rohs/weee-compliant …...112 us 800-626-6653 canaa 800-387-6600 memilacroncom menet rohs/weee...

Smart Series®

ROhS/WEEE-COMPLIANT

TEMPERATURE CONTROLS

FOR hOT RUNNER SYSTEMS

112

U.S. 800-626-6653 Canada 800-387-6600 [email protected] www.dme.net

RohS/WEEE CompliantAdvanced Temperature Control for hot Runner Systems

Smart Series®Sm

art S

erie

s®

| Ad

vanc

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empe

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re C

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ol fo

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Run

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yste

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Capability/RohS and WEEE CompliantDMEoffers2-,5-,8-,and12-zonestandardmainframesfor15Aoperationand1-,2-,3-,and5-zonestandardmainframesfor30Aoperation.Componentslistedinthiscatalogsatisfyallinternationalcompliances.ThisincludesRoHS(RestrictionofHazardousSubstances)thatprohibitsorrestrictstheuseofsixpotentiallyharmfulmaterialsinelectronicequipment,andWEEE(WasteElectricalandElectronicEquipment)thatrequiresequipmentmadeafterAugust2005tobetakenbackandrecycledbythemanufacturer,ratherthanjust“thrownaway.”

Two-Year WarrantyAllDMEtemperaturecontrollersarenowcoveredbyatwo-yearwarranty,excludingfusesandtriacs.

Electrical Noise ImmunityToenhanceimmunityfromelectricalnoise,powerandthermocouplewireareharnessedinseparatewirewayswithinthebodyoftheframe.Additionalnoiseimmunityisprovidedthroughtheuseofshieldedthermocouplewires.

TheDMESmartSeries®istheresultofintensiveanddedicatedresearchwithagoalofdesigningtoday’smostversatileandreliablelineoftemperaturecontrollers.DMEachievedthisgoalbynotonlyincorporatingthelatesttechnology,butbyalsomakingcertainthateachcontrolleriseasytoinstallandaboveall…easytooperate.

heavy Duty Welded ConstructionWithyearsofexperiencebehinditsdesign,theSmartSerieslineisbuilttolastunderthemostrigorousconditions.Themainframe’swelded16gaugesteelconstructionensureslonglifeandpeakperformance.Coolingfansintheframearestrategicallylocatedtoincreaseairventilation,maintaincoolerrunningconditions,andpromotecontrolmodulereliability.

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Control ModulesSSM (15 and 30 AMP): TheSSMmoduleprovidesaccuratetemperaturecontrol,includingSmartStart®heaterdryoutcircuitry,thermocouplefaultdisplaysandauto/manualmodesofoperation.TheSSMfeaturesautomaticormanualbumplesstransferwhich,intheeventofathermocouplefault,providesswitchovertomanualmodeattheproperpowersettingtocontinuemoldinguntilthefaultcanbecorrected.Thismodulecanalsotriggerremotestandbyheat(idle),boost,off,andalarmfunctionswhenusedwiththeTASmodule.

DSS (15 and 30 AMP): Forthosewhorequireindependentdualdisplaysforprocessandsetpointtemperatures,theDSSistheidealchoice.TheDSSmodulealsofeaturesautomaticormanualbumplesstransfer.ThismoduleisalsofullycompatiblewiththeTASmoduleforstandbyheatandalarmfunctions.

Accessory ModulesTAS: TheTASmoduleprovidesover/undervisualandaudiblealarms,boost,andstandbyheatcontrolwithcontrolmodulesasstatedabove.TheTASmodulecanaccommodateupto63zonesofcontrol.Alarmisactivatedat±30°F.Seepages143-144fordetails.

NOTE: TheTASaccessorymodulerequirestheuseof“MFC”stylecommunicationsmainframes. Non-communicationsframesmaybeupgradedon-sitewithinstallablekits.

Simplified Power hook-UpConcern for user convenience didn’t stop with improved operation features. DME went one step beyond to ensure that the power hook-up procedure goes smoothly as well. For this reason, detailed schematics for various hook-ups are provided directly on all mainframe back panels. If it is ever necessary to change the configuration, these diagrams will help ensure safe and proper connections. All wiring diagrams can be referenced at the end of this section.

SSh Controller (10 AMP)

TheSSHisastand-alonesinglezonecontrolleridealforusewithhotspruebushingsormachinenozzles.

Smart Series®

CE COMPLIANT! DME Mainframes and Modules comply with Electromagnetic compatibility and low voltage directives

Smart Series

® | CE COM

PLIANT! Control M

odules

SSM1512

DSS1512

SSH1022

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Smart Series® Temperature Control Systems

Smart Series®

Mainframe

Circuit Breaker/Disconnect

Mold Power Cable

Thermocouple Cable

Mold Power Input Connector

Insulated Crimp Connector

Thermocouple Connector

Terminal Mounting Boxes

Mainframe Blank Panels

Module Replacement Fuses

Control ModulesTABLE OF CONTENTS PAGEIntroduction ................................................................................................................................ 112-113

Typical System Configurations .......................................................................................................115

SSH Single Zone Controller ..................................................................................................... 116-117

Single and Two-Zone Mainframes and Accessories .......................................................... 118-121

Single Zone High Power Mainframes ............................................................................................121

Smart Series Mainframes ........................................................................................................ 122-124

Digital Current / Voltage Monitor ...................................................................................................125

Smart Series Accessories ...............................................................................................................126

Standard Mainframe Connector Wiring ........................................................................................127

Wiring Diagram for Hot Runner Molding System and Smart Series / G-Series Mold Connectors .........................................................................128

Wiring Diagram for Hot Runner Molding System and High Power Smart Series / G-Series Mold Connectors ...................................................129

Cables and Connector Kits ...................................................................................................... 131-132

Mold Connector Pocket Layouts ............................................................................................ 133-134

Terminal Mounting Boxes ........................................................................................................ 135-136

SSM Temperature Control Modules ...................................................................................... 137-138

DSS Temperature Control Modules ....................................................................................... 139-140

TSM Temperature Control Module with Color Touch Screen ........................................... 141-142

TAS Temperature Alarm / Standby Heat Modules .............................................................. 143-144

Replacement Parts and Service Items .................................................................................. 145-147

Input Power Wiring Diagrams ................................................................................................ 148-150

Alternate Cable Configuration ................................................................................................ 151-153

Terminal Box Detail & Mold Connectors – European .................................................................154

Cable Storage Basket.......................................................................................................................155

1

2

3

4

5

6

7

8

9

10

11

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Smart Series

® | Typical System Configurations

Typical System Configurations

Smart Series®

MFS512G

MFS512G

MFS512G

MFS512G

PTC12TBTS

PTC8TBTS

PTC5TBTS

5 Zones of Control (15 AMP)

X5

MFP5G

TC5C10G

MPC5C10G

SSM1512DSS1512

X5

SSM3012DSS3012

X8

SSM1512DSS1512

SSM1512DSS1512

MFP8G

TC8C10G

MPC8C10G

MFP12G

TC12C10G

MPC12C10G

MFHP2GMFHP3G

TC5C10G

MPCH23C10G

MTC5G

MTC5G

PTCH23TBG

MFHP5G

TC5C10G

MPCH5C10G

PTCH5TBG

PICH5G

PICH23G

5 Zones of high Power Control (30 AMP)

2 or 3 Zones of high Power Control (30 AMP)



MFS512G

X12

SSM3012DSS3012

X2 or 3X

+ + + +

+ + + +

+ + + +

+ + + ++

+ + + ++

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Smart Series®

RohS/WEEE CompliantSmart Series® Single Zone Temperature Controller

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Key Features• Large Digital Display -Foreasierreadabilityoftemperature,%powerandfaults• Setpoint Pushwheel -Forsettingdesiredsetpointtemperature -Allowsadjustmentofsetpointbeforeturningpoweron•AUTO % Power Display -Shows%poweroutputwhileinAUTOmode -Indicatesaverage%powerrequirementonthermocouple failure -Adiagnostictoolforsolvingproblems

