TTC 2100 / 2200 OPERATORS MANUAL

Version 7 Release Date: 23 December 2010

TEMPERATURE CONTROL SYSTEM

Gammaflux, L.P., 113 Executive Drive, Sterling, Virginia, 20166 U.S.A.

Tel: 800.284.4477 or 703.471.5050 Fax: 703.689.2131 e-mail: info@gammalux.com

Gammaflux Europe GmbH, Bahnstrasse 9a, Wiesbaden, Germany

Tel: 49-611-973-430 Fax: 49-611-973-4325 e-mail: info@gammaflux.de

Gammaflux, L.P. Far East, Pengin Mura B202, Nishi Kiwa-ku, Osawa, Yamaguchi, Ube 755-0151, Japan
Tel: +81 (1836) 54-4369 Fax: +81 (1836) 54-4369 e-mail: gammafluxjpn@gammaflux.com

www.gammaflux.com

TTC 2100 / 2200 OPERATORS MANUAL ___________________________________________________

Page

1 Safety of Operation
1.1 1.2 1.3 1.4 1.5 1.6 1.7 Introduction Reference to Standards .... Personal Protection ... Lockout/Tagout .... Housekeeping ... Safety Symbols Used in this Manual .... Safety Notes ....

6
6 6 6 6 6 7 7

2 General System Description

2.1 2.2 2.3 2.4 2.5 2.6 TTC 2100 Temperature Control System .. TTC 2200 Temperature Control System .. General Information .. TTC 2100 Features & Benefits ........ Specifications ...... Default Settings and Limits .

10
10 10 11 12 14 15

3 Cabinet
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 General Description .. Cabinet Dimensions .. Receiving and Unpacking .. System Set-Up and Input Power Connections . Circuit Breaker HA-3 Alarm Relay Output Connections . HA-4 Remote Input Connections ... Digital Communications Port .. Fusing ... Daisy Chaining of TTC 2100s Mold ID Feature .

16
16 17 17 18 18 18 22 23 23 24 24

4 Controller Touchscreen Operation 5 Groups

5.1 5.2 5.3 5.4 General Description . Temporary Groups . Instant Groups Permanent Groups .

25 27
27 28 30 32

6 Controllers Button 7 Graph Button

7.1 7.2 7.3 7.4 7.5 7.6 7.7 General Description .. Pilot Graph . Bar Graph . Line Graph . Tape Graph . SPC Graph . Data Table ..

33 35
35 35 36 37 38 39 40 1

7.8 7.9

Tool Graphic Graph Settings

.. .

41 42

8 Alarms
8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16 General Description Low Temperature Deviation Alarm .. High Temperature Deviation Alarm .. Thermocouple Open Alarm .. Thermocouple Reversed Alarm .. Thermocouple Short Alarm .. Fuse Open Alarm .... Heater Short Alarm (Heater Bakeout Feature) Heater Open Alarm .... Uncontrollable Zone Alarm .. Mold Monitor Heater Resistance Alarm Mold Monitor High / Low Wattage Alarm Critical Over Temperature Alarm .. Material Protection (Machine Cycling) Alarm Monitor Alarm . Status of OK to Run .

46
46 48 48 48 49 49 49 49 50 50 50 50 50 51 51 51

9 Basic Displays / Settings

9.1 9.2 9.3 9.4 9.5 9.6 9.7 Temperature Display .. .. Boost Button .. ... Standby Button .. .... Setpoint Button .. .... Power On / Off Buttons .. .. Zone Button ..... Options Button (Trim / Boost Settings / Auto Manual Output / Auto Load % / Power) .

54
54 54 55 56 57 58 59

10 Reports / Print Screens

10.1 10.2 10.3 10.4 10.5 10.6 10.7 General Description .. .. Print Screen ... View Setpoints (Print Setpoints) ... View SPC Summary (Print SPC Summary) . View Data Summary (Print Data Summary) View Alarm Summary (Print Alarm Summary) View SP Changes (Print SP Changes)

62
62 64 64 65 66 66 67

11 Menu Screens
11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 General Description .. .. Select a Menu ..... Restore .... Copy To Diskette/USB .. .. Delete .. .... View a Menu (Print a Menu) ..... New Menu Name and Save (Creating a New Menu) .. Copy From Diskette/USB ...

69
69 70 70 70 71 71 72 72

12 Information Screens (Setup)

12.1 12.2 12.3 12.4 12.5 General Description .... Job Information .. Security Levels .. Setup Setup Copy % Output ..

73
73 73 73 75 78 2

12.6 12.7 12.8 12.9 12.10 12.11 12.12 12.13 12.14

Options Mold Monitor Sequence Start Even Cool Sequenced Power Up .. Language Operator IDs . Edit Groups (Setting Up Permanent Groups) .. Stop Communications ..

80 83 84 86 87 88 89 90 90

13 Diagnostics Screens
13.1 13.2 13.3 13.4 13.5 13.6 General Description ... Find This Module .. .. View Configuration Now (Print Configuration Now) . View Versions .. View Voltage . Exit to Windows .. ..

91
91 92 92 93 94 95

14 Pdfs
14.1 General Description ... 14.2 Viewing and Transferring Pdf Files . 14.3 Viewing and Transferring Pdf Report Files .

96
96 96 97

15 Monitor Only Zones

15.1 General Description ... 15.2 Setting Up Monitor only Zones .

99
99 100

16 Databases
16.1 General Description 16.2 Setting Up a Database

102
. 102 . 102

17 Mold Doctor
17.1 17.2 17.3 17.4 17.5 General Description Wiring Analysis Fault Analysis Thermodynamic Analysis . Historical Mold Performance

105
105 106 107 108 109

18 Field Calibrator
18.1 18.2 18.3 18.4 18.5 18.6 General Description . Read Offsets . Calibrate Group (Performing Field Calibration) . Restore Old Offsets Zero Offsets . Print Report .

111
111 111 112 112 112 112

19Tuning
19.1 19.2 19.3 19.4 19.5 19.6 General Description ..... Display Tuning Set Tuning to Standard . Tune . Return to Old Tuning . Print Report

113
113 113 114 114 115 115 3

20 Change Configuration (Internal Zone Hardware Assignment)

20.1 20.2 20.3 20.4 20.5 20.6 20.7 20.8 20.9 20.10 General Description . Name Zones Software Rewire (of Thermocouples) Edit Configuration . Edit ID (Assign Zone Names) .... Move Zone Addresses Assign Inputs (Assign Thermocouples) ..... Type J or K Thermocouple Selection .. DC Zones (Data Concentrator Zones) . Locate Zones ..

116
116 117 118 119 121 122 123 124 125 126

21 Programmable Input / Output Functions

21.1 General Description .. 21.2 Inputs 21.3 Outputs

127
127 127 128

22 Networking via Ethernet

22.1 General Description . 22.2 Menu.txt Files ... 22.3 Setpoint.txt Files ...

129
129 129 129

23 International Interface
23.1 23.2 23.3 23.4 General Description .. Operator Interface Comparison of Features . Using International Interface as a Replacement Basic Operation and Advanced Setup / Troubleshooting Brochures ...

132
132 132 133 133

24 Mold ID
24.1 24.2 24.3 24.4 General Description .. Mold ID Wiring . Mold ID Screens Mold ID Pin Configurations ..

142
142 142 143 146

25 Screen Simplification 26 Troubleshooting Guide

General Description .. No Zone Found! Must Quit! Error Message . Loss of Communication Detected with the Following Module(s) Error Message .. Active Alarm ... Significant Temperature Over-Shoot During Start-Up .. Zone Indicates Correct Temperature, Molded Part Indicates that Actual Temperature is Too High .. 26.7 Zone Over Temperature, Heater Percent Output is Very Low 26.8 Zone Below Temperature, Heater Percent Output is Very High 26.9 Zone Above Temperature, Heater Percent Output is High .. 26.10 One Zone High Temperature with Very Low Heater Percent Output, Another Zone has Persistent Low Temperature with High Heater Percent Output . 26.11 Zone Does Not Achieve Setpoint 26.12 Zone Fluctuates Rapidly Between Setpoint and +10 to +20 F (+5.5 to +11 C).. 26.13 Roughly One-third of Zones are Below Temperature 26.1 26.2 26.3 26.4 26.5 26.6

149 150
150 150 150 151 151 151 151 151 151 152 152 152 152 4

27 Attaching a Printer 28 Maintenance

28.1 28.2 28.3 28.4 28.5 28.6 Cleaning the Exterior of the Cabinet Cleaning the Interior of the Cabinet Checking Power and Thermocouple Cables . Thermocouple Calibration . Checking the Earth Ground Connection Checking the Operation of Cooling Fans .

153 154
154 154 154 154 154 154

29 Training

155

1 ___________________________________________________ Safety of Operation

1.1 Introduction

High injection pressures, high temperatures, clamp speed, and forces are used in the operation of injection molds and machines. To protect the operator at the work place, ensure that all safety devices installed on the machine and mold are functioning correctly. Never disable or by-pass a safety device. Follow the machine and mold manuals for safe procedures and safety checks.

1.2

Reference to Standards

Important: For machine or mold rebuild, repair or maintenance, lockout/tagout procedures must be followed as recommended in ANSI Z244.1-1982 (The American National Standards Institute) and as specified in OSHA 29CFR PART 1910.147. Throughout this manual references are made to various standards: ANSI (American National Standards Institute), OSHA (Occupational Safety and Health Act) and CE (Conformity in Europe) for safety or operating protocol. We recommend that these standards be the minimum used. If there are more stringent local standards, these must be followed.

1.3

Personal Protection

The operator must wear safety glasses, face shield, heat-resistant gloves and protective clothing when working around the feed throat, purging the machine or clearing the gates of the mold. Operators must be aware of the possibility and danger of hot resin and/or gases spurting from gates, machine nozzle and feed throat of the hopper.

1.4

Lockout/Tagout

Throughout this manual instructions are given to lockout/tagout power sources. Usually no instructions are given to turn the power source back ON. This is assumed to have been covered by the instruction to perform any operation requiring the power source provided that all steps in the instructions prior to the power being applied have been completed. If the power source must again be turned OFF the instruction to lockout/tagout is repeated.

1.5

Housekeeping

Clearly define areas for the controller to be positioned. Provide clear access to the front and rear of the cabinet in case of an emergency. Check frequently for frayed or worn electrical cables located on the rear of the cabinet. Replace any frayed or worn cable immediately once it is found.

Never place any materials on or near the controller cabinet that would block air flow near the cabinet ventilation ports. Never clean the mold, machine or hot runner controller while it is operating. Never place any materials on the top of the hot runner controller cabinet. Make certain that all cable connectors on the rear of the cabinet are securely clamped down and held in place. If any are loose, secure them before operating the controller.

1.6

Safety Symbols Used in this Manual

There are several symbols used with text and graphics to convey safety messages in this manual. They follow the standards (except for color) in ISO 3864 (International Organization for Standardization) and ANSI Z535 (American National Standards Institute). Hazard Alert symbols are used to indicate the hazard alert message regardless of the hazard level. The hazard level is conveyed by the use of the appropriate signal word. Graphics within the triangle are used to further identify the specific hazard such as:

Electrical High Voltage, never remove the cover or try to open a cabinet, or disconnect cables without turning Off the mains circuit breaker or unless you are properly trained in electrical safety and authorized to work on the cabinet. There are live high voltage electrical circuits inside the cabinet.

Lockout/Tagout Required To safely perform the operations a lockout/tagout of the power source(s) must be done.

See Instructions See the safety information applicable to this controller.

1.7

Safety Notes

CAUTION: ALL CONTROLLERS HAVE A PROTECTIVE CONDUCTOR TERMINAL (EARTH LUG) ON THE REAR OF THE CABINET. WITH A 6AWG (16mm2) GREEN WIRE, CONNECT THE TERMINAL TO EARTH. THIS IS A SAFETY WIRE AND MUST BE INCLUDED IN THE CONTROLLER SETUP. UNAUTHORIZED PERSONNEL SHOULD NOT BE ALLOWED ACCESS TO THE INTERIOR OF THE CABINET.

CAUTION: ALWAYS LOCKOUT/TAGOUT THE MAIN POWER BREAKER BEFORE OPENING THE CONTROLLER ENCCLOSURE. DO NOT CLOSE THE MAIN BREAKER IF THE CONTROLLER CABINET IS OPEN.

CAUTION: ANY CONTROLLER USING J TYPE THERMOCOUPLES SHOULD NOT BE SET FOR A TEMPERATURE HIGHER THAN 400 DEGREES C (760 DEGREES F). AT THIS TEMPERATURE J TYPE THERMOCOUPLES CAN BEGIN TO OXIDIZE AND BECOME NON-LINEAR (LOSE THEIR CALIBRATION OR REPEATABILITY). IN ADDITION, MOST THERMOPLASTIC RESINS ARE MOLDED AT LOWER TEMPERATURES. HIGHER TEMPERATURES COULD CAUSE THE MATERIALS TO DEGRADE (BURN).

CAUTION: ALL POWER-UP PROCEDURES SHOULD BE DONE BY A TRAINED, QUALIFIED SETTER OR ELECTRICIAN. PROPER TRAINING PROVIDED BY GAMMAFLUX IS A MUST FOR QUALIFICATION TO SET-UP THE EQUIPMENT SAFELY.

CAUTION: BE SURE MAIN POWER IS LOCKED OUT/TAGGED OUT DURING PRE START-UP PROCEDURES.

CAUTION: MAKE CERTAIN THAT EACH CONNECTION IN ANY THERMOCOUPLE CIRCUIT IS BETWEEN EITHER TWO RED OR TWO WHITE WIRES. DO NOT CONNECT RED AND WHITE THERMOCOUPLE WIRES TOGETHER EVEN IF THIS MAY APPEAR TO CORRECT AN OPERATING PROBLEM.

CAUTION: THE THERMOCOUPLE WIRES ARE NOT RATED TO CARRY THE POWER-LINE VOLTAGE. ALWAYS LOCKOUT/TAGOUT THE MAIN POWER BREAKER WHEN WORKING ON THE THERMOCOUPLE OR MOLD POWER WIRES.

CAUTION: DO NOT USE A HIGH VOLTAGE TEST ON ANY TERMINALS WITHIN THE CABINET WHEN ALL THE ELECTRONIC CARDS ARE INSTALLED. THE HIGH VOLTAGE ASSOCIATED WITH THESE TESTS COULD DAMAGE ELECTRONIC CIRCUITS WITHIN THE CABINET. 8

CAUTION: IT IS COMMON FOR OUTPUT TRIACS TO SHORT WHEN A FUSE BLOWS. A SHORTED TRIAC CANNOT BE REGULATED AND WILL APPLY FULL POWER TO THE HEATER. ALWAYS CHECK A CONTROLLED ZONE THAT HAS A BLOWN FUSE BY ADJUSTING POWER FROM ZERO TO 100 % IN THE MANUAL MODE. THE VOLTAGE SHOULD GO FROM ZERO TO 240 VOLTS (OR FULL VOLTAGE) RESPECTIVELY.

WHEN REPLACING FUSES, MAKE CERTAIN THAT THE AC MAIN CIRCUIT BREAKER HAS BEEN TURNED OFF.

2 ___________________________________________________ General System Description

2.1 TTC 2100 Temperature Control System

The GAMMAFLUX TTC 2100 Series Hot Runner Temperature Controller system is a compact, industry hardened and attractively styled controller. The controller is based upon single module integrity using microprocessor based temperature control modules. The modular enclosure packaging allows for a small footprint (Section 3.2 Cabinet Dimensions). The TTC 2100 is available with a Single Heat Sink Enclosure (Figure 2.1a), a Dual Heat Sink Enclosure (Figure 2.1b) and a Quad Heat Sink Enclosure (Figure 2.1 c).

Figure 2.1a TTC 2100 1 Single Heat Sink Enclosure

Figure 2.1b TTC 2100-2 Dual Heat Sink Enclosure

Figure 2.1c TTC 2100-3, TTC2100-4 Quad Heat Sink Enclosure

2.2

TTC 2200 Temperature Control System

The TTC 2200 is the TTC 2100 with different packaging. The TTC 2200 is designed to be panel mounted and is typically mounted inside an injection molding machine control cabinet. The TTC 2200 can be connected to a remote screen. In many cases it can be connected directly to the injection molding machines operator interface screen. Because of the similarities in operation of the TTC 2100 and TTC 2200, references to the TTC 2100 throughout this manual will also apply to the TTC 2200.

10

Figure 2.2

TTC 22001 Single Heat Sink

2.3

General Information

The number of heat sinks required is determined by the number and amperage of control zones required. Each heat sink can accommodate up to 16 control slots. Control modules are available in three styles: 1) Module that contains one (1) 30A zone. Requires two slots. 2) Module that contains two (2) 15A zones. Requires one or two slots, depending on current draw. If the current draw for both zones added together is greater than 15A, it requires two slots. If the current draw for both zones added together is 15A or less, one slot is required. 3) Module that contains four (4) 3A zones. Requires one slot. Breaker size dictates the maximum number of zones that each heat sink can contain. Each control module has the Gammaflux proprietary PID2 control algorithm. This algorithm is time tested and proven on hot runner systems around the world. The TTC 2100 uses phase angle fired outputs. Phase angle firing provides major benefits compared to time proportioning outputs. With phase angle fired outputs, output voltage to the heater can be adjusted to any level from 0 VAC to full voltage with great precision. Time proportioning controllers are limited to providing 0 VAC or full voltage to heaters. The TTC 2100 computer normally comes with a 12.1 TFT, 800 x 600 pixel touchscreen that enables the operator access to all data pertinent to the operation of the TTC 2100 (an International Interface operator interface is also available, see Section 20 International interface). The screen design enables the operator to become quickly familiarized with the controller while giving the operator access to a wide array of tools to maximize hot runner performance. The TTC 2100 touchscreen includes a unique operator interface featuring icons to identify the control functions, process values and alarm status, in a simple and easily understood format. The use of easy-to- understand icons enables global users to gain a quick understanding of the TTC 2100. All hot runner set up, mold performance and monitoring information is accessed by using the touchscreen located on top of the enclosure (touchscreen can also be mounted remotely). With the proper security password, a user can customize many of the features of the TTC 2100. A USB memory drive (floppy drive in early models) is included for easy uploading and downloading of information as shown in Figure 2.3.

11

Figure 2.3

USB Memory Drive

The Gammaflux TTC 2100 is designed to provide the user with the most powerful hot runner diagnostic tools available. Features such as heater resistance monitoring (Mold Monitor), settable alarm limits, field calibration capability and interactive graphic representation of the mold are standard. The TTC 2100 supports digital communication using an RS-485 interface. To meet the needs of the international markets, the TTC 2100 accommodates field selection of J Type or K Type thermocouples, degrees F or degrees C temperature configuration, and either Delta or Wye main input power. If the thermocouple type is changed in the field, it should be remembered that the thermocouple wiring internal to the controller has not changed.

2.4

TTC 2100 Features & Benefits

The TTC 2100 has been designed to include a vast array of features that provide the user with the industrys best temperature control along with the industrys most complete package of process information and diagnostic tools. Features include: Ease of Use / Flexibility Expanded use of universally accepted icons 4 security levels increase or decrease operator options and availability of screens Flexible packaging includes in-machine control and remote screen placement On screen display of reports Data collection for up to the last 24 hours including summary reports Alarm History Monitor function enables user to alarm off temperature inputs that are not being controlled by the TTC 2100 such as cooling water temperatures Group tab creation - view all zones or only the zones in each group Instant grouping Tool graphics with real time zone data overlay Network communication capability Boost temporarily raises a zone or group of zones temperature to eliminate cold slugs on start up. Standby lowers a group of zones to the standby temperature while the process is idle. Selectable from the touchscreen or remote input. Trim permanent set point shift (e.g. 10F) for the zone or zones selected. User can quickly shift setpoint for a group of zones even if the setpoints are different. Operator Identification - Create an authorized users list with individual user codes that must be entered by an operator before changes can be made Selectable Hot start feature automatically returns to controlling at setpoint after temporary power outage. Sequenced Power Up feature enables user to program the power up using up to 3 menus and 2 timers. Auto load % feature for quick loading of manual percentages based on actual zone data Find this module LED enables user to quickly locate the hardware location of any zone. Global input power flexibility Daisy-chain 2 TTC 2100 enclosures, view on one screen Small footprint Control 12

Enhanced control algorithms employing proprietary Gammaflux PID 2 High resolution thermocouple input High resolution voltage output Automatic switching to learned manual setting when thermocouple fails Inputs Machine cycle/material protection Control Inhibit (turns off outputs) Remote Standby Outputs Resettable alarm output relay Non-resettable alarm output relay Critical high temperature alarm relay trip Auto Boost OK to Run contact (user configurable) to notify machine that temperatures are high enough to start molding Diagnostics Heater Bakeout provides superior heater protection during startup and during heater shorts. On startup, the TTC 2100 will initially provide a very low voltage (1-5 VAC) to the heater while heater current is monitored. If the current draw is excessive, the TTC 2100 will bakeout the heater by providing a low voltage pulse to the heater. Once the heater is dry, the TTC 2100 will ramp the zones output to full voltage in a few line cycles while continuing to monitor the current draw. Mold Monitor provides extensive on-line monitoring of the heaters resistance and wattage values to ensure efficiency and to provide preventative maintenance information. A machine cycling input signal can be monitored to ensure the injection molding machine is operating. If the machine stops for a designated period of time, the controllers outputs will go to Standby to reduce material degradation in the tool. Mold Doctor provides off-line tools to troubleshoot the mold. Tests include: Wiring analysis checks the tools wiring. The software clearly notifies the user of miswired zones along with any thermocouple or heater problems. Fault analysis quickly identify the following problems: thermocouple open, thermocouple reversed, thermocouple pinched, open fuse, heater open, heater wet and heater short. Thermodynamic analysis this test automatically ramps all selected zones 400 F (204 C) and down to 300 F (149 C). During the heating and cooling process Mold Doctor provides and records critical information. By providing zone-by-zone data for resistance, power consumption, heating and cooling rates, tool maintenance becomes a much easier task. This data is saved so that it can be compared to future tool data. Historical mold performance allows the user to easily compare a known good thermodynamic analysis baseline to the current thermodynamic analysis. Intuitively troubleshoot your mold with hard data. Field Calibrator enables in-house calibration at the users convenience. Databases can be sent to experts to assist in troubleshooting. Controller can be operated from a laptop computer in the event of a screen failure. Languages Languages include Czesky, Dansk, Deutsch, English, Espaol, Franais, Italiano, Nederlands, Polski, Portuguese, Svenska, Vlaams and Far Eastern character sets. Other languages easily available using Windows XP based language editor and character sets. Contact Gammaflux for more information.

13

2.5

Specifications
.2 F (.1C) +/- 1F (.5C) 8.5 msec (every half line cycle) at 60 Hertz 50 msec (20 times per second) Proprietary PIDD with added autotuning features Field Selectable 0-999F (0-537C) 0-240 VAC User selectable (0-999F, 0-537C) 22 132 VAC to activate

Calibration Accuracy Control Accuracy Power Control Time Process Sampling Control Algorithm Degrees F or C Operating Range Output Voltage Standby Temperatures Machine Interface I/O

Input Specifications:
Thermocouple Cold Junction Compensation External Resistance Temperature Variation Due to Thermocouple Length Type J (standard) or Type K (selectable). Grounded thermocouples only. Internal to enclosure 10 M ohms None

Electrical Specifications:
Input Power Frequency Ambient Temperature Humidity Range Output Module Range 160-265 VAC Delta 208, 380, 400, 415 VAC Wye 50/60 Hz 32-113F (0-45C) 0-95% non-condensing 4-zone, 3A, 720W per zone @ 240VAC 2-zone, 15A, 3600W per zone @ 240 VAC 1-zone 30A, 7200W per zone @240 VAC RS-485 or ProfiBus

Communications Performance Standard: Designed to Meet

I.E.C. 801-1, 801-2, 801-3, 801-4 Safety 508, UL-873 and CSA CE Mark EMC Directive 89/336/EEC EN 55081-2 EN 55011 EN 61000-6-2 EN 55022 See Section 3.2 Cabinet Dimensions.

