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
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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

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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
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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
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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
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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
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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

GLOBAL SUPPORT
© 2014 Mold-Masters (2007) Limited. All Rights Reserved.
Revised 1 Oct, 2014
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Trademarks & Patents
ACCU-VALVE, DURA, FLEX-DURA FLEX-SERIES, FUSION-SERIES, HOT EDGE, INJECTION-
EERING, MASTERPROBE, MASTER-SHOT, MOLD-MASTERS, MELT-DISK, MOLD-MASTERS
ACADEMY, MASTER-SERIES, MASTERSOLUTION, MASTERSPEED, MERLIN, MOLD-MASTERS
SYSTEM, MPET, SCAN-MASTER, STACK-LINK, are the registered trademarks of MOLD-MASTERS
(2007) LIMITED.
Information contained herein is, to our best knowledge, true and accurate, but all recommen-
dations or suggestions are made without guarantee. Since the conditions of use are beyond
our control, Mold-Masters disclaims any liability incurred in connection with the use of our
products and information contained herein. No person is authorized to make any statement
or recommendation not contained herein, and any such statement or recommendation so
made shall not bind Mold-Masters. Furthermore, nothing contained herein shall be con-
strued as a recommendation to use any product in conict with existing patents covering any
products or its use, and no license implied or in fact granted herein under the claims of any
patents.
No part of this publication may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopy, recording, or any information storage and retrieval system without
permission in writing from the publisher. All details, standards and specications may be altered in ac-
cordance with technical development without prior notication.
May be manufactured under one or more of the following U.S. Patents:
5284436, 5299928, 5312242, 5326251, 5334008, 5334010, 5346388, 5366369, 5366370, 5387099,
5405258, 5421716, 5427519, 5429491, 5437093, 5441197, 5443381, 5460510, 5474440, 5494433,
5496168, 5507635, 5507636, 5536165, 5591465, 5599567, 5614233, 5641526, 5644835, 5652003,
5658604, 5695793, 5700499, 5704113, 5705202, 5707664, 5720995, 5792493, 5795599, 5820899,
5843361, 5849343, 5853777, 5935615, 5935616, 5935621, 5942257, 5952016, 5980236, 6009616,
6017209, 6030198, 6030202, 6062841, 6074191, 6077067, 6079972, 6095790, 6099780, 6113381,
6135751, 6162043, 6162044, 6176700, 6196826, 6203310, 6230384, 6270711, 6274075, 6286751,
6302680, 6318990, 6323465, 6348171, 6350401, 6394784, 6398537, 6405785, 6440350, 6454558,
6447283, 6488881, 6561789, 6575731, 6625873, 6638053, 6648622, 6655945, 6675055, 6688875,
6701997, 6739863, 6752618, 6755641, 6761557, 6769901, 6776600, 6780003, 6789745, 6830447,
6835060, 6840758, 6852265, 6860732, 6869276, 6884061, 6887418, 6890473, 6893249, 6921257,
6921259, 6936199, 6945767, 6945768, 6955534, 6962492, 6971869, 6988883, 6992269, 7014455,
7018197, 7022278, 7025585, 7025586, 7029269, 7040378, 7044191, 7044728, 7048532, 7086852,
7105123, 7108502, 7108503, 7115226, 7118703, 7118704, 7122145, 7125242, 7125243, 7128566,
7131832, 7131833, 7131834, 7134868, 7137806, 7137807, 7143496, 7156648, 7160100, 7160101,
7165965, 7168941, 7168943, 7172409, 7172411, 7175419, 7175420, 7179081, 7182591, 7182893,
7189071, 7192268, 7192270, 7198740, 7201335, 7210917, 7223092, 7238019, 7244118, 7252498,
7255555, 7258536, 7270538, 7303720, 7306454, 7306455, 7314367, 7320588, 7320589, 7320590
7326049, 7344372, 7347684, 7364425, 7364426, 7370417, 7377768, 7381050, 7396226, 7407379,
7407380, 7410353, 7410354, 7413432, 7416402, 7438551, 7462030, 7462031, 7462314, 7465165,
7470122, 7507081, 7510392, 7513771, 7513772, 7517214, 7524183, 7527490, 7544056, 7547208,
7553150, 7559760, 7559762, 7565221, 7581944, 7611349, 7614869, 7614872, 7618253, 7658605,
7658606, 7671304, 7678320, 7686603, 7703188, 7713046, 7722351, 7731489, 7753676, 7766646,
7766647, 7775788, 7780433, 7780434, 7794228, 7802983, 7803306, 7806681, 7824163, 7845936,
7850442, 7874833, 7877163, 7891969, 7918660, 7918663, 7931455, 7963762, 7988445, 7998390,
8062025, 8066506, 8113812, 8142182, 8152513, 8167608, 8202082, 8206145, 8210842, 8241032,
8280544, 8282386, 8308475, 8308476, 8328546, D525592, RE38265, RE38396, RE38920,
RE39935, RE40478, RE40952, RE41536E, RE41648E+ Pending.
© 2014 MOLD-MASTERS (2007) LIMITED. ALL RIGHTS RESERVED

