MCSe Manual

FELLER ENGINEERING GmbH

MCS e
OPERATOR MANUAL
FELLER ENGINEERING GmbH Tel.: +49(6074)8949-0

Carl-Zeiss-Straße 14 Fax: +49(6074)8949-49
63322 Rödermark / Germany Hotline: +49(6074)8949-31
Internet: www.fellereng.de E-Mail: info@fellereng.de
Subject to technical changes Version: 2020/12
MCSe manual FELLER ENGINEERING GmbH
H1252/...
Inhaltsverzeichnis
Abbildungsverzeichnis .................................................................................................................. 4
1 Introduction................................................................................................................... 5
1.1 Symbols used: 5
1.2 Notations 5
2 Safety instructions ......................................................................................................... 5
2.1 Intended use 5
2.2 Information for operators and users 5
3 Structure and functionality ............................................................................................. 6
3.1 General information 6
3.2 Structure 6
3.2.1 MCSe front panel 7
3.2.2 Operating front 7
3.2.3 LED-strip 7
3.2.4 Power card 7
3.2.5 Fuses 7
3.2.6 Notification contact / Digital input 8
3.2.7 Identification on the controller 8
3.2.8 Wiring of the plug systems 8
4 Commissioning............................................................................................................... 9
4.1 Electrical connection 9
4.1.1 Mains power supply 9
4.1.2 Mains connection 9
4.1.3 Mold connection 9
4.2 Operating and display elements 10
4.2.1 Display elements 11
4.2.1.1 Status display............................................................................................................. 11
4.2.1.2 Zone display ............................................................................................................... 11
4.2.2 Operating elements 12
4.2.2.1 Main switch ............................................................................................................... 12
4.2.2.2 Soft keys .................................................................................................................... 12
5 Operation .................................................................................................................... 14
5.1 Zone selection 14
5.1.1 Selecting a zone 14
5.1.2 Selecting multiple zones 14
5.1.3 Selecting several consecutive zones 14
5.1.4 Selection of all zones 15
5.2 Operating mode 15
5.3 Setpoints 16
5.4 Output rate 17
5.5 Controller outputs 17
5.6 Parameter 18
5.6.1 Zone parameter 18
5.6.2 System parameter 19
5.7 Boost 20
5.8 Standby 20
6 Warning and error messages ........................................................................................ 21
Subject to technical changes Page 2

FELLER ENGINEERING GmbH MCS manual
6.1 Warnings 21
6.2 Alarms 22
7 Functions and parameterization ................................................................................... 25
7.1 Basic settings 25
7.1.1 Access authorizations 25
7.1.2 Fahrenheit display 26
7.1.3 Thermocouple type 26
7.2 Control behaviour 27
7.2.1 Control parameters P I D 27
7.2.2 Output level 27
7.2.3 Maximal output level 27
7.3 Heating 28
7.3.1 Softstart (Gentle heating) 28
7.3.2 Compound heating 28
7.4 Hot runner monitoring 29
7.4.1 Temperature monitoring 29
7.4.2 Average output level 31
7.4.3 Broken sensor 31
7.4.4 Heating current monitoring 31
7.4.5 Triac monitoring 32
7.5 Special functions 32
7.5.1 BOOST 32
7.5.2 STANDBY 33
7.5.3 Load detection 33
7.5.4 Default parameter 33
8 Parameter overview..................................................................................................... 34
8.1 Zone parameter 34
8.2 System parameter 35
9 Technical data .............................................................................................................. 36
10 Spare parts + accessories .............................................................................................. 37
11 Appendix ..................................................................................................................... 38
11.1 Terminal bridges of the star-delta supply 38
11.1.1 Terminal jumpers in star network (state at delivery!) 38
11.1.2 11.1.2 Terminal bridges in delta network 38
11.2 Notification contact / Digital input 39

MCSe manual FELLER ENGINEERING
GmbH
Abbildungsverzeichnis H1252/...
Figure 1 - MCSe front panel 7
Figure 2 – Type label 8
Figure 3 – Wiring of plug systems 8
Figure 4 – Operating and display elements 10
Figure 4 – Zone display 11
Figure 5 – Temperature monitoring 30
Figure 6 - Star-network 38
Figure 7 - Delta-network 38

