We Build Productivity Molding Systems - Temperature Controllers... · • Separate leaflet Runnerless Molding Systems • Separate leaflet Temperature Controllers • Main Frames

D-M-E Belgium C.V.B.A. • Industriepark Noord G 1 • B-2800 Mechelen (Belgium) • Tel. +int. 32.15 / 21 50 11 • Fax +int. 32.15 / 21 82 35

8 / 8024038 - 0897 - E Printed in Belgium - MD76081

Molding Systems

Hot Sprue Bushings• Separate leaflet

Runnerless Molding Systems• Separate leaflet

Temperature Controllers• Main Frames• Control Modules with Digital Display

and Communication• Self-tuning Microprocessor - Based Auto PID

tuning, Dual Indicating T° Control Modules• Microprocessor Based T° Control Modules• Alarm and Standby Heat Modules• Digital Current/Voltage Monitor• Single Zone Microprocessor T° Controllers• Two Zone Main Frames

MOLDING SYSTEMS

TemperatureControllers

Hot SprueBushings

RunnerlessMoldingSystems

We Build Productivity

D-M-E Belgium C.V.B.A. • Industriepark Noord G 1 • B-2800 Mechelen (Belgium) • Tel. +int. 32.15 / 21 50 11 • Fax +int. 32.15 / 21 82 35

Molding Systems

Temperature Controllers

• MFPX/MFCPX/MFHPX/MFHCPX - Main Frames

• CSS - Control Moduleswith Digital Display and Communication

• DSS - Self-tuningMicroprocessor-Based Auto PID tuning, Dual Indicating T° control Modules

• SSMX - Microprocessor-Based T° Control Modules

• TAS - Alarm andStandby Heat Modules

• CVK Digital Current/Voltage Monitors

• ESH - Single ZoneMicroprocessor T° Controllers

• MFFPRX-2G - Two Zone Main Frame

Smart Series® Temperature Controllers

ContentsPage

Main Frames MF(C)PX - MF(C)PX/CV - MFH(C)PX - ................................ 3 - 11MFH(C)PX/CV - MFFPRX BenefitsDiversityFeaturesOrdering InformationWiringSpare Parts

Microprocessor-Based T° Control Modules and Communications - CSS ... 12 - 17

Microprocessor-Based Auto PID Tuning, Dual Indicating T° Modules - DSS 8 - 22

Microprocessor-Based T° Control Modules SSMX ....................................... 23 - 26

Temperature Alarm/Standby Heat Modules - TAS ....................................... 27 - 28

Digital Current/Voltage Monitors - CVK ........................................................ 29

Single Zone T° Controller - ESH .................................................................. 30 - 33

Two-Zone Main Frame - MFFPRX-2G ......................................................... 33

D-M-E Temperature controllers2



The best solution... ● to reduce electrical noise and heat levels

● For increased capacity

● to put you a ”step-ahead” in your operation

● for greater versatility and performance

● for simplified power hook-up

BenefitsHeavy duty constructionWith years of experience behind its design, the Smart Seriesline is built to last under the most rigorous conditions. TheMain Frame's all-welded 16 gauge steel construction insureslong life and peak performance. A high gloss industrial fi-nish adds further to its appearance and surface durability.Cooling fans in the frame are strategically located to increa-se air ventilation, maintain cooler running conditions, andpromote control module reliability.

Reduced electrical noise and heat levelsTo decrease electrical noise, D-M-E has harnessed powerand thermocouple wires in separate wire patterns within thebody of the frame. Another advancement in the wiring sys-tem features an increase in the wire gauge size from 18 to14 gauge to carry added amperage and reduce heat build-up. D-M-E's Smart Series is the result of intensive and de-dicated research with a goal of designing today's most ver-satile and reliable line of temperature controllers. D-M-Eachieved this goal by not only incorporating the latest tech-nology, but by also making certain that each controller re-mained easy to install and above all.. easy to operate.

CE RegulationThe newly introduced CE regulations for EMC and Low-Voltage lead to almost invisible product enhancements.Improved noise immunity, shielded T.C. and power wiring,screw fixtures for the modules and high current power con-nectors are the most eye-caching improvements made.User safety and product reliability have been ensured bymeeting the demands of the CE directives.

Completely self containedSmart Series Main Frames require no external relays orcontactors, since they are self-contained in each frame.Other systems often list these items separately or, in somecases, do not provide them at all ! The previous mentionedcompatibility with G-Series accessories can provide addition-al savings when ordering. For example, mold connectors al-ready purchased and installed on the mold or compatible ca-bles from a previous ordered package need not be repur-chased as part of a new system. These factors, combinedwith Smart Series improved features make it a "step-ahead"system that will put you a "step-ahead" in your operation.

Control modulesThe Smart Series modules are also available to provideeven greater versatility and performance. They include: theSSMX Temperature Control Modules (15 and 30 Amp); theCSS Temperature Control Modules (15 and 30 Amp); theDSS Temperature Control Modules (15 and 30 Amp) andthe Alarm and Standby-heat module (5 Amp).

The Smart Series control modules are easy to program andeven easier to monitor. A digital LED display provides set-point, percent power or process temperature information at aglance. Fault diagnostics for shorted, open or reversed ther-mocouple are also spelled out on the digital display. Multi-colored indicator lights provide quick reference for over orunder temperature conditions.

Simplified power hook-upConcern for user convenience did not stop with improvedoperating features. D-M-E went one step beyond to insurethat the power hook-up procedure goes smoothly as well.For this reason installation drawings have been printed di-rectly on the Main Frame back panel for quick availabilityand reference whenever needed. Furthermore, D-M-E hastaken great care to make the installation drawings simpleand direct so that all power hook-ups are quick and easy.



Diversity

1 2 3 4 5

L3

6

L2

7

L1

8

Np

SMARTSERIES D-M-E

L1

1

0

SWITCH POWER "OFF" BEFOREINSERTING OR REMOVING MODULES

L3L2

SWITCH POWER "OFF"BEFORE INSERTING ORREMOVING MODULES

SMARTSERIES

VOLTSCHECK "0"VL 1VL 2VL 3

0

D-M-E

SPMA

68

1

7

1

5

43

2

AUTO

SMARTSERIES

0

D-M-E

1

MANUAL

0°F0°C

SETPOINT

PROCESSTEMP

-20-11 -5

-10 +20+10+5 +11

MANUAL %

15 AMPS MAX

SMART START

SSMX-15G

PROCESSTEMP

240VAC

LOAD

°F/°C

Modules Volt/Amp Mon. Main FramesSSMX-15-G CVK-5 MFPX-5-C 4,5-G/CV

CVK-8 MFPX-8-C 4,5-G/CVCVK-12 MFPX-12-C 4,5-G/CV

MFPX-5-C 4,5-GMFPX-8-C 4,5-GMFPX-12-C 4,5-G

Microprocessor-Based T° Control Modules withDigital Display

AUTO

D-M-ESMARTSERIES

0 1

SMARTSERIES D-M-E


0

L3

21 3 54

°F/°C15 AMPS MAX

MANUAL

+5+10

SSMX-15G

0°C0°F

-11-20

PROCESSTEMP

SETPOINT

-10-5

PROCESSTEMP

240VAC

SMART START

MANUAL %

+11+20

LOAD

L2

6 8

L1

7

CHECK "0"VOLTS

VL 3VL 2VL 1 A

MPS6

1

8 7

1 234

5

SMARTSERIES

Np

D-M-E

0

1

L1 L2


L3

F2F1

240VAC

SMART START

PROCESS TEMP

-5-10

F1

SMARTSERIES

DSS-15-02

0

-20-11

PWR

1

D-M-E

F2

AUTO

MAN

100%

+10+5

SETPOINT

0°F0°C +11

+20

15 AMPS MAX°F/°C

AUTO

D-M-ESMARTSERIES

0 1

MANUAL

SEL

ENT

°C

°F

-11 -5-20 -10

+5+10

0°C0°F

TEMP

AMPS

SET PT

+20+11

REMOTECONTROL

°F/°C15 AMPS MAX

SMARTSTART

240VACCSS-15-02 TAS-05-02

240 VAC NOM 1O

STANDBY HEAT

0

SMARTSERIES

0

0

2

1

4

1

D-M-E

1

3

ALARM

1

POWER

Modules Volt/Amp Mon. Main FramesTAS-05-2 CVK-5 MFCPX-5-C 4,5-G/CVSSMX-15 G CVK-8 MFCPX-8-C 4,5-G/CVCSS-15-02 CVK-12 MFCPX-12-C 4,5-G/CVDSS-15-02 MFCPX-5-C 4,5-G

MFCPX-8-C 4,5-GMFCPX-12-C 4,5-G

Microprocessor-Based T° Control Modules withDigital Display and Communication

AUTO

1

SMARTSERIES D-M-E

SMARTSERIES D-M-E


0

L3

LOAD

+20+11

MANUAL %

SMART START

240VAC

PROCESSTEMP

-5-10

SETPOINT

PROCESSTEMP

-20-11

0°F0°C

SSMX-30G

+10+5

MANUAL

30 AMPS MAX°C

1 2

L2

3

L1

CHECK "0"VOLTS

VL 3VL 2VL 1 A

MPS

1

1 23

SMARTSERIES D-M-E

0

1

L1 L2


L3

D-M-ESMARTSERIES D-M-E

SMARTSERIES

D-M-E

Modules Volt/Amp Mon. Main FramesSSMX-30-G CVK-2H MFHPX-2-C 4,5-G/CV

CVK-3H MFHPX-3-C 4,5-G/CVCVK-5H MFHPX-5-C 4,5-G/CV

MFHPX-2-C 4,5-GMFHPX-3-C 4,5-GMFHPX-5-C 4,5-G

High power Microprocessor-Based T° ControlModules with Digital Display

L3

D-M-ESMARTSERIES D-M-E

MANUAL

°C30 AMPS MAX

SSMX-30G

1

240VAC

LOADMANUAL %

SMART START

PROCESSTEMP

+20+11-5

-10-20-11

0°F0°C

+10+5

SETPOINT

PROCESSTEMP

1D-M-E

SMARTSERIES

AUTO

2

SMARTSERIES

0SWITCH POWER "OFF"BEFORE INSERTING ORREMOVING MODULES D-M-E

SMARTSERIES

3

L2 L1

VL 1VL 2VL 3

VOLTSCHECK "0"

321

1

SPMA

D-M-ESMARTSERIES

1

0

D-M-E

L1 L3


L2

MANUAL

D-M-ESMARTSERIES

0

AUTO

AMPS

TEMP

SET PT

REMOTECONTROL

30 AMPS MAX°F/°CCSS-30-02

240VAC

SMARTSTART

-10-5

-20-11

°F

°C

SEL

ENT

+10+5

0°F0°C +11

+20

1

FAULT CODES

SHI - SHORTED T/CbCI - REVERSED T/CoPI - OPEN T/CoPO - OPEN TRIACShO - SHORTED TRIACGFI - GROUND FAULT

SMARTSERIES D-M-E

+10+5

240VAC

-5-10 0°F

0°C-20-11

SMART START

PROCESS TEMP

DSS-30-02

PWR

AUTO

MAN

100%

SETPOINT

°F/°C

+11+20

30 AMPS MAX

0

1

FAULT CODES

SHI - SHORTED T/CbCI - REVERSED T/CoPI - OPEN T/C

STANDBY HEAT

0

SMARTSERIES

0

D-M-E

1

1

4

2

01

3

ALARM

1

TAS-05-02240 VAC NOM 1O

POWER

Modules Volt/Amp Mon. Main FramesTAS-05-2 CVK-2-H MFHCPX-2-C 4,5-G/CVSSMX-30 G CVK-3-H MFHCPX-3-C 4,5-G/CVCSS-30-02 CVK-5-H MFHCPX-5-C 4,5-G/CVDSS-30-02 MFHCPX-2-C 4,5-G

MFHCPX-3-C 4,5-GMFHCPX-5-C 4,5-G

High power Microprocessor-Based T° ControlModules with Digital Display and Communication

MANUAL

°F/°C10 AMPS MAX

ESH-10G

SMARTSERIES

0

240VAC

1 SMART START

0°C0°F

MANUAL %

-11-20 -10

-5

PROCESSTEMP

+20+5+10

+11

LOAD

PROCESSTEMP

SETPOINT

AUTO

D-M-E

Single Zone Microprocessor T° Controller

REF.ESH-10-02

21SMARTSERIES D-M-E


AUTO

1

D-M-E

0

SMARTSERIES

°F/°C

LOAD

240VAC

PROCESSTEMP

SSMX-15G

SMART START

15 AMPS MAX

MANUAL %

+11+5+10 +20-10

-5-11-20

PROCESSTEMP

SETPOINT

0°C0°F

MANUAL

Two-Zone Main Frame for T° Control

Modules Main FramesSSMX-15-G MFFPRX-2-G


Smart Series® Main Frames

Main Frames for TemperatureControlD-M-E's Smart Series is the result of intensive and dedica-ted research with a goal of designing today's most versatileand reliable line of temperature controllers. Completely wi-red and ready for use, these frames are available in stan-dard configuration for 5, 8 and 12 Zones

FeaturesHeavy duty construction. All welded 16 gauge steel con-struction insures long life and peak performances.