Switchable Options• Shorted Thermocouple Sensitivity Adjustment -Operationcanbetailoredtofastorslowreactiontimes -Sensitivitycanbeadjustedwithinternalswitches -Veryusefulforzoneswithlongstartuptimes• Switchable °C/°F Operation -Scaleindicatedatstartup• K Type Thermocouple Support• Cut Feature -Gaincutfeatureforsmallnozzlesandheaterswithungroundedinternalthermocouples

baCKwardThermoCouPle

TemP modefahrenheiT

TemP modeCenTigrade

ProCeSSTemP

manual% Power

fronT PanelloCKouT

loCKouTerror

ShorTedThermoCouPle

oPenThermoCouPle

bumPleSSTranSfer

Poweroff STandby

heaTbooST

Front Panel Digital LED Indicators

SSh1022/21 (10 AMP)

• Compact• Easy-to-use• Includesnew,improvedanduniquefeatures• Providesmicroprocessor-basedPIDcontrol• Moreaccuratethananalogorvariaccontrollers• Built-inthermocouplediagnostics• Idealforusewithahotspruebushing

or a machine nozzle

Operational Refinements• Improved SmartStart® -Amoregradualtemperatureriseleadstoamoreeffective heaterdryoutperiod, therebyextendingheaterlife -SmartStart®nowavailableasanoptioninmanualmode• SelectiveCycle® -Averyhighspeedpoweroutputapproach -Enablesaccuratetemperaturecontrolandlongerheaterlife•Bumpless Transfer -Whenathermocouplefailureoccurs,operationisautomatically continuedwithalearned%power -Uniquesoftwareaccuratelyassignspercentpowersetting• Third Fuse -Allowsfordisplayoflowtemperaturealarmwhentheload fusesareblown

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Smart Series®

RohS/WEEE CompliantSmart Series® Single Zone Temperature Controller

Smart Series

® | Smart Series Single Zone Tem

perature Controller

Controllerincludes19-footpowercord,matingmoldpowerandthermocoupleconnector(CKPTM1)andtwosparefuses(ABC10).Additionalcablesand/orconnectorsmustbeorderedseparately.SeePage121fordetailedinformationoncablesandconnectors. Warranty: Two year (excluding triac and fuses).

Front Panel Controls and Indicators1. Process Temperature Display:

Showsprocesstemperature,thermocouplefaultsandotheroperationalmodes.Displays%powerwhenswitch(3)ispresseddown.

2. Temperature Deviation Lights: Indicatesdeviationfromsetpoint.Outerlightsblinkatmorethan±40˚F(22˚C)fromsetpoint.

3. Auto / Manual / % Auto Power Switch: SelectsAUTOorMANUALcontrolmode.Shows%powerwhenpressedinto“%AUTO”position.

4. LED Mode Indicators: LeftLEDilluminatesduringmanualmode.RightLEDilluminateswhenpowerissuppliedtoheater.RightLEDblinksduringSmartStart®.

5. Setpoint Pushwheel: ThreedigitswitchprogramssetpointinAUTOmode.Righttwodigitsprogram%powerinMANUALmode.

6. Power On/Off Switch: ControlsACpowertomodule.

1. Mold Power and Thermocouple Output Connector: CKPTIC1connectstotheheaterandthermocouple.MatingconnectorCKPTM1issuppliedwithcontroller.

2. Power Input Cord: Nineteenfootcordsuppliespowertocontroller.PlugsuppliedwithSSH1021(120VAC)units.NoplugsuppliedwithSSH1022.

3. Load Fuse Receptacles: Providessafeandeasyreplacementofloadfuses.

Rear Panel

* ITEMS ORDERED SEPARATELY

SSh1022/21 (10 AMP)

1

3

2

35

21

6

4

CONTROLLERITEM NUMBER

VOLTS (VAC)

SSH1022 240

SSH1021 120

CABLE*ITEM NUMBER

LENGTH(FEET)

MPTC10 10

MPTC20 20

MOLD POWER ANDTHERMOCOUPLE CONNECTOR*

ITEM NUMBER

CKPTIC1

CKPTM1INCLUDED

Seepage119

Seepage119

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RohS/WEEE CompliantSmart Series® Single and 2-Zone Mainframes (10 AMP max.)

Smart Series®

ZONES

1

1

2

120

240

240

1200

2400

2400

MFP1G1

MFP1G

MFPR2G

ITEM NUMBERS** VOLTSWATTS

PER ZONECONNECTORS

SUPPLIED

(1) AC1512F (POWER IN)(1) CKPTM1 (POWER-T/C OUT)



Single and Two-Zone 10 AMP MainframesTheDMEPortable10AMPMainframesaredesignedforusewith10or15AMP*SmartSeriesorG-SeriesTemperatureControlModules.Mainframeissuppliedwith powerinputandpower-thermocoupleoutputconnectors.Circuitbreakerprovides safetyforoperation.Controlmodulesandcablesaretobeorderedseparately.

Recommended Mold Pocket Layout(For Mold Power-Thermocouple Input Connector CKPTIC1)

Single and Two-Zone 10 AMP Mainframes(50-60 hz, single phase)

NOTE: Maximumsafeoperatingamperageis10AMPSperzonewhenusing15AMPmodules.Ifapplicationwilldrawmorethan10AMPSperzone, use15AMPMainframe(MFFPR2G).

*UsermustinstallABC10(10AMP)fusesinthe15AMPcontrolmodulestoprotectthemainframe.

**Includesframeandconnectorslisted.Modulesandcablesorderedseparately.

NOTE: Replacementpowerconnectorsinframearealsoavailableonspecialorder.

DIMENSIONS(allframes)

7"Wx9"Hx10"D(9"Hdimensiondoesnot

includeconnectorsorhandle)

A: AC2024F(PowertoMainframe)

B: CKPTM1(Connectortoheater)

A: AC2024F(PowertoMainframe); AC1512FsuppliedwithMFP1G1

B: CKPTM1(Connectortoheater)

Thissingle-zonecontrollerisidealforusewithStraight-ShotandGate-Matehotspruebushings.

MFP1GMFP1G1

MFPR2G

Single zone, horizontal 10 amp controllers (SSH1022/21) also available. See page 116

A

B

A

B

ZONES ITEM NUMBERS ** VOLTS WATTS

PER ZONECONNECTORS

SUPPLIED

1 MFP1G1 120 1200 (1) AC1512F (POWER IN)(1) CKPTM1 (POWER-T/C OUT)

1 MFP1G 240 2400 (1) AC2024F (POWER IN)(1) CKPTM1 (POWER-T/C OUT)

2 MFPR2G 240 2400 (1) AC2024F (POWER IN)(1) CKPTM1 (POWER-T/C OUT)

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ITEM NUMBER

CKPTF1

CKPTF1L

Smart Series®

RohS/WEEE Compliant: Smart Series® Single and 2-Zone Mainframe Accessories (10 AMP)

Smart Series

® | Smart Series Single and 2-Zone M

ainframe Accessories

Mold Power-Thermocouple Input Connector

Replacement Connector Kits (for Controller & Cables)

Armored Mold Power-Thermocouple Cables

ASingle-ZonePower-ThermocoupleInputConnectorisavailableformountinginoronthemoldtoacceptthepower-thermocouplecablefromthemainframe.Waterresistant,theconnectorhasanintegralretaininglatchforasecurecableconnectionandnumberedscrew-typeterminalsforpowerandthermocoupleleadwires.*Canbemountedontopofmoldforusewithhotspruebushings.

Single-ZoneMoldPower-ThermocoupleCablesareconstructedofspecialleadwireforuseinhightemperatureenvironments,andareavailabletoconnectthemainframetotheconnectoronthemold.Availableinlengthsof10or20feet.Integralretaininglatchesonthemainframeandmoldconnectionsprovidesecurecableconnections.Connectorconfigurationsensureproperinsertionofcable.

AC1512F

AC2024F

CKPTM1

CKPTM1L

CKPTF1

CKPTF1L

MALE

1

23

45

W

B

-+

FEMALE

1

23

4

5

W

B

- +

forCKPTIC1andCKPTM1orCKPTM1L

forCKPTOC1andCKPTF1orCKPTF1L

PowerInputConnectorsForMainframe

MALE POWER – T/C CONNECTORS:CKPTM1isonMPTC10/20Cables;MateswithFrameorCKPTF1LonlyCKPTM1LMatesWithCKPTF1only

Power-ThermocoupleOutputConnector(forMainframeBulkhead)

For Use With MFP1G, MFP1G1, MFPR2G, SSh1022 and SSh1021

PTC210

FEMALE POWER – T/C CONNECTORS:CKPTF1isonMPTC10/20Cables;MateswithMoldorCKPTM1LonlyCKPTF1LMateswithCKPTM1only

ITEM NUMBER

PTC210

ITEM NUMBER

CKPTM1

CKPTM1L

ITEM NUMBER VOLTS

AC1512F 120

AC2024F 240

ITEM NUMBER

CKPTOC1

ITEMNUMBER

MPTC10

MPTC20

ITEMNUMBER

CKPTIC1

Terminal Mounting Boxes – Prewired (10 AMP) 5 PinTerminalMountingBoxesprovidetheeasiestandmosteconomicalmethodofmountingpowerandthermocoupleconnectorsonthemold.Constructedofplatedheavygaugesteel,eachboxisprecutanddrilledforquickmountingoftheboxtothemold(2-zone,prewiredterminalmountingboxwithterminalstripshownwithcoverplateremoved).