1 Introduction
1.1 Symbols used:
Caution/Warning Information on possible damage to property or personal injury
Information Important information
1.2 Notations
Menu structures between words are indicated by the > symbol and depicted in the same way on the
device.
Interaction with the operator is denoted by the finger symbol.
2 Safety instructions
Please read this document completely and carefully before commissioning or operating
the device.
2.1 Intended use

The hot runner controller is used to control the temperature of heating circuits and is designed for
use under precisely defined conditions, such as supply voltage and temperature. The operator must
therefore ensure that the controller is only used under operating conditions that comply with the
technical data. The manufacturer is not liable for damage resulting from non-compliance with the
intended use.
The hot runner controller is not suitable for use beyond the limits defined in the technical data and
during its design. In addition, the use of spare parts from third parties and the implementation of
non-described maintenance activities constitute failure to comply with the intended use.
Alterations, conversions and other modifications are made exclusively at the operator’s own risk and
could pose safety hazards. The manufacturer and distributor of this device cannot be held liable for
direct and indirect damage resulting from improper handling or treatment.
2.2 Information for operators and users

The controllers are operated on the low-voltage network. The relevant safety regulations must be
observed when connecting up the controller and performing maintenance on it. In addition, the local
and general safety regulations must be observed for its installation and operation. The operator is
responsible for compliance with these regulations. The operator must additionally make this docu-
mentation available to the user and provide instruction in the correct operation of the device. The
user must be familiar with this documentation. In order to ensure reliable and safe operation, the
individual user is required to observe the information and warnings.
The controllers may only be brought into operation by authorized specialist personnel. Under the
terms of these operating instructions, specialist personnel are persons who can recognise and assess
the dangers associated with the work entrusted to them on the basis of their specialist training, their
experience and their knowledge of standards.

The device is checked carefully prior to delivery and has passed the tests specified in H1252/...
the test plan for its production, in conformity with the manufacturer’s valid quality
guidelines. To prevent any damage to the controller, it must be transported and stored in the correct
manner. Further safety-related notices are marked in the individual sections of this documentation.
3 Structure and functionality
3.1 General information

MCSe hot runner controllers are especially suited to the temperature control of hot runner molds on
injection molding machines. In use, the controllers are connected directly to the mold via cables.
During operation, the hot runner controllers deliver electric current to the heating units for an injec-
tion mold. The so-called heating current leads to an adjustable temperature increase in the heating
units and hence in the mold. Continuous temperature monitoring takes place in parallel via connect-
ed thermocouples. In the event of deviations between the actual temperature recorded and the
temperature set on the hot runner controller, the heating current is automatically adjusted until the
two temperatures are identical.
The controllers are available in different variants. These differ solely in terms of the number of con-
trol circuits that are possible – which are also referred to as heating zones. Depending on the variant,
hot runner controllers are available with 2 to 12 heating zones (in steps of 2).
3.2 Structure
Housing front: MCSe hot runner controller is operated from the housing front. In addition to the
main switch for switching on and off, the controllers have 12 keys for convenient operation. Fur-
thermore, the front contains all visualization elements. The setpoint and actual values of the
individual zones are displayed via 7-segment displays. If required, the display can be switched over to
heating current and output rate. In addition, status LEDs provide information about operating modes
and messages of the individual zones. The controller status is visualized in color via a led strip visible
from afar. In control mode, without a current error or warning message, this display lights up green.
In case of a warning or alarm, the display changes to yellow or red (traffic light status). This allows a
quick assessment of the controller status even from a distance. A detailed description of the display
and operating functions can be found in chapters 4.2 and 5.
Back of housing: All connections are located on the back of the housing. In addition to the connecting
cable, which is used for connection to the supply voltage, the controllers offer a further connection
for a potential-free alarm contact and a 24V digital input for external control of the set-back opera-
tion. The connection to the hot-runner mold is established via plug-in systems.

