Touch the Advanced radio button to display all settings and functionality that can be assigned to Advanced Mode.
Page 65 User Guide v 2.0 — January 2023 Altanium Neo5 Table 6-2 describes the Advanced Setup screen default settings. When an item setting is Yes, the item is shown on the screen. If set to No, the item is not shown.
Page 66 2.0 — January 2023 Altanium Neo5 Table 6-2 Advanced Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Zone Edit Shows the entire Zone Edit menu in the Quick Set screen. Zone Name Shows the Zone Name setting in the Zone Edit QS - Zone Edit menu in the Quick Set screen.
Page 67 User Guide v 2.0 — January 2023 Altanium Neo5 Table 6-2 Advanced Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Manual Shows the entire Manual Standby menu in the Standby Quick Set screen. Temperature Shows the Temperature Setpoint setting in the Setpoint Manual Standby menu in the Quick Set screen.
Page 68 2.0 — January 2023 Altanium Neo5 Table 6-2 Advanced Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Remote Shows the entire Remote Standby menu in the Standby Quick Set screen. Temperature Shows the Temperature Setpoint setting in the Setpoint Remote Standby menu in the Quick Set screen.
Page 69 User Guide v 2.0 — January 2023 Altanium Neo5 Table 6-2 Advanced Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Remote Boost Shows the entire Remote Boost menu in the Quick Set screen. Temperature Shows the Temperature Setpoint setting in the Setpoint Remote Boost menu in the Quick Set screen.
Page 70 2.0 — January 2023 Altanium Neo5 Table 6-2 Advanced Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Advanced Shows the entire Advanced Settings menu in Settings the Quick Set screen. Output Power Shows the Output Power Limit setting in the...
Page 71 User Guide v 2.0 — January 2023 Altanium Neo5 Table 6-2 Advanced Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Control Shows the entire Control Settings menu in the Settings Quick Set screen. Control Mode Shows the Control Mode setting in the Control Settings menu in the Quick Set screen.
Page 72 2.0 — January 2023 Altanium Neo5 Table 6-2 Advanced Setup Default Settings (Continued) Default Item Available Settings Description Value Staging Staging Shows the Staging button on the Home screen. Mold Test Mold Test Shows the Mold Test button on the Home screen.
Page 73 User Guide v 2.0 — January 2023 Altanium Neo5 Table 6-2 Advanced Setup Default Settings (Continued) Default Item Available Settings Description Value Auto Save Mold Selects the Auto Save Mold Setup feature for Setup use. Monitor Zone Shows the Monitor Zone Settings panel.
Page 74 2.0 — January 2023 Altanium Neo5 Table 6-2 Advanced Setup Default Settings (Continued) Default Item Available Settings Description Value File Management Shows the File Management button on the Home screen and disables the File Management navigation button in the system footer.
Page 75: Basic Setup Screen
User Guide v 2.0 — January 2023 Altanium Neo5 Basic Setup Screen The Basic setup screen is used to configure what settings and functionality will be available when a user is in Basic mode. All changes made in this screen are automatically saved and are applied whenever a user logs in with a user profile configured for Basic mode or the Use Advanced Functionality box is deselected in the System Setup screen.
Page 76 2.0 — January 2023 Altanium Neo5 Table 6-3 Basic Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Zone Edit Shows the entire Zone Edit menu in the Quick Set screen. Zone Name Shows the Zone Name setting in the Zone Edit QS - Zone Edit menu in the Quick Set screen.
Page 77 User Guide v 2.0 — January 2023 Altanium Neo5 Table 6-3 Basic Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Manual Shows the entire Manual Standby menu in the Standby Quick Set screen. Temperature Shows the Temperature Setpoint setting in the Setpoint Manual Standby menu in the Quick Set screen.
Page 78 2.0 — January 2023 Altanium Neo5 Table 6-3 Basic Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Remote Shows the entire Remote Standby menu in the Standby Quick Set screen. Temperature Shows the Temperature Setpoint setting in the Setpoint Remote Standby menu in the Quick Set screen.
Page 79 User Guide v 2.0 — January 2023 Altanium Neo5 Table 6-3 Basic Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Remote Boost Shows the entire Remote Boost menu in the Quick Set screen. Temperature Shows the Temperature Setpoint setting in the Setpoint Remote Boost menu in the Quick Set screen.
Page 80 2.0 — January 2023 Altanium Neo5 Table 6-3 Basic Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Advanced Shows the entire Advanced Settings menu in Settings the Quick Set screen. Output Power Shows the Output Power Limit setting in the...
Page 81 User Guide v 2.0 — January 2023 Altanium Neo5 Table 6-3 Basic Setup Default Settings (Continued) Default Item Available Settings Description Value QS - Control Shows the entire Control Settings menu in the Settings Quick Set screen. Control Mode Shows the Control Mode setting in the Control Settings menu in the Quick Set screen.
Page 82 2.0 — January 2023 Altanium Neo5 Table 6-3 Basic Setup Default Settings (Continued) Default Item Available Settings Description Value Staging Staging Shows the Staging button on the Home screen. Mold Test Mold Test Shows the Mold Test button on the Home screen.
Page 83 User Guide v 2.0 — January 2023 Altanium Neo5 Table 6-3 Basic Setup Default Settings (Continued) Default Item Available Settings Description Value Auto Save Mold Selects the Auto Save Mold Setup feature for Setup use. Monitor Zone Shows the Monitor Zone Settings panel.
Page 84 2.0 — January 2023 Altanium Neo5 Table 6-3 Basic Setup Default Settings (Continued) Default Item Available Settings Description Value File Management Shows the File Management button on the Home screen and disables the File Management navigation button in the system footer.
Page 85: System Setup Screen
User Guide v 2.0 — January 2023 Altanium Neo5 6.2.1 System Setup Screen The System setup screen is used to configure what screen will be displayed after the controller is powered ON. All changes made in this screen are automatically saved. The choices are the Home, Neo View, Multi-Group View, or Text View screens.
Page 86 2.0 — January 2023 Altanium Neo5 In the Customized Functionality area of the System Setup screen, select the Export Settings button (refer to Figure 6-2). Figure 6-2 Export Customize Screen Settings A dialog window will show to say that the file was exported successfully.
Page 87 User Guide v 2.0 — January 2023 Altanium Neo5 Figure 6-4 Select an Import File Select the file that you want to import and then select the button to close the dialog. A dialog window will show to say that the settings were imported successfully.
Page 88: Default Screen Settings
2.0 — January 2023 Altanium Neo5 In the user’s row on the User Management screen, select the cell in the Functionality column for that user, so the cell is highlighted. Touch the Edit button in the left side of the User Management screen.