Physical Specifications:

14

2.6

Default Settings and Limits

Default English Off 0F 0% Automatic Operator Limit/Range

TTC Default/Limit Multiple Language Capability Power Status Automatic Set Point Manual Set Point Automatic Mode/Manual Mode Security Level

Multiple Languages On/Off 0-999F; 0-537C 0 - 100% Auto/Man Monitor, Operator, Supervisor, Engineer Security Codes - Up One Level at a Time, 321, 654, 987 Mon-Oper, Oper-Supr, 0 to go Down Supr-Engineer Tuning Autotune (0) -27 to 27 Temperature Set Point Maximum Limit 999F 0-999F; 0-537C Manual Percent Maximum Limit 100% 0-100% Temperature Deviation Alarm Set Point +/- 20F +/- 1-999F; +/- 1-537C Boost Set Point 20F User Selectable (0-999F; 0-537C) Boost Set Point Limit +/- 50F 0-999F; 0-537C(Range is bipolar) Boost Time Set Point 60 sec. 0-300 sec. Trim Set Point 0F User Selectable (0-999F; 0-537C) Trim Limit +/- 100F 0-999F; 0-537C Standby Set Point 220F 0-999F; 0-537C Standby Group None User Selectable Thermocouple Pinch Detection Time 0 (0 = 5 min) .1 54 minutes Slaved Power Output Disabled Enable/Disable Slaved Power Up Group None User Selectable Degrees F or C Selectable F F or C Thermocouple Input J J or K Alarms Latched Disabled Enable/Disable Operator ID None Enter Operator ID's to enable Material Protection Disabled Enable/Disable Material Protection Time (in seconds) 0 0-999 Heater Resistance Monitoring Disabled Enable/Disable Heater Wattage Monitoring Disabled Enable/Disable Watt High Alarm 8000 0-8000 Watt Low Alarm 0 0-8000 Critical Over Temperature Alarm 999F 0-999F; 0-537C Outputs on Power Up question Ask Always On, Ask, Always Off uninterrupted running Graph Setting Defaults Auto Scaling User Selectable Seconds Per Update 1 .5 seconds - 65.5 seconds Time Compression 1:1 1:1 - 1:300 Scale Max (both) 100 -999 - +999 Scale Min (both) 0 -999 - +999 Tool Pictures None User Generated Database Max File Size 1 Meg .1 - 100 Meg Database Time Compression 1:1 1:1 - 300:1 Database - What to do "On File Full" Keep Newest Keep Newest, Keep Oldest Report Length 1 Hour 1 - 24 Hours Report Type View View / Print Report Orientation (when Print is selected) Portrait Portrait / Landscape Job Screen Information Blank User Selectable

15

3 ___________________________________________________ Cabinet
3.1 General Description

The TTC 2100 hot runner mold controller is available in three cabinet configurations. The configurations include a single heat sink enclosure, a dual heat sink enclosure and a quad heat sink enclosure. Each heat sink can accommodate up to 16 control modules. The TTC 2200 hot runner mold controller is a unit that can be panel mounted internal to an injection machine cabinet. The screen can be mounted remotely. The TTC 2200 can also be set up to communicate with the injection molding machine operator interface screen. The maximum capacity of each type of enclosure (TTC 2100 and TTC 2200) is: Single Heat Sink Enclosure 16 slots: 8-30A zones or 16-15A zones (32-7.5A zones) or 64-3A zones or mix of each 32 slots: 16-30A zones or 32-15A zones (64-7.5A zones) or 128-3A zones or mix of each 64 slots: 32-30A zones or 64-15A zones (128-7.5A zones) or 256-3A zones or mix of each

Dual Heat Sink Enclosure

Quad Heat Sink Enclosure

In practice, the different style enclosures would typically be used in the following manner: Single Heat Sink Enclosure up to 32 tips & 8 manifolds Dual Heat Sink Enclosure up to 96 tips & 10 manifolds Quad Heat Sink Enclosure above 96 tips and 10 manifolds Primary AC power is distributed from the main circuit breaker to each output zone control module. To minimize phase imbalance in multi-zone three phase systems, the AC power is distributed so that the load is as equally distributed as possible. Zone output modules are sequentially wired to different phases. Regulated output power is routed from the output modules to the appropriate mold power connector on the rear of the cabinet. High current, plug in connectors are used to transfer AC power to and from the mold. In a similar fashion, the thermocouple signals are routed into the controller using plug-in connectors clearly marked for thermocouple inputs. The touchscreen can be mounted on top of the enclosure (standard) or mounted remotely.

16

Legend 1. Output Card 2. Thermocouple Input Card 3. Data Concentrator 4. Power Supply 5. Communications Cable 6. Module Heater Power Connector 7. Circuit Breaker 8. Thermocouple Connector 9. Heater Power Connector 10. Auxiliary Input Connector 11. Auxiliary Output Connector 12. Interface Power Connector 13. Interface Communication Cable 14. Ground Lug 15. Fan

Figure 3.1 TTC 2100 - 1 Single Heat Sink Enclosure Side and Back View (shown without operator interface) On larger TTC 2100 enclosures, boards are positioned on both sides of the enclosure in the same fashion shown in Figure 3.1 TTC 2100-1.

3.2

Cabinet Dimensions

The chart below indicates the dimensions of the controller cabinets and the mobile stands. Dimensions do not include screen.

Enclosure Type Single Heat Sink Dual Heat Sink Quad Heat Sink Casters (add) Panel Mount Single Heat Sink

Height (mm) 35 (889) 40 (1016) 54 (1372) +5.5 (+139.7) 32 (813) Figure 3.2

Width(mm) 9.3 (237) 19 (483) 30 (762) 19 (482)

Depth(mm) 20 (508) 20 (508) 30 (762) 7 (178)

Weight(kg) 85 (39) 150 (68) 200 (91) 75 (34)

Cabinet Dimensions

3.3

Receiving and Unpacking

The TTC 2100 controller and the mold cables are usually packaged in the same shipment container. Upon receipt, carefully check the shipping container for damage that may have occurred in transit. Note any damage on the shipping documents when receipt is verified. During unpacking of the shipment, if any hidden damage is discovered, the carrier should be notified immediately so that a claim can be filed. All technical drawings provided with the system should be retained for documentation and systems support.

17

3.4

System Set-Up and Input Power Connections

Place the control cabinet in position. The cables that correspond to the appropriate thermocouple and power output are labeled with letters so that they may be matched without confusion. When installing the cable sets, match the labels exactly. Match A on the cable set hood and cabinet respectively. The standard AC input power cable provided is Type SO and it is approximately 10 feet (3.048 meters) long with color-coded flying leads. Standard power input is 240 VAC three phase. Other voltage configurations are available. A step down transformer is available as an option. Wire/Phase Standard 4 Wire Function L1 RED L2 WHITE L3 BLACK NEUTRAL --Safety Earth Ground GREEN Optional 5 Wire Function RED ORANGE BLACK WHITE GREEN Optional European BROWN BLACK BLACK BLUE GRN/YEL

CAUTION: BEFORE APPLYING AC LINE POWER TO THE CONTROLLER, CHECK TO ENSURE THAT THE AC LINE POWER MATCHES THE POWER RATING INDICATED ON THE LABEL ATTACHED TO THE REAR OF THE TTC 2100 ENCLOSURE. CONFIRM THAT THE AC LINE POWER MATCHES THE CONTROLLER CONFIGURATION OF DELTA OR WYE (STAR), THE ACTUAL VOLTAGES DO NOT EXCEED THE CONTROLLER RATING, THE INPUT POWER WIRING IS CONNECTED PROPERLY, AND THAT THE CONTROLLER IS PROPERLY GROUNDED. INCORRECT WIRING OR APPLICATION OF VOLTAGES THAT EXCEED THE CONTROLLER RATING WILL RESULT IN SEVERE DAMAGE TO THE CONTROLLER.

3.5

Circuit Breaker

The circuit breaker size is determined at time of order entry based upon information supplied by the user. The circuit breaker is located directly above the cooling fan on the Single Heat Sink Enclosure. It is located on the front of the Dual and Quad Heat Sink Enclosures. Circuit breaker sizes for each style of enclosure are: Single Heat Sink Enclosure up to 100A circuit breaker Dual Heat Sink Enclosure up to 150A circuit breaker Quad Heat Sink Enclosure up to 250A circuit breaker

3.6

HA-3 Alarm Relay Output Connections

The HA-3 Alarm Relay Output Connector (shown in Figure 3.6a) is located at the bottom right corner of the back of the TTC 2100 controller. The HA-3 is used for alarm outputs and may be used to turn on an external alarm light or horn when alarms occur. The contacts can also be interfaced with the injection molding machine to prevent injection if the controller is not up to temperature. Resettable Alarm Contact When a zone continuously has an alarm active for five seconds, the alarm contact will turn ON. Pressing the Clear Alarm button will turn the alarm contact OFF. If a new alarm occurs after the Clear Alarm button is pressed and is active for five seconds, the alarm contact will turn ON again. The Resettable Alarm contact can be connected to a horn or external light. Pressing the Clear button will silence the alarm. 18

Non-Resettable Alarm Contact When any zone continuously has an alarm active for five seconds, the alarm contact will turn ON. Pressing the Clear Alarm button will not change the condition of the alarm contact. The alarm contact will turn OFF when all of the alarms in the controller are cleared. OK to Run Contact The controller can provide a contact closure to the injection molding machine to denote that the mold is heated and is ready for injection. The contact is of the NO type. The OK to Run contact is open (not OK) when one or more of the following is true: 1) The controller is not powered. 2) The interlink cable between the controller and the injection molding machine is not connected. 3) Any unlocked zone is off. 4) There is a zone alarm within the controller. 5) All of the zones in the controller are locked off. The OK to Run contact is closed (OK) when all of the following are true: 1) There is a least one zone that is not locked off. 2) All of the unlocked zones are turned On. 3) There are no zone alarms within the controller. The controller does not provide any voltage on these contacts. An external signal of 22-232VAC or 22232VDC is required. The contacts are fused with a 5 Amp 5*20mm fuse. The connector may be oriented differently than shown (e.g., rotated 90 degrees). Locate the notch to be sure of the pin numbers.

HA-3 Alarm Relay Output Connections

Figure 3.6a HA-3 Alarm Relay Output Connections

The HA-3 connector only provides room for 2 output functions while the controller has 3 functions available. The cable harness within the controller includes the wiring for all 3 functions. The unused functions have been terminated with wire nuts inside the enclosure and are available near the HA-3 connector. If a different function is desired, the connections can be swapped to provide the pinout desired.

19

Figure 3.6b describes the wires available within the cable harness: Function Resettable Alarm COM contact Resettable Alarm NO contact Non-Resettable Alarm COM contact Non-Resettable Alarm NO contact OK to Run NC contact OK to Run COM contact OK to Run NO contact Wire Label 2 3 5 6 7 8 9 Wire Color Black Yellow Black Red White Black Blue

Figure 3.6b Cable Harness Contact Wiring This internal cable harness only provides the NO contact for the Resettable Alarm and Non-Resettable Alarm functions. A special cable harness is available that provides the NC contact for the Resettable Alarm and Non-Resettable Alarm. This must be specified at the time that the controller is ordered. Figure 3.6c shows the default output functions provided prior to July 2009 with the cable harness schematic shown in Figure 3.6d: Pin 1 2 3 4 Function Non-Resettable Alarm NO contact Alarm COM contacts Resettable Alarm NO contact Enclosure Ground Connection Wire Label 6 2 & 5 & 8 3 Wire Color Red Black Yellow

Figure 3.6c Cable Harness Contact Wiring Prior to July 2009

NC
RESETTABL E ALARM

HA-3 CONNECTOR (male insert) PIN 1 "2 "3" BLACK YELLOW PIN 2 PIN 3 PIN 4

COM NO

NC
NON-RESET TABLE ALARM

COM NO

"5" "6"

BLACK RED

NC
'OK TO RU N'

"7" "8" "9"

WHITE BLACK BLUE

COM NO

Figure 3.6d Cable Harness Contact Schematic Prior to July 2009

20

Beginning in July 2009, the default selection of functions as shipped in the controllers was changed to the Non-Resettable Alarm and the OK to Run contacts as shown in the wiring table shown in Figure 3.6e and the wiring schematic shown in Figure 3.6f:

Pin 1 2 3 4

Function Non-Resettable Alarm NO contact Alarm COM contacts OK to Run NO contact Enclosure Ground Connection

Wire Label 6 5 & 8 9

Wire Color Yellow Black Blue

Figure 3.6e Cable Harness Contact Wiring Beginning in July 2009

NC
RESETTABL E ALARM

HA-3 CONNECTOR (male insert) PIN 1 "2 "3" BLACK YELLOW PIN 2 PIN 3 PIN 4

COM NO

NC
NON-RESET TABLE ALARM

COM NO

"5" "6"

BLACK RED

NC
'OK TO RU N'

"7" "8" "9"

WHITE BLACK BLUE

COM NO

Figure 3.6f Cable Harness Contact Schematic Beginning in July 2009

Figure 3.6g TTC Auxiliary Output Alarm Internal Wiring Beginning in July 2009

21

Resettable Alarm Buzzer Beginning July 2009 Beginning in July 2009, the Resettable Alarm function was removed from the HA-3 connector and replaced with the OK to Run function as shown in Figures 3.6e, 3.6f and 3.6g. The wiring for the Resettable alarm function is now available for an audible buzzer function that can be ordered with a new controller or can be retrofitted into existing controllers. If the buzzer is ordered with the controller, the buzzer is mounted to the front surface of the controller near the phase indicator lights as shown below in Figure 3.6h.

Figure 3.6h Alarm Reset Buzzer (Beginning in July 2009) Resettable Alarm Buzzer Retrofit (see Figure 3.6i) The warning buzzer can be retrofitted to existing controllers with an update kit WB00133. The kit contains the buzzer mounted to an HBE-24 cover plate and the required internal wire harness. The buzzer is installed to an unused output connector location on the rear of the controller. The wires to one of the internal fans is cut and the wire assembly is spliced to power the horn.

Figure 3.6i TTC Auxiliary Output Wiring to External Buzzer Beginning in July 2009

3.7

HA-4 Remote Input Connections

The HA-4 Remote Input Connector is located at the bottom right corner of the controllers shown in Figures 3.1a and 3.1b. The HA4 connector is used for remote control inhibit, remote standby, remote boost, remote sequenced power up and machine cycle (material protection) inputs. An incoming signal of 24 120VAC or VDC is required. The default pin assignments are: Pin 1 Return for all signals Pin 2 Remote Control Inhibit Input Pin 3 Remote Standby Input Pin 4 Machine Cycle (Material Protection) Input Ground Connection 22

These pin assignments can be changed. Other input signal features are available (Section 20.3 Inputs). The connector may be mounted differently than shown (e.g., rotated 90 degrees) in Figure 3.7. Locate the notch to be sure of the pin numbers.

Figure 3.7

HA-4 Remote Input Connections

3.8

Digital Communications Port

The communications port is a DB-9 female style connector located on the back of the cabinet. This port supports RS-485 communication. The communications cable that is shipped with the controller includes an RS232 to RS485 converter. This enables the user to run the controller from a laptop computer in the event of an operator panel failure.

3.9

Fusing

Each 30 Amp temperature output module is fused at 30 amps. Each 15 Amp temperature output module is fused at 20 amps. Each 3 Amp control output zone is fused at 5 amps. The system power supply for the TTC 2100 is fused at 3.15 amps. The remote outputs are fused at 5 amps on a board on the data concentrator. See Figure 3.9 for part numbers of fuses.

Module (# of each type fuse) 3A Output (4) 3A Output (1) 15A Output (4) 30A Output (2) System Power Supply (1) Remote Outputs (4) on Data Concentrator

Fuse Rating (Amps) at 250VAC 5 15 20 30 3.15 5

Gammaflux Part Number 8321-008 8323-015 8323-006 8322-030 None None

Manufacturer Part Number Buss BK/AGC-5 Buss BK/MDA-15 Buss BK/ABC-20 Buss BAN-30 Littelfuse F3.15A216 Littelfuse F5AL250V

Figure 3.9

Fuse Part Numbers

23

It is important to replace the fuses with the same style of fuse. In most cases, fast blow fuses are used. Regular fuses will not give adequate protection to the boards. Smaller fuses can be used if the zones are running at lower amperages. Never replace a fuse with a fuse rated for higher amperage than the factory standard.

3.10 Daisy Chaining of TTC 2100s

TTC 2100s can be daisy chained together. This is most often done when a tool has more zones than the users individual TTC 2100s. Two TTC 2100s can then be daisy chained together using a Gammaflux Daisy Chain cable (Gammaflux part number WB 0053). All zones from both TTC 2100s can be viewed on the screen of the first TTC 2100 (enclosure A). The procedure to daisy chain two TTC 2100s is as follows: 1) Turn off breakers on both TTC 2100 enclosures. 2) There are two rotary selector switches on each data concentrator (refer to Figure 3.1 TTC 2100-1 for location of data concentrator noting that another data concentrator may be mounted on the other side of the TTC 2100). The selector switch next to the ribbon cable on every data concentrator should always be set to 0. In enclosure B, the selector switch next to the LEDs needs to have its setting changed. Change the setting to the number of data concentrators that are in enclosure A. If enclosure B has more than one data concentrator, number them sequentially. Example: There are two data concentrators in enclosure A and two data concentrators in enclosure B. The data concentrators in enclosure A are already properly numbered 0 and 1. The da ta concentrators in enclosure B are also currently set to 0 and 1. The data concentrators settings in enclosure B need to be changed to 2 and 3. 3) Connect the enclosures with the Daisy Chain cable (Gammaflux part number WB 0053). 4) Power enclosure B first and then enclosure A. 5) A configuration error will appear due to the change in the data concentrator settings. This is expected. 6) Push the Create button to create a new configuration. This will bring up the Configuration Editor. 7) Enter the zone IDs for the zones using the Configuration Editor (Section 20.5 Edit ID). Then accept. 8) A message will appear stating that the Default.mnu is trying to load and that it has detected a different number of zones than were in the menu. This is expected. 9) Another message will appear stating that the Default.mnu does not match the configuration and setpoints will be initialized to standard values. This is expected. 10) The main screen will now appear with all setpoints set to 0. Notice the group tabs on the bottom of the screen. If a menu exists that was set up with these same tabs, it can be restored at this time using the Menus functions. If the user wants to create a new setup, then all setpoints should be entered at this time. The user can now also create new Group tabs at the bottom of the screen ( Section 5.4 Permanent Groups). 11) To disconnect the daisy chained TTC 2100s, turn power off to both units and disconnect the daisy chain cable. Then reset the data concentrator switches to original settings. Steps 5-10 will need to be repeated to set settings on both enclosures back to their desired settings.

3.11 Mold ID Feature

See Section 24.2 Mold ID Wiring for wiring information if the controller comes equipped with the Mold ID feature.

24

4 ___________________________________________________ Controller Touchscreen Operation

The 12.1 TFT, 800 x 600 pixel touchscreen displays are designed to give the user access to all information while maintaining an intuitive approach that makes it easy for the user to understand . The users security level (Section 12.3 Security Levels) determines the appearance of the screens. Features that are not available to the user (determined by the users security level) do not appear on the screen. They reappear when a user with a higher security level enters the appropriate code. This approach eliminates confusion by only showing buttons that the user can access. The user can select between English, Espaol, Deutsch, Danisch, Vlaams, Franais and Italiano (Section 12.6 Options). Far Eastern character sets are also included. Icons are used throughout the screens.

Figure 4

Sample TTC 2100 Screen

The following buttons are found at the top of most screens: Report (or Print): Pressing this button enables the user to view a variety of reports on screen, to print the existing screen or to print a variety of reports. A parallel printer interface connector is located on the side of the TTC 2100 touchscreen. Screens and functions associated with Reports (Print) are found in Section 10 Reports / Print Screens. Menus: Pressing this button enables the user to select from existing menus (setpoints, alarm values, zone names, etc.) or to set up new menus. Screens and functions associated with Menus are found in Section 11 Menus Screens. Information: Pressing this button enables the user to access setup information. Screens and functions associated with Information are found in Section 12 Information Screens.

25

Diagnostics: Pressing this button gives the user access to databases, the Mold Doctor diagnostic package, Field Calibration, Zone Configuration of the TTC 2100 and other diagnostic functions. Screens and functions associated with Diagnostics are found in Section 13 Diagnostic Screens. There are 2 general ways to view zone data on the screen. These are selectable on the 2nd row of buttons. They include Controllers (Section 6) and Graph (Section 7). The International Interface is an alternative to the Touchscreen and is described in Section 23 International Interface.

26

5 ___________________________________________________ Groups
5.1 General Description

It is important to understand the use of groups on the TTC 2100. All data displayed on the touchscreen and in reports is done on a group-by-group basis. A group is a set of zones (e.g. All, Tips, Tips 1-8, Man, Man 1-4) that the user can assign for convenient access for monitoring or making changes. Each group name is displayed at the bottom of the screen. In Figure 5.1, the groups are labeled Tip, Man, Spr and All. If the user wants to display data for all zones on the screen, the group tab All should be selected at the bottom of the screen. If the user wants to view a limited number of zones such as Tip or Man the user needs to set up those group tabs if they are not already present at the bottom of the screen. No matter which group is displayed, all zones are being continuously controlled and monitored. The name of the currently selected group is displayed below the Controllers, Graph and Alarm buttons (All in Figure 5.1).

Figure 5.1

Controllers View Displaying group All

NOTES: 1) All zones are usually included in the group ALL. 2) There is no limitation to the number of groups to which a zone can be assigned. For example, Tip 6 can be included in Tip and Tips 1-16. It is usually included in the group ALL. 3) A group can contain more than one ID name (e.g. a group can include selected Man zones, Tip zones and Sprue). 4) The use of Group tabs is an essential step in the effective use of the TTC 2100. Setpoints can be applied to one or all zones in a group at one time. Data is displayed a group at a time. Power can be applied or turned off to one or all zones within a group at one time. Special functions such as Boost or Standby can be applied to one or all zones in a group. Reports are generated using a group format. 27

5) There are three types of groups temporary (Section 5.2), instant (Section 5.3) and permanent (Section 5.4). Temporary group names always include an asterisk (*) as the first character of the name.

5.2

Temporary Groups

Temporary groups are groups that are not saved when power to the TTC 2100 is turned off. When the TTC 2100 is shut down, the temporary groups disappear. Temporary groups are usually set up by the user to temporarily monitor a set of zones more closely or to see what relationships exist between the grouped zones (e.g., the amperage for tips 1-8). Temporary groups are required when running Mold Doctor or Field Calibrator. All temporary group names have an asterisk as the first character of the name (e.g., *Man1Tip4). To set up a temporary group: 1) Press the Controllers button. 2) Press the New *Group button. A security level of Operator, Supervisor or Engineer is required. The screen in Figure 5.2a will appear. 3) There are two ways to select zones for the new temporary group: a) Touch the Range button. The Range button will appear to depress and the background of the button will turn white. Touch the lowest zone and then press the highest zone to be included in the temporary group. Selected zones will have their name box change from a light yellow background to a cyan background. The Range button will go back to its normal state. Zones can be added or subtracted by touching them. If a zone is included in the group, touching it will cause it to be removed from the group. If a zone is not in the group, touching it will add it to the group. b) Touch the individual zone buttons. Zones can be added or subtracted by touching them. Selected zones will have their name box change from a light yellow background to a cyan background. If a zone is included in the group, touching it will cause it to be removed from the group. If a zone is not in the group, touching it will add it to the group. 4) Press the Make * Group button at the bottom of the screen. The controller will automatically name the group. The name will be *(lowest zone ID selected in step 3) (highest zone ID selected in step 3) See Figures 5.2a and 5.2b.

Figure 5.2a Setting Up a Temporary Group 28

Figure 5.2b Displaying Temporary Group *Tip1-Tip5 To delete a temporary group: 1) Press the Controllers button. 2) Press the tab of the temporary group that is to be deleted. 3) Press the New *Group button. The screen in Figure 5.2c will appear. The Del * Group button at the bottom of the screen will only appear when a temporary group is being displayed. In Figure 5.2c, the temporary group *Tip1-Tip5 is being displayed so the Del * Group button icon appears. 4) Press the Del * Group button to delete the selected temporary group.

Figure 5.2c Deleting a Temporary Group 29

5.3

Instant Groups

The Instant Group is a convenient way to make a variety of changes to a number of zones within an existing group. Settings can be changed to the subset of zones in the following way: 1) Press the Controllers button. 2) Press the New *Group button. A security level of Operator, Supervisor or Engineer is required. The screen in Figure 5.2a will appear. 3) There are two ways to select zones for the new temporary group: a) Touch the Range button. The Range button will appear to depress and the background of the button will turn white. Touch the lowest zone and then press the highest zone to be included in the temporary group. Selected zones will have their name box change from a light yellow background to a cyan background. The Range button will go back to its normal state. Zones can be added or subtracted by touching them. If a zone is included in the group, touching it will cause it to be removed from the group. If a zone is not in the group, touching it will add it to the group. b) Touch the individual zone buttons (Tip 2, Tip3, Tip20 and Tip29 in Figure 5.3a). Zones can be added or subtracted by touching them. Selected zones will have their name box change from a light yellow background to a cyan background. If a zone is included in the group, touching it will cause it to be removed from the group. If a zone is not in the group, touching it will add it to the group. Note that these steps are the same as the first 3 steps shown in Section 5.2 Temporary Groups. The difference is that Step 4 is omitted. The selected groups in this Instant Group can now be changed.

