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TTC Family Manual
TTC Family Manual
OPERATOR‟S MANUAL
Version 7
Release Date: 23 December 2010
Gammaflux, L.P. Far East, Pengin Mura B202, Nishi Kiwa-ku, Osawa,
Yamaguchi, Ube 755-0151, Japan
Tel: +81 (1836) 54-4369 Fax: +81 (1836) 54-4369 e-mail: gammafluxjpn@gammaflux.com
www.gammaflux.com
TTC 2100 / 2200
OPERATOR‟S MANUAL
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Page
1 Safety of Operation 6
1.1 Introduction ……………………………………………………………………………… 6
1.2 Reference to Standards ……....…………………………………………………………… 6
1.3 Personal Protection …….…………..……………………………………………………… 6
1.4 Lockout/Tagout ……....………………………………………………………………… 6
1.5 Housekeeping ………….……..…………………………………………………………… 6
1.6 Safety Symbols Used in this Manual ..………..………………………………………… 7
1.7 Safety Notes …………………..…………………………………..…………………… 7
3 Cabinet 16
3.1 General Description ………………..……………………………………………………… 16
3.2 Cabinet Dimensions ………………..……………………………………………………… 17
3.3 Receiving and Unpacking ……..……………………………………………………… 17
3.4 System Set-Up and Input Power Connections …………………………………………. 18
3.5 Circuit Breaker ……………………………………………………………………………… 18
3.6 HA-3 Alarm Relay Output Connections .……………………………………………… 18
3.7 HA-4 Remote Input Connections .……………………………………………………….. 22
3.8 Digital Communications Port ……..……………………………………………………… 23
3.9 Fusing ………………………………………………………………………………... 23
3.10 Daisy Chaining of TTC 2100s ……………………………………………………………… 24
3.11 Mold ID Feature ……………………………………………………………………………. 24
5 Groups 27
5.1 General Description ………………………………………………………………………. 27
5.2 Temporary Groups ………………………………………………………………………. 28
5.3 Instant Groups …………………………………………………………………………… 30
5.4 Permanent Groups ………………………………………………………………………. 32
6 Controllers Button 33
7 Graph Button 35
7.1 General Description ………………………………………………………………….. 35
7.2 Pilot Graph ……………………………………………………………………………. 35
7.3 Bar Graph ……………………………………………………………………………. 36
7.4 Line Graph ……………………………………………………………………………. 37
7.5 Tape Graph ……………………………………………………………………………. 38
7.6 SPC Graph ……………………………………………………………………………. 39
7.7 Data Table .……………………………………………………………………………. 40
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7.8 Tool Graphic .……………………………………………………………………………. 41
7.9 Graph Settings ……………………………………………………………………………. 42
8 Alarms 46
8.1 General Description …………………………………………………………………… 46
8.2 Low Temperature Deviation Alarm ……..……………………………………………… 48
8.3 High Temperature Deviation Alarm ……..……………………………………………… 48
8.4 Thermocouple Open Alarm ……..…………………………………………………… 48
8.5 Thermocouple Reversed Alarm ……..…………………………………………………… 49
8.6 Thermocouple Short Alarm ……..…………………………………………………… 49
8.7 Fuse Open Alarm ……………..……..…………………………………………………… 49
8.8 Heater Short Alarm (Heater Bakeout Feature) …………………………………………… 49
8.9 Heater Open Alarm ……..…………………………………………………………….. 50
8.10 Uncontrollable Zone Alarm ………..…………………………………………………… 50
8.11 Mold Monitor Heater Resistance Alarm ………………………………………………… 50
8.12 Mold Monitor High / Low Wattage Alarm ………………………………………………… 50
8.13 Critical Over Temperature Alarm ……..…………………………………………………… 50
8.14 Material Protection (Machine Cycling) Alarm …………………………………………… 51
8.15 Monitor Alarm ……………….…………………………………………………………… 51
8.16 Status of “OK to Run” ……………………………………………………………………. 51
11 Menu Screens 69
11.1 General Description ……….. ……..…………………………………………………… 69
11.2 Select a Menu ………….…..…………………………………………………………….. 70
11.3 Restore ……….……..…………………………………………………………………. 70
11.4 Copy To Diskette/USB ….. ……..………………………………………………………… 70
11.5 Delete ……….. ……..………………………………………………………………….. 71
11.6 View a Menu (Print a Menu) ..……………………………………………………………... 71
11.7 New Menu Name and Save (Creating a New Menu) …………..…………………………… 72
11.8 Copy From Diskette/USB ……..……………………………………………………. 72
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12.6 Options ………………………………………………………………………………… 80
12.7 Mold Monitor …………………………………………………………………………… 83
12.8 Sequence Start …………………………………………………………………………… 84
12.9 Even Cool ………………………………………………………………………………… 86
12.10 Sequenced Power Up ……………………………………………………………………….. 87
12.11 Language ………………………………………………………………………………… 88
12.12 Operator ID‟s ……………………………………………………………………………. 89
12.13 Edit Groups (Setting Up Permanent Groups) ………………………………………….. 90
12.14 Stop Communications …..………………………………………………………… 90
13 Diagnostics Screens 91
13.1 General Description ……………..……………………………………………………. 91
13.2 Find This Module ……….. ……..………………………………………………………… 92
13.3 View Configuration Now (Print Configuration Now) …………………………………. 92
13.4 View Versions ……………..………………………………………………………… 93
13.5 View Voltage ……………………………………………………………………………. 94
13.6 Exit to Windows ……….. ……..………………………………………………………… 95
14 Pdfs 96
14.1 General Description ……………..……………………………………………………. 96
14.2 Viewing and Transferring Pdf Files ……………………………………………………. 96
14.3 Viewing and Transferring Pdf Report Files ………………………………………………. 97
16 Databases 102
16.1 General Description ……………………………………………………………………. 102
16.2 Setting Up a Database ……………………………………………………………………. 102
19Tuning 113
19.1 General Description ...……………………………………………………………………….. 113
19.2 Display Tuning ……………………………………………………………………………… 113
19.3 Set Tuning to Standard ……………………………………………………………………. 114
19.4 Tune ………………………………………………………………………………………. 114
19.5 Return to Old Tuning ……………………………………………………………………. 115
19.6 Print Report ………………………………………………………………………………… 115
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20 Change Configuration (Internal Zone Hardware Assignment) 116
20.1 General Description ….…………………………………………………………………… 116
20.2 Name Zones …………………………………………………………………………… 117
20.3 Software Rewire (of Thermocouples) ……………………………………………………… 118
20.4 Edit Configuration …………………………………………………………………………. 119
20.5 Edit ID (Assign Zone Names) …..………………………………………………………….. 121
20.6 Move Zone Addresses …………………………………………………………………… 122
20.7 Assign Inputs (Assign Thermocouples) ..……………………………………………... 123
20.8 Type J or K Thermocouple Selection ………………………………………………….. 124
20.9 DC Zones (Data Concentrator Zones) …………………………………………………. 125
20.10 Locate Zones ………………………………………………………………………….. 126
24 Mold ID 142
24.1 General Description .……………………………………………………………………. 142
24.2 Mold ID Wiring ……………………………………………………………………………. 142
24.3 Mold ID Screens …………………………………………………………………………… 143
24.4 Mold ID Pin Configurations ..…………………………………………………………… 146
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27 Attaching a Printer 153
28 Maintenance 154
28.1 Cleaning the Exterior of the Cabinet ……………………………………………………… 154
28.2 Cleaning the Interior of the Cabinet ……………………………………………………… 154
28.3 Checking Power and Thermocouple Cables …………………………………………………. 154
28.4 Thermocouple Calibration ………………………………………………………………. 154
28.5 Checking the Earth Ground Connection ………………………………………………… 154
28.6 Checking the Operation of Cooling Fans ………………………………………………. 154
29 Training 155
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1
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Safety of Operation
1.1 Introduction
High injection pressures, high temperatures, clamp speed, and forces are used in the operation of injection
molds and machines. To protect the operator at the work place, ensure that all safety devices installed on
the machine and mold are functioning correctly. Never disable or by-pass a safety device. Follow the
machine and mold manuals for safe procedures and safety checks.
Throughout this manual references are made to various standards: ANSI (American National Standards
Institute), OSHA (Occupational Safety and Health Act) and CE (Conformity in Europe) for safety or
operating protocol. We recommend that these standards be the minimum used. If there are more stringent
local standards, these must be followed.
1.4 Lockout/Tagout
Throughout this manual instructions are given to lockout/tagout power sources. Usually no instructions are
given to turn the power source back ON. This is assumed to have been covered by the instruction to
perform any operation requiring the power source provided that all steps in the instructions prior to the
power being applied have been completed. If the power source must again be turned OFF the instruction to
lockout/tagout is repeated.
1.5 Housekeeping
Clearly define areas for the controller to be positioned. Provide clear access to the front and rear of the
cabinet in case of an emergency.
Check frequently for frayed or worn electrical cables located on the rear of the cabinet. Replace any frayed
or worn cable immediately once it is found.
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Never place any materials on or near the controller cabinet that would block air flow near the cabinet
ventilation ports.
Never clean the mold, machine or hot runner controller while it is operating.
Never place any materials on the top of the hot runner controller cabinet.
Make certain that all cable connectors on the rear of the cabinet are securely clamped down and held in
place. If any are loose, secure them before operating the controller.
Electrical
High Voltage, never remove the cover or try to open a cabinet, or disconnect cables without turning Off the
mains circuit breaker or unless you are properly trained in electrical safety and authorized to work on the
cabinet. There are live high voltage electrical circuits inside the cabinet.
Lockout/Tagout Required
To safely perform the operations a lockout/tagout of the power source(s) must be done.
See Instructions
See the safety information applicable to this controller.
7
CAUTION: ALWAYS LOCKOUT/TAGOUT THE MAIN POWER BREAKER
BEFORE OPENING THE CONTROLLER ENCCLOSURE. DO NOT CLOSE THE MAIN
BREAKER IF THE CONTROLLER CABINET IS OPEN.
8
CAUTION: IT IS COMMON FOR OUTPUT TRIACS TO SHORT WHEN A
FUSE BLOWS. A SHORTED TRIAC CANNOT BE REGULATED AND WILL APPLY FULL
POWER TO THE HEATER. ALWAYS CHECK A CONTROLLED ZONE THAT HAS A BLOWN
FUSE BY ADJUSTING POWER FROM ZERO TO 100 % IN THE MANUAL MODE. THE
VOLTAGE SHOULD GO FROM ZERO TO 240 VOLTS (OR FULL VOLTAGE)
RESPECTIVELY.
9
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General System Description
Figure 2.1a TTC 2100 – 1 Figure 2.1b TTC 2100-2 Figure 2.1c TTC 2100-3, TTC2100-4
Single Heat Sink Enclosure Dual Heat Sink Enclosure Quad Heat Sink Enclosure
Because of the similarities in operation of the TTC 2100 and TTC 2200, references to the TTC 2100
throughout this manual will also apply to the TTC 2200.
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Figure 2.2 TTC 2200–1 Single Heat Sink
1) Module that contains one (1) 30A zone. Requires two slots.
2) Module that contains two (2) 15A zones. Requires one or two slots, depending on current
draw. If the current draw for both zones added together is greater than 15A, it requires two
slots. If the current draw for both zones added together is 15A or less, one slot is required.
3) Module that contains four (4) 3A zones. Requires one slot.
Breaker size dictates the maximum number of zones that each heat sink can contain.
Each control module has the Gammaflux proprietary PID2 control algorithm. This algorithm is time
tested and proven on hot runner systems around the world.
The TTC 2100 uses phase angle fired outputs. Phase angle firing provides major benefits compared to
time proportioning outputs. With phase angle fired outputs, output voltage to the heater can be adjusted to
any level from 0 VAC to full voltage with great precision. Time proportioning controllers are limited to
providing 0 VAC or full voltage to heaters.
The TTC 2100 computer normally comes with a 12.1” TFT, 800 x 600 pixel touchscreen that enables the
operator access to all data pertinent to the operation of the TTC 2100 (an International Interface operator
interface is also available, see Section 20 International interface). The screen design enables the operator to
become quickly familiarized with the controller while giving the operator access to a wide array of tools to
maximize hot runner performance. The TTC 2100 touchscreen includes a unique operator interface
featuring icons to identify the control functions, process values and alarm status, in a simple and easily
understood format. The use of easy-to- understand icons enables global users to gain a quick understanding
of the TTC 2100. All hot runner set up, mold performance and monitoring information is accessed by using
the touchscreen located on top of the enclosure (touchscreen can also be mounted remotely). With the
proper security password, a user can customize many of the features of the TTC 2100. A USB memory
drive (floppy drive in early models) is included for easy uploading and downloading of information as
shown in Figure 2.3.
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Figure 2.3 USB Memory Drive
The Gammaflux TTC 2100 is designed to provide the user with the most powerful hot runner diagnostic
tools available. Features such as heater resistance monitoring (Mold Monitor), settable alarm limits, field
calibration capability and interactive graphic representation of the mold are standard.
The TTC 2100 supports digital communication using an RS-485 interface.
To meet the needs of the international markets, the TTC 2100 accommodates field selection of “J” Type or
“K” Type thermocouples, degrees F or degrees C temperature configuration, and either Delta or Wye main
input power. If the thermocouple type is changed in the field, it should be remembered that the
thermocouple wiring internal to the controller has not changed.
Control
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Enhanced control algorithms employing proprietary Gammaflux PID 2
High resolution thermocouple input
High resolution voltage output
Automatic switching to learned manual setting when thermocouple fails
Inputs
Machine cycle/material protection
Control Inhibit (turns off outputs)
Remote Standby
Outputs
Resettable alarm output relay
Non-resettable alarm output relay
Critical high temperature alarm relay trip
Auto Boost
“OK to Run” contact (user configurable) to notify machine that temperatures are high enough to start
molding
Diagnostics
Heater Bakeout provides superior heater protection during startup and during heater shorts. On startup, the
TTC 2100 will initially provide a very low voltage (1-5 VAC) to the heater while heater current is
monitored. If the current draw is excessive, the TTC 2100 will “bakeout” the heater by providing a low
voltage pulse to the heater. Once the heater is dry, the TTC 2100 will ramp the zone‟s output to full voltage
in a few line cycles while continuing to monitor the current draw.
Mold Monitor provides extensive on-line monitoring of the heaters‟ resistance and wattage values to ensure
efficiency and to provide preventative maintenance information. A machine cycling input signal can be
monitored to ensure the injection molding machine is operating. If the machine stops for a designated
period of time, the controllers‟ outputs will go to Standby to reduce material degradation in the tool.
Mold Doctor provides off-line tools to troubleshoot the mold. Tests include:
Wiring analysis – checks the tools wiring. The software clearly notifies the user of miswired zones along
with any thermocouple or heater problems.
Fault analysis – quickly identify the following problems: thermocouple open, thermocouple reversed,
thermocouple pinched, open fuse, heater open, heater wet and heater short.
Thermodynamic analysis – this test automatically ramps all selected zones 400º F (204º C) and down to
300º F (149º C). During the heating and cooling process Mold Doctor provides and records critical
information. By providing zone-by-zone data for resistance, power consumption, heating and cooling
rates, tool maintenance becomes a much easier task. This data is saved so that it can be compared to
future tool data.
