Gammaflux TTC Setup guide

TTC
International interface
Advanced Setup/Troubleshooting
Version 2.0
English
450
C
449
TTC Scrolling
Errors
1
2
Row Scrolling
Select zones to scroll
Press both view area select and enter together
Selected rows will scroll
View zone(s) in a group
View rows automatically
Zone Scrolling
Select zones to scroll
Press both change area select and enter together
Selected zones will scroll
View zone(s) in a group individually
Change Area View AreaView Area
Select
Select
Enter
C
E-1
Power Up Error
E-0 = No zones found
E-1 = Configuration mismatch
Solutions (Change Area – Enter)
Instruct the interface to do one of the following:
1 – Read configuration from system (recommended)
2 – Send configuration to system from interface
3 – Locate zones (zone finder)
Menu Load Error
E-2 = Menu mismatch, will not load, press enter to clear
Gammaflux
Sterling, VA USA Tel. [phone]
Wiesbaden, Germany Tel. [phone]
Ube, Japan Tel. [phone]
Singapore Tel. [phone]
www.gammaflux.com; www.gammaflux.de

0 1 2 3
232
1
C
232
0
30
20
10
Row Selection Area
Row selected
Row in alarm
View Area
Actual value
Temperature
Select
% Output
Deviation from
automatic set point
AmpsDegree C if lit,
Degree F if dark
Change AreaZone Select /Status Area
Alarm Area
Group Selection Area
High temperature
(+20ºF/11ºC default)
Low temperature
(-20ºF/11ºC default)
Thermocouple (T/C) Open –
The T/C connection is broken
Thermocouple Reversed –
The T/C connection is wired
+ to - at some point
Thermocouple Pinched – The T/C is
pinched or the controller thinks it is
pinched. (Default: 100% output,
must see +20ºF/11ºC in 5 minutes).
True Pinch –Temperature reading too
far away to control – runaway.
False Pinch – Heater is too small to
heat the zone
Open Fuse – Fuse on module bad
Shorted Heater – The heater is
shorted or exceeds the maximum
rating of the module
Open Heater – The heater
connection is broken
Uncontrolled Output – The module
has an unregulated output. All zones
on module shut “off” automatically
Clear Alarm, turn off light/relay
“All Group” –
Selects all
zones in the
system
* “Custom Group” –
Stores user zone
group. Select
zones to save,
press custom
group button
until flashes
(5 seconds)
*Automatic
temperature
set point
change/ view
* Power “On”
(Lit when
all unlocked
zones are “On”)
* Power “Off”
(Lit when
all zones
are “Off”)
* Manual %
output
set point,
change/ view
Enter
Select
+10 0 +10 +1
-100 -10 -1
Trim – Permanent,
automatic set point
change for zone(s)
selected, (±20ºF / 11º C
default). Select zone(s),
enter change amount,
all selected zone(s)
will change
Boost – Temporary increase to
zone(s) selected. Temperature
and time limit adjustable in
advanced setup (To cancel boost,
press boost)
Standby – (selected zones)
Change automatic set point to
temperature in advanced setup
(220ºF/104ºC default); cut manual
% set point in half. May indicate
material protection/standby remote
input, see advanced set up.
(To cancel standby, press standby)
* Automatic/
manual/
locked
operation,
change/
view
Zone selected
when lit
Manual or %
operation when lit
Alarm for zone when lit.
Select zone,
check alarm area
High temperature alarm
(+20ºF/11ºC default)
selectable in advanced
setup
Temperature holding
set point (automatic) or
zone “On” (manual)
Low temperature alarm
(-20ºF/ 11ºC default)
selectable in advanced
setup
* Saved in menu

C
0
0
Advanced Setup
Advanced Setup Guide – Level 2 Security to Change
The TTC International interface is shipped to the
customer so that no setup 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 power. Many
customers require advanced features to satisfy
their operation. This page will describe the basics
of “Advanced Setup”. Please note that security
levels are not standard. To place security on the
TTC International Interface you must activate
security by selecting your own personalized
security codes.
Setup Number Scroll Up
Current Value Scroll Down
Access/Exit
Advanced Setup
Press both select
buttons at the same
time, hold and release.
Selection LED’s go
dark in advanced
setup mode.
