AHC Controller Operation Manual Please thoroughly read this manual before use. Please retain this manual in an easily accessible place for future reference. V1.00 Important Safety Instructions Name and role of each part Elements of LCD touch panel PROCEDURE UP TO MOLDING Installation of controller/ Inputting set values/ Procedure for starting molding/ Flow Chart for Molding Start-UP ADVANCED USAGE Heat retention and monitoring temperature/ Timer/ Status monitoring function/ Key lock/ Storage function MAINTENANCE Air filter cleaning/Fuse change TROUBLESHOOTING APPENDIX Controller Specification/ Standard for Heater out put/ External interface table / Drawing list
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AHC ControllerOperation Manual
Please thoroughly read this manual before use.Please retain this manual in an easily accessible placefor future reference.
V1.00
Important Safety InstructionsName and role of each partElements of LCD touch panel
PROCEDURE UP TO MOLDINGInstallation of controller/ Inputting set values/Procedure for starting molding/Flow Chart for Molding Start-UP
ADVANCED USAGEHeat retention and monitoring temperature/Timer/ Status monitoring function/ Key lock/Storage function
MAINTENANCEAir filter cleaning/Fuse change
TROUBLESHOOTING
APPENDIXController Specification/ Standard for Heater out put/ External interface table / Drawing list
The marks shown below are used in this manual to explain the respective types of controllers.
The TP type controllers are explained.
The TP type controls molds with built-in spears. The type D, G, ESP, and B spears can be used.
The controller comes in four types – AHC2TP2S, AHC2TP2T, AHC4TP4S, and AHC4TP2T.
The VP type controllers are explained.
The VP type controls molds with built-in valves, etc. In addition to valves SVP, SVY, SV32, and
SV25, other companies’ valves (200-240 V heater) can be used. The type of controller is
AHC2VP2
Types of controllers and symbols
The other marks used in this manual are explained. The marks shown below are used in this manual to
indicate important matters. Be sure to follow these instructions.
Mishandling can cause death or serious injury. Be sure to observe these warnings
to use the machine safely.
Mishandling can cause injury or property damage. Be sure to observe these
cautions to use the machine safely.
Important matters that should be observed during operation are described. Be sure
to read the explanation to prevent failure of the product, damage, and mishandling.
Matters that serve as references and supplementary explanations are shown.
Other marks
WARNING
CAUTION
IMPORTANT
REFERENCE
1
Table of Contents
Important Safety Instructions
Name and role of each part
PROCEDURE UP TO MOLDING
Installation of controller
Inputting set values
Initial screen
Initial setting
Main setting
Set value inputting and numeric keypad
Operation
Procedure for starting molding
Other operations
Flow Chart for Molding Start-UP
Timing Chart for the Tip Timer
ADVANCED USAGE
Other settings
Sub setting
Status monitoring function
Special functions
Storage function
MAINTENANCE
Periodical maintenance
Air filter cleaning
Replacement of backlight of LCD touch panel
Fuse change
TROUBLESHOOTING
Troubleshooting for Warning Messages
Warning Code List
When no message appears
APPENDIX
Specification
Drawing List
2
4
8
9
9
9
11
13
14
14
16
17
17
18
18
21
24
27
29
29
30
30
32
32
38
41
45
2
Important Safety Instructions
Following the safety tips mentioned bellow should assure safe operation.
Handling the system with the way which is not described in this manual may occur an unexpected
accident, fire or electric shock.
Only matched heaters can be connected to the respective controller.
Spears can be connected to TP type controller while Valves (200V rated heater) can be
connected to VP type controller.
Otherwise there may occur an electric shock caused by a short circuit, also fire, probe burn
out, controller failure caused by abnormally high heat generation.
Installation
Do not set up the controller where it is exposed to water, oil, or some kind of liquid.
Failure to follow these instructions may result in fire or electrical shock.
Follow the specification on voltage, capacity, frequency, and phase for power supply.
Failure to follow this instruction may result in fire, electrical shock, or damaging the controller.
The cord must be adequately grounded.
Inadequate grounding could result in electrical shock or operation error.
Properly and securely tighten screws when you connect power cord to the electrical
terminal.
Failure to follow this instruction could result in electrical shock.
Electric
Power supply
Do not damage the power cord and the wire.
Do not put heavy objects on the power cord and the cable.
Do not force bending, twisting or pulling on the power cord and the cable.
Keep the power cord and the cable away from heat such as a heating cylinder of the molding
machine.
Failure to follow these instructions could result in fire or electrical shock.
Replace the power cord and the cable when damaged or frayed.
Connection
Be sure to insert the connector thoroughly and lock it.
Failure to follow these instructions could result in fire or electrical shock.
Immediately turn the power off by turning the circuit breaker off if smoke, extreme heat,
or unfamiliar noise or smell is detected, and contact our service office.
It could result in fire or electrical shock.
Do not insert any foreign objects through any openings of the controller such as a vent.
Failure to follow this instruction could result in fire, electrical shock or damaging the controller.
