Mold-Masters TempMaster M1 Plus Series User manual

User Manual
version 6
Original Instrucons

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

Contents
Section 1 - Introduction ...................................................1-1
1.1 Intended Use ......................................................................................................1-1
1.2 Release Details ..................................................................................................1-1
1.3 Warranty Details .................................................................................................1-1
1.4 Returned Goods Policy.......................................................................................1-1
1.5 Movement or Resale of Mold-Masters Products or Systems .............................1-1
1.6 Copyright ............................................................................................................1-2
1.7 Units of Measure and Conversion Factors .........................................................1-2
Section 2 - Global Support ..............................................2-1
2.1 Corporate O󰀩ces................................................................................................2-1
2.2 International Representatives.............................................................................2-2
Section 3 - Safety..............................................................3-1
3.1 Introduction.........................................................................................................3-1
3.2 Safety Hazards ...................................................................................................3-2
3.3 Operational Hazards...........................................................................................3-5
3.4 General Safety Symbols.....................................................................................3-7
3.5 Wiring Check ......................................................................................................3-8
3.6 Lockout Safety....................................................................................................3-9
3.7 Electrical Lockout .............................................................................................3-10
3.7.1 Energy Forms and Lockout Guidelines....................................................3-11
3.8 Grounded Earth Connection.............................................................................3-12
3.9 Disposal............................................................................................................3-12
3.10 M1 Plus Controller User Hazards ...................................................................3-13
3.10.1 Operational Environment.......................................................................3-13
Section 4 - Overview ........................................................4-1
4.1 Specication .......................................................................................................4-1
4.2 The Controller Cabinet .......................................................................................4-2
4.2.1 Controller Modules.....................................................................................4-2
4.2.2 Thermocouple Inputs .................................................................................4-2
4.2.3 Central Processor Units (CPUs)................................................................4-2
4.2.4 Output Triacs .............................................................................................4-2
4.2.5 Power Supply.............................................................................................4-2
4.3 Screen Layout ....................................................................................................4-3
4.4 Main Page ..........................................................................................................4-4
4.4.1 Monitoring..................................................................................................4-4
4.5 Main Page – Display Options .............................................................................4-5
4.6 Main Page - Start, Stop and More Options.........................................................4-6
4.7 More Pages ........................................................................................................4-7
4.8 The User Interface..............................................................................................4-9
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© 2021 Mold-Masters (2007) Limited. All Rights Reserved. M1 Plus Controller User Manual

