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Operations manual

NR5000-v.3

Hotrunner temperature controller

from 10 up to 16 zones

Nolden Regelsysteme GmbH

Gewerbegebiet Volmershoven

Am Tonschuppen 2 · D-53347 Alfter

�++49/ 228 64 48 56 · �++49/ 228 / 64 03 09

[email protected]

© 08/14 All rights reserved

Operations manual NR5000-v.3

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Dear customer,

thank you for having chosen a NOLDEN temperature con-troller. This high quality device has been produced in our ISO 9001-certified factory and was shipped to you after a thourough quality test.

Unpack Check the device for eventual shipping damage. Don't connect damaged equipment ! Claim the damage with your shipping agent.

Read Please read carefully this operating manual be-fore bringing the device into service !

Connect Wiring the device should be done by your quali-fied electrician following the instructions given in this manual.

Warranty period is 2 years and includes all malfunctions clearly caused by material, production or design failures. Repair or replacement in this case are free of charge, you only pay the shipping cost to our factory. No further claims or requirements can be accepted, especially for consequential losses or damages.

Service We help you quickly and at resonable costs. Just send us the device with repair order and precise description of the malfunction.


NOLDEN Regelsysteme GmbH 3

Carefull packaging is essential for a safe shipment !

Small repairs up to 80,- EUR are done immediately without formal offer. In any other case, we contact you as soon as possible to determine the next steps.

To facilitate your orientation in this manual, you find the following symbols :

Safety advice

General information

Wiring- and installing advice


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Table of content Chapter Page 1 Features 5 2 Safety advice 6 3 Specification 8 4 Installation and wiring 10 5 Operation : 14 5.1 Operating elements and keys 14 5.2 Master switch 15 5.3 Display and operation modes 16 6 Settings : 27 6.1 Configuration level - device 27 6.2 Configuration level - zones 37 6.3 Operation level - Control parameters 47 6.4 Mould diagnosis function 52 6.5 Error messages 62 6.6 Factory default settings 63 7 Key word index 66 8 Appendix : 70 8.1 Custom pin assignment 8.2 Interface parameters (optional) 72 9 CE-Conformity declaration 78



1. 1. Features Ready to use compact multizone temperature controller for all 230V hotrunner systems - Compact unit for 10, 12 or 16 zones - Automatic self-tuning for every zone, also during current operation („Hot autotuning“) - LCD grafic display with plain language operation - Mould diagnosis function with wiring analysis and various self-monitoring functions - Heater load shedding to protect the hotrunner against overtemperature - Intelligent, programmable soft start routine - Stand-by operation for production stops - also to be activated via external switch - Boosting to free „frozen“ nozzles - Programmable alarm settings for every zone - Integrated heater current monitoring - Data interface as an option (e.g. Arburg)


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2 Safety advice 1. Please read this advice carefully. 2. Keep this operations manual for use near the machine. 3. This is an electral device driven with high voltage, please respect the usual VDE- and safety regulations. Mains voltage and every voltage greater than 42 volts is dangerous ! 4. Connect to a power source following the identification plate on the device. 5. Avoid contamination of the interior with debris, liquids or sprays. Risk of short-circuit, fire or electric shock ! 6. Before cleaning the device, disconnect from the power source. 7. Place the device in a stable manner and prevent it from slipping away. Take care of the tension load created by the wiring, fix the cables separately from the controller. 8. Don‘t place the device on hot machine surfaces or near radiation sources of hot parts. 9. Keep the power connection cable clear of hot parts or sharp edges.



10. Disconnect the power cable immediately, if - it was damaged, - liquid or parts penetrated the device, - the device was damaged by falling down or other mechanical impacts, - you have the suspicion of any malfunction. 11. The operator must be thoroughly instructed by a qualified person for the work to be carried out. 12. Intervention at the device must only be carried out by qualified staff members. For repair, the device should be send back to our factory. Attempted self-repair causes immediate termination of the warranty period ! If spare parts are required, only parts recom- mended by the supplier must be used. The use of other parts may cause damage and/or hazard for operation personnel. 13. Please respect further recommandations and warnings described in this operations manual. .


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3. Specification Mains voltage : 230V 3~, +/- 10%, 50/60Hz Nominal rating/nominal current : Max. load per zone 3.600W / 16A Total load of the device max. 17,25kW, 3x25A Fuses Heater : 16A FF, 6,3x32mm per zone Alarms: 2 alarms programmable per zone, each as temperature– or current alarm Sensor inputs : Thermocouple Fe-CuNi, type J, 0...800°C Internal zero point correction Thermocouple is monitored for cable breakage, short-circuit and polarity errors. Power control : 0...100% proportional, zero-voltage switching Triac rated up to 35A Display : Shows actual values en setpoints, load current, alarms, configuration parameters, control deviations and temperature curves Language settings English / German, plain text for control– and configuration-parameters



Automatic soft-start : (factory defaults) Powersetting 50% / temperature 80°C / time 5 min Sensor-/load-connectors : 16 or 24-pole standard-industry female plug 16A/400V Pin assignment NR-Norm, other norms available (see appendix) Standby / alarm-exit : 7-pin plug : 2 floating contacts (230VAC, max. 3A) for alarms. One floating input to activate the 2

nd (standby-)

temperature-setpoint for all zones simultaneously, wired in parallel with the internal “stand-by” switch. Accuracy : 0,25% FS Insulation voltage : 2,5kV mains/sensor circuit

Dimensions 429 x 380 x 167mm (WxDxH, 10 to 16 zones)

Colour Structured RAL3000 Casing Weight 16 kg (NR5016)


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4. Installation and wiring : 4.1 Installation : The installation site must provide easy access for the operator without hazard. Sufficient mechanical stability must be guaranteed, also secure the device from slipping on the installation surface. Protect from heat, radiation and allow free air circulation. Protect power cable from heat and mechanical stress. Do not place the device on hot surfaces. Take care of the tension load created by the wiring, fix the cables separately from the controller. 4.2 Connection of the power supply : This device must only be operated at the voltage indicated on the name plate. Please check for a sufficient fuse protection of the power outlet fore- seen for the device. Protective earth conductor must be provided ! 4.3 Connection of heater and thermocouples : Please compare the connecting diagram on the temperature controller (backside, near the outlet) with the diagram of the mould. Inappropriate con nection can destroy controller, heater and TC ! Available mould connecting cables contain heater– and FeCu-Ni compensation wires for TC. Never use compensation wires to connect a heater.



