Gammaflux GLC 2k User manual

Enter
Change Area
Automatic/
Manual Selectionl
Temperature Set Select
Zone select indication
Temperature holding set point
Low temperature alarm
Select
Zone Select/Status Area
GLC 2K Start Up Procedure
1 Dry Cycle Mold, Apply Full Tonnage, 3-4 Times (Pinch any wires in
advance of operation)
2 Turn Individual Zones “Off”
3 Turn “On” Main Disconnect
4 Select Zone or Zones, Press 1st Zone, Hold, Press Last Zone, Hold, Release.
All Zones Lit are Selected
5 Change Area – Select Temperature Set, Enter Set Point, Press Enter, All
Zones Selected will Change
6 Select Zone or Zones, Press 1st Zone, Hold, Press Last Zone, Hold, Release.
All Zones Lit are Selected
7 Change Area – Select Automatic/Manual Selection, Enter “0” for Automatic
Operation, Press Enter
8 Turn “On” Zone Power Switch. Apply Power to Manifolds first if required
by Manifold Supplier
9 Zones will read a Low Temperature Alarm, Zones are close or holding Set
Point When the Green Temperature Holding Set Point Light is Illuminated
Gammaflux
Sterling, VA USA Tel. [phone]
Wiesbaden, Germany Tel. [phone]
Ube, Japan Tel. [phone]
www.gammaflux.com; www.gammaflux.de
GLC 2k
Version 1.3
Advanced Setup/Troubleshooting
•Hot Runner Temperature Controller
•12 Zone Maximum per Tier
•1HBE-24 Female Connector for
Power per Tier (Standard)
•1HBE-24 Male Connector for
Thermocouple per Tier (Standard)
•Remote Mount Alarm Relay
•External Communications RS232/RS485

View Area
Actual
Temperature
Deviation from
automatic set point
Degree C if lit, degree F if dark Amps
Percent output
Select
Actual Value for zone
selected, if a group is
selected the lowest
zone is displayed
Zone Select Zone 1
Zone selected when lit
Alarm for zone when lit,
select zone, check alarm area
High temperature alarm
(+20°F Default)
(Selectable in
advanced setup)
Temperature holding
set point
Low temperature alarm
(-20°F Default)
(Selectable in
advanced setup)
Manual or % Operation
when lit
Zone Select Zone 2
Zone Select/Status Area
Alarm Area
High Temperature
Low Temperature
Thermocouple Open
Thermocouple Reversed
Thermocouple Pinched
Open Fuse
Shorted Heater
Open Heater
Clear Alarm
Turn Off External
Light/Alarm
+100 +10 +1
-100 -10 -1 Enter/confirm change
Select
Change Area
Trim – Permanent, automatic set point change for zone or zones
selected. (Select zones – press 1st zone and hold, press the last
zone, release, enter change amount, press enter, all zones lit will
change) (+/- 20º F Max)
Temperature set point, change/view
(Select zones – Press 1st zone and hold, press the
last zone, release, enter set point, press enter)
Manual % set point, change/view (Select zones – press 1st zone
and hold, press the last zone, release, enter % set point, press
enter, all zones lit will change)
Boost – Temporary increase to zones
selected, degrees increased selectable,
default in setup (20º F), Time increased
selectable in setup (1 min. default) (Select
zones – Press 1st zone and hold, press the
last zone, release, press boost – enter
boost amount, enter, all zones
lit will change (To cancel, press boost)
Standby – (all zones) Change automatic
set point to temperature in setup
(220º F default), cut manual % set
point in half (Press standby, press enter)
(To cancel press standby)
Automatic/manual selection (Select zones – press 1st zone hold,
press the last zone, release, enter 0 or 1, press enter)
“0”=Automatic or temperature control
“1”=Manual or % control
“I” = On, “O” = Off
Power Switch Zone 1

Advanced Set Up
Advanced Setup Guide – Level 2 Security to Change
The GLC 2K is shipped to the customer so that No set up work is required for basic operation. Set points in Automatic and
Manual may be entered and the zone will be controlled by turning on the zone’s power switch. Many customers require advanced
features to satisfy their operation. This page will describe the basics of “Advanced Set Up”. Please note that security level codes are
not standard. To place security on the GLC 2K you must activate security by selecting your own personalized security codes.