Do not touch the liquid when the liquid crystal display is damaged.
It may contain harmful and irritant substance. If in eyes or contact with skin, flush thoroughly
with water immediately for 15 minutes and call a physician. If in mouth, flush with water
immediately and call a physician.
Do not repair or remodel without consulting this manual.
Use only specified parts when repairing the controller.
Failure to follow this instruction could result in fire, electrical shock, or damaging the controller.
Molding
Cut the power off by turning the circuit breaker off when it is struck by disaster such as
power failure or earthquake.
Failure to follow this instruction could result in fire or electrical shock by unexpected system
operation.
Turn the power off by turning the circuit breaker off when you need to check inside of
the controller for repair or service purpose.
Failure to follow this instruction could result in electrical shock.
Maintenance
The molding must be adequately grounded when it is being heated without the molding
machine.
Inadequate grounding could result in electrical shock.
WARNING
3
Follow the safety tips mentioned bellow. Otherwise there may occur a injury or a physical
damage.
The controller should be placed on a level and stable surface.
Failure to follow these instructions may result in personal injury or damaging the controller and
adjacent machines.
Follow this manual for environmental specification.
Do not store or operate the controller where it will be exposed to excess moisture, heat or
dust.
Failure to follow this instruction may result in fire, damage to the controller or operation error.
Installation
Do not block the vent.
Failure to follow this instruction may result in fire by overheating the unit.
Do not connect/disconnect the connector when power is on.
Failure to follow this instruction may result in electrical shock or personal injury
Connection
Make sure to follow the specification when connecting the signal cable.
Failure to follow this instruction may result in electrical shock, fire, or damaging the molding
machine or controller.
When molding with the B-Spears is finished, make sure to turn off the Manifold heater
before the spear heater.
Failure to do so will damage the B-spear.
Do not touch the circuit breaker and the switches with wet hands.
Failure to follow this instruction may result in electrical shock or damaging the controller
Do not sit, stand on or put heavy objects on the air controller.
Failure to follow this instruction may result in electrical shock, damaging the controller or
personal injury.
Molding
Do not remove a cover when power is ON.
Do not operate with a cover removed.
Failure to follow these instructions could result in distraction to the temperature control, and it
cause unstable operation or damaging the controller.
Also could result in the destructive noise to the control unit, and it cause in unstable operation
or damaging the controller.
Maintenance
Clean or replace the filter semi-annually.
The clogged filter may cause the higher temperature and it may result in operation error, fire or
damaging the controller.
CAUTION
4
Name and role of each part
Front
Back
LCD touch panel
A display with a touch panel for operation of the controller
Power breaker
Used to turn ON/OFF the power.
Valve timing signal input connector
Used to connect the controller and
molding machine by a valve timing signal
cable. ( only)
Tip timing signal input cable
Used to connect the controller and molding
machine by a tip timing signal cable.
External interface connector
Used to connect the controller and molding
machine, etc. by a digital I/O signal cable.
Input/output connector
Used to connect the controller and mold by
a junction cable.
Cooling fan
Cools the inside of the controller.
Air filter
Prevents dust from entering the controller.
5
Inner part
Transformer voltage
changeover terminal
Quick-blow fuse
SSR
Control PCB
6
1Only shows up on the “Valve” screen.
Elements of LCD touch panel
7
8
Installation of controller
Controllers are precision machines. Take the environmental condition into consideration when
installing a controller in order to use it under the best condition.
Install the controller on a flat horizontal place, and keep the exhaust port open.
The range of the ambient temperature and humidity should be as follows:
Temperature: 0-40°C
Humidity: Up to 90%RH (Dew condensation not allowed)
Avoid installation in places with excess steam, oil vapor, smoke, corrosive gas, or inflammable gas.
The range of supply voltage and frequency should be as follows:
Voltage: Within ±10% of the voltage shown on the rating plate of the controller
Frequency: 50 or 60 Hz
Be sure to connect the ground wire to the grounding terminal for Type D Grounding (former Type 3
Grounding).
Connect one end of the junction cable to the connector at the back of the controller and the other
end to the connector box of the mold.
Connect the end of the tip timing signal cable with a connector to the TIP TIMING connector of the
controller. Connect the other end to the [Mold opening start signal] or [Mold opening completion
signal] of the molding machine.
Connect the end of the valve timing signal cable ( only) with a connector to the VALVE
TIMING connector of the controller. Connect the other end to the [Mold closing start signal] or
[Mold closing completion signal] of the molding machine.
IMPORTANT
The timing signal input cable comes in two types – one for contact input and the other for voltage input.
Check the specifications.
REFERENCE
The tip timing signal cable is the same as the valve timing signal cable.
Operating environment
Connection of power and ground
Connection of respective cables
9
Inputting set values
Set values only for [Initial setting] and [Main setting] of the AHC controller, and the basic molding
operation is possible with other settings remaining unchanged.
Turn on the power to the controller, and [Initialize] blinks for several seconds in the lower left section of
the screen, and the screen shown at left will appear.
Setting the zones to use
This function permits setting of the zones to use for molding.