Section 5 - Setup ..............................................................5-1
5.1 Introduction.........................................................................................................5-1
5.2 Setup the Console ..............................................................................................5-2
5.2.1 Create a First Tool .....................................................................................5-2
5.2.2 Setup Tool Parameters ..............................................................................5-2
5.2.3 Congure System Settings ........................................................................5-2
5.2.4 Setup Operating Parameters.....................................................................5-2
5.3 Create the First Tool ...........................................................................................5-2
5.4 Cards That May Be Detected .............................................................................5-3
5.5 Congure the Control Cards...............................................................................5-4
5.5.1 Set Zone Types..........................................................................................5-4
5.6 Precongured Setup Values ...............................................................................5-5
5.7 Congure the Controller .....................................................................................5-6
5.8 Global Parameters..............................................................................................5-7
5.9 Save the Congured Settings.............................................................................5-9
5.10 Set the Tool Parameters .................................................................................5-10
5.11 Tool Parameters..............................................................................................5-11
5.12 Set the Operating Parameters........................................................................5-13
5.12.1 Choose Zones .......................................................................................5-13
5.12.2 Set Probe and Manifold Temperatures ..................................................5-14
5.12.3 Save Settings to the Tool Bank..............................................................5-16
5.12.4 Setup Other Utilities...............................................................................5-16
5.12.5 Utilities Parameters................................................................................5-17
5.13 Password Security..........................................................................................5-20
5.13.1 Edit the System Password.....................................................................5-20
5.13.2 Edit the User Password .........................................................................5-20
5.13.3 Set the Password Timer.........................................................................5-20
5.13.4 Password Override ................................................................................5-20
5.14 Password Options ..........................................................................................5-21
5.14.1 Password Enabled.................................................................................5-21
5.14.2 Password Disabled................................................................................5-21
5.14.3 Password Active Times..........................................................................5-21
5.15 Password Application Table............................................................................5-22
5.16 Congure a Printer .........................................................................................5-23
5.17 More Utilities Function Buttons.......................................................................5-24
5.17.1 Export ....................................................................................................5-24
5.17.2 Exit.........................................................................................................5-24
5.17.3 Quad IO ................................................................................................5-24
Section 6 - Operation .......................................................6-1
6.1 Isolate the Controller ..........................................................................................6-1
6.1.1 Switch On ..................................................................................................6-1
6.1.2 Switch O󰀨 (Shutdown) ...............................................................................6-1
6.2 Control Modes for All Zones ...............................................................................6-2
6.3 Change or Set Zone Temperatures ....................................................................6-4
6.4 Change Modes ...................................................................................................6-5
6.5 Control for Individually Selected Zones ..............................................................6-6
6.6 More About Boost Mode .....................................................................................6-6
6.6.1 Manual Boost Display................................................................................6-6
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6.6.2 Remote Boost Display ...............................................................................6-7
6.7 More About Zone Slaving ...................................................................................6-7
6.8 Purge Function ...................................................................................................6-7
6.8.1 Mechanical Purge......................................................................................6-7
6.8.2 Chemical Purge .........................................................................................6-8
6.8.3 Congure Purge Parameters.....................................................................6-9
6.8.4 Preset Purge Parameters ..........................................................................6-9
6.8.5 Record a Color Purge Cycle....................................................................6-10
6.9 Check Zone Settings ........................................................................................6-10
6.10 Graph a Zone’s Past Performance .................................................................6-11
6.11 Alarms.............................................................................................................6-13
6.11.1 Mode Window ........................................................................................6-13
6.11.2 Status Window .......................................................................................6-14
6.11.3 Identify Zone Alarms ..............................................................................6-14
6.11.4 Beacon and Sounder Extension ............................................................6-15
6.12 Card Indicators ...............................................................................................6-15
6.13 Training and Demonstration Mode .................................................................6-15
6.13.1 About Demo Mode.................................................................................6-15
6.13.2 Select Demo Mode ................................................................................6-16
6.13.3 Deselect Demo Mode ............................................................................6-17
6.14 Use the ToolStore Page..................................................................................6-18
6.15 Create a New Tool ..........................................................................................6-19
6.16 Rename an Existing Tool................................................................................6-20
6.17 Load Tool Settings Locally..............................................................................6-22
6.18 Save Tool Settings (Remotely) .......................................................................6-23
6.18.1 Overwrite with Saved Settings...............................................................6-23
6.18.2 Save Old and New Settings...................................................................6-24
6.19 Delete a Tool...................................................................................................6-25
6.20 Backup Tool Settings ......................................................................................6-26
6.20.1 Backup All Tools.....................................................................................6-26
6.20.2 Backup One Selected Tool Setting ........................................................6-27
6.21 Restore Tool Settings .....................................................................................6-28
6.21.1 Restore All Tools ....................................................................................6-28
6.21.2 Restore a Single Tool.............................................................................6-29
6.22 QCIO - 4-Channel Input / Output Card ...........................................................6-30
6.22.1 Inputs.....................................................................................................6-30
6.22.2 Outputs ..................................................................................................6-31
6.22.3 Default Input / Output Selection and Connector Pin Table ....................6-32
Section 7 - Maintenance...................................................7-1
7.1 Print Out Facility .................................................................................................7-1
7.2 Export Facility .....................................................................................................7-2
7.3 Check Touchscreen Alignment ...........................................................................7-4
7.4 Self Diagnostic Tests ..........................................................................................7-5
7.4.1 Change Test Parameters ...........................................................................7-6
7.5 Run a Self Diagnostic Test .................................................................................7-6
7.6 System Diagnosis Results..................................................................................7-8
7.7 Interpret the Test Results....................................................................................7-8
7.7.1 Satisfactory Test ........................................................................................7-8
7.7.2 Unsatisfactory Test ....................................................................................7-8
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© 2021 Mold-Masters (2007) Limited. All Rights Reserved. M1 Plus Controller User Manual