Maximum load capacity for the heater when using mould connector VK24 (24-pol. + PE) or VK16 (16-pol. + PE) The maximum load capacity of the heater wires (1,5sqmm Cu) depends on the operating conditions (see also DIN VDE 0298 Part 2 and 4). @ op. condition : Continuous @ wire location : Individually, free installation on wall or floor @ ambiant Temperature : 30°C, free air circulation, no heat radiation VK 24 : VK 16 : 1 heater 12,5 A 1 heater 12,5 A 2 heaters 12,5 A 2 heaters 12,5 A 3 heaters 11,5 A 3 heaters 11,5 A 4 heaters 10,5 A 4 heaters 10,5 A 5 heaters 10,0 A 6 heaters 9,5 A Load and TC- connection NR24 : Load and TC- connection NR16 : Other pin assignment (see appendix page 70 of this manual)


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4.4 Alarm-/ Stand-by connection : For every zone, two alarm functions can be programmed individually. These alarms operate 2 common floating contacts as cumulative exits for all zones together, they are wired on a 7-pin connector on the back side. Default settings are one process- high temperature alarm (A1, pin 4 and 5) as well as one load-breakage alarm (A2, pin 2 and 3). To activate the 2nd temperature set-point (stand-by function), another floating contact is wired to pin 6 and 7. This function can also be activated manually with a button on the front panel .



1 2 3 4

Fig. : Back side NR 5016 5

1 Heating– and TC-connection 2 Data-interface (optional) 3 Alarm ouput / external Stand-By 4 Load fuses for every heating zone 5 Netzanschlußleitung


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5. Operation 5.1 Keys and operation elements 3 4 1 5 2 6 7 8 Fig. : Front view NR 5016

1 Display 2 Keys 3 Switch for stand-by operation 4 Boost-key 5 Switch to de-activate the heater load-shedding 6 Phase control lights (one for every phase) 7 Master switch 8 Load fuses for every heating zone



5.2 Master switch Before wiring the device, make sure that the master switch is in position OFF „0“. Herewith, all poles are disconnected from the mains voltage. Before working on the device itself or on a tool connected to it, the switch must be locked to prevent the device against unintentional restart. This can be done by retracting the power cable and securing it against re-connecting. After having finished the wiring completely, switch the device on with main switch in position ON „1“. In addition to the masterswitch itself, all 3 phase- control-lights must now be lighted. Is this not the case, one phase of the mains voltage is not active. The most common origin of this problem is o blown fuse in the electrical cabinet. Even if the display seems to work correctly, a part of the heating zones may not work in this case. Before continuing the start-up of the controller, you have to fix the problem with the mains voltage first.


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5.3 Display and keys Display : The device is equipped with a bright, sharp LCD- screen. After switching the unit on and internal test, the actual temperatures of all zones are being shown.

Zone: 14 Actual temperature: 110 °C Parameters and settings are mostly being displayed in plain text. The display can be set to other languages (see chapter 6.1 configuration level - device).



Keys : Zone selection Actual value and setpoint of the choosen zone Parameter selection in one choosen zone. Parameter setting (e.g. setpoint or control parameter) to higher or lower values. (altered, but not yet acknowledged values are being marked with a flashing „E“

Enter - Acknowledges the pre-set values and

saves them into power-independant memory

Menu - Configuration menu for the whole device or for one zone, depending on the actual screen beeing displayed „HOME“ - Back to home menu with display of actual temperature of all connected zones


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Tracing function. Shows the actual temperature curve of one zone (to be choosen first with the zone key) To turn off the tracing function, press the key again. Switch display from actual temperature of all zones to other screens : - Setpoint / Actual value of all zones - Process view (groups of 4 zones) - Tendency display - shows the temperature deviation vs. setpoint in all zones simultaneously, also display of eventual alarms per zone Contrast adjustment of the LCD-screen : Press „Enter “ and at the same time the „▲“ or „▼“ keys



Switch for stand-by operation Toggles all zones simultaneously from normal temperature setpoint SP1 to stand-by setpoint SP2, e.g. to lower the temperature during process interuptions to prevent the mass from „cooking“. Wired internally in parallel with the “stand-by” plug on the back side of the device. This permits the switching to stand-by mode also by an external contact, e.g. in the injection moulding press. If a higher setpoint SP2 is programmed, the controller can also be used to follow a triggered temperature curve in the process. Manual Boost - temporary temperature increase for all zones by a pre-set value (boost addiation SP3), e.g. to free „frozen“ nozzles. The activated boost-setpoint is hold for a given time (boost holding time), then the temperature is lowered again to the normal operation setpoint SP1. Switch to de-activate safety load shedding Prevents alarm A1 from switching off the total heating power of the controller in case of overtemperature (see next page) .


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Safety loadshedding Alarm A1 is wired as a safety switch-off directly to the master switch of the heating loads. Is alarm A1 active of one (or several) zone, the heating load is switched off for the whole controller. This prevents damage of the mould or hotrunner in case of a too high temperature somewhere in the system. As a factory default, alarm A1 is set as a process- high-alarm, but this can be modified in the zone configuration as needed. Mind the safety function of alarm A1 when changing the alarm configuration. Safety loadshedding can be deactivated with a dedicated key on the front panel, e.g. for a test or evalu- ation phase. In this case, no protection against thermal overload is granted. Phase controll lights for all 3 phases of the mains power source. Is one of the controll lights not lit, the according phase of the power source is not functioning, several heaters and/or the main control unit are not working properly. Before looking for malfunctions in the control device, check the correct power supply first. Master switch (see chapter 5.2)



Display modes with direct access by keys HOME - shows actual temperature of all zones in total view Error „Er.H“ : Upper range end exceeded or TC wire breakage in the concerned zone Error „Er.L“ : Lower range end exceeded or TC shortage in the concerned zone No indication : Concerned zone is switched OFF


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Zone detail view - shows actual temperature, setpoint and alarms of one zone.

Zone-Nr. : With the „ ▲“ and „▼ “ keys, adjust the setpoint value as needed. Altered, but not yet acknowledged values are being marked with a flashing „E“, acknowledge with the „Enter“ key. „PROC“ : Setpoint 1 active „PROC SP2“ : Setpoint 2 active „MANUAL“ : Manual powersetting active (Manual mode) Setpoint 2 is only adjustable in the menu „Configu- ration level - zones“ . Other indications : - „OUTPUT“ (power setting) in %: Shows the actual calculated output ratio in percent of the installed heating capacity. It can‘t be adjusted in this menu.



