Nolden5000 Usermanual

Operations manual NR5016
NR5016
Hotrunner
Multizone
Temperature controller
Operations manual
Nolden Regelsysteme GmbH

Gewerbegebiet Volmershoven
Am Tonschuppen 2 · D-53347 Alfter
++49/ 228 64 48 56 · ++49/ 228 / 64 03 09
info@nolden-regler.de
© 01/11 All rights reserved V2.0
NOLDEN Regelsysteme GmbH

Dear customer,
thank you for having chosen a NOLDEN temperature con-

troller. This high quality device has been produced in our
ISO 9001-certified factory and was shipped to you after a
thourough quality test.
Unpack Check the device for eventual shipping damage.

Don't connect damaged equipment !
Claim the damage with your shipping agent.
Read Please read carefully this operating manual be-

fore bringing the device into service !
Connect Wiring the device should be done by your quali-

fied electrician following the instructions given in
this manual.
Warranty period is 2 years and includes all malfunctions

clearly caused by material, production or design
failures. Repair or replacement in this case are
free of charge, you only pay the shipping cost to
our factory. No further claims or requirements
can be accepted, especially for consequential
losses or damages.
Service We help you quickly and at resonable costs.

Just send us the device with repair order and
precise description of the malfunction.
NOLDEN Regelsysteme GmbH 2

Carefull packaging is essential for a safe shipment !
Small repairs up to 80,- EUR are done immediately without

formal offer. In any other case, we contact you as soon as
possible to determine the next steps.
To facilitate your orientation in this manual, you find the

following symbols :
Safety advice
General information
Wiring- and installing advice

Table of content
Chapter Page
1 Features 5
2 Safety advice 6
3 Specification 8
4 Applications 10
5 Operating elements
5.1 Installation 11
5.2 Power supply 11
5.3 Heater and TC connection 11
5.4 Alarm wiring 13
6 Operation
6.1 Operating elements and keys 16
6.2 Bringing into service 19
6.3 Operation menu levels 27
6.3.1 Configuration level—general settings 30
6.3.2 Configuration level—individual settings 38
6.3.3 Parameter level 43
6.3.4 Operation level 48
7 Automatic start-up options 51
8 Error messages 52
9 Default settings 54
10 CE-Conformity declaration 55

1. Features
Ready to use compact multizone temperature controller

for all 230V hotrunner systems
- Compact unit for up to 16 zones
- Particularly designed for hotrunner applications
- Automatic self-tuning for every zone
- Safety load-shedding for process-high temperature
- Common start-up for all zones possible
- Boosting for „frozen“ nozzles possible
- Integrated heater current monitoring
- Intelligent, programmable soft start routine
- Programmable alarm settings for every zone
- Various self-monitoring functions

2 Safety advice
1. Please read this advice carefully.
2. Keep this operations manual for use near the

machine.
3. This is an electral device driven with high

voltage, please respect the usual VDE- and
safety regulations.
Mains voltage and every voltage greater than 42
volts is dangerous !
4. Connect to a power source following the

identification plate on the device.
5. Avoid contamination of the interior with debris,

liquids or sprays.
Risk of short-circuit, fire or electric shock !
6. Before cleaning the device, disconnect from the

power source.
7. Don‘t place the device on hot machine surfaces

or near radiation sources of hot parts.
8. Keep the power connection cable clear of hot

parts or sharp edges.

9. Disconnect the power cable immediately, if

- it was damaged,
- liquid or parts penetrated the device,
- the device was damaged by falling down or
other mechanical impacts,
- you have the suspicion of any malfunction.
10. The operator must be thoroughly instructed by

a qualified person for the work to be carried out.
11. Intervention at the device must only be carried

out by qualified staff members.
For repair, the device should be send back to

our factory. Attempted self-repair causes
immediate termination of the warranty period !
If spare parts are required, only parts recom-

mended by the supplier must be used. The use
of other parts may cause damage and/or
hazard for operation personnel.
12. Please respect further recommandations and

warnings described in this operations manual.

3. Specification
Mains voltage :
230/240V +/- 10%, 48...63 Hz
Nominal rating/nominal current :

17,25kW / 3 x 25A total
Heating-load per zone :

3,5 kW/16A
Fuses :
16A FF, 6,3x32mm, heating-loads
1,6A mT, 5x20mm, controller
Power control :
0...100% proportional,
zero-voltage switching
Automatic soft-start :
(factory defaults)
manipulated-value 50% / temperature 80°C /
time 5 min
LED-display :
Indicates actual values, set-points, configuration
parameters, load-current, alarms, tendencies
Sensor inputs :
Thermocouple Fe-CuNi, type J, 0...800°C
Internal zero point correction
Thermocouple is monitored for cable breakage,
short-circuit and polarity errors.