ITEM NUMBER

PTC210TBGTS

120


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Smart Series® 2-Zone Mainframes (15 AMP) and Accessories

Smart Series®

MFFPR2G

*IncludedwithMFFPR2G

AC1524M M2MJAC1240F

ForusewithMFFPR2Gonly

Two-Zone 15 AMP MainframesProvides15AMP(3600watts)perzone.ForusewithSmartSeriesorG-Seriesmodules.Suppliedwithbuilt-incoolingfan,powerinput,poweroutputandthermocoupleinputconnectors.Controlmodulesandcablesareorderedseparately.

Includesframeandconnectorslisted.Modulesandcablesorderedseparately.

NOTE: Replacementpartsinframearealsoavailablebyspecialorder. Seepages146-147.

FRAME DIMENSIONS:7"Wx9"Hx10"D(9"Hdimensiondoesnotincludeconnectorsorhandle)

TWO-ZONE 15 AMP MAINFRAME (240 VAC, 50-60 Hz, SINGLE PHASE)

Armored Mold Power –Thermocouple Cables (15 AMP)Single-ZoneMoldPower-ThermocoupleCableisconstructedofspecialleadwireforuseinhightemperatureenvironments.Thiscableconnectsthemainframetotheconnectoronthemold.Availableinlengthsof10or20feet.Retaininglatchesonthemoldconnectorprovidesecurecableconnections.

Terminal Mounting Boxes –Prewired (15 AMP)TerminalMountingBoxesprovidetheeasiestandmosteconomicalmethodofmountingpowerandthermocoupleconnectorsonthemold.Constructedofplatedheavygaugesteel,eachboxisprecutanddrilledforquickmountingoftheboxtothemold (2-zone,prewiredterminalmountingboxwithterminalstripshownwithcoverplateremoved).

NOTE: 6-pinconnectorsandpinsareavailableasaspecialorderonly.Thesearecrimpcontacts.(Seepages148-149formountingdimensions.)

ITEM NUMBERPTC2TBGTS

ITEM NUMBER

PTC0110

PTC0120ForusewithMFFPR2Gonly

ITEM NUMBERS DESCRIPTION

AC1240F* Female 240 VAC twist-lock power input connector(mates with male frame power input)

AC1524M* Male 240 VAC power output connector(mates with female frame power outputs)

M2MJ* Thermocouple mini-plug (mates with frame jack strip connector)

PTC2TBGTS 2 zone, pre-wired terminal mounting box with terminal strip(mounts to mold; mates with PTC0110 or PTC0129 cables)

ITEM NUMBER WATTS PER ZONE CONNECTORS SUPPLIED

MFFPR2G 3500(1) AC1240F (POWER IN)

(1) AC1524M (POWER OUT)(2) M2MJ (T/C IN)

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Smart Series®

Smart Series® Single Zone high Power Mainframes (30 AMP Max.)

Smart Series

® | Smart Series Single Zone High Pow

er Mainfram

es

NOTE: Overall dimensions shown include allowances for hardware (assembly screws) but not connectors

AC1240MAC1240F

M2MJ

MFHP1G

Single Zone 30 AMP Mainframes (240 VAC, 50-60 hz, Single Phase)

TheDMEPortableSingle-ZoneHighPowerMainframeisdesignedforusewith30AMPSmartSeriesorG-Seriestemperaturecontrolmodules.Mainframeissuppliedwithbuilt-incoolingfan,powerinput,poweroutput,andthermocoupleinputconnectors.Circuitbreakerprovidessafetyfortheoperator.Controlmodulesandcableareorderedseparately.

*Included with MFHP1G mainframe

FRAME DIMENSIONS:7"Wx9"Hx10"D(9"Hdimensiondoesnotincludeconnectorsorhandle)

TERMINAL MOUNTING BOXPTCH1TBG(Connectorsshownareorderedseparately)D: TCS1E: AC1240MI

Replacement Connectors and Accessories

ED

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MOLD POWER CABLE (10, 20 OR 30 FOOT)

THERMOCOUPLE CABLE (10, 20 OR 30 FOOT)

Smart Series®

Smart Series® Mainframes (15 AMP)

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Thermocoupleinput withretaining

latch

Power output with retaining

latch

WIDTH (W)

12"

9"

Main AC powerinput strain reliefCooling Fan

Smart Series® Mainframe (15 AMP Max.) Configurations The12configurationsillustratedbelowprovideawideselectionofzonecapacitiestosuitmostcontrolapplications.The5-,8-and12-zoneframes(MFP5,8,and12G)useindividualframesections.The16thru48zoneframesuse2,3,or4framesectionsrigidlyfastenedtogetherintooneprewiredintegralunitwhichrequiresonlyonemainACpowerinputconnection.TheCurrentVoltagemonitoroptionwillbefactoryinstalledwhenorderedatsametimeasMainframe.Controlmodules,cables,moldconnectorsandotheraccessoriesareorderedseparately(seetableonnextpage).

Eachframesection(MFP5G,MFP8G,andMFP12G)hasitsowncoolingfan.

Multi-sectionframeheightsaremultiplesof9"heightshown(e.g.MFP32Gis27"high).

MainACinputshownwillalwaysbeinbottomframesection.Forhigherpowerrequirements,individualpowerinputsandcircuitbreakerscanbefactoryinstalledineachsectionofastackframeonaspecialorderbasis.

ITEM NUMBER W*

MFP5G 143/16MFP8G 203/16MFP12G 283/16

*Dimensiondoesnotincludeconnectors

WORLDWIDE WIRING CAPABILITIESUnlessotherwisespecified,allSmartSeriesMainframeswillbesuppliedtoaccept240VAC,3phase,4-wire,50-60Hzinputpower.Wiringdiagram(includedontheaccesscover)illustratesthevarietyofothervoltage,phaseandloadbalancingarrangementspossible,suchas:(380-415V,3phase,5-wire,50-60Hz),(208-240V,singlephase,3-wire,50-60Hz)and(110-120V, singlephase,3-wire,50-60Hz). These wiring adjustments can be performed in the field to suit the requirements of the application. If specified at the time of original order, DME will supply the Mainframe required.

NOTE: Combinationframestoaccommodateboth15and30AMPmodules(withorwithoutcommunications)areavailablebyspecialorder.

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Smart Series

® | Smart Series

® Mainfram

es

Smart Series® Mainframes (15 AMP)

Smart Series®

NOTES: Combinationterminalmountingboxesareavailablewithconnectorsprewiredtoterminalstrips.Seepage135fordetails. Seepage136fordimensionaldetails.Forbelowflushmountingofconnectors,seemoldpocketlayoutsonpages133-134. Seepage125forcurrentvoltagemonitor.

SMART SERIES MAINFRAMES Optional Current Voltage Monitor

is Factory Installed in CV-Style Frames

CABLES AND MOLD CONNECTORS REQUIRED (Not included with Mainframes and Must be Ordered Separately)

Z O N E S

“MFP” TYPE FOR TEMP. AND

POWER CONTROL

“MFP” TYPE WITH CURRENT VOLTAGE

MONITOR

“MFCP” TYPE FOR TEMP. CONTROL AND COMMUNICATIONS

“MFCP” TYPE WITH CURRENT VOLTAGE

MONITOR

MOLD POWER CABLES C10=10 FT. C20=20 FT. C30=30 FT.

(SELECT LENGTH DESIRED)

THERMOCOUPLE CABLES C10=10 FT. C20=20 FT. C30=30 FT.


MOLD POWER INPUT CONNECTORS (INCL.