7.8 Service and Repair The Controller ...................................................................7-10
7.8.1 Replacement Parts ..................................................................................7-10
7.8.2 Cleaning and Inspection ..........................................................................7-10
7.9 Upgrade the Software.......................................................................................7-10
7.9.1 Preparation ..............................................................................................7-10
7.9.2 Procedure ................................................................................................7-11
7.10 Fuses and Overcurrent Protection..................................................................7-11
7.10.1 Replacement Fuses...............................................................................7-11
7.10.2 Supplementary Fuses............................................................................7-11
7.10.3 Controller Card Fuses............................................................................7-12
Section 8 - Troubleshooting ............................................8-1
8.1 Individual Controller Card Diagnostics ...............................................................8-1
8.2 Fault and Warning Messages .............................................................................8-2
8.3 System Warning Messages ................................................................................8-5
8.4 Other Issues .......................................................................................................8-5
Section 9 - Hot Runner Controller Wiring Details..........9-1
9.1 Three Phase Designation - Star / Delta Option ..................................................9-1
9.1.1 Set Power Rail to Star Conguration.........................................................9-2
9.1.2 Set Power Rail to Delta Conguration .......................................................9-3
9.2 Filter Option ........................................................................................................9-4
9.3 Alarm Output / Auxiliary Input .............................................................................9-4
9.4 USB Port.............................................................................................................9-4
9.5 Standard Tool Connections ................................................................................9-5
9.6 Touchscreen Schematic .....................................................................................9-7
Index ......................................................................................I
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M1 Plus Controller User Manual
© 2021 Mold-Masters (2007) Limited. All Rights Reserved.

The purpose of this manual is to assist users in the integration, operation
and maintenance of the M1 Plus controller. This manual is designed to cover
most system congurations. If you need additional information specic to your
system please contact your representative or a Mold-Masters o󰀩ce whose
location can be found in the “Global Support” section.
1.1 Intended Use
The M1 Plus Series controller together with the MTS console is an electrical
distribution and control device designed as a multi-channel temperature
controller for use in hot runner plastic molding equipment. It uses feedback
from thermocouples within the nozzles and manifolds to give precise
closed-loop temperature control, and it is designed to be safe during
normal operation. 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 written for use by skilled persons who are familiar with
injection molding machinery and their terminology. Operators should be
familiar with plastic injection molding machines and the controls of such
equipment. Maintenance persons should have su󰀩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.
1.2 Release Details
Table 1-1 Release Details
Document Number Release Date Version
M1P-UM-EN-00-05-10 July 2019 5-10
M1P-UM-EN-00-06 January 2021 6
1.3 Warranty Details
For current warranty information please refer to the documents available from
our website: https://www.moldmasters.com/support/warranty or contact your
Mold-Masters representative.
1.4 Returned Goods Policy
Please do not return any parts to Mold-Masters without pre-authorization and
a return authorization number supplied by Mold-Masters.
Our policy is one of continuous improvement and we reserve the right to alter
product specications at any time without giving notice.
1.5 Movement or Resale of Mold-Masters
Products or Systems
This documentation is intended for use in the country of destination for which
the product or system was purchased.
Mold-Masters takes no responsibility for documentation of products or
systems if they are relocated or resold outside the intended country of
destination, as stated on the accompanying invoice and/or waybill.
Section 1 - Introduction
1-1INTRODUCTION
© 2021 Mold-Masters (2007) Limited. All Rights Reserved. M1 Plus Controller User Manual