Standby / alarm-exit :
7-pin plug:
2 floating n.o. contacts (230VAC, max. 3A) for alarms.
One floating input to activate the 2nd (standby-)
temperature-value for all zones simultaneously, wired
in parallel with the internal “stand-by” switch.
Safety load-shedding :
Disconnection of all heating loads in case of process-
high alarm.
Sensor-/load-connectors :
16 or 24-pole standard-industry female plug 16A/400V
Accuracy :
0,25% FS
Insulation voltage :
2,5kV mains/sensor circuit
Dimensions :
570 x 180 x 340mm (w x h x d)
Colour :
Textured RAL7035 top/ground
RAL3020 side-parts
Weight :
ca. 12kg

4. Application :
The NL5000-concept was specially designed for

hotrunner-applications and therefore comes-up with
high temperature-stability, easy operation and
numerous self-monitoring-features.
All units are usable regardless to the mould
manufacturer.
This ready to use high quality temperature

controller offers an economic solution for use with
hotrunners up to 16 zones with heating loads up to
3,5kW per zone. The thermal characteristics of
every zone are analysed individually and the
controlling behaviour is automatically tuned
accordingly.

5. Installation and wiring :
5.1 Installation :
The installation site must provide easy access for
the operator without hazard. Sufficient mechanical
stability must be guaranteed, also secure the device
from slipping on the installation surface.
Protect from heat, radiation and allow free air circu-
lation. Protect power cable from heat and mechani-
cal stress. Do not place the device on hot surfaces.
5.2 Connection of the power supply :

This device must only be operated at the voltage
indicated on the name plate. Please check for a
sufficient fuse protection of the power outlet fore-
seen for the device.
Protective earth conductor must be provided !
L1
L2
L3
N
PE
5.3 Connection of heater and thermocouples :

Please compare the connecting diagram on the
temperature controller (backside, near the outlet)
with the diagram of the mould. Inappropriate
connection can destroy controller, heater and TC !
Available mould connecting cables contain heater–
and FeCu-Ni compensation wires for TC. Never use
compensation wires to connect a heater.

Maximum load capacity for the heater when using

mould connector VK24 (24-pol. + PE) or VK16 (16-pol.
+ PE)
The maximum load capacity of the heater wires

(1,5sqmm Cu) depends on the operating conditions (see
also DIN VDE 0298 Part 2 and 4).
@ op. condition : Continuous

@ wire location : Individually, free installation on wall
or floor
@ ambiant
Temperature : 30°C, free air circulation, no heat
radiation
VK 24 : VK 16 :
1 heater 12,5 A 1 heater 12,5 A

2 heaters 12,5 A 2 heaters 12,5 A
5 heaters 10,0 A
6 heaters 9,5 A
Heater– and TC-wiring

5.4 Alarm-/ Standby connection :
For every zone, two alarm functions can be pro-

grammed individually. These alarms operate 2
common floating contacts as cumulative exits for all
zones together, thea are wired on a 7-pin connector
on the back side. Default settings are one process-
high temperature alarm (A1, pin 4 and 5) as well as
one load-breakage alarm (A2, pin 2 and 3).
Exit A1 activates also the load shedding for all
zones, this function can be switched off with a
button on the pront panel.
To activate the 2nd temperature set-point (stand-by

function), another floating contact is wired to pin 6
and 7. This function can also be activated manually
with a button on the front panel.

Back side NR5000
1 Heater- and TC-connector
2 Auxiliary voltage fuse
3 Alarm connector
4 Power cable
5 Bus terminal (option)
Location of the heater load fuses on the side (shown :

right side)

Front view NR5000
1 Operating panel, see chapter 6.1 for details
2 Stand-by button, activates 2nd set-point
3 Mains indicator lights (3 phases)
4 Manual boost, temporary temperature increase
5 Mains masterswitch
6 Manual controller autotuning
7 Disable automatic load-shedding
8 Quick start guide

6. Operation
6.1 Operation panel and keys
1 Actual value zone 1…. n

2 Display „Parameter“
3 Display „Set“ - actual value of the parameter shown
in 2)
4 Display „Zone“
5 Key „Zone“ - Steps up one zone
6 Key „Up“ - increases the parameter shown in 3)
7 Key „Para“ - selects parameter for the zone 3)
8 Key „Down“ - decreases the parameter 3)
9 Function key „F1“ - shows actual power setting in %
for all zones simultaneously (default function, can be
programmed)
10 Key „Enter“ - confirms parameter entry
11 Function key „F2“ - toggle switch for different groups