Historical mold performance – allows the user to easily compare a known “good” thermodynamic analysis
baseline to the current thermodynamic analysis. Intuitively troubleshoot your mold with hard data.
Languages
Languages include Czesky, Dansk, Deutsch, English, Español, Français, Italiano, Nederlands, Polski,
Portuguese, Svenska, Vlaams and Far Eastern character sets. Other languages easily available using
Windows XP based language editor and character sets. Contact Gammaflux for more information.
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2.5 Specifications
Calibration Accuracy .2 F (.1C)
Control Accuracy +/- 1F (.5C)
Power Control Time 8.5 msec (every half line cycle) at 60 Hertz
Process Sampling 50 msec (20 times per second)
Control Algorithm Proprietary PIDD with added autotuning features
Degrees F or C Field Selectable
Operating Range 0-999F (0-537C)
Output Voltage 0-240 VAC
Standby Temperatures User selectable (0-999F, 0-537C)
Machine Interface I/O 22 – 132 VAC to activate
Input Specifications:
Thermocouple Type J (standard) or Type K (selectable).
Grounded thermocouples only.
Cold Junction Compensation Internal to enclosure
External Resistance 10 M ohms
Temperature Variation Due None
to Thermocouple Length
Electrical Specifications:
Input Power 160-265 VAC Delta
208, 380, 400, 415 VAC Wye
Frequency 50/60 Hz
Ambient Temperature 32-113F (0-45C)
Humidity Range 0-95% non-condensing
Output Module Range 4-zone, 3A, 720W per zone @ 240VAC
2-zone, 15A, 3600W per zone @ 240 VAC
1-zone 30A, 7200W per zone @240 VAC
Communications RS-485 or ProfiBus
Performance Standard:
Designed to Meet I.E.C. 801-1, 801-2, 801-3, 801-4
Safety 508, UL-873 and CSA
CE Mark
EMC Directive 89/336/EEC
EN 55081-2
EN 55011
EN 61000-6-2
EN 55022
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2.6 Default Settings and Limits
TTC Default/Limit Default Limit/Range
Multiple Language Capability English Multiple Languages
Power Status Off On/Off
Automatic Set Point 0F 0-999F; 0-537C
Manual Set Point 0% 0 - 100%
Automatic Mode/Manual Mode Automatic Auto/Man
Security Level Operator Monitor, Operator, Supervisor,
Engineer
Security Codes - Up One Level at a Time, 321, 654, 987 Mon-Oper, Oper-Supr,
0 to go Down Supr-Engineer
Tuning Autotune (0) -27 to 27
Temperature Set Point Maximum Limit 999F 0-999F; 0-537C
Manual Percent Maximum Limit 100% 0-100%
Temperature Deviation Alarm Set Point +/- 20F +/- 1-999F; +/- 1-537C
Boost Set Point 20F User Selectable (0-999F; 0-537C)
Boost Set Point Limit +/- 50F 0-999F; 0-537C(Range is bipolar)
Boost Time Set Point 60 sec. 0-300 sec.
Trim Set Point 0F User Selectable (0-999F; 0-537C)
Trim Limit +/- 100F 0-999F; 0-537C
Standby Set Point 220F 0-999F; 0-537C
Standby Group None User Selectable
Thermocouple Pinch Detection Time 0 (0 = 5 min) .1 – 54 minutes
Slaved Power Output Disabled Enable/Disable
Slaved Power Up Group None User Selectable
Degrees F or C Selectable F F or C
Thermocouple Input J J or K
Alarms Latched Disabled Enable/Disable
Operator ID None Enter Operator ID's to enable
Material Protection Disabled Enable/Disable
Material Protection Time (in seconds) 0 0-999
Heater Resistance Monitoring Disabled Enable/Disable
Heater Wattage Monitoring Disabled Enable/Disable
Watt High Alarm 8000 0-8000
Watt Low Alarm 0 0-8000
Critical Over Temperature Alarm 999F 0-999F; 0-537C
Outputs on Power Up question - Ask Always On, Ask, Always Off
uninterrupted running
Graph Setting Defaults Auto Scaling User Selectable
Seconds Per Update 1 .5 seconds - 65.5 seconds
Time Compression 1:1 1:1 - 1:300
Scale Max (both) 100 -999 - +999
Scale Min (both) 0 -999 - +999
Tool Pictures None User Generated
Database Max File Size 1 Meg .1 - 100 Meg
Database Time Compression 1:1 1:1 - 300:1
Database - What to do "On File Full" Keep Newest Keep Newest, Keep Oldest
Report Length 1 Hour 1 - 24 Hours
Report Type View View / Print
Report Orientation (when Print is selected) Portrait Portrait / Landscape
Job Screen Information Blank User Selectable
15
3
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Cabinet
The TTC 2200 hot runner mold controller is a unit that can be panel mounted internal to an injection
machine cabinet. The screen can be mounted remotely. The TTC 2200 can also be set up to communicate
with the injection molding machine operator interface screen.
The maximum capacity of each type of enclosure (TTC 2100 and TTC 2200) is:
In practice, the different style enclosures would typically be used in the following manner:
Single Heat Sink Enclosure up to 32 tips & 8 manifolds
Dual Heat Sink Enclosure up to 96 tips & 10 manifolds
Quad Heat Sink Enclosure above 96 tips and 10 manifolds
Primary AC power is distributed from the main circuit breaker to each output zone control module. To
minimize phase imbalance in multi-zone three phase systems, the AC power is distributed so that the load is
as equally distributed as possible. Zone output modules are sequentially wired to different phases.
Regulated output power is routed from the output modules to the appropriate mold power connector on the
rear of the cabinet. High current, plug in connectors are used to transfer AC power to and from the mold.
In a similar fashion, the thermocouple signals are routed into the controller using plug-in connectors clearly
marked for thermocouple inputs.
The touchscreen can be mounted on top of the enclosure (standard) or mounted remotely.
16
Legend
1. Output Card
2. Thermocouple Input Card
3. Data Concentrator
4. Power Supply
5. Communications Cable
6. Module Heater Power Connector
7. Circuit Breaker
8. Thermocouple Connector
9. Heater Power Connector
10. Auxiliary Input Connector
11. Auxiliary Output Connector
12. Interface Power Connector
13. Interface Communication Cable
14. Ground Lug
15. Fan
On larger TTC 2100 enclosures, boards are positioned on both sides of the enclosure in the same fashion
shown in Figure 3.1 TTC 2100-1.
17
3.4 System Set-Up and Input Power Connections
Place the control cabinet in position. The cables that correspond to the appropriate thermocouple and
power output are labeled with letters so that they may be matched without confusion.
When installing the cable sets, match the labels exactly. Match “A” on the cable set hood and cabinet
respectively.
The standard AC input power cable provided is Type SO and it is approximately 10 feet (3.048 meters)
long with color-coded “flying leads”. Standard power input is 240 VAC three phase. Other voltage
configurations are available. A step down transformer is available as an option.
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Non-Resettable Alarm Contact
When any zone continuously has an alarm active for five seconds, the alarm contact will turn “ON”.
Pressing the Clear Alarm button will not change the condition of the alarm contact. The alarm contact will
turn „OFF‟ when all of the alarms in the controller are cleared.
The „OK to Run‟ contact is „open‟ (not „OK‟) when one or more of the following is true:
1) The controller is not powered.
2) The interlink cable between the controller and the injection molding machine is not connected.
3) Any unlocked zone is off.
4) There is a zone alarm within the controller.
5) All of the zones in the controller are locked off.
The „OK to Run‟ contact is „closed‟ („OK‟) when all of the following are true:
1) There is a least one zone that is not locked off.
2) All of the unlocked zones are turned On.
3) There are no zone alarms within the controller.
The controller does not provide any voltage on these contacts. An external signal of 22-232VAC or 22-
232VDC is required. The contacts are fused with a 5 Amp 5*20mm fuse.
The connector may be oriented differently than shown (e.g., rotated 90 degrees).
Locate the notch to be sure of the pin numbers.
The HA-3 connector only provides room for 2 output functions while the controller has 3 functions
available. The cable harness within the controller includes the wiring for all 3 functions. The unused
functions have been terminated with wire nuts inside the enclosure and are available near the HA-3
connector. If a different function is desired, the connections can be swapped to provide the pinout desired.
19
Figure 3.6b describes the wires available within the cable harness:
This internal cable harness only provides the NO contact for the Resettable Alarm and Non-Resettable
Alarm functions. A special cable harness is available that provides the NC contact for the Resettable Alarm
and Non-Resettable Alarm. This must be specified at the time that the controller is ordered.
Figure 3.6c shows the default output functions provided prior to July 2009 with the cable harness
schematic shown in Figure 3.6d:
HA-3 CONNECTOR
(male insert)
NC PIN 1
COM "2 BLACK
RESETTABLE ALARM PIN 2
NO "3" YELLOW
PIN 3
PIN 4
NC
NC "7" WHITE
20
Beginning in July 2009, the default selection of functions as shipped in the controllers was changed to the
Non-Resettable Alarm and the „OK to Run‟ contacts as shown in the wiring table shown in Figure 3.6e and
the wiring schematic shown in Figure 3.6f:
HA-3 CONNECTOR
(male insert)
NC PIN 1
COM "2 BLACK
RESETTABLE ALARM PIN 2
NO "3" YELLOW
PIN 3
PIN 4
NC
NC "7" WHITE
Figure 3.6g TTC Auxiliary Output – Alarm Internal Wiring Beginning in July 2009
21
Resettable Alarm Buzzer – Beginning July 2009
Beginning in July 2009, the Resettable Alarm function was removed from the HA-3 connector and
replaced with the ‘OK to Run’ function as shown in Figures 3.6e, 3.6f and 3.6g.
The wiring for the Resettable alarm function is now available for an audible buzzer function that
can be ordered with a new controller or can be retrofitted into existing controllers.
If the buzzer is ordered with the controller, the buzzer is mounted to the front surface of the
controller near the phase indicator lights as shown below in Figure 3.6h.
The warning buzzer can be retrofitted to existing controllers with an update kit WB00133. The kit
contains the buzzer mounted to an HBE-24 cover plate and the required internal wire harness.
The buzzer is installed to an unused output connector location on the rear of the controller. The
wires to one of the internal fans is cut and the wire assembly is spliced to power the horn.
Figure 3.6i TTC Auxiliary Output – Wiring to External Buzzer Beginning in July 2009
An incoming signal of 24 – 120VAC or VDC is required. The default pin assignments are:
Pin 1 – Return for all signals
Pin 2 – Remote Control Inhibit Input
Pin 3 – Remote Standby Input
Pin 4 – Machine Cycle (Material Protection) Input
Ground Connection
22
These pin assignments can be changed. Other input signal features are available (Section 20.3 Inputs).
The connector may be mounted differently than shown (e.g., rotated 90 degrees) in Figure 3.7. Locate the
notch to be sure of the pin numbers.
3.9 Fusing
Each 30 Amp temperature output module is fused at 30 amps.
Each 15 Amp temperature output module is fused at 20 amps.
Each 3 Amp control output zone is fused at 5 amps.
The system power supply for the TTC 2100 is fused at 3.15 amps.
The remote outputs are fused at 5 amps on a board on the data concentrator.
See Figure 3.9 for part numbers of fuses.
23
It is important to replace the fuses with the same style of fuse. In most cases, fast blow fuses are used.
Regular fuses will not give adequate protection to the boards. Smaller fuses can be used if the zones are
running at lower amperages. Never replace a fuse with a fuse rated for higher amperage than the factory
standard.
24
4
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Controller Touchscreen Operation
The 12.1” TFT, 800 x 600 pixel touchscreen displays are designed to give the user access to all information
while maintaining an intuitive approach that makes it easy for the user to understand. The user‟s security
level (Section 12.3 Security Levels) determines the appearance of the screens. Features that are not
available to the user (determined by the user‟s security level) do not appear on the screen. They reappear
when a user with a higher security level enters the appropriate code. This approach eliminates confusion by
only showing buttons that the user can access.
The user can select between English, Español, Deutsch, Danisch, Vlaams, Français and Italiano (Section
12.6 Options). Far Eastern character sets are also included.
Icons are used throughout the screens.
Report (or Print): Pressing this button enables the user to view a variety of reports on screen, to print
the existing screen or to print a variety of reports. A parallel printer interface connector is located on
the side of the TTC 2100 touchscreen. Screens and functions associated with Reports (Print) are
found in Section 10 Reports / Print Screens.
Menus: Pressing this button enables the user to select from existing menus (setpoints, alarm values,
zone names, etc.) or to set up new menus. Screens and functions associated with Menus are found in
Section 11 Menus Screens.
Information: Pressing this button enables the user to access setup information. Screens and functions
associated with Information are found in Section 12 Information Screens.
25
Diagnostics: Pressing this button gives the user access to databases, the Mold Doctor diagnostic
package, Field Calibration, Zone Configuration of the TTC 2100 and other diagnostic functions.
Screens and functions associated with Diagnostics are found in Section 13 Diagnostic Screens.
There are 2 general ways to view zone data on the screen. These are selectable on the 2nd row of buttons.
They include Controllers (Section 6) and Graph (Section 7).
The International Interface is an alternative to the Touchscreen and is described in Section 23 International
Interface.
26
5
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Groups
If the user wants to display data for all zones on the screen, the group tab “All” should be selected at the
bottom of the screen. If the user wants to view a limited number of zones such as “Tip” or “Man” the user
needs to set up those group tabs if they are not already present at the bottom of the screen. No matter which
group is displayed, all zones are being continuously controlled and monitored.
The name of the currently selected group is displayed below the Controllers, Graph and Alarm buttons
(“All” in Figure 5.1).
NOTES:
1) All zones are usually included in the group ALL.
2) There is no limitation to the number of groups to which a zone can be assigned. For example, Tip 6
can be included in Tip and Tips 1-16. It is usually included in the group ALL.
3) A group can contain more than one ID name (e.g. a group can include selected Man zones, Tip zones
and Sprue).
4) The use of Group tabs is an essential step in the effective use of the TTC 2100. Setpoints can be
applied to one or all zones in a group at one time. Data is displayed a group at a time. Power can be
applied or turned off to one or all zones within a group at one time. Special functions such as Boost or
Standby can be applied to one or all zones in a group. Reports are generated using a group format.
27
5) There are three types of groups – temporary (Section 5.2), instant (Section 5.3) and permanent
(Section 5.4). Temporary group names always include an asterisk (“*”) as the first character of the
name.
28
Figure 5.2b Displaying Temporary Group *Tip1-Tip5
29
5.3 Instant Groups
The Instant Group is a convenient way to make a variety of changes to a number of zones within an existing
group. Settings can be changed to the subset of zones in the following way:
1) Press the Controllers button.
2) Press the New *Group button. A security level of Operator, Supervisor or Engineer is required.
The screen in Figure 5.2a will appear.
3) There are two ways to select zones for the new temporary group:
a) Touch the Range button. The Range button will appear to depress and the background of the
button will turn white. Touch the lowest zone and then press the highest zone to be included
in the temporary group. Selected zones will have their name box change from a light yellow
background to a cyan background. The Range button will go back to its normal state. Zones
can be added or subtracted by touching them. If a zone is included in the group, touching it
will cause it to be removed from the group. If a zone is not in the group, touching it will add it
to the group.
b) Touch the individual zone buttons (Tip 2, Tip3, Tip20 and Tip29 in Figure 5.3a). Zones can
be added or subtracted by touching them. Selected zones will have their name box change
from a light yellow background to a cyan background. If a zone is included in the group,
touching it will cause it to be removed from the group. If a zone is not in the group, touching
it will add it to the group.