Other indications (cont.) : - „CURRENT“ : Heater current in Ampere - Alarm : Alarm active, e.g. : A1 A - Status indications : Autotuning active : OPT Setpoint ramp active : RAMP Error message : E. xx (see chapter 6.4) Switch display mode - press 1x : Setpoint / process view of all zones Setpoint values can also be set in this display mode. To do so, press „Enter“ to activate the editing mode, move the cursor to the desired zone with the „Para“ and „Enter“ keys. Adjusting the values is the same as in the „Zone“ display mode. Move the cursor then to another zone as described, if needed.


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Switch display mode - press 2x : Process view (groups of 4 zones) This display mode shows the same information as in the „Zone detail view“, but in groups of 4 zones to allow a comparison of different zones. Moving the cursor and adjusting values works as decribed above. Switch display mode - press 3x :

Tendency display and alarms

This screen shows the temperature deviations and alarms A1 resp. A2. It allows a quick overview of the controll situation of all active zones.



: Temperature deviation vs. setpoint : < +/- 1% of the range

: Temperature deviation vs. setpoint :

+/- 1,5% of the range

: Temperature deviation vs. setpoint : > +/- 3% of the range

Line A1 : If Alarm A1 is active, „ ֠ “ is shown

under the concerned zone Line A2 : If Alarm A2 is active, „ ֠ “ is shown

under the concerned zone If a continuous current flow is detetcted (triac failure), „Current failure alarm“ is being displayed.

Tracing function

^ Shows the actual temperature development over the time for one choosen zone. Therefore, select first the desired zone with the „Zone“ key.


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The time axis is determined by the parameter „Sample time“ (see chapter 6.1). This tracing function enables the operator to observe the control behavior of any zone without the need of additional measurement equipment and to adjust the parameters accordingly, if needed. In the event of an failure, the development of the temperature prior to the failure can be studied afterwards to analyse eventual causes. Actual temperature is alwas being displayed symmetrically around the valid setpoint at this moment. It is also shown in the lower right corner of the screen.

Key „▲“ : Decrease scale based on active setpoint = Detailled indication Key „▼“ : Increase scale based on active setpoint = Approximate indication To turn off the tracing function and return to the zone detail view, press the - key again.



6 Settings 6.1 Configuration level - device Parameters determining the functioning of the entire device, thus, valid for all zones. Those parameters are already pre-set at delivery, altering them can cause malfunctions in some cases (e.g. the sensor configuration). - Press the „HOME“ key for the general overview of all zones, - then press „Menu“ key for 3 sec. The 1

st parameter

(mould diagnosis function ON) is shown. - Alter the actual parameter with the „▲“ and „▼ “ keys. - Save with „Enter“ key into power-loss save memory - Scroll through the list of parameters with the „Para“ key - If no entry is made for about 15 sec., the display switches back to the general overview of all zones. - Quit this menu : Press „Enter“ key 3 sec .


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List of all parameters with associated options : - Mould diagnosis ON function start : OFF Mould diagnosis function with the associated settings is described in a separate chapter (see 6.4). - Synchronisation ON OFF With „Synchronized heating“ active, all zones are heated up together, that means that all zones reach their setpoint at approximately the same time. This avoids that quick zones (e.g. the hot tips) reach their set-point temperature much earlier than slower ones (e.g. the manifolds), which could cause „cooking“ of the material in the tips or even a damage of the hotrunner system. - Adjustment lock - All parameters adjustable - Only setpoint 1 adjustable - Setpoints, alarm values and ramps adjustable - All parameters locked The parameters that have been locked can be displayed but not altered. Factory default (list see Chapter 6.6)



- Tracing function : 2,5 sec. ... 10 min. Sample time (factory default : 10 sec.) Time between two subsequent temperature values to be stored in the memory. The total time viewable at once with this sample time is shown on the display . Attention: The sample time must be inferior to the fastest change in actual temperature. Up to 90 temp. values can be stored. - Alarm A1 Configuration (wired to pins 4 and 5 of the alarm connector) Ko:0 Alarm OFF Ko:1 Signal contact (rel. to setpoint) off - on Ko:2 Limit contact (abs. value) off - on Ko:3 Limit contact (range) off - on - off Ko:4 Signal contact (rel. to setpoint) on- off Ko:5 Limit contact (abs. value) on - off Ko:6 Limit comparator (range) on - off - on Ko:7 Limit comparator with start-up suppression off - on - off Ko:8 Heater current monitoring Limit contact (abs. value) off - on Ko:9 Heater current monitoring Limit contact (abs. value) on - off Factory default (list see Chapter 6.6)


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- Alarm A1 Switching behavior (wired to pins 4 and 5 of the alarm connector) Direct Alarm active „ ֠ “ Contact closed Alarm not active Contact open Inverted Alarm active „ ֠ “ Contakt open Alarm not active Contact closed - Alarm A2 Configuration (wired to pins 2 and 3 of the alarm connector) Ko:0 Alarm OFF Ko:1 Signal contact (rel. to setpoint) off - on Ko:2 Limit contact (abs. value) off - on Ko:3 Limit contact (range) off - on - off Ko:4 Signal contact (rel. to setpoint) on - off Ko:5 Limit contact (abs. value) on - off Ko:6 Limit comparator (range) on - off - on Ko:7 Limit comparator with start-up suppression off - on - off Ko:8 Heater current monitoring Limit contact (abs. value) off - on Ko:9 Heater current monitoring Limit contact (abs. value) on - off Factory default (list see Chapter 6.6)



- Alarm A2 Switching behavior (wired to pins 2 and 3 of the alarm connector) Direct Alarm active „ ֠ “ Contact closed Alarm not active Contact open Inverted Alarm active „ ֠ “ Contakt open Alarm not active Contact closed - Alarm A1 5 Steps delay time (sec.) off = no delay Time delay, if Alarm A1 is set for current monitoring. Set-ting and display in seconds. The steps are calculated in-ternally depending on the current detection cycle time and the number of active controller zones. - Alarm A2 5 Steps delay time (sec.) off = no delay Same, if alarm A2 is set for heater current monitoring. Factory default (list see Chapter 6.6)