Page 89 User Guide v 2.0 — January 2023 Altanium Neo5 Figure 6-5 Default Settings Screen 6.3.1 Default Setup Screen Overview The panels in the Default Settings screen include all the parameters choices that are saved to a mold setup file on the following screens/locations: •...
Page 90 2.0 — January 2023 Altanium Neo5 6.3.2 Default Settings Screen Default Parameters Table 6-5 describes the default parameters on the Default Settings screen. Table 6-5 Default Parameters Default Value Panel Available Parameters (Imperial/Metric) Temperature Setpoint 350 °F / 177 °C...
Page 91 User Guide v 2.0 — January 2023 Altanium Neo5 Table 6-5 Default Parameters (Continued) Default Value Panel Available Parameters (Imperial/Metric) Temperature Setpoint 250 °F / 121 °C Temperature Minimum 100 °F / 38 °C Temperature Maximum 700 °F / 371 °C...
Page 92 2.0 — January 2023 Altanium Neo5 Table 6-5 Default Parameters (Continued) Default Value Panel Available Parameters (Imperial/Metric) Control Made P - Proportional I - Integral Control Settings D - Derivative P - ART I - ART D - ART Tuning Strategy ART 2.0...
Page 93 User Guide v 2.0 — January 2023 Altanium Neo5 Table 6-5 Default Parameters (Continued) Default Value Panel Available Parameters (Imperial/Metric) Enable Not Selected Override Limit 00:15:00 At Temp Window 5 °F / 3 °C Stage 1-4 Soak Timer 00:00:00 Stage 1 Temperature (350 °F) / (177 °C)
Page 94 2.0 — January 2023 Altanium Neo5 6.3.3.1 Export Default Screen Settings After you have set your Default screen settings, do the steps the follow: Insert a USB flash drive into the USB port on the Neo5 controller. Select the System Setup button on the Neo5 Home screen or in the screen header.
Page 95 User Guide v 2.0 — January 2023 Altanium Neo5 In the Default Settings area of the System Setup screen, select the Import Settings button (refer to Figure 6-7). Figure 6-7 Import Default Screen Settings A dialog window will show that lists the saved Default screen settings files on the USB...
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Page 97: Chapter 7 Mold Setups
2.0 — January 2023 Altanium Neo5 Chapter 7 Mold Setups The mold setup has the process parameters necessary to operate the hot runner system. File Management Screen The File Management screen stores and manages files such as mold setups, images, documents and reports.
Page 98 2.0 — January 2023 Altanium Neo5 Figure 7-1 File Management Screen You can use the File Directory checkboxes at the top right of the screen, to see just the mold files or the other system files. If Molds is selected, all the mold folders will be shown in the left- hand pane.
Page 99 User Guide v 2.0 — January 2023 Altanium Neo5 • CSVs - shows all Comma Separated Value (CSV) files stored in the Molds folders if Molds is selected in the File Directory. • All - shows all available file types stored in the Molds folders if Molds is selected in the File Directory.
Page 100 2.0 — January 2023 Altanium Neo5 7.1.1 Save Changes to a Mold Setup File After a mold setup file has been loaded, you can permanently save changes made to it. On the Mold Setup screen, touch the Save Changes button. This will show the Mold Setup - Save dialog box to confirm the mold and name of the file that the changes are to be saved to.
Page 101: Delete Files
User Guide v 2.0 — January 2023 Altanium Neo5 To load a different Mold Setup, do the following: On the File Management screen, select the Mold Setup folder that contains the Mold Setup file to be loaded. Touch the name of the mold setup file to be loaded.
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Page 103: Chapter 8 Process Adjustments
2.0 — January 2023 Altanium Neo5 Chapter 8 Process Adjustments You can adjust the process settings for a mold setup before starting the mold, or while the mold is running. This chapter explains how to use, monitor, and modify the system.
Page 104: Zone Groups
2.0 — January 2023 Altanium Neo5 Zone Groups You can make groups of zones with the use of the Quick Set screen. The groups let you easily identify selections of zones are used in the mold. When a group of zones is select, process adjustments can be made to all zones in the group at one time.
Page 105 User Guide v 2.0 — January 2023 Altanium Neo5 Do the steps that follow to assign names to one or more of the groups (1 through 10, as necessary): a. Touch the field to the right of the Group 1 Name.
Page 106 2.0 — January 2023 Altanium Neo5 8.2.2 Add Zones to Groups Do the steps that follow to assign zones to a group: Select the zones that you want to be in a group. Touch the field to the right of the Group button at the top of the Groups drop-down menu.
Page 107 User Guide v 2.0 — January 2023 Altanium Neo5 8.2.3 Remove a Zone from a Group Do the steps that follow to remove a zone from a group: Select the zone that you want to remove from the group. Touch the field to the right of the Group button at the top of the Groups drop-down menu.
Page 108 2.0 — January 2023 Altanium Neo5 Figure 8-7 Multi-Group View Screen You can change the screen to Full Screen view to see more information for the zones. Touch the Plus/Minus button to see the Full Screen view. Touch the button again to change back to Half Screen view.
Page 109 User Guide v 2.0 — January 2023 Altanium Neo5 The buttons on the Multi Group View screen are described in Table 8-1. Table 8-1 Multi Group View Screen Buttons Button Description Expands all group information lists. Collapses all group information lists.
Page 110 2.0 — January 2023 Altanium Neo5 Table 8-1 Multi Group View Screen Buttons (Continued) Button Description Opens the Quick Set screen with all of the zones automatically selected. NOTE: In the header of a group, this button opens the Quick Set screen with all zones selected in the group.
Page 111 User Guide v 2.0 — January 2023 Altanium Neo5 Continue to touch the boxes to put the groups in the order that you want to see them. Numbers will be shown in order with each group box that you select.
Page 112 2.0 — January 2023 Altanium Neo5 8.3.3 Change Header Colors To help identify a group, you can select a header color for that group that is shown on the Multi Group View screen. To change the header color, do the steps that follow: On the group header bar, select Change Color button.
Page 113 User Guide v 2.0 — January 2023 Altanium Neo5 8.3.4 Collapse and Expand Zones Shown in a Group You can collapse the zones in a group, so they are not shown. Only the group header is shown. This makes it easy to see only the group zones you want shown on the screen. To collapse the zones in a group, select the down arrow at the left of the group header.
Page 114 2.0 — January 2023 Altanium Neo5 Neo View Screen Overview The Neo View shows the zones in a graphical format. It is designed to provide an easy way to view the overall status of the mold without having to sort through detailed data.
Page 115 User Guide v 2.0 — January 2023 Altanium Neo5 Table 8-2 Temperature Bar Temperature Bar Description The bar in each zone shows the temperature of the zone. Segments of the bar are color coded. • The green area represents the molding window.