IMPORTANT
Unconnected zones
When is selected for unconnected zones, a heater disconnection error will be detected. Be sure to select for
unconnected zones.
REFERENCE
For the zones for which is selected, will be indicated in the box of the zone number on the main setting screen.
Individually set the zones of the body to use.
: Set this for zones for output and error
detection.
: Set this for zones that are not used.
Initial setting
Initial screen
The number of controlling points of the
controller is displayed.
Select a language to be used on the screen.
REFERENCE : The language can be changed on the
basic setting screen as well.
→ Initial setting: Basic setting (p.10)
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Individually set the zones of the manifold to use.
: Set this for zones for output and error
detection.
: Set this for zones that are not used.
10
Set temperature
of body
Set temperature
of manifold
Stand-by temperature of body
100°C
[Time]
[Temperature]
Basic setting
IMPORTANT
Delay off function
Because of the structural nature of the B type, the temperature around the spear lowers earlier than that of the manifold when
the manifold and body heaters are stopped simultaneously, possibly causing breakage of the spear (tip bending).
Therefore, it is necessary to lower the manifold temperature first and then lower the body temperature. The delay off function
automatically conducts that operation.
(1) The manifold output is stopped and the body temperature remains at the heat-retention temperature.
(2) The temperature of all the manifold lowers below 100°C, or all heaters stop output when 30 minutes pass.
Heat-up Delay off Stop
Set the unit of temperature.
: Celsius (°C) will be selected.
: Fahrenheit (°F) will be selected.
REFERENCE : The set value is automatically
converted when the unit is changed.
Set the delay off function.
: The delay off key is displayed on the
main setting and sub setting screens.
: The delay off key is not displayed on
the main setting and sub setting
screens.
→ Other operations (p.16)
REFERENCE : Keys can be selected in the
T P type only.
Select the language on the screen.
: Display in Japanese
: Display in English
: Display in Chinese
REFERENCE : The screen configuration is almost the
same in any language.
Set temperature
of body
Set temperature
of manifold
Stand-by temperature of body
100°C
[Time]
[Temperature]
Heat-up Delay off Stop
11
Manifold setting
REFERENCE
Standard setting
When D type spear is used: The molding machine cylinder temperature ±0°C to +20°C
When B type spear is used: The molding machine cylinder temperature - 20°C to +0°C
Body setting
REFERENCE
The standard temperature setting is the molding machine cylinder temperature ±0°C to 50°C.
Main setting
The present output value is displayed.
Set the manifold temperature.
The setting range is [0-450°C].
The present measured temperature is displayed.
REFERENCE : [999] is displayed when the sensor is not
connected.
The main setting screen is scrolled.
REFERENCE : alone permits shift to the valve
screen.
Set the body temperature.
The setting range is [0-450°C].
The present measured temperature is displayed.
REFERENCE : [999] is displayed when the sensor is not
connected.
The present output value is displayed.
: The current value [A] is displayed.
: The output value [%] is displayed.
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Tip setting
REFERENCE
Standard setting
: In general, set the timer so that the main heating will be started three seconds before injection starts and that it
will be stopped approximately when injection is completed.
Refer to the timing chart of the tip timer for the detailed method of setting.
→ Example of timing chart of tip timer (p.17)
: In general, start main heating three seconds before injection starts.
Adjust the value set in the timer so that the main heating will stop when pressure holding stops.
Set the pre-heating current.
: The setting range is [0.0-14.0 A].
: The setting range is [0-100%].
Set the main heating current.
: The setting range is [0.0-14.0 A].
: The setting range is [0-100%].
The present output value is displayed.
: The current value [A] is displayed.
: The output value [%] is displayed.
Set the delay time.
Set how many seconds later the main heater should
be turned on after the tip timing signal is input.
The setting range is [0.0-99.9 sec.].
Set the on time.
Set the heating time of the main heating current.
The setting range is [0.0-99.9 sec.].
13
Valve setting
REFERENCE
The standard number of valve control circuit is one. (A maximum of four circuits can be supported on the setting screen.)
The valve solenoid driving circuit (24 DVC) is provided as standard equipment.
In general, make adjustment so that the valve will open right before injection starts and that it will close when holding pressure
is completed.
Turn tip heater ON when opening or closing the valve.
The method to input a set value and operate the numeric keypad is explained using the manifold
screen.
REFERENCE
When a value beyond the input range is input and is touched, the value will be changed to a maximum value and
entered.
Set the delay time.
Set how many seconds later the valve should be
opened after the valve timing signal is input.
The setting range is [0.0-99.99 sec.].
Set the opening time.
Set the time during which the valve should be open.
The setting range is [0.0-99.99 sec.].
The valve is opened manually.
: Open
: Close
REFERENCE : Operation is possible only when
heat-up has been completed.
The condition of the valve is displayed.
: The valve is open.
: The valve is closed.
Touch the set value key to input.
• The cursor of the set value will be shown in reverse
video, and the numeric keypad will appear.
