1. Measure
Control
Automate
MCS Product Training
Simply convincing.

2. Content MCS product training
Basics
Functionality
Commissioning
Excercises

3. MCS Device Overview 6 housing sizes
2 … 128 control loops with a single device
MCS8
MCS16
MCS32
MCS64
MCSr96
MCSr128
MCS – with display of all zones
MCS r – no display of all zones

4. MCS Hot Runner Controller
Touch-Display und function keys
Fuses
Heatsink
LED stripe „Operating Condition“
Individual display of all zones

5. Display and Operating Elements
Outputs On / Off
Home
Boost
Parameter settings
Standby
Operating mode
Zone display
Operating condition (green, yellow, red)

6. Contact for Alarm and Warning
Connections
Control Inputs
Outputs
Thermo-couples
Contact for Alarm and Warning
Fuses

7. Content MCS product training
Basics
Functionality
Commissioning
Excercises

8. MCS Functionality Control behaviour
Automatic determination of the control parameters P I D During the heating nozzles and manifolds are classified (automatic detection between sluggish and fast control loops) and the PID control parameters determined.
Suppression of overshoots At aggressive control circuits, overshooting can be reduced when heating up.
Pulse mode / phase-fired control Pulse mode and phase-fired control are two different ways of controlling heating. Thus the controller reaches a high control precision, even in sensitive processes. (devices starting at 20 zones)

9. MCS Functionality Heating
Gentle heating Gentle heating by reducing the output rate in dependance of the temperature.
Group heating Zones are heated up so that they must only have a specific temperature difference from each other.
Sequential heating / cooling Zones can be heated and cooled sequentially.
Ramp The ramp function enables a slow and uniform heating / cooling of zones by specifying a rise / cooling curve.

10. MCS Functionality Zone monitoring
Temperature monitoring Supervision of the zones to under- or overtemperature.
Sensor monitoring The behavior at sensor break can be determined.
Material leakage monitoring Irregularities in heating e.g. material leakage can be detected
Leakage current monitoring Records leakage currents outside of a specified tolerance limit.
Heating current monitoring The heating currents are measured for each zone. A deviation from the nominal values ​​can be monitored and displayed.
Triac monitoring Device monitoring with LED indication with a defective triac.

11. MCS Functionality Special functions
BOOST Raising the temperature of groups or individual zones for a set period of time.
STANDBY Lowering of the temperature to a specific value.
Diagnosis Detecting wiring faults as well as heating and sensor defects.
Programs Recipes with setpoints, parameters and operation mode can be stored as programs and also be activated via the digital input.

12. Special functions … continued
MCS Functionality
Special functions … continued
Flexible expansion of the zone number Several controllers can be connected into a PLUS unit. The PLUS unit works virtually like one controller.
Communication For data exchange with the injection molding machine and remote monitoring of the device or for connecting the mobile control and diagnostic station MCScontrol.
Monitor function Individual zones can be used only for display and monitoring.
Standard parameter Resetting the parameters and settings to the factory settings.

13. Setting the Functions
The setting of the functions are carried out via parameter.
Zone parameters relate to each zone.
System parameters set the device function.
Zone parameters
System parameters

14. The parameters in detail
Zone parameters
System parameters

15. Functions and Parameter Settings
Use
„Functions and Parameter Settings“

16. … the most important ones
Functions and Parameter Settings
Beschreibung im Dokument:
Funktionen und
Parameter
… the most important ones

17. Temperature monitoring
Zone parameter
System parameter 1
L-Alarm 2
H-Alarm 3
dL/dH-Alarm HH
HH-Alarm AL
Alarm delay
Description
Supervision of the zones to under- or overtemperature
Example
Maximum upper temperature limit of all zones HH
HH-Alarm
Limit for overtemperature 2
H-Alarm
Upper limit of the tolerance band
Setpoint 3
dL/dH-Alarm
Lower limit of the tolerance band 1
L-Alarm
Limit for undertemperature