Page 116 2.0 — January 2023 Altanium Neo5 Figure 8-16 Neo View Operation Example Touch the Plus/Minus button and the screen will only show the temperatures of the zones (refer to Figure 8-17). Touch the button again to toggle back to the graphical view.
Page 117 User Guide v 2.0 — January 2023 Altanium Neo5 Text View Screen Overview The Text View screen gives zone information in a tabular format (refer to Figure 8-18). The screen is used to access detailed data for each zone and gives the most comprehensive view of the process.
Page 118 2.0 — January 2023 Altanium Neo5 Table 8-3 Text View Screen Descriptions Item Description Zone Row Each row in the Text view represents a heating zone in the system. Touching anywhere within the row will navigate to the Quick Set screen.
Page 119 User Guide v 2.0 — January 2023 Altanium Neo5 8.5.1 Zone Selection on the Text View Screen You can select one or multiple zones on the Text View screen that you want to work with on the Quick Set screen. To select one zone, touch anywhere on the zone row and the Quick Set screen will show with that zone highlighted.
Page 120: Quick Set Screen
2.0 — January 2023 Altanium Neo5 The Quick Adjustment panel lets you change the current setpoint, zone on/off, and regulation (Auto or Manual) with the use of the buttons in the panel. You will see the zone information change immediately after a panel function is selected.
Page 121: Frequently Used Fields
User Guide v 2.0 — January 2023 Altanium Neo5 Figure 8-20 Quick Set Screen 8.7.1 Frequently Used Fields The Frequently Used fields are the settings you may go to most often (refer to Figure 8-21). Figure 8-21 Frequently Used Fields...
Page 122: Zone Edit
2.0 — January 2023 Altanium Neo5 The Frequently Used fields are described in Table 8-4. Table 8-4 Frequently Used Fields Item Description Temperature Setpoint Touch this field to set the temperature for one or more zones. Power Setpoint Touch this field to set the percentage of power output for one or more zones that are in Manual regulation.
Page 123: Zone Name
User Guide v 2.0 — January 2023 Altanium Neo5 The Zone Edit fields are described in Table 8-5. Table 8-5 Zone Edit Fields Item Description Zone Name Touch this field to give a custom name to a zone or group of zones.
Page 124: Locked/Unlocked
2.0 — January 2023 Altanium Neo5 8.7.2.2 Locked/Unlocked You can lock one or more zones, so they cannot be changed on the Quick Set screen. Select the zones you want to lock and then touch the box to the right of the Locked/Unlocked button.
Page 125: Groups
User Guide v 2.0 — January 2023 Altanium Neo5 Select the zones that are OFF and then touch the box to the right of the Display/Hide button. The Zone Displayed/Hidden dialog shows (refer to Figure 8-26). Select Hide and then select the button to accept the change.
Page 126: Manual Standby
2.0 — January 2023 Altanium Neo5 The Setpoint Limits fields are described in Table 8-6. Table 8-6 Setpoint Limits Fields Item Description Temperature Minimum These values specify the range limits in which the Temperature Setpoint field can be set. Example: If the Minimum is set to 100°F and the Temperature Maximum Maximum to 600°F, you will not be able to enter a setpoint that is less...
Page 127 User Guide v 2.0 — January 2023 Altanium Neo5 Table 8-7 Manual Standby Fields Item Description Temperature Setpoint The temperature to which all zones are set when the Standby button is touched. This setting can be used to lower all zone temperatures to their Manual Standby temperature setpoint until the timer completes or the user touches the Standby button again.
Page 128: Manual Boost
2.0 — January 2023 Altanium Neo5 8.7.6 Manual Boost The Manual Boost drop-down tab is shown in Figure 8-29. Figure 8-29 Manual Boost Fields The Manual Boost fields are described in Table 8-9. Table 8-9 Manual Boost Fields Item...
Page 129: Remote Standby
User Guide v 2.0 — January 2023 Altanium Neo5 Table 8 -10 Manual Boost Operational Description Delay Remote Manual Time Input Mode Operation - BOOST Button Select Time Time 0:00:00 ---- ---- ---- System enters Boost indefinitely. X:XX:XX ---- ----...
Page 130 2.0 — January 2023 Altanium Neo5 Table 8-11 Remote Standby Fields (Continued) Item Description Power Setpoint Remote standby is started by a digital input signal from the IMM. This setting lowers all zones to their remote standby power setpoint until the timer completes or the input signal is off.
Page 131 User Guide v 2.0 — January 2023 Altanium Neo5 Table 8 -12 Remote Standby Operational Description (Continued) Manual Remote Delay Time Input Mode Operation - STANDBY Button Select Time Time ---- X:XX:XX 0:00:00 Trigger System delays for specified time and then enters Standby indefinitely.
Page 132: Remote Boost
2.0 — January 2023 Altanium Neo5 8.7.8 Remote Boost The Remote Boost drop-down tab is shown in Figure 8-31. Figure 8-31 Remote Boost Fields The Remote Boost fields are described in Table 8-13. Table 8-13 Remote Boost Fields Item...
Page 133 User Guide v 2.0 — January 2023 Altanium Neo5 Table 8-13 Remote Boost Fields (Continued) Item Description Duration The time that the zones will stay in the remote boost mode. NOTE: This setting applies to all zones. Delay The time that you want the system to wait from the time it receives the remote boost signal to when it enters the boost mode.
Page 134: Heater Types
2.0 — January 2023 Altanium Neo5 8.7.9 Heater Types The Heater Types drop-down tab is shown in Figure 8-32. Figure 8-32 Heater Types Use this screen to assign a heater type to one or more zones. To assign a heater type, do the steps that follow: Assign a name to one or more of the Custom Heater Types (1 thru 8) shown in the drop- down list.
Page 135 User Guide v 2.0 — January 2023 Altanium Neo5 b. Use the keyboard to enter in the heater type name or select one of the nine heater type names and then select the button. c. As necessary, do step a...
Page 136: Advanced Settings
2.0 — January 2023 Altanium Neo5 8.7.10 Advanced Settings The Advanced Settings drop-down tab is shown in Figure 8-35. Figure 8-35 Advanced Settings The Advanced Settings fields are described in Table 8-15. Table 8-15 Advanced Settings Fields Item Description...
Page 137: Control Settings
User Guide v 2.0 — January 2023 Altanium Neo5 Table 8-15 Advanced Settings Fields (Continued) Item Description Automatic Manual Control (AMC) lets the Altanium automatically apply a manual power output percentage to a heater based on a historical average if a thermocouple fails.
Page 138 2.0 — January 2023 Altanium Neo5 The Control Settings fields are described in Table 8-16. Table 8-16 Control Settings Fields Item Description Control Mode Set the Control Mode to Active Reasoning Technology (ART) or Proportional Integral Derivative (PID). ART automatically adjusts the control algorithm applicable to different heater requirements.
