Mold-Masters M2 User manual

Original Instructions
M2 Controller
User Manual
with TS/KTS Console
Mold-Masters (2007) Limited
A Milacron Company

REMOVE AND KEEP THIS
SHEET SOMEWHERE SAFE
Every machine leaves our factory with two levels of
password protection. We recommend that you remove
this sheet in order to establish your own security.
User Password - unix
System Password - linux

© 2014 Mold-Masters (2007) Limited. All Rights Reserved.
Revised 1 Oct, 2014
IV
www.moldmasters.com
Table of Contents
Section 1 - Introduction .......................................................1-1
1.1 INTENDED USE.......................................................................................................1-1
1.2 AUDIENCE ...............................................................................................................1-1
1.3 REQUIRED USER SKILLS ......................................................................................1-1
1.4 RELEASE DETAILS .................................................................................................1-1
Section 2 - Global Support ..................................................2-1
Section 3 - Safety Instructions............................................3-1
3.1 SAFETY NOTICES - AN EXPLANATION.................................................................3-1
3.2 WHERE TO USE THIS EQUIPMENT .....................................................................3-1
3.2.1 MOLD HEATING..............................................................................................3-1
Section 4 - Overview ............................................................4-1
4.1 SPECIFICATION ......................................................................................................4-1
4.2 HOW TO ISOLATE THE CONTROLLER .................................................................4-2
4.2.1 SWITCHING ON..............................................................................................4-2
4.2.2 MOLD HEATING..............................................................................................4-2
4.3 SWITCHING OFF (THE CONTROLLER).................................................................4-3
4.4 SCREEN LAYOUT AND NAVIGATION ....................................................................4-4
4.5 MAIN PAGE..............................................................................................................4-5
4.6 DISPLAY PAGE – OTHER SYMBOLS AND WHAT THEY MEAN ...........................4-6
4.7 DISPLAY PAGE – MONITORING (KTS SCREEN) ..................................................4-7
4.8 DISPLAY PAGE – MONITORING (TSA2 WIDE SCREEN)......................................4-9
4.9 DISPLAY PAGE – AUTOMATIC RESIZING FOR FEWER ZONES .......................4-11
4.9.1 BIG PANELS..................................................................................................4-11
4.9.2 MEDIUM PANELS .........................................................................................4-11
4.9.3 NORMAL PANELS.........................................................................................4-11
4.10 DISPLAY PAGE – MONITOR (ZOOM).................................................................4-12
4.11 DISPLAY PAGE – START, STOP AND MORE .....................................................4-13
4.12 MAIN PAGE – HOW TO SET TEMPERATURE ...................................................4-14
4.13 MORE PAGES......................................................................................................4-16
4.13.1 EASYVIEW..................................................................................................4-16
4.13.2 GRAPH PAGE .............................................................................................4-16
4.13.3 THE TOOLSTORE PAGE............................................................................4-16
4.13.4 THE PICTURE PAGE ..................................................................................4-17
4.13.5 THE UTILITIES PAGE .................................................................................4-17
4.13.6 THE TESTING PAGE ..................................................................................4-18
4.13.7 THE SETUP PAGE ......................................................................................4-18
4.14 USER INPUT........................................................................................................4-19
Section 5 - Set Up.................................................................5-1
5.1 STAGES INCLUDED IN SETTING UP A CONSOLE ...............................................5-2
5.1.1 CREATE A FIRST TOOL .................................................................................5-2
5.1.2 SET UP TOOL PARAMETERS........................................................................5-2
5.1.3 CONFIGURE SYSTEM SETTINGS ................................................................5-2
5.1.4 SET UP OPERATING PARAMETERS ............................................................5-2

