Mold-Masters TempMaster XL-2 Series User manual

XL-2-Series
user manual
revision 1.1
www.moldmasters.com

Amendment Record XL-2 Manual
Page 2 Mold-Masters®Revision 1.1
Amendment Record XL-2 Series Manual
Issue Date Amendments Author Authorised
1.0 July 04 First Issue DT JN
1.1 Nov 05 Re-organized format DT JN
Copyright © 2004 Mold-Masters®Developments
This manual is intended for use with the XL-2 Series Controller
Our policy is one of continuous improvement and we reserve the right to alter product
specifications at any time without giving notice.

XL-2 Manual Contents
Revision 1.1 Mold-Masters®Page 3
Contents
Amendment Record .........................................................................................2
Contents ..........................................................................................................3
Specifications...................................................................................................4
Safety Instructions ...........................................................................................5
Welcome..........................................................................................................6
Installation........................................................................................................7
Switching "On" and "Off"..................................................................................8
Navigation........................................................................................................9
XL-2 Operation Diagram ................................................................................12
The Controller Cabinet...................................................................................13
How the XL-2 Controller Works......................................................................14
Setting up your controller ...............................................................................15
Running your controller..................................................................................19
Customizing your controller ...........................................................................23
Troubleshooting .............................................................................................27
Appendix A ....................................................................................................30
Index ..............................................................................................................35

Specifications XL-2 Manual
Page 4 Mold-Masters®Revision 1.1
Specifications
The following are general specifications. The actual controller supplied may differ in
specified options.
Supply Voltage 380v 3 phase 50Hz with neutral, others available
220/60Hz Delta
Control Method PIDD self optimising
Operating Range 0…450°C
Control Accuracy +/-1°C
Earth Leakage
Measurement
Earth leakage measurement on individual cards
(set at 100KΩ)
Thermocouple input Iron Constantan Fe/Con type 'J', type ‘K’, or type 'L'.
Power output 16A/3600W
Temperature scale Centigrade (Celsius) or Fahrenheit
Output Overload
protection
16A super-quick acting (FF) fuse
Card Diagnostics LED's Zone1, Zone2, Ground Fault, T/C Fault, Temperature
Alarm, and Current Overload
Alarm Output Double-pole change-over volt-free contacts,
1A max burden
Interface Optional
Case Details Heavy duty metal cabinet

XL-2 Manual Safety Instructions
Revision 1.1 Mold-Masters®Page 5
Safety Instructions
DO NOT enter the cabinet without first ISOLATING the supplies –
there are unguarded terminals 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.
Safety Notices - an explanation
Within this manual, safety instructions are marked as follows:
A WARNING symbol and message, shown here, identifies 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.
WARNING
WARNING

Welcome XL-2 Manual
Page 6 Mold-Masters®Revision 1.1
Welcome
Mold-Masters®welcomes you to their XL-2 temperature
controllers for hot runner injection moulding tools. This particular
member of the proven family of Mold-Masters Hot Runner
Controllers is user friendly and retains the standard control
facilities associated with other Mold-Masters controllers.
How to use this manual
The purpose of this manual is to give you a complete
understanding of how best to use the controller and to assist
where there are problems or faults.
The “Navigation” section contains a brief technical description of
the system components and a portrayal of the Mold-Masters
operating philosophy that facilitates precision temperature control.
The following chapters then take you carefully through the stages
of setting up, and running, a new control system. After considering
system maintenance the final sections look at trouble shooting to
assist in the unlikely occurrence of a system fault.