Page 139: Art Settings
ART process and would not have to go through the process the next time the controller is started. NOTE: This is typically used in the Husky factory to set all zones as having completed the ART process before your controller ships.
Page 140: Zone Follower
2.0 — January 2023 Altanium Neo5 Table 8-17 ART Settings (Continued) Item Description Minimum P Enter the minimum Proportional (P) value Minimum I Enter the minimum Integral (I) value. Minimum D Enter the minimum Derivative (D) value. Default P Enter the default P value.
Page 141: Manually Setting One Zone As A Follower To Another Zone
User Guide v 2.0 — January 2023 Altanium Neo5 Once the error is cleared and reset, the follower value is stored to the database. The Quick Set screen for that zone shows the zone it now follows. The Automatic Follow function can be disabled in the System Setup screen.
Page 142: Zone Calibration
2.0 — January 2023 Altanium Neo5 Zone Calibration To run a satisfactory injection process, temperature accuracy of the zones is important. The Neo5 lets you make sure that your temperature readings are correct with the use of zone calibration.
Page 143 User Guide v 2.0 — January 2023 Altanium Neo5 When you open the Zone Calibration screen, the following actions occur: • The mode changes to ‘Calibration’. • The Start, Standby, and Boost buttons in the header become disabled. • All zone errors become disabled until you open a different the screen.
Page 144: Active Reasoning Technology (Art)
2.0 — January 2023 Altanium Neo5 12. Set the thermocouple simulator to 750 °F (400 °C if the temperature units in the controller are set to Celsius). 13. Wait about 5 seconds for the reading to be stable and then touch the Read High button on the left side of the Zone Calibration screen.
Page 145: 1Art Fault Handling
User Guide v 2.0 — January 2023 Altanium Neo5 8.10.0.1 ART Fault Handling If an error occurs during the ART process, the Alarms screen is shown automatically, and the error is recorded in the events log. An error stops the ART process immediately.
Page 146: 1Possible Causes Of Oscillation
2.0 — January 2023 Altanium Neo5 Table 8 -20 PID Values (Continued) Proportional Integral Derivative Type Example Slow Manifolds or heaters with externally located thermocouples Slow 8.10.2.1 Possible Causes of Oscillation It is possible to set the control terms incorrectly, which causes an oscillation. The most...
Page 147 User Guide v 2.0 — January 2023 Altanium Neo5 A heat capacity value, measured as zone gain in decibels (dBG), are returned by the control card that can be used for determining the heater type. Values for all the zones are sorted in ascending order and then the widest gap found between zones is determined.
Page 148 2.0 — January 2023 Altanium Neo5 Page 138...
Page 149: Chapter 9 Mold Diagnostics
2.0 — January 2023 Altanium Neo5 Chapter 9 Mold Diagnostics Diagnostics is a useful tool for troubleshooting problems with a mold or for verifying the wiring integrity of a mold after maintenance has been performed. You can also use diagnostics to analyze the thermal isolation between all the cavities in the mold.
Page 150 2.0 — January 2023 Altanium Neo5 On the Mold Test screen, select Settings button at the bottom, middle of the screen (refer to Figure 9-3). Figure 9-3 Mold Test Screen - Settings Button The Mold Test Setup Screen shows (refer to Figure 9-4).
Page 151: Mold Diagnostics Test
User Guide v 2.0 — January 2023 Altanium Neo5 Touch the box to the right of the Zone Cooling Time button, enter a wait time in the keypad, and then select the button. Refer to Section 9.2.1 for more information.
Page 152: Zone Cooling Time
2.0 — January 2023 Altanium Neo5 Select the desired zone(s) on the Mold Test screen. NOTE: Only the zones selected will be tested. Make sure that Neo5 is stopped. 10. If not already selected, touch the checkbox next to the test...
Page 153: Test Definitions
User Guide v 2.0 — January 2023 Altanium Neo5 9.2.3 Test Definitions Test Heaters — During heating, the maximum current and voltage are recorded, and the resistance is calculated. Also checks for blown fuses. Test Sensor — Tests the correct functioning of the thermocouple. For example, if a thermocouple is lost or reversed.
Page 154 2.0 — January 2023 Altanium Neo5 Table 9-1 describes the fields and buttons on the Mold Test Results screen. Table 9-1 Mold Test Results Screen Descriptions Item Description Zone Zone number Name Zone name Senor Indicates the number of the sensor being used for that zone.
Page 155 User Guide v 2.0 — January 2023 Altanium Neo5 Table 9-1 Mold Test Results Screen Descriptions (Continued) Item Description Wiring The wiring test tests for correct zone sensor assignment. This test determines whether sensor assignments match. If a sensor assignment does not match, the cross-talk findings test will fail.
Page 156: Automatic Thermocouple Wiring
2.0 — January 2023 Altanium Neo5 Table 9-2 shows the cross-talk percentage ranges that are identified by number in the Iso column of the Mold Test Results screen. Table 9-2 Cross-Talk Percentage Ranges and Isolation Rating Iso. Number Cross-Talk Range...
Page 157 User Guide v 2.0 — January 2023 Altanium Neo5 When the Compare function is enabled, the Mold Test Results screen will show two tables, one above the other. The top table shows the baseline results, and the bottom table shows the compare results.
Page 158 2.0 — January 2023 Altanium Neo5 Figure 9-8 Select Baseline Dialog Select the test that you want to use as the baseline and then select the button. Touch the Select Compare button. The Select Compare dialog shows (refer to Figure 9-9).
Page 159 User Guide v 2.0 — January 2023 Altanium Neo5 The Delete Result dialog will show (refer to Figure 9-10). Figure 9-10 Delete Result Dialog Select the test result you want to delete and then select the button. NOTE: When there are 20 test results tables in the database, the Save button will be disabled.
Page 160 2.0 — January 2023 Altanium Neo5 Page 150...
Page 161: Chapter 10 Heat The Mold
2.0 — January 2023 Altanium Neo5 Chapter 10 Heat the Mold This chapter describes how to start the Neo5 system and check for errors, and alarm conditions, if they occur. 10.1 Neo5 Startup To apply power to the zones, touch the Start button.
Page 162: Earth Leakage/Wet Heater Bake Out System
2.0 — January 2023 Altanium Neo5 10.2 Earth Leakage/Wet Heater Bake Out System Neo5 is equipped with an advanced Earth Leakage/Wet Heater Bake Out system. When the Neo5 is started, a check for earth leakage conditions on every heater is done simultaneously and continuously.