• Press some other set value key while the numeric
keypad is being displayed, and the position of the set
value will shift.
Input a set value from the numeric keypad.
: The input value is entered.
: The input value is set for all zones.
: The numeric keypad disappears.
Set value inputting and numeric keypad
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Operation
The operation key to operate the controller can be operated on the [Initial setting] and [Main setting]
screens.
1. Touch the Heat Up key.
2. Completion of heat-up (Ready For Molding)
Heat-up is completed when the actually measured temperatures in all zones enter the temperature
monitoring range.
REFERENCE
When the heat-up standby timer is set, the heat-up will be completed after the timer operation is completed.
→ Sub setting: Heat retention and monitoring temperature (p.18)
Procedure for starting molding
The power will be supplied to the heater and the
temperature will rise up to the set temperature.
: Heater power ON.
: Heater power OFF.
The light of Ready icon comes on.
The Ready dialog appears.
Touch the Confirm key and close the Ready dialog.
15
3. Tip heating
IMPORTANT
The standard tip heating time for starting molding is 10 seconds.
When the tip timing signal is taken from the mold opening signal, it is necessary to conduct initial tip heating manually.
Conduct a valve opening/closing test. ( only)
When heat-up is completed, open and close the valve manually to confirm the operation.
REFERENCE
For protection of molds, the valve can be opened or closed only when heat-up has been completed.
IMPORTANT
When a valve with a tip is used, be sure to heat the tip before opening or closing the valve.
Tip heating is conducted.
The set main heating current is supplied manually to
the tip heater.
: Tip heating ON
: Tip heating OFF
The valve is opened manually.
: All valves are opened.
: All valves are closed.
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4. Icon
The display of the operation key in each status is shown below.
Error icon
It blinks when some error occurs.
The screen will change from [Status menu] to [Self
diagnosis] automatically.
Tip timing signal icon
: The tip timing has been input.
: There is no signal.
REFERENCE : In general, input the mold opening start
signal or mold opening completion signal
of the molding machine.
Valve timing signal icon ( only)
: The valve timing has been input.
: There is no signal.
REFERENCE : In general, input the mold closing start
signal of the molding machine.
Other operations
The mode shifts to the heat retention (Stand-by)
mode.
The temperature of the manifold and body is raised up to
the heat retention temperature.
: Heat retention (Stand-by) mode
: Heat-up (stop) mode
Sub setting: Heat retention (Stand-by) and
monitoring temperature (p.18)
The mode shifts to the delay off mode.
( only)
The manifold temperature is lowered, and then the
body temperature is lowered.
: Delay off mode
: Heat-up (stop) mode
→ Initial setting: Basic setting (p.10)
REFERENCE : The key will appear only when [ON] is
selected for the delay off function.
Stop Heat-upmolding)Heat retention
(Stand-by)
The mode shifts to the boost mode.
In order to facilitate molding start-up, the
body temperature is raised by as much as
the boost temperature.
: Boost mode
: Heat-up (stop) mode
→ Sub setting: Heat retention and
monitoring temperature (p.18)
REFERENCE: The key will appear only when
the boost temperature is set.
17
Molding Machine Controller
Prepare the molding machine for molding.
(Mold open)
Select [Automatic] or [Semi-Automatic] and
close the safety door.
Prepare the controller for molding.
Start Manual Tip Heating.
Start the timing timer
Start the timing timer
Stop the timing timer
Timer on
Timer off. Finish Tip Heat
Generally the timer is set to turn the main heater on 3 sec. before the injection starts, and turn the main heater off when the
injection is completed. Set the main heater on 3 sec. before injection, and off when the injection is completed.
A desirable tolerance for Mold Open + Remove Item + Mold Close time is under 0.1sec.
REFERENCE
REFERENCE
Flow Chart for Molding Start-up (TP type)
Injection
Open Mold
Ejection Item
Tip Signal[Enable]
Tip Signal[Enable]
Tip Signal[Enable]Tip Signal[Enable]
Injection begins 510 sec.
after Manual Tip Heat starts.
Close
Start Tip Heat Timer on
Injection
Open Mold
Timing Chart for the Tip Timer
Open Remove
1.5sec. 2sec.
Injec Stand
Timing
timer
2.5sec.
Tip Heat Timer
Close
1.5sec.
Open Remove
1.5sec. 2sec.
Injec Stand
Timing
timer
2.5sec.
Tip Heat Timer
Close
1.5sec.
Tip Heat Tip Heat
4.5sec. 4.5sec.
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Other settings
Heat retention and monitoring temperature
The setting temperature for operation of the operation key and the monitoring temperature during
molding are set.
Set the boost temperature.
Set a relative temperature with respect to the set
temperature.
The setting range is [0-100°C].
When the boost temperature is set, the boost key will
appear.
REFERENCE : This function is provided to facilitate
gate opening when starting molding.
Set the heat retention (Stand-by) temperature.
The setting range is [0-450°C].
REFERENCE : This temperature is set so that the resin
will not be burned when molding is
stopped temporarily.
Sub setting
Set the temperature monitoring width.