3.2.1 MCSe front panel
3.2.2
Figure 1 - MCSe front panel
3.2.3 Operating front

The convenient operation of the MCSe hot runner controller is carried out on the front panel (Figure
1 - MCSe front panel) via 12 keys. The front also contains all visualization elements. The setpoints and
actual values of the individual zones are displayed via 7-segment displays. If required, the display can
be switched over to heating current and output level.
3.2.4 LED-strip
The status of the controller is displayed in color via a strip of LEDs visible from afar. This enables a
quick assessment of the current controller or tool status.
3.2.5 Power card
Inside the housing there are power cards which control connected heaters and record measured
temperatures of the thermocouples. Each zone is switched individually via relays on the power cards,
so that individual zones can be switched off separately and a seamless production process is always
guaranteed.
3.2.6 Fuses
The controllers have three different types of fuses inside the housing. Each zone has two fuses on the
power card. One fuse is used to protect the load output (fuse in the fuse holder below the heat sink).
The second fuse, on the other hand, is required for use in delta networks. In addition, another con-
trol fuse is located in a terminal on the bottom of the housing.

3.2.7 Notification contact / Digital input H1252/...

MCSe hot runner controllers have a potential-free message contact and a digital control input, which
are brought out via a 7-pin plug on the rear of the unit. A contact diagram of the built-in plug is given
in chapter Fehler! Verweisquelle konnte nicht gefunden werden..
The control input is PLC-compatible, i.e. it operates over a voltage range of 13…30 VDC with a typical
current consumption of approx. 8.5 mA. The controller can be switched to standby mode via the
input. The controller remains in this mode as long as the signal is present. Deactivation via the
standby button on the device is not possible.
The potential-free notification contact is used to transmit the controller status to an injection mold-
ing machine. When warnings or alarms occur, the contact opens. Accordingly, the contact is normally
closed (NC) and opens as soon as an alarm or warning is present. Chapter Fehler! Verweisquelle
konnte nicht gefunden werden. provides an overview of the behavior when messages occur.
3.2.8 Identification on the controller
The type label is mounted on the side of the controller housing. It contains the type designation with
the number of zones, the electrical connection data and the manufacturer’s data.
Typ / Type MCSe 6

S/N 20091 Prod. KW / CW 03 / 2020
Code E7H1-AKB4-C1Z6-87A
Versorgung / Supply ● Y 230/400 VAC 50/60 Hz
○ ∆ 230 VAC 50/60 Hz
Belastung / Load 3x 16 A
Schutzart / IP Class IP20
Temp. Fühler / Sensor Fe-CuNi Type J
FELLER ENGINEERING GmbH Made in Germany
Meldebuchse / Message Socket
Pin 1+3 Relay Sammelmeldung / collective message
Pin 2+6 Steuereingang / Digital input
Figure 2 – Type label
3.2.9 Wiring of the plug systems
The plugs for connecting the temperature sensors and heating elements to a hot runner are available
on the rear of the controller. The customer-specific wiring plan for the plug systems is located on the
side of the controller housing (see Figure 3 for an example).
Figure 3 – Wiring of plug systems

4 Commissioning
4.1 Electrical connection
Important! Before the device is connected to the supply voltage, a check must first be
performed to ensure that the mains electricity conditions comply with the specifica-
tions on the type plate.
The electrical connections must be performed by a qualified electrician. Commissioning

and operation while the controller is running are only to be carried out by authorized
qualified personnel!
Switching off all the outputs or individual zones will not protect any of the outputs
against hazardous voltages. Before working on the connected heating elements, the
associated connections must be unplugged, or the entire device disconnected from the
mains power.
Before the device is opened, it must be disconnected from the mains power!
4.1.1 Mains power supply

Before connecting the device to the supply voltage, a check must be conducted to ensure that the
mains electricity system is correct. The hot runner controllers are prepared by default for operation
in a star network (3x400VAC + N + PE) but can also be operated in a triangular network (3x230VAC +
PE). For operation in a triangular network without a neutral conductor, it is essential to follow the
local regulations for the installation of electrical systems. The terminals in the controller must be
bridged accordingly for use in a star or triangular network. Annex Fehler! Verweisquelle konnte
nicht gefunden werden. contains a clear terminal connection diagram.
4.1.2 Mains connection
To ensure correct operation, the hot-runner controller is connected to the low-voltage mains by us-
ing the connecting cable connected to the unit.
4.1.3 Mold connection
To connect the individual control zones to the corresponding injection mold, use must be made of
appropriate leads for the sensor and heating unit connection.
Please note: it must always be ensured that the internal wiring, the wiring of the cable
set and the wiring in the mold are suitably coordinated with each other.
Important! To exclude any effects of potential shifts, the injection molds that are con-
nected up must be properly earthed in all cases.