Page 163: Altastart
User Guide v 2.0 — January 2023 Altanium Neo5 10.3 AltaStart The AltaStart function is used for heat sequencing. This system analyzes the likely heat-up time of tip zones and scheduling each one to make sure that they get to their respective temperature setpoints within 3 minutes of the manifolds.
Page 164: Fast Heating
2.0 — January 2023 Altanium Neo5 10.5 Fast Heating The UniStart process heats the zones slowly, but evenly. When Fast Heating feature is enabled, the system pushes some zones to heat faster, as follows: • The system looks at all the zones to see if the Integral value (of PID) is less than 2. If it is, then the value is changed to the lesser of either: •...
Page 165: Adjusting The Soft Start Minimum Limit
User Guide v 2.0 — January 2023 Altanium Neo5 10.6.1 Adjusting 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 maintained throughout the soft start process and determines the gap between the coldest and hottest zones.
Page 166: Opening The Alarm Screen
2.0 — January 2023 Altanium Neo5 Table 10-2 describes the items on the Alarm screen. Table 10-2 Alarm Screen Descriptions Item Description Date/Time Date and time that the alarm was triggered. Source Cause of the alarm. Description Description of the problem that triggered the alarm.
Page 167: Clearing Alarms
User Guide v 2.0 — January 2023 Altanium Neo5 10.7.2 Clearing Alarms If an error occurs, Neo5 will turn on audible and visual alarms and show the alarm condition on the Alarm screen. To clear an alarm, do the following: To silence an audible alarm, touch the Silence Horn button.
Page 168 2.0 — January 2023 Altanium Neo5 Figure 10-4 Event History Screen On the Neo5 Home screen, touch Event History button to see the Event History screen (refer Figure 10-5). Figure 10-5 Event History Button NOTE: For a description of the alarm conditions displayed on the Event History screen and...
Page 169: Filtering Events
User Guide v 2.0 — January 2023 Altanium Neo5 Table 10-3 Event History Screen Descriptions (Continued) Item Description Mold Setup Indicates the mold setup that was loaded when the event occurred. Details Describes the event. 10.8.1 Filtering Events On the Event History screen, you can filter the events you want to see. One or more event types can be selected, and you can filter by dates.
Page 170: Alarm Conditions - Warning Errors
2.0 — January 2023 Altanium Neo5 10.9 Alarm Conditions — Warning Errors Alarm conditions are displayed on the Alarm screen and the Event History screen. The conditions shown in Table 10 -4 cause the audible and visual alarms to initiate. Because they are warnings, they will not shut any part of the system down.
Page 171: Abort Conditions - Shutdown Errors
User Guide v 2.0 — January 2023 Altanium Neo5 10.10 Abort Conditions — Shutdown Errors Abort conditions are displayed on the Alarm screen and the Event History screen. The conditions in Table 10 -5 initiate the audible and visual alarms. Since they are shut down errors, they will cause a zone or system shut down situation based on the PCM setting.
Page 172 2.0 — January 2023 Altanium Neo5 Table 10 -5 Shutdown Errors (Continued) Shut Down Error Description Over Voltage The A/C voltage read by the control card is greater than 280 VAC. • 280 volts is the highest level of voltage the control cards can withstand before permanent damage occurs.
Page 173: Chapter 11 System Setup Screen
2.0 — January 2023 Altanium Neo5 Chapter 11 System Setup Screen This chapter describes the functionality available in the System Setup screen, and provides instructions on setting some of the most commonly used system wide preferences. 11.1 System Setup Screen Use the System Setup screen to configure the Neo5 system.
Page 174 System Setup Screen Item Descriptions Item Description Serial Number The Serial Number is for informational purposes only. It is a number assigned to the system when it is manufactured. Husky support may ask for this number when troubleshooting or upgrading. Model Controller model name.
Page 175 User definable company name displayed in the system header. Software Version The Current Software Version is for informational purposes only. Husky support may ask for this number when troubleshooting or upgrading. Auto Save Mold Setup If checked, all changes to the current mold setup will be saved as they occur and cannot be discarded.
Page 176 • Process Monitoring Data • Current Mold Setup • Additional directory that contains diagnostic data for Husky software engineers Software Package Information Used to see the software packages installed on your system. Tuning Strategy Used to select the ART Classic or ART 2.0 tuning strategy. ART 2.0 is selected by default.
Page 177 User Guide v 2.0 — January 2023 Altanium Neo5 Table 11 -1 System Setup Screen Item Descriptions (Continued) Item Description Soft Start to ART Setpoint When enabled, the soft start routine is used when heating zones Enable to the tuning setpoint during the ART process.
Page 178 2.0 — January 2023 Altanium Neo5 Table 11 -1 System Setup Screen Item Descriptions (Continued) Item Description Auto Power Limiting Enable If checked, the Auto Power Limiting feature is enabled. Circuit Test State 4 Power Determines the power percentage applied during circuit test Level state 4.
Page 179: Changing The Number Of Zones In The System
User Guide v 2.0 — January 2023 Altanium Neo5 Table 11 -1 System Setup Screen Item Descriptions (Continued) Item Description Import Settings Used to import Customize screen setting values. The button is enabled if a USB drive is plugged into the USB port and the current user has the proper permission level.
Page 180 2.0 — January 2023 Altanium Neo5 Figure 11-4 Zone Slot Configuration Screen Touch the Slot Enable button. Touch the Enable or Disable button in the Slot Enable selection dialog. Touch the button. Restart the controller. Page 170...
Page 181: Chapter 12 Staged Startup And Shutdown
2.0 — January 2023 Altanium Neo5 Chapter 12 Staged Startup and Shutdown This feature allows the Neo5 to heat or cool zones in a predetermined order by using stages. Zones can be assigned to any of the four stages and can be configured with a separate set point for each stage.
Page 182 2.0 — January 2023 Altanium Neo5 On the Staging screen, select the zones or groups that will be included in Stage x Startup. NOTE: x = 1, 2, 3, or 4. Touch the Staged Startup button to show the drop-down menu.
Page 183: Setting Soak Timers
2.0 — January 2023 Altanium Neo5 12.2 Setting Soak Timers At the end of each stage during staged startup or shutdown, when all the zones are at the stage setpoint, they can be left to "soak" for a specified time before the next stage begins. Use the Staging screen to change the soak time lengths.
Page 184: Set The Stage Temperature And Power
2.0 — January 2023 Altanium Neo5 12.3 Set the Stage Temperature and Power On the Staging screen, select the Stage x (Startup) button to show the drop-down menu (refer to Figure 12-4). NOTE: x = 1, 2, 3, or 4.
Page 185: Chapter 13 Data Recording
2.0 — January 2023 Altanium Neo5 Chapter 13 Data Recording Data Recording is a useful tool to track the operation of a mold. This tool helps analyze the system to optimize the molding process, track errors, find the source of a recent error or predict where future errors may occur.