18. Sensor Monitoring Zone parameter System parameter 10 16 AP Description
Alternative Zone 16
Nominal output rate AP
Auto Power
Description
Behaviour at sensor break with the parameter AP Auto Power
AP=0
Output rate = 0%
The zone remains in Control Mode and must be switched manually to manual mode.
AP=1
Output rate = Medium Output rate
The zone is automatically switched to manual mode. The output rate will be queried. The medium output rate can be assumed or a new value must be entered manually.
AP=2
As AP=1 but without confirmation query
AP=3
Output rate = Nominal output rate
The zone with sensor break automatically switches to manual mode and applies the nominal output rate to be specified in parameter 16.
AP=4
Output rate = Alternative zone
Parameter 10 specifies the zone that delivers the output rate at sensor break. 16
Nominal output rate 10
Alternative Zone

19. Output rate monitoring
Zone parameter 17
Average output rate 18
Output rate monitoring average 19
Output rate monitoring tolerance
Description
The output rate monitoring serves to recognize irregularities in heating, e.g. at a leaking nozzle from which liquid plastic may leak (plug formation).
When the controller is in steady state and the process is stable the controller generates internally an average output level.
This average output level can be monitored for deviations (plus / minus).

20. Output rate monitoring
Zone parameter 17
Average output rate 18
Output rate monitoring average 19
Output rate monitoring tolerance
Method
Step 1
Heating ... Let the system work at the setpoint for approximately 10 min. The determined value is shown in the zone parameter No. 17.
Step 2
Enter this value as a kind of monitoring at the "output level setpoint" in zone parameter No. 18.
Step 3
Enter in zone Parameter No. 19 the desired tolerance as a % value.
Example
50% is the output level to be monitored, desired alarm at 45% and 55%, means the value "5" is to be entered in parameter No. 19.

21. Temperature raise / Temperature lowering
Zone parameter
System parameter 25
Boost Offset 26
Standby Temperature
b-t
Boost time
Boost
Temperature is raised by a fixed value for a specific time..
Standby
Temperature is lowered to a new setpoint
New setpoint
Current setpoint 25
Boost Offset
setpoint
Boost time 26
Standby Temperature
b-t
Boost time

22. Gentle heating 1 1 Zone parameter Soft start Description
Soft start = Gentle heating
All zones are gently heated separately of each other to max. 100 °C, independently of a higher target temperature set.
Up to a temperature of 50 °C, each zone is heated with a max. output rate of 50%.
From 50 – 100 °C, the output rate is determined based on the present temperature, i.e. from 60 °C onwards the output rate is 60%, etc.
After 100 °C are reached, the soft-start is complete and the zone can heat up at full output.
Soft start is already pre-set ex works.
Parameter
Zone parameter
Einstellungen 11
Soft start
0: No soft start
1: This zone with soft start
Standard value: 1

23. Group heating Zone parameter System parameter 12 Ct Description
Group (combined) heating Ct
Max temperature difference of the group
Description
Slow heating with consideration of the slowest zone
This is to prevent the complete tool, manifold and nozzles from being heated up with thermal dysbalances.
All zones are heated up so that they must only have a specific temperature difference from each other (system parameter Ct = Max temperature difference of the group).
The slowest zone works at the maximum output rate and the other zones will be limited in their output rate so that they must only advance by the set temperature difference.
The parameter 12 defines the assignment of a zone to the "Group".