Simple AC input power connections permit selection of volta-ge, phase and load balancing to suit the application. AllSmart Series Main Frames are supplied to accept 380/420VAC, 3 phase, 5 wire, 50-60 HZ input power. A variety ofother voltage, phase and load balancing arrangements pos-sible :

3 x 380 VAC + Np + ground220-240 V, 3 phase, 50-60 Hz208-240 V, single phase, 40-60 Hz110-120 V, single phase, 50-60 Hz (for 110 VAC heaters)

The 16 thru 48 zones frames use 2, 3 and 4 frame sectionsrigidly fastened together into one prewired integral stack unitwhich requires only one main AC power input connection.

Heavy duty, in-line circuit board connectors for module po-wer and thermocouple connectors. Large contact area foradded reliability. Exclusive dual grounding system for safety(modules are grounded before contact is made and groun-ded again when fully inserted).

Main AC disconnect switch (Electronic circuit breaker/discon-nect) with 3 power on indicator lights.

Cooling fan in the Main Frame is strategically located to in-crease air ventilation and maintain cooler running condition.

Upper and lower guides to simplify module insertion and re-moval.

Push-pull fasteners to quickly and easily lock modules andblank panels in position. No tools required. Alternatively,screwed-on modules and blank panels when required by re-gulations.

Heavy duty connectors with integral retaining latches for po-wer and thermocouple cables.

International symbols and installation drawings have beenprinted directly on the main frame back panel for quick avai-lability and reference whenever needed.

Numbered write-on areas for zone information

Tapped inserts to simplify mounting frame to floor stand.

Reduced electrical noise and heat levels.

The Smart Series high power (30 Amp) Main Frames at 2, 3and 5 zone capacities. Delivery on special request.

1 Main Frame 6 Insulated crimp connectors2 Circuit Breaker/Disconnect 7 Thermocouple connectors2a Current Voltage Monitor (option) 8 Mounting boxes3 Mold power cable 9 Blank panels4 Thermocouple cable 10 Fuses5 Mold power input connector 11 Modules

Ordering InformationSmart Series Main Frames (15 Amp max)The 12 configurations illustrated below provide a wide se-lection of zone capacities to suit most control application.The 5, 8 and 12 zone frames (MF(C)PX 5, 8 and 12) useindividual frame sections. The 16 thru 48 zone frames use2, 3 or 4 frame sections rigidly fastened together into oneprewired integral unit which requires only one main AC po-wer input connection. The Current/Voltage Monitor optionwill be factory installed when ordered at same time as MainFrame. Cables, mold connectors and other accessories areincluded, Control Modules are to be ordered separately.

- Each frame section has its own cooling fan.- Multi-section frame heights are multiples of 23 cm height

shown (e.g. MF(C)PX 32-C4,5-G is 69 cm)- Main AC input shown will always be in bottom frame sec-

tion. For higher power requirements individual power in-puts and circuit breakers can be factory installed in eachsection of stack frame on a special order basis.

1 2 43 5 6 7 98 10 11

L3

12

L1 L2

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10 11 12

1 32 4

1

1

2 3 4

2 3 4

5 6 7 8 9 10 1211

L2L1 L3

5 6 7

5 6 7

8 9

8 9

10 11 12

10 11 12

1 32 4

1

1

2 3 4

2 3 4

5 6 7 8 9 10 1211

L2L1 L3

5 6 7

5 6 7

8 9

8 9

10 11 12

10 11 12

1 2 3

1 2 3

954 6 7 8 10 11 12

L1 L2

94 5 6 7 8 10 11 12

L3

1

1

2 3 4

2 3 4

5 6 7

5 6 7

8 9

8 9

10 11 12

10 11 12

L1 L2 L3

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

1 2 3 94 5 6 7 8 10 11 12

L2L1 L3

51 2 3 4 6 7 8

1 2 3 4 5 6 7 8

1

1

2 3 4

2 3 4

5 6 7

5 6 7

8 9

8 9

10 11 12

10 11 12

L1 L2 L3

1 2 3 94 5 6 7 8 10 11 12

L2L1 L3

51 2 3 4 6 7 8

1 2 3 4 5

L3L2L1

1 2 3 4 5 6 7 8

L1 L2 L3

1 2 3 4 5 6 7 8 109 11 12

L2L1 L3

51 2 3 4 6 7 8

L2L1 L3

51 2 3 4 6 7 8

Main Frames (supplied with 50 Amp, 3 phase circuit breaker)

MFPX-5G MFPX-8G MFPX-12G




Stack Frames (supplied with 75 Amp, 3 phase circuit breaker)



Ordering informationSmart Series® Main Frames

Smart Series® Main Frames Cables and Mold Connectors Terminal Mounting Boxes*Z MFPX MFPX/CV MFCPX MFCPX/CV MPC TC PIC MTC PTCX PICXo T° Controller T°Controller T° Controller T° Controller Mold power Thermocouple Mold power Thermocouple For power Connectorsn & Volt/Amp with Communi- with Comm. cables cables input connect. connectors and TCe Monitor cation & Volt/Amp.s Monitor5 MFPX-5-C 4,5-G MFPX-5-C 4,5 G/CV MFCPX-5-C 4,5-G MFCPX-5-C 4,5-G/CV MPC-24-4,5-G TC-5-4,5-G PIC-24-G MTC-5-G PTCX-5K PICX-24-5K8 MFPX-8-C 4,5-G MFPX-8-C 4,5 G/CV MFCPX-8-C 4,5-G MFCPX-8-C 4,5-G/CV MPC-24-4,5-G TC-8-4,5-G PIC-24-G MTC-8-G PTCX-8K PICX-24-8K12 MFPX-12-C 4,5-G MFPX-12-C 4,5 G/CV MFCPX-12-C 4,5-G MFCPX-12-C 4,5-G/CV MPC-24-4,5-G TC-12-4,5-G PIC-24-G MTC-12-G PTCX-12K PICX-24-12K

High Power - Smart Series Main Frames Cables and Mold Connectors TerminalZ MFHPX MFHPX/CV MFCHPX MFCHPX/CV MPCH TC PICH MTC Mountingo T° Controller T°Controller T° Controller T° Controller Mold power Thermocouple Mold power Thermocouple Boxes*n & Volt/Amp with Communi- with Comm. cables cables input connect. connectors PICHe Monitor cation & Volt/Amp. For powers Monitor & TC Conn.2 MFHPX-2-C 4,5-G MFHPX-2-C-4,5G/CV MFCHPX-2-C 4,5-G MFCHPX-2-C 4,5-G/CV MPCH-23-4,5-G TC-5-4,5-G PIC-23-G MTC-5-G PICH-23-TB-G3 MFHPX-3-C 4,5-G MFHPX-3-C-4,5G/CV MFCHPX-3-C 4,5-G MFCHPX-3-C 4,5-G/CV MPCH-23-4,5-G TC-5-4,5-G PIC-23-G MTC-5-G PICH-23-TB-G5 MFHPX-5-C 4,5-G MFHPX-5-C-4,5G/CV MFCHPX-5-C 4,5-G MFCHPX-5-C 4,5-G/CV MPCH-5-4,5-G TC-5-4,5-G PIC-5-G MTC-5-G PICH-5-TB-G

Smart Series® Main Frames - High Power

* To be ordered separately

Included: Mold power cable, Thermocouple cable, Mold power input connector and Crimp connectors, Thermocouple connector and fuses.

Wiring capabilitiesWorldwide wiring capabilitiesUnless otherwise specified, all Smart Series Main Frameswill be supplied to accept 380-420 V, 3 phase, 5 wire, 50-60Hz - 208-240V, single phase, 3 wire, 50-60 Hz input power. Wiring diagram (included on the access cover) illustrates thevariety of other voltage, phase and load balancing arrange-ments possible, such as : 240 VAC, 3 phase, 4 wire, 50-60HZ and 110-120 V, single phase, 3-wire, 50-60 Hz. Thesewiring adjustments can be performed in the field to suit therequirements of the application. Or, if specified at the timeof original order, D-M-E will supply the Main Frame required.

Wiring instructions for D-M-E heatersPower wires can only be extended with crimp connectors(HWCC-1-2-5) and power wires of the same cross-sectionarea (total length max. 8 m)

Fe-Co Thermocouple wires can only be extended with Fe-Co wires. With the exception of the polarity of the extensioncable (US standards : red = negative, white = positive;European standards : red = positive, blue = negative). Onemust take care that the thermocouple wires are in good con-tact with the cable joint.Mold power input connector (PIC-24-G and PICH-23-G) andterminal mounting box (PTCX, PICX, PTC) must be connec-ted with the ground wire to the mold.Wiring has to be made according to the wiring diagram.Take care that wiring is correct to the position of the modu-les.Use Ohm-meter to check each heater for proper function pri-or to starting the D-M-E Hotrunner system.

1 2 3 4 5 6 7 8

SMARTSERIES

L1

D-M

1

0

SWITCH POWER "OFF" BEFORINSERTING OR REMOVING MOD

L3L2

SMARTSERIES D-M-E

PWR

100%

0

F1

1

F2

SETPOINT

AUTO

MAN

-20-11

0°F0°C-5

-10+11+20+10

+5

SMART START

PROCESS TEMP

15 AMPS MAX240VAC

DSS-15-02 °F/°C

MAN

100%

PWR

SMARTSERIES

0

F1

D-M-E

1

F2

15 AMPS MAX

PROCESS TEMP

SMART START

+5+10

AUTO

SETPOINT

-10-5-11

-200°C0°F

DSS-15-02

240VAC

+20+11

°F/°C

MAN

100%

PWR

SMARTSERIES

0

F1

D-M-E

1

F2

15 AMPS MAX

PROCESS TEMP

SMART START

+5+10

AUTO

SETPOINT

-10-5-11

-200°C0°F

DSS-15-02

240VAC

+20+11

°F/°C

MAN

100%

PWR

SMARTSERIES

0

F1

D-M-E

1

F2

15 AMPS MAX

PROCESS TEMP

SMART START

+5+10

AUTO

SETPOINT

-10-5-11

-200°C0°F

DSS-15-02

240VAC

+20+11

°F/°C

MAN

100%

PWR

SMARTSERIES

0

F1

D-M-E

1

F2

15 AMPS MAX

PROCESS TEMP

SMART START

+5+10

AUTO

SETPOINT

-10-5-11

-200°C0°F

DSS-15-02

240VAC

+20+11

°F/°C

MAN

100%

PWR

SMARTSERIES

0

F1

D-M-E

1

F2

15 AMPS MAX

PROCESS TEMP

SMART START

+5+10

AUTO

SETPOINT

-10-5-11

-200°C0°F

DSS-15-02

240VAC

+20+11

°F/°C

MAN

100%

PWR

SMARTSERIES

0

F1

D-M-E

1

F2

15 AMPS MAX

PROCESS TEMP

SMART START

+5+10

AUTO

SETPOINT

-10-5-11

-200°C0°F

DSS-15-02

240VAC

+20+11

°F/°C

MAN

100%

PWR

SMARTSERIES

0

F1

D-M-E

1

F2

15 AMPS MAX

PROCESS TEMP

SMART START

+5+10

AUTO

SETPOINT

-10-5-11

-200°C0°F

DSS-15-02

240VAC

+20+11

°F/°C

Thermocouple cable

Mold power cable



Mold Power connector wiringwith PIC-24-G with PIC-25-G

Zone 12 E3 - E4E1 - E2Zone 11C5 - D5Zone 10D3 - D4Zone 9D1 - D2Zone 8C3 - C4Zone 7C1 - C2Zone 6A5 - B5Zone 5B3 - B4Zone 4B1 - B2Zone 3A3 - A4Zone 2A1 - A2Zone 1

Zone No. Pin No.1 3 542

12

34

5

12

34

5

12

34

5

12

34

5

A

B

D

C

E

A9 - C9

C3 - C4C5 - C6C7 - C8

C1 - C2B6 - B7B4 - B5

A1 - A2

A5 - A6A3 - A4

A7 - A8B2 - B3

Pin No.