Access/Exit Advanced Setup
View Area
Change Area
To Access Advanced Set Up, Press both Select buttons at the same time,
hold and release.Selection LED’s go dark when in Setup Mode.
The View Area will display the Set Up Number.
The Change Area will display the CurrentValue.
To Scroll Up – Press the View Area Select Key
To Scroll Down – Press the Change Area Select Key
To Make a change – Press the + or - Keys.
To Confirm the Change – Press Enter.
To Set up the Controller please reference
the Advanced Set U
p
Guide.
Instructions
#Limit (Default) Explanation
(0) 0-4 (0) Restore Mold Set Up - Access Setup, 0-View Area, Select Mold Set Up 1-4 - Change Area, Enter
(1) 0-4 (0) Save Mold Set Up - Access Setup, 1-View Area, Save As 1-4 - Change Area, Enter
(2) +/- 100F or 50C (20F) Boost Set Point, Timed Automatic Temporary Set Point Change for the selected zones
(3) 999 Seconds (60 Sec) Boost Time Set Point - The amount of time the selected zone or zones will change temporarily
(4) 932F or 500C (932F) Automatic Set Point Limit - The Maximum Set Point the operator can enter in Automatic
(5) +/- 100F or 50C (20F) Temperature Deviation Alarm Set Point - Set Point activates temperature alarm at that # +/-
(6) 600F or 315C (220F) Standby Set Point - When Standby is Selected it will control to this number in Automatic
(7) -1 to 27 (0) Control Algorithm Adjustment, 0=Auto Select (1=Tip Tuning; 2=Man. Tuning). Manual Selections:
-1=Faster Control (Tips), 10=Tip; 11-17=Tip with increasing lag, 20=Manifold, 21-27=Manifold with increasing lag
(8) -1 to 2 (0) T/C Pinch Detection Time, 0 Normal = 100% Output, 20F in 5 Min. -1 Faster (Tips), 1-2 Slower (Manifolds)
(9) 0 or 1 (0) Slaved Power Up - Heat all zones to Set Point within 20F of one another, 0 - “Off” 1 – “On”
(10) 0 or 1 (0) Degree F or C Selectable, 0 = Degree F, 1= Degree C
(11) 0 or 1 (0) Type J or K Thermocouple Input, 0 = Type J, 1 = Type K
(12) 0 or 1 (0) Host Computer Protocol, 0 = Gammaflux Protocol (Mold Doctor, etc.), 1 = Euromap 17 Protocol
(13) 0-99 (0) Network Port Device Number – The address of the controller on the Euromap 17 Network.
(14) 0-3 (0) Host Baud Rate – Communication Speed; 0=9600, 1=4800, 2=2400, 3=1200
(15) - - - Reserved for Future Use
(16) - - - Reserved for Future Use
(17) 000 - 999 (None) Security Code Level 1 – You Must be in Level 2 to Change, Refresh procedure available, call the factory
(18) 000 - 999 (None) Security Code Level 2 – You Must be in Level 2 to Change, Refresh procedure available, call the factory
(19) 0-999 (Custom) Zone Finder – Activate Press 999, Hundreds show T/C inputs 1-3 Tiers, Tens/Ones show # of Output Modules
(20) 0 (0) LED Test - Enter 0, Press Enter. Turns “On” all LED’s for Troubleshooting
(21) 0-6 (0) Error Status, Select Zone, View Error. 0=No Error, 1=No Communication, 2=Zone Not Allocated,
3=Output Controller Not Receiving Temperatures, 4=No Sync/Lost Phase,
5=Communication Error/Checksum, 6=Communication Error/Exceeded Limit
(22) - - - Output Controller Software Version Number (Display Only), Select Zone, Version Displayed
(23) - - - Output Controller Software Revision Number (Display Only), Select Zone, Revision Displayed
(24) - - - Temperature Module Software Version Number (Display Only), Select Zone, Version Displayed
(25) - - - Temperature Module Software Revision Number (Display Only), Select Zone, Revision Displayed
(26) - - - Operators Panel Software Version Number (Display Only), Select Zone, Version Displayed
(27) - - - Operators Panel Software Revision Number (Display Only), Select Zone, Revision Displayed
(28) 000 - 999 (Level 2) Security Level Indicated, 0=Lockout, 1=Operator, 2=Supervisor. 0 - Enter, Drops one Level.