© 2014 Mold-Masters (2007) Limited. All Rights Reserved.
Revised 1 Oct, 2014
V
www.moldmasters.com
5.2 CREATE A FIRST TOOL ..........................................................................................5-3
5.3 SETUP PAGE - CARDS THAT MAY BE DETECTED...............................................5-4
5.4 PRE-CONFIGURED SETUP VALUES .....................................................................5-5
5.5 HOW TO CONFIGURE THE CONTROL CARDS ....................................................5-6
5.6 SET THE TOOL PARAMETERS...............................................................................5-8
5.7 THE TOOL PARAMETERS ......................................................................................5-9
5.8 CONFIGURE THE TOOL & SYSTEM SETTINGS .................................................5-12
5.9 THE TOOL SETTINGS ..........................................................................................5-13
5.10 THE SYSTEM SETTINGS....................................................................................5-18
5.11 SET OPERATING PARAMETERS........................................................................5-21
5.11.1 SELECTING ZONES ...................................................................................5-21
5.11.2 TO SET PROBE AND MANIFOLD TEMPERATURES ................................5-23
5.11.3 TO SET SPEAR (BODY AND TIP) TEMPERATURES ................................5-24
5.11.4 TO SET CAVITIES, WATER FLOWS AND CHILLERS................................5-26
5.12 SAVE EVERYTHING TO A TOOL BANK..............................................................5-27
5.13 SET UP EASYVIEW PAGES................................................................................5-28
5.14 PASSWORDS AND USER ACCESS EXPLAINED ..............................................5-31
5.14.1 SET UP USER ACCESS .............................................................................5-32
5.14.2 CONFIGURE USERS..................................................................................5-34
5.14.3 LIST CURRENT USERS .............................................................................5-35
5.14.4 USER ADMIN OPTIONS .............................................................................5-36
5.14.5 CONFIGURE USER LIMITATIONS .............................................................5-37
5.15 MELT LEAKAGE DETECTION.............................................................................5-38
5.15.1 CONFIGURING AUTO LEAKAGE DETECTION.........................................5-38
5.16 SET TIME AND DATE ..........................................................................................5-40
5.17 UTILITIES - ENERGY PAGE................................................................................5-41
5.18 PRINT PAGE ........................................................................................................5-42
5.18.1 USING A LOCALLY CONNECTED PRINTER ............................................5-42
5.18.2 USING A REMOTE NETWORK PRINTER .................................................5-42
5.18.3 PRINTING TO A USB MEMORY STICK......................................................5-42
5.19 EVENT LOG AND EXPORT PAGES ....................................................................5-43
Section 6 - Operation ...........................................................6-1
6.1 LOG IN ....................................................................................................................6-2
6.1.1 LOG OUT.........................................................................................................6-2
6.2 CONTROL MODES FOR ALL ZONES.....................................................................6-3
6.2.1 CONTROL FOR INDIVIDUALLY SELECTED ZONES ....................................6-4
6.3 MORE ABOUT USING BOOST................................................................................6-5
6.4 USE DISPLAY PAGE TO CHANGE TEMPERATURES ...........................................6-6
6.5 USE THE DISPLAY PAGE TO CHANGE MODES ...................................................6-7
6.6 MORE ABOUT SLAVING ZONES ............................................................................6-8
6.7 ABOUT EASYVIEW PAGE .......................................................................................6-9
6.8 USE EASYVIEW TO CHANGE TEMPERATURES................................................6-10
6.9 USE EASYVIEW TO CHANGE MODES ................................................................6-11
6.10 PURGE SEQUENCE............................................................................................6-12
6.11 PRE-SET PURGE PARAMETERS .......................................................................6-13
6.12 CHECK ZONE PAST PERFORMANCE (GRAPH)...............................................6-14
6.12.1 INSPECTING THE LAST 5 OR 30 MINUTES ............................................6-14
6.12.2 INSPECTING THE LAST 24 HOURS..........................................................6-15
6.13 THE EVENT LOG PAGE ......................................................................................6-16
6.13.1 BEACON AND SOUNDER EXTENSION ....................................................6-20
6.14 TRAINING AND DEMONSTRATION MODE ........................................................6-21
6.14.1 ABOUT DEMO MODE .................................................................................6-21