SAFETY INSTRUCTIONS
© 2014 Mold-Masters (2007) Limited. All Rights Reserved.
Revised 1 Oct, 2014
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Section 3 - Safety Instructions
The M2-Series Controller is an electrical distribution and control de-
vice which is designed to be safe during normal operation.
It is essential that the user DOES NOT open the cabinet without rst
ISOLATING the mains supplies to the equipment - there may be termi-
nals inside the cabinet which may have a dangerous potential across
them.
Where a three-phase supply is used then this potential may be at 380
volts or higher.
3.1 Safety Notices - an explanation
A WARNING symbol and message, shown here, identies where
there may be a hazardous situation which, if not avoided, may result in
death or injury to personnel.
Most warnings pertain to electrical aspects and you must comply with
them to minimise any personal danger.
A CAUTION identies where there may be a hazardous situation
which, if not avoided, may result in damage to property.
Caution warnings present no personal danger, but may cause the
equipment to fail or lose its memory.
3.2 Where to use this equipment
The display console and controller cabinet together are designed for
use in the plastic injection moulding industry as temperature control-
lers for third party hot runner systems as commonly used in mold
tools. They must not be used in residential, commercial or light-indus-
trial environments. Furthermore, they must not be used in an explosive
atmosphere, or where there is a possibility of such an atmosphere
developing.
The HRC cabinet and Touch Screen console should be installed in a
clean dry environment where the ambient conditions do not exceed
the following limits:
• Temperature 0 to +35°C.
• Relative Humidity 90% (non-condensing)
CAUTION

SAFETY INSTRUCTIONS
© 2014 Mold-Masters (2007) Limited. All Rights Reserved.
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3.3 Check your wiring
Before you energise the system, pay special attention to how the sup-
ply to your controller is wired and how it is connected to the mold.
Lack of attention to detail causes errors such as:
• Incorrect wiring of mains supply phases into the controller.
• Crossing heater supply feeds with thermocouple detection (al-
though this error can be eliminated by the adoption of
Mold-Masters Standard connections).
In such cases wiring errors have caused equipment failure.
Mold-Masters (UK) Ltd. cannot be responsible for damage caused to
the controller by customer wiring and/or connection errors.
3.4 Mold Heating
After the consoles have started and the main display screen is visi-
ble then the controller may, or may not, start to heat up the zones; it
depends on how the Console Startup option is congured. (See page
5-19.)
If Console startup is set to “Stop” then the tool remains at zero pow-
er and at room temperature. If it set to any of the other three options
(Startup, Standby, or Run) the controller applies power to the zones
so that they heat up.

OVERVIEW
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Revised 1 Oct, 2014
4-1
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Section 4 - Overview
4.1 Specication
The following are general specications. The actual controller/console
supplied may have contractual variations and differ in some specied
options.
Supply Voltage 415Vac 3 phase 50/60Hz with neutral, Other
available include 240/380/400 and 480 volts in
Star or Delta conguration.
Voltage Bandwidth Stable within 20% supply voltage swing
Supply ground-leakage trip 300mA (note: this is for tool protection)
Unit Overload protection Miniature Circuit Breaker
Output overload protection 15A super-quick acting (FF) fuse on both legs
Power output 15A/3600W per zone
Ground Fault Detection 40mA per zone
Thermocouple input Type ‘J’, or type ‘K’
Control Method Self tuning PID
Soft-Start with Auto Tune Unique low voltage method for heater safety
Temperature scale Centigrade (Celsius) or Fahrenheit
Operating Range 0 - 472°C or 32 - 882°F
Control Accuracy +/-1°C
Printer Output Connector USB Port
Data Communications RS-232 serial, DB9 male connector
Communication Protocol SPI, VNC and client over Ethernet
Alarm Output Closing volt-free contacts - 5A max 230V
Remote Input Voltage free pair to signal Boost or Standby
Interface Full colour LCD touch screen (choice of sizes)
Case Details Heavy duty metal cabinet with swing up console
Sizes in mm
M2XS: 310w × 450d × 450h
M2S : 360w × 450d × 800h
M2M: 450w × 540d × 860h
M2L: 450w × 540d × 1330h
Filter Option
In countries where noise across power lines is a concern,
Mold-Masters recommends that you t the model 63AYC10B in-line
lter which is supplied by TC Connectivity.

