Mold-Masters TempMaster MT Series User manual

version 4
Original Instrucons
User Manual

REMOVE AND KEEP THIS
SHEET SOMEWHERE SAFE
MT Controllers come with a xed password which is
entered via the two arrow keys.
The Password is:
(up, down, up, up, down)
followed by a check mark

Table of 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
1.8 Trademarks and Patents ....................................................................................1-3
Section 2 - Global Support ..............................................2-1
2.1 Manufacturing Facilities ......................................................................................2-1
2.2 Regional O󰀩ces .................................................................................................2-1
2.3 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 Disposal ............................................................................................................3-12
3.9 MT/MT2 Controller User Hazards .....................................................................3-13
Section 4 - Overview ........................................................4-1
4.1 Specication .......................................................................................................4-2
4.2 TMXL/MT Compatibility ......................................................................................4-2
4.3 Tool Connections ................................................................................................4-3
4.4 Controller Power Supplies ..................................................................................4-3
4.5 Filter Option ........................................................................................................4-3
4.6 Switch On and O󰀨...............................................................................................4-3
4.6.1 Switch On ..................................................................................................4-3
4.6.2 Switch O󰀨 Individual Modules ....................................................................4-3
4.6.3 Switch O󰀨 the Whole Controller .................................................................4-3
4.6.4 Switch O󰀨 Individual Zones .......................................................................4-4
4.7 Controller Cabinet ...............................................................................................4-4
4.7.1 Controller Modules ....................................................................................4-5
4.8 How the MT Controller Works .............................................................................4-6
4.8.1 Set the Ramp Feature (On / O󰀨) ...............................................................4-6
4.9 Program Menus ..................................................................................................4-7
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MT Controller User Manual

Section 5 - Setup ..............................................................5-1
5.1 Introduction .........................................................................................................5-2
5.2 Set Zone Numbering ..........................................................................................5-3
5.3 Set the Temperature Scale .................................................................................5-5
5.4 Change Zone PID Characteristics ......................................................................5-7
5.5 Set the Ramp Feature .......................................................................................5-9
5.6 Set Boost Value ................................................................................................5-11
5.7 Set Standby Value ............................................................................................5-13
5.8 Monitor Temperature Limits ..............................................................................5-15
5.8.1 Warning and Alarm Limits ........................................................................5-15
5.9 Set Ground Fault Detection ..............................................................................5-17
5.10 Set Mold Leak Detection ................................................................................5-19
5.11 Set Response to Thermocouple Failure .........................................................5-21
5.12 Restrict Access to Manual, Standby or Boost .................................................5-23
5.13 Extend Alarms for Manual, Standby or Boost Operation ................................5-25
5.14 Language ........................................................................................................5-27
5.15 Set the Required Zone Temperatures ............................................................5-28
Section 6 - Operation .......................................................6-1
6.1 Run Mode ...........................................................................................................6-1
6.2 OFF Mode (Single Zone) ....................................................................................6-2
6.3 O󰀨 Mode (Single Module) ...................................................................................6-2
6.4 Manual Mode ......................................................................................................6-3
6.5 Manual Mode - Power Level ...............................................................................6-4
6.6 Slave Mode .........................................................................................................6-5
6.7 Standby and Boost Mode ...................................................................................6-7
6.7.1 Standby – Whole Cabinet ..........................................................................6-7
6.7.2 Boost – Whole Cabinet ..............................................................................6-7
6.7.3 No Standby or Boost Option ......................................................................6-7
6.8 Standby Mode – Individual Zones ......................................................................6-8
6.9 Leaving Standby Mode .......................................................................................6-9
6.10 Boost Mode – Individual Zones ......................................................................6-10
6.11 Change Set Temperature (Auto or Manual) .................................................... 6-11
Section 7 - Maintenance...................................................7-1
7.1 Service and Repair The Controller .....................................................................7-1
7.1.1 Replacement Parts ....................................................................................7-1
7.1.2 Cleaning and Inspection ............................................................................7-1
7.2 Restore Factory Settings and Recalibration .......................................................7-2
7.2.1 Default Settings .........................................................................................7-3
7.2.2 Calibration Routine ....................................................................................7-3
7.2.3 Calibration Sequence ................................................................................7-3
7.2.4 M.Dis Option ..............................................................................................7-4
7.3 Fuses and Overcurrent Protection ......................................................................7-5
7.3.1 Fans ...........................................................................................................7-5
7.3.2 Controller Cards .........................................................................................7-6
7.3.3 Onboard Power Supply ..............................................................................7-6
7.3.4 Output Fuse Type: HRC High Speed .........................................................7-6
7.3.5 Input Fuse Type: Surface-Mount Quick-Blow ............................................7-6
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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
MT Controller User Manual