Key description
Zone selection
• Steps up the display „Zone“ by one

• Actual parameter and set-point for this zone are
being displayed
• After the last zone, the display goes back to „0“
Parameter preselection key
• Toggles between the different sets of

parameters of the chosen zone
• Changes made with the „Up“ and „Down“ keys for
the chosen parameter are reset to the initial value, if
not confirmed with „Enter“
• Automatic reset to the initial value, if not confirmed
within 30 seconds
Enter key
• Confirms parameter changes and

takes them over in actual control
• For confirmation, a running point is shown

temporarily in the set-point display „Set“

F1-Key
• Switches displays 1 to actual power

setting for all zones simultaneously
• Function only temporary, as long as the key is hit
• More functions of this key can be programmed via

zone „0“ in the different configuration menus
F2-Key
• Preselection of the values shown in

displays 1 (see below „Display : Actual values and
set-points)
Up / Down-Keys
• Increase or decrease of the chosen

parameter to the desired set-point
• One step if key hit shortly, quick run if key pressed

continuously
• Chosen set-point twinkles dark/light on the display

„set“, if not yet confirmed by „Enter“

6.2 Bringing into service
After wiring the device following chapter 5, press the

mains master switch, all green control lights must
now be on. During initialisation of the controller (1-2
sec.), all displays are lit.
During first start-up, the following default settings
are programmed from the factory for all zones :
- Temperature set-point 150°C

- Boosting 5°C
- 2nd Temperature set-point 100°C
(stand-by)
- Soft-start powersetting 50 %
- Soft-start temperature 80°C
- Soft-start duration 5 min
- Process-high Alarm A1 +50°C
(safety load shedding)
- Heater breakage Alarm A2 < 1A
- Residual current Alarm > 1A
(solid state short-cut)
The controller starts in the overview of all zones with

the actual temperature, zones not wired to a heater
show „heater error“. Therefore, we recommend to
switch them off as shown in the following chapters.

Display : Actual values and set-points
After start-up, the actual process values and set-points of

zones 1… 4 are being displayed :
P.SPx :
P: Process value (actual) to be displayed
SP1: Set-point 1
SP2: Set-point 2 (2nd set-point, if activated by external
contact „SP2 enable“ or button on the front panel).
01.04:
Display of the chosen value for Zone 1… Zone 4
Press key F2 : Toggle to actual process values and set-

points of Zones 5… 8 :
05.08:


09.12:

13.16:

Press key F2 : Toggle to actual process values

alternating between Zones 1… 8 /
Zones 9 ...16 :
Proc: Process values

Display of the chosen value for Zone 1…8 and
Zone 9...16, alternates every 5 seconds
Set : Shows the zones being displayed

01.08 : Zone 1...8
09.16 : Zone 9...16

Pressing key F2 again shows the temperature tendency

display :
tEn.: Tendency display (see chapter „Tendency display“)
01.16 : Zones 01...16
Press key F2 : Toggle to alarm status Zones 1… 16 :
1: Alarm A1 active
2: Alarm A2 active
-: no alarm on this Zone
01.16 : Zones 01...16

Press key F2 : Toggle to heater current Zones 1 … 8 :
Cur. : Current, heater process value

1. 8 : Zones 1...8
Press key F2 : Toggle to heater current Zones 9 … 16 :
Cur. : Current, heater process value

9. 16 : Zones 9...16
Press key F2 : Toggle back again to actual process

values and set-points of Zones 1 … 4

Tendency display
Please read the temperature tendency display as

follows :
For every zone, one 7-segment-display element is

available, the symbols are to be interpreted as
shown below :

Alarm status A1 and A2 :
For every zone, one 7-segment-display element is

available :
Element A :
Display = 1 , if Alarm exit 1 for this zone is active
Display = 3 , if Alarm exit 1 and 2 for this zone are active
Element C :
Display = 3 , if Alarm exit 1 and 2 for this zone are active
More Explanations can be found at chapter

„Configuration menu“
Example:
26
6.3 Operating levels
The operation of the controller is to carried out for

every zone in 3 configuration and operation menus.
In „Zone 0“, general configurations for the entire
device can be made.
Attention:
Changes made in „Zone 0“ can lead to malfunctions
of the controller, as some parameters are directly
related to the hardware of the device (e.g. the
sensor inputs). Normally, the device is preset in the
factory ready for use and no changes have to be
made.

