PCS VC-1F-240 User manual

VC-1F-240
SINGLE ZONE TEMPERATURE CONTROLLER
Installation, Operation, & Maintenance Manual
VC-1F-240
TEMPERATURE CONTROL SYSTEM
OPERATING
INSTRUCTIONS
PAGE – 2 ELECTRICAL LOCKOUT
PAGE – 2 LIFTING APPARATUS
PAGE – 3 ANTI-ARCING FEATURE
PAGE – 3 STANDARD OPERATING FEATURES
PAGE – 4 ERROR CODES
PAGE – 5 ERROR ALARMS & INDICATORS
PAGE – 6 MENU OPERATING PROCEDURES
PAGE – 6 MENU PARAMETER CHART
PAGE – 6 MENU PARAMETER SETTINGS
PAGE – 8 TROUBLE SHOOTING
PAGE – 9 OTHER FALSE ALARMS
PAGE – 10 PRODUCT SPECIFICATIONS
**Please read these instructions thoroughly before using this instrument.**
IMPORTANT: Make sure the control system power switch is “OFF” and the input power circuit breaker is “OFF”
before performing any maintenance on the system.
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VC-1F-240
SINGLE ZONE TEMPERATURE CONTROLLER
Installation, Operation, & Maintenance Manual
ELECTRICAL LOCKOUT:
THE ELECTRICAL POWER SOURCE MUST BE LOCKED OUT WHENEVER ANYONE IS
WORKING ON THE EQUIPMENT.
Each maintenance person should have a personal padlock, with only one key. When working on any equipment this
person should use the padlock to lock out the electrical controls. It is most important that the only available key for the
lock be in the pocket of the person who is working on the temperature control equipment. If other persons work on the
same equipment, each should use their own different lock at a separate lockout station for the controls of the equipment.
Accidental startup of the equipment may have tragic results.
In no case should the removal of, or work be performed on, this temperature control system without following proper
electrical lockout procedures.
LIFTING APPARATUS:
Temperature control equipment, like any other type of equipment, requires normal periodic maintenance or relocation
if the user is to get the most for the investment in the equipment. One of the most flagrant of safety violations is the use
of inadequate and unsafe lifting equipment. The temperature control equipment or parts thereof should be assembled,
disassembled and moved with lifting facilities that have the capability of gently and slowly lifting and lowering the
equipment or various parts.
WHEN USING A CRANE OR FORK LIFT, OPERATE WITHIN ITS RATED CAPACITY, THE SAFE
RATED CAPACITY INCLUDES WEIGHT OF HOOKS, BLOCKS, AND ANY OTHER HANDLING
DEVICES, SUCH AS CABLES, SLINGS, SPREADER BARS, ETC. CONSIDER THE WEIGHT OF
ALL THESE AS PART OF THE LOAD TO BE LIFTED.
WARNING:
Before performing any work on this system, power must be turned off and secured. Before replacing fuses the cause of
the problem must be found and corrected and the system must be inspected for damage by a qualified technician.
Damage caused to system as a result of improper fuses will not be covered under warranty.
PLANT SAFETY:
The safety procedures mentioned here do not eliminate all safety hazards found in the area of operation. However, they
do highlight some procedures that have been found through long experience to improve safety conditions around
temperature control systems. International Temperature Control Inc. welcomes inquiries about other suggested safety
procedures for use around their equipment.
OUT OF SERVICE:
When the system is out of service, the control system must be turned off.
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VC-1F-240
SINGLE ZONE TEMPERATURE CONTROLLER
Installation, Operation, & Maintenance Manual
STANDARD OPERATING FEATURES
NORMAL OPERATIONS: Auto Keys
When the power switch on the front of the cabinet is turned on, the control system will look at the existing zone
temperature and determine if the “SOFT START” cycle is needed. The “SOFT START” cycle will be activated
any time the zone temperature is below 212° Fahrenheit when the module is turned on. Upon completion of the
“SOFT START” cycle the system will automatically switch to the automatic control mode. At this time the
control system will apply the necessary power to bring the process temperature up to the set point temperature
and maintain it, if set point temperature is above 212° Fahrenheit.
SETTING OPERATING TEMPERATURE: Up & Down Key
The set point temperature is normally preset at 400° Fahrenheit at the factory. You can change the set point
temperature at any time by pressing the “UP” arrow or “DOWN” arrow keys. The control system will remember
the last entered set point temperature when it is shut off.
SOFT START:
The “SOFT START” cycle applies a reduced output power to the heater at start up. The controller only activates
“SOFT START” if the initial process temperature at start up is below 212° F. The output power is gradually
increased while the zone temperature is below 212° F. The “SOFT START” cycle time is factory set at 5 minutes.