Figure 5.3a Instant Group Zone Selection If the Setpoint button is pressed the screen in Figure 5.3b will appear. The new Setpoint can now be entered for the Zone (Tip 29 in Figure 5.3a), the Group (Tip group in Figure 5.3a) or the Instant Group (Tip2, Tip3, Tip20 and Tip29 in Figure 5.3a). Any time an Instant Group is used, it can be changed to a Temporary Group simply by pressing the Make * Group button. The Instant Group will remain until one of the group tabs at the bottom of the screen is pressed. The Instant Group will be available until any group tab is pressed at the bottom of the screen. At that time, the Instant Group will no longer exist until created again.

30

The Instant Group can be used to perform the following functions. a) Enter zone setpoint b) Turn zones On c) Turn zones Off d) Start Standby mode e) Start Boost mode f) Put zones into Automatic mode g) Put zones into Manual mode h) Lock zones Off i) Unlock zones

Figure 5.3b Setpoint Change for Instant Group The new Setpoint can now be entered into the Zone (Tip 29 in Figure 5.3a), the Group (Tip group in Figure 5.3a) or the Instant Group remains available until one of the group tabs at the bottom of the screen is pressed. The Instant Group button will then be removed from the settings entry forms. When an Instant Group is selected the On (Figure 5.3c) and Off (Figure 5.3d) buttons will show the Instant Group selection. The Boost and Standby pop-up screens will also show the Instant Group selection.

Figure 5.3c On Button for Instant Group

Figure 5.3d Off Button for Instant Group

The Instant Group can be used to perform the following functions. a) Enter zone setpoint b) Turn zones On c) Turn zones Off d) Start Standby mode e) Start Boost mode f) Put zones into Automatic mode g) Put zones into Manual mode h) Lock zones Off i) Unlock zones 31

5.4

Permanent Groups

Permanent groups are saved. When power is reapplied to the TTC 2100 following a shutdown, the permanent group tabs will reappear on the screen. Permanent groups are also saved with menus (Section 11 Menus Screens). The setup of permanent groups requires a Supervisor or Engineer security level. To set up a permanent group: 1) Press the Information Tab at the top of the screen. 2) Press the Edit Group button (requires Engineer or Supervisor security level). The screen in Figure 5.4 will appear. 3) Touch the space under New Group Name and type new group name (e.g., Overcap) into the Change To: area with the alphanumeric keypad that appears on the screen. 4) Select the ID names (e.g., Tip, Man) that will be applied, one ID name at a time from the Select From List of All IDs area. Press the right arrow to add it to the Select ID to Edit Zones in Group area. Repeat step 4 for each ID name that is to be included in the new permanent group. The left arrow can be used to remove it from the list. 5) Select an ID name from the Select ID to Edit Zones in Group area. It will appear in the ID box. 6) Select the Zone ID numbers (e.g., 1-6) that you want to add to (or delete from) the group. 7) Press Only if these are the only zones you want in the group. Press Add if you want to add them to the existing group. Press Del if you want to remove them from the existing group. 8) Repeat steps 5-7 to continue adding or deleting zones. 9) View the ID Zones Included area to confirm that you have correctly made the desired selections. 10) Press the Create New Tab button. The new group name tab will appear at the bottom of the screen with the other group tabs. The Copy From Tab button can be used to quickly form a new subgroup of an existing group. When the Copy From Tab button is pressed, the ID names and zones for that group will be available to form a new group using steps 3-10 above.

Figure 5.4

Edit Group Screen

At any time, a group tab at the bottom of the screen can be moved right, left or deleted using the Move Tab Left, Move Tab Right or Delete Tab buttons on the bottom of the screen shown in Figure 5.4. 32

6 ___________________________________________________ Controllers Button

Pressing the Controllers button causes data to be shown in a format that resembles rows of individual zone controllers plugged into a cabinet as shown in Figure 6a. To select a zone, simply touch the appropriate controller. IMPORTANT: Directly below the Controllers button is the name of the Group that is displayed (e.g., All is the Group shown in Figure 6a). Note that the name displayed is the same as the tab selected at the bottom left of the screen. Data is always shown on a group basis. For a description of the New * Group button, see Section 5.2 Temporary Groups.

Figure 6a

Controllers View Displaying Group All

All data is normally shown against a teal background. Data shown for each zone includes: Zone Name Temperature RED background indicates a thermocouple alarm Setpoint % Output TEAL background indicates zone is ON and in AUTOMATIC mode DARK GRAY background indicates zone is ON and in MANUAL mode Box is replaced by an O if the zone is OFF Box is replaced by a Lock icon if the zone is LOCKED OFF RED background indicates a heater alarm TEAL background indicates zone is ON and in AUTOMATIC mode 33

Amps

Box is replaced by an O if the zone is OFF Box is replaced by a Lock icon if the zone is LOCKED OFF Two bar graphs are displayed on the right side of each zone: Temperature Deviation Shown on the top half. The black centerline serves as the zero-degrees reference point. The deviation display is red if the deviation exceeds 20F (11C). The deviation display is otherwise green. % Output Bar Graph Shown on the bottom half. Indicates 0 to 100% output. The black centerline serves as the 50% mark. The Page Up, Up, Down and Page Down arrow buttons at the bottom right of the screen are used to access additional zones when there are zones in the group that do not fit on the screen. Pressing the Up or Down button causes the screen to move one row of controllers at a time. Pressing the Page Up or Page Down button causes the screen to move three rows of controllers at a time. A zone can be selected by touching the controller on the screen. The zone selected will turn green. Its data will be displayed at the top of the screen. A zone can also be displayed by selecting the ID name and Zone number at the upper right corner of the screen. When a zone is selected, the corresponding controller display will turn green. At the bottom right hand corner of the screen is the information (blue i) button. Press this button to see the screen tutor shown in Figure 6b.

Figure 6b

Tutor screen for Controllers View

34

7 ___________________________________________________ Graph Button

7.1

General Description

Pressing the Graph button causes data to be shown in a graphical or tabular format (See Figure 7.2). Any variable (e.g., temperature, heater resistance, wattage) can be displayed. The type of graph displayed is selectable using the Graph Type button that appears below the Graph button. The different types include Pilot Graph, Bar Graph, Line Graph, Tape Graph, SPC Graph, Data Table and Tool Graphic. IMPORTANT: Directly below the Graph button is the name of the Group that is displayed (e.g., All is the Group shown in Figure 6). Note that the label is the same as the tab selected at the bottom left of the screen. Data is always shown on a group basis.

7.2

Pilot Graph

The temperatures are shown in bar graph format with the setpoints overlaying the graph, appearing either as gray horizontal lines or right-facing triangles (when in zoom mode). All zones that are not in alarm are shown as green. All zones that are in alarm condition are shown as red (see zone 8 in Figure 7.2). Temperature is displayed at the top of the screen, one zone at a time. That zone is indicated on the bar graph as being a brighter shade than the other bars. The setpoint for that zone appears as a reddish-pink line or triangle (see Tip 14 in Figure 7.2). Another zone can be selected by simply touching another bar on the display, by entering a new zone number or by using the zone Up or Down buttons to the right of the zone number. Touching the Graph button will cause the display to zoom in and display only 10 zones with the last selected zone shown at the far left side of the screen. Touching the Graph button again will cause the display to zoom back out to display all zones in the group.

35

Figure 7.2

Pilot Graph Displaying Group Tip

7.3

Bar Graph

Data is shown in a format similar to Pilot Graph. Setpoint lines or triangles are not displayed (see Figure 7.3 Bar Graph). Up to two variables can be displayed at once. To select which variables are to be displayed, refer to Section 7.9 Graph Settings. Each variable has its own scaling. The first variable is shown in blue. The second variable is shown in purple. The colors do not change when an alarm is active. To select a zone, simply touch the bar display for the appropriate zone. The zone color will turn a brighter shade. Touching the Graph button again will cause the screen to zoom in to show 10 zones with the last selected zone shown at the far left side of the graph. Touching the Graph button again will cause the display to zoom back out to display all zones in the group.

36

Figure 7.3

Bar Graph Displaying Temperature and Heater Resistances for Tip Group

7.4

Line Graph

Data is shown as a line graph (see Figure 7.4). One zones data is displayed at a time. Up to two variables for the zone can be displayed at one time. To choose which variables are displayed, press the Graph Settings button (Section 7.9 Graph Settings) and make the desired selections. The first variable is shown in blue. The second variable is shown in purple. The colors are not affected by alarm status. In the example shown in Figure 7.4, Deviation and Percent Output are plotted. At the bottom of the screen, the average of each of the plotted values is shown. In addition, the average for each of the plotted values is represented by a dashed line (blue for the first variable, purple for the second variable) on the graph. See Section 7.9 Graph Settings for a description of how the settings are used for line graphs.

37

Figure 7.4

Line Graph Displaying Deviation and Percent Output

7.5

Tape Graph

Each zones data is displayed as a simulated-3D colored ribbon showing changes over a period of time as shown in Figure 7.5. This display can be useful in showing how different zones compare over time. Only one variable can be plotted at one time. In Figure 7.5, Deviation is plotted. See Section 7.9 Graph Settings for a description of how the settings are used for tape graphs. A Rotate View button at the bottom of the display enables the operator to view the data from multiple angles. Each time the screen is touched, the image rotates 10 degrees away from the position on the screen that is touched. Each time the left side of the screen is touched, the image rotates 10 degrees in a clockwise manner. Touching the Rotate View button again causes the graph to return to its original position. Two views are selectable: 2D Side View This is the view shown in Figure 7.5a. 2D End View This is the view shown in Figure 7.5b. While using the 2D End View, the user can select zone by touching the zone on the display. Tape graphs are commonly used to compare data (e.g., amperage, wattage) of 2 or more zones at a time. At times, the user may find it beneficial to display a tape graph of a temporary group of zones for diagnostic purposes.

38

Figure 7.5a Tape Graph - Displaying Wattage for Tip Group (Side View)

Figure 7.5b Tape Graph - Displaying Wattage for Tip Group (End View)

7.6

SPC Graph

This graph shows statistical process control data for any variable. In Figure 7.6, Actual Temperature data is displayed on the top graph. The lower control limit (LCLX-bar), the mean (X-bar-bar) and the upper control limit (UCLX-bar) are calculated and displayed beneath the top graph. The Range (R) of the value is 39

calculated and displayed in the lower graph along with the lower control limit (LCLR-bar), the mean range (R-bar) and the upper control limit (UCLR-bar). Regardless of what is being displayed, the TTC 2100 is always performing SPC sampling of all variables for all zones.

Figure 7.6 SPC Graph Displaying Actual Temperature for Tip 6 in Group All

7.7

Data Table

Data is shown in a tabular format as seen in Figure 7.7. Pressing any position in the table will cause the same zone to be displayed at the top of the screen. Data includes: Zone ID Zone Number Setpoint Automatic temperature setpoint. Value Actual temperature. Deviation Difference between Setpoint and Value. Active % - Percentage output. Amps Heater amps. Volts Volts applied to heater. A function of Active %. Ohms Heater resistance. Watts Volts times amps. Alarm If any alarm is active, an x will be displayed. Man % SP In manual mode, this percentage output is used. In automatic mode, the Man % SP is not used. 40

Manual If zone is in manual, an x will be displayed. If in automatic mode, the box will be empty. Off If zone is OFF, an x will be displayed. If zone is ON, the b ox will be empty. Locked If zone is Locked OFF, an x will be displayed. A zone must be unlocked before it can be turned on. If zone is unlocked, the box will be empty.

Figure 7.7

Data Table Displaying Group All

7.8

Tool Graphic

A picture file with a .wmf or .bmp extension can be shown on the screen as seen in Figure 7.8. Wmf files will stretch to fit the screen. An aspect ratio of 2.1:1 will provide an undistorted picture. Bmp files will be displayed 798 pixels wide by 380 pixels high. Pictures cannot be zoomed. Files are saved in the C:\TTC 2100\TOOL directory. Up to 50 interactive data readings (e.g., actual temperature, wattage, amperage) or setpoints can be placed anywhere on each picture. This enables the user to show a graphic display of the tool and choose a variable to display at critical places such as temperatures or wattages. Text will be green unless the zone is in alarm mode. When a zone is in alarm, the text for that zone will be red as shown in Figure 7.8. The user can set up a library of pictures in the c:\TTC 2100\TOOL directory and select which is to be displayed using the Graph Settings button. This is also where the user also can assign interactive setpoints or values to appear on the picture. Each group has its own picture and value settings. When a user touches one of the interactive boxes, the top of the TTC 2100 display will indicate data for that zone. This makes it easy for the user to make quick adjustments to that zone. Note: The interactive data will only be displayed on the picture when the correct group tab is selected. For example, if the data is showing setpoints for the Tip group as shown in Figure 7.8, the data will not appear on the picture when any other group (Man, Spr, All in Figure 7.8) is selected. See Section 7.9 Graph Settings for a description of how to select a tool graphic and how to display data on the picture. 41

Figure 7.8 Tool Graphic Displaying Actual Temperatures for Group Tip

7.9

Graph Settings

The Graph Settings button is located at the upper right corner of each graph. As seen in Figure 7.9a, the settings include: Graph Type The user can choose between Pilot, Bar, Line, Tape, SPC, Data Table and Tool Graphic. First and Second Selections The user can choose which variables to display on the graph. The choices include actual temperature, deviation, percent output, load current, load wattage, process setpoint and manual (percent output) setpoint. Up to two selections can be shown at once on Bar and Line graphs. One variable is the limit for Tape and SPC graphs along with Tool Graphics. Scale Maximum and Scale Minimum There are two sets of these shown on the screen. The Scale Maximum and Scale Minimum settings on the left are for the First Selection. The two settings on the right are for the Second Selection. These limits are only used when the user selects User Defined from the settings below. Max Auto, Min 0 - This is the default setting. This enables the TTC 2100 to automatically and continuously adjust the upper limit of the graphs y-axis to accommodate the highest reading while keeping the minimum at zero. This setting would not be recommended when displaying temperature deviation. If the minimum graph setting is zero, then temperature deviations of negative value (when actual temperatures are below setpoints) would not appear on the display. Max Auto, Min Auto - This selection enables the TTC 2100 to automatically and continuously adjust the upper and lower limits of the graphs y-axis. For example, if all temperatures are between 300F and 400F the graph limits may be 300F for the minimum and 400F for the maximum. If a temperature drops below 300F, the lower limit of the graph would be automatically lowered to include the data point. 42

User Defined This selection enables the user to choose his own upper and lower limits for the graph display. The settings for the First Selection are set using the Scale Maximum and Scale Minimum settings on the left. The settings for the Second Selection are set using the Scale Maximum and Scale Minimum on the right. The user should keep in mind that when the graph type or value displayed is changed, the User Defined settings may need to be changed to something more applicable. For example, in Figure 7.9b, the User Defined settings of +2 and 2 would make no sense for a graph displaying actual temperature. Other buttons that are applicable to the graph type selected will appear on the Graph Settings screen. Figure 7.9a will appear for Pilot, Bar, Line and Tape graphs. Figure 7.9b will appear for SPC graphs. Figure 7.9c will appear for Tool Graphic displays. Exit Door Pressing this button returns the user to the graph display.

Figure 7.9a Graph Settings For Bar Graphs

For Bar, Line and Tape Graphs: Additional settings include (as seen in Figure 7.9a): Time Compression This setting determines how often data is sampled for graphic display. A setting of 10:1 (settable from 1:1 to 300:1) would cause the TTC 2100 to display every tenth sample on the screen. This would have the effect of fitting ten times the normal time period of data on the graph. This would enable the user to see a longer-term picture than if the data is displayed on the 1:1 Time Compression Setting (default setting). Time to Fill Line Graph This is the amount of time it takes in hours:minutes:seconds to fill up the entire graph based on the Time Compression and Seconds per Update settings. Once the graph is full, it will continue to graph, keeping the newest data and dropping the oldest data. Seconds per Update This setting determines how often displayed data is updated. This setting is also used in determining how often databases collect data. The lower the setting, the faster the data is sampled and the faster display graphs fill up. Low settings result in short periods of data being displayed on the graph at one time. Higher settings result in long periods of data being displayed on 43

the graph at one time. This setting has no bearing on the sample rate for control purposes. The default setting is 1 second. The limits are .5 to 65.5 seconds.

Figure 7.9b Graph Settings For SPC Graphs

For SPC Graphs: Additional settings include: SPC Interval This setting determines how often the TTC 2100 will sample data for SPC purposes. Default setting is 1 minute. SPC Subgroup Size This setting determines how many samples the TTC 2100 will take at each interval. Default setting is 5. Time to Fill SPC Chart This is a calculation based on the selected SPC Interval, SPC Subgroup Size and Seconds per Update settings. The value shown is displayed in hours:minutes:seconds. Seconds per Update This setting determines how often each zones data is sampled at each SPC Interval. Default setting is 1 second. For example, in Figure 7.9b, actual temperatures will be sampled 5 consecutive times for every zone in the Tip group every minute. According to data shown in Figure 7.9b, it will take 1 hour, 40 minutes of data before the SPC graph is full. At this point, it will continue to display new data while the oldest data is removed. Clear SPC Data Pressing this button will cause the SPC graph to clear all SPC data and start over.

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Figure 7.9c Graphic Settings For Tool Graphic For Tool Graphic: Additional selections include: Select Tool Picture Touching this area will cause a drop-down list of available picture filenames from the C:\TTC 2100\Tool directory to appear. The user simply selects the desired picture file from this list. Select ----- to remove a picture. To place a picture in the C:\TTC 2100\Tool Directory, use the Copy from Diskette button described in Section 11.8 Copy from Diskette. Pictures are read from the diskette in an uncompressed format. Set Tool Positions Pressing this selection will enable the user to add and remove interactive buttons on the tool graphic. Up to 50 interactive setpoints / readings can be assigned to a picture. To add interactive buttons on a tool graphic: 1) Select Set Tool Positions as shown on Figure 7.9c. 2) Go to the picture by pressing the Exit icon on Figure 7.9c. 3) Select the ID Name and Zone at the top right hand corner of the screen (Tip1 in Figure 7.9c) to choose the zone for the next interactive button. 4) Touch the screen where the interactive button for that zone is to be located. 5) The interactive button can be relocated by touching next to the button (not on the button) and sliding it to the desired location before removing finger from screen. 6) Repeat steps 3 -5 for each zone that is to appear on the picture. 7) When finished, return to Graph Settings screen and press Set Tool Positions to remove the checkmark. This prevents the buttons positions on the picture from changing accidentally. To remove interactive buttons on a tool graphic: 1) Select Set Tool Positions as shown on Figure 7.9c. 2) Select the ID Name and Zone at the top right hand corner of the screen (Tip1 in Figure 7.9c) to choose the zone for which the interactive button will be removed. 3) Press the Remove Tool Icon button. 4) Repeat steps 2-3 for each zone that is to be removed. 5) Press Set Tool Positions button to remove the checkmark to prevent accidental changes. Seconds per Update This setting determines how frequently the value box data is updated. The default value is 1 second. It can be set from .5 to 65.5 seconds. 45

8 ___________________________________________________ Alarms

8.1

General Description

The Alarm button turns red and becomes animated whenever a new alarm is triggered. Pressing the Alarm button acknowledges the alarm and stops the animation. If there is still an alarm condition, the button remains red. If the alarm is no longer in effect and the alarm button has been acknowledged, the button color returns to gray. When the Alarm button is pressed, the screen indicates which alarms are currently active. If a new alarm occurs for more than 5 seconds, the alarm bar will turn red and once again become animated.

Figure 8.1a Active Alarms Displaying Group All

The user can view either Active Alarms or Alarm History by pressing the appropriate button on the lower right portion of the screen shown in Figure 8.1a. Pressing the Active button will result in the display of up to 20 active alarms for the group selected (All in Figure 8.1a). When viewing Active Alarms, zones with only a Low Temperature Deviation Alarm will be displayed below zones with other alarms. Pressing the History button will result in the display of the last 20 alarms to occur for the group selected as shown in Figure 8.1b. Alarms that are currently active appear as >x<. Alarms that occurred previously, but are no longer active, appear as x. Note: Pressing the Clear Alarm History button clears all historical alarms for all zones in all groups.

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Figure 8.1b Alarm History Displaying Group Man

Left to right, the icons at the top of the alarm table represent: Time of Alarm (Current Time shown on top of column) Low Temperature Deviation Alarm High Temperature Deviation Alarm Thermocouple Open Alarm Thermocouple Reversed Alarm Thermocouple Short Alarm Fuse Open Heater Short Heater Open Uncontrollable Zone Mold Monitor Heater Resistance Alarm Mold Monitor High or Low Wattage Alarm To the right of the alarm table are three additional animated alarm buttons: Critical Over Temperature Alarm Mold Monitor Material Protection (Machine Cycling) Alarm Monitor Alarm

At the bottom right corner of the screen there is an information or legend button, that when pressed will display the alarm legend shown in Figure 8.1c.

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Figure 8.1c TTC 2100 Alarm Screen Legend

8.2

Low Temperature Deviation Alarm

This alarm is activated whenever the measured temperature value is less than the temperature setpoint minus the Deviation Alarm Setpoint. For example, if the temperature setpoint is 400F and the Deviation Alarm Setpoint is 20F, then the alarm would be active whenever the temperature reading is below 380F. The alarm is only active when the zone is in Automatic mode (closed loop) control and the output is turned on. To set the alarm value, see Section 12.4 Setup. The controller default setting is 20F (11C). Low Temperature Deviation Alarms occur on start-up and stay active until temperatures exceed the low temperature deviation alarm setting. The Low Temperature Deviation Alarms are given the lowest priority on the Active Alarm screens and are displayed below any other active alarms.

8.3

High Temperature Deviation Alarm

This alarm is activated whenever the measured temperature value is greater than the Temperature Setpoint plus the Deviation Alarm Setpoint. For example, if the temperature setpoint is 400F and the Deviation Alarm Setpoint is 20F, then the alarm would be active whenever the temperature reading is above 420F. This alarm is only active when a zone is in Automatic mode (closed loop) control and the output is turned on. To set the alarm value, see Section 12.4 Setup. The controller default setting is 20F (11C).

8.4

Thermocouple Open Alarm

Indicates that at least one of the thermocouple input wires is open. This alarm is only active in automatic mode (closed loop) control. When a thermocouple fails on a zone, the zone output will switch to a learned manual output that has been determined by averaging the zones recent output level. This enables the controller to continue to make parts in the manual mode until the operator shuts power off to the TTC 2100 or changes the manual percentage output of the zone. In this case, the zone can be put into manual mode and run with an operator selectable percent output (manual) setpoint.

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8.5

Thermocouple Reversed Alarm

If a thermocouple wire is installed with the plus and minus leads reversed, applying heat will result in a decrease in the temperature reading while the actual temperature is rising. When the temperature reading goes below 0F (occurs when the actual temperature is approximately 140F), the Thermocouple Reversed Alarm is activated. A Thermocouple Reversed Alarm will cause the zone to shut off. The alarm is only active in Automatic mode (closed loop) control.

8.6

Thermocouple Short Alarm

A thermocouple may have its leads pinched or shorted together somewhere between the thermocouple junction at the mold and the hot runner temperature controller. When this occurs, the temperature reading will be that of the shorted location and not the temperature at the thermocouple tip. The Thermocouple Short Alarm will activate when the temperature climbs LESS than 20F (11C) while the output has been at 98% for a certain time duration. The duration is a timer setting, called T/C short Detection Time and is described in Section 12.4 Setup. The default setting for each zone is 5 minutes. For example, a thermocouple short may occur at a location where the temperature is room temperature. As the temperature attempts to raise the temperature to setpoint, the output will be at 100% output. While the temperature at the short continues to indicate to the controller that the temperature is only room temperature, the real temperature at the tip is climbing rapidly due to the heater receiving 100% output from the controller. As soon as the TTC 2100 output reaches 98% output or higher, a timer is energized (settable up to 54 minutes). If the temperature does not climb 20F before the timer times out, the output for that zone will be shut off. This can save the tool from heat-related damage. Note: The Low Temperature Alarm would also activate immediately following a short in this example since the temperature at the short would most likely be well under the Low Temperature Alarm setting.