Page 186: Change The Zones
2.0 — January 2023 Altanium Neo5 13.1.1 Change the Zones You can change the zones shown in the graphic charts with the steps that follow: Touch the box to the right of the Zone bar. Use the keypad and enter the new zone number and then touch the button.
Page 187: View A Specific Point On The Plot
User Guide v 2.0 — January 2023 Altanium Neo5 13.1.3 View a Specific Point on the Plot When you start the Neo5, the parameters for the selected zone will start to plot on the graph. You can select a point on the chart to see the data values recorded for a specific time on the plot.
Page 188 2.0 — January 2023 Altanium Neo5 Figure 13-3 Power Deviation Screen Table 13-1 describes the information shown on the Power Deviation screen. Power Deviation Screen Information Table 13-1 Item Description Zone Shows the zone number. Name Shows the assigned zone name.
Page 189: Configure The Power Deviation
User Guide v 2.0 — January 2023 Altanium Neo5 13.2.1 Configure the Power Deviation To use the process deviation application, do the steps that follow: Select the Quick Set button on the Neo5 Home screen. Select Heater Types on the Quick Set screen (refer to Figure 13-4).
Page 190 2.0 — January 2023 Altanium Neo5 Select the Setup button at the bottom left corner of the screen. The Power Deviation Setup dialog shows (refer to Figure 13-5). Figure 13-5 Power Deviation Setup Dialog Table 13-2 describes the settings on the Power Deviation Setup dialog.
Page 191: Troubleshooting
User Guide v 2.0 — January 2023 Altanium Neo5 Table 13-2 Power Deviation Setup Dialog Settings (Continued) Item Description User Specified If you do not want to use the calculated value determined by the Tolerance algorithm, then this value can be used instead. You must also un-check the ‘Use Auto Calculated Tolerance’...
Page 192: Can Information
The CAN Info screen is used for troubleshooting communication issues on the Controller Area Network (CAN) bus. The CAN field bus used to communicate between the control cards and the HMI. Husky Support will instruct you on the use of the screen, should communication issues arise.
Page 193 User Guide v 2.0 — January 2023 Altanium Neo5 Table 13-3 CAN Information Screen Descriptions (Continued) Item Description Shows the average power output percentage. This is used by Auto Following. This is the sensor number assigned to the zone. The sensor is assigned in the Quick Set screen.
Page 194 2.0 — January 2023 Altanium Neo5 Page 184...
Page 195: Chapter 14 Data Exchange
2.0 — January 2023 Altanium Neo5 Chapter 14 Data Exchange You can store reports and images to the Neo5 hard drive. From the file management screen, you can move the reports and images to a network or USB device for sharing, storing, or printing.
Page 196 2.0 — January 2023 Altanium Neo5 On the Data Exchange screen, select the reports that you want to save (refer to Table 14-1). Table 14-1 Report Selections Item Description Select Report Type Put a check mark in the checkbox next to the report that you want to save.
Page 197: Report Descriptions
User Guide v 2.0 — January 2023 Altanium Neo5 Table 14-1 Report Selections (Continued) Item Description Networking With the Interface Configuration settings, you select Static or dynamic (DHCP) property values: • Static settings: IP Address Subnet Mask Default Gateway •...
Page 198 2.0 — January 2023 Altanium Neo5 Table 14-2 Report Descriptions Report Type Description Zone Information — Brief From the Text View screen, the following will be saved to a file: • Zone Number • Setpoint and Units • Actual Temperature and Units Zone Information —...
Page 199 User Guide v 2.0 — January 2023 Altanium Neo5 Table 14-2 Report Descriptions (Continued) Report Type Description Mold Setup • Zone Number • Zone Name • Setpoint • Minimum Setpoint Limit • Maximum Setpoint Limit • Power Limit • Alarm •...
Page 200 2.0 — January 2023 Altanium Neo5 Table 14-2 Report Descriptions (Continued) Report Type Description Power Deviation Data • Date and Time • Mold Folder and Mold Setup • System Status • Power Deviation Enable • Use Calculated Limit •...
Page 201: Chapter 15 Digital I/O
The input and output connectors are located on the back of the Neo5 (see Section 16.2). If you need help to connect the Neo5 inputs and outputs, contact your Husky Regional Service and Sales Office. Select the Digital I/O button in the System Configuration group of the Neo5 Home screen.
Page 202 2.0 — January 2023 Altanium Neo5 Figure 15-1 Digital I/O Screen Table 15-1 describes the column headers on the Digital I/O screen. Table 15-1 Digital I/O Screen Column Headers Identifiers Description Active Indicates the logical state of the I/O signal. This displays the final state of the signal after the optional invert is applied.
Page 203: Digital I/O Connector Pin-Out Description
User Guide v 2.0 — January 2023 Altanium Neo5 15.1 Digital I/O Connector Pin-Out Description The sections that follow include the connection descriptions for all of the optional Inputs and Outputs available for the Neo5. 15.1.1 Digital Inputs Table 15-2 describes the Neo5 digital inputs.
Page 204: Input Connector Pin-Out
2.0 — January 2023 Altanium Neo5 15.1.3 Input Connector Pin-Out Table 15-4 shows the connection details for all the inputs wired for dry contacts (No voltage). CAUTION! Electrical hazard - risk of damage to the equipment. DO NOT apply a voltage to any of the Inputs.
Page 205: Output Connector Pin-Out
User Guide v 2.0 — January 2023 Altanium Neo5 15.1.4 Output Connector Pin-Out Table 15-6 shows the connection details for all of the outputs. CAUTION! Electrical hazard - risk of damage to the equipment. DO NOT apply a voltage greater than 30 VDC at 2 amps to any of the Outputs.
Page 206 2.0 — January 2023 Altanium Neo5 Page 196...
Page 207: Chapter 16 Maintenance
2.0 — January 2023 Altanium Neo5 Chapter 16 Maintenance This chapter describes the maintenance tasks required to maintain the Neo5. Do the maintenance tasks only when necessary. Periodically, and before starting the equipment, check that all cables and cable connections are free from wear or damage.
Page 208: Servicing The System
2.0 — January 2023 Altanium Neo5 16.1 Servicing the System The Neo5 systems are based on two user serviceable components: • X-Series or H-Series Intelligent Control Cards • Neo5 Operator Interface Figure 16-1 shows a Neo5 integrated configuration. Figure 16-2 shows a Neo5 freestanding configuration.
Page 209 User Guide v 2.0 — January 2023 Altanium Neo5 Figure 16-2 Neo5 Freestanding System Configuration (Single Stack) Figure 16-3 Figure 16-4 show the main power switch locations. WARNING! Hazardous voltages - risk of death or serious injury. Before servicing the Altanium Neo5 lock out and tag the Main Power switch in accordance with local codes.