The time duration may be changed by scrolling through the MENU for the “SSt” parameter. (range 0 to 30
minutes)
MANUAL OPERATION KEY:
To operate the controller manually, press the “MAN” key. The percentage of output power will be displayed in
the set point window. Push the “UP” or “DOWN” arrow keys to change the output percentage. If thermocouple
feedback is not available the process temperature window will show the error code “tCO” or “tCr”. When
switching from “AUTO” to “MAN” operating mode, there is a bump less transfer of power. NOTE: Other
Alarms will not operate in the manual mode.
AMPS KEY:
When the “AMPS” key is pressed the process temperature (left) window will display the amperage draw of the
heater circuit. To display process temperature press the “AMPS” key again.
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VC-1F-240 SINGLE ZONE TEMPERATURE CONTROLLER
Installation, Operation, & Maintenance Manual
ERROR CODES & ALARMS INDICATORS:
ERROR CODES - Displayed in process temperature (upper) window:
Error Code
Description
tCO
An open thermocouple condition. Activates if there is a
break within the thermocouple circuit which prevents a
complete circuit from being made. Module switches to
“APO” mode if selected, otherwise “OFF”.
tCr
Thermocouple wires are reversed. Activates if the control
has detected a thermocouple wired backwards. System will
disable power to the heater.
tCs
The thermocouple is shorted. Activates when there is a
condition within the thermocouple, or thermocouple wiring
which is causing a short. Module switches to “APO” mode
if selected, otherwise “OFF”.
tOh
The controller triac or the heater circuit is open. controller
will disable power to the heater.
tSh
Main triac is shorted. An over temperature condition has
occurred and current flow is detected. The system will
disable power to the heater.
HiC
High Current overrun. The control system detects current
greater than the value set in the MENU “HcL” parameter
and will disable power to the heater.
ERRORS & ALARMS INDICATORS:
OPEN SHORTED THERMOCOUPLE PROTECTION:
In the event a thermocouple fails in the open condition after reaching set point temperature, the control system
will automatically control temperature with stored APO (Average Power Output) information if the MENU
feature “tcb” is set to “APO”, otherwise power is disabled. This feature only operates at set point temperature.
REVERSED THERMOCOUPLE PROTECTION
The controller will scrutinize actual voltage through the thermocouple. In the event a negative voltage is
detected, the “tCr” error code will be displayed, and power will be not be applied to the heater.
SHORTED THERMOCOUPLE INDICATION:
In the event a thermocouple fails to detect a rise in temperature while power is being applied to the heater, the
control unit will activate an alarm, and the “tCS” error code will be displayed. The module activates “APO” if
selected, otherwise “OFF”.
OPEN TRIAC/OPEN HEATER:
The controller will alert the operator in the event of an open triac or heater, by displaying a “tOh” error message
in the upper window. This condition is detected if the heater fails to maintain temperature or rise to set point
temperature and there is an absence of current flowing to the heater. Control unit will disable power to heater.
SHORTED TRIAC PROTECTION:
Within the circuitry of the control system are relays which disable power to the heater in the event the main triac
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VC-1F-240 SINGLE ZONE TEMPERATURE CONTROLLER
Installation, Operation, & Maintenance Manual
is shorted. In a situation when power to the heater is detected when the temperature is well above the set point, the
system will disable power to the heater. A “tSh” error code will then be displayed in the left window so damage
to the mold or heater can be averted.
HIGH CURRENT WARNING:
To help protect valuable molds and other related equipment, a safety device will alarm if a heater is drawing
current above its rated capacity. To set a current value, scroll through the MENU for the “HCL” feature, using
the “up” or “down” keys set a value just above the heaters maximum current draw. The control system will trigger
an alarm and disable power to the heater if current exceeds the set value. Utilizing this feature can save time and
expense by calling attention to a problem before damage occurs. In MENU the range may be set between 1.0 and
16.0 amps.
HIGH AND LOW TEMPERATURE ALARM:
The high and low temperature alarms have been factory set at +/- 30º F. If the zone temperature drops 30º below
the set point or if the temperature exceeds 30º above the set point, the alarm will activate and the “HIGH” or
“LOW” LED will activate.
MENU MODE
MENU MODE OPERATING PROCEDURE:
1. To enter the “MENU” mode, press the “MENU” key to scroll through menu until the desired option appears in
the process temperature (left) window. As you scroll through the menu, the current setting of each option will be
displayed in the set point (right) window.
2. To scroll through the menu, continue to press the MENU key until the desired feature code appears in the left
window.
3. To change the setting of a parameter displayed in the left window, press the “UP” or “DOWN” arrow key.
4. To set the parameter and exit the “MENU” mode, continue to press the “MENU” key until you reach the end of
the menu of features. The controller will restart after storing the new values.