CRIMP CONNECTORS)

THERMOCOUPLE CONNECTORS

ITEM NUMBER

ITEM NUMBER (CV-STYLE)

ITEM NUMBER

ITEM NUMBER (CV-STYLE) QTY. ITEM

NUMBER QTY. ITEM NUMBER QTY. ITEM

NUMBER QTY. ITEM NUMBER

5 MFP5G MFP5GCV MFCP5G MFCP5GCV 1 MPC5C10G,C20GorC30G 1 TC5C10G,C20GorC30G 1 PIC5G 1 MTC5G




20 MFP20G MFP20GCV MFCP20G MFCP20GCV1 MPC8C10G,C20GorC30G 1 TC8C10G,C20GorC30G 1 PIC8G 1 MTC8G

1 MPC12C10G,C20GorC30G 1 TC12C10G,C20GorC30G 1 PIC12G 1 MTC12G












and and and and

and and and and

and and and and

and and and and

and and and and

NOTE:Fordetailsoncablesandconnectors,seepages130-132.


Z O N E S

ORDER ITEMS A and B or C(A)

FOR POWER INPUT CONNECTORS

(B) FOR THERMOCOUPLE CABLES

CONNECTORS

(C) COMBINATION POWER & TC

QTY. ITEM NUMBER QTY. ITEM


5 1 PIC512TBG 1 MTC5TBG 1 PTC5TBG




20 2 PIC512TBG1 MTC8TBG 1 PTC8TBG

1 MTC12TBG 1 PTC12TBG



1 MTC12TBG 1 PTC12TBGand and

and and

Z O N E S


FOR POWER INPUT CONNECTORS

(B) FOR THERMOCOUPLE CABLES

CONNECTORS

(C) COMBINATION POWER & TC











and and

and and

and and

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Smart Series®

Smart Series® high Power Mainframes (30 AMP)

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HIGH POWER MOLD POWER CABLE (10, 20 OR 30 FOOT)

THERMOCOUPLE CABLE (10, 20 OR 30 FOOT)(USE 5-ZONE CABLE) HIGH POWER

MOLD POWERINPUT CONNECTOR

INSULATEDCRIMPCONNECTORS(INCLUDED WITHMOLD POWERINPUTCONNECTOR)

MAINFRAME WITH CIRCUIT BREAKER DISCONNECT IS STANDARD; CURRENT

VOLTAGE MONITOR IS OPTIONAL

THERMOCOUPLE CONNECTOR

TERMINAL MOUNTING BOX (OPTIONAL)

50 AMP 3-PHASECIRCUIT BREAKER

9"

(14 3/16" WIDE)


9"

(20 3/16" WIDE)


(28 3/16" WIDE)

9"

The3configurationsillustratedatleftprovide2,3or5-zonesof30AMPcontrolforhigherwattageheaterapplications.TheCurrentVoltagemonitoroptionwillbefactoryinstalledwhenorderedatthesametimeasMainframe.Controlmodules,cables,moldconnectorsandotheraccessoriesareorderedseparately.

NOTE: Fordetailsoncablesandconnectors,seepages130-132.

SMART SERIES HIGH POWER MAINFRAMES Optional Current Voltage Monitor is Factory Installed in CV-Style Frames

Z O N E S

“MFHP” TYPE FOR TEMP. CONTROL

“MFHP” TYPE WITH CURRENT VOLTAGE MONITOR

“MFCHP” TYPE FOR TEMP. CONTROL AND COMMUNICATIONS

“MFCHP” TYPE WITH CURRENT VOLTAGE MONITOR

ITEM NUMBER


ITEM NUMBER


2 MFHP2G MFHP2GCV MFCHP2G MFCHP2GCV



CABLES AND MOLD CONNECTORS REQUIRED (Not included with Mainframes and Must be Ordered Separately)

Z O N E S

MOLD POWER CABLES C10=10 FT. C20=20 FT. C30=30 FT.


THERMOCOUPLE CABLES C10=10 FT. C20=20 FT. C30=30 FT.


MOLD POWER INPUT CONNECTORS

(INCL. CRIMP CONNECTORS)

THERMOCOUPLE CONNECTORS


NUMBER QTY. ITEM NUMBER QTY. ITEM

NUMBER

2 1 MPCH23C10G,C20GorC30G 1 TC5C10G,C20GorC30G 1 PICH23G 1 MTC5G




Z O N E S


FOR POWER INPUT CONNECTORS(B)

FOR THERMOCOUPLE CABLES CONNECTORS(C)

COMBINATION POWER & TC



2 1 PICH23TBG 1 MTC5TBG 1 PTCH23TBG



NOTE: Seepage135-136fordimensionaldetails.Forbelow-flushmountingofconnectors,seemoldpocketlayoutsonpages133-134.

NOTE: Combinationframestoaccommodateboth15and30AMPmodules(withorwithoutcommunications)areavailablebyspecialorder.

NOTE: Blankpanelscoverunusedzonesinframes(shadedpanelsabove).Forcommunications(MFCHP)typeframes,thesezonesmaybeusedforcommunicationmodules.

DIMENSIONS ABOVE DO NOT INCLUDE CONNECTORS

allframesare12"deep

125


Smart Series

® | Smart Series

® Digital Current/Voltage M

onitor

Smart Series® Digital Current/Voltage Monitor

Smart Series®

3

4

5

2

1

NOTE: TheDigitalCurrent/VoltageMonitorisafactoryinstalledoptionwhichreplacesthestandardcircuitbreaker/disconnect,andissuppliedwhen“CV-style”mainframesareordered. See pages 123 and 124 for appropriate mainframe item numbers.

Streamlined Design For Improved PerformanceThenewCurrent/VoltageMonitorissimpletooperateandfeaturesalargeeasy-to-readdigitaldisplay.Easeofoperationhasbeenenhancedbystreamliningtheunitandeliminatingunnecessaryswitchesandcontrols.Whensettingtheselectorswitchtothedesiredzonenumber,the‘AMPS’functionisselected.Themeterwillthendisplaytheamountofcurrentbeingdeliveredbytheselectedmodule.Inputvoltagetothesystemcanbemeasuredbyrotatingtheselectorswitchtooneofthethree‘linevoltage’positions.Thiswillsetthemeterinthe‘voltage’functionanddisplaythevoltageoftheselectedphase.

Current Supply To Each ZoneTomonitorthecurrentsupplytoeachzone,simplysettherotaryselectorswitchtothedesiredmodulezonenumber.The“AMPS”functionisthenautomaticallyselectedandisindicatedbytheletter’A’justtotherightofthenumbersinthedisplaywindow.Themeterdisplaysthecurrentbeingdeliveredtotheheaterloadinamperes.

Input Voltage From Each PhaseSettherotaryselectortothedesiredphasevoltageposition.Thisautomaticallyselectsthe‘volts’functionwhichisindicatedwhentheletter‘V’appearstotherightofthenumbersinthedisplaywindow.Themeterwilldisplaythelinevoltageoftheselectedphase.

1. CIRCUIT BREAKER/DISCONNECT – Appliesorremovespowertoallmodules intheframe.2. POWER ON LIGHT (amber) – IlluminateswhenCIRCUITBREAKERisinthe

ONposition.3. AMPS/VOLTS METER – Digitalmulti-scalemeterprovidesaccuratereadings

ofzonecurrent(AMPS)orinputvoltage(VOLTS).4. AMPS/VOLTS INDICATOR – AppearsautomaticallywheneitherAMPSor

VOLTSisselected.5. SELECTOR SWITCH – Multi-positionswitchautomaticallyselectszone

currentorphaselinevoltagetobemonitored.Forsystemswithmorethan12-zones,additionalmeterandselectorswitchpanelsaresupplied.

SpecificationsVoltmeter Range 190to290VAC(for240voltsystems) 90to145VAC(for120voltsystems)

Voltmeter Accuracy ±3%ofreading,50to60Hz

Maximum Voltmeter Input 400VAC

Input Voltage 240/120VAC,50to60Hz Ammeter Range 0to2;0to30;0to40amperes Ammeter Accuracy ±2%@0to100%DutyCycle,50-60Hz

Maximum Ammeter Input 30Amperes

126


28 1/4

Floorstandwidthadjustsfor8-and12-zone

mainframes

Smart Series®

Smart Series® Accessories

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Acc

esso

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3 SECTIONS

4 SECTIONS

2 SECTIONS

46"

25 3/4"

1 SECTIONS

Step-Down Transformer Kits (from 480 VAC to 240 VAC)TransformerKitsarepre-wiredandincludeenclosedtransformer(480VACinput,240VACoutput)withadjustabletransformervoltagetaps,one10-footcableforACpower-in(noconnector),one6-footcableformainframe(ACinput),onesafetyswitch,twoextrafuses,floorstand(MFS512G)andallmountingbracketsandhardwarerequired.Shippedwithinstructionsforeasyassembly.