Zone 3

9

7

5

C

Zone 12

Zone 10Zone 9

Zone 6Zone 7Zone 8

Zone 4Zone 5

Zone 11

3

1

AB

Zone 1Zone 2

Zone No.2

4

6

8

4

8

7

6

5

3

2

4

9

8

7

6

5

3

2

1

New mold power connector PIC-24-GAll new D-M-E Hotrunner systems will be fitted with the newPIC-24-G connector.The PIC-24-G replaces the PIC-25-G connector and provi-des for the higher continuous power requirements ofHotrunner systems and conforms to the new CE regulations.This modular connector, like its predecessor, connects 12heating zones to the temperature controller unit.The contacts are rated 20 Amps at 400 Volts and the con-nector's footprint is only slightly larger than before. The Main Frames MFPX-5, 8 and 12, are equipped with thenew power cable MPC-24-G that fits the new PIC-24-Gmold power connector.

To overcome the transition problems from the old to the newstyle, D-M-E offers the possibility to use adapter cables(length 0,5 m)

MPC-2524 : connects molds with the old PIC-25-G to thenew MPC-24-G power cable

MPC-2425 : connects molds with the new PIC-24-G tothe old MPC-25-G power cable.

Furthermore, the D-M-E terminal mounting boxes PTCX andPICX are provided with an extra plate so that both stylespower connectors can be fitted. (PIC-24-G and PIC-25-G)

Note :- Mating cable connectors are wired the same as frame

connectors shown.- Wires in frames are color coded for reference when rewi-

ring of frame connectors is necessary. Evenso, additional

coding of these wires to connector(s) being replaced issuggested to expedite rewiring and insure proper recon-nection.

- All grounds must be connected to ensure operator safety.

High power Main Frame connector wiring

1D-M-E

2SMARTSERIES


0

L1

1

L2 L3

Mold power cable (4,5m.)

Thermocouple cable (4,5m.)

High power Main Frame withcircuit breaker/disconnect (standard)and current/voltage monitor (optional)

Insulated crimpconnectors (optional)HWCC-1HWCC-2HWCC-5

Terminal mounting box (optional)

Thermocouple connectorMold power input connectorwith numbered leads

Guidelines for wiring the mold to the mo-dule & zone number

Zone number 1 is the probe nozzle /closest to the U-corner.This is stamped on the mold and indicates the position ofthe undersized leader pin.The numbers for the other probes/nozzles run in the mostlogical order (mostly clockwise). The distributor bores /hea-ters are next and the one closest to the U-corner takes thenext number. The remainder of the distributor bores /heatersare numbered working up through the different levels withthe central heated adapter taking the last number

U1

23

4 5

8

679

10

11

12

U

133

2

6

7

1 8

54

9 12

10 11



Spare PartsThermocouple accessories

MTCThermocouple connectors

REF. ZonesMTC- 5-G 5MTC- 8-G 8MTC-12-G 12

TCThermocouple cables

REF. Zones Cable lengthTC- 5-4,5-G 5 4,5 mTC- 8-4,5-G 8 4,5 mTC-12-4,5-G 12 4,5 m

To mold � � To frame

Spare parts T/C connectorsC 146 10 F

Housing bulkhead mountings

REF. a b c Cont.C 146 10 F 010 0011 83 93 43 10+C 146 10 F 016 0011 103 113 43 16+C 146 10 F 024 0011 130 140 43 24+

Fe-Co

Spare parts T/C cablesC 146 10 G

� Hoods end entry

REF. a b c Cont.C 146 10 G 010 1061 51 73 43 10+C 146 10 G 016 1061 61 93 43 16+C 146 10 G 024 1061 61 119,5 43 24+

C 146 10 G� Hoods top entry

REF.C 146 10 G 025 2002

C 146 10 AMale inserts

REF. a b c Cont.C 146 10 A 010 1021 57 64 34 10+C 146 10 A 016 1021 77,5 84,5 34 16+C 146 10 A 024 1021 104 111 34 24+

C 146 10 B� Female inserts

REF. a b c Cont.C 146 10 B 010 1021 57 64 34 10+C 146 10 B 016 1021 77.5 84,5 34 16+C 146 10 B 024 1021 104 111 34 24+

C 146 10 B� Female inserts (without contacts)

REF.VN 02

REF.C 146 10 B 025 0002

VN 02Socket contacts

Identification a b c Cont. REF.47 73 43 10+ C 146 10 G 010 2061

Hoods top entry (no view) 47 73 43 16+ C 146 10 G 016 206162 119,5 43 24+ C 146 10 G 024 2061

16 poles 0,5 mm2 (Fe Co) Oe 16 - 0,5 Fe-Co....mThermocouple cables (no view)

24 poles 0,5 mm2 (Fe Co) Oe 24 - 0,5 Fe-Co....m



Spare PartsPower accessories

PIC - PICHMold power input connectors

REF. Amp.PIC- 24-G 15PICH-23-G 30PICH -5-G 30

MPC - MPCHMold power cables

REF. Amp. Cable Conversion cableREF. Cable lengths Male Female

MPC- 24-4,5-G 15 4,5 m MPC-2524 0,5 m 24 25MPCH-23-4,5-G 30 4,5 m MPC-2425 0,5 m 25 24MPCH- 5-4,5-G 30 4,5 m

To mold � � To frame

Spare parts for PIC-24-GC 146 10 F

Housing bulkhead mountings

REF.C 146 10 F BA 24 P

C 146 10 AMale inserts (without contacts)

REF.C 146 10 A 2416

Spare parts for MPC-24-4,5-GC 146 10 G

� Hoods end entry

REF.C 146 10 G HL 24 P

C 146 10 B� Female inserts (without contacts)

REF.C 146 10 B 2416

C 146 10 G� Hoods top entry

REF.C 146 10 G 025 2002

C 146 10 A� Male inserts (without contacts)

REF.C 146 10 A 025 0002

Power Cables (1,5 mm2, 25 poles) without viewREF.

Oe-25-1,5.... m

MPC-24-4,5-G

REF.VN 01 - 2416

VN 01Pin contacts

REF.VN 02 - 2416

VN 02� Socket contacts

REF.VN 01

VN 01� Pin contacts



Spare PartsMounting boxes

PTCXTerminal mounting boxes for power and thermocouple connectors

REF. a b c x yInstallation

possibilities forPTCX- 5 K PIC-24-G/MTC- 5-GPTCX- 8 K 70 70 55 243 258 PIC-24-G/MTC- 8-GPTCX- 12 K PIC-24-G/MTC-12-G

PIC-24

MTG-Gx*y

a

b c*

*Distance of mounting screws on the mold with M5 X 15

PICXTerminal mounting boxes for power and thermocouple connectors

REF. Installation possibilities for

PTCX-24- 5 K PIC-24-G/MTC- 5-GPTCX-24- 8 K PIC-24-G/MTC- 8-GPTCX-24-12 K PIC-24-G/MTC-12-G

PIC-24

145*160

80

70 55*


50*

40min

.

17.5 M4x15

R12.5

E*

D

C

B

A

16

32

35

25

106*

R12.5

F*

Pocket for thermocouple connectors MTC-...-G

DimensionsFor connector

FMTC-5-G MTC-8-G MTC-12-GA 83 103 130B 41,5 51,5 65C 65 85 12D 32,5 42,5 56E 51 61 74,5F 102 122 149

Note: Drawingdepicts belowflush mounting.For surfacemounting,disregarddimensionsmarked with*.

90

103

122

323525

R12,5

R12,5

106

4040

Pocket for mold power input connectors PIC-24-G

Note: Drawing depictsbelow flush mounting.For surface mounting,disregard dimensionsmarked with*.

PICHTerminal mounting boxes for power and thermocouple connectors

REF. a b c x y Accepts

PICH-23-TB-G 251 267 PICH-23-G/MTC-5-GPICH- 5-TB-G

108 113 82265 281 PICH- 5-G/MTC-5-G

MTC-5-G

PICHxy

a

b c

PTCTerminal mounting boxes for power and thermocouple connectors

REF. a b c x yInstallation

possibilities forPTC- 5-TB-G 205 220 PIC- 5-G/MTC- 5-GPTC- 8-TB-G 105 60 38 225 240 PIC- 8-G/MTC- 8-GPTC-12-TB-G 253 265 PIC-12-G/MTC-12-G


Only for U.K.

Spare parts main framesMFBP

Blank panels

REF.MFBP-10-GMFBP-30-G

Spare parts main framesABC

Fuses for SSMX, CSS and DSS modules

REF. Amp.ABC- 1 1ABC- 5 5ABC-10 10ABC-15 15ABC-30 30



Spare PartsAssembly tools

Removal tools for pin contacts VN-01 and socket contacts VN-02

REF. REF.FG 0300-146 FGN 2416

Rear insertion

Contact to snap in audibly

Check longitudinal clearance of 0,2 mm

Front contact

Male contact

FG

FGN 2416For VN01 2416/VN02 2416

FG 0300-146For VN01/VN02

950Crimp tools

REF. For950 001.4 HWCC-1

FAContact crimp tools

REF. For

FA 0100-164VN 01VN 02

FANContact crimp tools

REF. For

FAN 2416VN 01 2416VN 02 2416

HWCCCrimp connectors

REF.HWCC-1 (Cool-One)HWCC-2 (Cool-One)HWCC-5 (Hot-One)

Smart Series® Microprocessor-Based T° Control Modules


Microprocessor-Based T° Control Modules - CSS with Digital Display and Communication facilities

Benefits

- Fully self-tuning, microprocessor-based PID control- Selective Cycle® power drive for reliable and pre-

cise control- Zero crossing triac triggering for minimum RFI- Patented, closed loop low voltage Smart Start® to

prolong heater life- Process temperature readout operational even in

manual mode as long as thermocouple is intact - Automatic T/C break protection and cold junction

compensation- High impedance potentiometric input allows long

distance T/C wiring- 100 % solid state circuitry, no mechanical relays- Completely self contained, no external output de-

vices or power supplies required- Fast acting fuses, or circuit breaker in the CSS-

30-02, are provided on both sides of the AC line- Plug in design for module interchangeability

Features

The CSS Communications Smart Series® module providesthe molder with the first fully comprehensive temperaturecontrol module. This microprocessor-based unit incorpo-rates the most complete list of control features while pro-viding full communications capability with the TAS-05-02(Temperature Alarm Standby Heat, see page 27 & 28).

The CSS module also provides the highest level of per-formance as a stand-alone module. When operating in-dependently the CSS offers these features : A multi-func-tion display, advanced diagnostics, improved control anda new patented interactive Smart Start®. A setpoint me-mory feature also allows the user to power up the modu-le with the same setpoint as the day before.

The advanced diagnostics will automatically alert the userto fault conditions. This is done by multiplexing one ofthe following fault codes with the normal display in threesecond intervals : Shorted T/C Shi, Open triac : oPO,Reversed T/C : bci, Shorted Triac : ShO, Open T/C :oPi, Ground Fault : GFI, Over and Under temperaturewarnings are indicated by flashing LED's directly underthe display.

With its unique Smart Start® function, the CSS has theability to dry out a heater which may have acquired moi-sture inside its case. Smart Start® automatically applieslow voltage to the heater after initial start-up. If a groundleakage is sensed, the module will go into a bake-outprocedure which drives moisture from the heater.