4.2 Operating and display elements H1252/...

The operation as well as all display elements of the hot runner controllers is carried out via the soft
keys on the front of the housing. The following illustration shows the front view of a 6-zone control-
ler, from which all operating and display elements are shown.
Figure 4 – Operating and display elements

4.2.1 Display elements

4.2.1.1 Status display
The status of the controller is indicated by a LED strip in the front. In control mode, this indicator
lights up green. In case of a warning or alarm, the display changes to yellow or red (traffic light sta-
tus).
Green signals all is well. The controller operates in normal
mode.
Yellow indicates warning messages that indicate a devia-
tion from the normal state.
Red indicates alarms. Depending on the fault, outputs of
corresponding zones are also deactivated.
4.2.1.2 Zone display
Each heating zone has two 7-segment displays and four LEDs for status indication. The 7-segment
displays show either the setpoint and actual value or the heating current and degree of operation. In
addition, the four LEDs can also be used to display the states shown below.
Figure 5 – Zone display

4.2.2 Operating elements H1252/...

4.2.2.1 Main switch
The main switch is located on the back of the housing.

The switch must be operated to switch the controller on
and off.
4.2.2.2 Soft keys
Operating element Description
Selection of zones
Each time the arrow keys are pressed, the display jumps one
zone further.
Change in value
Confirm button / Acknowledge error
Boost
Standby
Change operating mode
Parameterization / System information
Basic view: Display of all zones / Reject input

Shift key for the zone display
Display: actual value (ACT) and setpoint (SET)
Display: Current (I[A]) and output level (Y[%])
Activating / deactivating the controller outputs
Temperature unit of the display

5 Operation H1252/...
5.1 Zone selection

5.1.1 Selecting a zone
Step Operation Description
Each time the arrow keys are pressed, the display jumps one
zone further.
1. All other zones that are not selected are hidden.
5.1.2 Selecting multiple zones
Select zone
1.
Press confirmation key

2.
... repeat 1. and 2. To select any zones
5.1.3 Selecting several consecutive zones
1. Selection of the 1st zone to be selected
2. Keep confirmation key pressed
3. With each keystroke a zone is added to the selection

4. Release the confirmation key
5.1.4 Selection of all zones
1. The basic rule is:

In the basic view, all zones can be operated and are virtually
already selected for a value change.
"The Zones that you see can also be operated."
5.2 Operating mode
1. Select the zone(s) as described in 5.1
Selection of the operating mode
The display switches between
Manual mode
2.
Control mode
Zone off
Note: The display flashes and must be confirmed within 5 sec-

onds.
Confirm the entry

3.
The display stops flashing
Press the Home button to return to the overall display of all

4.
zones.

5.3 Setpoints H1252/...
Use the buttons to set the setpoint to the desired value.

2. The display flashes, indicating that the value has not yet been
accepted.
Confirm the entry

3.
The display stops flashing

4.
zones.

5.4 Output rate
Selection of the operating mode.

2.
Operate until manual mode is displayed.
3. Confirm selection
Switching the zone display to

4.
Current (I) and output rate (Y)
Use the buttons to set the output level to the desired value.
accepted.
Confirm the entry.

6.
The display stops flashing.

7.
zones.
5.5 Controller outputs
Activating / deactivating the controller outputs either switches

1. on all heating zones in control mode and manual operation or
switches off all zones.

5.6 Parameter H1252/...

5.6.1 Zone parameter
2. Press key to change to the parameterization level
Select parameter.
Each time the arrow keys are pressed, the parameter is incre-
mented or decremented.
3.
Use the buttons to set the value of the selected parameter to

the desired value.
Note! Password entry required before parameterization (default
4. "22"). Set the current password with the keys and confirm. The
parameter can then be changed
The display flashes. This means that the value has not yet been
accepted.
Confirm the entry.