Note that these steps are the same as the first 3 steps shown in Section 5.2 Temporary Groups. The
difference is that Step 4 is omitted. The selected groups in this Instant Group can now be changed.
If the Setpoint button is pressed the screen in Figure 5.3b will appear. The new Setpoint can now be
entered for the Zone (Tip 29 in Figure 5.3a), the Group (Tip group in Figure 5.3a) or the Instant Group
(Tip2, Tip3, Tip20 and Tip29 in Figure 5.3a). Any time an Instant Group is used, it can be changed to a
Temporary Group simply by pressing the Make * Group button. The Instant Group will remain until one
of the group tabs at the bottom of the screen is pressed. The Instant Group will be available until any group
tab is pressed at the bottom of the screen. At that time, the Instant Group will no longer exist until created
again.
30
The Instant Group can be used to perform the following functions.
a) Enter zone setpoint
b) Turn zones On
c) Turn zones Off
d) Start Standby mode
e) Start Boost mode
f) Put zones into Automatic mode
g) Put zones into Manual mode
h) Lock zones Off
i) Unlock zones
The new Setpoint can now be entered into the Zone (Tip 29 in Figure 5.3a), the Group (Tip group in Figure
5.3a) or the Instant Group remains available until one of the group tabs at the bottom of the screen is
pressed. The Instant Group button will then be removed from the settings entry forms.
When an Instant Group is selected the On (Figure 5.3c) and Off (Figure 5.3d) buttons will show the Instant
Group selection. The Boost and Standby pop-up screens will also show the Instant Group selection.
Figure 5.3c On Button for Instant Group Figure 5.3d Off Button for Instant Group
31
5.4 Permanent Groups
Permanent groups are saved. When power is reapplied to the TTC 2100 following a shutdown, the
permanent group tabs will reappear on the screen. Permanent groups are also saved with menus (Section 11
Menus Screens). The setup of permanent groups requires a Supervisor or Engineer security level.
The Copy From Tab button can be used to quickly form a new subgroup of an existing group. When the
Copy From Tab button is pressed, the ID names and zones for that group will be available to form a new
group using steps 3-10 above.
At any time, a group tab at the bottom of the screen can be moved right, left or deleted using the Move
Tab Left, Move Tab Right or Delete Tab buttons on the bottom of the screen shown in Figure 5.4.
32
6
___________________________________________________
Controllers Button
Pressing the Controllers button causes data to be shown in a format that resembles rows of individual zone
controllers plugged into a cabinet as shown in Figure 6a. To select a zone, simply touch the appropriate
controller.
IMPORTANT: Directly below the Controllers button is the name of the Group that is displayed (e.g.,
“All” is the Group shown in Figure 6a). Note that the name displayed is the same as the tab selected at the
bottom left of the screen. Data is always shown on a group basis.
For a description of the New * Group button, see Section 5.2 Temporary Groups.
All data is normally shown against a teal background. Data shown for each zone includes:
Zone Name
Setpoint
33
Box is replaced by an “O” if the zone is OFF
Box is replaced by a “Lock” icon if the zone is LOCKED OFF
Two bar graphs are displayed on the right side of each zone:
Temperature Deviation – Shown on the top half. The black centerline serves as the zero-degrees reference
point. The deviation display is red if the deviation exceeds 20F (11C). The deviation
display is otherwise green.
% Output Bar Graph – Shown on the bottom half. Indicates 0 to 100% output. The black centerline
serves as the 50% mark.
The Page Up, Up, Down and Page Down arrow buttons at the bottom right of the screen are used to access
additional zones when there are zones in the group that do not fit on the screen. Pressing the Up or Down
button causes the screen to move one row of controllers at a time. Pressing the Page Up or Page Down
button causes the screen to move three rows of controllers at a time.
A zone can be selected by touching the controller on the screen. The zone selected will turn green. Its data
will be displayed at the top of the screen.
A zone can also be displayed by selecting the ID name and Zone number at the upper right corner of the
screen. When a zone is selected, the corresponding controller display will turn green.
At the bottom right hand corner of the screen is the information (blue i) button. Press this button to see the
screen tutor shown in Figure 6b.
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7
___________________________________________________
Graph Button
IMPORTANT: Directly below the Graph button is the name of the Group that is displayed (e.g., “All” is
the Group shown in Figure 6). Note that the label is the same as the tab selected at the bottom left of the
screen. Data is always shown on a group basis.
35
Figure 7.2 Pilot Graph – Displaying Group “Tip”
36
Figure 7.3 Bar Graph – Displaying Temperature and Heater Resistances for “Tip” Group
See Section 7.9 Graph Settings for a description of how the settings are used for line graphs.
37
Figure 7.4 Line Graph – Displaying Deviation and Percent Output
2D End View – This is the view shown in Figure 7.5b. While using the 2D End View, the user can select
zone by touching the zone on the display.
Tape graphs are commonly used to compare data (e.g., amperage, wattage) of 2 or more zones at a time. At
times, the user may find it beneficial to display a tape graph of a temporary group of zones for diagnostic
purposes.
38
Figure 7.5a Tape Graph - Displaying Wattage for Tip Group (Side View)
Figure 7.5b Tape Graph - Displaying Wattage for Tip Group (End View)
Regardless of what is being displayed, the TTC 2100 is always performing SPC sampling of all variables
for all zones.
Up to 50 interactive data readings (e.g., actual temperature, wattage, amperage) or setpoints can be placed
anywhere on each picture. This enables the user to show a graphic display of the tool and choose a variable
to display at critical places such as temperatures or wattages. Text will be green unless the zone is in alarm
mode. When a zone is in alarm, the text for that zone will be red as shown in Figure 7.8.
The user can set up a library of pictures in the c:\TTC 2100\TOOL directory and select which is to be
displayed using the Graph Settings button. This is also where the user also can assign interactive setpoints
or values to appear on the picture. Each group has its own picture and value settings.
When a user touches one of the interactive boxes, the top of the TTC 2100 display will indicate data for that
zone. This makes it easy for the user to make quick adjustments to that zone.
Note: The interactive data will only be displayed on the picture when the correct group tab is
selected. For example, if the data is showing setpoints for the Tip group as shown in Figure 7.8, the
data will not appear on the picture when any other group (Man, Spr, All in Figure 7.8) is selected.
See Section 7.9 Graph Settings for a description of how to select a tool graphic and how to display data on
the picture.
41
Figure 7.8 Tool Graphic – Displaying Actual
Temperatures for Group “Tip”
Graph Type – The user can choose between Pilot, Bar, Line, Tape, SPC, Data Table and Tool
Graphic.
First and Second Selections – The user can choose which variables to display on the graph. The
choices include actual temperature, deviation, percent output, load current, load wattage, process
setpoint and manual (percent output) setpoint. Up to two selections can be shown at once on Bar and
Line graphs. One variable is the limit for Tape and SPC graphs along with Tool Graphics.
Scale Maximum and Scale Minimum – There are two sets of these shown on the screen. The Scale
Maximum and Scale Minimum settings on the left are for the First Selection. The two settings on the
right are for the Second Selection. These limits are only used when the user selects User Defined from
the settings below.
Max – Auto, Min –0 - This is the default setting. This enables the TTC 2100 to automatically and
continuously adjust the upper limit of the graph‟s y-axis to accommodate the highest reading while
keeping the minimum at zero.
This setting would not be recommended when displaying temperature deviation. If the minimum graph
setting is zero, then temperature deviations of negative value (when actual temperatures are below
setpoints) would not appear on the display.
Max – Auto, Min – Auto - This selection enables the TTC 2100 to automatically and continuously
adjust the upper and lower limits of the graph‟s y-axis. For example, if all temperatures are between
300F and 400F the graph limits may be 300F for the minimum and 400F for the maximum. If a
temperature drops below 300F, the lower limit of the graph would be automatically lowered to include
the data point.
42
User Defined – This selection enables the user to choose his own upper and lower limits for the graph
display. The settings for the First Selection are set using the Scale Maximum and Scale Minimum
settings on the left. The settings for the Second Selection are set using the Scale Maximum and Scale
Minimum on the right. The user should keep in mind that when the graph type or value displayed is
changed, the User Defined settings may need to be changed to something more applicable. For
example, in Figure 7.9b, the User Defined settings of +2 and –2 would make no sense for a graph
displaying actual temperature.
Other buttons that are applicable to the graph type selected will appear on the Graph Settings screen.
Figure 7.9a will appear for Pilot, Bar, Line and Tape graphs.
Figure 7.9b will appear for SPC graphs.
Figure 7.9c will appear for Tool Graphic displays.
Exit Door – Pressing this button returns the user to the graph display.
Time to Fill Line Graph – This is the amount of time it takes in “hours:minutes:seconds” to fill up the
entire graph based on the Time Compression and Seconds per Update settings. Once the graph is full,
it will continue to graph, keeping the newest data and dropping the oldest data.
Seconds per Update – This setting determines how often displayed data is updated. This setting is
also used in determining how often databases collect data. The lower the setting, the faster the data is
sampled and the faster display graphs fill up. Low settings result in short periods of data being
displayed on the graph at one time. Higher settings result in long periods of data being displayed on
43
the graph at one time. This setting has no bearing on the sample rate for control purposes. The default
setting is 1 second. The limits are .5 to 65.5 seconds.
SPC Interval – This setting determines how often the TTC 2100 will sample data for SPC purposes.
Default setting is 1 minute.
SPC Subgroup Size – This setting determines how many samples the TTC 2100 will take at each
interval. Default setting is 5.
Time to Fill SPC Chart – This is a calculation based on the selected SPC Interval, SPC Subgroup Size
and Seconds per Update settings. The value shown is displayed in “hours:minutes:seconds”.
Seconds per Update – This setting determines how often each zone‟s data is sampled at each SPC
Interval. Default setting is 1 second.
For example, in Figure 7.9b, actual temperatures will be sampled 5 consecutive times for every zone in
the Tip group every minute. According to data shown in Figure 7.9b, it will take 1 hour, 40 minutes of
data before the SPC graph is full. At this point, it will continue to display new data while the oldest
data is removed.
Clear SPC Data – Pressing this button will cause the SPC graph to clear all SPC data and start over.
44
Figure 7.9c Graphic Settings – For Tool Graphic
Set Tool Positions – Pressing this selection will enable the user to add and remove interactive buttons
on the tool graphic. Up to 50 interactive setpoints / readings can be assigned to a picture.
Seconds per Update – This setting determines how frequently the value box data is updated. The
default value is 1 second. It can be set from .5 to 65.5 seconds.
45
8
___________________________________________________
Alarms
The user can view either Active Alarms or Alarm History by pressing the appropriate button on the lower
right portion of the screen shown in Figure 8.1a. Pressing the Active button will result in the display of up
to 20 active alarms for the group selected (All in Figure 8.1a). When viewing Active Alarms, zones with
only a Low Temperature Deviation Alarm will be displayed below zones with other alarms. Pressing the
History button will result in the display of the last 20 alarms to occur for the group selected as shown in
Figure 8.1b. Alarms that are currently active appear as “>x<”. Alarms that occurred previously, but are no
longer active, appear as “x”.
Note: Pressing the Clear Alarm History button clears all historical alarms for all zones in all groups.
46
Figure 8.1b Alarm History – Displaying Group “Man”
Left to right, the icons at the top of the alarm table represent:
To the right of the alarm table are three additional animated alarm buttons:
At the bottom right corner of the screen there is an information or legend button, that when pressed
will display the alarm legend shown in Figure 8.1c.
47
Figure 8.1c TTC 2100 Alarm Screen Legend
48
8.5 Thermocouple Reversed Alarm
If a thermocouple wire is installed with the plus and minus leads reversed, applying heat will result in a
decrease in the temperature reading while the actual temperature is rising. When the temperature reading
goes below 0Fº (occurs when the actual temperature is approximately 140F), the Thermocouple Reversed
Alarm is activated. A Thermocouple Reversed Alarm will cause the zone to shut off. The alarm is only
active in Automatic mode (closed loop) control.
The Thermocouple Short Alarm will activate when the temperature climbs LESS than 20F (11C) while the
output has been at 98% for a certain time duration. The duration is a timer setting, called T/C short
Detection Time and is described in Section 12.4 Setup. The default setting for each zone is 5 minutes.
For example, a thermocouple short may occur at a location where the temperature is room temperature. As
the temperature attempts to raise the temperature to setpoint, the output will be at 100% output. While the
temperature at the short continues to indicate to the controller that the temperature is only room
temperature, the real temperature at the tip is climbing rapidly due to the heater receiving 100% output from
the controller. As soon as the TTC 2100 output reaches 98% output or higher, a timer is energized (settable
up to 54 minutes). If the temperature does not climb 20F before the timer times out, the output for that zone
will be shut off. This can save the tool from heat-related damage.
Note: The Low Temperature Alarm would also activate immediately following a short in this example since
the temperature at the short would most likely be well under the Low Temperature Alarm setting.
On startup, the TTC 2100 employs a very effective Heater Bakeout procedure. The TTC 2100 initially
provides a very low voltage (1-5 VAC) to the heater while monitoring the current. As long as the current is
within expected limits, the voltage will ramp up to full voltage over a few cycles while the current is
continuously monitored. If, at any point, the current draw exceeds expected limits, the Heater Short Alarm
will be activated and the cycle will be repeated. The TTC 2100 “bakes out” the heater by providing the low
voltage pulse to the heater. Once the heater is dry, the TTC 2100 will ramp the zone‟s output to full voltage
within a few line cycles while continuing to monitor the current draw.
A major benefit of this approach is that the TTC 2100 actually measures the current and applies the bakeout
procedure only when required.
49
Another benefit is that the use of a low voltage output during Heater Bakeout eliminates heater damage
caused by time proportioning controllers that cannot adjust the voltage level.
During regular operation, the TTC 2100 continues monitoring for heater shorts. If a short is detected, the
alarm will become active. The controller will cut back the output voltage, applying a very low voltage on a
repeating basis to determine if the short still exists.
50
8.14 Material Protection (Machine Cycling) Alarm
This alarm is functional only if the user has selected this feature to be active (Section 12.6 Options). The
alarm becomes active when the external input from the injection molding machine controller is not received
in the user-specified selected amount of time. The button changes background colors and is animated while
in the alarm condition. Zones that are assigned to the Remote Standby Group (Section 12.6 Options) will
be put in Standby while this alarm is active. Pushing the animated button clears the alarm and reinitializes
the timer.
51
The „OK to Run‟ contact is „open‟ (not „OK‟) when:
1) The controller is not powered.
2) The interlink cable between the controller and the injection molding machine is not connected.
3) Any unlocked zone is off.
4) There is a zone alarm within the controller.
5) All of the zones in the controller are locked off.
Pressing the Status of OK to Run button will display a screen indicating one of the following:
By default, the TTC 2100 alarm flasher bar mounted above the screen will not flash when the system is not
„OK To Run‟ unless it is set up to do so. This can be changed by the user if the user wants the alarm bar to
flash whenever the system is Not OK to Run. To make this change, the user must:
52
1) Exit the software (shuts down the TTC control functions) and go to Windows. This can be done by
pressing the Exit to Windows screen (Section 13.6 Exit to Windows) screen located at the bottom right
corner of the Diagnostics screen and entering the Engineering password.