Singlesectionframesmounttofrontorrearofstand.

Mainframenotincluded.Adapterplatesfornarrowerframesavailablebyspecialorder.*Comeswithplatesformounting8-zoneon12-zone“x”pattern**SuppliedwithMFS512GHDforthistransformersizeorlargerandtransformersmountedflat.NOTE: Powercapacityneededdependsontotalloadofsystem

(i.e.numberofzonesandheaterloadperzone).

Also Available: 1.Transformeronly

2.Transformerandcablesonly

3.Transformerswithothervoltage

orcurrentcapacities

4.IsolationTransformers

ContactDMEfordetailsandprices.

NOTE: Initialsupplyisprovidedwithmoldpower inputconnectors.

Insulated Crimp ConnectorsForconnectionofmoldpowerinputconnectorleadstoheaterleads.(195˚F/90˚Cmaximumtemperature)

Universal Floor StandTheUniversalFloorStandwillaccommodateall15or30ampMainframesfromonetofoursectionshigh.Standismadefromheavygaugesteelandincludeslockingcasters(400lb.rating). AllassemblyandMainframemountinghardwareisincluded. Heavydutyfloorstandavailableforlargersystems(1000lb.rating).

*HDstandnotshown.Floorstandcomeswithplatesfor5-zoneframemounting on8-zone“x”pattern

Module Replacement Fuses (sold in packages of 5)

ITEM NUMBER RATING

MFS512G 400LBS

MFS512GHD* 1000LBS

ITEM NUMBER RATING

TK61AG 6KVA

TK91AG* 9KVA

TK151AG* 15KVA

TK301AG** 30KVA

ITEM NUMBER AMPS RATING

HWCC1(Bagof30) 10-15 16-22RED

HWCC3(Bagof30) 10-15 14-16BLUE

HWCC2(Bagof20) 15-30 10-12YELLOW

Mainframe Blank PanelsUsed.tocoverunusedzonesinmainframes.Push-pullfastenersincludedinpanel. MFBP10G coversone15ampzone;MFBP30G coversone30ampzone(ortwo15ampzones).

ITEM NUMBER

MFBP10G

MFBP30G

ITEM NUMBER AMPS

ABC1 1

ABC15 15

ABC10 10

13X10 10

13X15 15

RPM0123 15

RPM0124 .062

127


Smart Series®

Smart Series® Mainframe Connector Wiring

Smart Series

® | Smart Series

® Mainfram

e Connector Wiring

SIDE OF MAINFRAME

High Power Mainframe Connector Wiring

SIDE OF MAINFRAME

Standard Mainframe Connector Wiring

128


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Wiring Diagram for DME hot Runner Molding System with Smart Series® Mold Connectors

Smart Series®

BLAC

K (+

)W

HITE

(-)

BLK

BLK

BLK

BETW

EEN

BLK

& W

HITE

LEA

DS.

CHEC

K CO

NN

ECTI

ONS

OF B

LACK

NO

TES:

Allgroundsmustbeconnectedtomoldtoensureoperatorsafety.

Allcrim

pconnectionscanbeeliminatedbyusingterminalmountingboxwithterminalstrip.Seepage135.

129


Smart Series®

Wiring Diagram for DME hot Runner Molding System with high Power Smart Series® Mold Connectors

Smart Series

® | Wiring D

iagram w

ith High Power Sm

art Series® M

old Connectors

BLAC

K (+

)

WHI

TE (-

)

BLAC

KW

HITE

CHEC

K CO

NN

ECTI

ONS

OF B

LACK

AN

D W

HITE

LEA

DS T

O EN

SURE

USE

OHM

MET

ER T

O M

EASU

RE B

ETW

EEN

F BL

ACK

AND

WHI

TE L

EADS

.

NO

TES:

Allgroundsmustbeconnectedtomoldtoensureoperatorsafety.

Allcrim

pconnectionsmaybeeliminated.Simplyremove6"leadsformPICconnectorsandwiredirectly.

130


Smart Series®

Mold Power and Thermocouple Cables

MPC12C10G

TC12C10G

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rmoc

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MoldPowerCablesareusedtoconnecttheMainframetothePowerInputConnectoronthemold.Availableinlengthsof10,20or30feet.Integralretaininglatchesonboththeframeandmoldconnectorsprovidesecurecableconnections.Connectorconfigurationsensureproperinsertionofcable.Cablesarewiredfor5,8or12zones(15AMP)and3or5zones(30AMP)forusewiththeappropriateSmartSeriesMainframesandMoldPowerInputConnectors.

Universal Mold Power Cable (15 AMP)TheMPC12C10G,20Gor30GMoldPowerCablealsoservesasauniversalcableforconnectingany15AMPSmartSeriesMainframetoany15AMPMoldPowerInputConnector.Themaximumnumberofzoneswillbedeterminedbytheconnectorinthemold.

ThermocoupleCablesareusedtoconnecttheMainframetotheThermocoupleConnectoronthemold,andareavailableinlengthsof10,20of30feet.Integralretaininglatchesonboththeframeandmoldconnectorsprovidesecurecableconnections.Connectorconfigurationsensureproperinsertionofcable.Cablesavailablearewiredfor5,8or12zonesforusewiththeappropriateSmartSeriesMainframesandThermocoupleConnectors.

Thermocouple Cables (for use with 15 or 30 AMP Mainframes)TheseThermocoupleCablesserveascablesforconnectingdissimilarMainframesandThermocoupleConnectors.Forexample.theTC8C10Gcouldbeusedtoconnecta12-zoneframetoan8-zoneMTC8Gconnector.Themaximumnumberofzoneswillbedeterminedbytheconnectorinthemold.

SPECIAL CABLESVirtuallyanytypeofConversionorSpecialCableconfigurationcanbeprovidedbyspecialorder

Mold Power Cables (15 AMP Max)10 FOOT LONG 20 FOOT LONG 30 FOOT LONG NUMBER

OF ZONES (MAX.)

FOR CONNECTIONS

ITEM NUMBER

ITEM NUMBER

ITEM NUMBER

FROM 15 AMP FRAME (S)

TO POWER INPUT CONNECTOR

MPC5C10G MPC5C20G MPC5C30G 5 5,8,12ZONE PIC5G

MPC8C10G MPC8C20G MPC8C30G 8 8,12ZONE PIC8G

MPC12C10G MPC12C20G MPC12C30G 12 12ZONE PIC12G

Mold Power Cables (30 AMP Max)10 FOOT LONG 20 FOOT LONG

NUMBER OF ZONES (MAX.)

FOR CONNECTIONS

ITEM NUMBER

ITEM NUMBER


TO POWER INPUT CONNECTOR

MPCH23C10G MPCH23C20G 3 2-3ZONE PICH23G

MPCH5C10G MPCH5C20G 5 5ZONE PICH5G

Thermocouple Cables10 FOOT LONG 20 FOOT LONG 30 FOOT LONG NUMBER

OF ZONES (MAX.)

FOR CONNECTIONS

ITEM NUMBER

ITEM NUMBER

ITEM NUMBER


TO THERMOCOUPLE CONNECTOR

TC5C10G TC5C20G TC5C30G 5 5,8,12ZONE MTC5G

TC8C10G TC8C20G TC8C30G 8 8,12ZONE MTC8G

TC12C10G TC12C20G TC12C30G 12 12ZONE MTC12G

*Usedwithall30AMPMainframes.

131


PIC5G

PIC8G

PIC12G

For 30 AMP Applications

PICH23G

PICH5G

Smart Series®

RohS/WEEE Compliant: Mold Power Input Connectors

Smart Series

® | Mold Pow

er Input Connectors

Mold Power Input Connectors

Insulated Crimp Connectors

MoldPowerInputConnectorsaremountedonthemoldtoacceptpowercable(s)fromtheMainframe.Theyaresuppliedwithsixinchesofnumberedleadsandagroundwire.Allthree15AMPconnectorsarethesamephysicalsizeanduse14-gaugewire.Onlythenumberofactivepinschange.The30AMPconnectorsaresuppliedwith10-gaugeleadsandareattachedtoscrewterminals.Eachisequippedwithanintegralretaininglatchtoprovideasecurecableconnection.Connectorconfigurationensuresproperinsertionofcable.Splicingof6"leadstoheaterpowerleadsiseasilyaccomplishedwiththeInsulatedCrimpConnectorssupplied.

