User Manual For KTS And TS Console With K-Series Cabinets
User Manual forKTS and TS Consolewith K-Series CabinetsPMS Systems LtdNetherwood Rd, RotherwasHereford, UK, HR2 6JUTel: 44 (0) 1432 265768Email: pms@pmssystems.comFax: 44 (0) 1432 263782
KEEP THIS SHEET SOMEWHERE SAFEEvery machine leaves our factory with two levels ofpassword protection. We recommend that you changethese as soon as possible to establish your own security.System Password - linuxUser Password - unix
IntroductionK Series User Manual with KTS or TS ConsoleK Series User Manual with KTS or TS ConsoleCopyright (c) PMS Systems Ltd. 2001This manual is intended for use with the KTS or TS Console and HRC K-Series Controller(Serial No.) with which it was supplied.(Where fitted, this controller is supplied with Alarm Key Switch Number .)This manual is written and prepared for Software Version – 7th December 2007Our policy is one of continuous improvement and we reserve the right to alter productspecifications at any time without giving notice.5
gesAuthorAuthorised1.015/7/97First formal IssueBNMAR2.07/11/97Revised to incorporate software developmentsBNMAR2.115/3/99Revised to incorporate software developmentsDHAR3.011/6/99Manual Revision. Includes recent minor softwarechanges.DHAR3.112/8/99Switching On/Off and disconnecting console detailsadded.DHAR3.219/8/99Error messages updated.DHAR3.320/9/99Changes to Chilled Water control and SPI devicesadded.DHAR3.405/01/00Special Limits - RTD & Water are made pro-active.DHAR3.506/09/00Changes to troubleshooting section because surfacemount control cards now have T/C input fuses.DHAR3.621/09/00Introduction of QwikFix AppendixDHAR4.023/01/01Introduction of EasyView Page to TouchScreen Consoleand separation of TS and TSi manualsDHAR4.113/02/01Graph page selection increased from six to twentyzonesDHAR4.221/01/02Configure Controller Options changed for BoostCommand and Display OptionDHAR4.311/02/02Cable mis-wiring disclaimer addedDHAR4.415/02/02Extra instructions for using Setup page to make groupsettingsDHAWR5.0Mar 2002* C and K manuals mergedDHAWR* Run controls moved to main Display page.* Display page has 40 -160 zone display options* EasyView mini-panel display controls changed.* Boost & Standby controls moved from Global toautonomous zones.* New Master Only Startup mode introduced* New remote option for Boost or Standby* Utilities-Mode sub page removed.* New Other Help in Troubleshooting* Network facility Introduced5.1July 2002Password timer-override introducedDHSK5.2Aug 2002Zero Power note addedDHAWR6.0Jan 2003New Setup page and Setting up procedureDHSK6.1Jan 2003Communication Speed addedDHSK6.2Feb 2003Export Data has Zone Min-Max feature addedDHSK6.3Mar 2003Qwikfix repair no longer required - Append D removedDHSK6.4April 2003KTS Console Function explainedDHSK6.5April 2003TC Offset and Zone-Grouping introducedDHAWR6.6May 2003Individual Zone BoostDHSK6.7Sept 2003Extra Boost InformationDHSK6.8Dec 2003Input Network Screens IntroducedDHSKIssue 12.0
IntroductionPublications7.0Feb 20048.0Jun 2004Stage Startup introduced and Configure Controllerchanged substantially for new Systems OptionsDHSKIntroduction of Standby Delay facilityDHSKIntroduction of Shut-down timerIntroduction of Spear StandbyZoom page and Calibrate Touch function added to MTSIntroduction of T/C Fail option in Setup page andchanges to Master Zone SelectionIntroduction of extra Display Data page on MTS consoleand withdrawal of Set, Actual and Power columns fromSetup page.SPI Interface control added to MTS Console8.1Mar 2005Extra connection information added to IO cards inAppendix BDHAWR8.2Apr 2005New Appendix items AI8 (Analogue Input Card) andWM0x (Water Manifolds) added to K-Series AppendixDHAWR8.3Apr 2005New information added regarding the KM series case forWater ManifoldsDHPK8.4May 2005Extra information about "Allow ToolLoad" option greyingout [Load] button on ToolStore PageDHAWR8.5July 2005Display Page Changes –DHSK Run and Stop button combined into the oneposition (i.e. Run OR Stop). Second button configurable as BOOST or STANDBYfor normal zones or fixed at BOOST for spearzones. Display Data option also availableConfig Option changes New Autostandby timer function replaces Spearstandby Time Connections function removed8.6July 2005Extra information for K-LV controllersDHPK8.7Aug 2005Shutdown Stages are introduced so that StagedShutdown may switch off in a different order to StagedStartupDHIE9.0Oct 2005“Demo” facility added for training or demonstration use.DHSK9.1Nov 2005Console Startup option addedDHIE9.2Nov 2005Appendix D added for Water Manifold installationDHPK9.3Feb 2006Button One mode allows Run button to becomeSTARTUP buttonDHIE9.4May 2006Controller Switch-On corrected to accommodateConsole-StartUp optionDHDH7