2) Attach a keyboard to the port located on the back of the TTC 2100 screen.
3) Locate the Gammaflux.txt file located at D:\TTC 2100\Gammaflux.txt.
4) Open the file and add the following line:
FlashWhenNotOkToRun = 1
5) Save the file. Remove the keyboard and reboot the system.
Note: The use of this function to activate the flasher on the operator panel will also cause the contacts for
the output of the Resettable Alarm output to remain on whenever the system is Not OK to Run.
53
9
___________________________________________________
Basic Displays / Settings
54
For operational purposes, all the operator has to do is press the button. The setpoints for the selected group
will be immediately boosted. Figure 9.2 shows what the screen displays while in the Boost mode. The
Boost button will become animated and the button‟s gray background turns white. The amount of boost
time left will appear and count down under the Boost button. Pressing the Boost button while in the Boost
mode will cancel Boost. In Figure 9.2, there are 55 seconds remaining in the boosting of the “Tip”.
Standby Timeout Timer (min) – When Standby is selected, a timer (default time is 999 minutes) will start.
All zones in the controller will turn off once the timer had timed out. An entry of 0 will disable the timeout
and Standby will remain in effect until the Standby button is pressed again to leave the Standby mode.
55
Figure 9.3a Standby Button
Note: If the unit is put in the Standby mode by an external signal, screen entries are overridden. The
group that will be affected by a remote standby signal is selected on the Information / Options screen
(Section 12.6 Options).
Figure 9.3b shows how the screen will next appear. When in Standby, the button becomes animated and the
button‟s gray background turns white. The setpoint display does not change. It continues to display the
setpoint that will be in effect when Standby is deactivated. If the unit is in Standby mode due to an external
signal, the unit can only be placed back into normal mode by deactivating the remote signal. If the unit is in
Standby mode due to an operator panel entry, press the Standby button again to leave the Standby mode.
If the Operator ID function (Section 12.6 Options) is being used, the operator will have to enter an assigned
3-digit code before the Enter Setpoint box will appear (Figure 9.4b). Once the code is entered, the operator
will be able to make changes until 2 minutes has elapsed since the last setpoint change. At that point, an
Operator ID code will be needed again to make changes.
Pressing the Off button will cause a box to appear as shown in Figure 9.5b. The user can then turn on all
zones, the zones in the group being displayed or just the zone displayed at the time. Pressing Do not turn
off any additional zones will cause the box to close with no action being taken.
57
Figure 9.5a Power On Screens
58
Figure 9.6 Selecting a Zone Using the Zone Button
Selections include:
Trim – Trim is a feature that enables the user to make a permanent setpoint change to a zone or group of
zones. The value selected in this area adds to the setpoint of the zone or group of zones when it is entered.
For example, if –5F is selected by the user and entered for the group, all setpoints in the group will be
59
lowered by 5F. In Figure, 9.7a, if the user enters –5 for the zone, the setpoint display would immediately
change to 375F. Default value is 0. It is settable from –100 to 100F (-55 to 55C).
Boost Setpoint – The Boost feature is described in Section 9.2. The Boost Setpoint is the number of
degrees the selected zone or group of zones will be temporarily boosted when the Boost button is pressed.
Default value is 20F (11C). It is settable from –50 to 50F (-28 to 28C).
Boost Time – The Boost feature is described in Section 9.2. The Boost Time is the amount of time that the
Boost will be applied to the selected zone or group of zones. Default value is 60 seconds. It is settable from
0 to 300 seconds.
Auto / Manual – The operator can change the auto / manual status of a zone or group of zones using these
two buttons. In Auto, the controller provides closed loop control using the thermocouple reading as
feedback to the controller. In Manual, the controller ignores the thermocouple reading and simply outputs
the percentage selected in the Manual % area. In Manual, the controller will still display the thermocouple
reading.
Auto / Load % - This is a powerful tool that enables the operator to retrieve the active percent output of a
zone (or group) and load the value(s) as the Manual % setpoint(s) for the zone(s). As stated in Section 8.4
Thermocouple Open Alarm, when a thermocouple fails the controller will switch to a “learned” percentage
output and continue molding. If the unit is turned off, the “learned” percentage is not saved. The Auto /
Load % setting enables the learned percentage to be saved as the Manual % output. This setting can be
recorded after the zones in the group have been controlling and stable for at least 30 minutes. The Power
button is used for changes in Auto / Manual modes.
Manual % - The user can enter a manual percent output of 0–100% or use the Auto / Load % button to
automatically set it. Entering a number does not put the unit into manual mode.
Unlock / Lock – If the user selects Unlock for a zone, the zone‟s on / off status can be changed. If the user
selects Lock for a zone, the zone is locked in the power OFF condition. To turn it back on, the operator
must first unlock the zone and then turn the zone on. The Lock feature is normally used to lock a zone in the
off position so that when the operator chooses to turn power on to all the zones in a group, the locked zone
remains off. This is useful in situations where a tip is blocked off in the tool and the user does not want to
apply heat to that tip zone.
61
10
___________________________________________________
Reports / Print Screens
62
Figure 10.1b Print Screen
Report Type:
View Report – This selection will cause reports to be viewed on screen, but not printed.
Print Report – This selection will cause reports to be printed if a printer is connected to the TTC
2100 and the proper printer driver has been installed. The Reports button on top of the screen will
change to Print. An orientation box will appear, asking the user to choose portrait or landscape
format. The five buttons above Report Type starting with the word “View…” will change to
“Print…” (e.g., View SP Changes will change to Print SP Changes). In the Menu screens, the
View Menu button (see Figure 11.1) will change to Print Menu. In the Diagnostics Screens, the
View Configuration Now button (see Figure 13.1) will change to Print Configuration Now.
Report Length – This setting determines how much data will be shown on the reports. Report
length is settable from 1 to 24 hours. The data shown on the screen is always the most recent data.
For example, if the report length is 1 hour, the report always shows the data for the past hour. Data
that occurred before that will not be used.
Clear all Report Data – This selection will clear out all report data for all groups. In effect, this
causes the report collection to start over.
Setup Reports – This selection is used to set up an automatic report collection whereby the
TTC 2100 collects data continuously for all zones. Placing a check in the box will cause that
report to be automatically generated and date-stamped as often as the Report Length (2 hours in
Figure 10.1b) and saved as a Pdf file in the D:\\TTC 2100\Network directory. These files include
the Zone Setpoint, SPC Report, Data Summary Report, Alarm Summary Report and Setpoint
Change Reports. They can be viewed with the Pdf viewer (see Section 14 Pdfs). They are stored
for one year. Then they are automatically deleted to conserve drive space.
63
Figure 10.1c Setup Reports Screen
Reports are different than databases. Databases (Section 16) can be recorded for any length of
time and the data is stored in a database file for future retrieval.
64
Figure 10.3 Zone Setpoint Report
The user can change the group that is displayed by simply selecting the desired group from the group tabs at
the bottom of the screen. Settings shown are the current settings for every zone in the group. Settings
cannot be changed from this screen.
Data is shown for each zone including average temperature, standard deviation and temperature range.
Minimum and maximum temperatures are shown. The Dev High and Dev Low columns indicate the
number of times that the alarms have been activated during the time length of the report. Average output
percentage, average current output, average heater watts and the average heater resistance values are also
shown for each zone in the group. Data is updated whenever the screen is displayed or scrolled. The
averages shown are calculated based upon the Report Length setting (Section 10.1 General Description).
66
Figure 10.6 Alarm Summary Report
The Alarm Summary Report will indicate every alarm that occurred for the group, what time it occurred and
what time it cleared (if it has).
67
Figure 10.7 Setpoint Change Report
Every change that has occurred in the group during the report time length is shown on the screen. For each
change, the screen will show the time of change, who made the change, the process setpoint, manual percent
output, the auto/manual output status, the on/off output status and latched / unlatched alarm status at the
time of the change. Changes are highlighted in yellow. If the Operator ID function is used, the user‟s ID
appears under the Who column. The user can change the group that is displayed by simply selecting the
desired group from the group tabs at the bottom of the screen.
68
11
___________________________________________________
Menus Screens
A menu is a file that contains a collection of zone setpoints, group settings and graph settings for all
permanent groups. For example, in Figure 11.1, the menus listed are not just for the Tip group, they apply
to all zones in the TTC 2100. Menus may be thought of as recipes for certain tools or applications. A user
may want to set up different menus for different days (August-1.mnu), tool tests or specific part runoffs.
Tool graphics are also associated with Menus.
The Menu name that is in effect is always shown in the upper right corner of the screen (A123 in Figure
11.1). A plus sign next to the menu name is shown (as shown in figure 11.1) whenever a setpoint has been
changed since loading the menu.
Menus can also be selected using the Mold ID feature if the unit is quipped with this option (see Section 23.
Mold ID).
Note that there are two menus shown in Figure 11.1 that include the word “Default”. The Default.mnu is
the current collection of all setpoints and settings being used by the TTC 2100. If the unit is turned off and
then on, the Default.mnu settings would be used on start-up until the user selects a different menu. Every
time a setpoint or setting is changed, a new Default.mnu menu is automatically created by the TTC 2100.
The previous menu is then automatically saved and named Default_1.mnu. Anytime a menu is saved with
an existing menu name, the previous menu will have a “_1” added to the menu name, just as the previous
Default.mnu was renamed Default_1.mnu.
11.3 Restore
Pressing the Restore button will cause the menu file displayed in the Menu Selected area to be used by the
TTC 2100. A message asking “Are you sure…?” will appear where the user can select “OK” or “Cancel”.
Software rewiring information (Section 20.3 Software Rewire (of Thermocouples)) can be part of a menu.
When a menu is restored that includes software rewiring information, a message appears asking the operator
if the swap information is to be loaded with the menu.
If the View Menu Data button is pressed, the screen in Figure 11.6b will be displayed.
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Figure 11.6b Menu Report Data Screen
Note: Copying a file from USB stick does not put the menu into instant use. If the user wants to use the
newly copied file as the current menu, then the file should be chosen from the Select a Menu list and then
the Restore button should be pressed.
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12
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Information Screens (Setup)
There are 4 security levels – Engineer, Supervisor, Operator and Monitor. Figure 12.3 shows which
functions are accessible for each security level. Contact Gammaflux for Security Codes.
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Engineer – Highest level. Total access to all settings and information in theTTC 2100. Required
for Mold Doctor and Field Calibration.
Supervisor – Typically used for setup of controller other than calibration, wiring, or tool
diagnostics.
Same as Engineer level except:
No access to Field Calibration
No access to Mold Doctor
Operator – Typically used to change setpoints without having access to more detailed setup
information.
Same as Supervisor level except:
No access to alarm setpoints
No access to upper and lower limits of setpoints
Monitor – Typically used when no access to any setpoints is desired. User can view operational
data, but is unable to change any control parameters.
Same as Operator level except:
No access to setpoints.
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12.4 Setup
Pressing the “Setup” button on the Information screen will give the supervisor or engineer level user access
to the TTC setup screens. The screen in Figure 12.4a will appear.
Settings can be made on a per zone / per group basis (“By Zone”) and for all zones at once (“System
Wide”). When a setting is changed in the “By Zone” area, a box appears that enables the user to make the
setting apply to just that zone or for the group that is selected with the group tab at the bottom of the screen
(Group “All” in Figure 12.4a).
Deviation Alarm – This setting sets the number of degrees plus and minus from setpoint that the
high and low temperature alarms will become active. Default setting is +/- 20F (+/- 11C). Range is
0-999F (0-537C).
Auto Standby – When the TTC is placed into the Standby Mode (either by touching the screen or
by the reception of an external signal), the setpoint of each zone goes to the Standby setpoint
assigned for that zone. Zones in manual output mode will go to 50% of the manual output
percentage setting. Upon exiting the Standby Mode, the zones return to their normal setpoints.
While there are other uses for this setting, the temperature setting is most commonly set to a
temperature that the user wants the zones to go to when the machine is not molding, but in an
idling condition. Default setting is 220F (104C). Range is 0-999F (0-537C).
Thermocouple Short Detection Time – The Thermocouple Short Alarm will activate if a
temperature has not changed 20F (11C) in a certain period of time, once the zone‟s output has
reached 98%. If this alarm activates, the output to that zone will be turned off. This setting
determines the period of time that the controller will wait before activating the alarm. Range is 0-
54 minutes. The 0 setting (default setting) indicates the default value of 5 minutes is in use.
Tuning Range Override – Normally this setting is set to zero for all zones, causing the zones to
be auto-tuned. On rare occasions, it may be determined that a zone‟s tuning setting can be
improved when a particular zone is faster or slower than normal. If a difficulty exists, it can also
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be due to factors such as thermocouple placement too near or too far from the heater, incorrect
heater size or intermittent connections.
Note: Slaving function (Section 12.6) will be inoperable when the Tuning Range Override
Setpoint for one or more zones in the Slaving group is set to “0”. This is due to the fact that zones
in the Slaving Group do not have the opportunity to auto-tune. They are being turned on and off
to keep all zones within 20F as they heat up. If Slaving is used, the following Tuning Range
Override settings are recommended as trial settings:
a) For tip zones - +10 (-1 for fast tips)
b) For manifold and manifold zones - +20
If these initial settings do not result in tight control, the settings can be adjusted to optimize
control. Here is a guide to the settings:
-31 to -30 = Ultra fast, low mass (-30 setting works well for tips such as Husky 250 Series)
-27 to -20 = Fast tip (-27 is fastest setting).
-17 to –10 = Fast manifold (-17 is fastest setting).
-1 = Manual entry for fast tips (not as fast as –27 to –20 settings)
0 = Standard tuning. The controller will determine if the setting should be 1 or 2.
1 = Controller displays this value when using standard tuning and zone behaves
like a tip.
2 = Controller displays this value when using standard tuning and zone behaves
like a manifold.
10 to 17 = Tip (17 is slowest setting).
20 to 27 = Manifold (27 is slowest setting).
Watt Alarm High –The High Watt Alarm can be used to determine if a zone is providing a higher
wattage than normal to maintain setpoint. If the watt alarms are to be used, they must be activated
in the setup procedure (Section 12.6 Options). Default setting is 8000 watts. Range is 0-8000
watts.
If the zone is set to Alarm on Sampled Wattage (see Section 12.6 Options):
The High Watt Alarm will be activated whenever this setting is reached or exceeded for ten
consecutive measurements while the controller is controlling near setpoint (within the high and
low temperature deviation settings).
If the zone is set to Alarm on Average Wattage (see Section 12.6 Options):
The High Watt Alarm will be activated whenever the average wattage value exceeds the high
wattage alarm limit for four consecutive sample periods. Each sample consists of 100
consecutive wattage readings (nominally 2 minutes).
Watt Alarm Low – The Low Watt Alarm can be used to determine if a zone is providing a lower
wattage than normal to maintain setpoint. If the watt alarms are to be used, they must be activated
in the setup procedure (Section 12.6 Options). Default setting is 0 watts. Range is 0-8000 watts.