8.7

Fuse Open Alarm

This alarm is active when an output module load fuse is open and the zone is turned on. The physical location of the fuse can be determined quickly using the Find This Module feature (Section 13.3 Find This Module).

8.8

Heater Short Alarm (Heater Bakeout Feature)

This alarm is active when the zone is turned on and the output module (3A, 15A or 30A) senses a heater load greater than the load the output module can carry. On startup, the TTC 2100 employs a very effective Heater Bakeout procedure. The TTC 2100 initially provides a very low voltage (1-5 VAC) to the heater while monitoring the current. As long as the current is within expected limits, the voltage will ramp up to full voltage over a few cycles while the current is continuously monitored. If, at any point, the current draw exceeds expected limits, the Heater Short Alarm will be activated and the cycle will be repeated. The TTC 2100 bakes out the heater by providing the low voltage pulse to the heater. Once the heater is dry, the TTC 2100 will ramp the zones output to full voltage within a few line cycles while continuing to monitor the current draw. A major benefit of this approach is that the TTC 2100 actually measures the current and applies the bakeout procedure only when required.

49

Another benefit is that the use of a low voltage output during Heater Bakeout eliminates heater damage caused by time proportioning controllers that cannot adjust the voltage level. During regular operation, the TTC 2100 continues monitoring for heater shorts. If a short is detected, the alarm will become active. The controller will cut back the output voltage, applying a very low voltage on a repeating basis to determine if the short still exists.

8.9

Heater Open Alarm

This alarm is active when the zone is turned on and the output module senses a load of less than 0.2 amperes (heater resistance of higher than 1200 ohms at 240 VAC) for the 3A and 15A output modules. On the 30A output module, a load of less than .5A will activate the heater open alarm.

8.10 Uncontrollable Zone Alarm

This alarm is activated if the TTC 2100 determines that a zone has become uncontrollable. This is determined by the TTC 2100 detecting that amperage exists when the zone is calling for zero output. This can occur if an output module triac or solid state relay has failed in the conducting mode. If the problem persists, the temperature may climb and activate the Critical Over Temperature Alarm Setting. When the alarm is active, the module with the uncontrollable zone will shut off all outputs on that output module (4 zones on a 3A module, 2 zones on a 15A module and 1 zone on a 30A module). The alarm can be cleared by switching the alarming zone's operating mode between AUTO and MANUAL (Section 9.7 Options Button).

8.11 Mold Monitor Heater Resistance Alarm

This is a unique feature that enables the controller to indicate when a heater is beginning to fail. This is an excellent preventative maintenance tool. If a zone is within 3F of setpoint and the heater deviates by more than 40% of its normal (baseline) value, this alarm will activate. To use this feature, see Section 12.6 Options.

8.12 Mold Monitor High / Low Wattage Alarm

This alarm will activate when the wattage of a zone output is lower than the user-selectable low alarm setting or higher than the user-selectable high alarm setting. The wattage value must be outside the limits for ten consecutive measurements while the temperature is within the high and low deviation alarm settings. See Sections 12.4 Setup and 12.6 Options for more detail.

8.13 Critical Over Temperature Alarm

This alarm is active when any zone in the TTC 2100 exceeds the Critical Over-Temperature Alarm setting selected by the user. The TTC 2100 shuts off all zones in the data concentrator (see Section 20.6 DC Zones) associated with the faulty zone. The alarm will remain activated until all temperatures are below the setting and the animated button is pushed to clear the alarm. This alarm is useful in situations where the user has miswired the tool, causing power to be incorrectly applied to one or more zones. The button changes background colors and is animated while in the alarm condition.

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8.14 Material Protection (Machine Cycling) Alarm

This alarm is functional only if the user has selected this feature to be active (Section 12.6 Options). The alarm becomes active when the external input from the injection molding machine controller is not received in the user-specified selected amount of time. The button changes background colors and is animated while in the alarm condition. Zones that are assigned to the Remote Standby Group (Section 12.6 Options) will be put in Standby while this alarm is active. Pushing the animated button clears the alarm and reinitializes the timer.

8.15 Monitor Alarm

Beginning in July 2009, Monitor Only zones were offered on the TTC 2100. These are zones that are monitored only (no control function) and can be alarmed. For more information, see Section 15 Monitor Only Zones. If the Monitor Alarm button turns red, at least one of the Monitor Only zones is in alarm. If the Monitor Alarm button is pressed while the Monitor Only zones group is selected on the bottom of the screen) a screen similar to one shown in Figure 8.15 will appear:

Figure 8.15 Monitor Only Alarm Screen

8.16 Status of OK to Run

In July, 2009 the Status of OK to Run screen was added to display the status of the OK To Run contact. The screen displays whether the system is OK or not OK. OK to Run Contact The controller can provide a normally open contact closure to the injection molding machine to denote that the mold is heated and is ready for injection.

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The OK to Run contact is open (not OK) when: 1) The controller is not powered. 2) The interlink cable between the controller and the injection molding machine is not connected. 3) Any unlocked zone is off. 4) There is a zone alarm within the controller. 5) All of the zones in the controller are locked off. The OK to Run contact is closed (OK) when: 1) There is a least one zone that is not locked off. 2) All of the unlocked zones are turned On. 3) There are no zone alarms within the controller. Pressing the Status of OK to Run button will display a screen indicating one of the following: 1- The system is OK to Run The OK to Run output contact should be set. 2- Waiting for OK to Run The OK to Run output contact should not be set. There are no errors. The controller is transitioning through the filtering process until the system is OK. 3- The system is not OK to Run The OK to Run output contact is not set. The system is not OK and the zone errors are listed as shown in Figure 8.16.

Figure 8.16 Status of OK to Run Screen Activate Flasher When the System is Not OK To Run By default, the TTC 2100 alarm flasher bar mounted above the screen will not flash when the system is not OK To Run unless it is set up to do so. This can be changed by the user if the user wants the alarm bar to flash whenever the system is Not OK to Run. To make this change, the user must:

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1) Exit the software (shuts down the TTC control functions) and go to Windows. This can be done by pressing the Exit to Windows screen (Section 13.6 Exit to Windows) screen located at the bottom right corner of the Diagnostics screen and entering the Engineering password. 2) Attach a keyboard to the port located on the back of the TTC 2100 screen. 3) Locate the Gammaflux.txt file located at D:\TTC 2100\Gammaflux.txt. 4) Open the file and add the following line: FlashWhenNotOkToRun = 1 5) Save the file. Remove the keyboard and reboot the system. Note: The use of this function to activate the flasher on the operator panel will also cause the contacts for the output of the Resettable Alarm output to remain on whenever the system is Not OK to Run.

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9 ___________________________________________________ Basic Displays / Settings

9.1

Temperature Display

The single zone temperature display is located in the top center portion of the screen. This value is the actual temperature value for the zone ID that is shown at the far right of the same row (e.g., 380F for Man 1 as shown in Figure 9.1). A small F or C is displayed next to the temperature value indicating Fahrenheit of Celsius. If the temperature display indicates ^ ^ ^ , the thermocouple is open. If the temperature display indicates _ _ _ , the thermocouple is reversed. If the temperature display indicates * * * , the zone is not communicating with the thermocouple module. Under normal circumstances, the temperature value will be displayed.

Figure 9.1

Typical Display Controllers View for Group Man

9.2

Boost Button

Boost is a feature that enables the user to automatically and temporarily raise (boost) the temperature setpoints for all the zones in the selected group of zones (e.g., Tips, Mans, All). Normally, Boost is used to quickly raise the tip temperatures just before cycling the machine after the tips have been in an idle or standby mode. This helps eliminate any cold slugs that may exist at the gates. The number of degrees that Boost adds to the setpoints and the amount of time Boost is applied depends on the settings made with the Trim/Boost/Power (Options) button (Section 9.7). 54

For operational purposes, all the operator has to do is press the button. The setpoints for the selected group will be immediately boosted. Figure 9.2 shows what the screen displays while in the Boost mode. The Boost button will become animated and the buttons gray background turns white. The amount of boost time left will appear and count down under the Boost button. Pressing the Boost button while in the Boost mode will cancel Boost. In Figure 9.2, there are 55 seconds remaining in the boosting of the Tip.

Figure 9.2

Tip Group Boosted

9.3

Standby Button

Standby is a feature that enables the operator to drop (or raise in unusual circumstances) the selected group of zones (e.g., Tips, Mans, All) to a predetermined Standby setpoint. The setpoint is selected in the setup procedure (Section 12.4 Setup). Normally, this feature is used to drop the tip and manifold settings to a lower temperature when the machine is not cycling. The temperature should be warm enough that the plastic does not freeze and cool enough that the plastic does not quickly degrade. The default value is 220F (104C). Standby can be selected by pressing the Standby button or by providing a remote signal (see Section 3.5 HA-4 Remote Input Connections). When the Standby button is pressed, the screen shown in Figure 9.3a will appear. Standby Timeout Timer (min) When Standby is selected, a timer (default time is 999 minutes) will start. All zones in the controller will turn off once the timer had timed out. An entry of 0 will disable the timeout and Standby will remain in effect until the Standby button is pressed again to leave the Standby mode.

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Figure 9.3a Standby Button Note: If the unit is put in the Standby mode by an external signal, screen entries are overridden. The group that will be affected by a remote standby signal is selected on the Information / Options screen (Section 12.6 Options). Figure 9.3b shows how the screen will next appear. When in Standby, the button becomes animated and the buttons gray background turns white. The setpoint display does not change. It continues to display the setpoint that will be in effect when Standby is deactivated. If the unit is in Standby mode due to an external signal, the unit can only be placed back into normal mode by deactivating the remote signal. If the unit is in Standby mode due to an operator panel entry, press the Standby button again to leave the Standby mode.

Figure 9.3b All Group in Standby Mode

9.4

Setpoint Button

Pressing the Setpoint button causes an Enter Setpoint box to appear as shown in Figure 9.4. An upper limit and lower limit will be displayed in the box. The user simply selects the new setpoint and enters it by pressing the Group or Zone button. Pressing the Group button will cause the setpoint to apply to all the 56

zones in the selected group (Man in Figure 9.4a). Pressing the Zone button will cause the setpoint to be applied to only the zone that is shown in the upper right corner of the screen. Pressing Cancel will cause the unentered setpoint selection to be discarded. If the Operator ID function (Section 12.6 Options) is being used, the operator will have to enter an assigned 3-digit code before the Enter Setpoint box will appear (Figure 9.4b). Once the code is entered, the operator will be able to make changes until 2 minutes has elapsed since the last setpoint change. At that point, an Operator ID code will be needed again to make changes.

Figure 9.4a Setpoint Entry

Figure 9.4b User ID Entry

9.5

Power On / Off Buttons

Pressing the On button will cause a box to appear as shown in Figure 9.5a. The user can then turn on the entire group (group Man in Figure 9.5a) or just the zone displayed at the time (Man 1 in Figure 9.5a). Pressing Do not turn on any additional zones will cause the box to close with no action being taken. Pressing the Off button will cause a box to appear as shown in Figure 9.5b. The user can then turn on all zones, the zones in the group being displayed or just the zone displayed at the time. Pressing Do not turn off any additional zones will cause the box to close with no action being taken.

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Figure 9.5a Power On Screens

Figure 9.5b Power Off Screens

9.6

Zone Button

Zone identifications (zone IDs) are defined by the combined label name (e.g., Tip, Man, Spr) and zone number. For example, in Figure 9.6, the zone ID is Man 1. Touching the area below the Zone setting will cause the label name to toggle among the available selections for that group. Pressing the Zone setting will cause a box to appear as shown in Figure 9.6 that enables the user to select a valid zone number. The user can also increase or decrease the zone number by using the Up or Down arrows to the right of the zone number. In all, the zone ID can be selected three ways: 1) Pressing the Zone buttons. 2) Pressing the Up and Down arrows. 3) Pressing a zones display on the graph or table.

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Figure 9.6 Selecting a Zone Using the Zone Button

9.7

Options Button (Trim / Boost Settings / Auto Manual Output / Auto Load % / Power)

The button that is located under the Standby and Setpoint buttons is called the Options button. When the button is pressed, an options box appears as shown in Figure 9.7a. From left to right, the icons on the button denote Trim, Manual Percent Setpoint and Auto / Manual Status.

Figure 9.7a Options Button Trim, Boost and Power Settings Selections include: Trim Trim is a feature that enables the user to make a permanent setpoint change to a zone or group of zones. The value selected in this area adds to the setpoint of the zone or group of zones when it is entered. For example, if 5F is selected by the user and entered for the group, all setpoints in the group will be 59

lowered by 5F. In Figure, 9.7a, if the user enters 5 for the zone, the setpoint display would immediately change to 375F. Default value is 0. It is settable from 100 to 100F (-55 to 55C). Boost Setpoint The Boost feature is described in Section 9.2. The Boost Setpoint is the number of degrees the selected zone or group of zones will be temporarily boosted when the Boost button is pressed. Default value is 20F (11C). It is settable from 50 to 50F (-28 to 28C). Boost Time The Boost feature is described in Section 9.2. The Boost Time is the amount of time that the Boost will be applied to the selected zone or group of zones. Default value is 60 seconds. It is settable from 0 to 300 seconds. Auto / Manual The operator can change the auto / manual status of a zone or group of zones using these two buttons. In Auto, the controller provides closed loop control using the thermocouple reading as feedback to the controller. In Manual, the controller ignores the thermocouple reading and simply outputs the percentage selected in the Manual % area. In Manual, the controller will still display the thermocouple reading. Auto / Load % - This is a powerful tool that enables the operator to retrieve the active percent output of a zone (or group) and load the value(s) as the Manual % setpoint(s) for the zone(s). As stated in Section 8.4 Thermocouple Open Alarm, when a thermocouple fails the controller will switch to a learned percentage output and continue molding. If the unit is turned off, the learned percentage is not saved. The Auto / Load % setting enables the learned percentage to be saved as the Manual % output. This setting can be recorded after the zones in the group have been controlling and stable for at least 30 minutes. The Power button is used for changes in Auto / Manual modes. Manual % - The user can enter a manual percent output of 0100% or use the Auto / Load % button to automatically set it. Entering a number does not put the unit into manual mode. Unlock / Lock If the user selects Unlock for a zone, the zones on / off status can be changed. If the user selects Lock for a zone, the zone is locked in the power OFF condition. To turn it back on, the operator must first unlock the zone and then turn the zone on. The Lock feature is normally used to lock a zone in the off position so that when the operator chooses to turn power on to all the zones in a group, the locked zone remains off. This is useful in situations where a tip is blocked off in the tool and the user does not want to apply heat to that tip zone.

Figure 9.7b Power Screen Displaying Group All 60

Power When this button is pressed, the screen in Figure 9.7b appears. The user has a view of the auto / manual / off status and locked / unlocked status of every zone in the group. Touching a blank space causes an X to appear in the box. Touching an X causes it to disappear. To turn a zone on in Figure 9.7b, the operator would simply press the X in the Off row, making the X disappear. To turn a Locked zone from Off to On, the user must first remove the X from the Locked position before toggling the X in the Off position. Any zone that does not have an X in the Off position is ON. Any zone that is ON and does not have an X in the In Man position is in Auto control mode. The user can exit the screen by pressing any touch sensitive icon or setpoint on the touchscreen.

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10 ___________________________________________________ Reports / Print Screens

10.1 General Description
The TTC 2100 can generate a wide array of useful reports. To generate a report on screen or to send a report to a printer, press the Reports (Print) button in the upper left hand corner of the screen. An Operator, Supervisor or Engineer security level is required. The screen shown in Figure 10.1a will appear if the Reports button is active. The screen in Figure 10.1b will appear if the Print button is active.

Figure 10.1a

Report Screen

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Figure 10.1b The user can make the following selections:

Print Screen

Report Type: View Report This selection will cause reports to be viewed on screen, but not printed. Print Report This selection will cause reports to be printed if a printer is connected to the TTC 2100 and the proper printer driver has been installed. The Reports button on top of the screen will change to Print. An orientation box will appear, asking the user to choose portrait or landscape format. The five buttons above Report Type starting with the word View will change to Print (e.g., View SP Changes will change to Print SP Changes). In the Menu screens, the View Menu button (see Figure 11.1) will change to Print Menu. In the Diagnostics Screens, the View Configuration Now button (see Figure 13.1) will change to Print Configuration Now. Report Length This setting determines how much data will be shown on the reports. Report length is settable from 1 to 24 hours. The data shown on the screen is always the most recent data. For example, if the report length is 1 hour, the report always shows the data for the past hour. Data that occurred before that will not be used. Clear all Report Data This selection will clear out all report data for all groups. In effect, this causes the report collection to start over. Setup Reports This selection is used to set up an automatic report collection whereby the TTC 2100 collects data continuously for all zones. Placing a check in the box will cause that report to be automatically generated and date-stamped as often as the Report Length (2 hours in Figure 10.1b) and saved as a Pdf file in the D:\\TTC 2100\Network directory. These files include the Zone Setpoint, SPC Report, Data Summary Report, Alarm Summary Report and Setpoint Change Reports. They can be viewed with the Pdf viewer (see Section 14 Pdfs). They are stored for one year. Then they are automatically deleted to conserve drive space.

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Figure 10.1c

Setup Reports Screen

Reports are different than databases. Databases (Section 16) can be recorded for any length of time and the data is stored in a database file for future retrieval.

10.2 Print Screen

Pressing this button will print the screen that was displayed at the time the user touched the Print (Reports) tab.

10.3 View Setpoints (Print Setpoints)

Pressing this button will cause the screen in Figure 10.3 to appear.

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Figure 10.3 Zone Setpoint Report The user can change the group that is displayed by simply selecting the desired group from the group tabs at the bottom of the screen. Settings shown are the current settings for every zone in the group. Settings cannot be changed from this screen.

10.4 View SPC Summary (Print SPC Summary)

Pressing this button will cause the screen in Figure 10.4 to appear.

Figure 10.4 SPC Report 65

The report shows the average temperatures and standard deviations of each zone in the group in 15 minute intervals. The averages are shown first with the standard deviations shown below.

10.5 View Data Summary (Print Data Summary)

Pressing this button will cause the screen in Figure 10.5 to appear.

Figure 10.5 Data Summary Report Data is shown for each zone including average temperature, standard deviation and temperature range. Minimum and maximum temperatures are shown. The Dev High and Dev Low columns indicate the number of times that the alarms have been activated during the time length of the report. Average output percentage, average current output, average heater watts and the average heater resistance values are also shown for each zone in the group. Data is updated whenever the screen is displayed or scrolled. The averages shown are calculated based upon the Report Length setting (Section 10.1 General Description).

10.6 View Alarm Summary (Print Alarm Summary)

Pressing this button will cause the screen in Figure 10.6 to appear.

66

Figure 10.6 Alarm Summary Report The Alarm Summary Report will indicate every alarm that occurred for the group, what time it occurred and what time it cleared (if it has).

10.7 View SP Changes (Print SP Changes)

Pressing this button will cause the screen in Figure 10.7 to appear.

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Figure 10.7 Setpoint Change Report

Every change that has occurred in the group during the report time length is shown on the screen. For each change, the screen will show the time of change, who made the change, the process setpoint, manual percent output, the auto/manual output status, the on/off output status and latched / unlatched alarm status at the time of the change. Changes are highlighted in yellow. If the Operator ID function is used, the users ID appears under the Who column. The user can change the group that is displayed by simply selecting the desired group from the group tabs at the bottom of the screen.

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11 ___________________________________________________ Menus Screens

11.1 General Description
When the Menu button is pressed, the screen in Figure 11.1 appears. An Operator, Supervisor or Engineer security level is required.

Figure 11.1 Menus Screen A menu is a file that contains a collection of zone setpoints, group settings and graph settings for all permanent groups. For example, in Figure 11.1, the menus listed are not just for the Tip group, they apply to all zones in the TTC 2100. Menus may be thought of as recipes for certain tools or applications. A user may want to set up different menus for different days (August-1.mnu), tool tests or specific part runoffs. Tool graphics are also associated with Menus. The Menu name that is in effect is always shown in the upper right corner of the screen (A123 in Figure 11.1). A plus sign next to the menu name is shown (as shown in figure 11.1) whenever a setpoint has been changed since loading the menu. Menus consist of: List of Zone IDs and Numbers Group Names and their Associated Zones Job Information including Title, Operator, Shift, Mold Number, Machine Number and Comments Date Created Boost Temperature Boost Temperature Setpoint Limit Boost Time Critical Over Temperature Setpoint 69

Temperature Setpoint Limit Manual Percent Output Limit Trim Setpoint Limit Slaved Power Up Status Slaving Group Name Standby Group Name Material Protection Timer Value Material Protection Enable Tool Picture Information including Picture File Name for each Group that has a Picture and Icon Positions Temperature Setpoints Manual Percent Output Setpoints On / Off, Auto / Manual, and Locked / Unlocked Status of each Zone Deviation Alarm Setpoints Auto Standby Setpoints Tuning Range Overrides Output Alarm Latched Status Short Detect Timeout Time Mold Monitor Heater Resistance Baselines Watt Alarm Enable Watt Alarm High Setpoint Watt Alarm Low Setpoint Software Rewiring Information

11.2 Select a Menu

All existing menus are shown in the Select a Menu area. To select a menu, simply select it from the list. The name of the selected menu will appear in the Menu Selected area. All menus are stored in the C:\TTC 2100\Menus directory. Menus are Microsoft Access 9.0 compatible. Menus can also be selected using the Mold ID feature if the unit is quipped with this option (see Section 23. Mold ID). Note that there are two menus shown in Figure 11.1 that include the word Default. The Default.mnu is the current collection of all setpoints and settings being used by the TTC 2100. If the unit is turned off and then on, the Default.mnu settings would be used on start-up until the user selects a different menu. Every time a setpoint or setting is changed, a new Default.mnu menu is automatically created by the TTC 2100. The previous menu is then automatically saved and named Default_1.mnu. Anytime a menu is saved with an existing menu name, the previous menu will have a _1 added to the menu name, just as the previous Default.mnu was renamed Default_1.mnu.

11.3 Restore
Pressing the Restore button will cause the menu file displayed in the Menu Selected area to be used by the TTC 2100. A message asking Are you sure? will appear where the user can select OK or Cancel. Software rewiring information (Section 20.3 Software Rewire (of Thermocouples)) can be part of a menu. When a menu is restored that includes software rewiring information, a message appears asking the operator if the swap information is to be loaded with the menu.

11.4 Copy to Diskette / USB

The user can copy any menu from the TTC 2100 to the on-board USB memory drive located on the back of the screen. Simply select the menu name from the Select a Menu area, make sure a USB stick is in the USB memory drive and press Copy to Diskette / USB. The TTC 2100 will compress the file before transferring the file to the USB stick. 70

11.5 Delete
The user can delete any menu from the TTC 2100 Menus directory. Simply select the menu name from the Select a Menu area and press Delete. A message asking Are you sure? will appear where the user can select OK or Cancel.

11.6 View a Menu (Print a Menu)

The View a Menu button enables the user to view information about the menu in the Menu Selected area as shown in Figure 11.6a. Data such as date of creation and any notes the creator recorded are shown. This helps the user to ensure that the correct menu is selected before any further action is taken.

Figure 11.6a

Menu Report Information Screen

If the View Menu Data button is pressed, the screen in Figure 11.6b will be displayed.

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Figure 11.6b

Menu Report Data Screen

11.7 New Menu Name and Save (Creating a New Menu)

To create a new menu: 1) Press the blank area under New Menu Name. 2) In the Change To: area, enter a name using the alphanumeric keypad that appears. All saved menus are automatically given a .mnu extension. For example, if the operator enters Menu1 as the name for a new menu, the TTC 2100 will name it Menu1.mnu. If the user enters an illegal menu name, the TTC 2100 will indicate an error when the enter button is pressed. If the user enters a name that is already used, an error will be indicated. The user can choose to overwrite the existing menu. 3) Press the Save button. The new menu will contain all setpoints and settings that are in use at the time the new menu name is created. The new menu name will appear in the Select a Menu list.

11.8 Copy From Diskette / USB

A menu can be loaded from a USB stick. When the Copy From Diskette / USB button is pressed, a screen will appear listing the valid menu files that are contained on the USB stick. The user then can select which file to copy. When the Enter button is pressed, the menu will be copied to the hard drive of the TTC 2100. Note: Copying a file from USB stick does not put the menu into instant use. If the user wants to use the newly copied file as the current menu, then the file should be chosen from the Select a Menu list and then the Restore button should be pressed.