CAUTION: While in the “MENU” mode, the system will not control temperature. Therefore it is
recommended that any changes be made at start up.
VC-1F-240 “MENU” Parameter Chart
CODE
FUNCTION
SETTINGS
C-F
Temperature display mode
ºC or (ºF)
AL
Audible Alarm
(On) or OFF
tCb
T/C break option (open/short)
(APO) – Average Power Output or OFF
SSt
Soft Start Time
0-30minutes (5)
HCL
Maximum Current
1.0 – 16.0 Amps (16.0)
J-K
Thermocouple Type
(J) or K
SSL
Soft Start Lock
(ON) or OFF
FPL
Front Panel Lockout
ON or (OFF)
**Factory settings in parenthesis.**
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VC-1F-240 SINGLE ZONE TEMPERATURE CONTROLLER
Installation, Operation, & Maintenance Manual
“MENU” - PARAMETER SETTINGS:
C-F CELSIUS OR FAHRENHEIT SETTING:
This parameter allows selection of either “C” or “F” temperature ranges – select “C” or “F”.
AL AUDIBLE ALARM SETTING:
Build in alarm – Select “ON” or “OFF”.
tCb THERMOCOUPLE OPEN PARAMETER SETTING:
(APO – Average Power Output). If this option is set to “APO” and thermocouple input is lost during
operation the control module will alarm and indicate that the thermocouple input is open. However, instead
of disabling power to the heater, the instrument will continue to apply the same average power to the heater
as applied just prior to losing the thermocouple signal. Factory set to “APO” but may be turned “OFF”.
SSt SOFT START SETTING:
Select 0 to 30 minutes. Factory set at 5 minutes.
HCL HIGH CURRENT LIMIT SETTING:
J-K
Select 1 – 16amps. Factory set at 16 amps. If the control system detects a current draw that exceeds the set
value, it will cut power to the heater and display an “HiC” warning. This option allows for setting a current
warning level just above the maximum draw of the heater. When the instrument detects a current greater than
the set value, it will alarm and shut off power to the heater.
THERMOCOUPLE TYPE:
This parameter allows theoperator to select either “J” to “K” type thermocouple, depending on the
requirements. Factory set to “J”.
SSL SOFT START LOCK:
This parameter prevents the Soft Start parameter from being overridden from the front panel. The Soft Start
cycle must be completed prior to entering either manual or automatic control mode. Factory set to “ON” or
select “OFF”.
FPL FRONT PANEL LOCK SETTING:
This parameter locks the front panel keys with the exception of “AMPS” & “MENU”. This lockout prevents
accidental changing of temperature settings, etc. Select “ON” for lock or “OFF” for un-lock. Factory set to
“OFF”.
TROUBLE SHOOTING
NOTE:
It is assumed that the VC-1F-240 hot runner temperature control system has been installed in accordance to the proper
instructions, that all wiring is correct and that power to the system is as specified on the controller.
Normally problems have two basic forms:
First, relate to the Controller, Wiring, Heaters or Thermocouples. These problems usually present themselves as
abnormal indications on the control system, i.e. absence of or blinking lights & displays and error codes.
Second, revolve around the design and/or manufacturing of the mold, the hot runner system (manifold), or the actual
processing conditions. These problems are often more difficult to identify and not covered in this manual.
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VC-1F-240 SINGLE ZONE TEMPERATURE CONTROLLER
Installation, Operation, & Maintenance Manual
PROBLEMS: SOLUTIONS:
The system will not turn on: 1. Check input power.
2. Check power cord connections.
3. Check that system is turned on.
4. Check fuses (Bussman ABC-15), if blown
check for wiring short.
5. Return defective system for repairs.
Temperature won’t settle on set point: 1. Give the control system more time to settle on set
point.
2. Molding process may have a wide variation in
temperature. Check to see if changes in display
temperature are in the same cycle as molding process.
Lights on unit dim: 1. Check actual input voltage, it should be same as
the units rating.
Tool is unusually cold: 1. Allow tool to warm up in Soft Start mode.
2. Check thermocouple/heater wiring.
3. Thermocouple/Heater not wired to proper
zone.
4. Thermocouple/Heater defective.
5. Make sure input power voltage is correct.
6. Return defective unit for repairs.
Temperature above set-point: 1. Thermocouple shorted or not wired correctly.
2. Triac shorted.
Tool overheats: 1. Temperature range set to Foor Co
2. Check thermocouple.
3. Replace triac.
4. Return defective unit for repairs.
Open thermocouple: 1. Check thermocouple & mold wiring.
Reversed thermocouple: 1. Correct thermocouple mold wiring.
Control Unit blows fuses: 1. Make sure heater size does not exceed the rating of
the control unit.