5.

6.
zones.

5.6.2 System parameter
Press and hold for 2s.

1. The display changes to the system parameter level.
This level contains system information that cannot be changed:
System Information
However system parameters and system functions can be

… 2s changed. The representation is made as or :
System Parameter
System Function
2. Select system parameters.
Set the value of the selected parameter to the desired value

using the arrow keys.
Note! Password entry required before parameterization (default
"22"). To do this, set the current password with the keys and
confirm. The parameter can then be changed
accepted.
Example: System parameter with value 500
Confirm the entry.

4.

5.
zones.

5.7 Boost H1252/...
Pressing the Boost button increases the setpoint value for the
selected zones by the value stored in the zone parameters.
2. The duration of the boost process is stored in parameters.
If necessary, the standby mode is ended by the boost.
5.8 Standby
Pressing the standby button lowers the setpoint to the value

stored in zone parameters.
Confirming again deactivates the standby mode.
1. The standby mode terminates the boosting if necessary.
The standby mode can also be activated via the digital 24V con-
trol input.

6 Warning and error messages

MCSe controllers provide information about the current status via status and 7-segment display.
Warnings and alarms are shown as abbreviations in the 7-segment display. In addition, the LED band
indicates the controller status in green, yellow and red. In the standard state, the LED band lights up
green. An existing warning is displayed in yellow. Warning messages alert the plant operator to pos-
sible problems. However, production operation is continued. A suddenly occurring alarm is displayed
in red. If it occurs, the plant operator must intervene. For critical alarms, an error acknowledgement
or a device restart may be necessary. The following subchapters contain a detailed list of all warnings
and alarms.
6.1 Warnings
Warnings are shown in yellow by the status display (LED stripe).
7 segm. Notification
• Description / Causes
display contact
Positive temperature deviation
• The actual value of the sensor is above the tolerance
Warning is
band set as zone parameter .
displayed
- Tolerance band (zone parameter ) too small, if
oscillation occurs due to the process.
Negative temperature deviation
• The actual value of the sensor is below the tolerance
band set as zone parameter .
Warning is
- Controller is in the heat-up phase
displayed
- Tolerance band (zone parameter ) too small
- Heat output may not be sufficient
- Heating could be defective
- Sensor not in contact with this zone
Broken sensor
• No connection to the sensor.
- No sensor connected Warning is not
- Sensor cables / connecting cable defective displayed
- Sensor plug connections defective
Zone operates with the average output level in manual
mode

6.2 Alarms H1252/...

Alarme werden durch die Störmeldeanzeige (LED-Band) in Rot dargestellt.
display contact
Shut-off temperature
• - The actual value of the sensor is above the maximum
permissible temperature (system parameter ).
• All outputs are switched off. The controller can only be
restarted by restarting or acknowledging the error by Alarm is
. The actual value must also be below the parameter displayed
.
- Setpoint too close to value
- Triac malfunction. This results in current flowing and
heating without output level
Over temperature
• The measured actual value of the sensor is greater than
the limit value set under Zone parameter (Hi-
Alarm).
• The corresponding zone is switched off until the actual Alarm is
value falls below the value of the parameter again. displayed
- Alarm limit (zone parameter ) is too close to the
setpoint
- Triac malfunction. This results in current flowing and
heating without output level
Under temperature
• The actual value of the sensor is below the limit value
set under zone parameter (Lo alarm).
- Alarm limit (zone parameter ) is too close to the
Alarm is
setpoint
displayed
- Heat output may not be sufficient
- Heating could be defective
- Sensor not in contact with this zone
- Sensor polarity reversal
- Controller is heating up