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12 ___________________________________________________ Information Screens (Setup)

12.1 General Description
The Information button is used to gain access to tool information, selection of security levels and controller setup. When the Information button is pressed, the screen shown in Figure 12.1 will appear.

Figure 12.1 Job Information Screen

12.2 Job Information

The User can enter information into any of the Title, Operator, Shift, Mold Number, Machine Number, Comments and Note areas using the alphanumeric keypad that appears on the screen when an area is touched. If a menu is stored after entering information on this screen, all information other than that shown in the Note area it will be saved with the menu.

12.3 Security Levels

Security levels can be used to limit access to the TTC 2100. This serves two functions. First, it enables supervisors to set up parameters that cannot be changed by personnel with lower security levels. Second, it simplifies the screens for the user. Any buttons that the user cannot access are automatically removed from the screen, thereby eliminating confusion. The buttons reappear when the higher security level is reentered. There are 4 security levels Engineer, Supervisor, Operator and Monitor. Figure 12.3 shows which functions are accessible for each security level. Contact Gammaflux for Security Codes. 73

Engineer Highest level. Total access to all settings and information in theTTC 2100. Required for Mold Doctor and Field Calibration. Supervisor Typically used for setup of controller other than calibration, wiring, or tool diagnostics. Same as Engineer level except: No access to Field Calibration No access to Mold Doctor Operator Typically used to change setpoints without having access to more detailed setup information. Same as Supervisor level except: No access to alarm setpoints No access to upper and lower limits of setpoints Monitor Typically used when no access to any setpoints is desired. User can view operational data, but is unable to change any control parameters. Same as Operator level except: No access to setpoints.

Functions
Turn Zones On/Off Acknowledge Alarms Change Zones Auto/Manual Status Change Setpoints Access Menus Access Reports /Print / Graphs Access Help Screens Create Temporary Groups Create Permanent Groups Access Databases Change Setpoint Limits Change Options (Trim, Boost) Change Language Basic Diagnostics (Mold Monitor) Enable / Disable Mold ID (if available) Advanced Diagnostics (Mold Doctor, Field Calibrator) Change Operator IDs Exit to Windows Figure 12.3

Engineer Supervisor Operator Monitor

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

Security Level Access Definition

To increase the level of security, use the following procedure: 1) Touch the box under Security Level. 2) Enter the security code for the level immediately above the level displayed. The level can only be changed one security level at a time in order to maximize security (e.g., from Monitor to Operator or from Operator to Supervisor or from Supervisor to Engineer). 3) To increase another level, repeat steps 1 and 2. To decrease the level of security, use the following procedure: 1) Touch the box under Security Level. 2) Enter 0 to decrease the security level one level from the level displayed. 3) To decrease the level again, repeat steps 1 and 2.

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12.4 Setup
Pressing the Setup button on the Information screen will give the supervisor or engineer level user access to the TTC setup screens. The screen in Figure 12.4a will appear.

Figure 12.4a

Setup Screen

Settings can be made on a per zone / per group basis (By Zone) and for all zones at once (System Wide). When a setting is changed in the By Zone area, a box appears that enables the user to make the setting apply to just that zone or for the group that is selected with the group tab at the bottom of the screen (Group All in Figure 12.4a). In the By Zone portion of the screen the settings include: Deviation Alarm This setting sets the number of degrees plus and minus from setpoint that the high and low temperature alarms will become active. Default setting is +/- 20F (+/- 11C). Range is 0-999F (0-537C). Auto Standby When the TTC is placed into the Standby Mode (either by touching the screen or by the reception of an external signal), the setpoint of each zone goes to the Standby setpoint assigned for that zone. Zones in manual output mode will go to 50% of the manual output percentage setting. Upon exiting the Standby Mode, the zones return to their normal setpoints. While there are other uses for this setting, the temperature setting is most commonly set to a temperature that the user wants the zones to go to when the machine is not molding, but in an idling condition. Default setting is 220F (104C). Range is 0-999F (0-537C). Thermocouple Short Detection Time The Thermocouple Short Alarm will activate if a temperature has not changed 20F (11C) in a certain period of time, once the zones output has reached 98%. If this alarm activates, the output to that zone will be turned off. This setting determines the period of time that the controller will wait before activating the alarm. Range is 054 minutes. The 0 setting (default setting) indicates the default value of 5 minutes is in use. Tuning Range Override Normally this setting is set to zero for all zones, causing the zones to be auto-tuned. On rare occasions, it may be determined that a zones tuning setting can be improved when a particular zone is faster or slower than normal. If a difficulty exists, it can also 75

be due to factors such as thermocouple placement too near or too far from the heater, incorrect heater size or intermittent connections. Note: Slaving function (Section 12.6) will be inoperable when the Tuning Range Override Setpoint for one or more zones in the Slaving group is set to 0. This is due to the fact that zones in the Slaving Group do not have the opportunity to auto-tune. They are being turned on and off to keep all zones within 20F as they heat up. If Slaving is used, the following Tuning Range Override settings are recommended as trial settings: a) For tip zones - +10 (-1 for fast tips) b) For manifold and manifold zones - +20 If these initial settings do not result in tight control, the settings can be adjusted to optimize control. Here is a guide to the settings: -31 to -30 = Ultra fast, low mass (-30 setting works well for tips such as Husky 250 Series) -27 to -20 = Fast tip (-27 is fastest setting). -17 to 10 = Fast manifold (-17 is fastest setting). -1 = Manual entry for fast tips (not as fast as 27 to 20 settings) 0 = Standard tuning. The controller will determine if the setting should be 1 or 2. 1 = Controller displays this value when using standard tuning and zone behaves like a tip. 2 = Controller displays this value when using standard tuning and zone behaves like a manifold. 10 to 17 = Tip (17 is slowest setting). 20 to 27 = Manifold (27 is slowest setting). Watt Alarm High The High Watt Alarm can be used to determine if a zone is providing a higher wattage than normal to maintain setpoint. If the watt alarms are to be used, they must be activated in the setup procedure (Section 12.6 Options). Default setting is 8000 watts. Range is 0-8000 watts. If the zone is set to Alarm on Sampled Wattage (see Section 12.6 Options): The High Watt Alarm will be activated whenever this setting is reached or exceeded for ten consecutive measurements while the controller is controlling near setpoint (within the high and low temperature deviation settings). If the zone is set to Alarm on Average Wattage (see Section 12.6 Options): The High Watt Alarm will be activated whenever the average wattage value exceeds the high wattage alarm limit for four consecutive sample periods. Each sample consists of 100 consecutive wattage readings (nominally 2 minutes). Watt Alarm Low The Low Watt Alarm can be used to determine if a zone is providing a lower wattage than normal to maintain setpoint. If the watt alarms are to be used, they must be activated in the setup procedure (Section 12.6 Options). Default setting is 0 watts. Range is 0-8000 watts. If the zone is set to Alarm on Sampled Wattage (see Section 12.6 Options): The Low Watt Alarm will be activated whenever the wattage falls below this setting for ten consecutive measurements while the controller is controlling near setpoint (within the high and low temperature deviation settings). If the zone is set to Alarm on Average Wattage (see Section 12.6 Options): The High Watt Alarm will be activated whenever the average wattage value falls below the low wattage alarm limit for four consecutive sample periods. Each sample consists of 100 consecutive wattage readings (nominally 2 minutes). Power Priority Low mass or extremely small hot runner nozzles are a unique challenge to control. To smooth the power and ultimately the melt heat history, Gammaflux has created Power PriorityTM . Power PriorityTM smoothes the power output to individual zones. Users have the option to manually apply a Power PriorityTM setpoint from 1 (light effect) to 4 (heavy effect), providing unparalleled control for applications where it is most needed. A Power PriorityTM setpoint of 0 disables the Power PriorityTM function for that zone. Normally, this setting should be set to 0 unless low mass (extremely small) hot runners are in use. 76

Alarms Latched Placing a check in this box causes all alarms to appear on the screen. At times, an alarm may occur and clear between screen updates (based upon the Seconds per Update setting in Section 7.9 Graph Settings). With the Seconds per Update setting set to its default value of 1 second, an alarm would have to occur and clear in less than a second for the Alarms Latched feature to show an alarm that would not otherwise appear on the screen. This can be valuable in detecting an intermittent problem such as a momentary heater short. Default setting is unlatched. In the System Wide portion of the screen the settings include: Critical Over Temperature Alarm The TTC 2100 will turn off all zone outputs if this temperature setting is exceeded in any zone. This setting is used to help prevent an uncontrollable zone from rising to a temperature that might damage the tool. It can also provide useful protection in the event of a miswired tool. The default setting is 999F (537C). Range is 0-999F (0-537C).

CAUTION: DO NOT SET THE CRITICAL OVER TEMPERATURE ALARM SETTING TO A VALUE THAT THE CONTROLLER WILL EXCEED UNDER NORMAL CIRCUMSTANCES. Temperature Setpoint Maximum Limit This setting limits how high individual zone setpoints can be set. This prevents a user from setting a setpoint too high. Default value is 999F (537C). Range is 0-999F (0-537C). Manual Percent Maximum Limit The setting limits how high a manual output level can be set on any zone. This setting does not set the manual percentage. It only limits how high it can be set. Default value is 100%. Range is 0-100%. Trim Limit Trim is a feature that enables the user to raise or lower the setpoint of a zone or group of zones by a certain number of degrees even if all of the setpoints are different. The trim limit setting determines the maximum number of degrees a user can trim (plus or minus) a zone or group of zones at one time. This setting does not set the trim setpoint. It only limits how high the trim setting can be set. Default trim limit setting is 100F (56C). Range is 0 to 999F (0 to 537C). Boost Limit Boost is a feature that enables the operator to temporarily raise (or lower) the setpoint of a zone or group of zones by a certain pre-set number of degrees (boost) for a pre-set amount of time (boost time). When time has expired, the setpoints automatically return to their previous values. This feature is commonly used to heat tips to ensure that the plastic at the gates is molten just before restarting machine cycling. Default boost limit is 50F (28C). Range is 0-999F (0-537C). Group Data - When the Group Data button is pushed, the screen shown in Figure 12.4b will appear. Settings are shown for all the zones in the selected group. Pressing the Group Data button at the bottom of the screen will return the user to the previous screen shown in Figure 12.4a. The two buttons on the Group Data Screen are: Group Data Pressing this button will return the operator to the Setup Screen shown in Figure 12.4. Save Actual Tuning to Setpoint In Figure 12.4b, the Group Data screen shows 0 as the tuning setting. The actual tuning setting calculated by the controller is not indicated. The calculated tuning setting can be locked in and used as a manual tuning override if desired. To do so, press the Save Actual Tuning to Setpoint button. The actual tuning setpoint at that moment will now be locked in and displayed on both the screen shown in Figure 12.4a and on the Tuning Range Override setting on the Setup screen in Figure 12.4a. Please note, that if this setpoint is locked in, the controller will no longer auto-tune those zones. 77

Figure 12.4b

Group Data Screen

Setup Monitor Zones is a button that is positioned near the bottom right portion of the screen shown in Figure 12.4a. For more information regarding Monitor Zones, see Section 15 Monitor Zones.

12.5 Setup Copy % Output

The Setup Copy % Output button shown in Figure 12.4 can be used to tie one zones output to one or more other zones outputs. This can be useful when one zone has a bad thermocouple or when a manifold zone has two separate heaters, but only one thermocouple. When the Setup Copy % Output button is pressed, the screen shown in Figure 12.5a appears. Pressing on the The % Output of the Zone box will cause the zone selection drop-down box to appear as shown in Figure 12.5b. Select a zone from the list on the left and then a different zone that the output is to be copied to from the list on the right. The changes are applied to the controller when the selection is made. The list of zones that can be linked is limited to the zones within the current group (the All group in Figure 12.5a) and the within the same data concentrator. Press Display Assignments to view the linkages currently in use. The screen in Figure 12.5c will appear. In the example shown in Figure 12.5c, Tip1s output is linked to Tip2. This means that Tip2 will use the same % output value that Tip1 is using. Also, from the example shown in Figure 12.5a, Tip3 is linked to Tip4 and Tip5 is linked to Tip6. The linking will remain intact until the operator removes the link on this screen. Even if Tip2 is placed in manual, Tip2 will still use the same output value that Tip1 is using. When this feature is used, the message Copy Output will appear in the top right corner of the screen directly under the current menu name.

78

Figure 12.5a

Copy Zone % Output Screen

Figure 12.5b

Copy Zone % Output Zone Selection Screen

79

Figure 12.5c

Copy Zone % Output Display Assignments Screen

Remove the Copy Output Wiring for this Zone Press this button to remove the linkage between the zones displayed in The % Output of the Zone and Will be sent to the Zone boxes (Tip5 to Tip6 in Figure 12.5c. Remove All Copy Output Wiring Press this box to remove all linkages.

12.6 Options
When the Options button at the bottom right side of the Information screen (Figure 12.1) is pressed, the screen shown in Figure 12.6a will appear.

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Figure 12.6a The following settings are available:

Options Screen

Slaving Group Slaving is a feature that forces all zones in the selected group to stay within 20F (11C) of the coldest zone in that group during start-up or following a setpoint change. This is commonly used to bring tips up to temperature along with the slowest manifold zone, thereby ensuring that the tips are not at setpoint for a long time waiting for the manifolds to come up to temperature. In Figure 12.6a, the group selected is All. A selection of -------- will disable the Slaving function. Note: The Slaving function cannot be initiated if one or more of the zones in the Slaving Group have a Tuning Override Setpoint (Section 12.4 Setup) set to 0. The Slaving Group box will appear in yellow (see Figure 12.6b) when this is the case and a pop-up message will appear to notify the operator when this is the case. See Section 12.4 Setup for a description of how to change the Tuning Override Setpoint settings.

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Figure 12.6b

Slaving Group Prohibited

Remote Standby Group The Remote Standby function will operate only on the Group that is selected with this setting. In Figure 12.6a, the selected group is All, which means all zones will be put into Standby when the remote standby signal is received. This setting does not apply to the regular Standby mode that is energized by pressing the Standby button on the screen. A selection of -------- will disable the Remote Standby function. Remote Boost Group - The Remote Boost function will operate only on the Group that is selected with this setting. In Figure 12.6a, the selected group is Tip, which means all zones associated with the Tip group will be put into Boost when the remote boost signal is received. The Boost is not cancelled by the removal of the remote boost signal. Boost can be restarted while in progress by removing and reapplying the remote boost signal. A selection of -------- will disable the Remote Boost function. The Remote Boost Group setting is not related to the regular Boost mode which is energized by pressing the Boost button on the screen. Outputs on Power Up This setting determines what state the heater outputs will be in when the power is turned on by the main breaker: Always Off This selection causes outputs to remain off following power up or when a menu is restored (Section 11.3 Restore). The user must use the Power buttons to turn the zones ON. This is commonly used to give the user time to select what he wants to do before the zones start heating. Ask The outputs will initially be as they were when power was lost. A box will appear, asking the user if the zones that were ON should remain ON. If the user does not respond in 10 seconds, power to all zones will be turned OFF. Ask is the default setting. Auto On This selection enables the zones on / off status to automatically return to the same status following power up. Plants that have frequent power outages may want to use this selection so that the user does not need to go to every controller to power up the heaters after a short power outage. Temperature Scale The user can select F (Fahrenheit) or C (Celsius). All setpoints and values are automatically converted. Default setting is F. Enable Entry of Temperature Setpoint in Tenth of a Degree - The TTC 2100 reacts to .1F temperature changes whether this feature is selected or not. Selecting this feature enables the user to read the temperature and to set the setpoint to .1F or .1C resolution. 82

12.7 Mold Monitor

Pressing the Mold Monitor button causes the screen shown in Figure 12.7 to appear. The selections on this screen include: Enable Material Protection (Machine Cycle Detection) Material Protection is a feature that requires a signal from the injection molding machine. If the signal is not present for a selected period of time, the TTC will activate the Remote Standby Group (Section 12.6 Options). This feature is used to help prevent material degradation due to high temperatures when the machine is not cycling. Default setting is DISABLED. Material Protection Timer in Seconds This setting determines the time the signal from the injection molding machine must be absent before the zones are shut off. For example, if 20 seconds is used, the zones in the Remote Standby Group (Section 12.6 Options) will go to Standby if the TTC does not receive a signal from the machine within 20 seconds. The timer will not be active until all low temperature alarms have cleared on startup. The timer will not be active until all low temperature alarms have cleared on startup. If the timer times out, the timer must be reset by pressing the Material Protection Alarm button (Section 8.14 Material Protection Alarm) on the Alarm screen. Default setting is 0 seconds. Range is 0-999 seconds. Enable Heater Resistance Alarm If this feature is selected, the Heater Resistance Alarm will be enabled. This function triggers an alarm whenever the heater resistance for a zone varies by 40% or more when compared to its baseline measurement. Default setting is DISABLED. Take Baseline The TTC will record the heater resistances of all zones when this button is pushed. It is recommended that the user wait at least a couple of hours after startup before taking a new baseline. Heaters, by nature, tend to change resistance when they heat up. The TTC 2100 retains the baseline readings in memory when power is turned off. Baseline values are also stored in menus. Enable Watt Alarm If this feature is selected, the Watt Alarm High and Watt Alarm Low alarms will be enabled. Value settings for the alarms are shown in Figure 12.4a. The default settings are 0 watts and 8000 watts which disable the alarm. The Watt Alarm for a zone will be activated whenever the zone output exceeds the alarm setpoints while the zone is turned on and is controlling near setpoint. This alarm can be used to determine if a zone is providing a higher or lower output than normal to maintain setpoint. For example, the High Watt Alarm might be used to alarm if a thermocouple or heater becomes coated in plastic due to leakage. The Low Watt Alarm might be used to indicate that a heater that is wired in parallel with others has failed. The Watt Alarm can be set to trigger using either of the following two methods: Alarm on Sampled Wattage - The alarm is activated if the zone wattage is outside of the alarm setpoint band for ten consecutive measurements while the controller zone is controlling near setpoint. Any sample within the allowed wattage range will reset the counter. Any sample where the zone wattage is 0 will reset the counter. Any sample where the zone is in temperature deviation alarm will reset the counter. This is the default setting and on earlier software versions was the only method available. Alarm on Average Wattage The average is calculated over 100 screen update samples (nominally less than two minutes). The average wattage has to exceed the Watt Alarm Setpoints for 4 consecutive sample periods before the alarm is triggered. This detection method can handle zones that are oscillating several degrees whereas the other detection method cannot. An oscillating zone may at times go to 0% output which would reset the counter when using the Alarm on Sampled Wattage method. Tolerance to apply to High Watt Alarm Setpoints Another way to set the High Watt alarm is to choose a value that is a certain percentage (tolerance) above the normal wattage value for each zone. The default tolerance setting is 10% as shown in Figure 12.7. Once the machine is running and making good parts for half an hour, press the Set High Watt Alarm Setpoints button. A High Watt alarm will occur whenever this value is exceeded. If a setpoint is changed, the Set High 83

Watt Alarm Setpoints button should be pressed again after the temperature is stable for half an hour. This will ensure that the alarm settings are appropriate for the new temperature setpoints.

Figure 12.7 Mold Monitor Screen

12.8 Sequence Start

The Sequence Start function operates by turning ON groups of zones based upon actual temperature status and/or time. Up to 4 stages can be implemented. Each stage performs the following steps: - Turn a group of zones ON - Then wait for all of the zones within the group to get within the zone temperature deviation setpoints - Then wait the time set by the Delay Timer. Group of Zones to Turn On - Each stage will only turn the specified group of zones ON. Any zones that were turned on prior to starting the Sequence Start function or any zones turned on in any previous stage will remain on. The stages do not turn any zones OFF. Wait for Zones to get Within Deviation - Place a check in the Wait for Zones to get Within Deviation box if all of the zones within that group have to rise to within the zone temperature deviation setpoints before progressing to the next step. The temperature portion of the stage can be bypassed by not placing a check in the box. Delay Timer - The maximum entry for the Delay Timer is 999 minutes. Entries can be made to .1minute. The Delay Timer portion of the stage is disabled with an entry of 0. The example below shows that two (2) stages have been setup. Typically a stage would use either the temperature test or the Delay Timer, though both can be used at the same time. A Sequence Start message is displayed under the Boost button to note that the Sequence Start function is in operation. The background of the border of the message provides an indication of the overall progress of the function. The progress is calculated as a combination of the number of stages used, the actual temperatures, and the expired delay times. A green highlight is used to denote what part of what stage is in operation. A progress bar is displayed for each stage of the function. All is shown on Figure 12.8a. 84

Cancel Sequence Start - Use this button to end the Sequence Start. Information - Pressing the information (blue i) button nest to the exit button will cause the Sequence Screen Tutor Screen to appear as shown in Figure 12.8b. Done Press this button to return to the screen shown in Figure 12.6a.

Figure 12.8a

Sequence Start Screen

Figure 12.8b

Sequence Start Tutor Screen 85

Once the Sequence Start function is set up, it can be initialized by pressing the On button and then Sequence Start Heatup button on the pop-up screen shown in figure 12.8c.

Figure 12.8c

Sequence Start Initialization

12.9 Even Cool

The Even Cool function controls the cool down operation of a group of zones, keeping them within approximately 15F of each other before they are automatically turned off once they reach the endpoint temperature setpoint. When the Even Cool function is set up, the screen shown in Figure 12.9a will appear when the Off button is selected.

Figure 12.9a

Off Button Screen when Even Cool Is Set Up

Even Cool Group - The temperature setpoints are automatically adjusted so that all of the zones in the group selected remain within ~15F of each other as they cool. Even Cool Endpoint Temperature - All of the zones in the controller will be turned off when all of the zones in the Even Cool Group drop lower than the Even Cool Endpoint Temperature setpoint (220F shown as an example in Figure 12.9b). Done Press this button to return to the screen shown in Figure 12.6a.

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Figure 12.9b

Even Cool Screen

12.10 Sequenced Power Up

Pressing this Sequenced Power Up button shown in Figure 12.6a causes the screen in Figure 12.10 to appear. The operator can select up to 3 menus that will be sequenced as a function of the 2 timers. Sequenced Power Up is often used for staging the start-up of a tool. The buttons that appear on the Sequenced Power Up Screen include: Sequence Menu 1 This is the initial menu that the TTC will use when the Start Sequence button is pressed or when a signal is received at the back of the TTC for Remote Sequenced Power Up (Section 21Programmable Input / Output Functions). To select a menu, touch the area to the right of the Sequence Menu 1 button. Select the menu from the list of existing menus that appears (M1 in Figure 12.10). The highlighted menu shows which menu is in use at that moment as does the display in the upper right corner. Sequence Timer 1 Enter the number of minutes that Sequence Menu 1 is to be used (20 minutes in Figure 12.10). Sequence Menu 2 To select a menu, touch the area to the right of the Sequence Menu 2 button. This is the menu that will be used when Sequence Timer 1 times out. Sequence Timer 2 Enter the number of minutes that Sequence Menu 2 is to be used. If only 2 Sequence Menus are required, set Sequence Timer 2 to 0 minutes and use the same menu in Sequence Menu 3 that is used in Sequence Menu 2. Sequence Menu 3 To select a menu, touch the area to the right of the Sequence Menu 3 button. This is the menu that continues to be used when the sequenced power up is completed or when the End Sequence button is pressed. Start Sequence Pressing this button causes the TTC 2100 to use Sequence Menu 1 and start Sequence Timer 1. The Sequenced Power Up icon appears at the top of the screen until the end of the Sequenced Power Up as shown in Figure 12.10. 87

End Sequence Pressing this button will interrupt the Sequenced Power Up. The TTC 2100 will use Sequence Menu 3. Information The blue i button will cause the Sequenced Power Up tutorial screen to appear. Done Press this button to return to the screen shown in Figure 12.6a.

Figure 12.10

Sequenced Power Up Screen

12.11 Language
Pressing the Language button causes the screen in Figure 12.11 to appear. The user can select the language for all screen verbiage from the language selections that appear. Languages include Czesky, Dansk, Deutsch, English, Espaol, Franais, Italiano, Nederlands, Polski, Portuguese, Svenska, Vlaams and Far Eastern character sets. Other languages easily available using Windows XP based language editor and character sets. Kanji and other double byte character sets are also now available. Contact Gammaflux for more information.

88

Figure 12.11

Language Screen

12.12 Operator IDs

Operator IDs can be used to add security and tracking of which operator made changes to the settings. Pressing this Operators ID button shown in Figure 12.6a causes the screen in Figure 12.12 to appear. If Operator IDs are used, a screen will appear requiring the user to enter a valid Operator ID before a setpoint change can be made (Section 9.4 Setpoint Button). The operator will be able to make changes without reentering the User ID until 2 minutes has elapsed from the last setpoint change. If Operator IDs are used, the Setpoint Changes report will identify all changes each operator makes to setpoints. Operators are identified by both an ID number and a name. Up to 999 Operators IDs can be functional at one time.