8IntroductionPublications9.5July 2006WT4, a 12-channel J or K-Type monitor card isintroduced and added to the appendix.DHSK10.0Aug 2006New Configure options include: Allow Set Zone Off, Auto Stop Mode Flow Units Limit Exceed, Master IP Address, User Password.DHIEOther Changes include new Utilities – Remote page10.1Aug 2006Extra information about linked controller cabinetsDHIE10.2Sept 2006TSA can now use USB Memory sticks for Tool andPicture Load and SaveDHSKC E Variations dropped from ManualDHIE10.3OctChanges to Setup and Config options include:2006 Startup Mode introduced Second Startup introduced Shutdown Temp introduced I/O Card Options (any 4 from 8) introduced Master IP Address moved to the Utilities: Remotepage10.4Jan 2007Manual made genericDHDH10.5Mar 2007New features include:DHIEDHIE10.6Apr 2007 Auto-Detect moved to “New Tool” procedure. Display page zone headers have alternative colourscheme that is user configurableQuad IO card configuration moved to the Utilities pageto allow selection of Inputs and OutputsAppendix A Wiring standard includes Dual Supply option10.7May 2007More information added about the Auto-tune sequenceand affecting factorsDHSK10.8June 2007Individual Setup information added to Setup and Configpages.DHIE10.9Oct 2007New Printer Setup pageDHSK10.10Nov 2007Changes to accommodate larger KTS3 ConsoleDHSK11.0Dec 2007Input Signal changed to include Stop and AutoStop.Also Input Timer takes over from Autostandby Timerand Standby DelayDHIE12.0Feb 2008New reduced manual version with more imagesand less textDHAWRIssue 12.0
IntroductionContentsContentsIntroduction.10Setting up your controller .22Setting up - System Utilities .23Setting up - Global and Tool parameters.28Setting the Tool parameters .33Setting the Global Parameters .36Setting up - Operating Parameters.41Setting up – EasyView Pages .47Running your controller.50Customising your controller .68Maintaining your controller.82Troubleshooting.93APPENDIX A.103APPENDIX B.105APPENDIX C.107APPENDIX D:.113Index .1149
onThe following are general specifications. The actual controller/console supplied may havecontractual variations and differ in some specified options.Supply Voltage415 Volts 3 -phase 50/60 Hz with neutral. Other available include240/380/400 and 480 volts in Star or Delta configuration.Voltage BandwidthStable within (20% supply voltage swingSupply earth-leakagetrip300mA (note: this is for tool protection)Overload protectionMiniature Circuit BreakerMains Voltage outputpatternBurst-fired with zero voltage crossoverLow Voltage outputpatternTypically 24 volts AC. User configurable between burst-fired or phaseangle.Output overloadprotectionHigh-speed semiconductor fuse linksTemperature controlmethodClosed-loop (Auto) or open-loop (Manual) with HR SoftwareControl range0 – 472 Centigrade (Celsius), 32-881 FahrenheitTemperature ScaleCentigrade (Celsius) or FahrenheitPrinter OutputConnectorUSB PortDataCommunicationsRS-232 serial, DB9 male connectorAlarm OutputClosing Contact Relay 5 Amp maxT/C Tool ConnectorHarting type Han A or equivalentHeater ToolConnectorHarting type Han E or equivalentIssue 12.0
IntroductionSafety InstructionsSafety InstructionsDO NOT open the cabinet without first ISOLATING the supplies -there areunguarded terminals inside the cabinet which may have a dangerous potential acrossthem.Where a three-phase supply is used then this potential may be at 415 volts or higher.Safety Notices - an explanationA WARNING symbol and message, shown here, identifies where there may be ahazardous situation which, if not avoided, may result in death or injury to personnel.Most warnings pertain to electrical aspects and you must comply with them tominimise any personal danger.A CAUTION warning identifies where there may be a hazardous situation which, ifnot avoided, may result in damage to property.Caution warnings present no personal danger, but may cause the equipment to fail orlose its memory.Where to use this equipmentThe display console and controller cabinet together are designed for use in the plasticinjection moulding industry as temperature controllers for third party hot runnersystems as commonly used in mould tools. They must not be used in residential,commercial or light-industrial environments. Furthermore, they must not be used inan explosive atmosphere, or where there is a possibility of such an atmospheredeveloping.The HRC cabinet and Touch Screen console should be installed in a clean dryenvironment where the ambient conditions do not exceed the following limits: Temperature0 to 35 C. Relative Humidity 90% (non-condensing)Check your wiringBefore you energise the system, pay special attention to how the supply to yourcontroller is wired and how it is connected to the mould.Lack of attention to detail causes errors such as: incorrect wiring of mains supply phases into the controller crossing heater supply feeds with thermocouple detection (although this errorcan be eliminated by the adoption of PMS Standard connections)In such cases wiring errors have caused equipment failure.PMS Systems Ltd. cannot be responsible for damage caused to the controller bycustomer wiring and/or connection errors.11
