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Service Manual
Hot Runner Controllers
HR & HRD
Rev. 1.00.02
02/2014
Translation of original
Service Manual
PSG Plastic Service GmbH
Service Manual Hot Runner Controllers HR & HRD
Table of Contents
1
1.1
Typographical Conventions ............................................................................................................... 2
Additional and continuative documents ................................................................................................ 2
2
2.1
2.1.1
2.1.2
2.1.3
2.2
2.3
2.3.1
2.3.2
System Configuration ......................................................................................................................... 3
Components ........................................................................................................................................... 3
Main board .............................................................................................................................................. 3
Power supply card.................................................................................................................................. 3
Power controller card STP6 / STP6 II ................................................................................................... 4
Schematic presentation ......................................................................................................................... 5
Setup....................................................................................................................................................... 6
DIP switch 1 to 3 - Addressing .............................................................................................................. 6
DIP switch 4 – Deactivate phase synchronization ............................................................................... 6
3
Status LED's ......................................................................................................................................... 7
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
Messages on LED Display.................................................................................................................. 8
Message E100 – Identification of malfunction of power controller card at system start..................... 8
Message E101 – Identification of malfunction of power controller card at system start..................... 8
Message E102 - Identification of change in system configuration ...................................................... 9
Message E103 – Identification of short circuit ...................................................................................... 9
Message E104 – Version incorrect on power controller card .............................................................. 9
Message E110…114 – Timeout of interface to power controller card .............................................. 10
Message E115 – Timeout of interface to power supply card............................................................. 10
Message E120…E124 – Error phase synchronization ...................................................................... 11
Message E130…E134 - EEPROM error ............................................................................................ 12
Message E140…E144 - Temperature alarm ..................................................................................... 12
Message E150…E154 - Potential error .............................................................................................. 12
5
5.1
Appendix ............................................................................................................................................. 13
Version History ..................................................................................................................................... 13
Right to technical changes reserved
Rev. 1.00.02
1
PSG Plastic Service GmbH
Service Manual Hot Runner Controllers HR & HRD
1
Typographical Conventions
Symbols and conventions are used in this manual for faster orientation for you.
Caution
Note
1.1
With this symbol, references and information are displayed which are
decisive for the operation of the device.
In case of non-compliance with or inaccurate compliance there can result
damage to the device or injuries to persons.
The symbol refers to additional information and declarations, which serve for
improved understanding.
Example
With the symbol, a function is explained by means of an example.
Reference
With this symbol, information in another document is referred to.
FAQ
Here FAQ (Frequently Asked Questions) are answered.
Equations
Calculation specifications and examples are represented in this way.
Additional and continuative documents
Operation
See operating instructions hot runner controllers HR/HRD
Input by
interface
See project planning - and configuration tool WinKonVis
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PSG Plastic Service GmbH
Service Manual Hot Runner Controllers HR & HRD
2
System Configuration
2.1
Components
The hot runner controller consists of the components:
 main board
 power supply card
 power controller card STP6 (HR 12…30) / STP6 II (HRD 06…30)
 power supply card/power controller card STP6H (HR 06)
2.1.1
Main board
Includes:
 Micro Controller and peripherals
 Keys (membrane keypad)
 LED displays
 Interface RS485
 Interface CAN
 Digital inputs/-outputs
The functions are:
 temperature control
 communication with the connected power controller cards
 communication with superior control
 IO handling (alarms, etc)
 system monitoring
2.1.2
Power supply card
Includes:
 Micro Controller and peripherals
 Interface RS485
The functions are:
 the identification of voltage zero crossing for network synchronous output of actuating signal (only
HR)
 control of fan
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Service Manual Hot Runner Controllers HR & HRD
2.1.3
Power controller card STP6 / STP6 II
Includes:
 Micro Controller and peripherals
 Status LED's
 Interface RS485
 Analog inputs for temperature registration
 complete power controller units (thyristor, fuse) for control of electric heaters
The functions are:
 communication with main board
 measured value recording
 output of actuating signals
 identification of residual current
 the identification of voltage zero crossing for network synchronous output of actuating signal (only
HRD)
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PSG Plastic Service GmbH
Service Manual Hot Runner Controllers HR & HRD
2.2
Schematic presentation
Hot runner controller HR 06
RS485
Power supply
card
Main board
CAN
RS485
Power
controller
card
I/O
~
Hot runner controller HR 12, HR 18, HR 24, HR 30
...
RS485
Main board
CAN
RS485
Power supply
card
I/O
Power
controller
card
...
Power
controller
card
~
Hot runner controller HRD 06…30
...
RS485
Standard
Power supply
Main board
CAN
RS485
I/O
Power
controller
card
...
Power
controller
card
~
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PSG Plastic Service GmbH
Service Manual Hot Runner Controllers HR & HRD
2.3
Setup
Each card (power supply card and power controller card) is identified uniquely by check sum. As default the
setup data is on the main board. Thereby system errors/defects can immediately and clearly be identified
and remedied.
A setup must be executed after each system change (e.g. replacement of cards) (Enter code number 5 by
membrane keypad or interface, procedure see corresponding manuals chapter 1.1).
2.3.1
DIP switch 1 to 3 - Addressing
The cards are sequentially addressed starting with 0, view from the front side from the left to the right. The
address is stipulated by DIP1…DIP3.
DIP switch
Card number
1
1 2 3 4
ON
2
1 2 3 4
ON
3
1 2 3 4
ON
4
1 2 3 4
ON
5
1 2 3 4
ON
2.3.2
DIP switch 4 – Deactivate phase synchronization
The exact identification of zero crossing can for example not be guarantied at operation in "instable"
networks. Therefore the phase synchronization can be deactivated by DIP switch.
DIP switch
Phase
synchronization
Active
1 2 3 4
ON
Deactive
1 2 3 4
ON
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Service Manual Hot Runner Controllers HR & HRD
3
Status LED's
Due to a self diagnosis, that is executed by the hot runner controller directly after switch on, all
display segments are activated to test them.
On the cards of the hot runner controller are LEDs, which are only visible after opening of the cover of the
hot runner controller.
The opening of the cover of the hot runner controller may be carried out by authorized persons
only. Only skilled and on the risks trained persons may use the device. The relevant accidental
regulations as well as other general approved safety-relevant, occupational-medical norms
have to be obeyed.
Before opening of the device always switch-off the mains switch and unplug the mains plug or
make sure that the device is de-energized. Protect against unintentional reclosing.
OK-LED (yellow*)
SIO-LED (yellow)
Flashing = Boot
Continuous light = OK
Flashing = Boot
Continuous light = OK
Power supply card
Power controller
card STP6H
Flashing = Interface operation
Flashing = Interface operation
*) STP6II OK-LED (green)
LEDs at relay (yellow)
Power controller
card STP6
Power controller
card STP6 II
Continuous light = Relay switched
Flashing = Output percentage
Continuous light = Relay switched
Flashing = Output percentage
Power supply card
Power controller card STP6H
...
Power controller card STP6
Power controller card STP6 II
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Service Manual Hot Runner Controllers HR & HRD
4
Messages on LED Display
4.1
Message E100 – Identification of malfunction of power controller card at
system start
The cards plugged in the hot runner controller are sequentially addressed from 0 (see chapter 2.3.1) as
defined in the setup (see chapter 2.3) by default. Is a gap detected, e.g. by identification of a malfunction of a
power controller card (not the one, with the highest address), the message alternates with the display HR??.
Hot runner controller
≥ HR 12, ≥ HRD 12
Reason
Phase missing
Incorrect plug connection
Start
Trouble Shooting
Incorrect addressing
Power controller card electrical defect
4.2
Operating status