Figure 12.12

Operator ID Screen

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The buttons that appear on the Operator ID Screen include: Add New Operator When this button is touched, a keypad will appear that enables the user to enter an ID number and a name that will appear in the next available line on the table shown in Figure 12.6j. Remove Operator To remove an operator, touch this button and select the operator from the table that is to be removed. Done Press this button to return to the screen shown in Figure 12.6a.

12.13

Edit Group (Setting Up Permanent Groups)

While temporary (Section 5.2 Temporary Groups) and instant groups (Section 5.3 Instant Groups) are set up using the Controllers and New*Group buttons, permanent groups are set up using the Edit Groups button. Pressing the Edit Groups button will cause the screen in Figure 5.4 to appear. Permanent groups are saved in menus and when power is turned off. Temporary groups are groups that are not saved in menus or when power is turned off. See Section 5.4 Permanent Groups for all procedures relating to permanent groups.

12.14 Stop Communications

Pressing this key will cause to TTC 2100 to disable all communications and disk access, making it safe to turn off power at the circuit breaker. A message will appear asking the operator Are you sure?. This message is followed by a message stating It is now safe to shut down the system.. Finally, a message will appear asking Do you want to resume system operation?. Note: If the user wants to leave the software and outputs running when leaving the TTC software, the Exit to Windows button (Section 13.6 Exit to Windows) should be used.

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13 ___________________________________________________ Diagnostics Screens

13.1 General Description
The Diagnostic screens are used to run diagnostic programs and to supply diagnostic related information to the user. . A Supervisor or Engineer security level is required. Databases record all data and display it in meaningful formats that assist the project engineers and maintenance people alike. See Section 16 Databases. Mold Doctor is an off line tool for diagnosing thermocouple, heater and wiring problems as well as tool inefficiencies. An Engineer security level is required. See Section 17 Mold Doctor. Field Calibrator is an off - line tool that enables thermocouple calibration at the users convenience. An Engineer security level is required. See Section 18 Field Calibrator. Edit Configuration enables the user to assign zone names and addresses to thermocouple and output module hardware. An Engineer security level is required. See Section 20 Edit Configuration. Tuning is used to gain access to and change the tuning of one or more zones. Pressing the Diagnostics button at the top of the screen will cause the screen in Figure 13.1 to appear.

Figure 13.1 Diagnostic Screen

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13.2 Find This Module

This function is available to help the user quickly locate the hardware associated with the zone selected in the Zone area of the screen (upper right corner). When the Find This Module button is touched, the screen shown in Figure 13.2 appears. Slot location, fuse location, power connector pin numbers, thermocouple input location and thermocouple connector pin numbers that are associated with the zone selected in the upper right hand corner of the screen (Tip 1 in Figure 13.3) will be displayed. A module light can be used to indicate the hardware location of a zone or group of zones depending upon the selection made under: Show Module Light for: Selected Zone Module light lights on the output board that includes the zone indicated in the upper right corner of the screen (Tip 1 in Figure 13.3). Scroll Through Group Module light scrolls through each zone in the group selected on the screen (Tip in Figure 13.3). Pause Scrolling Module light stops scrolling until this selection is pressed again.

Figure 13.2

Find This Module Screen

13.3 View Configuration Now (Print Configuration Now)

Pressing the View Configuration will cause a screen to appear with a data table as shown in Figure 13.3.

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Figure 13.3

Zone Configuration Report Screen

For a description of System Zone, DC Zone Number, DC Zone Address, Output Slot, T/C Module and T/C Module Zone see Section 20 Edit Configuration. The Power Connector, Power Pins, T/C Connector and T/C pins describe the connector label and the actual pins on the connector that are associated with each zone in the group. No changes can be made from this screen.

13.4 View Versions

Pressing the View Versions button will cause a screen to appear that lists the software and hardware versions of the different boards in the system. Press the Read Versions button to update the version data.

93

Figure 13.4 View Versions Screen

13.5 View Voltages

Pressing the View Voltages button will cause the screen shown in Figure 13.5 to appear. This screen is very useful in determining if there is a problem with incoming power on any of the phases.

Figure 13.5 Systems Line Voltages Screen

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13.6 Exit to Windows

Pressing the Exit to Windows button will cause the TTC 2100 software to close. A screen message will appear warning the user that the outputs of the zones do not turn off when exiting to Windows. If the user touches OK, then the screen in Figure 13.6 will appear. Engineer security level is required to use this button. The computer will exit to the Windows XP operating system. Note: If the user wants to stop communications without exiting to Windows, the Stop Communications button (Section 12.14 Stop Communications) should be used.

Figure 13.6 Exit to Windows Screen

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14 ____________________________________________________ Pdfs
14.1 General Description
Pressing the Pdf button will allow the user to select a file from the Pdf files in the Pdf directory of the TTC software as shown in Figure 14.1. The English version of the TTC manual is always present. Other manual translations can be copied from the Customer Resource CD shipped with the unit onto a USB memory drive and copied into the TTC using the Copy from Diskette/USB button.

Figure 14.1 Pdf File Selection Screen

14.2 Viewing and Transferring Pdf Files

To handle the viewing and transferring of a Pdf file, the following buttons are used: View Pdf Press this button to view the Pdf File Selected. Delete Pdf Press this button to delete the Pdf File Selected. Copy to Diskette/USB Press this button to copy the Pdf File Selected to a USB memory drive. Copy from Diskette/USB Press this button to copy files from a USB memory drive to the Pdf directory. When completed, the new Pdf files will show up in the list on the left side of the screen. It is important to note that any Read Only attributes of a Pdf file should be removed before importing the file into the TTC computer. The Delete button will be unable to delete the file if the Read Only attributes are not first removed. Select All By selecting Select All, all Pdf files shown on the left side of the screen can be exported to a USB memory drive or deleted at the same time. 96

14.3 Viewing and Transferring Pdf Report Files

The TTC can be set up to automatically record reports such as the Zone Setpoints Report, SPC Report, Data Summary Report, Alarm Summary Report and the Setpoint Changes Report (see Section 10 Reports/Print Screens). The View Pdf, Delete Pdf, Copy to Diskette/USB, Copy from Diskette/USB and Select All buttons mentioned in Section 14.2 Viewing and Transferring Pdf Files are all used to view and transfer Pdf Report Screens. To locate the available reports, press the Find Pdf Reports button. Find Pdf Reports Press this button to show the collected reports (see Section 10 Reports/Print Screens). The column on the right will show the month and year of the directories (2010_12 shown in Figure 14.3a indicates the directory was created December, 2010). Choosing one causes the list of available reports for that month to appear in the column on the left as shown in Figure 14.3a. The file names on the left indicate the date and hour of completion (Data_12_14_09 indicates a Data Summary report that was completed or printed at 9AM on December 14). If a file is completed within the same hour as a previous report, an A will appear at the end of the older files name (such as Data_12_14_11_A shown in Figure 14.3a). Any or all of these files can be copied to a USB memory stick using the Copy to Diskette/USB and Copy from Diskette/USB buttons on the screen. To view, select one (SPC_12_14_11.pdf in Figure 14.3a) and press View Pdf. The report will appear on the screen (sample shown in Figure 14.3b). The Find Pdf Reports button will not appear on the screen if no reports have been saved.

Figure 14.3a

Report Pdf File Selection Screen

97

Figure 14.3b

Sample SPC Report Pdf

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15 ____________________________________________________ Monitor Only Zones

15.1 General Description
In addition to the temperature zones that the TTC 2100 controls, additional process temperatures such as water temperatures can be monitored and alarmed. This function is for monitoring and alarming only. There are no operational control outputs associated with these zones. High and/or low alarm settings can be set for each monitored temperature. The presence of a Monitor alarm activates the operator panel alarm flasher and closes the alarm contacts. The presence of a Monitor alarm can be set to perform no action, to change the status of the "OK to Run" contact, to place the controller in Standby or to turn off all of the zones in the controller. The Monitor function is accomplished by adding an output zone for each Monitor zone to be tested. A connection is made to the thermocouple input for that zone. No output control cabling is used for these Monitor zones. All of the hot runner zones and the Monitor zones must be of the same type J or type K setting. A zone that has been set to operate as a Monitor zone will appear as Monitor in place of Auto or Manual in the box located below the On and Off buttons. The Monitor zone information is included in the on-screen and printed Setpoint and Menu Reports. Changes to the Monitor High Alarm and Low Alarm setpoints are not reported in the Setpoint Change Reports. To get started, press the Setup Monitor Zones button on the Setup screen shown in Figure 15.1

Figure 15.1 Setup Screen 99

15.2 Setting Up Monitor Only Zones

To set up a group of Monitor zones: 1) Make a permanent group to contain the Monitor Only zones (refer to Section 5.2 Permanent Groups to review). This allows setpoint entry to be performed by group without affecting the non-monitor zones. This also allows the graphing and charting of Monitor zones like any other group of zones. 2) Lock off all zones in this Monitor group (refer to Section 9.7 Options Button to review). This will prevent the zones from being turned ON and generating any Open Heater alarms or any thermocouple alarms. 3) Press the Information tab and select Setup. Then select Setup Monitor Zones. A screen similar to the one shown in Figure 15.2a Monitor Only Setup Screen will appear. 4) Place a Y (Yes) in the grid for those zones to be tested for high a larm. 5) Place a Y in the grid for those zones to be tested for low alarm. 6) Enter the high and/or low absolute (not deviation) temperature alarm setpoints. 7) Place a Y at the top of the grid for those zones to be monitored and alarmed.

Figure 15.2a Monitor Only Zones Setup Screen Press the Setup Alarm Action bottom shown in the bottom left corner of Figure 15.2a. A screen similar to the one shown in Figure 15.2b will appear.

100

Figure 15.2b Monitor Only Zones Alarm Setup Screen Choose which action is desired for when a Monitor Only zone goes into alarm. The choices are: Alarm only The alarm screen will indicate there is an alarm, but no other action will be taken. Activate Standby for the Remote Standby group when a Monitor Alarm is detected The presence of a Monitor alarm will place the controller into Standby. The Remote Standby group on the Options screen (refer to Section 12.6 Options to review) is used to select which zones in the controller will be set to Standby when an alarm is detected. If an alarm occurs and the Remote Standby group is put into Standby, the unit can be reset by using the following procedure: 1) Press the Standby button to release the Standby operation. 2) Press the Monitor Alarm button on the Alarm screen to acknowledge the Monitor alarm. If the Monitor alarm is still present, the controller will go back into Standby Turn Off all of the zones in the controllers when a Monitor Alarm is detected - The presence of a Monitor alarm will turn off ALL of the zones in the controller. To reset the alarm, use the following procedure: 1) Press the Monitor Alarm button on the Alarm screen to acknowledge the Monitor alarm. 2) Press the green ON button at the top of the screen to turn the zones back on again. If the Monitor alarm is still present, the zones in the controller will be turned off again. Include Monitor Zone Alarms in the OK to Run output If this box is checked, a Monitor Zone Alarm will affect the status of the OK to Run output.

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16 ____________________________________________________ Databases
16.1 General Description
Databases record data for all zones, not just one group. Unlike reports, databases are stored with a filename, can be reviewed anytime and can be downloaded to disks. The Database button is used to set up the name and parameters of a new database or to select an existing database for review. The TTC 2100 continues to control no matter what is being displayed on the screen. The user can Playback a database for a previously run tool while still continuing to control the tool that is currently in the machine. Pressing the Database button will cause the screen in Figure 16.1 to appear.

Figure 16.1 Database Screen

16.2 Setting Up a Database

Settings on this screen include: Recording Status: Monitor Only When this box is selected, the TTC 2100 is not recording data. It will continue to display current data. Record Data If this selection is chosen, the TTC 2100 will immediately begin recording data in the file shown to the left (33mm Shield.mdb in Figure 16.1). If the user wants to record to a different file name or a new file name, the area to the left of Record Data should be pressed. The user will have a choice of choosing a new database file name with the alphanumeric keypad that appears or typing in the name of an existing database. Each database file name has an mdb extension. If the user does not enter it, the TTC 2100 will automatically do so. Database files 102

created by the TTC 2100 are compatible with Microsoft Access 9.0. So, in addition to viewing databases on the TTC 2100 screen, databases can be downloaded to a USB flash drive (floppy disk on earlier units) and viewed on any computer running Microsoft Access 9.0 software. Playback Data To playback a database, touch the area to the far left of the Playback button. Once a file is selected from the drop down menu that appears, Playback can be selected. Figure 16.2 shows an example of the playback of a database. The top central part of the screen is replaced with a Database Playback slide bar along with a Time indicator of the time the displayed data was recorded. Fast Reverse, Reverse, Stop (Pause), Forward and Fast Forward controls appear below the Database Playback slide bar. All variables (e.g., temperature, wattage, load amperage) are automatically recorded. Data can be shown using any format available (e.g., bar graphs, SPC graphs, Controllers view). The Menus button is removed from the screen when Databases are played back.

Figure 16.2 Playback of Database On File Full: Keep Newest If this selection is chosen, the database file will fill to the chosen size and then write over the existing data so the data is always the most recent. This is the default setting. Keep Oldest If this selection is chosen, the database file will fill up and then stop recording. Max File Size The file size is directly related to the Time to Fill File value shown at the bottom of the screen. The user should choose a file size that results in the number of hours or days of data that is desired. Time Compression This setting is also directly related to the Time to Fill File value. It can be thought of as a data sampling rate. The default setting is 1:1 (data is normally sampled every 3 seconds for database storage), but if disk space is limited the user may want to compress time. A setting of 2:1 would cause the TTC to store data every 6 seconds or half as frequently as it normally would. The limit is 300:1. Time to Fill File This is a calculation made by the controller. The calculated time is a function of the number of zones, the file size and the time compression.

103

Select Database If the user wants to preview, delete or copy an existing database, the appropriate database should be selected by touching the area under Select Database. The user can then select the database from the list of existing databases that appears on the screen. Preview Database Pressing this button will cause the screen in Figure 16.1 to appear. It will show information relating to the file shown in the Select Database field. Information includes date and time of creation along with users notes. The purpose of this selection is to give the user the opportunity to confirm that this is the file the user wants to access.

Figure 16.2 Preview Database Information Delete Pressing this button will cause the file displayed in the Select Database area to be deleted. Copy to Diskette/USB - Pressing this button will cause the file displayed in the Select Database area to be compressed and copied to a USB flash drive (diskette on earlier units) if inserted in the slot on the back of the TTC 2100 screen. If the database exceeds the available space on the diskette/USB, the user will be prompted to insert another diskette/USB when the disk is full. Copy from Diskette/USB Pressing this button will cause a screen to appear that lists the files that are located on the diskette/USB mounted on the back of the TTC 2100 screen. Select the appropriate file and enter. The file will be copied into the list of databases on the TTC 2100. If multiple diskettes/ USB flash drives are required to enter the database data, a prompt will be displayed when the controller is ready for the user to insert the next disk.

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17 ____________________________________________________ Mold Doctor

17.1 General Description
Mold Doctor is an off-line set of diagnostic tools that enables the user to detect tool problems or inefficiencies. Ideally, these tests would be run in the tool room before the tool is placed in the machine. This way, diagnosed problems can be fixed before they result in lost production time on the floor. The four major tests include: 1) Wiring Analysis The TTC 2100 locates any thermocouple or heater problems in the tool. In addition, the test will reveal if any zones have been miswired. 2) Fault Analysis This test is the same as the Wiring Analysis test, except that it does not check for zones that have been miswired. 3) Thermodynamic Analysis This test measures a variety of important variables including heater resistances, percent outputs, amperages, heating rate per zone and cooling rate per zone. 4) Historical Mold Performance This test compares the results of any two Thermodynamic Analysis tests. It will highlight differences between the two, thereby indicating how the tool has changed since it was last tested. When the Mold Doctor button is pressed, the screen shown in Figure 17.1a will appear. Note: Mold Doctor only works on temporary groups. If the temporary group does not already exist, the user needs to set it up using the procedure described in Section 5.2 Temporary Groups. In Figure 17.1a, the temporary group *Tip1-Tip20 is being used. To the right of the Mold Doctor selections, a text area appears, reminding the operator to set up a temporary group and to update job information.

Figure 17.1a

Mold Doctor Screen 105

For the Wiring Analysis, Fault Analysis and Thermodynamic Analysis, the initial screen will ask for the Starting Temperature for Mold Doctor Tests as shown in Figure 17.1b for the Wiring Analysis. Mold Doctor tests will not start until the temperature of all zones are lower than the Starting Temperature. It should be set at least 200F lower than the expected production setpoints for those zones. The default setting is 200F.

Figure 17.1b

Mold Doctor Starting Temperature Selection Screen

17.2 Wiring Analysis

The Wiring Analysis procedure detects open thermocouples, reversed thermocouples, shorted thermocouples, shorted heaters, open heaters and open fuses. It also detects cross-wired zones, which cause one zone to heat another zone. The controller powers up the first zone of the temporary group being used, determines if the zone is heating and then determines if any other zone is heating. Once the testing of the first zone is completed, it repeats the same test for each zone in the group. While the test is being run, the screen shown in Figure 17.2 will appear. The horizontal blue bar is continuously updated, displaying how much of the testing has been completed. It generally takes 2 minutes per zone. The results of the test are shown on the screen and can be printed along with the most recently entered job information using the Print Report button. The test can be aborted at any time using the Cancel button.

106

Figure 17.2 Wiring Analysis

17.3 Fault Analysis

The Fault Analysis procedure detects open thermocouples, reversed thermocouples, shorted thermocouples, shorted heaters, open heaters and open fuses. It is similar to the Wiring Analysis, except that it does not check for cross-wiring of zones. This test is often run once the tool is known to be wired correctly. This test generally takes 5 minutes for the entire test. The result of the test is shown on the screen and can be printed along with the most recently entered job information using the Print Report button. The test can be aborted at any time using the Cancel button.

107

Figure 17.3 Fault Analysis

17.4 Thermodynamic Analysis

The Thermodynamic Analysis provides information that can be used by a variety of personnel. While providing preventative maintenance information such as heater resistance of each zone, it also indicates heating and cooling rates of each zone for process engineering personnel. With this test, the key is to locate zones that are inconsistent with similar zones. For example, the user may run a test on a temporary group similar to *Tip1-Tip20 as shown in Figure 17.2. If one tip is heating up at a much slower rate than similar tips, it may be an indication that the heater is starting to burn out or that the thermocouple and heater have different spacing than other tips. A review of heater resistances or percent outputs for the suspicious zones may further indicate if the problem is with the heater. Upon initialization of the test, the controller will bring all zones in the temporary group to approximately 200F (93C). Then the temperature is ramped up to 400F (204C) and then ramped back down to 300F (149C). To get the most out of the test, cooling water should be applied in order that the cooling rate can be calculated and displayed more accurately. If cooling water is not available, the user can choose for the controller to skip the cooling part of the test. This test generally takes about 30 minutes to perform, partly dependent upon the cooling efficiency of the tool test. The test can be aborted at any time using the Cancel button. Results can be stored for future review. To store the results, press the Save Analysis Data button and enter a file name using the alphanumeric keypad that appears. Then press the Enter button. Results can also be printed using the Print Report button.

108

Figure 17.4 Thermodynamic Analysis

17.5 Historical Mold Performance

This test automatically compares any two Thermodynamic Analysis tests. The user selects the file names of the two files to be compared. The controller will then display the data, specifically showing which data has changed and by what percentage. If the data for a particular value in both files is within 10%, the word OK will appear in the table. Changes in heater resistances, output percentages and other data could be an early indication that a heater is about to fail. To get the most out of this report, the two Thermodynamic Analysis tests being compared should be completed under similar conditions. For example, if cooling rate data is being compared, it is important that the same water temperature and water flow rates were used in the two Thermodynamic Analysis tests. Otherwise, it would be expected that the test using the colder cooling water would result in faster cooling rates. The result of the test is shown on the screen and can be printed along with the most recently entered job information using the Print Report button. The test can be aborted at any time using the Cancel button.

109

Figure 17.5 Historic Analysis

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18 ___________________________________________________ Field Calibrator

18.1 General Description
Field Calibrator is an off - line procedure that can be performed at the convenience of the user. A calibrated thermocouple simulator is required to provide an accurate thermocouple signal to the TTC. If the user does not have a calibrated thermocouple source, one can be obtained from a variety of sources. Gammaflux field personnel sometimes use the Omega CL23A Digital Temperature Calibrator available from Omega Engineering in Stamford, CT at (203) 359-1660. During calibration, the target temperature is compared against the incoming thermocouple signal. Any error found between the target and the actual is corrected by the TTC 2100 assigning a New Offset for each zone. The controller remembers both the New Offset and the Old Offset, which was the setting from the previous calibration procedure. Pressing the Field Calibrator button will cause the screen in Figure 18.1 to appear.

Figure 18.1 Field Calibrator Screen

18.2 Read Offsets

When Field Calibration is performed (Section 18.3), use the Read Offsets button to display the offsets (corrections) that the Field Calibration has calculated and applied. The data will appear as shown in Figure 18.1.

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18.3 Calibrate Group (Performing Field Calibration)

The steps required to perform a field calibration are as displayed on Figure 18.1 and state: 1. Create new temporary groups that contain only those zones that can be connected to the thermocouple source at one time. Groups may be created on the Controllers screen using the New*Group button to create the group. Note: Only temporary groups, those that have an * as the first character may be calibrated.

(A connector can be made up by the user or by Gammaflux that would have all the positive thermocouple signal pins jumpered together and all the negative thermocouple signal pins jumpered together. Then, the thermocouple simulator could be wired to one pair on the connector and plugged into the appropriate thermocouple connector on the back of the TTC enclosure. This will enable the user to calibrate the zones in groups instead of one zone at a time.) 2. Update Job information on information screen for report.

(This is for reference information. It is helpful to the operator to know when the calibration was done.) 3. Connect the thermocouple source to the zones in the temporary group to be calibrated and select the group. Set the source and the Target setpoint to the same temperature value.

4.

(It is common to select a temperature that is close to the normal temperatures that most of the tools run. Common temperatures include 400F and 200C.) 5. Touch the Calibrate Group button.

When the Calibrate Group button is pressed, the table at the bottom of the screen will be filled in such as the one shown in Figure 18.1. This group is now calibrated. Field Calibrator has an accuracy of 0.2 F or 0.1 C. To continue with the rest of the zones, repeat the 5 steps shown above.

18.4 Restore Old Offsets

Pressing the Restore Old Offsets button causes the newly calculated New Offsets to be replaced by the previous Old Offsets shown in Figure 18.1. This might be used if, for any reason, the old values are more accurate or if the user is not confident in the accuracy of the thermocouple simulator being used.

18.5 Zero Offsets

Pressing the Zero Offsets button will cause the zones to display temperature values with no offset. This might be used during troubleshooting. Even after offsets are zeroed, the Restore Old Offsets button can be used to restore Old Offsets from the previous calibration procedure.

18.6 Print Report

Pressing the Print Report button will cause the report to be sent to the printer.

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19 ___________________________________________________ Tuning
19.1 General Description
The TTC 2100 automatically determines its tuning parameters. The Tuning screens enable the user to display existing tuning parameters and to make changes in those unusual situations where tuning needs to be adjusted. Like with the Mold Doctor and Calibration procedures, Tuning procedures are done on temporary groups only. Tuning is done automatically by the controller. Tuning values can be manually changed by entering different numbers in the using the Tuning Range Override setting during Setup (see Section 12.4 Setup). One of the key factors in tuning is delay time. This is the measured amount of time that it takes for a change in heater output to be sensed by the thermocouple. Zones with long delay times are considered to be slower than other zones. Zones with short delay times are considered to be faster than other zones. Manifold zones tend to have more delay than tip zones. Low mass or extremely small hot runner nozzles are a unique challenge to control. To smooth the power and ultimately the melt heat history, Gammaflux has created Power PriorityTM . Power PriorityTM smoothes the power output to individual zones. Users have the option to manually apply a Power PriorityTM setpoint from 1 (light effect) to 4 (heavy effect), providing unparalleled control for applications where it is most needed (see Section 12.4 Setup).