Operating level (for every zone individually) :

In this level, set-points and alarms are entered. The set-
point is adjusted (as every other parameter) with the „UP“
and „DOWN“ keys. Every entry needs to be confirmed
with „ENTER“.
By pressing the „PARA“ key, all the other parameters
(e.g. alarms) of the operating level can be selected and
adjusted via the „UP“ and „DOWN“ keys.
Parameter level (for every zone individually) :

In the parameter level, the adaptation of the controller to
the controlled system and the functional criteria is made.
Access the parameter level by keying „PARA“ and
„ENTER“ at the same time (less than 5 sec.). Selection
and adjustment of the parameters are made as described
above for the operating level.
Configuration level - general settings: Access via

„Zone 0“ :
Configuration level can be accessed by keying „PARA“
and „ENTER“ at the same time at least 5 sec. . By
selecting the configuration level in zone 0, general
settings for the entire device can be changed. Please
take the actual, invariable hardware of the controller
(wiring of the sensor inputs) into account !
28
Configuration level - individual settings for every

zone: Access via „Zone 1 … 16“ :
Configuration level can be accessed by keying „PARA“
and „ENTER“ at the same time at least 5 sec. . By
selecting the configuration level in every individual zone,
settings and functional criteria for this zone can be
changed.
• Controller configuration
• Sensor configuration
• Set-point limits
In every configuration level, a copy function is avalable to
easily copy parameters of one zone to others or all zones.

6.3.1 Configuration level - general settings:

(for all zones, access via „ZONE 0“ and keying
„PARA“ and ENTER“ at the same time for 5 sec. )
Display Parameter Display

"Parameter" „SET“
P- tc Sensor inputs wired by the factory,

changes lead to
malfunction !
Co.A1 Configuration
Alarm 1 OFF alarm OFF, no
alarm signalisation
(ex works)
1 signal contact
off - on
2 limit contact
off - on
3 limit comparator
off - on - off
4 signal contact
on - off
5 limit contact
on - off
6 limit comparator
on - off - on
7 limit comp. with
start-up
suppression
off - on - off
8 Heater current
limit contact
off - on
9 Heater current
limit contact
off - on
30
Please note :
The individual temperature alarms A1 of all zones are
connected to the main, common contact A1 (switches
relay A1). The selected configuration is effective for all
control zones.
Care should be used to ensure, that the setpoints of the
alarm contacts are programmed within the selected
measuring range. If a setpoint ramp has been
programmed, the alarms that are relative to the setpoint
(signal contact, limit comparator) follow the setpoint up
the ramp.
In case of sensor error the alarms will react in the same
way as range override. The alarm contacts therefore do
not offer protection against all types of plant breakdown.


rE.A1 Relay A1 dir on: LED = „1“

switching Relay A1 "activated"
Behaviour off: LED = „1“
Relay A1"not active"
inv on: LED = „1“

off: LED = „1“
Relay A1 "activated"
Co.A2 Alarm 2- see Co.A1 (alarm 1 - configu-

Configuration ration)
rE.A2 Relay A2 dir on: LED = „1“

switching Relay A2 "activated"
Behaviour off: LED = „1“
inv on: LED = „1“

off: LED = „1“
Relay A2 "activated"
32
Current monitoring
The following parameters are only displayed, if the

current monitoring is activated as follows :
Monitoring by relay A1 :
Alarmconfiguration
Co.A1 set on „8“ or „9“
Monitoring by relay A2 :
Alarmconfiguration
Co.A2 set on „8“ or „9“
In both cases, the current value to be monitored needs to

be set as an absolute value in the operating level.
See : Operating level, Parameter „A1“ or „A2“ (page 50)
Please define this value in a way that eventual voltage

drops in the mains power do not lead to a underrun of the
current, if not, the alarm is switched.
If the current drops below the chosen value, the alarm

(switching of the relay) is delayed by the time defined as
Parameter „dL.Ax“. This assures that a faulty
measurement or peak value does not switch the alarm
immediately.
After switching the mains power on, the alarm is also

suppressed until the current values of all zones are
correctly measured for the first time.
All monitoring functions described above and the associa-

ted settings are active on all zones.


dL.A1 Alarm delay 5 Steps

If Alarm A1 is OFF = no delay
set for current
Monitoring Setting and display in seconds
The Steps are calculated

internally with the following
formula :
dL = Zn x Cu.CY x F
with
dL = Alarm delay
Zn = Number of active zones
Cu.CY = Current monitoring
interval
F = fixed delay factor (internal)
Factory default setting = OFF
dL.A1 Alarm delay 5 Steps

If Alarm A2 is OFF = no delay
set for current
Monitoring Setting see dL.A1
Cu.CY Current 1 … 60 sec.

monitoring Time between the current
interval measurements of two
subsequent zones
34
Cx.x Min. residual OFF; 0,0 … 99,9A