XL-2 Manual Installation
Revision 1.1 Mold-Masters®Page 7
Installation
Where to use this equipment
Mold-Masters Hot Runner temperature controllers are designed
for use in the plastic injection moulding industry as temperature
controllers for hot runner systems as commonly used in mould
tools. The controllers must not be used in residential, commercial
or light-industrial environments. Furthermore, they must not be
used in an explosive atmosphere or where there is a possibility of
such an atmosphere developing.
They should be installed in a clean dry environment where the
ambient conditions do not exceed the following limits:
* Ambient temperature 0 to +50°C.
* Relative Humidity 90% (non-condensing)
When in use this equipment does not emit audible noise in excess
of 10dBA.
Controller — Tool Connections
The various connections to the system using the cables supplied
with the equipment are specified in Appendix A.
Controller Power Supplies
The control cabinet can be manufactured to accept a wide range
of supplies and sequence of phases. Refer to the serial plate in
the controller cabinet for confirmation of the supply requirements.
If the local supply is outside the specified range please contact our
Service department for advice.
Tel.: [phone]
(1) 800-450-2270
Fax: [phone]
WARNING

Switching "On" and "Off" XL-2 Manual
Page 8 Mold-Masters®Revision 1.1
Switching "On" and "Off"
The main Power Switch is a rotary Switch at the back of the
cabinet. This Switch is sufficiently rated to disconnect the total
load current during switch “On” and switch “Off”. You can use a
suitably- sized padlock, or similar device, to lock the switch in the
“Off” position to prevent operation during maintenance.
Although the main switch has the capacity to switch the whole
system “Off”, we recommend that you only do this in an
emergency situation. A sequenced method for switching “On” and
“Off” protects the controller and keeps the switched load to a
minimum to extend the life of the main Isolator.
Switching On
Once the controller card is on, it gets into “Run” mode
automatically to start heating the tool.
Switching Off (or Shutting Down)
We recommend that you use the controller to shut down the
heating load, and only use the main isolator to switch off the whole
system once it is idle.
1. Shut down the heating
Use I/O switch to turn off each controller card.
2. Shut down the Controller
Now use the Main Rotary Switch on the cabinet to isolate all the
power from the whole system.

XL-2 Manual Navigation
Revision 1.1 Mold-Masters®Page 9
Navigation
This part of the manual introduces you to the controller card to
show what facilities are available and what information is
available.
Main Screens
Once the controller card is turned on, it always shows
Temperature Display Screen of the first zone in controller card.
There are three main screens in total, they always display actual
temperature on top display, and bottom displays are set
temperature, current reading, and power output percentage in that
specific zone. A decimal point beside the top right digit indicates
the amount of output power.
Temperature Display ➞Current Display ➞Power Output Display
•Use to rotate through different screens
Zones Switching
There are two zones per controller card. The two blue LEDs on
the right indicate which zone’s information is currently shown.
Zones can be switched anytime in Temperature Display, Current
Display, or Power Output Display to show reading accordingly.
•Use to switch between two zones to view display.
Function Menu
In this menu, you can put the controller into particular working
mode. However, Program Menu is used for changing controller
set-up. Manual and boost mode can be set independently in each
zone; however, standby mode always activate in both zones when
the mould-tool is paused.
Manual Mode (Hnd) ➞Standby Mode (tdn) ➞Boost Mode (tUP)
➞Program Mode (Prog)
•From any of the main screens, press and hold for at least 2
seconds to get into Function Menu.
•Use or to scroll through the menu.
•Press to enter into your desire mode, or press to get
back to Temperature Display Screen without changing to other
mode.

Navigation XL-2 Manual
Page 10 Mold-Masters®Revision 1.1
Program Menu
Within this menu there are a number of controls that are provided
for you to customize your controller. You can select this menu
from the Function Menu only. Each zone has its own program
menu items to meet its own needs; however, there are some
items shared by two zones. Refer to “Customize your controller”
section for detailed explanation on each parameter in the menu.
•In Function Menu, use to scroll to “Prog”, and then press
to enter into Program Menu.
•Scroll through the menu by using or to. Top display
shows menu item, bottom shows setting. You cannot change
setting when bottom display is flashing.
•Press to gain access for any changes by, bottom display
then stays.
•Use or to change setting, press to save the change.
Bottom display starts flashing again. If bottom display stays,
pressing to escape from Program Menu without changing
setting.
•After changes are made, press to return to Temperature
Display Screen.