If the zone is set to Alarm on Sampled Wattage (see Section 12.6 Options):
The Low Watt Alarm will be activated whenever the wattage falls below this setting for ten
consecutive measurements while the controller is controlling near setpoint (within the high and
low temperature deviation settings).
If the zone is set to Alarm on Average Wattage (see Section 12.6 Options):
The High Watt Alarm will be activated whenever the average wattage value falls below the
low wattage alarm limit for four consecutive sample periods. Each sample consists of 100
consecutive wattage readings (nominally 2 minutes).
Power Priority – “Low mass” or extremely small hot runner nozzles are a unique challenge to
control. To smooth the power and ultimately the melt heat history, Gammaflux has created Power
PriorityTM . Power PriorityTM smoothes the power output to individual zones. Users have the
option to manually apply a Power PriorityTM setpoint from 1 (light effect) to 4 (heavy effect),
providing unparalleled control for applications where it is most needed. A Power PriorityTM
setpoint of 0 disables the Power PriorityTM function for that zone. Normally, this setting should
be set to 0 unless low mass (extremely small) hot runners are in use.
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Alarms Latched – Placing a check in this box causes all alarms to appear on the screen. At times,
an alarm may occur and clear between screen updates (based upon the Seconds per Update setting
in Section 7.9 Graph Settings). With the Seconds per Update setting set to its default value of 1
second, an alarm would have to occur and clear in less than a second for the Alarms Latched
feature to show an alarm that would not otherwise appear on the screen. This can be valuable in
detecting an intermittent problem such as a momentary heater short. Default setting is unlatched.
Critical Over Temperature Alarm – The TTC 2100 will turn off all zone outputs if this
temperature setting is exceeded in any zone. This setting is used to help prevent an uncontrollable
zone from rising to a temperature that might damage the tool. It can also provide useful protection
in the event of a miswired tool. The default setting is 999F (537C). Range is 0-999F (0-537C).
Temperature Setpoint Maximum Limit – This setting limits how high individual zone setpoints
can be set. This prevents a user from setting a setpoint too high. Default value is 999F (537C).
Range is 0-999F (0-537C).
Manual Percent Maximum Limit – The setting limits how high a manual output level can be set
on any zone. This setting does not set the manual percentage. It only limits how high it can be set.
Default value is 100%. Range is 0-100%.
Trim Limit – Trim is a feature that enables the user to raise or lower the setpoint of a zone or
group of zones by a certain number of degrees even if all of the setpoints are different. The trim
limit setting determines the maximum number of degrees a user can trim (plus or minus) a zone or
group of zones at one time. This setting does not set the trim setpoint. It only limits how high the
trim setting can be set. Default trim limit setting is 100F (56C). Range is 0 to 999F (0 to 537C).
Boost Limit – Boost is a feature that enables the operator to temporarily raise (or lower) the
setpoint of a zone or group of zones by a certain pre-set number of degrees (boost) for a pre-set
amount of time (boost time). When time has expired, the setpoints automatically return to their
previous values. This feature is commonly used to heat tips to ensure that the plastic at the gates is
molten just before restarting machine cycling. Default boost limit is 50F (28C). Range is 0-999F
(0-537C).
Group Data - When the Group Data button is pushed, the screen shown in Figure 12.4b will appear.
Settings are shown for all the zones in the selected group. Pressing the Group Data button at the bottom of
the screen will return the user to the previous screen shown in Figure 12.4a. The two buttons on the Group
Data Screen are:
Group Data – Pressing this button will return the operator to the Setup Screen shown in Figure
12.4.
Save Actual Tuning to Setpoint – In Figure 12.4b, the Group Data screen shows “0” as the
tuning setting. The actual tuning setting calculated by the controller is not indicated. The
calculated tuning setting can be locked in and used as a manual tuning override if desired. To do
so, press the Save Actual Tuning to Setpoint button. The actual tuning setpoint at that moment
will now be locked in and displayed on both the screen shown in Figure 12.4a and on the Tuning
Range Override setting on the Setup screen in Figure 12.4a. Please note, that if this setpoint is
locked in, the controller will no longer auto-tune those zones.
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Figure 12.4b Group Data Screen
Setup Monitor Zones is a button that is positioned near the bottom right portion of the screen shown in
Figure 12.4a. For more information regarding Monitor Zones, see Section 15 Monitor Zones.
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Figure 12.5a Copy Zone % Output Screen
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Figure 12.5c Copy Zone % Output Display Assignments Screen
Remove the Copy Output Wiring for this Zone – Press this button to remove the linkage between the
zones displayed in The % Output of the Zone and Will be sent to the Zone boxes (Tip5 to Tip6 in Figure
12.5c.
Remove All Copy Output Wiring – Press this box to remove all linkages.
12.6 Options
When the Options button at the bottom right side of the Information screen (Figure 12.1) is pressed, the
screen shown in Figure 12.6a will appear.
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Figure 12.6a Options Screen
Slaving Group – Slaving is a feature that forces all zones in the selected group to stay within 20F
(11C) of the coldest zone in that group during start-up or following a setpoint change. This is
commonly used to bring tips up to temperature along with the slowest manifold zone, thereby
ensuring that the tips are not at setpoint for a long time waiting for the manifolds to come up to
temperature. In Figure 12.6a, the group selected is All. A selection of “--------” will disable the
Slaving function.
Note: The Slaving function cannot be initiated if one or more of the zones in the Slaving Group
have a Tuning Override Setpoint (Section 12.4 Setup) set to “0”. The Slaving Group box will
appear in yellow (see Figure 12.6b) when this is the case and a pop-up message will appear to
notify the operator when this is the case. See Section 12.4 Setup for a description of how to
change the Tuning Override Setpoint settings.
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Figure 12.6b Slaving Group Prohibited
Remote Standby Group – The Remote Standby function will operate only on the Group that is
selected with this setting. In Figure 12.6a, the selected group is All, which means all zones will be
put into Standby when the remote standby signal is received. This setting does not apply to the
regular Standby mode that is energized by pressing the Standby button on the screen. A selection
of “--------” will disable the Remote Standby function.
Remote Boost Group - The Remote Boost function will operate only on the Group that is selected
with this setting. In Figure 12.6a, the selected group is Tip, which means all zones associated with
the Tip group will be put into Boost when the remote boost signal is received. The Boost is not
cancelled by the removal of the remote boost signal. Boost can be restarted while in progress by
removing and reapplying the remote boost signal. A selection of “--------” will disable the Remote
Boost function. The Remote Boost Group setting is not related to the regular Boost mode which is
energized by pressing the Boost button on the screen.
Outputs on Power Up
This setting determines what state the heater outputs will be in when the power is turned on by the
main breaker:
Always Off – This selection causes outputs to remain off following power up or when a menu is
restored (Section 11.3 Restore). The user must use the Power buttons to turn the zones ON. This
is commonly used to give the user time to select what he wants to do before the zones start heating.
Ask – The outputs will initially be as they were when power was lost. A box will appear, asking
the user if the zones that were ON should remain ON. If the user does not respond in 10 seconds,
power to all zones will be turned OFF. Ask is the default setting.
Auto On – This selection enables the zones‟ on / off status to automatically return to the same
status following power up. Plants that have frequent power outages may want to use this selection
so that the user does not need to go to every controller to power up the heaters after a short power
outage.
Temperature Scale – The user can select F (Fahrenheit) or C (Celsius). All setpoints and values
are automatically converted. Default setting is F.
Enable Entry of Temperature Setpoint in Tenth of a Degree - The TTC 2100 reacts to .1F
temperature changes whether this feature is selected or not. Selecting this feature enables the user
to read the temperature and to set the setpoint to .1F or .1C resolution.
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12.7 Mold Monitor
Pressing the Mold Monitor button causes the screen shown in Figure 12.7 to appear. The selections on this
screen include:
Enable Material Protection (Machine Cycle Detection) – Material Protection is a feature that
requires a signal from the injection molding machine. If the signal is not present for a selected
period of time, the TTC will activate the Remote Standby Group (Section 12.6 Options). This
feature is used to help prevent material degradation due to high temperatures when the machine is
not cycling. Default setting is DISABLED.
Material Protection Timer in Seconds – This setting determines the time the signal from the
injection molding machine must be absent before the zones are shut off. For example, if 20
seconds is used, the zones in the Remote Standby Group (Section 12.6 Options) will go to Standby
if the TTC does not receive a signal from the machine within 20 seconds. The timer will not be
active until all low temperature alarms have cleared on startup. The timer will not be active until
all low temperature alarms have cleared on startup. If the timer times out, the timer must be reset
by pressing the Material Protection Alarm button (Section 8.14 Material Protection Alarm) on the
Alarm screen. Default setting is 0 seconds. Range is 0-999 seconds.
Enable Heater Resistance Alarm – If this feature is selected, the Heater Resistance Alarm will be
enabled. This function triggers an alarm whenever the heater resistance for a zone varies by 40%
or more when compared to its baseline measurement. Default setting is DISABLED.
Take Baseline – The TTC will record the heater resistances of all zones when this button is
pushed. It is recommended that the user wait at least a couple of hours after startup before taking a
new baseline. Heaters, by nature, tend to change resistance when they heat up. The TTC 2100
retains the baseline readings in memory when power is turned off. Baseline values are also stored
in menus.
Enable Watt Alarm – If this feature is selected, the Watt Alarm High and Watt Alarm Low
alarms will be enabled. Value settings for the alarms are shown in Figure 12.4a. The default
settings are 0 watts and 8000 watts which disable the alarm. The Watt Alarm for a zone will be
activated whenever the zone output exceeds the alarm setpoints while the zone is turned on and is
controlling near setpoint. This alarm can be used to determine if a zone is providing a higher or
lower output than normal to maintain setpoint. For example, the High Watt Alarm might be used
to alarm if a thermocouple or heater becomes coated in plastic due to leakage. The Low Watt
Alarm might be used to indicate that a heater that is wired in parallel with others has failed.
The Watt Alarm can be set to trigger using either of the following two methods:
Alarm on Sampled Wattage - The alarm is activated if the zone wattage is outside of the
alarm setpoint band for ten consecutive measurements while the controller zone is controlling
near setpoint. Any sample within the allowed wattage range will reset the counter. Any
sample where the zone wattage is 0 will reset the counter. Any sample where the zone is in
temperature deviation alarm will reset the counter. This is the default setting and on earlier
software versions was the only method available.
Alarm on Average Wattage – The average is calculated over 100 screen update samples
(nominally less than two minutes). The average wattage has to exceed the Watt Alarm
Setpoints for 4 consecutive sample periods before the alarm is triggered. This detection
method can handle zones that are oscillating several degrees whereas the other detection
method cannot. An oscillating zone may at times go to 0% output which would reset the
counter when using the Alarm on Sampled Wattage method.
Tolerance to apply to High Watt Alarm Setpoints – Another way to set the High Watt alarm is
to choose a value that is a certain percentage (tolerance) above the normal wattage value for each
zone. The default tolerance setting is 10% as shown in Figure 12.7. Once the machine is running
and making good parts for half an hour, press the Set High Watt Alarm Setpoints button. A High
Watt alarm will occur whenever this value is exceeded. If a setpoint is changed, the Set High
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Watt Alarm Setpoints button should be pressed again after the temperature is stable for half an
hour. This will ensure that the alarm settings are appropriate for the new temperature setpoints.
Group of Zones to Turn On - Each stage will only turn the specified group of zones ON. Any zones that
were turned on prior to starting the Sequence Start function or any zones turned on in any previous stage
will remain on. The stages do not turn any zones OFF.
Wait for Zones to get Within Deviation - Place a check in the “Wait for Zones to get Within Deviation”
box if all of the zones within that group have to rise to within the zone temperature deviation setpoints
before progressing to the next step. The temperature portion of the stage can be bypassed by not placing a
check in the box.
Delay Timer - The maximum entry for the Delay Timer is 999 minutes. Entries can be made to .1minute.
The Delay Timer portion of the stage is disabled with an entry of 0.
The example below shows that two (2) stages have been setup. Typically a stage would use either the
temperature test or the Delay Timer, though both can be used at the same time.
A “Sequence Start” message is displayed under the Boost button to note that the Sequence Start function is
in operation. The background of the border of the message provides an indication of the overall progress of
the function. The progress is calculated as a combination of the number of stages used, the actual
temperatures, and the expired delay times. A green highlight is used to denote what part of what stage is in
operation. A progress bar is displayed for each stage of the function. All is shown on Figure 12.8a.
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Cancel Sequence Start - Use this button to end the Sequence Start.
Information - Pressing the information (blue i) button nest to the exit button will cause the Sequence
Screen Tutor Screen to appear as shown in Figure 12.8b.
Done – Press this button to return to the screen shown in Figure 12.6a.
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Once the Sequence Start function is set up, it can be initialized by pressing the On button and then Sequence
Start Heatup button on the pop-up screen shown in figure 12.8c.
Even Cool Group - The temperature setpoints are automatically adjusted so that all of the zones in the
group selected remain within ~15F of each other as they cool.
Even Cool Endpoint Temperature - All of the zones in the controller will be turned off when all of the
zones in the Even Cool Group drop lower than the Even Cool Endpoint Temperature setpoint (220F shown
as an example in Figure 12.9b).
Done – Press this button to return to the screen shown in Figure 12.6a.
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Figure 12.9b Even Cool Screen
Sequence Menu 1 – This is the initial menu that the TTC will use when the Start Sequence
button is pressed or when a signal is received at the back of the TTC for Remote Sequenced Power
Up (Section 21Programmable Input / Output Functions). To select a menu, touch the area to the
right of the Sequence Menu 1 button. Select the menu from the list of existing menus that appears
(M1 in Figure 12.10). The highlighted menu shows which menu is in use at that moment as does
the display in the upper right corner.
Sequence Timer 1 – Enter the number of minutes that Sequence Menu 1 is to be used (20 minutes
in Figure 12.10).
Sequence Menu 2 – To select a menu, touch the area to the right of the Sequence Menu 2 button.
This is the menu that will be used when Sequence Timer 1 times out.
Sequence Timer 2 – Enter the number of minutes that Sequence Menu 2 is to be used. If only 2
Sequence Menus are required, set Sequence Timer 2 to 0 minutes and use the same menu in
Sequence Menu 3 that is used in Sequence Menu 2.
Sequence Menu 3 – To select a menu, touch the area to the right of the Sequence Menu 3 button.
This is the menu that continues to be used when the sequenced power up is completed or when the
End Sequence button is pressed.
Start Sequence – Pressing this button causes the TTC 2100 to use Sequence Menu 1 and start
Sequence Timer 1. The Sequenced Power Up icon appears at the top of the screen until the
end of the Sequenced Power Up as shown in Figure 12.10.
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End Sequence – Pressing this button will interrupt the Sequenced Power Up. The TTC 2100 will
use Sequence Menu 3.
Information – The “blue i” button will cause the Sequenced Power Up tutorial screen to appear.
Done – Press this button to return to the screen shown in Figure 12.6a.
12.11 Language
Pressing the Language button causes the screen in Figure 12.11 to appear. The user can select the
language for all screen verbiage from the language selections that appear. Languages include Czesky,
Dansk, Deutsch, English, Español, Français, Italiano, Nederlands, Polski, Portuguese, Svenska, Vlaams and
Far Eastern character sets. Other languages easily available using Windows XP based language editor and
character sets. Kanji and other double byte character sets are also now available. Contact Gammaflux for
more information.