Current Monitoring of the heater
Threshold circuit for eventual
permanent current due to
SSR short-cut
Normally, solid state relays (SSR) always show

a residual current, particularly if wired with a
RC-circuit. These residual currents sum up and
can lead in total to a noticeable permanent
residual current. This actual residual
current is indicated in the display „PARAMETER. In the
display „SET“, a minimum residual current threshold can
be programmed, such as this current is not taken into
account for the alarm.
If a permanent current is measured in one zone, the
alarm relay switches and the display indicates „Er.Cu“ just
like a current value undershooting.
The zone in which the permanent current is measured
should then checked by verifying the actual temperature
(actual value too high?).
In this case, no specific identification via the tendency or
alarm display takes place.
Residual current: 0,2A

Residual current treshold : 1,0A
Residual current detected in one zone, error blinking :


Sync Zone synchro- ON enabled

nisation OFF disabled
This function assures equal

heating of all zones. Quick
zones such as light hot tips are
slowed down to make sure that
all zones reach the assigned
set-point temperature at the
same time.
Caution : If a softstart is enabled, this is

done first at start-up. Then,
zone selftuning takes place,
thereafter, zone synchroni-
sation performes common
heating of all zones to the
assigned set-point.
Co.F1 Select function OFF no function

of „F1“ key OPt. Selftuning algorithm
can be activated by
pressing key „F1“
in the selected
zone. „F1“ and „E“:
stop selftuning.
Y Shows the actual
percentage output
ratio, while pressing
„F1“in display
„PARAMETER“: Y
36
LEd.t Lamp (LED) test,

while pressing „F1“.
LOC Adjustment lock OFF No adjustment lock

(factory default)
P C Parameter and
configuration
levels locked
n.SP1 All parameters
except SP1 locked
(not SP1)
ALL All parameters
locked
All parameters that have been locked with
„LOC“ can be selected and read,but not altered.
Zo.OF Zones offset OFF No offset selected

preselection Zones indication
1 … 16
1 –91 Zones are
numbered with
selected offset,e.g.
Zo.OF = 16 ->
Zone numbering
17 … 32
Prot disabled
Adr disabled
For disabled
bAUD disabled
Adr disabled
tiM disabled
bAUD disabled
21xx disabled
EL.xx Control number
No function. End of configuration level

6.3.2 Configuration level - individual settings for zone

1 … 16
(selection via zone „n“ and pressing key „Para“
and „Enter“ simultaneously for appr. 3 sec.)

ZonE Zone on/off OFF Measuring or

heating zone off
on Measuring or
heating zone on
ConF Controller 2P h 2-point controller

(not alterable)
Sen Sensor J8°C Thermocouple

configuration FeCuNi, Type J
0 … 800°C
Pre-determined by device wiring, changes lead
to malfunction !
SP.Hi Higher set-point Programming range

limitation top end
SP.Lo Lower set-point Programming range

limitation bottom end
38
COPY Copy function to 1 ... to x

Copy all configuration data of
the actual zone 1 to zone x.
Select the target zone 1, 2 ....
or „to A“ (all) with the „up /
down“ - keys and press
„E“ (enter). After this, the
data will be copied.
SoSt Softstart OFF Softstart disabled

On Softstart enabled,
select following
parameters
So.Y Softstart output ratio 10 ...100%
So.SP Softstart setpoint Range SP.Lo … SP.Hi
So.ti Softstart duration OFF; 0,1 … 10,0 min
General remarks about softstart :

During the softstart, the controllers output response is
limited to a preselected ratio, in order to achieve a slow
baking out of high performance heating cartridges.
Simultaneously, the output clock frequency is quadrupled.
Once the process value reaches the softstart setpoint, it

remains stable at this value for a preselected hold-
duration time. At the end of this period, the process value
rises to the assigned setpoint.

If the softstart is active, the controllers autotune function

cannot be operated (Er.OP).
If a setpoint-ramp has been programmed, the softstart
has priority, and the ramp will only become active after
the softstart has been completed.
The softstart works, if
- the parameter „1 P“ (prop. band, xp) is program-
med > 0,1%.
- the controller is switched on and / or
- the actual temperature is below the softstart
setpoint So.SP minus 5% of the range
(e.g. range: 400°C -> 5%= 20°C).
The softstart can be activated and programmed for every

zone individually.
40
HAnd Manual output ratio OFF, Auto, Man
Setting: OFF Function not active
Setting: Auto
In the case of a sensor break, the
controller automatically maintains the
last valid output ratio as the actuating
signal.
Displays „process“:
Error warning „Er.H“ or „Er.L“
Displays 1...8:
„H“ (heating-function) will be
displayed in the first digit,
followed by the actual output
ratio value.
H99 = 100% heating
After selecting a zone (key „zone“), the

output ratio can be altered in steps of
min. 1%.
Display „PARAMETER“: Y.HA
Display „SET“: Actual output
ratio, -100...+100 %
To change, press
the „up/down“-keys.
Ackn. with „Enter“
Under the following circumstances, the

output ratio will be 0% :
- if the output ratio at time of
the sensor break was 100%.
- if the controller is working
along a setpoint-ramp.