Page 210: Cable Connections
2.0 — January 2023 Altanium Neo5 Figure 16-4 Neo5 Main Power Switch - Freestanding Configuration (Single Stack) 16.2 Cable Connections Depending on the Neo5 configuration, there will be cable connections at the back and front of the controller. The insulation level of control cables and devices connected to the Neo5 connectors are: •...
Page 211: Cable Connections - Freestanding Configuration
User Guide v 2.0 — January 2023 Altanium Neo5 Figure 16-6 Cable Connections - Rear of Neo5 Table 16-1 Cable Connections (Integrated Configuration) Item Cable Connection Description Horn Audible alarm. LCD1 (HDMI) Video signal to touch monitor. Touch Screen Touch screen signal to the touch monitor.
Page 212: Intelligent Control Cards
2.0 — January 2023 Altanium Neo5 Table 16-2 Cable Connections (Freestanding Configuration) Item Cable Connection Description 100-240 VAC In Main AC power from the Altanium mainframe. Output COMM CAN bus communication to the Altanium mainframe. Touch Screen Touch screen signal to the touch monitor.
Page 213 User Guide v 2.0 — January 2023 Altanium Neo5 Figure 16-9 H-Series Intelligent Control Card Both series of cards plug into backplanes that are installed into the bays of the Neo5 mainframe (refer to Figure 16-10). The cards manage the power being delivered to the heaters, the thermocouple feedback and control and circuit protection.
Page 214: Replacing An Intelligent Control Card
2.0 — January 2023 Altanium Neo5 16.3.1 Replacing an Intelligent Control Card To replace an intelligent control card, do the steps that follow: 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 215 User Guide v 2.0 — January 2023 Altanium Neo5 Loosen the top and bottom slotted fasteners on the heat sink (refer to Figure 16-12). NOTE: These two fasteners are captive so they will not fall into the system or get lost on the floor.
Page 216: Replacing A Blown Fuse On An Intelligent Control Card
2.0 — January 2023 Altanium Neo5 CAUTION! Static electricity hazard - risk of damage to the equipment. The Intelligent Control Cards are electrostatic discharge sensitive. Do not, under any circumstances, place any Intelligent Control Card on carpets, rugs, or other material that is likely to create a static charge.
Page 217: Neo5 Operator Interface
Figure 16-14 ICC Fuse Locations Install a fuse with one that is of identical type and rating as the fuse that was removed. NOTE: Husky recommends SIBA 712540 Series or equivalent fuses. Make sure the fuse is fully seated. NOTE: Poor seating will cause a hot spot, which can cause problems for the system Slide the new card into to the slot and push the card slowly and firmly back into place.
Page 218 2.0 — January 2023 Altanium Neo5 Figure 16-15 Neo5 Integrated Operator Interface Figure 16-16 shows the touch monitor and MCU for a freestanding configuration. Figure 16-16 Neo5 Freestanding Operator Interface Page 208...
Page 219: Replacing The Touch Monitor - Integrated Configuration
User Guide v 2.0 — January 2023 Altanium Neo5 16.4.1 Replacing the Touch Monitor — Integrated Configuration To replace the touch monitor on an integrated configuration system, do the steps that follow: WARNING! Electrical and mechanical hazard - risk of damage to the equipment. Turn off all power to the system and disconnect it completely from the main input power.
Page 220 2.0 — January 2023 Altanium Neo5 This will expose the mini-USB connector, HDMI connector and top set of fasteners holding the touch monitor to the mounting bracket (refer to Figure 16-18). Figure 16-18 Mini-USB and HDMI Connectors Disconnect the mini-USB and HDMI connectors at the back of the touch monitor, as...
Page 221 User Guide v 2.0 — January 2023 Altanium Neo5 Loosen the two top fasteners using a 4mm socket wrench or nut driver (refer to Figure 16-20). IMPORTANT! Only loosen the fasteners. The mounting holes in the bracket holding the touch...
Page 222 2.0 — January 2023 Altanium Neo5 Securely grip the touch monitor and slide it upwards until the fasteners have cleared the top mounting slots and bottom key holes. Pull forward to remove the touch monitor from the mounting bracket. Refer to Figure 16-22.
Page 223: Replacing The Mcu - Integrated Configuration
User Guide v 2.0 — January 2023 Altanium Neo5 16.4.2 Replacing the MCU — Integrated Configuration To replace the MCU on an integrated configuration system, do the steps that follow: WARNING! Electrical and mechanical hazard - risk of death, serious injury and/or damage to the equipment.
Page 224 2.0 — January 2023 Altanium Neo5 Unplug the touch screen and LCD1 connectors at the front of the MCU (refer to Figure 16-25). Figure 16-25 Remove Touch Screen and LCD1 Connectors Locate and remove two mounting fasteners holding the MCU in place at the back of the...
Page 225 User Guide v 2.0 — January 2023 Altanium Neo5 Put your hand on the front of the MCU and push it backwards to disengage the hidden hooks that hold it in place on top of the mainframe (refer to Figure 16-27).
Page 226 2.0 — January 2023 Altanium Neo5 Carefully remove the power and communication connectors from the pocket at the bottom of the MCU and continue to rotate the unit upwards until it is resting on its front face (refer to Figure 16-29).
Page 227: Replacing The Touch Monitor - Freestanding Configuration
User Guide v 2.0 — January 2023 Altanium Neo5 After the power and communication cables are disconnected, carefully lift the MCU from the mainframe (refer to Figure 16-31). Figure 16-31 Remove the MCU from the Mainframe step 1 through step 8 in reverse order to install the new MCU.
Page 228 2.0 — January 2023 Altanium Neo5 Figure 16-32 Rotate the Monitor on a Freestanding Configurated System Unplug the mini-USB and HDMI connectors at the back of the touch monitor and loosen the two top fasteners using a 4mm socket wrench or nut driver (refer to Figure 16-33).
Page 229 User Guide v 2.0 — January 2023 Altanium Neo5 Figure 16-33 Loosen the Top Fasteners Rotate the touch monitor to the full back position and completely remove the two bottom fasteners (refer to Figure 16-34). NOTE: These mounting holes are not slotted, so the nut has to be removed completely to allow the touch monitor to be removed.
Page 230 2.0 — January 2023 Altanium Neo5 Securely grip the touch monitor and slide it upwards until the fasteners have cleared the top mounting slots and pull forward to remove the touch monitor from the mounting bracket (refer to Figure 16-35).
Page 231: Replacing The Mcu - Freestanding Configuration
User Guide v 2.0 — January 2023 Altanium Neo5 16.4.4 Replacing the MCU — Freestanding Configuration To replace the MCU on a freestanding configuration system, do the steps that follow: WARNING! Electrical and mechanical hazard - risk of death, serious injury and/or damage to the equipment.