When the Smart Start® bake-out function is in operation,the unit is monitored for leakage current. If the groundfault current becomes excessive, the module inhibits out-put power to the heater and signals a ground fault inter-rupt. When necessary, the module automatically repeatsthe bake-out procedure for a maximum of nine minutes.If at any time during the bake-out procedure the leakagecurrent falls within acceptable limits, the module will auto-matically switch to normal operation.

CSS-15-02

CSS-30-02




Front Panel Controls andIndicators

1. Digital LED display : Indicates setpoint temp. percent power, process tem-perature, load current, and fault conditions.

2. Temperature deviation indicators : Show deviation from setpoint.

3. Smart Start® light : Indicates Smart Start® is on.

4. SPI protocol light : Indicates control is from a remote computer or mol-ding machine, disabling the user from making frontpanel changes to setpoint or auto/manual operation.

5. Up arrow key :Increases the desired setpoint value.

6. Down arrow key :Decreases the desired setpoint value.

7. Select/Enter key :Selects either Setpoint (temperature/percent power),Amps (load current) or Process Temperature. Also al-lows for immediate entry of setpoint after making achange. Changes to the setpoint are automatically dis-carded after 2,5 seconds if this button is not pressed.

8. Setpoint light :Indicates Setpoint is on display. Setpoint has beenchanged but not entered if flashing.

9. Amps light : Indicates load current is on display.

10.Temp. light :Indicates process temperature is on display.

11.Side arrow key :Auto/manual select. To enable automatic bumplesstransfer, depress side arrow key while simultaneouslyturning the power on. When power to the CSS isturned off then on, Smart Start® will automatically bereactivated.

12.Auto light : Auto mode selected.

13.Manual light : Manual mode selected.

14.F1/F2 lights : Illuminate when fuse has blown.

15.Power ON/OFF switch

16.°F/°C light :Illuminates when the °C switch is closed or ON.

Note : CSS-30-02 is twice as wide as the above, andhas circuit breaker instead of the items 14 and 15.

OperationAutomatic Mode :The microprocessor maintains temperature using a closedloop PID control method. Closed loop means the unitcontinuously looks at the process temperature to determi-ne whether or not to adjust the power delivered to theheater. With PID control, it anticipates the system char-acteristics to make accurate adjustments and correct forerror.

Automatic Mode :For open thermocouple or thermocouple failure, openloop-percent power is used. In manual mode, the micro-processor maintains a power level using an open looppower control method. Open loop means the processtemperature is not used to determine whether or not ad-justments should be made. This enables the user to con-tinue production and override thermocouple wire breaks,short circuits, or lead reversal until the problem has beenresolved. Manual mode overrides thermocouple breakprotection, reversed thermocouple, and any normal mo-des.

Smart Start® :Smart Start® is automatic on start-up in the auto mode,and provides the application of low voltage for heater ba-ke-out. Smart Start® is completed upon detecting that theheater is dried out, to a maximum of nine minutes.

0

F1F2

D-M-E

1

MANUAL

AUTO

15 AMPS MAX

°F

°C

ENT

SEL

-11-20 -10

-50°F0°C

240VAC

SMARTSTART

CSS-15-02

SET PT

AMPS

TEMP

+10+5 +11

+20

REMOTECONTROL

°F/°C

4

1

2

8

9

10

12

13

15

3

5

16

7

6

11

14

SERIESSMART

CSS-15-02

CSS-30-02




Power-Up : Upon power-up, the unit retains the same set point andoperation mode as when the unit was turned off.

Input Fault : Thermocouple break protection, and shorted or reversedthermocouple all override Smart Start® and normal modes.Output is inhibited, unless automatic bumpless transfer isselected.

CSS Communications : The D-M-E CSS module can control temperatures withoutany communications module present. The CSS has itsown microprocessor, which tunes the PID control algo-rithm with parameters designed for the characteristics ofplastics processing. It also has the ability to run diagnos-tics on the heater, which includes our Smart Start® heatermoisture dry-out routine. The diagnostics also places theheater output in the safest mode, as well as alerting themolder to the problem. This module plugs into a D-M-EMain Frame that has a communication strip installed.

Performance specificationsAuto and Manual Control : Time proportioning/Selective Cycle®

Temperature Range : Ambient to 537°C

Control Accuracy : +/- 0,5°C dependent on the totalthermal system

Temperature Stability : +/- 0,5 % of full scale over the am-bient range of 0 to 50°C

Calibration Accuracy : Better than 0,2 % of full scale

Cycle Time : 0,0166 seconds at 60 Hz, 0,020seconds at 50 Hz

Power Response Time : 0,0083 seconds at 60 Hz, 0,010seconds at 50 Hz

Reset : Automatically corrects reset to nomore than 1°C at all settings

Manual Control : Adjustable from 0-99 %.Maintains output power to within1% of setting using the SelectiveCycle® power drive

Advanced Diagnostics Indicators : LED's and 3-digit, 7-segment dis-play

Smart Start® (SS) : Variable voltage steps from 0 to240 volts repeatable over a 9 minu-te period. Will escape from thismode if leakage falls below 120 mAlimit. If dry out is not required thena fast pass check of voltage is im-plemented over 30 seconds.

SS® Duration : 30 seconds to 9 1/2 minutes

SS® Override Temperature : 93°C

Operational Mode Priority : - Ground fault overrides all modes- SS® precedes auto mode- Shorted output overrides SS® and

Auto modes- T/C break overrides SS® and Auto

modes- Reversed or shorted T/C overri-

des SS® and Auto mode

- Open output overrides SS® andAuto modes

- Manual control overrides T/Cbreak, reversed T/C and Auto mo-des

- The output is inhibited during allfault conditions in the Auto mode,(unless automatic bumpless trans-fer is invoked)

- Remote control overrides localcontrol

Input specificationsT/C Sensor : Type "J" grounded or ungrounded

External T/C Resistance : High impedance potentiometric in-put allows long distance T/C wiring

T/C Isolation Isolated by control circuit powersupply

Cold Junction Compensation : Automatic, better than 0,01°C/°C

T/C Break Protection : Automatically inhibits power to hea-ter (unless automatic bumplesstransfer is invoked)

Reversed T/C Protection : Automatically inhibits power to hea-ter, (unless automatic bumplesstransfer is invoked)

Shorted T/C Protection : Automatically inhibits power to hea-ter, (unless automatic bumplesstransfer is invoked)

Input Type : Potentiometric

Input Impedance : 22 Megohms

Input Protection : Diode clamp, RC filter

Input Amplifier Stability : 0,01°C/°C

Input Dynamic Range : 550°C

Common Mode Rejection Ratio : Greater than 100 db

Power Supply Rejection Ratio : Greater than 90 db

Communication Inputs : Data alliance is optically coupled at2500 volts isolation

Output specificationsVoltage/Power Capability : 15 AMP : 240 VAC nominal, single

phase. 120 VAC available, 3600watts a 240 VAC (1800 watts @120 VAC)30 AMP : 240 VAC nominal, singlephase. 120 VAC available, 7200watts @ 240 VAC (3600 watts @120 VAC)

Output Drive : Internal solid state triac, triggeredby zero AC crossing pulses

Overload protection : 15 AMP : Fuses are provided onboth sides of AC line30 AMP : Fast acting circuit bre-aker provided on both sides of ACline

Transient Protection : dv/dt and transient pulse suppres-sion included

Power Line Isolation : Optically and transformer isolatedfrom AC lines, Isolation voltage isgreater than 2500 volts




Controls and indicators Auto/Manual Selection : Push button switch toggles mode.

LED indicates mode of operation.

Setpoint Control : Two buttons up and down, one but-ton used to enter setpoint Range : 0 - 537°CResolution : 1°C

Manual (% power) Control : Two buttons up and down, one but-ton used to enter setpoint Digitaldisplay indicationRange : 0 to 99 %

Power ON/OFF : 16 Amp rocker switch, UL, CSA,VDE approved. On the CSS-30-02a 30 Amp circuit breaker that isalso approved.

Process Temp Selection : One push button with one LED in-dicator. Selected by select/enterpush button.

Load Current Selection : One push button with one LED in-dicator. Selected by select/enterpush button.

Multi-function Display : (3) 7-segment LED's, 15 mm digitaldisplays with decimal point used inload current display. Alarm characters also display.

Smart Start® Indicator : LED above display window illumina-tes.

°F/°C Indicator : LED illuminates indicating °C mode.

Blown Fuse Indicator : 2 neon indicators.

Shorted T/C : Digital display (Shi) alternates withnormal display.

Shorted Output (Triac) : Digital display (Sho) alternates withnormal display.

Open T/C : Digital display (oPi )alternates withnormal display

Open Output (Triac) : Digital display (oPO) alternates withnormal display.

Ground Fault : Digital display (GFi) alternates withnormal display.

SPI Protocol Indicator : LED above display window illumina-tes.

Temperature Deviation Indicators: +/- 11°C Red+/- 5°C Yellow+/- 0°C Green

Bumpless transfer Bumpless transfer is defined as a thermocouple failurecausing the module to automatically switch into manualpercent power mode, if the module has learned the per-cent power. The CSS requires approximately 2 minutesof stable temperature control before the bumpless featureis enabled. To force the module into this mode press the"AUTO/MAN" key simultaneously while turning the poweron. The display will show "AUt" indicating that automaticbumpless transfer mode has been selected. This modewill now be stored in the module’s permanent memory.To deactivate the bumpless transfer mode repeat the po-wer on procedure while pressing the "AUTO/MAN" key.

This will cause the module to display "inh" in the display,indicating that the output power will be inhibited uponthermocouple failure. The user will have to then placethe unit in the manual mode to gain control of the outputpower.

Once the Auto mode setpoint is reached, and the control-ler is placed in the Standby Heat mode (using TAS-05-02,see page 27 & 28), if a T/C failure occurs, the CSS willset power level to 3 %, (no output). When the CSS isreleased from the Standby Heat mode, the unit will usethe last valid percent power it learned prior to enteringthe Standby Heat mode and it will continue to control po-wer in the Manual percent power mode.If the module has not reached setpoint in the Auto mode,and the T/C fails, the unit will switch to Manual percentpower mode and continue with the last valid manual per-cent power stored before the T/C failure occurred, or thefactory setting of 0 %. If the unit is now instructed toswitch to the Standby Heat mode, the unit will set the po-wer level to 0 % (no output). If the module is in StandbyHeat mode and the T/C fails, the CSS will set the powerlevel to 3 %. Upon release from Standby Heat mode theunit will use the last valid percent power it learned priorto entering the Standby Heat mode and it will continue tocontrol power in the manual percent power mode.

Activating Shi Shorted input override, Shi, is defined as a conditionwhen the T/C is shorted and the unit does not detect arising temperature that corresponds to the output powerbeing delivered. If the thermocouple is shorted and thetemperature rise does not change at a rate of more than17°C in 65 seconds, this is interpreted as a Shorted Inputand the unit will automatically switch to the manual modeand set the percent power to a previously learned percentpower, if one was learned (with automatic bumplesstransfer). When automatic bumpless transfer is not selec-ted, the output will be inhibited.If position 2 of dip switch 1, (DS1), on the main circuitboard is in the ON position, this means Shi override is in-hibited. If the switch is in the OFF position, this meansthe module is in the factory setting or normal operationmode.

Standby heat When the D-M-E TAS-05-02 module initiates a StandbyHeat signal, any CSS modules in the Auto mode will im-mediately set the setpoint temperature to 93°C. Thefunction is useful for the continuous application of low po-wer to heaters to prevent moisture build-up and initiatequick start-ups (A communication style Main Frame is re-quired to support this feature).If a thermocouple failure occurs while in standby heat,then 3 % power will be output.




Temperature mode °F/°CTo operate the CSS module in the °F mode, move posi-tion 1 of dip switch 1 (DS1) to the OFF position. To ope-rate the CSS module in the °C mode, move position 1 tothe ON position. When the °C mode is selected, thetemperatures displayed will be in °C and the °F/°C LEDon the front panel will be illuminated.