Check mains voltage before fuses
Check connection to ribbon cable
Replace ribbon cable if necessary
Check DIP switch setting (see chapter 2.3.1)
Check LEDs on power controller card (see chapter 3)
Replace power controller card or send hot runner
controller in for repair
Message E101 – Identification of malfunction of power controller card at
system start
Is detected that, opposite to the default setup (see chapter 2.3)
 a malfunction of the power controller card with the highest address has occurred
 cards were added or removed
the message alternates with the display HRXX.
By pressing the key h again, a new SCAN can be activated and the new configuration can be transferred.
Hot runner controller
> HR 06, > HRD 06
Reason
Phase missing
Incorrect plug connection
Incorrect addressing
Power controller card electrical defect
Operating status
Start
Trouble Shooting






Check mains voltage before fuses
Check connection to ribbon cable
Replace ribbon cable if necessary
Check DIP switch setting (see chapter 2.3.1)
Check LEDs on power controller card (see chapter 3)
Replace power controller card or send hot runner
controller in for repair
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PSG Plastic Service GmbH
Service Manual Hot Runner Controllers HR & HRD
4.3
Message E102 - Identification of change in system configuration
The message is displayed, when a changed system configuration is detected, e.g. by replacement of a
power controller card.
In case this is no error, by pressing the key h again, a new SCAN can be activated and the new
configuration can be transferred.
Hot runner controller
≥ HR 06, ≥ HRD 06
Reason
Changed DIP switch
4.4
Start/Operation
Trouble Shooting