NOTES: ConnectorPICH23GisdimensionallyidenticaltothermocoupleconnectorMTC8G.Seenextpage.

ForPICH23GandPICH5G,directwiringwithoutcrimpconnectorsispossiblebyremoving6"leads.

NOTE: Replacementpartsandextractiontoolscanbefoundonpage146

NOTE: Initialsupplyisprovidedwithmoldpowerinputconnectors.Also,seepage126.

NOTE: Groundwiremustbeconnectedtomoldtoensureoperatorsafety.

NOTE: Dimensionsshownmayvaryslightly.

For 15 AMP Applications

132


Smart Series®

RohS/WEEE Compliant: Mold Thermocouple Connectors

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ocou

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Conn

ecto

rs

*Usewith2,3and5-zone,30AMPmainframes

MTC12G

TPC0001

ThermocoupleConnectorsaremountedonthemoldtousewiththermocouplecable(s)fromtheMainframe.Screwtypeterminalsforusewithiron(+)andconstantan(-)thermocoupleleadsarenumberedandcodedonthesideandbottomofeachconnector.Allthreeconnectorsareequippedwithintegralretaininglatchestoprovideasecurecableconnection.Connectorconfigurationensuresproperinsertionofcable.Pinsaremadeofcopperalloyandaresilverplated.Experiencehasproventhatironandconstantanarenotrequired.

MTC8G

MTC5G

MOLD THERMOCOUPLE CONNECTOR MTC5GMTC8GMTC12G

MOLD POWER AND THERMOCOUPLE CONNECTOR TPC0001

NOTE: MOLDPOWERINPUTCONNECTORPICH23GISDIMENSIONALLYIDENTICALTOMTC8G

133


Smart Series®Sm

art Series® | M

old Connector Pocket Layouts

Mold Connector Pocket Layouts

WherespaceormoldhandlingandstoragerequirementsdonotpermittheuseofTerminalMountingBoxes,theconnectorscanbebelow-flushorsurfacemounted.Seedrawingsbelowandnextpagefordimensions.

NOTE: Drawingdepictsbelow-flushmounting.Disregarddimensionsmarkedwith*forsurfacemounting.

NOTE: Disregarddimensionsmarkedwith*forsurfacemounting.

NOTE: MoldpowerinputconnectorPICH23GisdimensionallyidenticaltoMTC8G.

134


Smart Series®

Mold Connector Pocket Layouts

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NOTE: Drawingdepictsbelow-surfacemounting.Disregarddimensionsmarkedwith*forsurfacemounting.

(Usepocketdimensionsshownonpages131-132asdetailedforthermocoupleconnectorMTC8G.)

135


Smart Series®

RohS/WEEE Compliant: Terminal Mounting Boxes

Smart Series

® | Terminal M

ounting Boxes

PTC12TBGTS

Includesterminalstripforeaseofwiring,allnecessaryconnectorsinstalled,andpowerconnectorpre-wiredtoaterminalstrip.Allunitsshownwithoutcovers.

PTC2TBGTSisnottobeusedwithSSH1022,SSH1021,MFP1G,MFP1G1,MFP2G, MFPR2Gcontrols&mainframes

Pre-wired Combination Terminal Mounting Boxes

PTC5TBGTS

PTC210TBGTS

PTC12TBTSPTC8TBTSPTC5TBTS

PTC8TBGTS

Combination Terminal Mounting Boxes – with Terminal StripITEM NUMBER X Y H M1 M2 ACCEPTS

PTC210TBGTS* 2.75 4.88 4.25 1.500 4.250 MPTC10/MPTC20

PTC2TBGTS* 2.75 4.88 4.25 1.500 4.250 PTC0110/PTC0120

PTC5TBGTS** 2.75 8.66 4.25 1.500 8.031 MPC5C(10or20)G/TC5C(10or20)G



PTC24TBGTS** 4.18 10.53 4.10 3.25 9.91 (2)MPC12C(10or20)G/(2)TC12C(10or20)G

PTC36TBGTS** 4.18 16.50 4.10 3.25 15.88 (3)MPC12C(10or20)G/(3)TC12C(10or20)G,

PTC5TBTS** 5.00 6.13 5.12 2.625 5.000 MPC5C(10or20)G/TC5C(10or20)G



**Comeswithallnecessaryconnectorsinstalledandpowerconnectorpre-wiredtoaterminalstrip.*Powerandthermocoupleconnectorsarepre-wired.

136


Smart Series®


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Term

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Mou

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xes

† Overall dimensions shown include allowances for hardware (assembly screws) but not connectors (example: For Item Number PTC0012 the “X” dimension is 4.29 not including screw heads)

†


†

†

* Used with 2-zone, 15 AMP mainframe MFFPR2G ** Used with 1-zone, 30 AMP mainframe MFHP1G† Overall dimensions shown include allowances for hardware (assembly screws) but not connectors (example: For Item Number PTC0012 the “X” dimension is 4.29 not including screw heads)

†


†

†

* Used with 2-zone, 15 AMP mainframe MFFPR2G ** Used with 1-zone, 30 AMP mainframe MFHP1G

PIC512TBG

PTC0012

TerminalMountingBoxesprovidetheeasiestandmosteconomicalmethodofmountingpowerandthermocoupleconnectorsonthemold.Constructedofplatedheavygaugesteel,eachboxisprecutanddrilledforquickmountingoftheconnectortothebox,andboxtothemold.Connectormountinghardwareissupplied.Connectorsareorderedseparately.


PTC8TBG

PTC5TBG

PTC210

137


Smart Series®

RohS/WEEE Compliant: Microprocessor-Based Temperature Control Modules with Digital Display and Setpoint Pushwheel

Smart Series

® | Control Modules w

ith Digital D

isplay

COMPATIBLE WITH TAS0512

ALARM AND SYSTEM CONTROL

FUNCTIONS. SEE PAGES 143-144.

SSM1512/11 (15 AMP) & SSM3012 (30 AMP)

NOTE: SSM3012istwiceas wideasaboveandhas circuitbreakerinstead ofpoweron/offswitch.

TheSSM1512isthesecondgenerationofthepopularSSM15G.Thisversionmaintainssimplicityofoperationwithsimultaneousdisplayofsetpointandtemperature.Othernew,improved,anduniquefeaturesinclude:

Key Features•LargeDigitalDisplay -Foreasierreadabilityoftemperature,%powerandfaults•Setpoint Pushwheel-Forsettingdesiredsetpointtemperature-Allowsadjustmentofsetpointbeforeturningpoweron•Auto%PowerDisplay-Shows%poweroutputwhileinAUTOmode-Indicatesaverage%powerrequirementonthermocouplefailure-Servesasadiagnostictoolforsolvinghotrunnersystemproblems

Operational Refinements•Improved SmartStart®

-Amoregradualtemperatureriseleadstoamoreeffectiveheaterdry-outperiod,therebyextendingheaterlife

-SmartStart®nowavailableinMANUALmode(optional) •SelectiveCycle®

-Averyhighspeedpoweroutputapproach-Enablesaccuratetemperaturecontrolandlongerheaterlife•Bumpless Transfer-Whenathermocouplefailureoccurs,operationisautomaticallycontinuedwithalearned%power-Uniquesoftwareaccuratelyassignspercentpowersetting•Third Fuse-Allowsforalarmoutputwhentheloadfusesareblown-Protectsmodulefromapplicationofexcessivevoltage•Anti-Arcing Feature-Protectscircuitboardfromdamagewhenmoduleiseitherinsertedorremovedunderpower

Switchable Options•Boost, Idle and Power Off Features-Providessystem-wideadjustmentoftemperatures-Enablesalarmaudio/visualoutputandremotealarms-RequiresTAS0512moduleandcommunicationsmainframe(Seepages148-149formoreinformationonthesecapabilities)•Unique AutoBoost Option -Instantaneouslyopensfrozengatesonstartup-TASmoduleormainframecommunicationsarenotrequired•Lights Out Feature-Afterstabilizingatsetpoint,displayturnsoff;whenafaultoccurs,displayisturnedonandflashes-Foreasierdetectionoffaults•Shorted Thermocouple Sensitivity Adjustment-Operationcanbetailoredtofastorslowreactiontimes-Sensitivitycanbeadjustedwithinternalswitches-Veryusefulformanifoldzoneswithlongstartuptimes•Switchable °C/°F Operation-Scaleindicatedatstartup• K Type Thermocouple Support• Cut Feature -Gaincutfeatureforsmallnozzlesandheaterswithungroundedinternalthermocouples

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RohS/WEEE Compliant: Microprocessor-Based Temperature Control Modules with Digital Display and Setpoint Pushwheel

Smart Series®

Warranty: Twoyears(excludingtriacandfuses)

Fuse Requirements (15 AMP only)(2)ABC15fuses(Bussmanonly)(2)sparefusesincluded

withmodule NOTE: Standard(240VAC)modulesarecompatiblewithmainframeswiredforeither 240VACthreephase(standard)or240VACsinglephase.