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General remarks about alarm configuration : The parameters A1 and A2 define the type of alarm and the switching behavior of the associated alarm relay : - Temperature or heater current monitoring - Absolute or relative alarm limit value The previously described configuration options are defined as follows : Signal contact : Alarm limit value is relative to the active setpoint temperature and changes simultaneously, it can so act as a process-high or process-low alarm. Example: Alarm value : +50°C Setpoint : 230°C -> Alarm from 280°C Limit contact : Alarm limit value is absolute and independent from the actual setpoint temperature. Limit comparator (range) : Alarm limit value range is relative to the active setpoint temperature and changes simultaneously, it acts as a process-high and process-low alarm. Example: Alarm value : 50°C Setpoint : 230°C -> Alarm up to 180°C and from 280°C



Limit comparator with start-up suppression : As before, but the alarm contact is first closed after initial start-up and opens, if the alarm value has reached once the good range. Every alarm contact acts as a common alarm for all zones. All alarm limit values in the different zones programmed as A1 switch relay A1 (pins 4 and 5), all values programmed as A2 switch relay A2 (pins 2 and 3 of the alarm connector). The previsously described alarm configuration for A1 and A2 is valid for all active zones. The different alarm limit values can be set individually for every zone in the operation level - control parameters „Alarm A1“ and „Alarm A2“ (see chapter 6.3). - Current monitoring : The following parameters are only displayed, if one of the two alarms A1 or A2 is set for current monitoring (Ko8 or Ko9). Current detection 1 ... 60 sec. (Factory default : cycle time (sec.) 2 sec) Time between the current measurement of two sub-sequent zones .


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- Min. leakage OFF; 0,0 … 99,9A (Factory current threshold default : 0,3A) Monitoring of the heater circuit for eventual leakage current due to SSR short-cut. If a leakage current is detected, the alarm relay will be activated. The status will be displayed as follows: See „Zone information“: „Er.Cu“ (Error Current) flashes See „Tendency display“: „Permanent current“ The zone with permanent current can only be determined by checking the actual temperature values (will be too high). - Zones offset : off; 1 - 91 Continuous numbering of controller zones, if more than one device is used. Example : offset =off zones numbering: 1-4, 1-6 or 1-8 offset =4 zones numbering: 5-8, 5-10 or 5-12 Factory default (list see Chapter 6.6)



- Sensors : Pre-set : Pt100-resistance thermometer or thermocouple (TC) ? all zones TC; all zones Pt100 After the pre-set in the device settings is done, every zone has to be set to the connected sensor type and its range in the zone configuration (see Chapter 6.2). Attention: The sensor type is defined by the factory through the internal wiring of the device. Altering the parameter without change of the wiring will definitely cause malfunctions in temperature measurement and control ! - Language : deutsch / german englisch / english - Device code : EL.xx - Current transformer ratio : 1:1000 Defined by the current transformer installed in the system, altering this value will definitely cause errors in the heater current measurement. Factory default (list see Chapter 6.6)


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- Interface-protocol : This parameter and the following ones are only shown if the device is equipped with a serial data interface (option). The associated settings are described in a sepa-rate chapter (see 8.2) . - Time-out autotuning : 5 ... 200 min Factory default : 15; Maximum duration for the autotuning function, after this time is expired, autotuning is stopped and the pre-set standard PID values are loaded. - Back to factory OFF, ON default settings: Overwrites all device and zone-specific parameters with the factory default settings (list see chapter 6.5). End of this parameter level. Back to top of list : „Start mould diagnosis function“.



6.2 Configuration level - zones Parameters determining the functioning of each zone individually. Also these parameters are already pre-set at delivery, altering them can cause malfunctions in some cases (e.g. the sensor configuration).

- Press the „Zone“ key to show the desired zone - then press „Menu“ key for 3 sec. The 1

st parameter

(zone on/off) is shown. - Alter the actual parameter with the „▲“ and „▼ “ keys. - Save with „Enter“ key into power-loss save memory - Scroll through the list of parameters with the „Para“ key - If no entry is made for about 15 sec., the display switches back to the detail view of this zone. - Quit this menu : Press „Enter“ key 3 sec .


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List of all parameters with associated options : - Zone on/off on Measuring- or controller zone active (default) off Measuring- or controller zone switched off - Controller AUTOMATIC (factory default ) Output mode : In event of sensor break the controller automatically maintains the last valid output ratio. MANUAL The controller now operates only as an actuator = manual mode. The controll function (PID) is not active. If MANUAL is set or activated trough a sensor break, the output ratio can be set manually just like a setpoint as follows : Press „ zone“-key to display the desired zone PROCESS: Error warning: Er.H or Er.L. MANUAL: The actual output ratio is shown. Set the desired output ratio with the „▲“ and „▼ “ keys. The altered value flashes until acknowledged with the „Enter“ key. Factory default (list see Chapter 6.6)



- Setpoint 2 off; Adjustment range: Lower setpoint limitation... Upper setpoint limitation (factory default : 100°C) Setpoint 2 is valid for all zones, if the „Stand- by“ switch on the front panel is actuated or if the external contact (pins 6 and 7) is closed. If Setpoint 2 = Off : Setpoint 1 is still valid, even if contact K1 is closed. - Boost addition : 0 … 99°C (factory default : 5°C) Manual Boost - the valid operational temperature setpoint SP1 is temporarily increased for all zones by a pre-set value (boost addiation SP3), e.g. to free „frozen“ nozzles. The activated boost-setpoint is hold for a given time (boost holding time), then the temperature is lowered again to the normal operation setpoint SP1. Example: Setpoint 1 = 200°C, Boostaddition = 10°C, gives a Boost-setpoint of 210°C The boost-setpoint is activated automatically once during every start-up (actuating of the master switch), alternatively by choosing the temporary boost with the dedicated „Boost“- key on the front panel. (The boost-function is only available during normal operation with setpoint 1, not in stand-by operation with setpoint 2. De-activation of the boost is done by entering a boost-addition of „0°C“


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- Boost-holding time: off; 0 … 90 sec. (factory default: 30 sec.) - Softstart : off : Softstart function on / off not active on : Softstart function active (factory default) If „on“, set the following parameters : - Softstart : 10... 100% output ratio ( % ) (factory default : 50) - Softstart : Range : Setpoint min..... setpoint (°C) setpoint max. (factory default : 80) - Softstart : off; 0,1... 10,0 min. duration time (min.) (factory default : 5,0)



General remarks about softstart : Setpoint 1 Softstart- Setpoint Softstart-output ratio Softstart- Duration time During the softstart, the controllers output response is limited to a preselected softstart output ratio in order to achieve a slow baking out of high perfor- mance heating cartridges. Once the process value reaches the softstart setpoint, it remains stable at this value for a preselected softstart duration time. At the end of this period, the process value rises to the assigned setpoint. During the softstart phase, autotuning can not be activated. If a setpoint gradient is programmed, it is also not active during the softstart.