# Limit (default) Explanation (*saved in menu)
(0) 0-10 (0) Restore mold setup – access advanced setup. 0 – view area. Select menu 1-10. Enter to restore
(1) 0-10 (0) Save mold setup – access advanced setup. 1 – view area. Select menu 1-10. Enter to save
(2) +/-100ºF/55ºC (20ºF / 11ºC) Boost temperature set point. 2 – view area. Amount of temperature added to automatic set point during a boost
(3) 0- 300 seconds (60) Boost time set point. 3 – view area. The amount of time boost is active
(4) -31 to 27 (0) Algorithm set point (view only). View auto tuning selection or manual tuning value.
(5) 0-1000ºF/537ºC (20ºF/11ºC) Temperature deviation alarm set point. Actual temperature activates individual zone alarm at this amount +/- set point
(6) 0-1000ºF/537ºC (220ºF/104ºC) Standby set point (individual). When standby is activated, all automatic zones in the standby group will control to this set point
(7) -31 to 27 (0) Control algorithm adjustment (individual). 0 = auto selection. To view actual tuning value select code 4
Manual Selections: 10 to 17 fast tuning with increasing lag. 20 to 27 slow tuning with increasing lag
-1 = very fast tuning; -17 to -10 fast manifold tuning with increasing lag. -27 to -20 very fast tuning with increasing lag
-30 and -31 ultra fast low mass tuning. P = auto selection tune performed (view area)
(8) 0 to 54.0 minutes (5) T/C pinched detection time (individual). 0 = normal (98+% output, 20ºF /11ºC in 5 minutes). Change alarm timer amount
(9) 0-1000ºF/537ºC (999ºF/537ºC) Critical over temperature alarm. If this temperature is exceeded for 8 seconds, all zones in automatic are turned “Off”
(10) 0-1000ºF/537ºC (999ºF/537ºC) Automatic set point limit. The maximum set point an operator can enter in automatic
(11) 0-100% (100%) Manual set point limit. The maximum set point an operator can enter in manual
(12) 0-1000ºF/537ºC (50ºF/28ºC) Boost limit. The maximum amount of degrees an operator can raise or lower the zone(s) during a boost
(13) 0-1000ºF/537ºC (100ºF/56ºC) Trim limit. The maximum amount of degrees an operator can permanently change the zone(s) during a trim
(14) 0 or 1 (0) Enable material protection input. Must see input repeat in time selected or will activate standby group. 0 = “Off”; 1 = “On”
(15) 0 to 1000 seconds (0) Material protection time. Amount of time from 22-132 VAC/VDC input signal to activate standby group unless signal repeats
(16) 0- 2 (0 = all zones) Set standby group. Select zone(s) to go into standby when activated by remote input. 0 = all; 1 = display; 2 = store
(17) 0- 2 (0 = all zones) Set slaved power-up group. Select zone(s) to heat within 20ºF / 11ºC of one another until set point. 0 = all; 1 = display; 2 = store
(18) 0- 4 (0) Power Priority™. 0 = (off). 1-4 = increased smoothing of power output. A = Power Priority™ is active (view area)
(19) 0 or 1 (0) Enabled slaved power-up. 0 = “Off”; 1 = “On”
(20) 0 or 1 (0) Degree F or C selection. 0 = “degree F”; 1 = “degree C”
(21) 0 or 1 (0) Type J or K thermocouple selection. 0 = “type J”; 1 = “type K”
(22) 0 or 1 (0) Zone power status on power up. 0 = “all zones turned Off”; 1 = “zones On when shut down last, stay On”
(23) - - - Reserved for future use
(24) - - - Reserved for future use
(25) 0- 999 (none) Security code level 1. You must be in level 2 to change. Refresh procedure available, call Gammaflux
(26) 0- 999 (none) Security code level 2. You must be in level 2 to change. Refresh procedure available, call Gammaflux
(27) 0- 999 (custom) Zone finder (locate zones). Finds new hardware, to activate enter 999. Displays number of zones available in the system
(28) 0 (0) LED test. To activate, enter 0. Turns “On” all LEDs for troubleshooting
(29) - - - Output module software version number (display only), select zone, version displayed
(30) - - - Output module software revision number (display only), select zone, revision displayed
(31) - - - T/C input software version number (display only), select zone, version displayed (16 zones per module)
(32) - - - T/C input software revision number (display only), select zone, revision displayed (16 zones per module)
(33) - - - Data concentrator software version number (display only), select zone, version displayed
(34) - - - Data concentrator software revision number (display only), select zone, revision displayed
(35) - - - Operator panel software version number (display only), version displayed
(36) - - - Operator panel software revision number (display only), revision displayed
(37) 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
Set individually by zone
Change Area View Area
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Basic Troubleshooting
General Troubleshooting – Turn “Off” Main Disconnect
Thermocouple (T/C) Open – The T/C connection is
broken, follow general troubleshooting
Thermocouple Reversed – The T/C connection is wired
+ to - at some point. Visually inspect each connection,
for type J US standard, red wire should connect to red
wires, not red to white
Open Fuse – Fuse on module bad. Turn “Off” main
disconnect. Locate module, check all fuses.