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Figure 12.11 Language Screen
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The buttons that appear on the Operator ID Screen include:
Add New Operator – When this button is touched, a keypad will appear that enables the user to
enter an ID number and a name that will appear in the next available line on the table shown in
Figure 12.6j.
Remove Operator – To remove an operator, touch this button and select the operator from the
table that is to be removed.
Done – Press this button to return to the screen shown in Figure 12.6a.
Permanent groups are saved in menus and when power is turned off. Temporary groups are groups that are
not saved in menus or when power is turned off.
See Section 5.4 Permanent Groups for all procedures relating to permanent groups.
Note: If the user wants to leave the software and outputs running when leaving the TTC software, the Exit
to Windows button (Section 13.6 Exit to Windows) should be used.
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13
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Diagnostics Screens
Databases record all data and display it in meaningful formats that assist the project engineers and
maintenance people alike. See Section 16 Databases.
Mold Doctor is an off – line tool for diagnosing thermocouple, heater and wiring problems as well as tool
inefficiencies. An Engineer security level is required. See Section 17 Mold Doctor.
Field Calibrator is an off - line tool that enables thermocouple calibration at the user‟s convenience. An
Engineer security level is required. See Section 18 Field Calibrator.
Edit Configuration enables the user to assign zone names and addresses to thermocouple and output module
hardware. An Engineer security level is required. See Section 20 Edit Configuration.
Tuning is used to gain access to and change the tuning of one or more zones.
Pressing the Diagnostics button at the top of the screen will cause the screen in Figure 13.1 to appear.
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13.2 Find This Module
This function is available to help the user quickly locate the hardware associated with the zone selected in
the Zone area of the screen (upper right corner). When the Find This Module button is touched, the screen
shown in Figure 13.2 appears. Slot location, fuse location, power connector pin numbers, thermocouple
input location and thermocouple connector pin numbers that are associated with the zone selected in the
upper right hand corner of the screen (Tip 1 in Figure 13.3) will be displayed.
A module light can be used to indicate the hardware location of a zone or group of zones depending upon
the selection made under:
Selected Zone – Module light lights on the output board that includes the zone indicated in the upper right
corner of the screen (Tip 1 in Figure 13.3).
Scroll Through Group – Module light scrolls through each zone in the group selected on the screen (Tip
in Figure 13.3).
Pause Scrolling – Module light stops scrolling until this selection is pressed again.
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Figure 13.3 Zone Configuration Report Screen
For a description of System Zone, DC Zone Number, DC Zone Address, Output Slot, T/C Module and T/C
Module Zone see Section 20 Edit Configuration.
The Power Connector, Power Pins, T/C Connector and T/C pins describe the connector label and the actual
pins on the connector that are associated with each zone in the group.
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Figure 13.4 View Versions Screen
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13.6 Exit to Windows
Pressing the Exit to Windows button will cause the TTC 2100 software to close. A screen message will
appear warning the user that the outputs of the zones do not turn off when exiting to Windows. If the user
touches OK, then the screen in Figure 13.6 will appear. Engineer security level is required to use this
button. The computer will exit to the Windows XP operating system.
Note: If the user wants to stop communications without exiting to Windows, the Stop Communications
button (Section 12.14 Stop Communications) should be used.
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14
____________________________________________________
Pdfs
To handle the viewing and transferring of a Pdf file, the following buttons are used:
View Pdf – Press this button to view the Pdf File Selected.
Delete Pdf – Press this button to delete the Pdf File Selected.
Copy to Diskette/USB – Press this button to copy the Pdf File Selected to a USB memory drive.
Copy from Diskette/USB – Press this button to copy files from a USB memory drive to the Pdf
directory. When completed, the new Pdf files will show up in the list on the left side of the screen.
It is important to note that any “Read Only” attributes of a Pdf file should be removed before
importing the file into the TTC computer. The Delete button will be unable to delete the file if the
“Read Only” attributes are not first removed.
Select All – By selecting Select All, all Pdf files shown on the left side of the screen can be
exported to a USB memory drive or deleted at the same time.
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14.3 Viewing and Transferring Pdf Report Files
The TTC can be set up to automatically record reports such as the Zone Setpoints Report, SPC Report, Data
Summary Report, Alarm Summary Report and the Setpoint Changes Report (see Section 10 Reports/Print
Screens). The View Pdf, Delete Pdf, Copy to Diskette/USB, Copy from Diskette/USB and Select All
buttons mentioned in Section 14.2 Viewing and Transferring Pdf Files are all used to view and transfer Pdf
Report Screens. To locate the available reports, press the Find Pdf Reports button.
Find Pdf Reports – Press this button to show the collected reports (see Section 10 Reports/Print Screens).
The column on the right will show the month and year of the directories (2010_12 shown in Figure 14.3a
indicates the directory was created December, 2010). Choosing one causes the list of available reports for
that month to appear in the column on the left as shown in Figure 14.3a. The file names on the left indicate
the date and hour of completion (Data_12_14_09 indicates a Data Summary report that was completed or
printed at 9AM on December 14). If a file is completed within the same hour as a previous report, an “A”
will appear at the end of the older file‟s name (such as Data_12_14_11_A shown in Figure 14.3a). Any or
all of these files can be copied to a USB memory stick using the Copy to Diskette/USB and Copy from
Diskette/USB buttons on the screen. To view, select one (SPC_12_14_11.pdf in Figure 14.3a) and press
View Pdf. The report will appear on the screen (sample shown in Figure 14.3b). The Find Pdf Reports
button will not appear on the screen if no reports have been saved.
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Figure 14.3b Sample SPC Report Pdf
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15
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Monitor Only Zones
The presence of a Monitor alarm activates the operator panel alarm flasher and closes the alarm contacts.
The presence of a Monitor alarm can be set to perform no action, to change the status of the "OK to Run"
contact, to place the controller in Standby or to turn off all of the zones in the controller.
The Monitor function is accomplished by adding an output zone for each Monitor zone to be tested. A
connection is made to the thermocouple input for that zone. No output control cabling is used for these
Monitor zones.
All of the hot runner zones and the Monitor zones must be of the same type J or type K setting.
A zone that has been set to operate as a Monitor zone will appear as „Monitor‟ in place of „Auto‟ or
„Manual‟ in the box located below the On and Off buttons. The Monitor zone information is included in the
on-screen and printed Setpoint and Menu Reports.
Changes to the Monitor High Alarm and Low Alarm setpoints are not reported in the Setpoint Change
Reports.
To get started, press the Setup Monitor Zones button on the Setup screen shown in Figure 15.1
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15.2 Setting Up Monitor Only Zones
To set up a group of Monitor zones:
1) Make a permanent group to contain the Monitor Only zones (refer to Section 5.2 Permanent Groups
to review). This allows setpoint entry to be performed by group without affecting the non-monitor
zones. This also allows the graphing and charting of Monitor zones like any other group of zones.
2) Lock off all zones in this Monitor group (refer to Section 9.7 Options Button to review). This will
prevent the zones from being turned ON and generating any Open Heater alarms or any thermocouple
alarms.
3) Press the Information tab and select Setup. Then select Setup Monitor Zones. A screen similar to
the one shown in Figure 15.2a Monitor Only Setup Screen will appear.
4) Place a „Y‟ (Yes) in the grid for those zones to be tested for high alarm.
5) Place a „Y‟ in the grid for those zones to be tested for low alarm.
6) Enter the high and/or low absolute (not deviation) temperature alarm setpoints.
7) Place a „Y‟ at the top of the grid for those zones to be monitored and alarmed.
Press the Setup Alarm Action bottom shown in the bottom left corner of Figure 15.2a. A screen similar to
the one shown in Figure 15.2b will appear.
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Figure 15.2b Monitor Only Zones Alarm Setup Screen
Choose which action is desired for when a Monitor Only zone goes into alarm. The choices are:
Alarm only – The alarm screen will indicate there is an alarm, but no other action will be taken.
Activate Standby for the “Remote Standby” group when a Monitor Alarm is detected – The
presence of a Monitor alarm will place the controller into Standby. The „Remote Standby‟ group on the
„Options‟ screen (refer to Section 12.6 Options to review) is used to select which zones in the
controller will be set to Standby when an alarm is detected. If an alarm occurs and the Remote Standby
group is put into Standby, the unit can be reset by using the following procedure:
Turn Off all of the zones in the controllers when a Monitor Alarm is detected - The presence of a
Monitor alarm will turn off ALL of the zones in the controller. To reset the alarm, use the following
procedure:
1) Press the „Monitor Alarm‟ button on the Alarm screen to acknowledge the Monitor alarm.
2) Press the green ON button at the top of the screen to turn the zones back on again. If the
„Monitor‟ alarm is still present, the zones in the controller will be turned off again.
Include Monitor Zone Alarms in the “OK to Run output – If this box is checked, a Monitor Zone Alarm
will affect the status of the “OK to Run” output.
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Databases
Recording Status:
Monitor Only – When this box is selected, the TTC 2100 is not recording data. It will continue to
display current data.
Record Data – If this selection is chosen, the TTC 2100 will immediately begin recording data in
the file shown to the left (33mm Shield.mdb in Figure 16.1). If the user wants to record to a
different file name or a new file name, the area to the left of Record Data should be pressed. The
user will have a choice of choosing a new database file name with the alphanumeric keypad that
appears or typing in the name of an existing database. Each database file name has an mdb
extension. If the user does not enter it, the TTC 2100 will automatically do so. Database files
102
created by the TTC 2100 are compatible with Microsoft Access 9.0. So, in addition to viewing
databases on the TTC 2100 screen, databases can be downloaded to a USB flash drive (floppy disk
on earlier units) and viewed on any computer running Microsoft Access 9.0 software.
Playback Data – To playback a database, touch the area to the far left of the Playback button.
Once a file is selected from the drop down menu that appears, Playback can be selected. Figure
16.2 shows an example of the playback of a database. The top central part of the screen is
replaced with a Database Playback slide bar along with a Time indicator of the time the
displayed data was recorded. Fast Reverse, Reverse, Stop (Pause), Forward and Fast Forward
controls appear below the Database Playback slide bar. All variables (e.g., temperature, wattage,
load amperage) are automatically recorded. Data can be shown using any format available (e.g.,
bar graphs, SPC graphs, Controllers view). The Menus button is removed from the screen when
Databases are played back.
On File Full:
Keep Newest – If this selection is chosen, the database file will fill to the chosen size and then
write over the existing data so the data is always the most recent. This is the default setting.
Keep Oldest – If this selection is chosen, the database file will fill up and then stop recording.
Max File Size – The file size is directly related to the Time to Fill File value shown at the bottom
of the screen. The user should choose a file size that results in the number of hours or days of data
that is desired.
Time Compression – This setting is also directly related to the Time to Fill File value. It can be
thought of as a data sampling rate. The default setting is 1:1 (data is normally sampled every 3
seconds for database storage), but if disk space is limited the user may want to compress time. A
setting of 2:1 would cause the TTC to store data every 6 seconds or half as frequently as it
normally would. The limit is 300:1.
Time to Fill File – This is a calculation made by the controller. The calculated time is a function
of the number of zones, the file size and the time compression.
103
Select Database – If the user wants to preview, delete or copy an existing database, the
appropriate database should be selected by touching the area under Select Database. The user can
then select the database from the list of existing databases that appears on the screen.
Preview Database – Pressing this button will cause the screen in Figure 16.1 to appear. It will
show information relating to the file shown in the Select Database field. Information includes date
and time of creation along with user‟s notes. The purpose of this selection is to give the user the
opportunity to confirm that this is the file the user wants to access.
Delete – Pressing this button will cause the file displayed in the Select Database area to be deleted.
Copy to Diskette/USB - Pressing this button will cause the file displayed in the Select Database
area to be compressed and copied to a USB flash drive (diskette on earlier units) if inserted in the
slot on the back of the TTC 2100 screen. If the database exceeds the available space on the
diskette/USB, the user will be prompted to insert another diskette/USB when the disk is full.
Copy from Diskette/USB – Pressing this button will cause a screen to appear that lists the files
that are located on the diskette/USB mounted on the back of the TTC 2100 screen. Select the
appropriate file and enter. The file will be copied into the list of databases on the TTC 2100. If
multiple diskettes/ USB flash drives are required to enter the database data, a prompt will be
displayed when the controller is ready for the user to insert the next disk.
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Mold Doctor
1) Wiring Analysis – The TTC 2100 locates any thermocouple or heater problems in the tool. In
addition, the test will reveal if any zones have been miswired.
2) Fault Analysis – This test is the same as the Wiring Analysis test, except that it does not check
for zones that have been miswired.
4) Historical Mold Performance – This test compares the results of any two Thermodynamic
Analysis tests. It will highlight differences between the two, thereby indicating how the tool has
changed since it was last tested.
When the Mold Doctor button is pressed, the screen shown in Figure 17.1a will appear.
Note: Mold Doctor only works on temporary groups. If the temporary group does not already exist, the
user needs to set it up using the procedure described in Section 5.2 Temporary Groups. In Figure 17.1a, the
temporary group *Tip1-Tip20 is being used.
To the right of the Mold Doctor selections, a text area appears, reminding the operator to set up a temporary
group and to update job information.
The controller powers up the first zone of the temporary group being used, determines if the zone is heating
and then determines if any other zone is heating. Once the testing of the first zone is completed, it repeats
the same test for each zone in the group.
While the test is being run, the screen shown in Figure 17.2 will appear. The horizontal blue bar is
continuously updated, displaying how much of the testing has been completed. It generally takes 2 minutes
per zone. The results of the test are shown on the screen and can be printed along with the most recently
entered job information using the Print Report button. The test can be aborted at any time using the
Cancel button.
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Figure 17.2 Wiring Analysis
107
Figure 17.3 Fault Analysis
Upon initialization of the test, the controller will bring all zones in the temporary group to approximately
200F (93C). Then the temperature is ramped up to 400F (204C) and then ramped back down to 300F
(149C). To get the most out of the test, cooling water should be applied in order that the cooling rate can be
calculated and displayed more accurately. If cooling water is not available, the user can choose for the
controller to skip the cooling part of the test.
This test generally takes about 30 minutes to perform, partly dependent upon the cooling efficiency of the
tool test. The test can be aborted at any time using the Cancel button. Results can be stored for future
review. To store the results, press the Save Analysis Data button and enter a file name using the
alphanumeric keypad that appears. Then press the Enter button. Results can also be printed using the Print
Report button.
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Figure 17.4 Thermodynamic Analysis
Changes in heater resistances, output percentages and other data could be an early indication that a heater is
about to fail. To get the most out of this report, the two Thermodynamic Analysis tests being compared
should be completed under similar conditions. For example, if cooling rate data is being compared, it is
important that the same water temperature and water flow rates were used in the two Thermodynamic
Analysis tests. Otherwise, it would be expected that the test using the colder cooling water would result in
faster cooling rates.
The result of the test is shown on the screen and can be printed along with the most recently entered job
information using the Print Report button. The test can be aborted at any time using the Cancel button.
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Figure 17.5 Historic Analysis
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Field Calibrator
During calibration, the target temperature is compared against the incoming thermocouple signal. Any error
found between the target and the actual is corrected by the TTC 2100 assigning a New Offset for each
zone. The controller remembers both the New Offset and the Old Offset, which was the setting from the
previous calibration procedure. Pressing the Field Calibrator button will cause the screen in Figure 18.1 to
appear.