The setting range is [0-999°C].
When the actually measured temperature of all
zones enter the temperature monitoring range
during heat-up, the soak timer begins operation.
When the soak timer stops operation, the
heat-up completion is displayed.
When the temperature changes beyond the
temperature monitoring range during molding,
the temperature error is displayed, and the
machine conducts operation according to the
procedure selected to cope with the error.
19
Timer
Set various timers.
REFERENCE
Timer operation
Timer Start Operation when time is over Resetting condition
Setting
range
Heating up
delay timer
Heater power ON
Heat-up start 0-99 min.
Watching
heat-up
timer
Heat-up start
• Heater power OFF
• Heat-up time monitor error Error
Heat-up completion
1-99 min.
Soak timer
All zones enter
temperature monitoring
range.
Heat-up completion
At least one zone is out
of the temperature
monitoring range.
0-30 min.
Suspend
timer
Heat-up completion Heat retention ON
• Controller operation
• Timing signal input
1-99 min.
Tip heat on
over timer
Tip heating ON
Tip heating OFF 1-120 sec.
Input the tip heat on over time.
This timer automatically stops tip
heating.
→
The actual values set in
respective timers are displayed.
Set the heating up delay time.
Turn on the heater power, and the timer begins operation,
starting heat-up when the operation is completed.
REFERENCE : Touch the heater power key, and the
heating up delay timer operates. When
the operation of the heating up delay timer
is completed (time-up), heating-up
operation starts.
Set the watching heat-up time.
The heat-up time is monitored, and an error is displayed
when heat-up is not completed even if the preset time
comes.
REFERENCE : Detection of heater and sensor
disconnection is possible.
Set the soak time.
When the temperatures of all zones enter the
temperature monitoring range during heat-up, the timer
begins operation, preventing heat-up completion until the
operation is completed.
REFERENCE : The function is the same as the cold
start-up prevention timer of the molding
machine.
Set the suspend time.
The timer operates at all times during heat-up completion.
The timer is reset by the operation of the controller or input
of a timing signal. The operation shifts to heat retention
(Stand-by) when the timer operation is completed.
: The operation delay timer is used.
: The operation delay timer is not used.
REFERENCE : When the molding machine stops due to an
error, the timer shifts the operation to heat
retention (Stand-by).
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Set temperature of
body
Set temperature of
manifold
Stand-by temperature
of body
[Time]Completion of
manifold
Manifold temperature monitoring range
[Temperature]
Option
Set various values for molding.
REFERENCE
2-step heat up function
Set the 2-step heat up.
The body is on standby at the heat retention
temperature until the manifold heat-up is completed.
: The 2-step heat-up function is used.
: The 2-step heat-up function is not used.
REFERENCE : This function raises the probe
temperature when the manifold heat-up is
completed, which is slower than general
heat-up speed, in order to prevent resin
burning in the body.
Set the auto heat up.
When the controller power is turned on, the system
automatically enters the heat-up state.
: The auto heat-up function is used.
: The auto heat-up function is not used.
REFERENCE : Used together with the calendar timer, etc.
of the molding machine.
Set the manifold soft heat up.
The temperature will rise according to a certain heat-up
curve pattern (30°C/min.) when stress should not be
applied to the heater.
: The manifold soft heat-up function is used.
: The manifold soft heat-up function is not
used.
REFERENCE : This function is also effective when the
heater absorbs moisture and the earth
leakage breaker trips.
21
Self-diagnosis function
The status of the system is monitored at all times during operation.
When an error occurs, the screen will automatically change to the self-diagnosis screen, entering the
state selected for troubleshooting in advance.
The error signal of the digital I/O connector is output as well
REFERENCE
Kinds of errors to monitor
Sensor disconnection ··············································· This error is detected when the sensor is disconnected.
Crossed sensor error ················································ The response error between the sensor and heater is detected.
Sensor reverse connection error ······························ The erroneous connection of the + and – terminals of the sensor is
detected.
Temperature error ····················································· The temperature out of the temperature monitoring range during molding
is detected.
Heater burned out····················································· This error is detected when the heater is disconnected.
Overcurrent protection circuit operation···················· This error is detected when the overcurrent protection circuit (OCP)
operates.
Heat-up time watching error ····································· This error is detected when the heat-up time exceeds the value set in the
timer.
Air pressure drop error·············································· The air pressure drop signal is monitored.
External error ···························································· The contact input is monitored.
Kinds of system errors
Output device breakage error··································· Breakage of the output device in the state of short circuit is detected.
Watchdog timer error ················································ The error of the control board program is detected.
M24C64 communication error ·································· The error of the control board program is detected.
Gain non-adjusted error············································ The error of the control board program is detected.
Display of PW1
When an error occurs primarily in the mold and
junction cable, “Error code, “Error message,” and
“Error zone” are displayed.
Status monitoring function
Display of system error
The system error that occurred in the controller is
displayed.
Error reset key
The error state is cancelled.
REFERENCE : When the cause of the error has not
been removed, the error code and error
message appear again.