Section 8 - Troubleshooting ............................................8-1
8.1 Individual Card Diagnostics ................................................................................8-1
8.2 Other Possible Fault Conditions .........................................................................8-3
8.2.1 Rapid Temperature Fluctuations ................................................................8-3
8.2.2 Ground Fault Detection ..............................................................................8-3
8.3 Module Removal .................................................................................................8-3
Section 9 - Wiring Details ................................................9-1
9.1 Single Phase Supply Cable ................................................................................9-1
9.2 Three Phase Designation ...................................................................................9-2
9.2.1 Five Wire Star 380VAC ..............................................................................9-2
9.2.2 Set Power Terminal Block to STAR Conguration .....................................9-3
9.2.3 For Four Wire Delta 240V ..........................................................................9-4
9.2.4 Set Power Terminal Block To DELTA Conguration ...................................9-5
9.3 Filter Option ........................................................................................................9-6
9.4 Alarm Output .......................................................................................................9-6
9.5 Standard Tool Connections ................................................................................9-7
9.5.1 MT-02-02 ...................................................................................................9-7
9.5.2 MT-02-02 For UK and Europe ...................................................................9-7
9.5.3 MT-02-02 For India ....................................................................................9-8
9.5.4 MT-02-02 For North America .....................................................................9-9
9.5.5 MT-04-04 .................................................................................................9-10
9.5.6 MT-06-06 ................................................................................................. 9-11
9.5.7 MT-12-12 and MT-18-xx ..........................................................................9-12
9.5.8 MT-12-12 and MT-18-xx for UK and Europe............................................9-12
9.5.9 MT-12-12 and MT-18-xx for North America .............................................9-14
Index ......................................................................................I
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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
MT Controller User Manual

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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
MT Controller User Manual
List of Tables
Table 1-2 Units of Measure and Conversion Factors ...............................................1-2
Table 3-1 Safety Hazards .........................................................................................3-3
Table 3-2 Typical Safety Symbols .............................................................................3-7
Table 3-3 Energy Forms, Energy Sources and General
Lockout Guidelines ...........................................................................................3-11
Table 4-1 General Specications ..............................................................................4-2
Table 5-1 Factory Settings ........................................................................................5-2
Table 7-1 Factory Settings ........................................................................................7-3
Table 7-2 Fan Fuses .................................................................................................7-6
Table 7-3 Onboard Power Supply Fuse ....................................................................7-6
Table 7-4 Output Fuse Type .....................................................................................7-6
Table 7-5 Input Fuse Type ........................................................................................7-6
Table 8-1 Alarm Conditions .......................................................................................8-1
Table 9-1 Cable Markings for Single Phase Supply Cable
(MT-02-02) ..........................................................................................................9-1
Table 9-2 Cable Markings - 5 Wire Star ....................................................................9-1
Table 9-3 Cable Markings for Four Wire Star ...........................................................9-3
Table 9-4 HAN4A Pin Connections ...........................................................................9-5
Table 9-5 MT-02-02 Pin Conguration for UK and Europe .......................................9-6
Table 9-6 MT-02-02 Pin Conguration for India ........................................................9-7
Table 9-7 MT-02-02 Pin Conguration for North America .........................................9-8
Table 9-8 MT-04-04 Pin Conguration ......................................................................9-9
Table 9-9 MT-06-06 Pin Conguration ....................................................................9-10
Table 9-10 MT-12-12 / MT-18-xx Pin Conguration for UK
and Europe .......................................................................................................9-12
Table 9-11 MT-12-12 / MT-18-xx Pin Conguration for
North America (Plug 1) .....................................................................................9-13
Table 9-12 MT-12-12 / MT-18-xx Pin Conguration for
North America (Plug 2) .....................................................................................9-14

List of Figures
Figure 3-1 Injection molding machine hazard areas .................................................3-2
Figure 4-1 MT controller ...........................................................................................4-1
Figure 4-2 MT2 controller .........................................................................................4-1
Figure 4-3 MT Menu .................................................................................................4-7
Figure 4-4 MT2 Menu ...............................................................................................4-7
Figure 7-1 Fuse location on a controller card ...........................................................7-5
Figure 9-1 Connect the neutral - position shown by blue
arrow ...................................................................................................................9-2
Figure 9-2 Install the three way link ..........................................................................9-2
Figure 9-3 Remove the neutral wire - position shown by the
blue arrow ...........................................................................................................9-4
Figure 9-4 Install the three 2-way links .....................................................................9-4
Figure 9-5 HAN4A connector ....................................................................................9-5
Figure 9-6 Harting Han 10 A® insert for MT-02-02 ....................................................9-6
Figure 9-7 Harting Han 10 A® cut out dimensions ....................................................9-6
Figure 9-8 Harting Han 16 E® insert for MT-02-02 ....................................................9-7
Figure 9-9 Harting Han 16 E® cut out dimensions ....................................................9-7
Figure 9-10 Harting Han 10 E® insert for MT-02-02 .................................................9-8
Figure 9-11 Harting Han 10 E® cut out dimensions ..................................................9-8
Figure 9-12 Insert for MT-04-04 ................................................................................9-9
Figure 9-13 MT-04-04 cut out dimensions ................................................................9-9
Figure 9-14 Insert for MT-06-06 ..............................................................................9-10
Figure 9-15 MT-06-06 cut out dimensions ..............................................................9-10
Figure 9-16 Inserts for MT-12-12 and MT-18-xx ..................................................... 9-11
Figure 9-17 MT-12-12 AND MT-18-xx cut out dimensions -
UK and Europe .................................................................................................9-12
Figure 9-18 MT-12-12 and MT-18-xx inserts (Plug 1 and Plug 2) ..........................9-13
Figure 9-19 MT-12-12 AND MT-18-xx cut out dimensions -
North America ...................................................................................................9-14
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© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
MT Controller User Manual

Section 1 - Introduction
The purpose of this manual is to assist users in the integration, operation and
maintenance of the MT and MT2 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 MT Series controllers have been designed as a multi-channel
temperature controllers 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, and they are 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
MT-UM-EN-00-04-5 July 2019 04-5
1.3 Warranty Details
Warranty details are provided with your order documentation.
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.
1-1
© 2020 Mold-Masters (2007) Limited. All Rights Reserved.
INTRODUCTION
MT Controller User Manual