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18.3 Calibrate Group (Performing Field Calibration)
The steps required to perform a field calibration are as displayed on Figure 18.1 and state:
1. Create new temporary groups that contain only those zones that can be connected to the
thermocouple source at one time. Groups may be created on the Controllers screen using the
“New*Group” button to create the group. Note: Only temporary groups, those that have an
“*” as the first character may be calibrated.
(A connector can be made up by the user or by Gammaflux that would have all the positive
thermocouple signal pins jumpered together and all the negative thermocouple signal pins
jumpered together. Then, the thermocouple simulator could be wired to one pair on the connector
and plugged into the appropriate thermocouple connector on the back of the TTC enclosure. This
will enable the user to calibrate the zones in groups instead of one zone at a time.)
(This is for reference information. It is helpful to the operator to know when the calibration was
done.)
3. Connect the thermocouple source to the zones in the temporary group to be calibrated and
select the group.
4. Set the source and the Target setpoint to the same temperature value.
(It is common to select a temperature that is close to the normal temperatures that most of the tools
run. Common temperatures include 400F and 200C.)
When the Calibrate Group button is pressed, the table at the bottom of the screen will be filled in
such as the one shown in Figure 18.1.
This group is now calibrated. Field Calibrator has an accuracy of ± 0.2º F or ± 0.1º C.
To continue with the rest of the zones, repeat the 5 steps shown above.
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Tuning
-31 to -30 = Ultra fast, low mass (-30 setting works well for tips such as Husky 250 Series)
-27 to -20 = Fast tip (-27 is fastest setting).
-17 to –10 = Fast manifold (-17 is fastest setting).
-1 = Manual entry for fast tips (not as fast as –27 to –20 settings)
0 = Standard tuning. The controller will determine if the setting should be 1 or 2.
1 = Controller displays this value when using standard tuning and zone behaves
like a tip.
2 = Controller displays this value when using standard tuning and zone behaves
like a manifold.
10 to 17 = Tip (17 is slowest setting).
20 to 27 = Manifold (27 is slowest setting).
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Figure 19.2 Display Tuning Screen
19.4 Tune
To re-tune zones, use the following procedure:
1) Create new temporary groups containing only those zones to be tuned. Groups may be
created on the Controllers screen using the “New*Group” button to create the group. Note:
Only temporary groups, those that have an “*” as the first character may be tuned.
2. Update Job information on information screen for report. (This is for reference information.
It is helpful to the operator to know when the tuning was done.)
3. Wait for the temperatures to be stable. Temperatures must change less than one degree F (1/2
degree C) for 30 seconds before tuning may start.
4. Touch the Tune button to start tuning. During the tuning procedure, the Tune Rite area of the
screen will be replaced by a horizontal blue bar that shows the progress of the tuning
procedure. The instructions area will be replaced with a description of what is occurring at the
moment. Upon completion, the tuning data will appear in the table.
Note: This is the procedure for automatically re-tuning the TTC 2100. The user can also enter tuning
constants manually using the Tuning Range Override setting on the Information / Setup Screen as
described in Section 12.4 Setup.
114
19.5 Return to Old Tuning
Pressing the Return to Old Tuning button causes the tuning values shown in the New Tuning area to be
swapped with the tuning values shown in the Old Tuning area.
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Change Configuration
CHANGES MADE IN THESE AREAS CAN SIGNIFICANTLY AFFECT ON THE OPERATION OF THE
TTC 2100. CHANGES SHOULD ONLY BE MADE WITH A THOROUGH UNDERSTANDING OF THEIR
IMPLICATIONS. IF THERE IS ANY QUESTION ABOUT HOW TO PROCEED, CONTACT GAMMAFLUX
PERSONNEL FOR ASSISTANCE.
To access the configuration portion of the software, touch the Diagnostics tab at the top of the screen and
then select Change Configuration from the Diagnostics screen shown in Figure 20.1a. The screen shown
in Figure 20.1b will appear.
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Figure 20.1b Change Configuration Screen
117
To make changes, use the following procedure:
1) Use the From and To areas to Select Range of System Zones numbers (e.g., 1 and 12) that are to have
their ID Names changed.
2) Assign an ID name (e.g., Tip) for these selected zones by touching the appropriate selection in the
“Select ID for selected range of system zones from the list” area. The controller will assign zone
numbers for each ID name starting with 1. For example, designating System Zone Numbers 65-71 as
Man causes the table to automatically assign System Zone Numbers 65-71 as Man 1-7.
3) If the user needs to create a new ID name that is not shown (e.g., Bar for Barrel), then press “Add ID to
List” key and type in the new name in the Change To: area on the alphanumeric keypad that appears.
An ID should contain no more than 5 characters. If you would like to delete an ID name from the list,
simply select the ID name that is to be deleted and press “Remove ID from List”.
4) The changes the user makes will appear in the area above the Accept and Undo buttons.
5) Press the Accept on the right side of the screen to accept your changes. The changes will appear on
the table shown.
6) If desired, the Undo button can still be used to clear the last “accepted” change.
7) Repeat steps 1-6 to make additional changes.
8) To enter the changes as shown on the table and exit the screen, press the Accept button on the left side
of the screen.
9) If the user chooses to undo all the changes made during this configuration session and exit the screen,
press the No Changes button. If the user wants to undo all the changes made during this configuration
session and stay on the Configuration screens, press the Restore Original button.
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The software rewiring of thermocouples can be accomplished using the following procedure:
1) Select the first zone or group of sequential System Zones that is to be repositioned (Zones 3-4 in Figure
20.3).
2) Select the zone or group of sequential System Zones that is to be swapped with the zone(s) selected in
step 1 (Zones 7-8 in Figure 20.3). The same number of zones must be selected in each step. An error
message will notify the operator if an attempt to swap zones is made with an unequal number of zones.
3) Press Swap Inputs. The results of the swap appears in the table at the bottom of the screen (Tips 7-8
have been moved into the Tips 3-4 original position, Tips 3-4 have been moved into the Tips 7-8
original position). System Zones that have been swapped appear with a red background (and will
continue to be shown with a red background the next time the Software Rewire Inputs screen is
accessed). These changes do not become official until the Accept button is pressed.
4) The swap can be undone by pressing Undo Last Swap.
5) More swaps can be made at this time by repeating steps 1-3.
6) Pressing Restore Original undoes all swaps that have been made since the operator last accessed the
screen. If multiple swaps have been made during the session, all will be undone.
7) Pressing Undo All Rewiring undoes all swaps that have been done at any time using the existing
menu.
8) To make swaps official and to leave the screen, press Accept.
To ignore swaps and restore conditions to what they were when the screen was accessed, press the No
Changes (exit door icon) button.
Software rewiring information can be saved to the menu (Section 11 Menus). When a menu is restored that
includes software rewiring information, a message appears asking the operator if the swap information is to
be loaded with the menu.
119
There is a slide bar at the bottom of the screen than enables the user to see and edit configuration for all the
zones.
Much can be learned by studying the data table. Data shown includes:
System Zone Number – This number is assigned left to right by the TTC 2100.
ID Name - This is chosen by the user. The name can be edited using the procedure described in Section
20.5 Edit ID.
ID Number – This number is assigned by the TTC 2100. The controller automatically numbers zones,
starting with number 1 for each new ID Name (e.g., Tip in Figure 20.4).
DC – DC is the abbreviation for Data Concentrator (communication module). Each data concentrator is
associated with up to 64 zones. They are numbered 0,1,2,3 etc.
DC Zone Number - The zone number is assigned by the TTC 2100 by numbering the zones from the first
zone on the first board to the last zone of the last board for each data concentrator. Each data concentrator
has up to 64 zone numbers (numbered 0 to 63).
DC Zone Address – The addresses are assigned by the TTC 2100. The number assigned depends upon the
type of output module (3A, 15A or 30A), which position the zone has on the output module and the slot
number where the board resides. It is not necessary to know how the DC Zone Address is calculated, but
for those who do want to know, the calculation description follows:
Examples: a) Tip 2 is the 2nd zone on a 3A output module and the board is in slot 1.
The DC Zone Address would be 4 x (1-1) + (2-1) = 1 as shown in Figure 20.4.
b) Tip 12 is the 4th zone on a 3A output module and the board is in slot 3.
The DC Zone Address would be 4 x (3-1) + (4-1) = 11as shown in Figure 20.4.
Example: A zone is the 2nd zone on a 15A output module and the board is in slot 5.
The DC Zone Address would be 2 x (5-1) + (2-1) + 64 = 73.
3) 30A zones – Each 30A output module contains 1 zone of control and fills 2 slots.
The DC Zone Addresses range from 128-191.
The formula the TTC 2100 uses to calculate the DC Zone address number is:
Example: A zone is the 1st zone on a 30A output module and the board is in slot 1.
The DC Zone Address would be (1-1) + 128 = 128
Slot – There are 16 slots for each data concentrator for a maximum of 64 slots (numbered 1 to 64)
for a quad heat sink enclosure. Slots can be filled with 4-zone 3A cards (1 slot), 2-zone 15A cards (1 or 2
slots depending upon current draw of heaters) and 1-zone 30A cards (2 slots). The data table indicates the
slot for every zone.
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Power Connector – The data table indicates which heater output cable is associated with each zone. This
is only changeable by Gammaflux personnel.
Pins – The data table indicates which pins on the heater cable are associated with each zone. This is only
changeable by Gammaflux personnel.
TC Module – Each Thermocouple Module contains 16 thermocouple inputs. The data table indicates
which thermocouple input position is associated with each zone.
TC Module Zone – This number (0 to 15) is the input address for each Thermocouple Module. For
example, the eighth thermocouple input on the card would be TC Module Zone 7.
TC Connector - The data table indicates which thermocouple cable is associated with each zone. This is
only changeable by Gammaflux personnel.
Pins – The data table indicates the pin numbers for the plus and minus thermocouple inputs for each zone.
This is only changeable by Gammaflux personnel.
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Figure 20.5 Edit ID Screen
When the Move Zone Address button is pressed, a screen shown in Figure 20.6 will appear.
A user may want to change a group of zones if a different ID Number is desired. For example, the user may
want Tip 5-8 to be displayed on the TTC 2100 screen as Tip 1-4 as shown in figure 20.6. The user can
select Tip 5-8 and move them in front of Tip 1. This will result in the TTC 2100 sequentially renumbering
the zones from left to right. Now, the original Tip 5-8 will be labeled Tip 1-4 as desired. The original Tip
1-4 will now be moved to the right and labeled Tip 5-8. Since these Tip zones were already adjacent to
each other, the other Tip zones are not affected.
When a group of zones is moved, the top 4 rows (System Zone, ID Name, ID Number and Data
Concentrator) in the data table remain the same. All data in the other rows shift with the zones that are
moved.
123
To make a change in the configuration of the thermocouples:
1) Enter The Range of System Zones numbers for the thermocouples that are to be reassigned using the
From and To areas (Zones 9-12 and 13-16 in Figure 20.7).
Note: Each thermocouple module contains 16 thermocouple inputs. Only one module can be
reassigned at a time.
2) Enter the Thermocouple Module and Zone in Thermocouple Module settings for the thermocouple
that the user wants to associate with the zone shown in the From entry.
The rest will automatically be assigned to the rest of the zones selected in the From - To range.
3) Press the Assign button. The changes will appear on the screen.
4) To undo the most recent change, press the Undo Assign button.
5) Repeat steps 1-4 to make additional changes.
6) To enter the changes as shown on the table and exit the screen, press the Accept button.
7) If the user chooses to undo all the changes made during this configuration session and exit the screen,
press the No Changes button. If the user wants to undo all the changes made during this configuration
session and stay on the Configuration screens, press the Restore Original button.
125
Figure 20.9 DC Zones Screen
Caution: Do not press the Locate Zones button unless boards have been added or
removed from the TTC 2100. The replacement of a board does not require the Locate Zones procedure to
be used.
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Programmable Input / Output Functions
21.2 Inputs
Control Inhibit, Remote Standby (Section 12.6 Options) and Material Protection (Section 12.6 Options)
inputs are already wired as standard and require no programming to be used. If the user wants to use
Remote Boost or Remote Sequenced Power Up, an io.txt file must be created in Windows using Notepad
and saved to the C:\\TTC 2100 directory. Do not create the io.txt file unless changes are being made.
Each feature has a designation that is used in creating the io.txt file. Designations include:
InA=Remote Standby
InB=Material Protection
InC=Remote Boost
InD=Remote Sequenced Power Up
Up to 3 of the 4 Input features (InA, InB, InC, InD) can be wired to the HA-4 remote input connector.
Figure 21.2a shows how the TTC 2100 is normally shipped. Figure 21.2b shows what input options are
available and their feature designation. The feature designation is used in the io.txt to indicate where the
feature will be wired.
Anytime there are 3 input features selected that do not include Control Inhibit, the user must remove the
wire currently connected to the back of Pin 2 of the HA-4 connector and swap it with the spare wire
available at the back of the connector.
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Available Feature
Features Designation
Control Inhibit None
Remote InA
Standby
Material InB
Protection
Remote Boost InC
Remote InD
Sequenced
Power Up
Example 1:
Use Remote Standby and Remote Boost inputs.
The io.txt file would be written as:
InA=1
InC=2
This would program the TTC 2100 to assign Remote Standby (Feature Designation InA) to Pin 3 (Program
Code 1) of the HA-4 connector.
Example 2:
Use Remote Standby, Remote Boost and Remote Sequenced Power Up.
The io.txt file would be written as:
InA=1
InC=2
InD=3
This would program the TTC 2100 to assign Remote Standby to Pin 3, Remote Boost to Pin 4 and Remote
Sequenced Power Up to Pin 2. Note that Control Inhibit is already wired to Pin 2. The user would need to
remove the screws from the HA-4, remove the wire that is on the back of Pin 2 of the connector and swap it
with the spare wire that is available behind the connector.
Example 3:
Activate Remote Standby whenever an input signal is received on Pin 3 or Pin 4.
The io.txt file would be written as:
InA=1
InA=2
This would program the TTC 2100 to activate the Remote Standby Feature (Feature Designation InA)
anytime a signal is received on Pin 3 (Program Code 1) or Pin 4 (Program Code 2) of the HA-4 connector.
21.3 Outputs
Please see Section 3. HA-3 Alarm Relay Output Connections for a description of the output functions
available on the TTC 2100.
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Networking via Ethernet
To list the available menus, create a file named Menu.txt is created with the line: “List”. This file is sent to
the Network folder. The operators panel software will create a text file called „MenusList.txt‟ and put it in
the Network folder. This may then be moved up the network and viewed there.
To activate a menu (e.g., “Sample.mnu”) stored in the operators panel, a file named Menu.txt is created
with the line: “Activate = Sample.mnu”. This file is sent to the Network folder. The operator panel
software will read this file and load the Sample.mnu menu stored within the TTC 2100.
In a similar way a menu may be retrieved from the TTC to the Network folder with the line: “Get =
Sample.mnu”, sent to the TTC from the Network folder with the line: “Send = Sample.mnu”, and deleted
from the TTC with the line: “Delete = Sample.mnu”.
More than one line may appear in the Menu.txt file. The commands are executed in the order they appear
in the file. For example, the following sample will retrieve the menu Mold123.mnu, delete it from the TTC
and list the remaining menus in the TTC.