display contact
Broken sensor
• No connection to the sensor, in addition the average
output level could not yet be recorded. Alarm is
displayed
- No sensor connected
- Sensor cables / connecting cable defective
- Sensor plug connections defective
Sensor polarity
• The polarity of the sensor is reversed
• Due to incorrect polarity, negative temperature values
can be measured by the controller. Therefore the cor-
Alarm is
responding zone is switched off at -15°C and can only
displayed
be switched on again after the polarity has been
changed.
- Sensor wrong polarity. This causes the measured tem-
perature to show falling values during heating.
Fuse
Alarm is
• Zone is not supplied with power
displayed
- Fuse defective
Triac
• Without control of the outputs a current flows
- - Triac defective, switches through permanently Alarm is
displayed
Note: The relevant zone is switched off and the alarm out-
put opens. After exchanging the triac, the controller can be
operated again.
Sensor voltage
• The voltage potential on the sensor cable is impermis-
sibly high Alarm is
displayed
- Wiring error
- Cable or plug defective
- Cable pinching

H1252/...
display contact
No current flow
• When controlling the outputs with a output level > 0%
no current flows
Alarm is
- Cable or plug defective displayed
- Heating defective
- Triac defective, does not switch through
- No heating connected
Relay
• Internal hardware error - Output relay of the zone de-
Alarm is
fective
displayed
• Message must be acknowledged
- Defect of the device hardware
Current deviation
• The rated current set in zone parameter deviates
from the current monitoring tolerance set in zone pa-
Alarm is
rameter .
displayed
- Heating defective or partially failed
- Correct rated current set under zone parameter ?
- Tolerance band (zone parameter ) too small
Load short circuit
• An impermissibly high current flows through a short
circuit in the heating circuit
Alarm is
• Message must be acknowledged
displayed
- Wiring error
- Cable or plug defective
- Line pinch
CAN-Bus fault
• - Communication error of the internal power card
Alarm is
- Identical address assigned twice displayed
- Cable not connected correctly
- Missing final resistance of the last participant

7 Functions and parameterization
7.1 Basic settings

(see chapter 5.6.2 System parameter)
7.1.1 Access authorizations
Description System parameter : Password

The control unit is protected against unauthorized settings by a password =
identification code . The password can be individualized after it has been
entered.
The release is done

with code "22"
System parameter : User level

The parameter determines the degree of locking, with which the device is
locked against inputs.
0= No interlock
1= Only setpoints and operating modes free
2= All parameters locked
is always only accessible via the code
System parameter : Pin Code

If the password has been changed and is subsequently unknown, the pass-
word can be reset via the parameter . A master password must be generated
by the manufacturer via the pin shown.
Parameter System parameter Settings
ID Code 0…999, Default value = 22
ID Level 0…2, Default value =1
ID Pin Code (read only, value cannot be changed)

7.1.2 Fahrenheit display H1252/...
Description This parameter indicates the temperature unit in which the controller is dis-
played and operated. During operation, the setting can also be read off via LED
indicators on the display.
• 0: °C
• 1: °F

Fahrenheit-display 0 / 1, Default value = 0 °C
7.1.3 Thermocouple type
Description
The parameter specifies the type of thermocouples used for the entire con-
troller.
0: Fe/CuNi Typ J
1: Ni/CrNi Typ K with temperature
Thermocouple type
range max. 800°C
Default value = 0

7.2 Control behaviour

7.2.1 Control parameters P I D
Description The automatic determination of the control parameters P I D is called classifica-

tion. It is performed automatically after the controller outputs are switched on
and overwrites all previous settings of the control parameters.
PID-Parameter
When classifying the zones, the controller sends a defined heating impulse to
each zone in order to automatically determine the heating behaviour of e.g. the
nozzle or manifold. The controller determines the suitable control parameters
for P, I and D and stores them in the parameters , and .
The process can be recognized by the flashing green LED band and can take up
to 60s for large, sluggish objects. The determined classification can be viewed
for each zone under Parameter .
Activate and deactivate classification

To obtain special settings of the P, I and D parameters in any case, the classifi-
cation per zone can be switched off with the parameter = "0".
Parameter Zone parameters Settings
P-Band 0…100%
Tn Reset time 0…999s
Tv Derivative time 0…999s
OFF = 0
Activate classification ON = 1
Default value = 1
 Classification of the zone Read only
7.2.2 Output level
The parameter specifies the output level for manual operation. If the controller
Description is already in manual mode, the setting of can also be made as described in
section Fehler! Verweisquelle konnte nicht gefunden werden..
Parameter Zone parameters Settings
0…100%
Output level Default value: 0%
7.2.3 Maximal output level
Description This parameter limits the maximum output power of the heaters via the output
level.
Parameter Zone parameter Settings
0…100%
Maximal output level Default value: 100%