© 2014 Mold-Masters (2007) Limited. All Rights Reserved.
Revised 1 Oct, 2014
VI
www.moldmasters.com
6.14.2 SELECT DEMO MODE ...............................................................................6-21
6.14.3 DE-SELECT DEMO MODE.........................................................................6-22
6.15 TOOL STORE PAGE ............................................................................................6-23
6.16 CREATE A NEW TOOL ........................................................................................6-24
6.17 RENAME A USED TOOL......................................................................................6-27
6.18 LOAD TOOL SETTINGS (LOCALLY) ...................................................................6-29
6.18.1 LOAD TOOL SETTINGS (REMOTELY) ......................................................6-29
6.19 SAVE TOOL SETTINGS.......................................................................................6-30
6.19.1 OVER-WRITING THE LAST SETTINGS WITH NEW SAVED SETTINGS .6-30
6.19.2 SAVE MODIFIED SETTINGS, WITHOUT LOSING EXISTING ONES .......6-31
6.20 DELETE A TOOL ..................................................................................................6-32
6.21 BACK-UP TOOL SETTINGS ................................................................................6-33
6.21.1 TO SAVE (BACKUP) ALL THE TOOLS: ......................................................6-33
6.21.2 TO SAVE (BACKUP) ONE SELECTED TOOL SETTING ...........................6-34
6.22 RESTORE TOOL SETTINGS...............................................................................6-35
6.22.1 TO RESTORE ALL THE TOOLS .................................................................6-35
6.22.2 TO RESTORE A SINGLE TOOL..................................................................6-36
6.23 SEQUENCE TOOLS AND SETTINGS .................................................................6-37
6.23.1 SETTING AN EXAMPLE STARTUP SEQUENCE FOR THIS EXAMPLE ...6-38
6.24 THE PICTURE PAGE ...........................................................................................6-39
6.24.1 TO VIEW AN IMAGE ...................................................................................6-39
6.24.2 TO LOAD A NEW IMAGE ............................................................................6-40
6.24.3 TO SAVE AN IMAGE ...................................................................................6-42
6.24.4 TO DELETE AN IMAGE ..............................................................................6-43
6.25 THE 4-CHANNEL INPUT/OUTPUT CARD:..........................................................6-44
6.25.1 DISPLAY PAGE ...........................................................................................6-44
6.25.2 QUAD WATCHDOG TIMER .......................................................................6-45
6.25.3 INPUTS........................................................................................................6-45
6.26 OUTPUTS ............................................................................................................6-46
6.27 DEFAULT INPUT/OUTPUT SELECTION AND CONNECTOR PIN TABLE .........6-47
6.28 HOW TO USE THE IO5 CARD FOR REMOTE TOOL SELECTION....................6-48
6.29 DYNAMIC REMOTE TOOL LOAD PROCESS.....................................................6-49
Section 7 - Maintenance.......................................................7-1
7.1 PRINT OUT FACILITY (TO PRINTER).....................................................................7-2
7.1.1 OPTION 1 - A SCREEN PICTURE .................................................................7-2
7.1.2 OPTION 2 - TABLE FORMAT..........................................................................7-2
7.2 PRINT OUT TO FILE................................................................................................7-3
7.3 EXPORT FACILITY ..................................................................................................7-5
7.4 SELF DIAGNOSTIC TESTS.....................................................................................7-7
7.4.1 WHY YOU MAY NEED TO CHANGE YOUR TEST PARAMETERS ...............7-7
7.5 HOW TO RUN A SELF DIAGNOSIS TEST ..............................................................7-8
7.5.1 TO SELECT SOME ZONES ............................................................................7-8
7.5.2 TO SELECT EVERY ZONE.............................................................................7-8
7.6 SYSTEM DIAGNOSIS RESULTS...........................................................................7-10
7.7 HOW TO INTERPRET THE TEST RESULTS ........................................................7-10
7.7.1 SATISFACTORY TEST..................................................................................7-11
7.7.2 UNSATISFACTORY TEST.............................................................................7-11
7.8 SERVICING AND REPAIRING YOUR CONTROLLER ..........................................7-12
7.8.1 REPLACEMENT PARTS ...............................................................................7-12
7.8.2 CLEANING AND INSPECTION.....................................................................7-12
7.9 HOW TO UPGRADE THE CONSOLE SOFTWARE ..............................................7-13
7.9.1 PREPARATION .............................................................................................7-13

© 2014 Mold-Masters (2007) Limited. All Rights Reserved.
Revised 1 Oct, 2014
VII
www.moldmasters.com
7.9.2 PROCEDURE................................................................................................7-13
Section 8 - Troubleshooting ................................................8-1
8.1 FAULT AND WARNING MESSAGES.......................................................................8-1
8.2 SYSTEM WARNING MESSAGES ...........................................................................8-4
8.3 INDIVIDUAL CONTROLLER CARD DIAGNOSTICS ...............................................8-4
8.4 TOUCHSCREEN - REMOVAL AND RECONNECTION ..........................................8-5
8.4.1 REMOVING A CONSOLE................................................................................8-5
8.4.2 RECONNECTING A CONSOLE......................................................................8-6
8.5 OTHER PROBLEMS WITH THE TOOL ...................................................................8-7
8.6 M2 FUSES................................................................................................................8-9
8.6.1 REPLACEMENT FUSES.................................................................................8-9
Appendix A - HRC Wiring Details.......................................A-1
Appendix B - Optional Cards..............................................B-1
Appendix C - Network Information ....................................C-1
Appendix D - Water Manifolds............................................ D-1
Appendix E - Sequence Valve Gate ................................... E-1