Page 232 2.0 — January 2023 Altanium Neo5 Locate the four fasteners holding the MCU to the mounting bracket (refer to Figure 16-39). NOTE: The bracket is located between the Touch Monitor and the MCU enclosure. Figure 16-39 Fastener Locations Loosen the two top fasteners holding the MCU to the mounting bracket using a 4mm...
Page 233 User Guide v 2.0 — January 2023 Altanium Neo5 Figure 16-40 Loosen the MCU Top Fasteners Locate and completely remove the two bottom fasteners (refer to Figure 16-41). NOTE: These mounting holes are not slotted, so the screws must be removed completely to allow the MCU to be removed.
Page 234 2.0 — January 2023 Altanium Neo5 Securely grip the MCU and slide it upwards until the fasteners have cleared the top mounting slots and pull forward to remove the MCU from the mounting bracket. step 1 through step 6 in reverse order to install the new MCU.
Page 235: Replacing The Operator Interface - Freestanding Configuration
User Guide v 2.0 — January 2023 Altanium Neo5 16.4.5 Replacing the Operator Interface — Freestanding Configuration To replace the operator interface for a Neo5 freestanding configuration system, so the steps that follow: WARNING! Electrical and mechanical hazard - risk of death, serious injury and/or damage to the equipment.
Page 236 2.0 — January 2023 Altanium Neo5 Disconnect the power and communication connectors, as shown in Figure 16-44. Figure 16-44 Disconnect Operator Interface Power and Communication Connectors Remove the two fasteners holding the operator interface at the front of mainframe...
Page 237 User Guide v 2.0 — January 2023 Altanium Neo5 Remove the two fasteners holding the operator interface at the back of mainframe (refer Figure 16-46). NOTE: This step requires a screwdriver short enough to clear the MCU located above the fasteners.
Page 238: Neo5 Mobile Stand
2.0 — January 2023 Altanium Neo5 16.5 Neo5 Mobile Stand The Neo5 integrated configuration is available with a mobile stand as a paid option. The mobile stand allows the touch monitor of the Neo5 integrated configuration to be raised to an optimal viewing height (1320 mm –...
Page 239: Installing Neo5 On The Mobile Stand
User Guide v 2.0 — January 2023 Altanium Neo5 16.5.1 Installing Neo5 on the Mobile Stand The Neo5 mobile stand and controller come as separate pieces and must be assembled. To install the Neo5 on the mobile stand, do the steps that follow:...
Page 240 2.0 — January 2023 Altanium Neo5 Place the mobile stand in an open flat area of the floor and set the brakes, located on the front wheels (refer to Figure 16-50). IMPORTANT! Ensure that the correct stand and controller combination is used. This will prevent the assembly from becoming top heavy and tipping over.
Page 241 User Guide v 2.0 — January 2023 Altanium Neo5 Put the Neo5 in the center of the top plate (Figure 16-51), so that the mounting holes in the top plate align with the threaded holes at the bottom of the Neo5.
Page 242 2.0 — January 2023 Altanium Neo5 Use the tray at the bottom of the stand to store cables related to the controller (refer to Figure 16-53). Figure 16-53 Mobile Stand Bottom Tray Page 232...
Page 243: Cleaning The System
User Guide v 2.0 — January 2023 Altanium Neo5 16.6 Cleaning the System WARNING! Electrical and mechanical hazard - risk of death, serious injury and/or damage to the equipment. Turn off all power to the system and disconnect it completely from the main input power.
Page 244: Basic Troubleshooting
2.0 — January 2023 Altanium Neo5 16.7 Basic Troubleshooting Table 16-3 give the possible solutions for issues that could occur. 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 245 User Guide v 2.0 — January 2023 Altanium Neo5 Table 16-3 Troubleshooting Procedures (Continued) Problem Potential Cause Solution Ground Fault Bad heater. Consult the mold electrical prints Short in wiring. and use an ohmmeter or insulation Bad Card. resistance meter to inspect the Mis-wired mold, cable or controller.
Page 246 2.0 — January 2023 Altanium Neo5 Table 16-3 Troubleshooting Procedures (Continued) Problem Potential Cause Solution Reverse T/C Thermocouple has been connected Insufficient heat can be low supply with reversed polarity. voltage. Check the supply voltage Card is not calibrated.
Page 247: Appendix A Glossary Of Terms
2.0 — January 2023 Altanium Neo5 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...
Page 248 2.0 — January 2023 Altanium Neo5 Table A-1 Glossary of Terms and Symbols (Continued) Master Control Unit Millimeter(s) Network Time Protocol  Ohm or ohms OPC UA Open Platform Communication Unified Architecture Priority Control Mode Proportional, Integral, and Derivative...
Page 249: Index
Index ART 2.0 Abort conditions ART settings, Quick Set screen Accept/cancel buttons Assign advanced or basic mode to user Active Reasoning Technology profile ART 2.0 Automatic thermocouple wiring settings, quick set Add user Bake out cycles, configuring Administration and security Bake out, wet heater Advanced settings, Quick Set Basic setup screen...
Page 250 system and user management Default screen settings system configuration default parameters temperature management overview zone views Define group layout order Delete user Determine heater size Cable connections Diagnostics, mold freestanding configuration Digital I/O integrated configuration pin-out descriptions Calibration, zone digital inputs Cleaning digital outputs mainframe...
Page 251 Frequently used fields settings, Quick Interface, operator Set screen Introduction Function buttons Fuse, replacing ICC Keyboards, screen Keypads, screen General safety Glossary of terms Graphic plot point, view Layout order, define group Graphic process traces Leakage, earth Groups Lifting instructions, controller add zones to Limit, earth leakage change header color...
Page 252 Mold Operator interface heat circuit test description heating maintenance alarms monitor, replace integrated earth leakage Operator interface, replacement event history Override, security assignments soft start routine setups startup Password, change user tuning, ART 2.0 Plot point, view Mold diagnostics 139–149 Power test deviation...
Page 253 Security Ratings, equipment assignments override Recording, data enable 175–183 Remote boost, Quick Set screen screens Remote standby, Quick Set screen settings list Report descriptions settings screen Restrictions of equipment use Security and administration Selection menus, screen Servicing the system Safety Setpoint limits, Quick Set screen general Setpoints, enter value with keypad...
Page 254 Temperature Warning errors control, hot runner Weights and dimensions management buttons Wet heater bake out open loop control Wiring, input staging, set types of control Zone edit settings, Quick Set Terms, glossary of screen Test display/hide zones automatic thermocouple wiring lock/unlock zones heat circuit zone name...

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