Error code
Error zone
Error message
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Conditions to Detect Abnormality
Abnormality
Start
Observation
Finish
ObservationSet Action Manifold Body Tip
Sensor Burned Out
Heat Up Heat UpEmergency
action setup
Crossed Sensor
Heat UpReady
Heat Off
Sensor Reverse
Heat UpReady
Heat Off
Temp. Monitoring
Ready
Heat Up
or
5
Emergency
action setup
Heater Burned Out
Heat Up Heat UpEmergency
action setup
Over Current
Protection
Heat Up Heat Up Emergency
action setup
Watching Heat-Up
Time
Heat Up
Ready
Heat Off
External
Heat Up Heat Up Action On
External Alarm
Out Put Device
Burned Out Controller On Power Off Heat Off
1. In case output device breaks down during short mode,output power cannot be turned off.
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Troubleshooting
Set the troubleshooting method.
System operation history
The number of total shots of the controller and the number of operation shots after resetting are
displayed.
Select the action on alarm.
: The heat-up state is maintained.
: Shifting to the heat retention (Stand-by)
state.
: Shifting to the stop state.
→ Status monitoring function (p.21)
Select the action from ext. interlock.
: The heat-up state is maintained.
: Shifting to the heat retention (Stand-by)
state.
: Shifting to the stop state.
→ Status monitoring function (p.21)
REFERENCE : The external error signal is input through
the EXT. INTERFACE connector.
Set the external error alarm output.
: An error signal is output when an
external error signal is input.
: No error signal is output.
REFERENCE : This function does not loop the error
signal from the molding machine.
Total counter running hours
The running hours after shipment from the factory are
displayed.
Total counter shot
The number of shots after shipment from the factory is
displayed.
Resettable counter shot
The number of shots after resetting is displayed.
Used to reset the resettable counter.
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Selection of sensor
Set the sensor type.
IMPORTANT
Be sure to use a junction cable suitable for the selected sensor type.
Output fixed control (Regulated Control)
In order to continue molding even if the sensor is disconnected and temperature control is impossible,
fix the output value to tentatively continue molding.
IMPORTANT
Make a note of the output value during normal operation to provide for sensor disconnection.
Excessively high output will cause resin burning and mold breakage.
REFERENCE
Set , and will appear in the box of zone number on the main setting screen.
Special functions
Set the manifold output fixed control value.
The setting range is [0-100%].
Set the zone subject to manifold output fixed
control.
: Output fixed control is conducted.
: Temperature control is conducted.
Set the zone subject to body output fixed control.
: Output fixed control is conducted.
: Temperature control is conducted.
Set the body output fixed control value.
: The setting range is [0.0-4.0 A].
: The setting range is [0-100%].
Set the sensor type for the body.
: The K type is set.
: The J type is set.
Set the sensor type for the manifold.
: The K type is set.
: The J type is set.
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Key lock and password lock functions
The key lock function and password lock function are provided to prevent operation errors.
Locking and unlocking procedure
Set (Disable).
The lock function is not used in this state.
REFERENCE : is invalid.
Set the key lock function.
All the keys including the operation key are locked.
Set the password lock function.
Unless the password is input, set values cannot be
changed. This function is used to protect all set
values.
Touch .
Input a correct password on the screen that
appears when is touched, and Lock and
Unlock will change alternately.
Keep touching for more than two seconds,
and Lock and Unlock will change alternately.
Key lock function
IMPORTANT
The password is shown on the last page.
Password lock function
The status of the lock key changes.
: Locked state
: Unlocked state
3
The input value is
entered.
The screen returns
to the original
screen.
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Temperature control setting
For prevention of operation errors, the screen will change to the temperature control setting screen after
the password is input.
Self-tuning operation
The temperature control constants of the manifold and body can be set manually. Do not change them
unless there is a problem with temperature control.
Self-tuning operation
The controller automatically selects the temperature control constants of the manifold and body.
REFERENCE
Temperature control constant (P.I.D)
P is the size of the proportional band. (400 = 40°C) Make P smaller, and the response will be better. However, excessively
small P may cause instability. When P is larger, the response will be deteriorated but the stability will improve.
I is the integration constant. Make I larger, and the continuous followingness will improve (offset removal is faster), but hunting
will result easily. It is recommended not to make I larger unnecessarily.
D is the differential constant. Make D larger, and the foresighted followingness will improve, stabilizing the temperature when a
6D spear is used. However, excessively large D may cause temperature fluctuation.
Set the manifold temperature control constant (PID).
REFERENCE : Setting is possible when the self-tuning
function is off.
Set for self-tuning.
Set the body temperature control constant (P.I.D).
REFERENCE : Setting is possible when the self-tuning
function is off.
Set for self-tuning.
Since constant setting is conducted automatically, the
respective P.I.D setting keys in reverse video will
disappear.
REFERENCE : conducts self-tuning of the manifold
only.
The automatically set
constant is displayed.
REFERENCE: The numbers
correspond to board
1-4 sequentially
from the left.
Touch the menu.