Elevate One Security Level at a Time with your Customized Code. Then Press Enter.

Basic Troubleshooting
General Troubleshooting – Turn “Off” Main Disconnect
Alarm Area
Clear Alarm – Turns Off External Light/Alarm
Thermocouple Pinched – TheThermocouple is
pinched or the controller thinks the thermocouple
is pinched. (Default: 100% output, must see +20°F
in 5 Minutes), Selectable detection times in
Advanced Setup. True Thermocouple Pinched –
The Thermocouple is Sensing the Temperature
Further away from the Heat Source than intended.
Without alarm, Temperature reads low, controller
applies power, runaway heat. False Thermocouple
Pinched – The heater is too small to heat the zone
or the T/C is located too far away.
Replace heater, move the T/C or adjust Alarm.
Open Heater – The Heater Connection is Broken
Somewhere, Follow General Troubleshooting.
Open Fuse – Turn “Off” Main Disconnect, Remove
top cover, locate zone module, Check both fuses.
Thermocouple Open – The Thermocouple
Connection is Broken Somewhere,
Follow General Troubleshooting
Low Temperature – The Temperature of the zone
selected is below the deviation band in Setup
(-20°F Default)
High Temperature – TheTemperature of the zone
selected exceeds the deviation band in Setup
(+20°F Default)
Shorted Heater –The Heater is Shorted or Exceeds
the Rating of the Controller, Follow General
Troubleshooting
Thermocouple Reversed –The Thermocouple
Connection is cross wired + to – at some
connection point.Visually inspect each connection
point, forType J US Standard Red wire should
connect to Red Wires, not Red to White.
1 Check Resistance from Pin to Pin, at the Mold. Thermocouple should read 3-5 ohms. Heater should read greater than 16 ohms. If there is no continuity (Open Line) =
Broken Connection, Open Heater or Open Thermocouple.
2 Check Resistance from Pin to Ground, at the Mold. Heaters Only – No Continuity (Open Line) is Good. Some Resistance is bad (Shorted).
3 Reattach the Cable to the Mold, Detach the Cable from the Controller. Check Resistance from Pin to Pin. If there is no Continuity (Open Line) = Connection broken
in the Cable Set or the connectors are not making contact.
4 Reattach the Cable to the Mold, Detach the cable from the Controller. Check Resistance from Pin to Ground. Heaters Only – If you see any resistance to ground,
wires are shorted in the cable set or the connectors are shorting to Ground.
5 At this point if everything is fine, the problem is in the Controller. (1) Remove the top cover, (2) Check Fuses on top of the Output Module, (3) Swap bad output
module into known good spot, Replace Cover, Test Zone – Same Problem = Bad Module. Problem not duplicated – return module to slot, Replace Cover,
Access Setup Code #21, Explanation on Advanced Set Up Page.
6 If the Problem is not explained, or you need spare parts please call Gammaflux at [phone] , [phone] or [phone] .
2
6
7
5
1
3
4
8
9
10
11
12
13
14
15
16
Module Power Connector
Communications Bus
(Below Power Connector)
Thermocouple Input Module
Output Switch (Operator Side)
Power Outputs (Zones 1-12)
1
2
3
9
Fuses
10
Output Module
11
Power Supply
12
CPU Board (Under Power Supply)
13
RS 232/RS 485 Communications
14
Resetable Alarm Output, Remote
Standby, Control Inhibit
15
Fan
16
T/C Inputs (Zones 1-12)
4
5
Input Power Cable
6
Ground Lug
7
Main Disconnect
8