1. Process Temperature Display Indicatesprocesstemperature,thermocouplefaultsandotheroperationalmodes. Displays%powerwhenswitch(3)isin“%Auto”position.

2. Temperature Deviation Lights Indicatesdeviationfromsetpoint.Outerlightsblinkwhentemperatureismore than±40˚F(22˚C)fromsetpoint.

3. Auto/Manual/Auto % Power SwitchSelectsAUTOorMANUALcontrolmode.Shows%powerwhenpressedinto “%AUTO”position.

4. LED Mode Indicators LeftLEDilluminatesduringMANUALmode.RightLEDilluminateswhenpowerissuppliedtoheater.RightLEDblinksonandoffduringSmartStart®.

5. Setpoint PushwheelThree-digitswitchprogramssetpointinAUTOmode.Righttwodigitsprogram %powerinMANUALmode.

6. Power On/Off Switch ControlsACpowertomodule.

Front Panel Controls and Indicators


SSM1512SSM1511SSM3012

240120240

151530

360018007200

MODULEITEM NUMBER

VOLTAGE(VAC) AMPS WATTS

SSM1512/11 (15 AMP) & SSM3012 (30 AMP)

1

2

3

6

5

4

139


Smart Series®

RohS/WEEE Compliant: Microprocessor-Based Temperature Control Modules with Dual Digital Display

Smart Series


ith Dual D

igital Display

TheDSS15SmartSeriesModulehasdualdigitaldisplaysprovidingreadoutsofbothprocessandsetpointtemperaturesataglance.Closed-loop,fuzzylogicPIDcontrol,andauto-tuningofPIDparametersprovideprecisecontrolevenunderthemostadverseprocessingconditions.

Intheeventofathermocouplefailure,theDSScanautomaticallyinvokebumplesstransfertoapercentpowermodebasedonthelastvalidpercentagelearnedbeforethethermocouplefailure.Ifdesired,manualbumplesstransfermaybeselected,inwhichcaseathermocouplefaultwillturnoffpowertotheheateruntilthemanualpercentpowermodeisactivatedbytheoperator.

AuniquefeatureoftheDSSisa100%poweroption.Foraswitch-selectable,intervalof15or30seconds,fullpowercanbeimmediatelydeliveredtotheheatertorapidlybreakthroughfrozengatestoachievequickerstart-ups.The100%powermodecanbedisengagedatanytimebysimplypressinganyfrontpanelbutton.

Indicatorlightsprovidequickreferenceformodulecontrolmodes,temperaturedeviationandblownfuses.Theprocesstemperaturedisplayalsoprovidesquickdiagnosticsofthermocouplefaults,usingthefollowingabbreviatedcodes: Shi=ShortedThermocouple oPi=OpenThermocouple bci=ReversedThermocoupleTheDSSmodulealsoincludesaSmartStart®modetosafelybakeoutdamaginginternalheatermoistureatsystemstart-upandtoprolongheaterlife.Fastorslowloadmodesmayalsobeselectedtoprotectsmallerheatersorcompensatefor“slow”loadssuchasexternallyheatedmanifolds.Anaccurate,durableandfull-featuredmodule,theDSSisfullycompatiblewithallSmartSeriesorG-Series®15ampmainframes.

DSS1512/11 (15 AMP) & DSS3012 (30 AMP)


NOTE: DSS3012istwiceas wideasabove;has circuitbreakerinstead ofF1/F2lightsandpower on/offswitch.

COMPATIBLE WITH TAS MODULE ALARM AND STANDBY HEAT FUNCTIONS. SEE PAGES 143-144.

1. Smart Start Light IndicatesSmartStartison. 2. Process Temperature Display Indicatesprocesstemperatureandthermocouplefaultsasdescribedabove. 3. Temperature Deviation Lights Indicatesdeviationfromsetpoint.Outerlightsblinkatmorethan±30°Ffromsetpoint. 4. Setpoint Display Indicatessetpointtemperatureorpercentpower,dependingoncontrollermode. 5. Auto/Manual Switch Selectsautoormanualcontrolmode. 6. Auto Light Indicatesautomode. 7. Manual Light Indicatesmanualmode. 8. 100% Power Switch Indicates100%poweroutputforselectableintervalof15or30seconds. 9. 100% Power Light Indicates100%powermode. 10. Up Arrow Increasesdesiredsetpointvalue.11. Down Arrow Decreasesdesiredsetpointvalue.12. F1/F2 Lights Illuminatewhenfuseisblown.13. Power On/Off Switch

10

11

2

3

456

78

9

12

13

1


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Microprocessor-Based Temperature Control Modules with Dual Digital Display

Smart Series®

DSS1512/11 (15 AMP) & DSS3012 (30 AMP)

Smart Series Microprocessor-Based Temperature Control Modules

ITEM NUMBER DSS1512 DSS3012

(240 VAC, standard)

AMPS 15 30

WATTS 3600 7200

(120 VAC, optional)ITEM NUMBER

DSS1511AMPS

15WATTS

1800

NOTE: Standard(240VAC)modulesare compatiblewithmainframeswired foreither240VACthreephase (standard)or240VACsinglephase.FOR °C OPERATION: Switchto°Confrontpanel.FUSE REQUIREMENTS (15 AMP ONLY): (2)ABC15Fuses(Bussmanonly)NOTE: (2)sparefusesincludedwithmodule.WARRANTY: Twoyears(excludingtriacandfuses)

Performance SpecificationsAuto and Manual Control Modes: Timeproportioning/SelectiveCycle®Temperature Range: Ambient to 999°F (537°C)Control Accuracy: ±1°F(0.5°C)dependentonthetotalthermalsystemTemperature Stability: ±0.5%offullscaleovertheambientrangeof32to120°F(0to50°C)Calibration Accuracy: Betterthan0.2%offullscalePower Response Time: 0.538seconds.Manual Control: Adjustablefrom0-100%,maintainsoutputpowertowithin1%ofsetpoint.Smart Start®: Linearvoltageramping.Maximum Smart Start Duration: 5minutesSmart Start Override Temperature: 256°F(124°C)100% Power: Applies100%powertotheoutput.SoftwareselectableinhibitorS=15,L=30seconds.Operational Mode Priority: ·SmartStart®precedesautomode. ·Thermocouple(T/C)break,reversedorshortenedT/CoverridesSmartStartandautomodes. ·Manualcontroloverridesautomode,T/Cbreaks,reversedorshortenedthermocouples.

·Outputisinhibitedduringallfaultconditions

Input SpecificationsThermocouple Sensor: TypeJ,groundedorungrounded.External T/C Residence: Lessthan0.1°F/ .T/C Isolation: IsolatedbycontrolcircuitpowersupplyCold Junction Compensation: Automatic,betterthan0.03°F/F(0.015°C/°C).T/C Break, Reversed & Shorted Protection: Automaticallyinhibitspowertoheaterunless bumplesstransferisinvoked.Input Impedance: 5.6MegohmsInput Amplifier Stability: Greaterthan0.02°F/°F(0.01°C/°C).Common Mode Rejection Ratio: Greaterthan120dB.Power Supply Rejection: Greaterthan110dB.