- if the control deviation was

more than 0,25% of the total
range at the time of sensor
break.
- if the prop. band (P; xp) = 0.
- if the soft start was active at
the time of the sensor break.
Setting: Man
The controller now operates only as an
actuator. Within the operation level, an
output ratio can be entered instead of the
setpoint. In this case, the control action
(PID-function) is switched of.
Displays „process“:
Actual process temperature value
Displays 1...8:
„H“ (heating-function) will be
displayed in the first digit, followed
by the actual manual output ratio
value.
H99 = 100% heating
After selecting a zone (key „zone“), the

output ratio can be altered in steps of
min. 1%.
Display „PARAMETER“: Y.HA
Display „SET“: Actual output
ratio, -100...+100 %
To change, press
the „up/down“-keys.
Ackn. with „Enter“
42
6.3.3 Parameter level - individual settings for zone

1 … 16
(selection via zone „n“ and pressing key „Para“
and „Enter“ simultaneously )

Y valid output ratio 0...100 %

The output ratio shows
the actual calculated
output ratio in percent of
the installed heating
capacity. It cannot be
altered.
1Y.Hi output ratio limit 0...100 %

„heating“ Limitation of the output
ratio is only necessary
when the heating energy
supply is largely
overdimensioned
compared to the power
required. Under normal
circumstances, no
limitation is needed
(default setting = 0%).
The limitation becomes
effective, when the
controllers calculated
output ratio is greater
than the defined limit.
Warning!
The output ratio limitation does not work
during autotune.


1P Xp (prop.-band) OFF; 0,1 … 100%

„heating“ If „1P“ = OFF, continue
with parameter „1 Sd“
1d Tv (D-rate) OFF; 1 … 200 sec.

„heating“
1i Tn (I-rate) OFF; 1 ...1000 sec.

„heating“
Normally the controller works using PD/I
control behavior. This means, controlling
without deviation and with almost no
overshoot during start-up.
The control behavior can be modified by
making the following adjustments to the
parameters:
a. no control action, on-off
(setting P = OFF)
b. P-behavior (setting D and I = 0)
c. PD-behavior (setting I = 0)
d. PI-behavior (setting D = 0)
e. PD/I modified PID-behavior by
changing parameters P,d and i
44
1C Cycle time 0,8 sec. - fix

„heating“ The cycle time determi-
nes the switching fre-
quency of the actuator. It
is the total time to switch
on and off once.
1 Sd Control sensivity Only if: 1 P = Xp = OFF

output „heating“ (On-off action, without
feedback)
OFF; 0,1...80,0 °C
(factory default : 0,1)


OPt Selftuning OFF self tuning out of

(autotune) action
on self tuning on
request (once)
AUTO self tuning at
every start-up
The tuning algorithm determines the characteristic values

within the controlled process, it calculates the valid close-
loop parameters ( P,D,I ) and the cycle time ( C = 0.3 x
D ) of a PD/I-controller for a wide section of the range.
The self tuning during start-up activates shortly before the
setpoint is reached. The setpoint must amount to at least
5% of the total range.
If activated after the setpoint has already been reached
(„on request“), the temperature will first drop by approx.
5% of the total range, in order to detect the exact
amplification of the process.
During self tuning „Opt“ is shown in the display,alternating
with the setpoint value.
Self tuning active: „SPx“ flashes with „OPt“ - indication in
display „PARAMETER“.
The tuning algorithm can be activated at any time by

selecting the OPT=on and pressing the „E“-key. For all
zones simultaneously, it can be activated by pressing the
Key 6 on the front panel.
After having calculated the correct feedback parameters,

the controller will lead the process value to the setpoint.
46
Self-tuning can be stopped by selecting the option OPT =

OFF and pressing the „E“ - key.
Selftuning can also be activated by pressing the „F1“-key
after having selected the desired zone. To do so, the
„Co.F1“ parameter needs to be set to „OPt“.
Selftune in the „AUTO“-mode :

If this setting is chosen, selftuning is done at every start-
up (switching mains power-on) after having finished the
soft-start.
The selftune-setpoint equals the initial setpoint +3% of
the valid temperature range.
Example :
Initial setpoint = 100°C, valid temperature range = 800°C
-> selftune-setpoint is 124°C
The selftune process is only initiated, if all zones have

finished the soft-start phase.