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The softstart works, if - the controller is switched on and the actual temperature is below the softstart setpoint minus 5% of the range (e.g. range: 400°C -> 5%= 20°C). - the parameter „1 P“ (prop. band, xp) is programmed > 0,1%. The softstart can be activated and programmed for every zone individually. - Setpoint limitation: Highest adjustable setpoint max. setpoint value (factory default: 400°C) - Setpoint limitation: Lowest adjustable setpoint min. setpoint value (factory default: 0°C) - Copy all parameters The „Zone Configuration“ and of this zone to the following controller parameters (described in chapter 6.3 and programmed in this zone) can be copied to each other zone, if all zones have the same kind of sensors. We recommend to program first one zone enti- rely, set the desired control parameters and copy then to all other zones as needed.



Destination zone number, to which all parameters will be copied. Set with the „▲“ und „▼“ keys. „All“ : copy to all zones. Parameter are being copied, after the „ Enter “ - key is pressed While the copy function is active : „COPY“ is shown. - Max. output ratio 0...100 % limit „%“ : Limitation of the output ratio is only necessary when the heating element is largely overdi- mensioned. Under normal circumstances, no limitation is needed (default setting = 100%). Attention ! The output ratio limitation does not work during autotuning. - Rising ramp off; 0,1 ...99,9 ° C/min. or °F/min. (factory default : off) 0,01...9,99 °C/min. or °F/min. if a range with decimal point is selected - Falling ramp off; 0,1 ...99,9 ° C/min. or °F/min. (factory default : off)


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A programmed ramp is always activated when the setpoint is altered or when the mains supply is switched on. The ramp can be activated for both setpoint 1 and setpoint 2. - P-value off; 0,1...100,0 % Proportional (default : 3,0) band If „off“, go to parameter „Cycle time“. - I-value off; 1...1000 secs. (default : 150) Reset time (sec.) - D-value off; 1...200 sec. (default : 30) Rate time (sec.) General remarks about control behavior : Normally the controller works using PID control b e - havior. This means, controlling without deviation and with almost no overshoot during start-up. The optimal PID-parameters for every system (=mould) are mostly found by performing a so called „self-optimizing“ or „autotuning“ by the controller itself. Those parameters are convenient in most cases and guarantee a stable, precise temperature control. That‘s why introducing PID parameters by hand is only required in exceptional cases, e.g. design faults of the mould as wrong position of the temperature sensor.



The previously determined PID-parameters are then overwritten and aren‘t available anymore for control purpose. If the manual introduction of PID parameters does not lead to a improved control behavior, another autotuning must then be performed again. - Process-Offset : - 999... off… 1000 °C / °F - 9,9... off… 10,0 °C / °F This parameter serves to correct the input signal, e.g. for the correction of a gradient between the measuring point and the sensor tip or correction of the control devition when using P- or PD-action. Example : Offset value is set to +5°C, then the real temperature measured by the sensor (when process is ba- lanced) is 5°C less than the setpoint and the displayed process value. Make shure that the actual temperature value including the offset does not exceed the actual range.


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- Sensor type : TC Fe-CuNi (J), 0 ... 400 °C TC NiCrSi-Ni (N), 0 … 1.200 °C TC NiCr-Ni (K), 0 … 1.200 °C TC Fe-CuNi (J), 0 ... 800 °C TC Fe-CuNi (L), 0 ... 800 °C TC Fe-CuNi (L), 32 ... 752 °F TC Fe-CuNi (L), 0 ... 400 °C Or, if resistance thermometer is pre-set in the device configuration : Pt 100, - 50,0 ... 100,0 °C Pt 100, - 58 ... 212 °F Pt 100, - 90,0 ... 205,0 °C Pt 100, -130 ... 401 °F Pt 100, 0 ... 400 °C Pt 100, 32 ... 752 °F Pt 100, 0 ... 800 °C Ni 120, 0 ... 250 °C Ni 120, 32 ... 482 °F Attention: The sensor type is defined by the factory through the internal wiring of the device. Altering the parameter without change of the wiring will definitely cause malfunctions in temperature measurement and control ! End of this parameter level. Next Display : Zone on/off



6.3 Operation level - Control parameters Parameters determining the control behavior of each zone individually. Also these parameters are already pre-set at delivery.

- Press the „Zone“ key to show the desired zone - then press the „Para“ key, the 1

st parameter (set-

point 1) is shown. - Alter the actual parameter with the „▲“ and „▼ “ keys. - Save with „Enter“ key into power-loss save memory - Scroll through the list of parameters with the „Para“ key


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List of all parameters with associated options : - Setpoint 1 Adjustment range: Lower setpoint limitation ... Upper setpoint limitation (factory default : 150°C) Setpoint 1 will only be displayed here, if the controller is in „MANUAL“ mode (manual output ratio). - Alarm A1 Alarm value : Depending on the alarm configuration (see chap. 6.1 device configuration) as temperature- or current alarm as well as on the type of alarm (signal contact, limit contact or limit comparator) : As temperature alarm : Off = -200; -199 … 199°C /°F (factory default 50) As current alarm : Off =0,0; 0,1 … 99,9 A - Alarm A2 Alarm value : Depending on the alarm configuration (see alarm A1) As temperature alarm : Off = -200; -199 … 199°C /°F



As current alarm : Off =0,0; 0,1 … 99,9 A (factory default 1,0) - Self optimizing : off Autotuning (autotuning) out of order (default) on Autotuning activated for this zone all Autotuning activated for all zones Automatically at every start-up (mains power-on) Autotuning determines automaticly the optimal PID- parameters for every controlled system (=mould). Only this guarantees a stable and precise temperature control, that‘s why performing an autotuning at least once for every mould is essential for a stable operation. General information about self-optimizing (autotuning) : The optimizing algorithm calculates automatically the op-timal PID-parameters (Xp, Tv and Tn) and the switching-cycle time. With the setting „Automatic“, the autotuning is performed at start-up after the softstart-phase below the setpoint temperature. This one must be at least be 5% of


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the actual range (typically 800°C). Autotuning at start-up

If the autotuning is engaged manually during current ope-ration, a small temperature drop of appr. 5% of the range is first made to calculate the PID-parameters.