24. Group heating … Cont. Parameter Zone parameter Settings 1212
Group (combined) heating
0: This zone without group
1..8: Zone/group in group heating. Higher values are heated up first.
System parameter Ct
Max temperature difference of the group
Can be set from 1° … 100°
Standard value: 25°
Example
Zones 1 to 6 are to be heated together. The temperature difference during this heating process is to be 20 °C at most. Zones 7 and 8 are not to be part of the heating group.
Settings:
Zone 1 to zone 6: Parameter 12 = 1
Zone 7 and zone 8: Parameter 12 = 0
System parameter Ct = 20

25. Sequential heating / cooling
Zone parameter
System parameter 12
Group (combined) heating Ct
Max temperature difference of the group
COL
Cooling Limit
Description
Zones are heated or cooled ina sequentiel order
The heating process starts with the zones/groups that have the highest set value at the parameter 12 = group heating (max. 8). This is followed by the zones with the lower values.
A group or zone will start its heating phase only when the preceding group or zone has reached 10 °C below the setpoint.
If no zones or groups are summarized for parameter composite heating, all zones will start without delay without the function sequential heating.
Sequential cooling works according to the same rules as heating, but in the reverse order.

26. Sequential heating / cooling
Example
Zone 1 is to be heated first
then zones 2,3,4 are heated together.
Only then should zone 5 be heated.
Settings of the parameter 12 "Group heating"
Parameter 12, Zone 1 = 3
Parameter 12, Zone 2,3,4, = 2
Parameter 12, Zone 5 =1

27. Content MCS product training
Basics
Functionality
Commissioning
Excercises

28. After switching on the controller …
No setpoints
All zones are off (outputs deactivated)

29. Display - and operating elements
Outputs On / Off
Home
Boost
Parameter settings
Standby
Operating mode
Zone display
Operating condition (green, yellow, red)

30. Commissioning steps Use Quickstart! Select Zone / Group Operating Mode
Setpoints
Parameters
Activate outputs
Use Quickstart!

31. Step 1: Select Zone / Group
7-Seg.
Touch

32. Step 1b: Define Groups
 Zone parameter P31
7-Seg.

33. Step 1b: Define Groups
Touch

34. Step 2: Operating Mode
7-Seg.

35. Step 3: Setpoints
7-Seg.
Touch

36. Step 4: Parameters
7-Seg.
System-parameter:
Touch

37. Step 5: Activate outputs

38. After activating the outputs
… with factory settings:
Classification The controller calculates the control parameters P I D (while the flashing LED strip)
Soft-start The tool is in soft start heated (increasing output ratio with increasing temperature)
Upon reaching 100 ° C the soft start is complete
Group heating Group Heating with maximum temperature deviation of the zones of 25 ° C (standard value of system parameter “Ct”)

39. Warnings and Alarms
Use „Troubleshooting MCS“!

40. Content MCS product training
Basics
Functionality
Commissioning
Excercises

41. Exercises Groups Operating mode Setpoints
Temperature monitoring - Low Alarm - High Alarm - Tolerance band
Behavour at sensor break
Heating: in groups, sequential, soft-start
Boost / Standby
Programs

42. Excercise 1 Groups: Zone 1 to 3 = Group 1 Operating mode
Setpoints: All zones: setpoint 80° C
Temperature monitoring
Low Alarm: 50°
High Alarm: 110°
Maximum deviation to the setpoint: 20°
Maximum temperature of all zones: 150°

43. … Excercise 1
Activate outputs

44. … Excercise 1 Heating? Watch output rates and temperatures
Watch alarms
Analyze errors
Which messages are displayed?
Meaning?
Activate troubleshooter
Use „Troubleshooting MCS“- document

45. Excercise 2 Behavour at sensor break
A zone should automatically switch to manual mode and continue to work with the output level of an alternative zone
 Simulate sensor break

46. Excercise 3 Sequentiel Heating First Zone 1 Then Zone 2 Finally Zone 3
Max. temperature difference +20°

47. Excercise 4 no Soft start and no group heating
Watch output rates and temperatures

48. Excercise 5 Boost Standby Boost-Offset: 10° Boost-time: 30sec
Standby-Temperature: 60°

49. Excercise 6 Programs Current settings are saved in Program 1
Select new Programm 2 and change:
New alarm limits
New setpoints
Select Programm 1 again
Verify settings of program 1