12IntroductionIsolate the ControllerIsolate the ControllerThe main power switch is sufficiently rated to disconnect the total load currentduring switch On and switch Off. To prevent its operation, during maintenance, youcan use a suitably-sized padlock, or similar device, to lock the switch in the Offposition.Larger controllers may have multiple supplies with multiple isolators. For suchcontrollers then all Isolators must be turned off for safe access into the cabinet.Switching OnSwitching ON the Main Isolator for the controller may, or may not, start to heat upthe zones; it depends on how the Console-Startup option is configured. (see page 37).If Console startup is set to “Stop” then the tool remains at zero power and at roomtemperature. If it set to any of the other three options (Startup, Standby, or Run) thecontroller applies power to the zones so that they heat up.Switching Off (or Shutting Down)We recommend that you use the console to shut down the heating load, and only usethe main isolator to switch off a dormant controller.1. Shut down the heating.On the main page, select the [Stop] mode andreduce the heating to zero.2. Shut down the ConsoleOn the Utils page, touch the [Exit] button and thiswill shut down the Console Computer.3. Shut down the ControllerFinally, use the main power switch to isolate all thepower to the whole system.Issue 12.0
IntroductionScreen Layout and Navigation (Common to all pages)Screen Layout and Navigation (Common to all pages)NavigationTop tabs to move from page to pageControlSide command buttons that change frompage to pageMonitor & InformationBottom row shows :Current Run Mode,Current health status,miscellaneous information13
14IntroductionEight Main PagesEight Main Pages1) The Display pageCan be used for Monitor – see zone condition Control – Start/Stop & Boost/Standby immediately available. All other(“Standby, Shutdown, Stop“) available from [Mode] button Set – select any one or more zones to get [Set] function to set or alter zonesetpoints or run modes.MonitorHealthy Zone - shows:Zone Name (Alias)Actual TemperatureScale Set TemperatureApplied PowerDeviation between Actual and SetTemperatureGreen text on BlackbackgroundWarning ZoneDeviation exceeds 1st stage (Warning)Black Text on YellowBackgroundAlarm ZoneDeviation exceeds 2nd stage (Alarm)White text on RedBackgroundFatal ZoneProblem detected (see page 93 for details)White text on RedBackgroundZone OffIndividual zone switched offDifferent header coloursUser-configurable coloursIssue 12.0
IntroductionDisplay Page - MonitoringDisplay Page - MonitoringUse [Page Up] or [Page Down] to scroll upand down to see more zonesOrUse [Display] button to show 70 Zones - each zone shows Title, Actual andSet110 Zones - each zone shows Title and Actual160 Zones - each zone shows ActualTemperatureData page which shows the setup and data forall the console zones.15
16IntroductionDisplay Page – Monitor (Zoom)Display Page – Monitor (Zoom)Touch any zone and [Zoom]Zoom page shows:* Zone Settings* Recent Temperature Deviation* Zone Power Levels (Historical)Issue 12.0
IntroductionDisplay Page – Start, Stop and moreDisplay Page – Start, Stop and moreButton 1Can appear as [Run/Stop] or[Startup/Shutdown]Button 2Can appear as [Boost] or [Standby]Button 3 – ModeReveals all run mode options17
18IntroductionDisplay Page – Setting TemperatureDisplay Page – Setting TemperatureTouch one zoneTouch anotherTouch [Range]Touch [Set][Mode] bar to set zone asClosed (Auto Temperature)Open (Manual Power),or Slave (to another zone)[Value] bar to Set, Raise or LowertemperaturesIssue 12.0
IntroductionMore PagesMore Pages2) EasyViewShows zone temperature and their position inthe tool.Shows Zone StatusCan be used to Set zone temperatures3) Graph PageShows graphs, of temperature versus time, forup to twenty zones at a time.4) The ToolStore pageis a tool bank in which you can store up to 200tool configurations.5) The Picture pageSave, and display, up to 20 drawings orpictures.19