19.2 Display Tuning

When the Display Tuning button is pressed, it displays the existing tuning parameters of the temporary group selected (Group *Tip1-Tip12) in Figure 19.2. The tuning number displayed indicates that the zone is set up as the following: -31 to -30 -27 to -20 -17 to 10 -1 0 1 2 10 to 17 20 to 27 = Ultra fast, low mass (-30 setting works well for tips such as Husky 250 Series) = Fast tip (-27 is fastest setting). = Fast manifold (-17 is fastest setting). = Manual entry for fast tips (not as fast as 27 to 20 settings) = Standard tuning. The controller will determine if the setting should be 1 or 2. = Controller displays this value when using standard tuning and zone behaves like a tip. = Controller displays this value when using standard tuning and zone behaves like a manifold. = Tip (17 is slowest setting). = Manifold (27 is slowest setting).

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Figure 19.2 Display Tuning Screen

19.3 Set Tuning to Standard

Pressing the Set Tuning to Standard button causes the New Tuning values to be set to 0. This button might be used if the user manually entered tuning values using the Tuning Range Override setting on the Information / Setup Screen as described in Section 12.4 Setup that are not performing well. For example, if a tool change occurs, the manually entered Tuning Range Override may not apply anymore.

19.4 Tune
To re-tune zones, use the following procedure: 1) Create new temporary groups containing only those zones to be tuned. Groups may be created on the Controllers screen using the New*Group button to create the group. Note: Only temporary groups, those that have an * as the first character may be tuned. 2. Update Job information on information screen for report. (This is for reference information. It is helpful to the operator to know when the tuning was done.) Wait for the temperatures to be stable. Temperatures must change less than one degree F (1/2 degree C) for 30 seconds before tuning may start. Touch the Tune button to start tuning. During the tuning procedure, the Tune Rite area of the screen will be replaced by a horizontal blue bar that shows the progress of the tuning procedure. The instructions area will be replaced with a description of what is occurring at the moment. Upon completion, the tuning data will appear in the table.

3.

4.

Note: This is the procedure for automatically re-tuning the TTC 2100. The user can also enter tuning constants manually using the Tuning Range Override setting on the Information / Setup Screen as described in Section 12.4 Setup.

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19.5 Return to Old Tuning

Pressing the Return to Old Tuning button causes the tuning values shown in the New Tuning area to be swapped with the tuning values shown in the Old Tuning area.

19.6 Print Report

Pressing the Print Report button will cause the report to be sent to the printer.

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20 ___________________________________________________ Change Configuration

20.1 General Description
Configuration is the assignment of zone names and addresses to thermocouple and output module hardware. Configuration of the TTC is done prior to shipment at Gammaflux per customer specifications.

CHANGES MADE IN THESE AREAS CAN SIGNIFICANTLY AFFECT ON THE OPERATION OF THE TTC 2100. CHANGES SHOULD ONLY BE MADE WITH A THOROUGH UNDERSTANDING OF THEIR IMPLICATIONS. IF THERE IS ANY QUESTION ABOUT HOW TO PROCEED, CONTACT GAMMAFLUX PERSONNEL FOR ASSISTANCE.

To access the configuration portion of the software, touch the Diagnostics tab at the top of the screen and then select Change Configuration from the Diagnostics screen shown in Figure 20.1a. The screen shown in Figure 20.1b will appear.

Figure 20.1a

Diagnostics Screen

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Figure 20.1b

Change Configuration Screen

20.2 Name Zones

Pressing the Name Zones button will cause the screen shown in Figure 20.2 to appear. An Engineer level security code is required to make changes using the Name Zones screen.

Figure 20.2 Name Zones Screen

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To make changes, use the following procedure: 1) Use the From and To areas to Select Range of System Zones numbers (e.g., 1 and 12) that are to have their ID Names changed. 2) Assign an ID name (e.g., Tip) for these selected zones by touching the appropriate selection in the Select ID for selected range of system zones from the list area. The controller will assign zone numbers for each ID name starting with 1. For example, designating System Zone Numbers 65-71 as Man causes the table to automatically assign System Zone Numbers 65-71 as Man 1-7. 3) If the user needs to create a new ID name that is not shown (e.g., Bar for Barrel), then press Add ID to List key and type in the new name in the Change To: area on the alphanumeric keypad that appears. An ID should contain no more than 5 characters. If you would like to delete an ID name from the list, simply select the ID name that is to be deleted and press Remove ID from List. 4) The changes the user makes will appear in the area above the Accept and Undo buttons. 5) Press the Accept on the right side of the screen to accept your changes. The changes will appear on the table shown. 6) If desired, the Undo button can still be used to clear the last accepted change. 7) Repeat steps 1-6 to make additional changes. 8) To enter the changes as shown on the table and exit the screen, press the Accept button on the left side of the screen. 9) If the user chooses to undo all the changes made during this configuration session and exit the screen, press the No Changes button. If the user wants to undo all the changes made during this configuration session and stay on the Configuration screens, press the Restore Original button.

20.3 Software Rewire (of Thermocouples)

Software Rewire is used to change the assignment of thermocouples to zones. It is most commonly used when it is discovered that two or more thermocouples are wired incorrectly in the tool. Instead of taking the time to open the tool and correct the problem, it may be desirable to temporarily change the thermocouple assignment in software. After pressing the Diagnostics tab and Change Configuration, press Software Rewire to view the Software Rewire screen (Figure 20.3).

Figure 20.3

Software Rewire Inputs Screen

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The software rewiring of thermocouples can be accomplished using the following procedure: 1) Select the first zone or group of sequential System Zones that is to be repositioned (Zones 3-4 in Figure 20.3). 2) Select the zone or group of sequential System Zones that is to be swapped with the zone(s) selected in step 1 (Zones 7-8 in Figure 20.3). The same number of zones must be selected in each step. An error message will notify the operator if an attempt to swap zones is made with an unequal number of zones. 3) Press Swap Inputs. The results of the swap appears in the table at the bottom of the screen (Tips 7-8 have been moved into the Tips 3-4 original position, Tips 3-4 have been moved into the Tips 7-8 original position). System Zones that have been swapped appear with a red background (and will continue to be shown with a red background the next time the Software Rewire Inputs screen is accessed). These changes do not become official until the Accept button is pressed. 4) The swap can be undone by pressing Undo Last Swap. 5) More swaps can be made at this time by repeating steps 1-3. 6) Pressing Restore Original undoes all swaps that have been made since the operator last accessed the screen. If multiple swaps have been made during the session, all will be undone. 7) Pressing Undo All Rewiring undoes all swaps that have been done at any time using the existing menu. 8) To make swaps official and to leave the screen, press Accept. To ignore swaps and restore conditions to what they were when the screen was accessed, press the No Changes (exit door icon) button. Software rewiring information can be saved to the menu (Section 11 Menus). When a menu is restored that includes software rewiring information, a message appears asking the operator if the swap information is to be loaded with the menu.

20.4 Edit Configuration

Pressing the Edit Configuration button causes the screen shown in Figure 20.4 to appear after the operator is asked to enter in the Engineering Security Code.

Figure 20.4

Edit Configuration Screen

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There is a slide bar at the bottom of the screen than enables the user to see and edit configuration for all the zones. Much can be learned by studying the data table. Data shown includes: System Zone Number This number is assigned left to right by the TTC 2100. ID Name - This is chosen by the user. The name can be edited using the procedure described in Section 20.5 Edit ID. ID Number This number is assigned by the TTC 2100. The controller automatically numbers zones, starting with number 1 for each new ID Name (e.g., Tip in Figure 20.4). DC DC is the abbreviation for Data Concentrator (communication module). Each data concentrator is associated with up to 64 zones. They are numbered 0,1,2,3 etc. DC Zone Number - The zone number is assigned by the TTC 2100 by numbering the zones from the first zone on the first board to the last zone of the last board for each data concentrator. Each data concentrator has up to 64 zone numbers (numbered 0 to 63). DC Zone Address The addresses are assigned by the TTC 2100. The number assigned depends upon the type of output module (3A, 15A or 30A), which position the zone has on the output module and the slot number where the board resides. It is not necessary to know how the DC Zone Address is calculated, but for those who do want to know, the calculation description follows: 1) 3A zones Each 3A output module contains 4 zones of control. The DC Zone Addresses range from 0-63. The formula the TTC 2100 uses to calculate the DC Zone address number is: 4 x (Slot number 1) + (position of zone on the output module - 1) Examples: a) Tip 2 is the 2nd zone on a 3A output module and the board is in slot 1. The DC Zone Address would be 4 x (1-1) + (2-1) = 1 as shown in Figure 20.4. b) Tip 12 is the 4th zone on a 3A output module and the board is in slot 3. The DC Zone Address would be 4 x (3-1) + (4-1) = 11as shown in Figure 20.4.

2) 15A zones Each 15A output module contains 2 zones of control. The DC Zone Addresses range from 64-127. The formula the TTC 2100 uses to calculate the DC Zone address number is: 2 x (Slot number 1) + (position of zone on the output module - 1) + 64 Example: A zone is the 2nd zone on a 15A output module and the board is in slot 5. The DC Zone Address would be 2 x (5-1) + (2-1) + 64 = 73.

3) 30A zones Each 30A output module contains 1 zone of control and fills 2 slots. The DC Zone Addresses range from 128-191. The formula the TTC 2100 uses to calculate the DC Zone address number is: (Slot number 1) + 128 Example: A zone is the 1st zone on a 30A output module and the board is in slot 1. The DC Zone Address would be (1-1) + 128 = 128

Slot There are 16 slots for each data concentrator for a maximum of 64 slots (numbered 1 to 64) for a quad heat sink enclosure. Slots can be filled with 4-zone 3A cards (1 slot), 2-zone 15A cards (1 or 2 slots depending upon current draw of heaters) and 1-zone 30A cards (2 slots). The data table indicates the slot for every zone.

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Power Connector The data table indicates which heater output cable is associated with each zone. This is only changeable by Gammaflux personnel. Pins The data table indicates which pins on the heater cable are associated with each zone. This is only changeable by Gammaflux personnel. TC Module Each Thermocouple Module contains 16 thermocouple inputs. The data table indicates which thermocouple input position is associated with each zone. TC Module Zone This number (0 to 15) is the input address for each Thermocouple Module. For example, the eighth thermocouple input on the card would be TC Module Zone 7. TC Connector - The data table indicates which thermocouple cable is associated with each zone. This is only changeable by Gammaflux personnel. Pins The data table indicates the pin numbers for the plus and minus thermocouple inputs for each zone. This is only changeable by Gammaflux personnel.

20.5 Edit ID (Assign Zone Names)

Every zone has a System Zone number, which is assigned by the controller. The user can assign an ID Name to each System Zone number. An ID Name could be a label such as Tip, Man or Sprue. The TTC 2100 automatically assigns the ID Number. To make changes, use the following procedure: 1) Use the From and To areas to Select Range of System Zones numbers (e.g., 1 and 12) that are to have their ID Names changed. 2) Assign an ID name (e.g., Tip) for these selected zones by touching the appropriate selection in the Select ID for selected range of system zones from the list area. The controller will assign zone numbers for each ID name starting with 1. For example, in Figure 20.5, designating System Zone Numbers 65-71 as Man causes the table to automatically assign System Zone Numbers 65-71 to Man 17. 3) If the user needs to create a new ID name that is not shown (e.g., Bar for Barrel), then press Add ID to List key and type in the new name in the Change To: area on the alphanumeric keypad that appears. An ID should contain no more than 5 characters. If you would like to delete an ID name from the list, simply select the ID name that is to be deleted and press Remove ID from List. 4) The changes the user makes will appear in the area above the Accept and Undo buttons. 5) Press Accept on the right side of the screen to accept your changes. The changes will appear on the table shown. 6) If desired, the Undo button can still be used to clear the last accepted change. 7) Repeat steps 1-6 to make additional changes. 8) To enter the changes as shown on the table and exit the screen, press the Accept button on the left side of the screen. 9) If the user chooses to undo all the changes made during this configuration session and exit the screen, press the No Changes button. If the user wants to undo all the changes made during this configuration session and stay on the Configuration screens, press the Restore Original button.

CAUTION: THE NO CHANGES AND RESTORE ORIGINAL BUTTONS CLEAR ALL CHANGES MADE DURING THE SESSION IN EDIT ID, MOVE ZONE ADDRESS, ASSIGN INPUT AND TYPE J OR K. IT DOES NOT MATTER WHICH SCREEN IS BEING DISPLAYED AT THE TIME.

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Figure 20.5 Edit ID Screen

20.6 Move Zone Address

The Move Zone Address button is used to modify which ID Names and ID Numbers match up with the output modules. Changes are NOT RECOMMENDED. When the Move Zone Address button is pressed, a screen shown in Figure 20.6 will appear.

Figure 20.6 Move Zone Address Screen 122

Changes should only be made by personnel thoroughly familiar with the TTC 2100. Mistakes made in this area will cause mismatching of hardware and can result in significant problems. If there is any doubt about how to proceed, contact Gammaflux personnel for assistance. A user may want to change a group of zones if a different ID Number is desired. For example, the user may want Tip 5-8 to be displayed on the TTC 2100 screen as Tip 1-4 as shown in figure 20.6. The user can select Tip 5-8 and move them in front of Tip 1. This will result in the TTC 2100 sequentially renumbering the zones from left to right. Now, the original Tip 5-8 will be labeled Tip 1-4 as desired. The original Tip 1-4 will now be moved to the right and labeled Tip 5-8. Since these Tip zones were already adjacent to each other, the other Tip zones are not affected. When a group of zones is moved, the top 4 rows (System Zone, ID Name, ID Number and Data Concentrator) in the data table remain the same. All data in the other rows shift with the zones that are moved. NOTE: Zones cannot be moved from one data concentrator to another. To Move Zone Addresses: 1) Enter the System Zone Numbers of the range of zones that are to be moved using the From and To areas. 2) Enter the System Zone Number for where the zones being moved are to be inserted in the Move zones in range BEFORE this zone area. For this example, to move System Zones 67-68 in front of System Zones 65-66, enter 65 in the Move zones in range BEFORE this zone area, because 65 is the zone to be shifted to the right. The hardware that was previously associated with System Zone 65-66 will now be shifted two columns to the right and labeled System Zone 67-68. The ID Number is assigned by the TTC 2100. 3) Press the Move Zones button. The changes will appear on the screen. 4) To undo the most recent change, press the Undo Move button. 5) Repeat steps 1-4 to make additional changes. 6) To enter the changes as shown on the table and exit the screen, press the Accept button. 7) If the user chooses to undo all the changes made during this configuration session and exit the screen, press the No Changes button. If the user wants to undo all the changes made during this configuration session and stay on the Configuration screens, press the Restore Original button.

CAUTION: THE NO CHANGES AND RESTORE ORIGINAL BUTTONS CLEAR ALL CHANGES MADE DURING THE SESSION IN EDIT ID, MOVE ZONE ADDRESS, ASSIGN INPUT AND TYPE J OR K. IT DOES NOT MATTER WHICH SCREEN IS BEING DISPLAYED AT THE TIME.

20.7 Assign Input (Assign Thermocouples)

The Assign Input screen is used to assign thermocouple inputs to zones. Pressing the Assign Input button will cause the screen shown in Figure 20.7 to appear. If the user is temporarily swapping thermocouples between zones, it may be better to use Software Rewire (see Section 20.3 Software Rewire). If the user does not correctly and completely enter all changes, some thermocouples may be assigned to multiple zones and some may not be assigned to any zones. Thermocouples that are assigned to more than one zone will display the thermocouple data in red text. Thermocouple modules contain 16 thermocouples each (numbered 0-15). Since a data concentrator has a maximum capacity of 64 zones, there are up to 4 thermocouple modules per data concentrator (numbered 0-3). 123

To make a change in the configuration of the thermocouples: 1) Enter The Range of System Zones numbers for the thermocouples that are to be reassigned using the From and To areas (Zones 9-12 and 13-16 in Figure 20.7). Note: Each thermocouple module contains 16 thermocouple inputs. Only one module can be reassigned at a time. 2) Enter the Thermocouple Module and Zone in Thermocouple Module settings for the thermocouple that the user wants to associate with the zone shown in the From entry. The rest will automatically be assigned to the rest of the zones selected in the From - To range. 3) Press the Assign button. The changes will appear on the screen. 4) To undo the most recent change, press the Undo Assign button. 5) Repeat steps 1-4 to make additional changes. 6) To enter the changes as shown on the table and exit the screen, press the Accept button. 7) If the user chooses to undo all the changes made during this configuration session and exit the screen, press the No Changes button. If the user wants to undo all the changes made during this configuration session and stay on the Configuration screens, press the Restore Original button.

CAUTION: THE NO CHANGES AND RESTORE ORIGINAL BUTTONS CLEAR ALL CHANGES MADE DURING THE SESSION IN EDIT ID, MOVE ZONE ADDRESS, ASSIGN INPUT AND TYPE J OR K. IT DOES NOT MATTER WHICH SCREEN IS BEING DISPLAYED AT THE TIME.

Figure 20.7 Assign Input (Assign Thermocouple) Screen

20.8 Type J or K Thermocouple Selection

The Type J or K thermocouple selection screen (shown in Figure 20.8) enables the user to select the type of thermocouple that is attached to the TTC 2100. The selection applies to all the thermocouples. If this selection is changed, the extension wire between the thermocouple module(s) should also be changed to prevent errors. 124

CAUTION: THE NO CHANGES AND RESTORE ORIGINAL BUTTONS CLEAR ALL CHANGES MADE DURING THE SESSION IN EDIT ID, MOVE ZONE ADDRESS, ASSIGN INPUT AND TYPE J OR K. IT DOES NOT MATTER WHICH SCREEN IS BEING DISPLAYED AT THE TIME.

Figure 20.8 Type J or K Thermocouple Selection Screen

20.9 DC Zones (Data Concentrator Zones)

The Data Concentrator Zones screen describes the number of zones in each data concentrator as shown in Figure 20.9. This data cannot be changed.

CAUTION: THE NO CHANGES AND RESTORE ORIGINAL BUTTONS CLEAR ALL CHANGES MADE DURING THE SESSION IN EDIT ID, MOVE ZONE ADDRESS, ASSIGN INPUT AND TYPE J OR K. IT DOES NOT MATTER WHICH SCREEN IS BEING DISPLAYED AT THE TIME.

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Figure 20.9 DC Zones Screen

20.10 Locate Zones

The Locate Zones button is used only when hardware has been added or removed from the TTC 2100. After the TTC has completed locating the existing zones, the Edit ID screen shown in Figure 20.1c will be displayed. Data shown will include an ID Name and Number assigned by the TTC 2100, along with the hardware locations of the new hardware. If desired, a user can change the configuration data using the Edit Configuration procedure described in Section 20 Edit Configuration.

Caution: Do not press the Locate Zones button unless boards have been added or removed from the TTC 2100. The replacement of a board does not require the Locate Zones procedure to be used.

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21 ___________________________________________________ Programmable Input / Output Functions

21.1 General Description
There are several features that are available to TTC 2100 users that are not prewired to the alarm relay output connector (Section 3.6 HA-3 Alarm Relay Output Connections) and the remote input connector (Section 3.7 HA-4 Remote Input Connections). These features include the inputs Remote Boost (Section 12.6 Options) and Remote Sequenced Power Up (Section 12.6 Options) and output OK to Run. There is also an input OK to Run feature, but the feature must be wired at the Gammaflux factory.

21.2 Inputs
Control Inhibit, Remote Standby (Section 12.6 Options) and Material Protection (Section 12.6 Options) inputs are already wired as standard and require no programming to be used. If the user wants to use Remote Boost or Remote Sequenced Power Up, an io.txt file must be created in Windows using Notepad and saved to the C:\\TTC 2100 directory. Do not create the io.txt file unless changes are being made. Each feature has a designation that is used in creating the io.txt file. Designations include: InA=Remote Standby InB=Material Protection InC=Remote Boost InD=Remote Sequenced Power Up Up to 3 of the 4 Input features (InA, InB, InC, InD) can be wired to the HA-4 remote input connector. Figure 21.2a shows how the TTC 2100 is normally shipped. Figure 21.2b shows what input options are available and their feature designation. The feature designation is used in the io.txt to indicate where the feature will be wired. Anytime there are 3 input features selected that do not include Control Inhibit, the user must remove the wire currently connected to the back of Pin 2 of the HA-4 connector and swap it with the spare wire available at the back of the connector. It is also possible to program a feature to be activated whenever an input is received at one of 2 or 3 locations. For example, Remote Standby can be activated by a signal received on Pin 3 or Pin 4 (see Example 3). This is, in effect, a logical OR statement.

HA-4 pins 1 2 3 4

Program Code

3 1 2

Prewired As Input common Control Inhibit Remote Standby Material Protection

Figure 21.2a

Input Options As Normally Shipped

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Available Features Control Inhibit Remote Standby Material Protection Remote Boost Remote Sequenced Power Up Figure 21.2b

Feature Designation None InA InB InC InD

Programmable Input Options

Here are some examples: Example 1: Use Remote Standby and Remote Boost inputs. The io.txt file would be written as: InA=1 InC=2 This would program the TTC 2100 to assign Remote Standby (Feature Designation InA) to Pin 3 (Program Code 1) of the HA-4 connector. Example 2: Use Remote Standby, Remote Boost and Remote Sequenced Power Up. The io.txt file would be written as: InA=1 InC=2 InD=3 This would program the TTC 2100 to assign Remote Standby to Pin 3, Remote Boost to Pin 4 and Remote Sequenced Power Up to Pin 2. Note that Control Inhibit is already wired to Pin 2. The user would need to remove the screws from the HA-4, remove the wire that is on the back of Pin 2 of the connector and swap it with the spare wire that is available behind the connector. Example 3: Activate Remote Standby whenever an input signal is received on Pin 3 or Pin 4. The io.txt file would be written as: InA=1 InA=2 This would program the TTC 2100 to activate the Remote Standby Feature (Feature Designation InA) anytime a signal is received on Pin 3 (Program Code 1) or Pin 4 (Program Code 2) of the HA-4 connector.

21.3 Outputs
Please see Section 3. HA-3 Alarm Relay Output Connections for a description of the output functions available on the TTC 2100.

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22 ___________________________________________________ Networking via Ethernet

22.1 General Description
A series of networking functions provide for easy sending and receiving of menus, setpoints and process values over an Ethernet network. In the TTC 2100 folder is a folder named Network. The Network folder should have the shared attribute set when the operator panel is set up by the administrator. Manipulation of setpoints and files is done by sending simple text only files of the type created by Windows Notepad. Start each command at the first position of the line.