Alarm output When the D-M-E TAS-05-02 module is installed in theMain Frame, this CSS output feature will activate thealarm output feature on the TAS-05-02 module. The TASmodule will produce an audio alarm and provide a relaycontact closure when a temperature alarm occurs. Thisfeature is disabled upon power-up until the process tem-perature is within - 12°C of setpoint temperature, or untilan error occurs. It is also disabled when changing to orfrom the Standby Heat mode (a communication styleMain Frame is required to support this feature).Once the setpoint temperature is reached, a deviation of±17°C will activate the alarm.If the module has not reached setpoint in the Auto mode,and the T/C fails, the unit will switch to manual percentpower mode and when standby is engaged, the alarm isinactive until the process falls to 99°. When leavingStandby Heat the alarm is inactive until the process iswithin +/-17°C of setpoint.

In the manual mode the alarm is inactive except for er-rors. Errors always cause an alarm. If the unit is in out-put inhibit mode, the alarm occurs during an error and iscleared by placing the unit in the manual mode. If theCSS is in the auto-bumpless mode, the alarm will stay oneven though the unit goes to the manual key. The usercan silence the alarm by pressing the auto/manual key.When auto-bumpless occurs, the automatic setpoint willcontinue to be displayed until the user acknowledges thealarm condition by pressing the auto/manual key. Afteracknowledgement, the manual setpoint is displayed.When errors are corrected and the unit is back in automode the alarm is inactive until the process reaches±17°C of setpoint.

Electrical power specificationsInput Voltage : 240/120 VAC +10 % -20 %

Frequency : 50-60 Hz

DC Power Supplies : Internally generated, regulated andcompensated

Module power usage : Less than 5 watts, excluding load

Dimensions : 15 AMP : 5 x 18 x 19 cm 30 AMP : 10 x 18 x 19 cm

Note : Standard 240V modules are com-patible with Main Frames wired foreither 240 VAC three phase or 240VAC single phase

Fuse requirements : (2) ABC-15 fuses (2 spare fuses in-cluded with module, applies toCSS-15-02 only)

Circuit breaker : A special 30 AMP circuit breaker isused in 30 AMP modules to protectthe module

DiagnosticsThe CSS diagnostics automatically alerts the user to afault condition.

Shorted thermocouple displays flashing ”Shi” in theauto mode (output inhibited), or is on steady in themanual mode.

Troubleshooting : Check for damage to the thermocouplelead wire. Also, check for bare, twisted or pinched leads.Excessive distance between heaters and thermocouplesor excessive interaction between neighboring manifold zo-nes may trigger this diagnostic also, as should undersizedheaters or low voltage.

Open thermocouple indicated by ”oPi” flashing whilein the auto mode (output inhibited), or on steady inthe manual mode.

Troubleshooting : Check the thermocouple connectionsand wires for broken leads or check for damage to thesensor.

Reversed thermocouple displays flashing ”bci” whilein the auto mode (output inhibited), or on steady inthe manual mode.

Troubleshooting : Check thermocouple wiring for reversedleads.

Shorted triac warning is indicated by ”ShO” flashingwhile in auto mode.

Troubleshooting : Check triac for short or replace module.

Open output is indicated by ”oPO” flashing while inauto mode

Troubleshooting : Check heater wiring for open connec-tions. Check for defective heater. Check for defectivetriac (open) device.

Excessive heater current flowing to ground is indica-ted by ”GFI” flashing in auto mode.

Troubleshooting : Replace damp heater. Check for possi-ble problems with deteriorating wire insulation or moisturein wire channels.




Over/Under temperature. The red deviation LED onthe left flashes when the process temperature is be-low setpoint by 17°C or more. The red deviation LEDon the right flashes when the process temperature isabove setpoint by 17°C or more.

Troubleshooting : Check for : Under temperature : heaterfailure, low line voltage, TC problem Over temperature :output failure, shorted triac, interacting zones.

Calibration procedurel. Insert controller into the calibration jig and turn power

on.

2. Set the simultation temperature to 93° C.

3. Press the CSS "SEL/ENT" key to select "TEMP".

4. Adjust the OFFSET trimpot, R48, to get 93°C on thedisplay.

5. Set the simulation temperature to 427°C.

6. Adjust the GAIN trimpot, R24 to get 427°C on the dis-play.

7. Repeat steps 2 thru 6 until no further trimpot adjust-ment is needed.

8. Turn power off. Thread a 1,5 mm2 insulated strandedwire through the GFI transformer, T3.

9. Turn power on.

10. Send a variable AC GFI current through the 1,5 mm2

wire. The CSS should display GFI for a GFI currentwithin the range of 1.5 Amp +/- 20 % (1.2 - 1.8 A).See test current setup diagram herewith. If GFI is notactivated, reduce R14; if GFI is activated below 1.2 A,reduce R15.

11. Turn power off.

12. Thread 1,5 mm2 wire through the current transformer,T2.

13. Turn power on. Press "SEL/ENT" key to select"AMPS" display. Adjust simultation temperature to 427°C then to -18°C.

14. Send 10 Amps through the no. 16 wire. The CSSshould display 10.0 +/- 0.5 Amp. If the displayedcurrent is too low, reduce R20; if the current is toohigh, reduce R19.

15. Turn power off and remove the controller from the ca-libration fixture.

Communication connector com-patibility :The Communication Connector strip in your Main Framecommunicates to all the other modules in the rack. If thecommunications connector in your Main Frame has pins 3& 4 missing, you must order a new communication stripfrom D-M-E to allow the alarm feature in this module tocommunicate properly with the TAS-05-02 module. It willnot work without these pins installed.

220 VACA

0,5 Ohm50 Watt

AMP. MeterFLUKE 8062A

5 V220 V

Variac

50 VAGFI or CurrentTransformerin CSS module

1,5 mmwire

Notice

pins 3 & 4 are not

inserted

Communication Connector

not compatible



Microprocessor-Based Auto PID tuning, Dual Indicating T° ControlModule DSS

Benefits

- Fully auto-tuning : Fuzzy logic, microprocessor-based PID control.

- Dual Display : Upper display shows process tem-perature while lower display shows desired set-point temperature.

- Smart Start® : Safely bakes out damaging internalheater moisture.

- 100 % Power Option : Breaks through cavity gatefreeze off.

- EMI Resistant : Stable/reliable operation.- Auto/Manual Indicator : Flexibility in control mo-

des.- Input Fault Indication : Alerts operator to a pro-

blem and takes corrective action.- Bumpless Transfer : Minimizes setpoint

adjustment when switching to manual mode.- Standby Heat : Applies a low temperature setpoint

to heaters to prevent moisture build-up, and mate-rial degradation.

- Temperature Alarm : Sends a signal to a D-M-ETAS-05-02 module which produces an audio/visualalarm and provides a relay contact.

Features

The DSS is a Smart Series®, dual indicating temperaturecontrol module. This microprocessor-based control moduleis designed to maintain the desired setpoint temperatureeven under the most adverse processing variables. Theunit incorporates features common to both the SSM andthe CSS controls, such as heater bake out, input failurealarms, auto or manual operation, and solid state outputs.Other features include 100 % power switch, bumplesstransfer, and enhanced noise immunity. The DSS module is designed to survive the elements thatdegrade control performance. Specialized circuitry is usedto guard against electrical noise and static discharge.Fuzzy logic is used to prevent setpoint overshoot on star-tup and over and undershoots when changing setpoint.


1. Smart Start® Light : Indicates Smart Start® is on.

2. Process Temperature Display : Shows process temperature and error codes.

3. Temperature Deviation Indicators : Displays the magnitude of process temperature de-viation from setpoint.

4. Set Point Display : The auto and manual set points are displayed here.

5. Auto/Manual Switch : Selects automatic closed loop (temperature setpoint)or manual (% power) open loop control modes.

DSS-15-02

DSS-30-02




6. Auto Light : Auto mode is selected.

7. Manual Light : Manual mode is selected.

8. 100 % Power Switch : Initiates 100 % power output. Time out is jumperselectable.

9. 100 % Power Light : Indicates control is in 100 % power mode.

10.Up Arrow : Increases desired set point value.

11.Down Arrow : Decreases desired setpoint value.

12.F1/F2 Lights :Illuminated when fuse has blown (15 Amp unit only).

13.Power On/Off Switch: (Circuit breakerused on DSS-30 unit)

Note : DSS-30-02 is twice as wide as above,and has acircuit breaker instead of items 12 & 13.

OperationAutomatic Mode :The microprocessor maintains temperature using a closedloop PID control method. Closed loop means the unitcontinuously looks at the process temperature to determi-ne whether or not to adjust the power delivered to theheater. With PID control, it anticipates the system char-acteristics to make accurate adjustments and correct for

errors. "Fuzzy logic" is used to minimize overshoots andundershoots of setpoint.

Auto-Tuning :Auto-tuning PID parameters are automatically indicatedafter power up, or when the setpoint is changed by grea-ter than 38°C .Auto-tuning begins when the process temperatures is at80 % of setpoint. During auto-tuning the heat proportion-al band is set to 0, and the control goes into the On/Offmode at 90 % of the established setpoint. Once the con-trol finishes "learning" the system, it returns to a standardPID control with the heat PID values are automatically setas a result of auto-tuning.

Bumpless Transfer :While in the auto mode and within - 15°C of setpoint,the control periodically calculates and records the averagepercent power required to keep the process temperatureat setpoint. When the control is switched to manual mo-de, the last stored percent power becomes the manualsetpoint. The percent power is stored before the fault oc-curs.

Bumpless Transfer is defined as a thermocouple failurecausing the module to automatically switch into manualpercent power mode, if the module has learned the per-cent power. To force the module into this mode, pressthe "AUTO/MAN" key simultaneously while turning the po-wer on. The upper display will show "AUt" and the lowerdisplay will show "bPL" for 3 seconds indicating that auto-matic bumpless transfer mode has been selected. Thismode will now be stored in the modules permanent me-mory. To deactivate the bumpless transfer mode - repeatthe power on procedure while pressing the "AUTO/MAN"key. This will cause the module to display, "inh" in theupper display, and "Out" in the lower display, indicatingthat the output power will be inhibited upon thermocouplefailure. The user will have to then place the unit in themanual mode to gain control of the output power.Once the Automode setpoint is reached, and the control-ler is placed in the Standby Heat mode ( by using a TAS-05-02, see page 27 & 28), if a T/C failure occurs, theDSS will set power level to 0 %, (no output). When theDSS is released from the Standby Heat mode, the unitwill use the last valid percent power it learned prior toentering the Standby Heat mode and it will continue tocontrol power in the Manual percent power mode.If the module has reached setpoint in the Auto mode, andthe T/C fails, the unit will switch to Manual percent powermode and continue controlling power. If the module isthen instructed to switch to the Standby Heat mode, theunit will set power level to 0 % (no output).If the module has not reached setpoint in the Auto mode,and the T/C fails, the unit will switch to Manual percentpower mode and continue with the last valid Manual per-cent power stored before the T/C failure occurred, or thefactory setting of 0 %. If the unit is now instructed toswitch to the Standby Heat mode, the unit will set the po-

1

2

3

4

9

13

5

10

°F/°C

PROCESS TEMP

15 AMPS MAX

F2

D-M-ESMARTSERIES

0

F1

100%

PWR

MAN

AUTO

SETPOINT-11-20 -10

-5 0°C0°F

+5+10

240VAC

SMART START

DSS-15-02

1

+20+11

6

7

12

11

8

DSS-15-02

DSS-30-02




wer level to 0 %, (no output). If the module is inStandby Heat mode and the T/C fails, the unit will switchto Manual mode and will continue controlling power at alearned by temporary percent power, or 0 % if a valuehas not been properly learned while in Standby Heat.Upon release from Standby Heat mode, the unit will usethe last valid percent power it learned prior to enteringthe Standby Heat mode and it will continue to control po-wer in the Manual percent power mode.

Power-up :Upon power-up, the unit retains the same setpoint andoperation modes as when the unit was turned off. If theunit is turned off while at 100 % power, upon power-upit returns to the mode and setpoint retained before swit-ching to 100 % power.

Input Fault :Thermocouple break protection, and shorted or reversedthermocouple all override Smart Start® and normal modes.Output is inhibited, although bumpless transfer may beused to override, automatically or manually.