Get=Mold123.mnu
Delete=Mold123.mnu
List
To set a setpoint enter a line in the Setpoints.txt file as shown by the example:
This will set the process temperature setpoint of zone Tip 17 to 400F. Note that the first entry of the line is
the zone ID followed by a space which is then followed by a colon(:). It very important to start the line in
this manner and to spell the ID correctly. It may be easier to create an AllSetpoints.txt file (described later)
and modify it than to create one from scratch. Any number of the setpoints may be included on the line if
more than one setpoint per zone is to be changed. For example:
This will set the process temperature setpoint to 210C, the manual setpoint to 15.3%, turn off manual mode
(turn on automatic mode), and turn the zone on.
Any number of zones may be set in one file, just use a new line for each zone.
In addition to setting setpoints the Setpoints.txt file may include the following special instructions.
Adding the Setpoints=1 instruction causes the TTC to create an AllSetpoints.txt file in the Network folder.
The AllSetpoints.txt is a list of all of the four setpoints for each zone. The AllSetpoints.txt file may be
renamed Setpoints.txt and copied to the Network folder to cause all setpoints to be set. In this way a form
of menu retrieval and restoring can be performed without using the database based “x.mnu” files. The
process temperature setpoints will be in degrees C or F based upon the last setting of Scale.
Adding Values = 1 instruction caused a file named Values.csv to be created in the Network folder. This
file is updated (recreated) at the rate of the TTC display updates. Only the last file is available. This is a
“comma separated values” file and may be imported directly into Microsoft Excel, Microsoft Word and
others. All of the values for all of the zones are always included in every Values file. Each zone is on a
separate line. Like the Setpoints file the zone ID is followed by a space followed by the zone number
within the ID. This is followed by a comma. After the comma is a list of all of the following values, in the
order:
Zone name
Process value
Active percent output
Amps
Volts
Manual mode
Zone On
Alarm status.
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Alarm status is a binary number with the following bit assignments
Bit Assignment Weight
0 Thermocouple Open 1
1 Thermocouple Reversed 2
2 Uncontrolled Output 4
3 Heater Short 8
4 Heater Open 16
5 Open Fuse 32
6 Deviation High 64
7 Deviation Low 128
8 Thermocouple Short 256
9 Heater Resistance 512
10 Zone Off 1024
11 Manual Mode 2048
12 Auto Standby 4096
13 Control Inhibit 8192
14 Undefined 16384
15 Watt alarm 32768
The following is an example of two lines in the Values.csv file. Note that Tip 1 is in manual mode, On and
has a low alarm. Tip 2 is in Automatic mode, On and has a low alarm.
Tip 1,351.2,29.7,.87,94.1,1,1,2176
Tip 2,350.7,26.5,.79,89.4,0,1,128
Adding the setting Values=0 to the Setpoints.txt file will cause the automatic updating to stop. This may
improve performance at the TTC. Note that the setting of Values=0 or 1 is NOT SAVED when the TTC is
powered down or exited and restarted. The power up default is to not create the file.
Adding Scale = C to the Setpoints.txt file causes both the AllSetpoints.txt process temperature setpoints
and the Values.csv process values to be reported in degrees C. Scale = F causes those values to be in
degrees F. The power up default is degrees F. The scale setting is NOT SAVED when the TTC is powered
down or exited and restarted.
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International Interface
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International / Windows XP
International
Windows NT
Operator Panel Comparison
Operational Features
Maximum zones 129 256
International Menu storage 10 1000
Interface Programmable groups 4 20
Auto load manual remembered % output X
Operator identification X
Tool graphics with real time data overlay X
Thermocouple "rewire" X
On-line help X
Volts, Watts, Ohms display X
Alarms
Heater resistance monitoring (predict failure) X
Heater wattage monitoring (predict leaks) X
Alarm history X
Software Features
Gammavision (SPC data/graphing) X
Touchscreen Instant data reporting (up to 24 hours) X
Mold Doctor (advanced troubleshooting) X
Interface
Field Calibrator X
On screen printing X
Networking X
Remote troubleshooting X
Inputs
Sequenced power up (also manually activated) X
Remote boost X
Figure 23.2 Comparison of Features Available with International Interface and Touchscreen
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134
135
136
137
138
139
140
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Mold ID
An HA10 connector is mounted on the back of the controller if the Mold ID is specified. The tool number
is determined by reading the position of a set of user-installed jumpers on the connector‟s mating connector.
An internal digital input module sends a low level voltage through the HA10 and reads the signals coming
back from the mating connector. The information is then conveyed to the TTC 2100 operator panel via an
ethernet connection.
This mating connector is placed into a connector hood. The assembly is latched onto the controller when the
tool is connected to the controller.
The connector and hood act like a “Mold ID key”. The mold would ideally include a latching hood for
storage of the key while the tool is not loaded into the press. When production is done with the tool, the
mold is removed from the machine, the key is attached to the mold and they are placed back into storage.
The next tool to be run is brought to the machine, the power and T/C cables are attached, and the key is
connected to the controller.
Mold ID continuously monitors the inputs. It watches for instances where the address key is attached and
detached. When the address key is attached, no action is taken for several seconds to verify that the
connection is permanent. Mold ID loads menus only when the Mold ID address key connection is made.
No action will be taken if the Mold ID is changed while the address key is still attached. The user can still
use the hot runner screens normally by changing setpoints, saving menus and restoring menus.
Use the table provided (Table #1) at the end of this document to install the correct combination of jumpers.
In Figure 24.2b, the jumper pattern shown would be associated with a Mold ID “5”.
It is recommended that the insert be attached to the mold to ensure that the correct key is used with each
mold.
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HA 10 MALE INSERT
WITH ADDRESS JUMPERS HOOD
INP UT 2 M
- O LD ID
A DDRESS +1 7 2 INP UT 3 -M O LD IDA DDRESS +2
INP UT 4 M
- O LD ID
A DDRESS +4 8 3 INP UT C O M
INP UT 6 M
- O LD ID
A DDRESS +1 6 9 4 INP UT 5- M O LD IDA DDRESS +8
REAR VIEW
H A 1 0 M A LE INSERT
Pressing the Menu Selection button on the top of the screen causes the following screen shown in Figure
24.3a to appear.
The Status section of the screen shows the condition of each of the inputs and the Mold ID address that has
been determined.
The table shown in Figure 24.3a lists the menus that have been linked to the Mold ID addresses. The menu
listed next to each Mold ID is the menu that will be automatically entered when the mold key (HA10 with
jumper pattern covered by mating connector) is attached. If a menu has been deleted by the user, but is still
shown on this table, that menu will be highlighted with a yellow cell background.
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Figure 24.3a Mold ID Menu Selection
Pressing on a Menu to Restore cell on the grid will display a list of menus that are present within the TTC
2100 (shown in Figure 24.3b Mold ID Menu Listings). The menu that is selected from the list is placed into
the Menu to Restore cell location.
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A menu can be removed from the table by selecting that menu and then selecting the blank menu entry “- - -
- - - - -“ from the list of available menus. No action is taken when an address key attachment is made for a
Mold ID that does not have a menu selected for it.
Pressing the Setup button on the top of the screen causes the following screen in Figure 24.3c to appear:
Placing a check in the box for Enable Menu Restore enables the Mold ID program to automatically
perform the menu restore operations when a mold is attached. This setting cannot be changed while at the
Monitor security level. Operator, Supervisor or Engineer security level is required.
Placing a check in the box for Turn OFF Outputs When Mold ID is Disconnected causes the TTC 2100
to turn off its outputs when the mold is disconnected from the TTC. This setting cannot be changed while at
the Monitor security level. Operator, Supervisor or Engineer security level is required.
A box is used to display the IP Address of the input module. The address can be changed by touching one
of the numbers. This will to bring up the numeric entry window. Each number is entered separately. The
Engineer security level is required to change this address.
Place a check in the box for Update Inputs to read the inputs from the input module. If this box is not
checked, the last jumper pattern read will be maintained.
The Exit to Windows button should not be used to leave the Mold ID screens. Use the TTC 2100 button
for that function. The Exit to Windows button will cause the TTC software to terminate and Windows
software to appear. See Section 13.6 Exit to Windows for more information
To avoid accidental installation of a menu, the following procedures have been put in place:
No menu restore action will be taken when the Mold ID program is started.
No menu restore action will be taken when communications with the input module is enabled
by checking the Update Inputs on the screen.
No menu restore action will be taken when communications with the input module is enabled
by checking the Enable Menu Restore on the screen.
No menu restore action will be taken when communications with the input module has been
re-established after a loss of communications.
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24.4 Mold ID Pin Configurations
The following diagrams show the jumper pin configurations for each Mold ID.
MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS
#1 #2 #3 #4 #5 #6
6 1 6 1 6 1 6 1 6 1 6 1
7 2 7 2 7 2 7 2 7 2 7 2
8 3 8 3 8 3 8 3 8 3 8 3
9 4 9 4 9 4 9 4 9 4 9 4
10 5 10 5 10 5 10 5 10 5 10 5
MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS
#7 #8 #9 #10 #11 #12
6 1 6 1 6 1 6 1 6 1 6 1
7 2 7 2 7 2 7 2 7 2 7 2
8 3 8 3 8 3 8 3 8 3 8 3
9 4 9 4 9 4 9 4 9 4 9 4
10 5 10 5 10 5 10 5 10 5 10 5
MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS
#13 #14 #15 #16 #17 #18
6 1 6 1 6 1 6 1 6 1 6 1
7 2 7 2 7 2 7 2 7 2 7 2
8 3 8 3 8 3 8 3 8 3 8 3
9 4 9 4 9 4 9 4 9 4 9 4
10 5 10 5 10 5 10 5 10 5 10 5
MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS
#19 #20 #21 #22 #23 #24
6 1 6 1 6 1 6 1 6 1 6 1
7 2 7 2 7 2 7 2 7 2 7 2
8 3 8 3 8 3 8 3 8 3 8 3
9 4 9 4 9 4 9 4 9 4 9 4
10 5 10 5 10 5 10 5 10 5 10 5
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HA10 MALE INSERT - REAR VIEW
MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS
#25 #26 #27 #28 #29 #30
6 1 6 1 6 1 6 1 6 1 6 1
7 2 7 2 7 2 7 2 7 2 7 2
8 3 8 3 8 3 8 3 8 3 8 3
9 4 9 4 9 4 9 4 9 4 9 4
10 5 10 5 10 5 10 5 10 5 10 5
MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS
#31 #32 #33 #34 #35 #36
6 1 6 1 6 1 6 1 6 1 6 1
7 2 7 2 7 2 7 2 7 2 7 2
8 3 8 3 8 3 8 3 8 3 8 3
9 4 9 4 9 4 9 4 9 4 9 4
10 5 10 5 10 5 10 5 10 5 10 5
MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS
#37 #38 #39 #40 #41 #42
6 1 6 1 6 1 6 1 6 1 6 1
7 2 7 2 7 2 7 2 7 2 7 2
8 3 8 3 8 3 8 3 8 3 8 3
9 4 9 4 9 4 9 4 9 4 9 4
10 5 10 5 10 5 10 5 10 5 10 5
MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS
#43 #44 #45 #46 #47 #48
6 1 6 1 6 1 6 1 6 1 6 1
7 2 7 2 7 2 7 2 7 2 7 2
8 3 8 3 8 3 8 3 8 3 8 3
9 4 9 4 9 4 9 4 9 4 9 4
10 5 10 5 10 5 10 5 10 5 10 5
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HA10 MALE INSERT - REAR VIEW
MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS
#49 #50 #51 #52 #53 #54
6 1 6 1 6 1 6 1 6 1 6 1
7 2 7 2 7 2 7 2 7 2 7 2
8 3 8 3 8 3 8 3 8 3 8 3
9 4 9 4 9 4 9 4 9 4 9 4
10 5 10 5 10 5 10 5 10 5 10 5
MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS MOLD ID AD D R ESS
#55 #56 #57 #58 #59 #60
6 1 6 1 6 1 6 1 6 1 6 1
7 2 7 2 7 2 7 2 7 2 7 2
8 3 8 3 8 3 8 3 8 3 8 3
9 4 9 4 9 4 9 4 9 4 9 4
10 5 10 5 10 5 10 5 10 5 10 5
6 1 6 1 6 1
7 2 7 2 7 2
8 3 8 3 8 3
9 4 9 4 9 4
10 5 10 5 10 5
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Screen Simplification
Section 12.3 Security Levels describes how the security level can determine what functions and screens are
visible on the TTC 2100 monitor. In addition, if the operator does not want to use one or more of the
following functions, these screens can be hidden in order to further simplify the screens displayed:
OK to Run Status
Sequence Start
Even Cool
% Copy Output
Pdfs
To remove any of these screens, the file D:\TTC2100\Gammaflux.txt must be edited. To do this:
1. Exit the TTC 2100 software (as described in Section 13.6 Exit to Windows) by going to Diagnostics and
pressing Exit to Windows. The engineering security level and password is required to exit.
2) Attach a standard PC keyboard to the operator panel. The operator panel may have to be restarted to
recognize the keyboard.
3) Open the file D:\TTC2100\Gammaflux.txt using Notepad.
4) To disable a function, enter the corresponding line of text from below and save. For example, to
suppress the Even Cool screens, type DisableEvenCool = 1 as a line item in the file and save.
DisableMonitorZones = 1
DisableOkToRunStatus = 1
DisableSequenceStart = 1
DisableEvenCool = 1
DisableCopyOutput = 1
DisablePdf = 1
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Troubleshooting
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3) The data concentrator may be bad. – Replace the data concentrator. Anytime a data concentrator is
replaced, make sure the address selector switches on the new module are set to the same value as the
one being replaced.
Also, the zone could be miswired, receiving heat from another zone‟s heater. Run Mold Doctor.
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CAUTION: ALWAYS LOCK OUT/TAG OUT THE AC POWER MAIN
CIRCUIT BREAKER BEFORE REMOVING OR INSTALLING TEMPERATURE OUTPUT
MODULES.
26.10 One Zone High Temperature with Very Low Heater Percent
Output, Another Zone has Persistent Low Temperature with
High Heater Percent Output
The tool power or thermocouple cables are cross-wired. Run Mold Doctor Wiring Analysis to determine
the problem.
1) Watch the zone in question. When the % output drops off, start timing and continue timing until the %
output returns to the original level and then drops off again. If this period of time is repeated
consistently, the thermocouple is most likely loose. Instantaneous changes in temperature that are
inconsistent or erratic are probably due to a broken wire or loose connection in the thermocouple
wiring.
2) There is also a possibility that the thermocouple wires may have AC power wired to them.
This usually indicates that one of the three phases is either missing or running at too low of a voltage. This
can be checked using the View Voltages screen described in Section 13.6 View Voltages.
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Attaching a Printer
The user can attach a printer to the back of the TTC 2100 screen. The procedure is dependent upon the
hardware and software version of the TTC 2100. Please contact Gammaflux for assistance in setting up a
printer.
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Maintenance
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Training
A TTC 2100 Basic Operation Video is delivered with the TTC 2100 that describes normal everyday use of
the TTC 2100. Training is also available from Gammaflux on the TTC 2100 controller. Please consult
Gammaflux using the contact information shown on the front cover of this manual to inquire about
upcoming training classes and locations.
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