IMPORTANT The password is shown
on the last page.
The input value is entered.
The screen returns to the
original screen.
Touch the temperature
control setting menu.
Input the password to shift to the temperature control
setting screen.
27
Set value storage for each mold
Name the molding condition, and a maximum of 16 cases can be stored and called up.
Storing procedure
: Enter the input name to store the molding condition.
: The screen changes to the name input (number) screen.
: The screen changes to the name input (alphabet) screen.
: Storing operation is stopped, retuning to the previous screen.
REFERENCE
A maximum of 12 characters can be input as a name to store.
Input an alphanumeric name, and touch .
Storage function
The stored names are displayed.
The present value is stored.
Touch of the mold No. to store.
Touch of the mold No. to store.
Mold No.
The stored set value is called up.
Touch of the mold No. to call up.
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The set value dialog for each mold appears.
Calling-up procedure
: The set value for each mold, which is displayed in the
dialog, is called up.
: Calling up is stopped, and the dialog is closed.
Mold No. display
The [Mold No.] is displayed when the stored set value for each mold is displayed.
REFERENCE
The [Mold No.] display will disappear when the set value is changed.
Touch of the mold No. to call up.
The present mold No. is displayed.
The present mold No. is displayed.
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Periodical maintenance
WARNING
Before maintenance
When inspecting the inside of the controller or changing parts, turn off the power breaker to stop power
supply to the controller, and then remove the cover from the controller, otherwise an electric shock or
fire will result.
REFERENCE
It is recommended to make a note of the connection destination and installation position in order to prevent incorrect wiring or
installation.
The filter can be removed for cleaning.
WARNING
When the controller with a clogged filter is used, the temperature inside the controller will rise, not only preventing the controller
from delivering its performance sufficiently but also causing breakage of the controller or fire.
Washing air filter with water
When the filter cannot be cleaned by a vacuum cleaner, it is possible to remove it and wash it with water. When the filter is
washed with water, drain the water sufficiently and dry the filter before installing it again.
Water remaining on the filter will cause trouble.
IMPORTANT
Clean the filter frequently when used in a dusty environment.
It is necessary to clean the air filter at the suction port at least every year.
When removing the air
filter, remove the screws in
four places and then
remove the cover.
Air filter cleaning
Apply a vacuum cleaner to the slit
and suck the dust.
Screw
2
Screw
3
Screw
4
Clean the air filter on the
opposite side in the same
manner.
Screw
1
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When the LCD touch panel blacks out and the LED in the lower left section of the LCD touch panel
comes on in orange (green when normal), the backlight has burned out.
IMPORTANT
When the backlight burns out, the screen blacks out and the display becomes invisible. Since input on the touch panel is valid,
however, improper touch panel operation may result when the touch panel is touched confusing the situation with the backlight
off state.
REFERENCE
When the LED is lit in green while the backlight is off, the function that protects the display element of the LCD touch panel is
activated.
The backlight will go out automatically when the touch panel is not operated for five minutes.
The life of the backlight is approx. five years when used normally.
When the backlight burns out, it must be replaced with a new one. The type is PS300-BU00 (digital).
You can contact our company also for replacement of the backlight.
1. Remove the side panel.
The fuse is on the right side when viewed from the front of the controller.
Replacement of backlight of LCD touch panel
Fuse change
When the LED comes on in
orange, the backlight has burned
out.
Screw
1
Screw
2
Screw
3
Screw
4
Remove the screws
in four places.
Remove the side panel.
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2. Replacement of blown fuse
AHC2VP2
AHC4TP4S
WARNING
Be sure to substitute a specified fuse. Any fuse other than the specified one may cause trouble.
IMPORTANT
Check the cause of the fuse blowing. When the blown fuse is replaced with a new one without removing the cause, the new
fuse will be blown repeatedly.
Do not apply excessive force when putting in and out the fuse, otherwise the glass tube may be broken.
The manifold fuse cannot be confirmed
visually. Use a tester for confirmation.
Select the resistance range of the tester and
apply the probes to both ends of the fuse.
Unless the resistance is approx. “0,” the fuse
has been blown.
When the manifold fuse is blown
Replace it with a reserve fuse (fast-blow fuse
20A for semiconductor protection).
Type of fuse: 314020 (Little fuse)
When the valve fuse is blown
Replace it with a reserve fuse (fast-blow fuse
10A for semiconductor protection).
Type of fuse: 312010 (Little fuse)
Visually check the fuse.
Manifold
Valve
The manifold fuse cannot be confirmed
visually. Use a tester for confirmation.
Select the resistance range of the tester and
apply the probes to both ends of the fuse.
Unless the resistance is approx. “0Ω,” the fuse
has been blown.
Manifold
When the manifold fuse is blown
Replace it with a reserve fuse (fast-blow fuse
20A for semiconductor protection).