OFSt process value -99 ... OFF ...100 °C

Offset -9,9 ... OFF ... 10,0°C
This parameter serves to correct the
input signal, e.g. for:
- the correction of a gradient
between the measuring point and
the sensor tip, or
- correction of the control deviation
when using P- or PD - behavior.
If for example the offset value is set
to +5°C, then the real temperature
measured by the sensor (when
process is balanced) is 5°C less
than the setpoint and the displayed
process value.
It needs to be ensured, that the process

value does not exceed the lower and higher
limit (SP.Lo and SP.Hi, see page 38) of the
temperature range incl. the offset value.
6.3.4 Operation level - individual settings for zone

1 … 16

SP1 Setpoint 1 SP.LO … SP.Hi
SP2 Setpoint 2 OFF; SP.Lo … SP.Hi

The 2nd setpoint is active for all
zones, if the „Standby“ switch on
the front panel is set or the exter-
nal contact „SP2 enable“is closed
(7-pin connector on the rear).
48
boSt Boostaddition 0 … 99°C

(Boost function to free „frozen“ hotrunner tips)
To the setpoint SP1, a constant boost value is
added.
Example : SP1 = 200°C, Boost = 10°C, then
boost setpoint = 210°C
The boost-setpoint is activated once for all
zones at every start-up (mains power on) or
manually at any time when the „Boost“-switch
on the front panel is pressed. After reaching
the boost setpoint once, the temperature is
automaticly lowered to SP1. Boostaddition is
only working for SP1, if SP2 is activated by
switch or external contact, boosting is not
available. Deactivating the boostaddition is
done by entering „0°C)
SP - rising ramp OFF; 0,1...100,0 °C/min.
SP - falling ramp OFF; 0,1...100,0 °C/min.
A programmed ramp is always activated when

the setpoint is altered or when the mains
supply is switched on.
The ramp defines itself out of the actual
process value and the pre-selected setpoint. If
the ramp is active, the corresponding LED
lights up on the operating panel. The ramp can
be activated for both SP1 and SP2.
By programming the second setpoint accor-
dingly, a setpoint profile can be obtained
(please see example next page).

Ramp function depending on „Standby“-switch or external

contact „SP2 enable“
A1 Alarm value A1 Temperature monitoring

(switches relay A1) (switching point)
Limit comparator, limit contact
OFF; -999 … 1000°C
OFF; -99,9 … 100,0°C
OFF; 9 … 1000°C
or
Heater current monitoring
(switching point)
limit contact
OFF; 0,0 … 99,9 A
ATTENTION : Alarm output A1 is internally wired
to a relay for load shedding at high
temperature, that means, when
A1 is activated, all zones are
simultaneously switched off.
If the safety function „load shedding“
shall be deactivated (f.e. during
optimizing of critical heaters), press
the switch (7) on the front panel.
A2 Alarm value A2 Temperature monitoring

(switches relay A2) (switching point)
See „Alarm value A1“
50
7. Automatic start-up options
As a factory default, the following functions are

activated for hotrunner use:
- Softstart
- Autotuning
- Zone synchronisation
- Boost addition
- Safety load-shedding,
linked to alarm output A1
Softtstart, autotuning and boost addition are set for

every zone individually.
Zone synchronisation is set for all zones together at
„zone 0“.
The controller software is defined such as at first,
all zones perform a softstart until the softstart
duration is expired. Thereafter, autotuning is done.
When all zones have finshed their autotuning, zone
synchronisation starts with parallel heating-up of all
zones until the boost-setpoint is reached. After one
zone has reached the boost-setpoint, this zone then
lowers down to setpoint SP1, all other zones
perform accordingly.
Setpoint SP1
Synchronised
heating-up
Autotuning
Softstart

8. Error messages
Error Meaning Corrective action, if any
SP.Lo lower temperature limit reached
SP.Hi higher temperature limit reached
LOC Parameter change is

prohibited (locked) deactivate lock (if
appropriate)
Er.H Top range end has Check sensor and cable

been exceeded
sensor defect
Er.L Bottom range end Check sensor and

has been exceeded cable
sensor defect
Er.OP Self tuning error Extinguish error signal by

pressing the „E“-key.
Check the self tuning
conditions and restart.
Er.SY System error Extinguish error signal by

pressing the „E“-key.
Check all parameters.
If the error signal con tinues, please
send the controller for examination.
Co.A1 Alarmconfiguration No alarm signal available

of alarm A1: OFF
52
8. Error messages
Error Meaning Corrective action, if any
Co.A2 Alarmconfiguration No alarm signal available

of alarm A2: OFF
Er.Cu Residual current Check

in one or more
zones
Can be caused by defective solid-state relay.