(Locate module light – press clear alarm button with
zone selected)
Shorted Heater – The heater is shorted or exceeds
the maximum rating of the module, follow general
troubleshooting
Open Heater – The heater connection is broken,
follow general troubleshooting
Clear alarm, turn off light/external relay. Press to
illuminate “find this module light” on zone
selected for 15 seconds
High Temperature (+20ºF/11ºC default) – The temperature of
the zone exceeds the deviation band in advanced setup
Low Temperature (-20ºF/11ºC default) – The temperature of
the zone is below the deviation band in advanced setup
Thermocouple Pinched – The T/C is pinched or the
controller thinks it is pinched. (Default: 98+% output,
must see +20ºF /11ºC in 5 minutes). True pinch – the T/ C
is sensing the temperature further away from the heat source
than intended. Without alarm, temperature reads low, controller
applies power, runaway heat. False T/ C pinch – heater is too
small to heat the zone or the T/C is located too far away.
Replace heater; move T/C or adjust alarm. Selectable detection
times in advanced setup
Uncontrolled Output – The module has an unregulated output.
All zones on module shut “Off” automatically
When the high temperature alarm is also illuminated (flashing),
the critical over temperature alarm has been activated
Alarm Area
Check resistance from pin to pin, at the mold. T/C should read 3-50 ohms at
room temperature. Heater should read greater than 8 ohms. If there is no
continuity (open line) = broken connection, open heater or open T/C
Check resistance from pin to ground, at the mold. Heaters only – no continuity
(open line) = good. Some resistance is bad, heater shorted
Reattach the cable to the mold, detach the cable from the controller. Check
resistance from pin to pin on the cable. T/C should read 3-50 ohms at room
temperature. Heater should read greater than 8 ohms. If there is no continuity
(open line) = broken connection, open heater or open T/C. The connection is
broken in the cable set or the connectors/pins are not making contact
Reattach the cable to the mold, detach the cable from the controller. Check
resistance from pin to ground on the cable. Heaters only – no continuity
(open line) = good. Some resistance is bad, heater shorted. The wires are
either shorted in the cable set or the connectors are shorting to ground
At this point if everything is fine, the problem is in the controller. (1) turn “Off”
main disconnect, (2) locate problem module, (3) check fuses on module,
(4) swap bad module into a known good location, (5) turn “On” main
disconnect, (6) test the zone. If the problem follows the module = bad module.
If the problem stays with the original zone, the error is between the module
and the connectors on the rear of the enclosure. If available, try replacing the
T/C input module for that module or the data concentrator (communications
module) for that module
If the problem is not explained, or you need spare parts, please contact:
Gammaflux USA Tel. [phone]
[email protected]; www.gammaflux.com
Gammaflux Europe Tel. [phone]
[email protected]; www.gammaflux.de
Gammaflux Asia Pacific
Japan Tel. [phone]
Singapore Tel. [phone]
[email protected]
Output module
Thermocouple input module
Data concentrator
(communications module)
Power supply
(under data concentrator)
Module communications cable
Module power input/output
connector
Main disconnect
Thermocouple input connector
Power output connector
Auxiliary input connector
Auxiliary output connector
Interface power connector
Interface communications
connector
Ground lug
Fan
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