Output SpecificationsVoltage Power Capability: 15AMP:240nominal,singlephase,120VACavailable,15amperes,3600watts@240VAC(1800watts@120VAC). 30AMP:30amperes,7200watts@240VACOutput Drive: Internalsolidstatetriac,triggeredbyzeroACcrossingpulses.Overload Protection: 15AMP:FusesareprovidedonbothsidesofACline. 30AMP:Fastactingcircuitbreaker.Transient Protection: dv/dtandtransientpulsesuppressionincluded.Power Line Isolation: OpticallyandtransformerisolatedfromAClines.Isolationvoltageisgreaterthan2500volts.

Controls and IndicatorsAuto/Manual Selection: Push-buttonswitchwithLEDindicatorsadjacenttoswitch.Setpoint Adjustment: Push-buttonup&downarrowkeys.100% Power Selection: Push-buttonswitchwithLEDindicatoradjacent.Power On/Off: 16amprockerswitch(15amp)or30ampcircuitbreaker(30amp).BothareUL,CSA,VDEapproved.Setpoint Display: Three0.4",sevensegmentdigitdisplay.Process Display: Three0.56",sevensegmentdigitdisplay.Alsodisplaysalarmcodesandflashing“100”for100˚poweroperation.100% Power Indication: RedLEDadjacentto100%powerkeyflashes.Processdisplayflashes“100.”Auto Indication: IlluminatesgreenLEDadjacenttoAuto/Mankey.Manual Indication: IlluminatesyellowLEDadjacenttoAuto/Mankey.Smart Start Indication: IlluminatesgreenLEDabovetheprocessdisplay.Shorted T/C Indication: Flashes“Shi”inprocessdisplay.Opened T/C Indication: Flashes“oPi”inprocessdisplay.Reversed T/C Indication: Flashes“bci”inprocessdisplay.Temperature Deviation Indicators: FiveseparateLEDs: ±20°F/11°C=Red ±10°F/5°C=Yellow 0°=Green.Blown Fuse Indicators: 2neonindicators(15amponly)

Electrical Power SpecificationsInput Voltage: 240/120VAC+10%-15%Frequency: 50/60HzDC Power Supplies: Internallygenerated,regulatedandcompensatedModule Power Usage: Lessthan6watts,excludingload.Dimensions: 15AMP:2"Wx7"Hx71/2"D(5.08x17.78x19.05cm) 30AMP:4"Wx7"Hx71/2"D(10.06x17.78x19.05cm)

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RohS/WEEE Compliant: Microprocessor-Based Temperature Control Modules with Color Touch Screen Display

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TSM-15-12

TheTSM15SmartSeriesModulehasacolortouchscreendigitaldisplayprovidingreadoutsforActualTemperature,CurrentMode,PercentagePowerandCurrentReading.Closed-loop,fuzzylogicPIDcontrol,andauto-tuningofPIDparametersprovideprecisecontrolevenunderthemostadverseprocessingconditions.

Intheeventofathermocouplefailure,theTSMcanautomaticallyinvokebumplesstransfertoapercentpowermodebasedonthelastvalidpercentagelearnedbeforethethermocouplefailure.Ifdesired,manualbumplesstransfermaybeselected,inwhichcaseathermocouplefaultwillturnoffpowertotheheateruntilthemanualpercentpowermodeisactivatedbytheoperator.

TheTSMboostleveloptionlimitsboostingofthetemperatureby75°Cor135°Ftolimitthedegradationofmaterial.

TheTSMmodulealsoincludesaSmartStart®modetosafelybakeoutdamaginginternalheatermoistureatsystemstart-upandtoprolongheaterlife.Fastorslowloadmodesmayalsobeselectedtoprotectsmallerheatersorcompensatefor“slow”loadssuchasexternallyheatedmanifolds.Anaccurate,durableandfull-featuredmodule,theTSMisfullycompatiblewithallSmartSeriesorG-Series®15AMPmainframes.

LeakDetectioncapabilities(referenceTSM1512UserManual)

TSM15 SmartSeries® Controller with Default Settings (Factory Settings)

Zone temperature 260ºC or 500ºFStandby level 100ºC or 180ºFBoost level 75ºC or 135ºFOver temperature range

10ºC or 18ºFUnder temperature rangeRamp OnAuto-Manual OnExtended alarms for Manual, Standby and Boost

Off

When reconfiguring your controller for a new tool or environment, this chapter of the manual shows how to alter controller default settings to your preferred values and afterward to save them.

Shouldanythingseemwrongwithyournewsettingsthenitispossibletorestorethedefaultsettingsatanytime.

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Actual temperature (and scale)

Current mode shows set-point

Current reading

Percentage power applied


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RohS/WEEE Compliant: Microprocessor-Based Temperature Control Modules with Color Touch Screen Display

Individual Card Diagnostics

Thecontrolsystemhasseveralfeatureswhichprovideadiagnosisoffaultsinthecontrolsystem,thetoolheatersandthermo-couplesensors.

IfazonetemperatureisseentodeviatefromtheactualsettingbeyondthealarmlimitsthenthedisplaywillchangetoWhitetextinRedboxandgeneratearemotealarm.

The following is a list of alarm conditions that may be detected and which will also activate the output contacts.

ERROR MESSAGE CAUSE ACTION

ERR!

Littleornotemperaturerisehasbeendetectedinthatzone.Whentheconsolestartstoapplypoweritexpectstoseeanequivalentheatriseatthethermocouple.Ifthethermocouplehasbeentrappedandpinchedelsewhereinthetoolorcablethenitcannotsensethefullheatrisethatoccursatthetip.Ifleftuncorrected,thereisadangerthatthezonecouldoverheatanddamagethetip.Insteadthecircuitmaintainstheoutputatwhateverlevelitreachedwhenthemonitorcircuitdetectedthefault.

Checkthermocouplewiring;itmaybereversed.Heaterwiringmaybefaultyorelementmaybeopencircuit.

FUSE

Theoutputfuseforthatzonehasfailed.Pleasenote:Afusecanonlyfailduetoafaultexternaltothecontroller.Identifyandrectifythefaultbeforereplacingthefuse.Note:Thefusedetectioncircuitrequiresacontinuouslowlevelcurrentthroughahighimpedancebleedresistortomaintainthealarmcondition.Asaresulttheloadcircuitisstillconnectedtothemain’svoltagesupplyanditisnotsafetoattempttorepairorreplacethefusewithoutfirstisolatingthecircuit.Ifthefuseinquestionismountedonacontrolcardthenitissafetounplugtheboardinordertoisolatethecircuitandreplacethefuseonthecard.

Replacethefusewithoneofthesameratingandtype;i.e.HighRuptureCurrentloadfuse.Theblownfuseislocatedonthecontrolcard.

GND Thesystemhasdetectedangroundfault.Checkyourheaterwiringforalowimpedancepathtotheground.

LINE

Nomainssupplysynchronizationpulsesbeingreceived.The3-phasesupplyisusedinacross-overdetectioncircuittogener-atetimingpulsesforaccuratephasecontrolandfiringthetriac.IfthephasedetectionfailsononeortwophasesthenthereisnopulsetousetomeasurephaseangleandtheLINEerrormes-sageisgenerated.Meanwhile,allcircuitsonthehealthyphaseswillcontinuetoworknormally.

ThereisaphasedetectioncircuitoneachTMS15-Seriescardandacommonphasedetectioncircuitonallothercontrollertypes.AlthoughafaultinsuchcircuitsmaycausetheLINEerrormessage,suchfaultisveryrarelyseen.Themostcommonerroriseithertheabsenceofonephaseor,ifaplughasbeenre-wiredincorrectly,aswappedphaseandneutral.IfaLINEerrormessageoc-cursthenswitchoffandisolatethecontrollerthenchecksupplywiringforpresenceofallthreephases.

REVThecardhasdetectedanabnormalinputattheT/Cterminationthatindicatesashortedorreversedthermocouple.

IftheREValarmpersists,switchoffthecontrollerandinvestigatetheoffendingzone.

T/CAnopencircuitthermocouplehasbeendetectedandnoauto-responsehasbeenselectedintheT/COpenErrorcolumnoftheSetuppage.

Forimmediaterecovery,changetoopenloopcontrol.Makeanoteoftheaboveactionsothatwhenthecontrollerisfreeyoucanchecktoseewhethertheinputfuseonthecontrolcardhasruptured.Ifthefuseisgoodthenyoumayneedtocheckthewiringforfaultsorevenreplacethethermocouple.

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