7.3 Heating H1252/...

7.3.1 Softstart (Gentle heating)
Description All zones are gently heated separately to 100°C, independent of a higher set-
point temperature. Up to a temperature of 50°C, each zone is heated with a
maximum degree of operation of 50%.
From 50 - 100°C the degree of operation is determined according to the existing

temperature, i.e. from 60°C with a degree of operation of 60% etc.
After reaching 100°C, the soft start is completed and the zone can heat at full
power.
Softstart is already set at the factory.
0: Without Softstart
Softstart 1: With Softstart
Default value: 1
7.3.2 Compound heating
Description Joint heating with respect to the slowest zone

This is to prevent the complete mold, manifold and nozzles from heating up
with thermal imbalances.
All zones are heated in such a way that they may only have a certain tempera-
ture difference to each other (system parameter )
The slowest zone (whose number can be read off as information in the system
parameter ) works with maximum output. The other zones are limited in the
degree of operation in such a way that they may only advance by the set tem-
perature difference. The parameter defines the assignment of a zone to
the "compound.
0: Zone without compound
Compound heating
1: Zone with compound
System parameter Settings
Max temperature difference Adjustable from 1° … 100°
of the compound Default value: 10°
Slowest channel Read only
Example
Zones 1 to 6 should be heated together. The temperature difference during the
heating process should not exceed 20° C. Zones 7 and 8 should not be part of
the heating compound. The settings:
Zone 1 to zone 6 : Parameter =1
Zone 7 and Zone 8: Parameter =0
System parameter = 20

7.4 Hot runner monitoring

7.4.1 Temperature monitoring
Description Monitoring of the zones for under- or overtemperature
Limit value for undertemperature: Lo alarm

If the process value is below this value, an alarm is given. The LED band lights up
red and the alarm contact is switched.
Limit value for overtemperature: Hi alarm:

If the process value is above this value, the zone is switched off until the pro-
cess value falls below the Hi-alarm again. The LED band lights up red and the
alarm output is switched.
Negative temperature deviation: dL tolerance band

In case of a dL alarm, the process value deviates too much from the setpoint
and is below the specified tolerance band. The LED band lights up yellow and
the alarm output is switched. The zone is NOT switched off. The size of the tol-
erance band is set in parameter .
Positive temperature deviation: dH- tolerance band

In case of a dH alarm, the actual value deviates too much from the setpoint and
is above the specified tolerance band. The LED band lights up yellow and the
alarm output is switched. The zone is NOT switched off. The size of the toler-
ance band is set in parameter .
Shut-off temperatur: HH-Alarm

The parameter defines the shut-off temperature of the device. If the -value
is exceeded, an alarm is generated and all zones are switched off. The LED band
lights up red.
-15…600°C (800°C for NiCrNi as Thermocouple)
Lo-Alarm
Default value: 0°C
1…600°C (800°C for NiCrNi as Thermocouple)
Hi-Alarm
Default value: 400°C
dL / dH
1…600°, Default value: 15°C
Tolerance band
System parameter
0…600°C (800°C for NiCrNi as Thermocouple)
HH-Alarm
Default value: 400°C

H1252/...
Example The set point is 200°C.
Above and below the setpoint, a limit value should be set at intervals of 15°C.
A warning is to be issued when these limits are exceeded or undercut. The LED
band lights up yellow and the alarm output switches.
If the temperature exceeds 250°C an alarm is to be triggered and the zone

switched off.
The LED-band lights red and the alarm output switches.
If the temperature falls below 150°C an alarm should also be triggered.