22.2 Menu.txt Files

Menus are manipulated with a text file named Menu.txt. When the Menu.txt file is read by the TTC it automatically deletes it. If an error is found in the file a Menu_Error.txt file is created (which is just the Menu.txt file renamed). Some operations may still be completed in the event of an error. To list the available menus, create a file named Menu.txt is created with the line: List. This file is sent to the Network folder. The operators panel software will create a text file called MenusList.txt and put it in the Network folder. This may then be moved up the network and viewed there. To activate a menu (e.g., Sample.mnu) stored in the operators panel, a file named Menu.txt is created with the line: Activate = Sample.mnu. This file is sent to the Network folder. The operator panel software will read this file and load the Sample.mnu menu stored within the TTC 2100. In a similar way a menu may be retrieved from the TTC to the Network folder with the line: Get = Sample.mnu, sent to the TTC from the Network folder with the line: Send = Sample.mnu, and deleted from the TTC with the line: Delete = Sample.mnu. More than one line may appear in the Menu.txt file. The commands are executed in the order they appear in the file. For example, the following sample will retrieve the menu Mold123.mnu, delete it from the TTC and list the remaining menus in the TTC. Get=Mold123.mnu Delete=Mold123.mnu List

22.3 Setpoint.txt Files

The procedure to change setpoints is similar to that of changing menus (Section 22.2 Menu.txt files). A simple text file named Setpoints.txt is created as above and copied to the Network folder. When the Setpoints.txt file is read by the TTC it automatically deletes it. If an error is found in the file a Setpoints_Error.txt file is created (which is just the Setpoints.txt file renamed). Some operations may still completed in the event of an error. Four types of setpoints may be changed using the Setpoints.txt file: 1) Process temperature setpoints (can be set in either degrees F or degrees C) 2) Manual percent setpoints, 3) Manual or automatic mode 4) On / Off status The valid setpoint designators are as follows: 129

F= process temperature setpoint in degrees F C= process temperature setpoint in degrees C %= Manual percent setpoint M=(1 for manual mode, 0 for automatic mode) O=(1 for zone on, 0 for zone off) To set a setpoint enter a line in the Setpoints.txt file as shown by the example: Tip 17: F=400 This will set the process temperature setpoint of zone Tip 17 to 400F. Note that the first entry of the line is the zone ID followed by a space which is then followed by a colon(:). It very important to start the line in this manner and to spell the ID correctly. It may be easier to create an AllSetpoints.txt file (described later) and modify it than to create one from scratch. Any number of the setpoints may be included on the line if more than one setpoint per zone is to be changed. For example: Man 3: C=210, %=15.3, M=0, O=1 This will set the process temperature setpoint to 210C, the manual setpoint to 15.3%, turn off manual mode (turn on automatic mode), and turn the zone on. Any number of zones may be set in one file, just use a new line for each zone. In addition to setting setpoints the Setpoints.txt file may include the following special instructions. Setpoints=1 Values=1 Values=0 Scale=C Scale=F (create a new AllSetpoints.txt file) (to create Values.csv file automatically) (to stop creating the Values.csv file) (for degrees C) (for degrees F)

Adding the Setpoints=1 instruction causes the TTC to create an AllSetpoints.txt file in the Network folder. The AllSetpoints.txt is a list of all of the four setpoints for each zone. The AllSetpoints.txt file may be renamed Setpoints.txt and copied to the Network folder to cause all setpoints to be set. In this way a form of menu retrieval and restoring can be performed without using the database based x.mnu files. The process temperature setpoints will be in degrees C or F based upon the last setting of Scale. The following is a few lines within an AllSetpoints.txt file: Tip 1: F=410, %=15.0, M=0, O=1 Tip 2: F=410, %=15.0, M=0, O=1 Tip 3: F=415, %=17.0, M=0, O=1 Tip 4: F=415, %=17.0, M=0, O=1 Adding Values = 1 instruction caused a file named Values.csv to be created in the Network folder. This file is updated (recreated) at the rate of the TTC display updates. Only the last file is available. This is a comma separated values file and may be imported directly into Micr osoft Excel, Microsoft Word and others. All of the values for all of the zones are always included in every Values file. Each zone is on a separate line. Like the Setpoints file the zone ID is followed by a space followed by the zone number within the ID. This is followed by a comma. After the comma is a list of all of the following values, in the order: Zone name Process value Active percent output Amps Volts Manual mode Zone On Alarm status. 130

Alarm status is a binary number with the following bit assignments Bit Assignment Weight 0 Thermocouple Open 1 1 Thermocouple Reversed 2 2 Uncontrolled Output 4 3 Heater Short 8 4 Heater Open 16 5 Open Fuse 32 6 Deviation High 64 7 Deviation Low 128 8 Thermocouple Short 256 9 Heater Resistance 512 10 Zone Off 1024 11 Manual Mode 2048 12 Auto Standby 4096 13 Control Inhibit 8192 14 Undefined 16384 15 Watt alarm 32768 The following is an example of two lines in the Values.csv file. Note that Tip 1 is in manual mode, On and has a low alarm. Tip 2 is in Automatic mode, On and has a low alarm. Tip 1,351.2,29.7,.87,94.1,1,1,2176 Tip 2,350.7,26.5,.79,89.4,0,1,128 Adding the setting Values=0 to the Setpoints.txt file will cause the automatic updating to stop. This may improve performance at the TTC. Note that the setting of Values=0 or 1 is NOT SAVED when the TTC is powered down or exited and restarted. The power up default is to not create the file. Adding Scale = C to the Setpoints.txt file causes both the AllSetpoints.txt process temperature setpoints and the Values.csv process values to be reported in degrees C. Scale = F causes those values to be in degrees F. The power up default is degrees F. The scale setting is NOT SAVED when the TTC is powered down or exited and restarted.

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23 ___________________________________________________ International Interface

23.1 General Description
The International Interface can be used as an operator interface in place of the Touchscreen. The International Interface is an exceptionally easy-to-use operator interface with fewer features than those available with the Touchscreen. Those familiar with the Gammaflux GLC 2k controller will note the similarities in the operation of the International Interface. Both types of interfaces can be exchanged without turning off power to the TTC. The user is also able to switch between the two interfaces styles without turning off power. Note that the replacement interface will contain the setpoints from the last time it was used, while the TTC will continue to use the setpoints that were in use before the replacement interface was installed.

CAUTION: WHEN AN OPERATOR INTERFACE (TOUCHSCREEN OR INTERNATIONAL) IS REPLACED, THE SETPOINTS IN THE REPLACEMENT INTERFACE MAY DIFFER FROM THOSE IN THE TTC OUTPUT CARDS. THE TTC WILL CONTINUE TO USE THE SETPOINTS IN THE OUTPUT CARDS UNTIL THE UNIT IS CYCLED OFF/ON OR UNTIL THE USER CHANGES THE SETPOINTS FROM THE REPLACEMENT INTERFACE.

23.2 Operator Interface Comparison of Features

Shown in Table 23.2 is a comparison of what features are available with the two styles of operator interfaces.

132

International

International Interface

Touchscreen Interface

Operational Features Maximum zones Menu storage Programmable groups Auto load manual remembered % output Operator identification Tool graphics with real time data overlay Thermocouple "rewire" On-line help Volts, Watts, Ohms display Alarms Heater resistance monitoring (predict failure) Heater wattage monitoring (predict leaks) Alarm history Software Features Gammavision (SPC data/graphing) Instant data reporting (up to 24 hours) Mold Doctor (advanced troubleshooting) Field Calibrator On screen printing Networking Remote troubleshooting Inputs Sequenced power up (also manually activated) Remote boost

129 10 4

256 1000 20 X X X X X X X X X X X X X X X X X X

Figure 23.2 Comparison of Features Available with International Interface and Touchscreen

23.3 Using International Interface as a Replacement

When replacing an existing interface (Touchscreen or International) with an International Interface, the following procedure should be followed: 1) On power up, an error message E-1 will appear if the configuration in the TTC 2100 does not match the configuration of the International Interface. 2) Generally, the user wants to use the configuration that is in the TTC 2100, not in the new International Interface. To send the configuration from the TTC 2100 to the International Interface, the user should enter a 1 in the change area and press the Enter button. The unit is now ready for operation.

23.4 Basic Operation and Advanced Setup / Troubleshooting Brochures

Gammaflux has created Basic Operation and Advanced Setup / Troubleshooting brochures for the TTC International Interface. To get a copy of these brochures, contact Gammaflux. The content of these brochures is reproduced on the following eight pages.

133

Windows NT

International / Windows XP Operator Panel Comparison

134

135

136

137

138

139

140

141

24 ___________________________________________________ Mold ID
24.1 General Description
Mold ID enables the TTC 2100 to automatically select a menu based on the detection of the tool that is connected to the controller. Up to 63 tools can be independently detected and associated with menus. This feature is not available with the International Interface (Section 21 International Interface). An HA10 connector is mounted on the back of the controller if the Mold ID is specified. The tool number is determined by reading the position of a set of user-installed jumpers on the connectors mating connector. An internal digital input module sends a low level voltage through the HA10 and reads the signals coming back from the mating connector. The information is then conveyed to the TTC 2100 operator panel via an ethernet connection. This mating connector is placed into a connector hood. The assembly is latched onto the controller when the tool is connected to the controller. The connector and hood act like a Mold ID key. The mold would ideally include a latching hood for storage of the key while the tool is not loaded into the press. When production is done with the tool, the mold is removed from the machine, the key is attached to the mold and they are placed back into storage. The next tool to be run is brought to the machine, the power and T/C cables are attached, and the key is connected to the controller. Mold ID continuously monitors the inputs. It watches for instances where the address key is attached and detached. When the address key is attached, no action is taken for several seconds to verify that the connection is permanent. Mold ID loads menus only when the Mold ID address key connection is made. No action will be taken if the Mold ID is changed while the address key is still attached. The user can still use the hot runner screens normally by changing setpoints, saving menus and restoring menus.

24.2 Mold ID Wiring

A number of short wire jumpers are inserted into an HA10 male insert. The jumpers are inserted in a binary pattern to identify the tool. The HA10 is then covered with the mating connector as shown in Figure 24.2a. Use the table provided (Table #1) at the end of this document to install the correct combination of jumpers. In Figure 24.2b, the jumper pattern shown would be associated with a Mold ID 5. It is recommended that the insert be attached to the mold to ensure that the correct key is used with each mold.

142

HA 10 MALE INSERT WITH ADDRESS JUMPERS

HOOD

Figure 24.2a HA10 with Mating Hood

INP UT C O M INP UT 2 M - O LD ID A DDRESS +1 INP UT 4 M - O LD ID A DDRESS +4 INP UT 6 M - O LD ID A DDRESS +1 6 INP UT C O M

6 7 8 9 10

1 2 3 4 5

INP UT 1 - C O NNEC T O R INST A LLED INP UT 3 M O LD IDA DDRESS +2 INP UT C O M INP UT 5- M O LD IDA DDRESS +8 INP UT 7- M O LD IDA DDRESS + 3 2

REAR VIEW

H A 1 0 M A LE INSERT

Figure 24.2b Connector Pin (Example shown is Mold ID 5)

24.3 Mold ID Screens

To access to the Mold ID screens, press the Mold ID button on the lower right corner of the screen. In the same fashion, press the TTC 2100 button on the bottom right corner of the screen to leave the Mold ID screens and return to the rest of the TTC screens. The Mold ID section consists of 2 screens: 1) Menu selection for a tool (Figure 24.3a Mold ID Menu Selection) 2) Other settings (Figure 24.3c Mold ID Setup) Pressing the Menu Selection button on the top of the screen causes the following screen shown in Figure 24.3a to appear. The Status section of the screen shows the condition of each of the inputs and the Mold ID address that has been determined. The table shown in Figure 24.3a lists the menus that have been linked to the Mold ID addresses. The menu listed next to each Mold ID is the menu that will be automatically entered when the mold key (HA10 with jumper pattern covered by mating connector) is attached. If a menu has been deleted by the user, but is still shown on this table, that menu will be highlighted with a yellow cell background.

143

Figure 24.3a Mold ID Menu Selection Figure 24.3a Mold ID Selection

Pressing on a Menu to Restore cell on the grid will display a list of menus that are present within the TTC 2100 (shown in Figure 24.3b Mold ID Menu Listings). The menu that is selected from the list is placed into the Menu to Restore cell location.

Figure 24.3b

Mold ID Menu Listings

144

A menu can be removed from the table by selecting that menu and then selecting the blank menu entry - - - - - - - from the list of available menus. No action is taken when an address key attachment is made for a Mold ID that does not have a menu selected for it. Pressing the Setup button on the top of the screen causes the following screen in Figure 24.3c to appear:

Figure 24.3c

Mold ID Setup

Placing a check in the box for Enable Menu Restore enables the Mold ID program to automatically perform the menu restore operations when a mold is attached. This setting cannot be changed while at the Monitor security level. Operator, Supervisor or Engineer security level is required. Placing a check in the box for Turn OFF Outputs When Mold ID is Disconnected causes the TTC 2100 to turn off its outputs when the mold is disconnected from the TTC. This setting cannot be changed while at the Monitor security level. Operator, Supervisor or Engineer security level is required. A box is used to display the IP Address of the input module. The address can be changed by touching one of the numbers. This will to bring up the numeric entry window. Each number is entered separately. The Engineer security level is required to change this address. Place a check in the box for Update Inputs to read the inputs from the input module. If this box is not checked, the last jumper pattern read will be maintained. The Exit to Windows button should not be used to leave the Mold ID screens. Use the TTC 2100 button for that function. The Exit to Windows button will cause the TTC software to terminate and Windows software to appear. See Section 13.6 Exit to Windows for more information To avoid accidental installation of a menu, the following procedures have been put in place: No menu restore action will be taken when the Mold ID program is started. No menu restore action will be taken when communications with the input module is enabled by checking the Update Inputs on the screen. No menu restore action will be taken when communications with the input module is enabled by checking the Enable Menu Restore on the screen. No menu restore action will be taken when communications with the input module has been re-established after a loss of communications. 145

24.4 Mold ID Pin Configurations

The following diagrams show the jumper pin configurations for each Mold ID.
HA10 MALE INSERT - REAR VIEW
MOLD ID AD D R ESS #1 MOLD ID AD D R ESS #2 MOLD ID AD D R ESS #3 MOLD ID AD D R ESS #4 MOLD ID AD D R ESS #5 MOLD ID AD D R ESS #6

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

MOLD ID AD D R ESS #7

MOLD ID AD D R ESS #8

MOLD ID AD D R ESS #9

MOLD ID AD D R ESS #10

MOLD ID AD D R ESS #11

MOLD ID AD D R ESS #12

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

MOLD ID AD D R ESS #13

MOLD ID AD D R ESS #14

MOLD ID AD D R ESS #15

MOLD ID AD D R ESS #16

MOLD ID AD D R ESS #17

MOLD ID AD D R ESS #18

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

MOLD ID AD D R ESS #19

MOLD ID AD D R ESS #20

MOLD ID AD D R ESS #21

MOLD ID AD D R ESS #22

MOLD ID AD D R ESS #23

MOLD ID AD D R ESS #24

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

146

HA10 MALE INSERT - REAR VIEW

MOLD ID AD D R ESS #25 MOLD ID AD D R ESS #26 MOLD ID AD D R ESS #27 MOLD ID AD D R ESS #28 MOLD ID AD D R ESS #29 MOLD ID AD D R ESS #30

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

MOLD ID AD D R ESS #31

MOLD ID AD D R ESS #32

MOLD ID AD D R ESS #33

MOLD ID AD D R ESS #34

MOLD ID AD D R ESS #35

MOLD ID AD D R ESS #36

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

MOLD ID AD D R ESS #37

MOLD ID AD D R ESS #38

MOLD ID AD D R ESS #39

MOLD ID AD D R ESS #40

MOLD ID AD D R ESS #41

MOLD ID AD D R ESS #42

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

MOLD ID AD D R ESS #43

MOLD ID AD D R ESS #44

MOLD ID AD D R ESS #45

MOLD ID AD D R ESS #46

MOLD ID AD D R ESS #47

MOLD ID AD D R ESS #48

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

147

HA10 MALE INSERT - REAR VIEW

MOLD ID AD D R ESS #49 MOLD ID AD D R ESS #50 MOLD ID AD D R ESS #51 MOLD ID AD D R ESS #52 MOLD ID AD D R ESS #53 MOLD ID AD D R ESS #54

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

MOLD ID AD D R ESS #55

MOLD ID AD D R ESS #56

MOLD ID AD D R ESS #57

MOLD ID AD D R ESS #58

MOLD ID AD D R ESS #59

MOLD ID AD D R ESS #60

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

MOLD ID AD D R ESS #61

MOLD ID AD D R ESS #62

MOLD ID AD D R ESS #63

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5

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25 ___________________________________________________ Screen Simplification

Section 12.3 Security Levels describes how the security level can determine what functions and screens are visible on the TTC 2100 monitor. In addition, if the operator does not want to use one or more of the following functions, these screens can be hidden in order to further simplify the screens displayed: OK to Run Status Sequence Start Even Cool % Copy Output Pdfs To remove any of these screens, the file D:\TTC2100\Gammaflux.txt must be edited. To do this: 1. Exit the TTC 2100 software (as described in Section 13.6 Exit to Windows) by going to Diagnostics and pressing Exit to Windows. The engineering security level and password is required to exit. 2) Attach a standard PC keyboard to the operator panel. The operator panel may have to be restarted to recognize the keyboard. 3) Open the file D:\TTC2100\Gammaflux.txt using Notepad. 4) To disable a function, enter the corresponding line of text from below and save. For example, to suppress the Even Cool screens, type DisableEvenCool = 1 as a line item in the file and save. DisableMonitorZones = 1 DisableOkToRunStatus = 1 DisableSequenceStart = 1 DisableEvenCool = 1 DisableCopyOutput = 1 DisablePdf = 1

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26 ___________________________________________________ Troubleshooting

CAUTION: ONLY TRAINED AND QUALIFIED SET-UP OR ELECTRICAL PERSONNEL SHOULD PERFORM THE TROUBLESHOOTING PROCEDURES. PROPER TRAINING PROVIDED BY GAMMAFLUX IS A MUST FOR QUALIFICATION TO TROUBLESHOOT THE EQUIPMENT SAFELY.

26.1 General Description

The troubleshooting procedure that is shown on the preceding page (last page of Section 23.4 Basic Operation and Advanced Setup / Troubleshooting Brochures) is a good guide to general troubleshooting. The following sections provide additional information pertaining to specific problems.

26.2 No Zone Found! Must Quit! Error Message

If a message appears in a yellow box stating No Zones Found! Must Quit!, it means that the computer is unable to communicate with the data concentrator. This can be due to the following reasons: 1) Failure of the computer, located in the screen. Replace computer / screen. 2) Failure of a data concentrator board. Replace data concentrator. Anytime a data concentrator is replaced, make sure the address selector switches on the new module are set to the same value as the one being replaced. 3) Failure of the RS242 / RS485 cable that connects the back of the TTC 2100 with the COMM 2 port. Replace the cable. 4) The RS242 / RS485 cable is plugged into the COMM 1 port instead of the COMM 2 port. Attach the cable to the COMM 2 port. 5) The interior RS242 / RS485 cable is disconnected internally. Check the connections from the rear of the cabinet to the Data Concentrator module. 6) None of the data concentrator addresses is set to 0. Some TTTC 2100s have multiple data concentrators, based on the number and types of zones. There are 2 address selector switches on each data concentrator module. One is next to the LEDs on the board. Make sure that at least one of the data concentrator modules in the TTC 2100 has this switch set to 0. There is another selector switch mounted next to the ribbon cable on each data concentrator module. This should always be set to 0.

26.3 Loss of Communication Detected with the Following Module(s) Error Message
If a message appears in a yellow box with the heading of Loss of communication with the following module(s), it will either list data concentrators or outputs that are no communicating. If the table lists a data concentrator, the troubleshooting steps shown in Section 26.2 No Zone Found! Must Quit! Error Message apply. If the table lists output zones that are not communicating, the following list applies: 1) The ribbon cable at the data concentrator or on the listed modules may be bad or disconnected. Check connections or replace cable. 2) The output module may be bad. - Swap the module with one that is working properly. Note if problem follows the module or if problem remains on same zone numbers. If problem moves with module, replace module. If problem stays with zone, the output module is not the problem. 150

3) The data concentrator may be bad. Replace the data concentrator. Anytime a data concentrator is replaced, make sure the address selector switches on the new module are set to the same value as the one being replaced.

26.4 Active Alarm

For a complete description of each alarm, refer to Section 8 Alarms.

26.5 Significant Temperature Over-Shoot During Start-Up

This can occur when the distance between the thermocouple and the heater is too large. Check the mold configuration and ensure that the thermocouples and heaters are properly matched. Additional tuning can be done using the procedures described in Section 19 Tuning.

26.6 Zone Indicates Correct Temperature, Molded Part Indicates that Actual Temperature is Too High
There can be several causes of this: 1) The TTC 2100 is displaying Celsius (a C is present in the temperature display), but the user set the setpoint thinking it was Fahrenheit. 2) A Type K thermocouple is being used where a Type J thermocouple is supposed to be. 3) The thermocouple is not placed where a true indication of part temperature can be detected. 4) A thermocouple input may be assigned to more than one zone.

26.7 Zone Over Temperature, Heater Percent Output is Very Low

The melt entering the zone is hotter than the setpoint temperature. This condition is often caused by shear induced heat in the melt. Reduce the temperature in the upstream zones, reduce injection pressure or reduce both. Also, the zone could be miswired, receiving heat from another zones heater. Run Mold Doctor.

26.8 Zone Below Temperature, Heater Percent Output is Very High

One cause could be a shorted thermocouple. Another cause could be that the melt entering the zone is too cold or the heater power is inadequate. Increase the temperature in the upstream zones or install a higher wattage heater. NOTE: Temperature stability is best when the heater wattage is about twice the average power that is required to maintain the desired temperature.

26.9 Zone Above Temperature, Heater Percent Output is High

Set the zone in question to Manual mode and enter a 0 Manual % setpoint. If the temperature continues to rise, turn the AC Power Main Circuit Breaker to the OFF position. Replace the temperature output module.

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CAUTION: ALWAYS LOCK OUT/TAG OUT THE AC POWER MAIN CIRCUIT BREAKER BEFORE REMOVING OR INSTALLING TEMPERATURE OUTPUT MODULES.

26.10 One Zone High Temperature with Very Low Heater Percent Output, Another Zone has Persistent Low Temperature with High Heater Percent Output
The tool power or thermocouple cables are cross-wired. Run Mold Doctor Wiring Analysis to determine the problem.

26.11 Zone Does Not Achieve Setpoint

There can be several causes of this: 1) There is a thermocouple short as signified by the thermocouple short alarm. 2) There is no thermocouple short and the thermocouple short alarm is active anyway. This can occur when the heater is undersized. When the heater does not raising the temperature 20F (11C) in the time allotted, the thermocouple short alarm becomes active. If the zone performed well before, the problem could be that the heater needs to be replaced. If the zone never performed well, the problem may be that the heater wattage needs to be increased. 3) The heater wiring could be faulty, causing the power to be going to more than one zone. 4) There may be a partial short to ground, bleeding off current that would normally be going to the heater. 5) The thermocouple may be located too far from the heater and is not able to get a true reading. 6) The thermocouple may be miswired. 7) Incoming power may be low on one or more phases. Run Mold Doctor diagnostics to determine the problem.

26.12 Zone Fluctuates Rapidly Between Setpoint and +10 to +20 F (+5.5 to +11 C)
A broken or loose thermocouple wire will cause erratic fluctuations. A loose thermocouple or heater will cause consistent fluctuations. The following check should be made on the system (mold and controller). 1) Watch the zone in question. When the % output drops off, start timing and continue timing until the % output returns to the original level and then drops off again. If this period of time is repeated consistently, the thermocouple is most likely loose. Instantaneous changes in temperature that are inconsistent or erratic are probably due to a broken wire or loose connection in the thermocouple wiring. 2) There is also a possibility that the thermocouple wires may have AC power wired to them.

26.13 Roughly One-third of Zones are Below Temperature

This usually indicates that one of the three phases is either missing or running at too low of a voltage. This can be checked using the View Voltages screen described in Section 13.6 View Voltages.

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27 ____________________________________________________ Attaching a Printer

The user can attach a printer to the back of the TTC 2100 screen. The procedure is dependent upon the hardware and software version of the TTC 2100. Please contact Gammaflux for assistance in setting up a printer.

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28 ____________________________________________________ Maintenance
28.1 Cleaning the Exterior of the Cabinet
Apply a high strength cleaner containing a grease cutter that is non-abrasive and will not attack plastic. Apply the cleaner to a soft cloth and gently wipe down the metal portions of the cabinet. To clean the screen of the TTC 2100, use a soft, moist cloth and gently wipe it down. Do not spray liquids directly on the screen or into the cabinet.

28.2 Cleaning the Interior of the Cabinet

No attempt should be made to clean the interior of the cabinet. Should cleaning ever be required, please contact Gammaflux.

28.3 Checking Power and Thermocouple Cables

It is very important to routinely check all the cables on the rear of the cabinet. These routine checks should be carried out by a qualified electrician every six months. Make certain all the thermocouple and power cable connectors are well seated and all latches are secured in their locking positions. Inspect all cables for possible wear and/or abuse that would necessitate replacing a cable. If a cable pulls away from its housing strain relief, the cable should be replaced immediately. Any visible nicks or flat spots in cables should be viewed as good candidates for replacement. If any part of a connector base or hood appears loose, the repair should be done immediately or replaced if necessary.

28.4 Temperature Calibration

The maintenance schedule for recalibration of all temperature zones in the TTC 2100 system is dependent upon the nature of your molding process and the standards you are required to follow. We recommend that your calibration be checked at least every two years by a qualified technician. This can be readily accomplished by using the FIELD CALIBRATOR procedure described in Section 18.

28.5 Checking the Earth Ground Connection

Checking the earth ground connection should also be performed every six months. Installation and connection of the green ( yellow/green Europe) earth wire from the TTC 2100 cabinet lug to ground is a MUST. In most locations, it is a LAW to have all the safety connections that are required by the local electrical codes. Therefore, it is a must that this connection be routinely checked, not only for connection but for continuity.

28.6 Checking the Operation of Cooling Fans

Every six months, check the internal fans of the TTC 2100 for operation. Usually a strip of paper held over the vented areas of the cabinet will flutter when the fans are operational. If one of the fans has failed, the fan should be replaced immediately. 154

29 ___________________________________________________ Training
A TTC 2100 Basic Operation Video is delivered with the TTC 2100 that describes normal everyday use of the TTC 2100. Training is also available from Gammaflux on the TTC 2100 controller. Please consult Gammaflux using the contact information shown on the front cover of this manual to inquire about upcoming training classes and locations.

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