In this case, check actual process temperature
(must be too high).
Send the device to the
factory for repair.
-no- Parameter not

-pa- available in this
zone

9. Factory default settings
Common settings (zone 0) :

P-tc -16
Co.A1 1
rE.A1 dir
Co.A2 9
rE.A2 dir
dL.A1 OFF
dL.A2 OFF
Cu.CY 2
Cx.x 1.0
Synch ON
Co.F1 Y
LOC OFF
Zo.OF OFF
Individual settings (identical for all zones) :

ZonE on
ConF 2P h SP1 150°C
SEn J8°C SP2 100°C
SP.Hi 800°C boSt 5K
SP.Lo 0°C SP - OFF
So.St on SP - OFF
So.Y 50% A1 50°C
So.SP 80°C A2 1,0A
So.ti 5,0min
HAnd Auto
1Y.Hi 100%
1P 3,0%
1d 30sec.
1i 150sec.
1C 0,8sec.
1 Sd OFF
OPt Auto
OFSt OFF
54
DECLARATION OF CONFORMITY
This declaration is valid for the following products :
Device type: Multizone-Temperature controller

Model designation: NR5016
Hereby is confirmed, that these products meet in their design

and accomplishment as marketed by the manufacturer and if
properly used the following EU-directives :
EU-Low voltage directive (73/23/EWG)

EU-Directive for electro-
magnetic compatibilty (89/336/EWG)
Applicable harmonized norms: DIN EN 50081-2

DIN EN 50082-2
DIN EN 61010
This declaration is binding for the manufacturer
NOLDEN Regelsysteme GmbH

Am Tonschuppen 2 - Industrial estate Volmershoven
D-53347 Alfter - Germany
Alfter, 1st of August 2010 Hans Werner Müller, General manager

Nolden5000 Usermanual

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Operations manual NR5016

Nolden Regelsysteme GmbH

© 01/11 All rights reserved V2.0

NOLDEN Regelsysteme GmbH

thank you for having chosen a NOLDEN temperature con-

Unpack Check the device for eventual shipping damage.

Read Please read carefully this operating manual be-

Connect Wiring the device should be done by your quali-

Warranty period is 2 years and includes all malfunctions

Service We help you quickly and at resonable costs.

NOLDEN Regelsysteme GmbH 2

Carefull packaging is essential for a safe shipment !

Small repairs up to 80,- EUR are done immediately without

To facilitate your orientation in this manual, you find the

Wiring- and installing advice

NOLDEN Regelsysteme GmbH 3

7 Automatic start-up options 51

NOLDEN Regelsysteme GmbH 4

Ready to use compact multizone temperature controller

- Compact unit for up to 16 zones

- Particularly designed for hotrunner applications

- Automatic self-tuning for every zone

- Safety load-shedding for process-high temperature

- Common start-up for all zones possible

- Boosting for „frozen“ nozzles possible

- Integrated heater current monitoring

- Intelligent, programmable soft start routine

- Programmable alarm settings for every zone

- Various self-monitoring functions

NOLDEN Regelsysteme GmbH 5

1. Please read this advice carefully.

2. Keep this operations manual for use near the

3. This is an electral device driven with high

4. Connect to a power source following the

5. Avoid contamination of the interior with debris,

6. Before cleaning the device, disconnect from the

7. Don‘t place the device on hot machine surfaces

8. Keep the power connection cable clear of hot

NOLDEN Regelsysteme GmbH 6

9. Disconnect the power cable immediately, if

10. The operator must be thoroughly instructed by

11. Intervention at the device must only be carried

For repair, the device should be send back to

If spare parts are required, only parts recom-

12. Please respect further recommandations and

NOLDEN Regelsysteme GmbH 7

Nominal rating/nominal current :

Heating-load per zone :

NOLDEN Regelsysteme GmbH 8

NOLDEN Regelsysteme GmbH 9

The NL5000-concept was specially designed for

This ready to use high quality temperature

NOLDEN Regelsysteme GmbH 10

5. Installation and wiring :

5.2 Connection of the power supply :

5.3 Connection of heater and thermocouples :

NOLDEN Regelsysteme GmbH 11

Maximum load capacity for the heater when using

The maximum load capacity of the heater wires

@ op. condition : Continuous

1 heater 12,5 A 1 heater 12,5 A

Heater– and TC-wiring

NOLDEN Regelsysteme GmbH 12