Manual Mode : For open thermocouple or other thermocouple failure,open loop-percent power is used. In manual mode, themicroprocessor maintains a power level using an openloop power control method. Open loop means the pro-cess temperature is not used to determine whether or notadjustments should be made. This enables the user tocontinue production and override thermocouple wire breaks, short circuits, or lead reversal until the problemhas been resolved. Manual mode overrides thermocouplebreak protection, reversed thermocouple, shorted thermo-couple, and any normal modes.

Smart Start® :Smart Start® is automatic on start-up in the auto mode,and provides a linear ramp to setpoint for heater bakeout. Smart Start® is complete when five minutes expireor when setpoint is reached.

100 % Power :When 100 % PWR is pressed, the output is full on untilthe timeout period is complete. Maximum time durationfor 100 % power is determined by the J1 jumper.Located on the printed circuit board, S = 15 seconds, L =30 seconds, & INH = inhibit 100 % power. Pressing anykey before timeout returns the unit to its previous modeand setpoint.

Load type selection :The type of load is selected by depressing the down ar-row key simultaneously while powering the unit on. Thiswill select a fast or a slow load. A fast load is describedas a mold temperature rise of no less than 2°C in 60 se-conds. A slow load is a change of no less than 2°C in250 seconds. This feature is provided so that a fast or

slow load can be selected allowing the easy detection ofa shorted thermocouple input. For proper protection ofheaters and the molding system, a fast response shouldbe selected unless slow temperature rise is expected, asis the case with manifold or barrel heaters.

Standby Heat :When the D-M-E TAS-05-02 module initiates a StandbyHeat signal, any DSS module in the auto mode will im-mediately set the setpoint temperature to 93°C. This func-tion is useful for the continuous application of low powerto heaters to prevent moisture build-up and initiate quickstart-ups. A communication style Main Frame is requiredto support this feature.

Temperature mode F/C :To set the temperature mode in degrees F or C, pressthe up arrow key, (increment key), while simultaneouslyturning the power on to the unit. The word "dEg" will ap-pear in the upper display and either F or C will appear inthe lower display. To change the mode, turn the poweroff for 5 seconds and then turn power back on whilepressing the increment key. The display will then indicatewhich mode the unit is in.

Alarm Output :When the D-M-E TAS-05-02 module is installed in the D-M-E Main Frame, this DSS output feature will activatethe alarm output feature on the TAS-05-02 module. TheTAS module will produce an audio alarm and provide arelay contact closure when a temperature alarm occurs.This feature is disabled upon power-up until the processtemperature is within +/-5°C of setpoint temperature, oruntil an error occurs. It is also disabled when changingto or from the Standby heat mode. Once the setpointtemperature is reached, a deviation of +/- 17°C will acti-vate the alarm. The process must get within +/- 5°C toturn the alarm off.When standby heat is engaged, the alarm is inactive un-til the process falls to 99°C. When leaving standby heatthe alarm is also inactive until the process is within +/-5°C of setpoint. This prevents alarms during ramping.In the manual mode the alarm is inactive except for er-rors. Errors always cause an alarm. If the unit is in out-put inhibit mode, the alarm occurs during an error and iscleared by auto-bumpless mode, the alarm will stay oneven though the unit goes to the manual mode. Theuser can silence the alarm by pressing and holding theauto/manual key for one second. When errors are cor-rected and the unit is back in auto mode the alarm is in-active until the process reached +/- 5°C of setpoint.

Performance specificationsAuto and Manual Control Modes : High Speed Time proportioning

Selective Cycle®


Control Accuracy : +/- 0,5°C dependent on the totalthermal system




Temperature Stability : +/- 0,5 % of full scale over the am-bient range of 0 to 50°C


Power response time : 0,538 seconds

Manual Control : Adjustable from 0 - 100 %, main-tains output power within 1 % ofsetpoint

Smart Start® : Linear voltage ramping

Maximum Smart Start® Duration : 5 minutes

Smart Start® Override T° 124°C

100 % Power : 100 % power to the output Jumper selectable inhibit, or S = 15seconds, or L = 30 seconds

Operational Priority : Smart Start® precedes auto mode

Thermocouple (T/C) break, reversedor shorted T/C overrides Smart Start® and auto modes.Manual control overrides the automode, T/C breaks, reversed orshorted thermocouples. Output isinhibited during all fault conditions,unless bumpless transfer is selec-ted.

Input Specifications :Thermocouple Sensor : Type "J", grounded or ungrounded

T/C Isolation Resistance : Less than 0,17°C/Ohm

T/C Isolation : Isolated by control circuit powersupply


TC Break, Reversed & Shorted Automatically inhibits power to hea- Protection : ter, or invokes bumpless transfer

Input Impedance : 5.6 Megohms

Input Amplifier Stability : Greater than 0,01°C/°C

Common Mode Rejection Ratio : Greater than 120 dB

Power Supply Rejection Ratio: Greater than 110 dB

Output Specifications :Voltage/Power Capability : 240 VAC nominal, single phase,

15 Amp : 3600 watts @ 240 VAC30 Amp : 7200 watts @ 240 VAC

Output Drive : Internal solid state triac, triggeredby zero AC crossing pulses.

Overload Protection : 15 Amp : Fuses are provided onboth sides of AC line30 Amp : Fast acting circuit breaker


Power Line Protection : Optically and transformer isolatedfrom AC lines, isolation voltage greater than 2500 volts

Controls and Indicators :Auto/Manual Selection : Push-button switch with LED indicators adjacent toswitch.

Set Point Adjustment : Push-button up & down arrow keys.

100 % Power Selection : Push-button switch with LED indicator adjacent.

Power On/Off : 16 Amp rocker switch. On the DSS-30, a 30 Amp circuitbreaker is used. Both are UL, CSA, VDE approved.

Set Point Adjustment : Push-button up & down arrow keys.

Set Point Display : Three 10 mm, seven segment digit display.

Process Display : Three 14 mm, seven segment digit display. Also displaysalarm codes and flashing "100" for 100 % power opera-tion.

100 % Power Indication : Red LED adjacent to 100 % power key flashes. Processdisplay flashes "100".

Auto Indication : Illuminates green LED adjacent to Auto/Man key.

Manual Indication : Illuminates yellow LED adjacent to Auto/Man key.

Smart Start® Indication : Illuminates green LED above the process T° display.

Shorted T/C Indication : Flashes "Shi" in process display.

Open T/C Indication : Flashes "oPi" in process display.

Reversed T/C Indication : Flashes "bci" in process display.

Temperature Deviation Indicators : Five separate LED's +/- 17°C = flashing red, +/- 11°C =red, +/-5°C = Yellow, 0°C = green

Blown Fuse Indicators : Two orange indicators for Fuse 1 (F1) and Fuse 2 (F2)/(15 Amp unit only).

Electrical power specificationsInput Voltage : 240/120 + 10 %/-15 %

Frequency : 50/60 Hz

DC Power Supplies : Internally generated, regulated, andcompensated. Transformer isolatedfrom AC lines.

Module Power Usage : Less than 6 watts, excluding load.

Dimensions : 15 Amp : Width 5 cm Height 18 cm Depth 19 cm

30 Amp : Width 10 cm Height 18 cm Depth 19 cm




DiagnosticsThe DSS diagnostics automatically alerts the user to afault condition.

Shorted T/C displays flashing "Shi" alternating withthe process T° every 7 seconds.

Troubleshooting : Check for damage to the thermocouplelead wire. Also check for bare, twisted or pinched leads.Excessive distance between the heater and thermocoupleor low watt density may also trigger this diagnostic. Slowloads such as externally heated manifolds may triggerthis diagnostic when a fast load is selected.See load type selection section to select a slow load res-ponse.

Open T/C indicated by "oPi" flashing while in the au-to mode (if output is inhibited), or on steady in themanual mode.

Troubleshooting : Check the T/C connections and wiresfor broken leads or check for damage to the sensor.

Reversed T/C. Displays flashing "bci" while in theauto mode ( if output is inhibited), or on steady inthe manual mode.

Troubleshooting : Check thermocouple wiring for reversedleads

Over/Under temperature. The red deviation LED onthe left flashes when the process temperature is be-low setpoint by 17°C or more. The red deviation LEDon the right flashes when the process temperature isabove set point by 17°C or more.

Troubleshooting : Under temperature : Check for heaterfailure, open wiring or low voltage conditions.Over temperature : Check for shorted triac, shorts to other heater leads or interaction with other zones of heat.

Calibration ProcedureEquipment needed :1. Type ”J” Cold Junction Compensator2. Precision Millivolt Source.

Test Procedure1. Connect the cold junction compensator between the

T/C inputs on the DSS and the Millivolt source.

2. Insert jumpers in both of the 100 % power timer se-lect positions. The inhibit position does not require ajumper.

3. Power the unit on. The displays shall read "CAL 0".

4. Set the Millivolt source to 0.00 mv (0°C) and wait fiveseconds.

5. Press the decrement key, (down arrow). After ap-proximately 10 seconds the displays shall read "CAL999".

6. Set the Millivolt source to 29.515 mv (537°C) and waitfive seconds.

7. Press the 'AUTO/MAN" key. After approximately 10seconds the displays shall read "CAL END".

8. Press the 100 % Power key. The upper display shallread "999" and the lower display shall read "75".

9. The unit is now calibrated.

10. Reset the unit for °C if necessary (see T° mode F/C).

Communication Connector Compatibility :The Communication Connector strip in your Main Framecommunicates to all the other modules in the rack. If thecommunications connector in your Main Frame has pins 3and 4 missing, you must order a new communication stripfrom D-M-E allowing the alarm feature in this module tofunction properly with the TAS-05-02 module. It will notwork without these pins installed.

Notice

pins 3 & 4 are not

inserted


not compatible



Microprocessor-Based T° Control Module SSMX

Benefits

- Fully self-tuning, fuzzy logic, microprocessor ba-sed PID control.

- High speed time proportioning power drive for re-liable and precise control.

- Zero crossing triac triggering for minimum RFI.- Automatic linear Smart Start® to prolong heater life.- Process temperature readout operational even in

manual mode as long as T/C is intact.- Automatic T/C break protection and cold junction

compensation.- High impedance potentiometric input allows long

distance T/C wiring.- 100 % solid state circuitry, no mechanical relays.- Completely self contained, no external output de-

vices or power supplies required.- Fast acting fuses are provided on both sides of

the AC line.- Electrically isolated with grounded front panel for

operator safety.- Plug in design for module interchangeability.- Compatible with all Smart Series Main Frames.

Features

The Smart Series module combines today's electronicswith D-M-E's keen sense for human engineering, makingit the most user friendly controller on today's market.From its versatile, easy to read multi-function digital read-out to its unique Smart Start® heater dry out circuitry, it isindeed a module that is not only productive but instructi-ve.

During start-up, the module's microprocessor analyzes allinitial conditions and computes the amount of power re-quired to uniformly raise the heater temperature from am-bient to setpoint. After the start-up function, Smart Start®

procedure automatically kicks in. This procedure usespredetermined power output levels to safely dry out anyheater moisture, thereby prolonging heater life. WhenSmart Start® ends, the heater advances to setpoint andnormal automatic operation takes over.

The multi-function digital readout displays setpoint tempe-rature (auto mode) or percentage of power (manual mo-de), and can provide a readout of actual process tempe-rature at the touch of a button. Diagnostics faults foropen, reversed or shorted thermocouple are also display-ed digitally, and the module automatically inhibits powerto the heater load unit until such faults are corrected.The modules LED display indicators (located at the topright of each digit) show the mode of operation and serveto indicate when the readout is displaying process tempe-rature or percentage of power. The power to heater loadLED doubles as a Smart Start® indicator by blinking du-ring Smart Start®. Five separate color-coded LED's loca-ted under the display, indicate temperature deviation andover/under temperature conditions at a glance.

SSMX-15-G

SSMX-30-G



Microprocessor-Based T° Control Module SSMX

Front Panel Controls andIndicators1. Digital LED Multi-Function Display &

Display Mode Indicators (located in the display at the top right of each digit): (3) 7-segments LED's, 12 mm digital display, indicatethe conditions shown above, and displays either pro-cess temperature, setpoint temperature (auto),or %power (manual) and advanced diagnostics. LoadLED indicates that power is being supplied to the he-ater (blinks during Smart Start®).