OVERVIEW
© 2014 Mold-Masters (2007) Limited. All Rights Reserved.
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4.2 How to Isolate the Controller
The main Power Switch is sufciently rated to disconnect the total
load current during switch On and switch Off. To prevent its operation,
during maintenance, you can use a suitably-sized padlock, or similar
device, to lock the switch in the Off position.
4.2.1 Switching On
Main Cabinet
Switch ON the Main Isolator to energise the main cabinet.
KTS Console
The KTS Console has a main On/Off switch, at the rear right-hand side of the
console case, which is normally left switched “on”.
If left on then the console will start its boot up sequence as the cabinet is
powered up.
If the cabinet is switched on and the console does not start then check this
switch has not been turned off.
TSA2 Console
The TSA2 Console has a non-latching push button at the bottom right hand
side of the screen. After switching on the main cabinet on you then need to
briey press the start button until it illuminates. Release the button and the
console will start its normal boot-up sequence.
4.2.2 Mold Heating
After the consoles have started and the main display screen is visi-
ble then the controller may, or may not, start to heat up the zones; it
depends on how the Console Startup option is congured. (on page
5-19.)
If Console startup is set to “Stop” then the tool remains at zero pow-
er and at room temperature. If it set to any of the other three options
(Startup, Standby, or Run) the controller applies power to the zones
so that they heat up.
Console Switch
Console Switch

OVERVIEW
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4.3 Switching Off (the Controller)
We recommend that you use the console to shut down the heating
load, and only use the main isolator to switch off a dormant controller.
1. Shut down the heating.
On the Display page, choose [Stop] to reduce the heating to zero.
2. Shut down the Console
On the Utils page, choose [Exit] to shut down the Console Computer.
3. Shut down the Controller
Finally, use the <Main Power Switch> to isolate all the power to the
whole system.

OVERVIEW
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4.4 Screen Layout and Navigation
This page introduces the console to show what functions are available
and what information is given.
Navigation - Top of page
Top tabs to switch between the different pages.
Control - Side of page
Contains various command buttons that change from page to page.
Monitor & Information - Bottom of page
The lower left side shows Run Mode while the centre has messages,
such as prompts when a password is required.
On the right is operator name or admin-level, and lastly the controller
health status.

OVERVIEW
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4.5 Display Page
Can be used for
• Monitor – observe zone condition.
• Control – Start/Stop & Boost/Standby immediately available. All
other (“Standby, Shutdown, Stop“) available if you choose [Mode].
• Set – select any one or more zones to get [Set] function to set or
alter zone set-point or run modes.
Monitoring
This Healthy Zone shows:
Zone Name (user congurable)
Actual Temperature (may be Coarse at
whole degree steps or Fine at tenth of a
degree steps)
Scale and Set Temperature
Applied Power (%)
Applied Current (Amps)
Deviation - between Actual
& Set Temperature
Green text
on Black
background
Warning Zone
Deviation exceeds 1st stage (Warning)
Black Text
on Yellow
Background
Alarm Zone
Deviation exceeds 2nd stage (Alarm)
White text
on Red
Background
Fatal Error
Problem detected. (See page 6-37 for
details.)
White text
on Red
Background
Zone Off
Individual zone switched off

OVERVIEW
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4.6 Display Page – other Symbols and what
they mean
The previous page shows the more common parameters that you
expect to see on a temperature controller – however there are more
values or quantities which are as listed here:
Parameters that are Set
Temperature
Degree C Degree F
Flow (monitoring coolant ow with analogue or digital devices)
Gallons per minute Litre per minute
Pressure (monitoring coolant pressure with analogue devices)
Bar PSI
Other
Percentage (a set percent-
age power output for a zone
with no thermocouple or
closed loop)
Parameters that are Measured (and displayed)
(seen in lower half of panel)
Percentage (power output for
that zone)
Ampere (Cur-
rent measured
in a zone)
Delta (a “difference” symbol
used when comparing ow
or pressure between two
points)
Ohms (Resist-
ance value of
a zone cal-
culated from
stated voltage
and measured
current)
Reynolds Number
(an indication of the quality
of coolant ow in a circuit)
Blank (no quan-
tity currently on
display

OVERVIEW
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4.7 Display Page – Monitoring (KTS screen)
The basic page shows 40 zones where each zone shows:
Title, Actual, Set, Power, Current and Temperature Deviation.
To view more zones:
1. Use [Page p] or [Page q] to scroll up and down to see other
zones.
2. Choose [Display] button to show more zones 70 Zones - each
zone shows Title, Actual and Set .
3. Touch it again to show 110 Zones - each zone shows Title and
Actual.