2. Make sure this is not the result of a shorted heater
or a short in the tool wiring. Do not replace unit’s
fuses until problem is corrected as damage may result.
NOTE: Blown fuses are not caused by the control
system, they are caused by an outside factor.
Temperature Oscillation: 1. This is usually caused by the location, or the
thermocouple being too far from the heater it is
controlling. Proper procedures dictate that the heater
& thermocouple should be within 1/2” of each other.
2. Oscillation can also be caused when the melt
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VC-1F-240 SINGLE ZONE TEMPERATURE CONTROLLER
Installation, Operation, & Maintenance Manual
Temperature is significantly above or below the set
point.
Temperature too high: 1. Normally this is caused by heat from adjacent
zones.
2. The melt temperature of the plastic is hotter than
the set point for the zone.
3. Thermocouple may not be wired to the same
controller as the heater.
No heat indication: 1. Heater is not connected.
2. Heater is too small.
3. Heater is burned out.
4. Heater is too far from thermocouple.
It is also possible something has occurred electrically to upset the microprocessor within the control
system. It indicates that there is more interference in the power line to the control system than the
filtering in the power supply can accommodate. A random occurrence is not cause for concern. The
solution usually is to connect the controller as close to the electrical service supply as possible, and
not to the molding machine, where motors, solenoids, etc can cause interference.
OTHER FALSE ALARMS:
•You may experience false alarms due to the time settings of certain options. The factory time settings may not be
the proper setting for your particular heating characteristics.
•Zones that heat slowly may need extended time for open heater (tOh) and shorted thermocouple (tcS) detection.
Conversely you may want to decrease the time for zones that heat to rapidly.
•If you are in a situation where mold changes are frequent and you do not want to take the time to adjust these
settings to the mold characteristics, you can set all of the settings to the highest level or in some cases turn them
off. However, this will substantially reduce the control system’s many diagnostic benefits and its ability to prevent
heater runaway and mold damage.
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VC-1F-240 SINGLE ZONE TEMPERATURE CONTROLLER
Installation, Operation, & Maintenance Manual
PRODUCT SPECIFICATIONS:
Voltage................................................................. 208 to 240vac, single phase
Current............................................................................. 15amps
Frequency............................................................. 50/60 Hz
Wattage............................................................................ 3600
Physical Configuration ........................................ An inclusive self-contained system
Size .................................................................. 6-1/2” Wide, 1-1/2” High, 10” Deep,
Weight ........................................................................ 3 #
DC Power Supply ................................................ Internally generated regulated and compensated
Control Systems Power Usage ............................ Less than 5 watts, excluding load
Set point Range .............................................................. 0oto 999oF (537oC)
Control Accuracy................................................. +/- 1oF (0.5oC) dependent on total thermal system
Calibration Accuracy ........................................... Better than 0.2% of full range
Operating Temperature Range............................. 32 to 120 degrees F
Thermocouple ...................................................... Type J, or Type K grounded or ungrounded
External Thermocouple Resistance..................... .High impedance potentiometer input allows long distance T/C
wiring
Thermocouple Isolation........................................Isolate from ground & supply voltage
Output Drive ........................................................ Internal solid state triac, zero crossing AC pulses
High/Low Te mperature Alarm............................ Factory set @ +/- 30 degrees F
Overload Protection ............................................. Fuses on both sides of AC line
Transient Protection ............................................ dv/dt and transient pulse suppression
Shorted Triac Heater Protection .......................... Highly sensitive, fast acting relays cut power to load
Power Line Isolation ........................................... Optically and transformer isolated from AC lines. Isolation voltage
greater than 2500 volts
Display................................................................. Dual LED displays, 3-digit, 7-segment
Manual Mode........................................................Maintains constant output power to within 1% of manual set power.
Adjustable from 0 to 100%
Soft Start .............................................................. Variable stepped voltage, phase fired
Soft Start Duration............................................... 5 Minutes (Adjustable) up to 212 degrees F
Soft Start Override Temperature........................... 212oF
Operational Modes ............................................. ..Soft Start precedes Auto Mode.
Thermocouple break overrides Soft Start and Auto Mode.
Reversed or shorted thermocouple overrides Soft Start and Auto
Mode.
Manual Mode overrides thermocouple break, reversed, shorted
thermocouple and Auto Mode.
Output is disabled during all fault conditions.
Cold Junction Compensation ............................... Automatic, better than 0.02oF/Fo(0.01oC/C)
Open Thermocouple Protection .......................... Automatically disables power to heater or Average Power Output
(APO). Selectable
Reversed Thermocouple Protection..................... Automatically disables power to heater.
Shorted Thermocouple Protection ....................... . Automatically disables power to heater or Average Power Output
(APO). Selectable
Warranty.......................................................................... 2-Years (exclude fuses and triac)
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