INTRODUCTION
© 2014 Mold-Masters (2007) Limited. All Rights Reserved.
Revised 1 Oct, 2014
1-1
www.moldmasters.com
1.1 Intended Use
This manual is intended for use with the M2-Series Controller together with
either the TS or KTS Console
It is written and prepared for Software Version – 14th January 2014
Mold-Masters Hot Runner Controllers such as this M2 series have been
designed as a multi channel temperature controller for use in Hot Runner
plastic molding equipment. They use feedback from thermocouples within the
nozzles and manifolds to give precise closed-loop temperature control.
Any other uses would fall outside the engineered intent of this machine which
may be a safety hazard and would void any and all warranties.
This manual is designed to cover most system common congurations. If you
need additional information specic to your system please contact your repre-
sentative or a Mold-Masters ofce whose location can be found in the “Global
Support” section.
1.2 Audience
This manual is written for use by skilled persons who are familiar with Hot
Runner Controllers and their terminology.
1.3 Required User Skills
Operators should be familiar with plastic injection molding machines and the
controls of such equipment.
Maintenance persons should have sufcient understanding of electrical safety
to appreciate the dangers of 3-phase supplies. They should know how to take
appropriate measures to avoid any danger from electrical supplies.
BEFORE YOU OPERATE THE CONTROLLER
We recommend that you read the manual fully before connecting up
or using the controller.
We recommend that you run a Self Diagnostic routine on page 7-8
to check that all zones are correctly sequenced and that there is no
cross-wiring between zones or between heater outputs and thermo-
couple inputs.
1.4 Release Details
Document Id Release Date Version
M2K_UM_EN_V3_3 01 October 2014 3
Our policy is one of continuous improvement and we reserve the right to alter
product specications at any time without giving notice.
Section 1 - Introduction

GLOBAL SUPPORT
© 2014 Mold-Masters (2007) Limited. All Rights Reserved.
Revised 1 Oct, 2014
2-1
www.moldmasters.com
Section 2 - Global Support
GLOBAL HEADQUARTERS
CANADA
Mold-Masters Limited
233 Armstrong Avenue
Georgetown, Ontario
Canada L7G 4X5
tel: [phone]
fax: [phone]
[email protected]
EUROPEAN HEADQUAR-
TERS
GERMANY
Mold-Masters Europa GmbH
Postfach/P.O. Box 19 01 45
76503 Baden-Baden, Germany
Neumattring 1
76532 Baden-Baden, Germany
tel: [phone]
fax: [phone]
[email protected]
ASIAN HEADQUARTERS
CHINA/HONG KONG/
TAIWAN
Mold-Masters (KunShan) Co, Ltd
Zhao Tian Rd
Lu Jia Town, KunShan City
Jiang Su Province
People’s Republic of China
tel: [phone]
fax: [phone]
[email protected]
SOUTH AMERICAN
HEADQUARTERS
BRAZIL
Mold-Masters do Brasil Ltda.
Estrada Municipal Mineko Ito,
nº4305 -
Loteamento Industrial Veccon Zeta
- Sumaré / SP
CEP: 13178-903
tel: [phone]
fax: [phone]
[email protected]
INDIA
Mold-Masters Technologies
Private Limited
# 247, Alagesan Road,
Shiv Building, Saibaba Colony.
Coimbatore T. N.
India 641 011
tel: [phone]
fax: [phone]
[email protected]
JAPAN
Mold-Masters K.K.
1-4-17 Kurikidai, Asaoku
Kawasaki, Kanagawa
Japan, 215-0032
tel: [phone]
fax: [phone]
[email protected]
UNITED KINGDOM
Mold-Masters (UK) Ltd
Netherwood Road
Rotherwas Ind. Est.
Hereford, HR2 6JU
United Kingdom
tel: [phone]
fax: [phone]
[email protected]
U.S.A.
Mold-Masters Injectioneering LLC
103 Peyerk Court
Romeo, MI 48065, USA
tel: [phone] (USA only)
tel: [phone]
fax: [phone]
[email protected]
Manufacturing Facilities
AUSTRIA / East and South
East Europe
Mold-Masters Handelsges.m.b.H.
Pyhrnstrasse 16
A-4553 Schilerbach
Austria
tel: [phone]
fax: [phone]
of[email protected]
CZECH REPUBLIC
Mold-Masters Europa GmbH
Hlavni 823
75654 Zubri
Czech Republic
tel: [phone]
fax: [phone]
[email protected]
FRANCE
Mold-Masters France
ZI la Marinière,
2 Rue Bernard Palissy
91070 Bondoue
tel: [phone]
fax: [phone]
[email protected]
Regional Ofces