Manual Control Indicator : LED in display windowilluminates

Process Temp. Indicator : LED in display windowilluminates

Shorted T/C Indicator : Digital display (Sho) al-ternates with normal dis-play

Open T/C Indicator : Digital display (oPE) al-ternates with normal dis-play

Reversed (Backward) T/C Digital display (bAC) al-Indicator : ternates with normal dis-

play

2. Temperature Deviation Lights : Indicate amount of deviation from setpoint temperatu-re. Outer lights blink when extreme over or undertemperature conditions exist.

Temperature Deviation +/- 17°C = Flashes RedIndicators : +/- 11°C = Red

+/- 5°C = Yellow+/- 0°C = Green

3. View Process Temp Button :Depress to show process temp. on display. Releaseto return display to setpoint (in auto mode) or % po-wer (in manual mode).

4. Setpoint/ % Power Adjustment Knob : Precision 10 turn potentiometer adjusts setpoint (au-to) or % power (manual)

Auto (Setpoint) Control : Precision 10 turn potentio-meter.Range : 0 to 537°CResolution 1°C

Manual (% Power) Control : Precision 10 turn potentio-meter Digital display indi-cation Range : 0 to 99 %Resolution : 1 %

5. Auto/Manual Switch :Toggle switch, selects automatic (setpoint temp.) ormanual (% power) control mode.

6. Power ON/OFF Switch :Control AC power to module. 16 Amp rocker switch,UL, CSA, VDE approved. SSMX-30-G has a highspeed circuit breaker instead, UL, VDE, CSA appro-ved.

Note : SSMX-30-G is twice as wide as above ; has cir-cuit breaker instead of Power ON/OFF switch.

OperationAutomatic Mode :The microprocessor maintains temperature using a closedloop PID control method. Closed loop means the unitcontinuously looks at the process temperature to determi-ne whether or not to adjust the power delivered to theheater. With PID control, it anticipates the system cha-racteristics to make accurate adjustments and correct forerrors. "Fuzzy logic" is used to minimize overshoot onstart up and to prevent over and undershoots when chan-ging setpoints.

1

2

3

5

6

4

D-M-ESMARTSERIES

0

MANUAL

AUTO

1

°F/°C15 AMPS MAX

PROCESSTEMP

SETPOINT

-20-5-11-10 +10

+50°F0°C

240VAC

SMART START

PROCESSTEMP

MANUAL %

SSMX-15G

+11+20

LOAD

SSMX-15-G

SSMX-30-G



Microprocessor-Based T° Control Modules SSMX

Manual Mode :For open thermocouple or thermocouple failure, openloop-percent power is used. In manual mode, the micro-processor maintains a power level using an open looppower control method. Open loop means the processtemperature is not used to determine whether or not ad-justments should be made. This enables the user to con-tinue production and override thermocouple wire breaks,short circuits, or lead reversal until the problem has beenresolved.Manual mode overrides thermocouple break protection,reversed thermocouple, and any normal automatic mode.

Smart Start® :Smart Start® is automatic on start-up in the auto mode,and provides a linear ramp to setpoint for heater bakeout. Smart Start® is complete when four minutes thirtyseconds expire or when setpoint is reached, or whentemperature exceeds 93°C

Power-up :Upon power-up, the unit retains the same setpoint andoperation mode as when the unit was turned off.

Input Fault :Thermocouple break protection, and shorted or reversedthermocouple all override Smart Start® and normal modes.Output is inhibited.

Performance SpecificationsAuto and Manual control modes: Time proportioning


Control Accuracy : 0,5°C dependent on the total ther-mal system

Temperature Stability +/- 0,5 % of full scale over theambient range of 0 to 50° C


Cycle Time : 0,33 seconds

Power Response Time : Less than 0,13 seconds

Reset : Automatically corrects reset to nomore than +/- 1°C at all settings

Manual Control : Adjustable from 0-99%. Maintains output power to within 1 % of setting

Advanced Diagnostics Indicators : LED's and 3-digit, 7-segment dis-play

Smart Start® (SS) : Linear ramp from initial temperatureto setpoint

SS® Duration : 4 1/2 minutes

SS® Override Temperature: 93°C

Operational Mode Priority : SS® precedes auto mode.Thermocouple break overrides SS®

and Auto modes.Reversed or shorted T/C overridesSS® and Auto modes. Manual con-trol overrides T/C break, reversedT/C and Auto mode.The output is inhibited during allfault conditions in automatic mode.

Input Specifications :Thermocouple (T/C) Sensor : Type "J", grounded or ungrounded

External T/C Resistance : High impedance potentiometric in-put allows long distance T/C wiring

T/C Isolation : Isolated by control circuit powersupply.


T/C Break Protection : Automatically inhibits power to hea-ter in automatic mode

Reversed T/C Protection : Automatically inhibits power to hea-ter in automatic mode

Shorted T/C Protection : Automatically inhibits power to hea-ter in automatic mode



Input Protection : Diode clamp, RC filter


Input Dynamic Range: 550°C

Common Mode Rejection Ratio: Greater than 100 db

Power Supply Rejection Ratio : Greater than 90 db

Output Specifications :Voltage/Power Capability : 15 Amp : 240 VAC nominal, single

phase, 3600 Watt @ 240 VAC30 Amp : 240 VAC nominal, singlephase, 7200 Watts @ 240 VAC

Output Drive : Internal solid state triac, triggeredby zero AC crossing pulses

Overload Protection : 15 Amp : Fuses are provided onboth sides of AC line30 Amp : Fast acting circuit breaker


Power Line Isolation : Optically and transformer isolatedfrom AC lines. Isolation voltage isgreater than 2500 Volts

Electrical Power SpecificationsInput Voltage : 240 VAC + 10 % - 20 %


DC Power Supplies : Internally generated, regulated andcompensated

Module Power Usage : Less than 5 Watts, excluding load.

Dimensions : 15 Amp : 5,08 x 17,78 x 19,05 cm30 Amp : 10.06 x 17,78 x 19,05cm

Fuse Requirements : (2) ABC-15 fuses for SSMX-15-G

Note : Standard modules are compatiblewith Main Frames wired for either240 VAC three phase (standard or240 VAC single phase).



Microprocessor-Based T° Control Modules SSMX

DiagnosticsThe SSMX diagnostics automatically alerts the user to afault condition.

Shorted T/C displays flashing ”Sho” in the auto mode(output inhibited), or is on steady in the manual modewhen reading process temperature.

Troubleshooting : Check for damage to the thermocouplelead wire. Also, check for bare, twisted or pinched leads,or excessive distance between the heater and thermo-couple.

Open T/C indicated by ”oPE” flashing while in the au-to mode (output inhibited), or on steady in the manu-al mode when reading process temperature.

Troubleshooting : Check the thermocouple connectionsand wires for broken leads or check for damage to thesensor.

Reversed T/C displays flashing ”bAC” while in the au-to mode (output inhibited), or on steady in the manu-al mode when reading process temperature.

Troubleshooting : Check T/C wiring for reversed leads.

Over/Under temperature. The red deviation LED onthe left, flashes when the process temperature is be-low setpoint by 17°C or more. The red deviation LEDon the right flashes when the process temperature isabove setpoint by 17°C or more.

Troubleshooting : Check for : Under temperature ; heaterfailure, low line voltage, T/C problem.Over temperature ; output failure, shorted triac, interactingzones.

Calibration procedure1. Insert controller into the calibration jig and turn power

on.


3. Adjust the OFFSET trimpot, R13, to read 92°C on thedisplay.


5. Adjust the SLOPE (GAIN) trimpot, R17, to read 427°Con the display.

6. Repeat steps 2 thru 5 until no further trimpot adjust-ment is needed.

7. Turn power off and remove from calibration fixture.

Communication connector compatibility :The Communication Connector strip in your Main Framecommunicates to all the other modules in the rack. If thecommunications connector in your Main Frame has pins 3and 4 missing, you must order a new communication stripfrom D-M-E allowing the alarm feature in this module tofunction properly with the TAS-05-02 module. It will notwork without these pins installed.

Notice

pins 3 & 4 are not

inserted


not compatible



Temperature Alarm/Standby Heat Module TAS

Benefits

- Simple to use - requires no special training- It can set up to 63 DSS or CSS modules in

Standby Heat mode.- It can receive a temperature alarm signal

from up to 63 SSMX, DSS or CSS modules in a D-M-E Main Frame

- Provides the user with a relay contact when a temperature alarm condition exists.

FeaturesThis new Temperature Alarm and Standby Heat moduleoffers exciting avenues to D-M-E customers. With thenew Standby Heat function a machine operator can setthe unit in Standby Heat mode, close up shop for thenight, and return the next morning to find the machineready to go without waiting for the machine to warm up.

With the built in Temperature Alarm function, the unit canalert an operator to an over or under temperature condi-tion. This alarm is visual and can be made audible withthe flick of a switch. This module also offers a pair of re-lay contacts, through the front panel connector, that closeor open upon temperature alarm condition.

The alarm features incorporated into this new D-M-E mo-dule are compatible with SSMX-15-G and SSMX-30-G se-ries temperature control modules, and D-M-E MainFrames that have a communications strip. The CSS andDSS temperature controls are also compatible with boththe alarm and Standby heat functions .

Operation :To activate the Standby Heat mode, simply flip theStandby Heat switch, located just above the pull hand, tothe "1" position. Note that the symbol above the "1"shows a partially heated heater (Standby Heat). This op-tically coupled signal will communicate to compatible DSSand CSS modules and set the temperature of the modu-les to 93°C.The Temperature Alarm is optically coupled to compatibleSSMX and compatible DSS and CSS modules. When anSSMX module reaches an alarm temperature conditionthe TAS module will alert the user with a lamp indicatoron the front panel, open/close a relay contact, and ifenabled, alarm the user with a sound emitting device.Note the symbol above the "Alarm" switch, it looks like aspeaker. In the "1" position the audible device is enab-led. In the "0" position the audible device is disabled.This does not affect the relay contacts.


1. Power-on Indicator : LED is illuminated when power is applied to module

2. Audio Alarm : Device emits loud sound when switch (6) is placed inthe "1" position and a temperature alarm condition issent by a compatible module.

3. Alarm Indicator : LED is illuminated when a temperature alarm condi-tion is sent by a compatible module.

4. Standby Heat Indicator : LED is illuminated when the Standby Heat switch (8)is placed in the "1" position.

TAS-05-02



Temperature Alarm/Standby Heat Module TAS

5. Power ON/OFF Switch : Controls AC power to module. 16 Amp rocker switch,UL, CSA, VDE approved.

6. Alarm Switch : This switch turns the audio alarm (2) ON or OFF.

7. Alarm Relay Connector : Provides the user one 5 Amp normally open contact,and one 5 Amp normally closed contact for tempera-ture alarm conditions.Note : D-M-E provides the mating connector forthis relay output.

8. Standby Heat Switch : This switch controls the signal that turns on theStandby Heat mode in the modules. When it is inthe "1" position the Standby Heat mode is selected.

Performance SpecificationsAdvanced Diagnostic Indicator : LED's and audible deviceRelay Contacts : One normally open contact, one

normally closed contact. Contactsrated at 5 Amps

Input SpecificationsAlarm Temperature Input : 5 VDC required to activate tempe-

rature alarmVoltage/Power Capability : 240 VAC nominal, single phase.

Overload Protection : Fuses are provided on both sidesof AC line


Power Line Isolation : Optically and transformer isolatedfrom AC lines, Isolation voltage isgreater than 2500 Volts

Output SpecificationsRelay Contacts : One form C (one normally open

and one normally closed) relay con-tact rated to 5 Amps, 240 VAC

Electrical Power SpecificationsInput Voltage : 240 VAC + 10 % -20 %Frequency : 50/60 HzDC Power Supplies : Internally generated, regulated and

compensatedModule power usage : Less than 5 WattsFuse requirements : (2) ABC-1 fusesDimensions : 5 x 18 x 19 cmNote : Standard (240 VAC) modules are

compatible with Main Frames wiredfor either 240 VAC three phase(standard or 240 VAC single phase).