Check DIP switch setting (see chapter 2.3.1)
Message E103 – Identification of short circuit
Hot runner controller
≥ HRD 06
Reason
Ground fault
Sensor at heating output
4.5
Operating status
Operating status
Start heating
Trouble Shooting


Check heating
Check wiring
Message E104 – Version incorrect on power controller card
Hot runner controller
≥ HRD 06
Reason
Old firmware version on power
controller card
Operating status
Start
Trouble Shooting


Replace power controller card
Firmware update by manufacturer necessary, send
power controller card or hot runner controller in for
repair
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PSG Plastic Service GmbH
Service Manual Hot Runner Controllers HR & HRD
4.6
Message E110…114 – Timeout of interface to power controller card
E110 matches timeout on card 1, E111 matches timeout on card 2, etc.
Hot runner controller
≥ HR 06, ≥ HRD 06
Reason
Incorrect plug connection
Operation
Trouble Shooting
Loose connection DIP switch



Power controller card electrical defect

4.7
Operating status
Check connection to ribbon cable
Replace ribbon cable if necessary
Replace power controller card or send hot runner
controller in for repair
Replace power controller card or send hot runner
controller in for repair
Message E115 – Timeout of interface to power supply card
Hot runner controller
≥ HR 06, ≥ HRD 06
Reason
Incorrect plug connection
Power supply card electrical defect
Operating status
Operation
Trouble Shooting



Check connection to ribbon cable
Replace ribbon cable if necessary
Replace power supply card or send hot runner
controller in for repair
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PSG Plastic Service GmbH
Service Manual Hot Runner Controllers HR & HRD
4.8
Message E120…E124 – Error phase synchronization
E120 matches error on card 1, E121 matches error on card 2, etc.
Hot runner controller
= HR 06
Reason
Phase missing
Fuse defective
Hot runner controller
Reason
Phase missing
Fuse defective
Operating status
Start/Operation
Trouble Shooting



≥ HR 12
Check mains voltage before fuses
Check fuse on power supply card
Replace power supply card or send hot runner
controller in for repair
Operating status
Start/Operation
Trouble Shooting


Check mains voltage before fuses
Check fuse on power supply card, replace if necessary
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PSG Plastic Service GmbH
Service Manual Hot Runner Controllers HR & HRD
Hot runner controller
≥ HRD 06
Reason
Phase missing
Fuse defective
4.9
Operating status
Start/Operation
Trouble Shooting


Check mains voltage before fuses
At least one of the zone fuses is defective, check and
replace if necessary
(see fuse holder/side of housing)
Message E130…E134 - EEPROM error
E130 matches error on card 1, E131 matches error on card 2, etc.
Hot runner controller
≥ HR 06, ≥ HRD 06
Reason
Defect EEPROM or check sum error in
EEPROM
4.10
Operating status
Start/Operation
Trouble Shooting

Replace power controller card or send hot runner
controller in for repair
Message E140…E144 - Temperature alarm
E140 matches error on card 1, E141 matches error on card 2, etc.
The heat sink temperature has exceeded 80 °C.
All outputs on the power controller card are switched off. Output of alarm message current tolerance.
Hot runner controller
≥ HR 06, ≥ HRD 06
Reason
High temperature at installation location
Overload
4.11
Operation
Trouble Shooting



Mechanical defect of fan
Operating status
Check environmental conditions at installation location
Check, that the power controller card is operated only
with 50% duty ratio at full load for all 6 channels
Check fan and clean if necessary
Message E150…E154 - Potential error
E150 matches error on card 1, E151 matches error on card 2, etc.
Hot runner controller
≥ HRD 06
Reason
Voltage on measurement input
Operating status
Operation
Trouble Shooting

Check wiring
Right to technical changes reserved
Rev. 1.00.02
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PSG Plastic Service GmbH
Service Manual Hot Runner Controllers HR & HRD
5
Appendix
5.1
Version History
Version
Date
Changes
1.00.02
1.00.01
1.00.00
02-20-2014
04-16-2010
11-09-2009
DIP Switch phase synchronisation inverted
Complete revision
First publication E120…E124
PSG Plastic Service GmbH
Pirnaer Straße 12-16
68309 Mannheim
Germany
Tel. +49 621 7162 0
Fax +49 621 7162 162
www.psg-online.de
[email protected]
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