Autotuning on an already

reached setpoint-temperature („hot autotuning“)



- Coupling a zone off; 1 … 16 to another one Attention : By doing so, this zone gets the same powersetting as the „leading zone“ (e.g. in case of a sensor break! Thus coupling a zone is best done with a similar zone, e.g. the neighbour zone nearby in the hotrunner. End of this parameter level. Next Display : „Setpoint 1“ or „Alarm value A1“


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6.4 Mould diagnosis function The mould diagnosis function performs a wiring check of all connected thermocouples and heating elements on good allocation to the same zone. Check of good functioning of every thermocouple and heater itself is done continuously during current operation and does not require a mould diagnosis. Malfunctions are immediately displayed in the zone detail view and also shown as an alarm. The mould diagnosis is a separate function of the controller and can only be performed outside current operation. The continuous heating is switched off, no production can be run during mould diagnosis. The mould diagnosis function is being start-up from the menu „Configuration level - device“, it is the first parameter on top of the list (see chapter 6.1). The mould diagnosis function can only be performed on a cold mould, so, starting it up at a hot mould does not make sense. For the mould diagnosis function, an own set of parameters is required. As for all parameters, factory default settings are defined (see chapter 6.6). If a correct mould diagnosis cannot be performed with those factory default settings, they must then be adapted for every zone step-by-step according to the zone‘s individual characteristics (very fast of very slow).



Diagnosis sequence : The mould diagnosis function is executed in several steps : - Check of diagnosis start conditions - Phase 1 - Phase 2 - Display of the diagnosis result Check of diagnosis start conditions : - Zone is set „ON“ - No thermocouple failure in the active zones - Actual temperature less than 100°C - Parameter „Diagnosis testing time“ is set in at least one active zone Test phase 1 : In phase 1 of the mould diagnosis is first checked, if all zones are in a stationary state, which means that no temperature increase is measured without active heating. This could happen e.g. with a short - circuited solid state relay. In this case, the mould diagnosis is stopped and the error „Starting conditions not met“ is displayed. For each control zone, the parameter „Max. diagnosis time“ must be set. If this time is set to „OFF“, the corresponding zone does not participate in the mould diagnosis process. The duration of test phase 1 is equivalent to the max. diagnosis time.


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During the mould diagnosis process, the following screen is displayed : Test phase 2 : If test phase 1 is successfully executed, test phase 2 begins. Starting with zone N

o 1, all participating zones are

successively heated. This starts with a very weak pulse, which should be sufficient to see already a detectable temperature increase in quick control zones (such as e.g. small hot tips). If this is not the case, the heating pulse is amplified step by step. As soon as the diagnosis function detects a temperature increase, the testing process for this zone is finished. The minimum temperature increase to be detected in that zone is a also a parameter to be set. The detected heater/thermocouple combination (normally, this should be Zone1 / Heater 1 etc.) is saved into the memory. Before the next zone is tested, all active control outputs are shut off, until no zone shows a temperature increase anymore. Then, the test of the following zone commences.



During diagnosis phase 2, the following screen is being displayed. The testing time is count down for every zone, beginning with the max. testing time. To highlight this value, the display is inverted in this zone (see zone 1 in the example below) : During the diagnosis process, the zone actually being tested can be skipped with the „UP“-key, e.g. when you forgot to switch it off. Display of the diagnosis result : If the mould diagnosis process was executed without any failure, the message „Diagnosis finished successfully“ is shown in the lower part of the screen (see below).


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As a result, the detected correlation of heaters and thermocouples is displayed. You can see if any wiring errors are present in the whole system (mould + cables etc.). In a correct state, the same number for „Heater“ and „Thermocouple“ must be shown in the corresponding zone. Diagnosis failures : If not all zones are correctly corresponding, the error „Error: See manual“ is being displayed in the lower part of the screen. The corresponding zone is inverted (blue on white, see example above) as follows : „-“ (Zone 3 as well as Zone OFF 9 to 16) : No failure. This zone was switched off or the parameter „Diagnosis testing time“ was set to „OFF“. „?“ (Zone 4) : Correlation failed. The following causes could have happened :



- Thermocouple failure or wire broken - Heater failure of wire broken TC/ Thermocouple 5 is linked to Heater heater 6 . Check the follwing exchanged. possible causes : - TC exchanged - Heater exchanged „->“ Zone Zone was skipped during the skipped. test by pressing the „UP“-key. Back to normal control operation To go back to normal control operation, the device must be recycled once by switching the main power off and on again. Attention: When activating the mould diagnosis function, all temperature setpoints are set to 25°C . Before restarting production, you must set the desired values again or reset the device to factory default values (see Chapter 6.1, last parameter).


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Possible errors during the diagnosis process : „Starting conditions not met - Error“ This error is displayed if one of the following failures is detected : - TC failure in the active zones - Actual temperature in an active zone >100°C - No parameter „Diagnosis testing time“ set in at least one active zone „Error: See manual“ This error is displayed if one of the following failures is detected : - One heater, for which no TC could be found - „Diagnosis testing time“ set too short - „Diagnosis increase“ set too high - During Phase 1, an excessive temperature increase was detected (e.g. caused by a short-circuited solid state relay) - A TC failure happened during testing phase 1 or 2 - Max. temperature exceeded in one zone „Diagnosis alarm value“ - Correlation of heater and TC not correct - One zone skipped by the user, no correlation possible



Mould diagnosis function - Parameter Parameters determining the diagnosis behavior of each zone individually. Also these parameters a r e already pre-set at delivery.