Communication Connector CompatibilityThe Communication Connector strip in your Main Framecommunicates to all the other modules in the rack. If thecommunications connector in your Main Frame has pins 3and 4 missing, you must order a new communication stripfrom D-M-E allowing the alarm feature in this module tofunction properly with the TAS-05-02 module. It will notwork without these pins installed.

Remarks : Tas module compatibility :Alarm and Standby Heat functions : CSS-15-02/CSS-30-02

DSS-15-02/DSS-30-02Alarm function only : SSMX-15 G/SSMX-30 G

2

3

4

5

7

4

STANDBY HEAT

D-M-ESMARTSERIES

0

0 1

1

POWER

ALARM

2

1

3

0 1

240 VAC NOM 1O

TAS-05-02

1

6

8

5 Amp

5 Amp

TAS-05-02

Notice

pins 3 & 4 are not

inserted


not compatible



Digital Current/Voltage Monitor CVK

Features :Streamlined design for improved performance.The Current/Voltage Monitor is simple to operate and fea-tures a large easy-to-read digital display. Ease of opera-tion has been enhanced by streamlining the unit and eli-minating unnecessary switches and controls. When set-ting the selector switch to the desired zone number the"Amps" function is automatically selected and the meterwill then display the amount of current being delivered bythe module. Input voltage to the system can be mea-sured by rotating the selector switch to one of the threephase "Voltage" positions. This will automatically set themeter in the "Voltage" function which enables it to displaythe voltage of the selected phase.

OperationCurrent supply to each zoneTo monitor the current supply to each zone, simply setthe rotary selector switch to the desired module zonenumber. The "Amps" function is then automatically selec-ted and is indicated by the letter "A" just to the right ofthe numbers in the display window. The meter displaysthe current being delivered to the heater load in Amps.

SpecificationsVoltmeter Range: 190 to 290 VAC

Voltmeter Accuracy : +/- 3% of reading, 50 to 60 Hz

Maximum Voltmeter input : 400 VAC

Input Voltage : 240 VAC, 50 to 60 Hz

Ammeter Range : 0 to 2, 0 to 30, 0 to 40 Amps

Ammeter Accuracy : +/- 2% à 0 to 100 %Duty Cycle, 50-60 Hz

Maximum Ammeter Input: 40 Amps

NOTE :The Digital Current/Voltage Monitor is a fac-tory installed option which replaces the stan-dard circuit breaker/disconnect, and is sup-plied when "CV-style" Main Frames are orde-red.


1. Circuit Breaker/Disconnect : Applies or removes power to all modules in the fra-me

2. Power ON Light (amber) : Illuminates when Main Switch or Breaker is in theON position.

3. AMPS/VOLTS Meter: Digital multi-scale meter provides accurate readingsof zone current (Amps) or input voltage (Volts).

4. AMPS/VOLT Monitor : Appears automatically when either AMPS or VOLTSis selected.

5. Selector Switch : Multi-position switch automatically selects zone cur-rent or phase line voltage to be monitored. For sys-tems with more than 12 zones, additional meter andselector switch panels are supplied.

REF For Main FrameCVK 5 5 zones 15 AmpsCVK 8 8 zones 15 AmpsCVK 12 12 zones 15 AmpsCVK 2-H 2 zones 30 AmpsCVK 3-H 3 zones 30 AmpsCVK 5-H 5 zones 30 Amps

CVK 5 CVK 2-H

CVK 8 CVK 3-H

CVK 12 CVK 5-H

Smart Series® Single-Zone Temperature Controllers


Smart Series® Single-Zone Temperature Controllers - ESH

Benefits

- Compact and self-contained- Provides microprocessor-based PID control- More accurate than analog, variac or slower time

proportioned systems- Built-in thermocouple fault diagnostics- Ideal for use with Hot-Sprue Bushings and

Nozzles

FeaturesThis new Smart Series® unit combines today's electronicswith D-M-E's keen sense for human engineering, makingit the most user friendly controller on today's market.From its versatile, easy to read multi-function digital read-out to its unique Smart Start® heater dry out circuitry, it isindeed a unit that is not only productive but instructive.

During start-up, the unit's microprocessor analyzes all ini-tial conditions and computes the amount of power requi-red to uniformly raise the heater temperature from am-bient to setpoint. After this start-up function, the SmartStart® procedure then uses predetermined power outputlevels to safely dry out any heater moisture, thereby pro-longing heater life. When Smart Start® ends, the heateradvances to setpoint and normal automatic operation ta-kes over.


1. Digital LED multi-funtion display & display mode indicators (located in the display at the top right of each digit) :

(3) 7-segment LED's 12,7 mm digital displays, indica-te the conditions shown above, and displays eitherprocess temperature, setpoint temperature (auto) or% power (manual) and advanced diagnostics. LoadLED indicates that power is being supplied to theheater (blinks during Smart Start®).

SMARTSERIES

0 D-M-E

110 AMPS MAX

ESH-10-02240VAC °F/°C

-10-5-11

-20+5+10

0°C0°F

SMART STARTPROCESSTEMP

MANUAL %

MANUAL

+20+11

AUTO

LOAD

PROCESSTEMP

SETPOINT

6 1 5 4

2 3

EHS-10-02

The multi-function digital readout displays setpoint tempe-rature (auto mode) or percentage of power (manual mo-de), and can provide a readout of actual process tempe-rature at the touch of a button. Diagnostics faults foropen, reversed or shorted thermocouple are also display-ed digitally, and the unit automatically inhibits power tothe heater load until such faults are corrected.

The units LED display indicators (located at the top rightof each digit) show the mode of operation and serve toindicate when the readout is displaying process tempera-ture or percentage of power. The power to heater loadLED doubles as a Smart Start® indicator by blinking du-ring Smart Start®. Five separate color-coded LED's loca-ted under the display, indicate temperature deviation andover/under temperature conditions at a glance.




Manual Control Indicator: LED in display window il-luminates

Process Temp. Indicator : LED in display windowilluminates

Shorted T/C Indicator : Digital display ”Sho” alterna-tes with normal display

Open TC Indicator : Digital display ”oPE” alternateswith normal display

Reversed (Backward) T/C Indicator : Digital display”bAC” alternates with normal display

2. Temperature deviation lights :

Indicate amount of deviation from setpoint temperatu-re. Outer lights blink when extreme over or undertemperature conditions +/- 17 °C exist.

Temperature Deviation indicators (5 separate LED's) :+/- 17°C = Red Flashes+/- 11°C = Red+:- 5°C = Yellow0° C = Green

3. View process temp. button :

Depress to show process temp. on display. Releaseto return display to setpoint (in Auto mode) or % po-wer (in Manual mode).

4. Setpoint / % power adjustment knob : Precision 10 turn potentiometer adjusts setpoint(Auto) or % power (Manual).

Auto (Setpoint) Control : Manual (% Power) ControlPrecision 10 turn potentiometer Precision 10 turn potentiometerRange : 0 to 537°C Resolution : 1 %Resolution : 1°C Range : 0 to 99 %

5. Auto/Manual switch :

Toggle switch, selects automatic (setpoint temp.) ormanual (% power mode).

6. Power ON/OFF switch :

Controls AC power to unit, 16 amp rocker switch, UL,CSA, VDE approved.

Operation

Automatic Mode :

The microprocessor maintains temperature using a closedloop PID control method. Closed loop means the unitcontinuously looks at the process temperature to determi-ne whether or not to adjust the power delivered to theheater. With PID control, it anticipates the system cha-racteristics to make accurate adjustments and correct forerrors. "Fuzzy logic" is used to minimize overshoot onstart ups and to prevent over and undershoots whenchanging setpoints.

Manual Mode :

For open thermocouple or thermocouple failure, openloop-percent power is used. In manual mode, the micro-processor maintains a power level using an open looppower control method. Open loop means the processtemperature is not used to determine whether or not ad-justments should be made. This enables the user to con-tinue production and override thermocouple wire breaks,short circuits, or lead reversal until the problem has beenresolved. Manual mode overrides thermocouple breakprotection, reversed thermocouple, and any normal auto-matic modes.

Rear Panel1. Mold power / Thermocouple output

connector :

is connected to the mold heater and thermocoupleconnections.

2. Power inlet connector :

is connected to the line voltage to operate the unit at120 or 240 VAC.

TC 14

3 2

5 +

- 240 VAC

Performance SpecificationsAuto and Manual Control :Modes : High speed time proportioning


Control Accuracy : 0,5°C dependent on the total ther-mal system

Temp. Stability : +/- 0,5% of full scale over the am-bient range of 0 to 50°C

Calibration Accuracy : Better than 0,2% of full scale

Cycle Time : 0,33 seconds

Power Response Time : Less than 0,13 seconds

Reset : Automatically corrects reset to nomore than +/- 1°C at all settings

Manual Control : Adjustable from 0-99%. Maintainsoutput power to within 1% of set-ting

Advanced Diagnostics LEDs and 3-digit, 7-segment dis-Indicators : play

Smart Start® (SS) : Linear ramp from initial temp. tosetpoint

SS® Duration : 4 1/2 minutes

SS® Override Temp 93°C

Operational Mode Priority : SS® precedes auto mode.T/C break overrides SS® and Automodes.Manual control overrides T/C break,reversed T/C and Auto modes.The output is inhibited during allfault conditions in automatic mode.

Input Specifications

T/C Sensor : Type "J" grounded or ungrounded

External T/C Resistance: High impedance potentiometric in-put allows long distance T/C wiring.

T/C Isolation : Isolated by control circuit powersupply.


T/C Break Protection : Automatically inhibits power to hea-ter in automatic mode

Reversed T/C Protection : Automatically inhibits power to hea-ter in automatic mode


Shorted T/C Protection : Automatically inhibits power to hea-ter in automatic mode



Input Protection Diode clamp, RC filter


Input Dynamic Range : 550°C

Common Mode Rejection Ratio : Greater than 100 dB

Power Supply Rejection Ratio : Greater than 90 dB

Output SpecificationsVoltage/Power 240 VAC nominal, single phase, 10

Amp

Capability : 2400 watts @ 240 VACOutput Drive : Internal solid state triac, triggered

by zero AC crossing pulses.

Overload Protection : Fuses are provided on both sidesof AC line

Transient Protection : dv/dt and transient pulse supressionincl.

Power Line Isolation : Optically and transformer isolatedfrom AC lines. Isolation voltage isgreater than 2500 vollts.

Electrical Power SpecificationsInput Voltage : 240 VAC +10% -20%


DC Power supplies Internally generated, regulated andcompensated.

Power Usage : Less than 5 watts, excluding load.

Dimensions : 18 x 7 x 22 cm



No view No view

Spare PartsABC

REF.ABC-10

* To be ordered separately, rest is included with the Single Zone Temperature Controller.

FusesC 146 10A

REF.C 146 10A 004 0024

Male InsertC 146 10F

REF.C 146 10F 003 0004

HousingC 146 10 G

REF.C 146 10G 003 2004

Hood top entryMCC

REF.MCC-0001*

Power & TC Cable

C 146 10B

REF.C 146 10B 004 0024*

Female Insert




Two-Zone Main Frames for Temperature Control MFFPRX-2-G

SpecificationsInput voltage : 240 VAC, 50/60 Hz

Max. Load : 15 A / zone

Dimensions : L:160 mm, W: 180 mm, H: 190 + 20 mm

Weight : 4 kg

Items included when ordering a MFFPRX-2-G main frame:2 power-output connectors PIC-12 Thermocouple mini plugs TC-P1 Power-input connector PN-30

Remarks : modules to be ordered separately

MFFPRX-2-G

Spare PartsRear PanelPN-30

Power inputconnector

PIC-2Power inputconnector

TCS-2Thermocouplestrip

PIC-1Power outputconnector

GS-1Power inputsocket

ABC-15Fuses

GD-1Power outputsocket

TC-PThermocoupleconnector

MFBPBlank panel

THERMOCOUPLE INPUT :Type " J "

NOT USED :Nr 3

GROUND :

Nr 1 + 2 -

3

2 1

3

2 1

N

L

GROUND

POWER OUTPUT :

POWER INPUT =>

TYPE " J "

21+ __+

Zone 2

Zone 1

A.C. IN

PN-30

PIC-1

TC-P

NOTES

NOTES

Documents

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