Type of fuse: 314020 (Little fuse)
Valve 2
Valve 2
Valve 1
Valve 1
Manifold 1
Manifold 1
Manifold 2
Manifold 2
Manifold 4
Manifold 4
Manifold 3
Manifold 3
Manifold 1
Manifold 1
Manifold 2
Manifold 2
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Troubleshooting for Warning Messages
This section explains about troubleshootings when error message displays on the screen of AHC
controller.
Status monitor error System error Other errors
Sensor Burned Out Failed Output Device
Heater Burned Out Watched Timer Error
Crossed Sensor M24C64 Error
Sensor Reverse Calibration Error
Temp. Too Low
Temp. Too High
Over Current Protection Circuit Action
Timed Up Watching Heat Up Timer
Air Pressure Too Low
External Alarm
Code Description Component to be checked
Manifold Temp. Too Low
Body Temp. Too Low Spear BodyValve Body
Manifold Temp Too High
Body Temp Too High Spear BodyValve Body
External Alarm
Air Pressure Is Too Low
Opened Manifold Sensor
Opened Body Sensor Spear BodyValve Body
Body Heater Burned Out Spear Body
Tip Heater Burned Out Spear TipValve Tip
Body O.C.P Spear Body
Tip O.C.P Spear TipValve Tip
Timed Up Watching Timer
Manifold Sensor Reverse
Body Sensor Reverse Spear BodyValve Body
Crossed Manifold Sensor
Crossed Body Sensor Spear BodyValve Body
Watched Timer Error
M24C64 Error
Failed Output Device
Calibration Error
Warning Code List
higher-level communication
error (02:XX)
Japanese characters
show up even on English
language display.
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CorrectionCause
Status monitor error
Imperfect contact of sensor connector
Remove the junction cable from the controller, and check to see if the
connector pin has receded, causing imperfect contact.
Disconnection of sensor
Disconnection of junction cable
Measure the resistance on the junction cable side (mold side) with an
ohmmeter of a tester. When the needle points at infinity, the sensor,
junction cable, or connector box is out of order. Check it. (The
normal resistance is from several tens of Ω to several kΩ.)
Imperfect contact of spear sensor
Spear
Imperfect contact of valve sensor
Valve
When the condition is normal after inspection for “imperfect contact”
and “disconnection of sensor and junction cable,” it is possible that
disconnection sometimes occurs depending on the body temperature.
Imperfect contact of output connector
Check to see if the connector pin has receded, causing imperfect
contact.
Disconnection of heater
Disconnection of junction cable
Measure the resistance on the heater and junction cable side with an
ohmmeter of a tester. When the needle points at infinity, the heater or
wiring is disconnected. Check it. (The normal resistance is from
several tens of Ω to several kΩ.)
Failure of output board
Spear Valve tip
Touch the error reset button to see if disconnection recurs. If it surely
recurs, the output board may have failed.
Imperfect contact of spear heater When the error occurs occasionally or at the rate of several times per
month, disconnection may be caused by thermal expansion when the
temperature is raised
The sensor and heater are not
responding correctly.
Check the wiring and make adjustment so that the sensor and heater
will response correctly.
The set temperature is more than 50°C
lower than the actual temperature.
Wait until the actually measured temperature lowers, and then raise
the temperature again.
REFERENCE
A response error is displayed when the actually measured temperature exceeds the set value + 50°C during heat-up.
[Sensor disconnection error] Spear Valve Manifold
[Heater disconnection error] Spear Valve tip
[Sensor response error] Spear Valve Manifold
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The ± terminals of the sensor are
connected reversely.
Check and correct the wiring.
REFERENCE
An error is displayed when the actually measured temperature rises on the minus side and lowers up to the room
temperature – 50°C.
The monitoring temperature range is
too small.
Displayed when the actually measured temperature drops below “Set
temperature – Temperature setting range] during molding because of
some trouble.
→ Sub setting: Heat retention and monitoring temperature (p.18)
REFERENCE
: When a spear is used, the body temperature changes
periodically by intermittent heating of the tip heater.
The set temperature was changed
beyond the temperature monitoring
range during molding.
Change the setting temperature little by little, or turn off the heater
power once and then raise the temperature again.
→ Main setting (p.11)
The manifold heater was disconnected.
Manifold heater
The valve body heater was
disconnected.
Valve body
Measure the resistance on the heater and junction cable side with an
ohmmeter of a tester. When the needle points at infinity, the heater or
wiring is disconnected. Check it. The normal resistance is from
several tens of Ω to several kΩ.
The fuse was blown.
Manifold
Valve body
→ Periodical maintenance: Fuse change (p.30)
The power has an open phase. Check to see if the three phases of the controller power is supplied
normally.
The temperature monitoring range is
too small.
Displayed when the actually measured temperature exceeds “Set
temperature + Temperature setting range] during molding because of
some trouble.
→ Sub setting: Heat retention and monitoring temperature (p.18)
REFERENCE : When a spear is used, the body temperature changes
periodically by intermittent heating of the tip heater.
The set temperature was changed to
out of the temperature monitoring range
during molding.0
Wait until the actually measured temperature lowers.
The pre-heating is excessive.
Spear
Excessive pre-heating does not permit body temperature control.