- Press the „Menu“ key in the display mould diagnosis function - Choose the first parameter with the „ Para “ -key (Diagnosis testing time) . - Alter the actual parameter with the „▲“ and „▼ “ keys. - Save with „Enter“ key into power-loss save memory - Scroll through the list of parameters with the „Para“ key - Diagnosis testing time „OFF“; 1 … 99,9 min.) (factory default : 3 Min.) First choose a zone with the „Zone“ -key The diagnosis testing time depends on the response time of the corresponding zone, that‘s why the parameter needs to be set for every zone individually. During this testing time, the temperature must increase at least by the set „diagnosis temperature increase“ (next parameter) to be detected. If a zone is switched off, it does not participate actively in the diagnosis, but is moni-


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tored nevertheless in the background, as it could happen to heat its thermocouple when a wiring error prevails. - Diagnose temperature 5°C … 100°C) increase (factory default : 5 °C) Minimum temperature increase to detect the correlation to a thermocouple in a zone. This value should normally not be altered, it is valid for all zones. - Diagnosis alarm value 0°C … 800°C) max. temperature (factory default : 120 °C) To avoid overheating in a zone, a maximum temperature value can be defined. If this value is exceeded, the mould diagnosis process is stopped immediately. This value should normally not be altered, it is also valid for all zo-nes. End of this parameter level. Next Display „Start mould diagnosis function“. factory default (list see chapter 6.5)



6.5 Error displays Display Cause Possible remedy LOC Parameter has been Unlock, if needed. locked See: Device Configuration - > Adjustment lock LOC EXT Parameter has been Open external contact locked by ext. contact Er.H Top range end has Check sensor and cable been exceeded, sensor defect Er.L Bottom range end Check sensor and cable has been exceeded, sensor defect E.OP Self tuning error Delete error signal by pressing the „E“ - key. Check the self tuning conditions and restart. E.SY System error Delete error signal by pressing the „E“ - key. Check all parameters. If the error signal continues please send the controller for examination. E.O System error Please send the controller for examination.


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Error displays (cont.) Display Cause Possible remedy REMO Manual adjusting or Set parameter „remote“: off programming of (Profibus DP) parameters not possible. Remote-status, maybe controlled by the serial interface. KONF Alarm configur. off Set „Alarm configuration“ No alarm value See: Device Configuration adjustable. -> Alarm Configuration. E.SP2 Setpoint 2 active Setpoint 2 can not be adjusted in display „zone information“. Adjustment only in level „Control parameter“ possible.



6.6 Factory default settings 1. Device configuration Parameter Setting - Mould diagnosis start off - Synchronisation off - Adjustment lock All parameters adjustable - Tracing function sample time 10 sec. - Alarm A1, configuration Ko:1 - Alarm A1, relais switching behavior Direct - Alarm A2, configuration Ko:9 - Alarm A2, relais switching behavior Direct - Current detection cycle time 2 sec. - Min. leakage current thresholt 0,3 A - Sensors All zones TC - Language English - Zone offset off - Device number xx.xx - Current transformer ratio 1:1000 ( - Ser. interface protocol Nolden Standard) ( - Ser. interface device adress 1 ) ( - Ser. interface data format 7 data bit ) even parity ) 1 stop bit ) ( - Ser. interface Baud rate 9,6K ) - Service interface device adress 1 - Timeout autotuning 15 min - Back to factory default settings off


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2. Zone configuration Parameter Setting - Zone 1-16 on / off on - Controller output mode Automatic - Setpoint2 100°C - Boost addition 5°C - Boost holding time 30 sec. - Softstart on - Softstart output ratio 50% - Softstart setpoint 80°C - Softstart duration time 5 min - Setpoint limitation max. 400°C - Setpoint limitation min. 0°C - Copy all parameters to off - Max. output ratio limit 100% - Ramp rising off - Ramp falling off - Proportional band 6,0% - Rate time 30 sec. - Reset time 150 sec. - Process offset off - Sensor configuration TC Fe-CuNi (J) 0 - 400°C



3. Control parameter Parameter Setting - Setpoint 1 150°C - Alarm A1 alarm value 50°C - Alarm A2 alarm value 1,0 A - Autotuning off - Zone coupling to zone N

o off

4. Parameter mould diagnosis function Parameter Setting - Diagnosis-testing time 3 Min. - Diagnosis-temperature- 5°C increase - Diagnosis-alarm value 120°C


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8. Key word index Subject : Page : A Adjustment lock 28 Alarm connector 12 Alarm on- / off 49 Alarm values 49 Alarm configuration 29 Alarm - switching behavior 29 Alarm indication 24 (Alarm-) limit contact 32 Arrow keys 17 Autotuning 50 Autotuning - Timeout 50 B Baudrate 74 Boost 14, 19 Boost-Addition 39 Boost-holding time 40 Bus adress 74 C Controller output mode 38 Copy function 43 Coupling to another zone 52 Current leakage treshold 34 Current measurement heater - parameter 33 Current alarm 29 Cycle time current measurement 33 D Data format 74 Data interface 74 Diagnosis-testing time 60



8. Key word index (cont.) Subject : Page : D Diagnosis-temperature increase 61 Diagnosis-alarm value 61 Differential time (Rate time) 45 Display 14, 21 E Enter-key 17 F (Reset to) factory default values 36 Fuses (heating) 8, 14 H Heating current 22 Heating current monitoring 29, 33 High current alarm 29 ff. High temperature alarm 29 ff. I Integral time (Reset time) 44 Interface protocol 25, 74 L Language 35 (Min.) leakage current thresholt 34 (Alarm-) limit comparator 32 Low current alarm 29 ff. M Manual output mode 38 Main switch 15 Mains supply 10, 13 Mould connection cable 10 ff. Mould diagnosis function 52 O Output ratio limitation 44


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8. Key word index (cont.) Subject : Page : P PID-parameter 44 Proces value zone 16 Process value-offset 45 Proportional band 44 R Ramp function - see setpoint ramp 44 Reset to factory default values 36 S Sample time (tracing function) 29 Sensor-configuration 35 Sensor-type 46 Setpoint temperature zone 22 ff. Setpoint limitation 42 Setpoint ramp 44 Signal contact 32 Single zone 22 Softstart 40 Softstart 40 Softstart setpoint 41 Softstart output ratio 40 Softstart time 41 Stand-by 19 T Temperature alarm 29 Tendency display 24 Timeout - see autotuning 34 Tracing function 25



8. Key word index (cont.) Subject : Page : Z Zone on/off 38 Zone - copying parameters 43 Zone - offset 34 Zone - general view 16


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8 Appendix : 8.1 Custom specific pin assignment (actual version is marked with a cross) SN 10-24 („HASCO“) SN 03-24 SN 04-24 SN 05-24/24 (TC / heater separated) TC Heater



