Service Manual

Hot Runner Controllers

HR & HRD

Rev. 1.00.02
02/2014
Translation of original
Service Manual
 PSG Plastic Service GmbH 1
Service Manual Hot Runner Controllers HR & HRD

Table of Contents

1 Typographical Conventions ............................................................................................................... 2

1.1 Additional and continuative documents ................................................................................................ 2
2 System Configuration ......................................................................................................................... 3
2.1 Components ........................................................................................................................................... 3
2.1.1 Main board .............................................................................................................................................. 3
2.1.2 Power supply card.................................................................................................................................. 3
2.1.3 Power controller card STP6 / STP6 II ................................................................................................... 4
2.2 Schematic presentation ......................................................................................................................... 5
2.3 Setup....................................................................................................................................................... 6
2.3.1 DIP switch 1 to 3 - Addressing .............................................................................................................. 6
2.3.2 DIP switch 4 – Deactivate phase synchronization ............................................................................... 6
3 Status LED's ......................................................................................................................................... 7
4 Messages on LED Display.................................................................................................................. 8
4.1 Message E100 – Identification of malfunction of power controller card at system start..................... 8
4.2 Message E101 – Identification of malfunction of power controller card at system start..................... 8
4.3 Message E102 - Identification of change in system configuration ...................................................... 9
4.4 Message E103 – Identification of short circuit ...................................................................................... 9
4.5 Message E104 – Version incorrect on power controller card .............................................................. 9
4.6 Message E110…114 – Timeout of interface to power controller card .............................................. 10
4.7 Message E115 – Timeout of interface to power supply card............................................................. 10
4.8 Message E120…E124 – Error phase synchronization ...................................................................... 11
4.9 Message E130…E134 - EEPROM error ............................................................................................ 12
4.10 Message E140…E144 - Temperature alarm ..................................................................................... 12
4.11 Message E150…E154 - Potential error .............................................................................................. 12
5 Appendix ............................................................................................................................................. 13
5.1 Version History ..................................................................................................................................... 13

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Service Manual Hot Runner Controllers HR & HRD

1 Typographical Conventions
Symbols and conventions are used in this manual for faster orientation for you.

Caution 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.
Note 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.

1.1 Additional and continuative documents

Operation See operating instructions hot runner controllers HR/HRD

Input by See project planning - and configuration tool WinKonVis

interface

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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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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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2.2 Schematic presentation

Hot runner controller HR 06
RS485

Power
Main board Power supply controller
card card

CAN RS485 I/O ~

Hot runner controller HR 12, HR 18, HR 24, HR 30

RS485
...

Main board Power supply Power

controller
... Power
controller
card
card card

CAN RS485 I/O ~

Hot runner controller HRD 06…30

RS485
...

Main board Standard Power

controller
... Power
controller
Power supply
card card

CAN RS485 I/O ~

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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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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)

Power supply card Flashing = Boot Flashing = Interface operation
Continuous light = OK
Power controller Flashing = Boot Flashing = Interface operation
card STP6H Continuous light = OK

*) STP6II OK-LED (green)

LEDs at relay (yellow)

Power controller Continuous light = Relay switched Flashing = Output percentage
card STP6
Power controller Continuous light = Relay switched Flashing = Output percentage
card STP6 II

Power supply card Power controller card STP6H

...

Power controller card STP6 Power controller card STP6 II

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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 Operating status Start

Reason Trouble Shooting

Phase missing  Check mains voltage before fuses
Incorrect plug connection  Check connection to ribbon cable
 Replace ribbon cable if necessary
Incorrect addressing  Check DIP switch setting (see chapter 2.3.1)
Power controller card electrical defect  Check LEDs on power controller card (see chapter 3)
 Replace power controller card or send hot runner
controller in for repair

4.2 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 Operating status Start

Reason Trouble Shooting

Phase missing  Check mains voltage before fuses
Incorrect plug connection  Check connection to ribbon cable
 Replace ribbon cable if necessary
Incorrect addressing  Check DIP switch setting (see chapter 2.3.1)
Power controller card electrical defect  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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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 Operating status Start/Operation

Reason Trouble Shooting

Changed DIP switch  Check DIP switch setting (see chapter 2.3.1)

4.4 Message E103 – Identification of short circuit

Hot runner controller ≥ HRD 06 Operating status Start heating

Reason Trouble Shooting

Ground fault  Check heating
Sensor at heating output  Check wiring

4.5 Message E104 – Version incorrect on power controller card

Hot runner controller ≥ HRD 06 Operating status Start

Reason Trouble Shooting

Old firmware version on power  Replace power controller card
controller card  Firmware update by manufacturer necessary, send
power controller card or hot runner controller in for
repair

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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 Operating status Operation

Reason Trouble Shooting

Incorrect plug connection  Check connection to ribbon cable
 Replace ribbon cable if necessary
Loose connection DIP switch  Replace power controller card or send hot runner
controller in for repair
Power controller card electrical defect  Replace power controller card or send hot runner
controller in for repair

4.7 Message E115 – Timeout of interface to power supply card

Hot runner controller ≥ HR 06, ≥ HRD 06 Operating status Operation

Reason Trouble Shooting

Incorrect plug connection  Check connection to ribbon cable
 Replace ribbon cable if necessary
Power supply card electrical defect  Replace power supply card or send hot runner
controller in for repair

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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 Operating status Start/Operation

Reason Trouble Shooting

Phase missing  Check mains voltage before fuses
Fuse defective  Check fuse on power supply card
 Replace power supply card or send hot runner
controller in for repair

Hot runner controller ≥ HR 12 Operating status Start/Operation

Reason Trouble Shooting

Phase missing  Check mains voltage before fuses
Fuse defective  Check fuse on power supply card, replace if necessary

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Hot runner controller ≥ HRD 06 Operating status Start/Operation

Reason Trouble Shooting

Phase missing  Check mains voltage before fuses
Fuse defective  At least one of the zone fuses is defective, check and
replace if necessary
(see fuse holder/side of housing)

4.9 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 Operating status Start/Operation

Reason Trouble Shooting

Defect EEPROM or check sum error in  Replace power controller card or send hot runner
EEPROM controller in for repair

4.10 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 Operating status Operation

Reason Trouble Shooting

High temperature at installation location  Check environmental conditions at installation location
Overload  Check, that the power controller card is operated only
with 50% duty ratio at full load for all 6 channels
Mechanical defect of fan  Check fan and clean if necessary

4.11 Message E150…E154 - Potential error

E150 matches error on card 1, E151 matches error on card 2, etc.

Hot runner controller ≥ HRD 06 Operating status Operation

Reason Trouble Shooting

Voltage on measurement input  Check wiring

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5 Appendix

5.1 Version History

Version Date Changes

1.00.02 02-20-2014 DIP Switch phase synchronisation inverted

1.00.01 04-16-2010 Complete revision
1.00.00 11-09-2009 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
info@psg-online.de

Right to technical changes reserved

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