20IntroductionMore PagesMore Pages6) The Utilities pageContains several sub pages:System- change the passwords and the system clock.Printer - select a driver for your printerEvent Log - to find changes that have been made to thecontroller settingsNetwork - set up the Controller to communicate over anetworkExport - obtain historical performance data for anyzones over the last 24 hours.Remote - view any other networked computer via aVirtual Networked Computer (VNC) protocol and set upa remote Master IP address.Quad IO - set up Quad IO card Inputs and relayoutputs.7) The Testing pageCheck the condition of a mould tool after commissioningor maintenance.8) The Set-up pageFor setting up the system.Issue 12.0
IntroductionThe User InterfaceThe User InterfaceWhere the configuration of parameters requires a user interface then either akeyboard or a keypad is displayed.Keyboardfor Alpha-numeric inputKeypad 1Basic numericKeypad 2Basic keypad PLUSValue – Set, Temp, Add andSubtractandMode – Auto, Manual and SlaveKeypads – 3 & 4More buttons to select andconfigure synchro-tips21
22Setting up your controllerSetting up your controllerNew Touch Screen consoles and controllers are provisionally configured at thefactory and you may not need this section for a new system.However, to set up a Touch Screen console for a new tool or environment then youcan use this part of the manual.Four Steps for Setting Up1 - System Utilities- basic criteria such as passwords, date and time settings, and printer settings.2 - Console and Tool parameters- global settings such as startup and boost and tool parameters such as alarms andlimits, which are all configured on the Setup page.3 - Operating parameters- includes zone temperatures, coolant temperatures and flow levels.4 - EasyView- attach a picture to a mould then insert and position mini information panels.Issue 12.0
Setting up - System UtilitiesSetting up - System UtilitiesSystem PageSoftware DateThe System page has a date to show which software version is loaded and it isautomatically reconfigured if ever the software is upgraded. It is helpful if you make anote of the Software version date before you contact your supplier with any technicalquery.Passwords OptionsThree levels of Password controlIf the User Password option (see page 40) is set to [Enabled] then there are threelevels of control 1. Open Level - includes various functions that need no password such as Startand Stop.2. User (or Level 1) password which gives low level access to: switch the tool on and off, alter temperatures, select different tools3. System (or Level 2) password which gives high-level access to: all user-level functions, set the user password, re-configure the settings for a new tool, store and load new tool settings to/from the discTwo Levels of Password ControlIf the User Password option is set to [Disabled] then all functions that normallyneed a User (Level 1) Password become Open level.Higher level functions that require a System (Level 2) password retain their Passwordprotection.About password active timesAfter you key in a password, access is possible while you continue to input data. Eachkey-touch resets the timer but, when no more input is detected, it times out and thendenies unauthorised access. This is the same for both User (level 1) and System (level2) passwords.If, while the System password is active, you visit a lower level page that only requiresUser (Level 1) password level (eg Display) or none at all (eg Graph) then the Systempassword will expire after 20 seconds but, on doing so, it becomes a User (Level 1)password which would allow you to continue setting lower level parameters.23
24Setting up - System UtilitiesPassword Application TableHere is a detailed list of what level of password is required for various functions onthe different pages.Page/ScreenNo Password requiredto useLevel 1 (User)password requiredto use:DisplayRun/Stop/ChangeModes.Set (Altertem
6.2 Feb 2003 Export Data has Zone Min-Max feature added DH SK 6.3 Mar 2003 Qwikfix repair no longer required - Append D removed DH SK 6.4 April 2003 KTS Console Function explained DH SK 6.5 April 2003 TC Offset and Zone-Grouping i
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CAN ISO 11898, ISO 15765-4 (OBD), CAN Single Wire, CAN Low Speed, ISO 13400 (Diagnostics over IP), other vehicle-specific protocols Voltage measurement Oscilloscope KTS 590 Resistance measurement KTS 590 ECU diagnosis and enhanced measurement technology (2-channel multimeter, 2-channel oscilloscope) KTS 560 ECU diagnosis and measurement technology
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