Custom specific pin assignment (cont.) (actual version is marked with a cross) SN 10-16 („HASCO“) SN 04-16 SN21-16 „Euromap 14“ (TC / heater separated) Heater TC


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8.2 Interface parameter Serial interface NOLDEN-multizones controllers of the NR5000 series can be equipped with a serial interface RS232, RS485 or 0/20mA (half-duplex). This allows to set and to read the process- and configuration datas by a higher level computer or PLC (here called: master). The communication is always controlled by the master. The controller operates as a slave with its own adress and different zones. The adress of the slave has to be programmed in the configuration level of the controller. If there are transmission or other errors detected by the slave (controller), it doesn‘t accept this data. The old parameter values are still valid. All datas are transfered in a hexadecimal, ASCII-coded format. Display Data flow : Indication „DATA“ always, when data exchange (communication) takes place. It is not possible to operate the device via the keyboard, if it is set to remote-operation by the master. The setting of interface parameters takes place in the device configuration (see chapter 6.1) after the parameter „Zone offset“. Is no interface present, the parameter „Sample time“ is next as described in chapter 6.1.



- Ser. interface - Standard Nolden Nolden standard-protokol pre-set : protokol - ARBURG ARBURG / ENGEL or all other injection moulding machines with „HB-Therm“ protocol - Gateway Protokol valid for InterBus-S.

Only with RS 485- interface - Ser. interface 1 .... 255 (factory default: 1) Device adress : This is the adress a master device communicates with the controller. Each ontroller must have ist own adress. Max. 32 controllers can be connected to a RS485-bus. - Ser. interface Data format : 7 data bit, even parity, 1 stop bit (factory default) 7 data bit, odd, 1 stop bit 7 data bit, even, 2 stop bit 7 data bit, odd, 2 stop bit 7 data bit, no, 2 stop bit 8 data bit, even, 1 stop bit 8 data bit, odd, 1 stop bit 8 data bit, no, 1 stop bit (Gateway) 8 data bit, no, 2 stop bit - Ser. interface Baudrate : off; 0,3 ... 9,6 kBaud (factory default: 9,6) InterBus-S Gateway = 9,6 kBaud


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CANopen interface NOLDEN-multizones controllers of the NR5000 series can be equipped with a CANopen interface. Note: A CAN-network has to be terminated on both ends with terminating resistors (120 Ohm). The control action only will start, if the controller is set into „operational“ via the CANopen-interface. In this case it is no longer possible, to adjust parameters on the keyboard of the controller. - CANopen 1 .... 127 (factory default: 1) Device adress : Every device must have ist own adress - CANopen 10k, 20k, 50k, 100k, 125k, 250k, 500k, Baudrate : 1000k Baud (factory default: 20) - CANopen- CANopen Master: no specifikation : CANopen Slave: yes Extended Boot-up: no Minimum Boot-up: yes COB ID Distribution: yes; default via SDO Node ID Distribution: no; via device keyboard No. of POD´s: 0RX, 1TX PDO Modes: async. Variable PDO mapping: no Emergency message: yes Life guarding: yes No. of SDO`s: 1RX, 1TX Device Profile: CiA DS-404



Profibus DP interface NOLDEN multizone controllers of the NR5000 series can be equipped with a Profibus-DP-interface according to EN 50170.

Interface: RS485 Twisted pair 2-wire connection. see EN 50170, Chapt. 2 Network- Linear bus system with active bus Topology: termination on both ends. Spot lines are possible (depending on the used cable type): 3-12Mbit/sec. = max. lenght : 1,5m 1,5Mbit/sec. = max. lenght : 6,5m Baud rate and wiring lenght (without repeater): The baudrate will be detected by the Profibus-master automatically. The maximal wiring lenght depends on the used baud rate.

Connections: The terminals (signals) VP and GND are only to be used to connect the external terminating resistors. There

Baud rate Max. wiring lenght

93,745 kbit/sec. 1200m

187,5 kbit/sec. 1000m

500 kbit/sec. 400m

1,5 Mbit/sec. 200m

3 – 12 Mbit/sec. 100m


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Device Adress: Each device has it‘s own adress (1...125), which will be programmed via parameter „Device adress“. There are up to 32 device adresses in one segment programmable. With the help of a repeater, up to 127 devices can be connected. The single controller zones are called up within the protocol. Special: - Configuration channel für reading and writing of all available parameters. - Configurable process data moduls. - Diagnostic warnings, to detect sensor- and/or system errors. - Easy connection to IPC‘s or PLC‘s. Informations about the Profibus- communication: Select Parameter „Profibus DP : Baudrate“. Bus-Status: No Connection Profibus not connected or master not active. Wait Param Master detected . Device expects parameter Data Exchange Data Exchange Modus Error xxxx Profibus-system error Important: Parameter „remote“ has to be set to „on“, otherwise, it is not possible to write data into the device.



- PROFIBUS DP off Profibus: read-only / opera-Remote : tion on the device possible. Profibus can read parameters but not alter them. on Profibus: read / write Operation on the device not possible. (factory default) - PROFIBUS DP 1 .... 125 (factory default : 1) Device adress : - PROFIBUS DP Baudrate is detected and displayed auto-Baudrate maticly. It can not be altered Display : Not detected 12 MBaud 6 MBaud 3 MBaud 1,5 MBaud 500 kBaud 187,5 kBaud 93,75 kBaud 45,45 kBaud 19,2 kBaud (not supported) 9,6 kBaud (not supported)


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DECLARATION OF CONFORMITY This declaration is valid for the following products :

Model designation : Multizone-temperature controller Type : NR5008 up to NR5016

Hereby is confirmed, that these products meet in their design and accomplishment as marketed by the manufacturer and if properly used the following EU-directives : EU-Low voltage directive 2004/108/EG EU-Directive for electro- magnetic compatibility 2006/95/EG Applicable harmonized norms : EN 60204 Part 1 EN 61000-6-1 EN 61000-6-3 This declaration is binding for the manufacturer

NOLDEN REGELSYSTEME GMBH

Am Tonschuppen 2 · Gewerbegebiet Volmershoven D-53347 Alfter · Germany

Alfter, 01.08.2014 Hans Werner Müller, General manager

operations manual - nolden regelsystemeoperations manual nr5000-v.3 nolden regelsysteme gmbh 15 5.2...

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