GLOBAL SUPPORT
© 2014 Mold-Masters (2007) Limited. All Rights Reserved.
Revised 1 Oct, 2014
2-2
www.moldmasters.com
Regional Ofces - contd.
ARGENTINA
Sollwert S.R.L.
La Pampa 2849 2∫ B
C1428EAY Buenos Aires
Argentinia
tel: [phone]
fax: [phone] Ext. 35
sollwert@bertel.com.ar
AUSTRALIA
Comtec I P E
1084 South Road,
Edwardstown, South Austra-
lia 5039
PO Box 338, Magill,
South Australia 5072
tel: [phone]
fax: [phone]
[email protected]
BULGARIA
Mold-Trade OOD
62, Aleksandrovska St.
Ruse City
Bulgaria
tel: [phone]
fax: [phone]
[email protected]
DENMARK, NORWAY, SWEDEN
H. & G. Englmayer A/S
Skenkelsoevej 9, Postbox 35
DK - 3650 Oelstykke, Denmark
tel: [phone]
fax: [phone]
[e-mail]
FINLAND
Oy Scalar Ltd.
Viertolantie 12
11120 Riihimaki, Finland
tel: [phone]
fax: [phone]
info@scalar.
GREECE
Ionian Chemicals S.A.
21 Pentelis Ave.
15235 Vrilissia
Athens
Greece
tel: [phone]
fax: [phone]
m.pavlou@ionianchemicals.
gr
IRELAND
Bray Engineering Services
Mr. Liam Shortt
Unit F3
Network Enterprise Business
Park
Kilcoole, Co. Wicklow, Ireland
tel: [phone]
fax: [phone]
info@BrayEngineeringSer-
vices.com
ISRAEL
ASAF INDUSTRIES Ltd.
29 Habanai Street
PO Box 5598 Holon 58154
Israel
tel: [phone]
fax: [phone]
[email protected]
ITALY
Commerciale Isola SPA
Via G.B. Tiepolo 3
35010 Cadoneghe, (Padova)
Italy
tel: [phone]
fax: [phone]
[email protected]
PORTUGAL
Gecim LDA
Rua Fonte Dos Ingleses,
No 2
Engenho
2430-130 Marinha Grande,
Portugal
tel: [phone]
fax: [phone]
[email protected]
ROMANIA
Tehnic Mold Trade SRL
Str. W. A Mozart nr. 17
Sect. 2
020251 Bucharesti
Romania
tel: [phone]
fax : [phone]
[email protected]
RUSSIA
PORTMOLD Company LC
Gefsimanskie prudy 4,
141307 Sergiev Posad
Russia
tel: [phone]
fax: [phone]
[email protected]
VIETNAM
Mold-Masters
Singapore PTE. Ltd.
No 48 Toh Guan Road East
#06-140 Enterprise Hub
Singapore 608586
Republic of Singapore
tel: [phone]
fax: [phone]
[email protected]
KOREA
MM Systec Company, Ltd
J-502, Kuro Distribution Business Center
636-62, Kuro-Dong, Kuro-Ku,
Seoul, Korea
tel: [phone]
fax: [phone]
e-mail: [e-mail]
MEXICO
Intec-Plast S.A. de C.V.
185 Av. Once Bod 8
Col. San Juan, Xalpa
Iztapalapa 09850
México City, D.F.
tel: [phone]
tel: [phone]
fax: [phone]
e-mail: [email protected]
POLAND
Mold-Masters Europa GmbH
ul. Ratuszowa 11 - lok. 72
03-450 Warszawa
Poland
tel: [phone]
fax: [phone]
e-mail: [email protected]
SINGAPORE / MALAYSIA
INDONESIA / THAILAND
Mold-Masters Singapore PTE. Ltd.
No 48 Toh Guan Road East
#06-140 Enterprise Hub
Singapore 608586
Republic of Singapore
tel: [phone]
fax: [phone]
[email protected]
SPAIN
TEIN INGIENER, S.L.
C/ Sepúlveda 32
08015 - Barcelona - Spain
tel: [phone]
fax: [phone]
e-mail:
sandra.romero@tein-moldmasters.
com
TURKEY
MMG Consulting & Engineering
Yesil Çesme Sok No:30/3
Çiftehavuzlar 81060, Istanbul,
Turkey
tel: [phone]
fax: [phone]
[email protected]
International Representatives