The LED band is red and the alarm output switches.
A value of 400°C should be set as the maximum upper temperature limit for all
zones. If this value is exceeded, all zones are switched off.
The following settings must be made:

Lo-Alarm 150°C
Hi-Alarm 250°C
dL / dH
15°C
Tolerance band
System parameter
HH-Alarm 400°C
The following figure illustrates the relationships:
Figure 6 – Temperature monitoring

7.4.2 Average output level
Description
This parameter is calculated during regular control operation.
Note! After a set point change, the average output is temporarily deleted and
recalculated. The output is also deleted if a zone is put into manual mode.
 Average output level Is determined by the controller

Procedure Start up the system. Let it work at the setpoint for approx. 10 minutes. After-
wards the determined value can be read in the zone parameter .
7.4.3 Broken sensor
Description
A sensor break is automatically detected by the controller.
In the event of a sensor break, the controller automatically switches over to the
average output level. This sets the zone to manual mode and accepts the pa-
rameter as the new output level. After the sensor break has been rectified, the
zone automatically returns to control operation.
The sensor break is shown as an alarm in the display.
Note! If no average output was saved before the sensor break occurred, the
zone switches off the corresponding output in case of an alarm.
Example Zone 2 has a current setpoint of 110°C. According to parameter , the average
output of the zone is 35%. In the event of a sudden sensor break, zone 2 would
now be put into manual operation and 35% would be specified as the degree of
operation.
7.4.4 Heating current monitoring
Description The current flow to a heater can be continuously controlled by the heating cur-
rent monitor.
Current: Reference value
To activate the heating current monitoring, the nominal current ("normal" cur-
rent) of the heating element must be entered in Parameter . The current
measurement monitors this value with the tolerance according to parameter
.
• 0,0: no heating current monitoring
• > 0: this value is monitored
Current: Tolerance
Parameter defines the tolerance for heating current monitoring. The cur-
rent measurement monitors the value of parameter with this tolerance.
Current: Reference value 0,0…25,0A, Default value=0,0A
Current: Tolerance 0,0…16,0A, Default value=0,5A

7.4.5 Triac monitoring H1252/...
Description Each zone has its own triac monitoring (triac = electronic power switch which
directly controls the heating circuits), in order to be able to detect a possible
control interruption of a zone, e.g. nozzle heating.
A defective triac is detected if a current flows without controlling the outputs.
If a current flows, this zone is switched off and an error message is dis-
played.
7.5 Special functions

7.5.1 BOOST
Description By executing the boost function, the temperature in selected zones is raised by
a fixed value - the boost offset (parameter ) - for a certain time (parameter
).
The control is carried out via the "Boost button".

Boost-Offset 0…50K, Default value=0K
Boost-Duration 0…900s, Default value=60s

7.5.2 STANDBY
Description The use of the standby function is recommended in order to protect the tools
and the raw material they contain as well as to reduce energy costs during
downtimes. The standby temperature can be set according to the materials
used.
It is controlled via the "Standby button". The standby function always applies to
all zones.

Standby 0…300°C
temperature Default value=20°C
7.5.3 Load detection
Description With this parameter the load detection of the controller can be deactivated.
This allows error-free control of very small nozzles with heating currents
< 100 mA.
1 = Deactivate load detection

0, 1
Load detection
Default value: 0
7.5.4 Default parameter
Description
System parameter
With this parameter a reset of all settings to the factory setting can be initiated.
1 = Load default parameters

0, 1
Default parameter
Default value: 0

8 Parameter overview H1252/...
8.1 Zone parameter
Zone parameter Short description Chapter

Lower temperature limit value / under- 7.4.1
Lo-Alarm
temperature
Upper temperature limit value / excess tem- 7.4.1
Hi-Alarm
perature
Permitted deviation of actual temperature 7.4.1
dL/dH-Tolerance band
from setpoint
P-Band Parameter of the PID-Controller 7.2.1
Tn Reset time Parameter of the PID-Controller 7.2.1
Tv Derivative time Parameter of the PID-Controller 7.2.1
Classification Activate / deactivate classification 7.2.1
Softstart Gentle heating due to limitation of output 7.3.1
Compound heating Common, slow heating of zones 7.3.2
Boost-Offset Brief increase of the target temperature 7.5.1
Boost-Duration Time of temperature rise at BOOST 7.5.1
Maximal output level Output level limitation to maximum value 7.2.3
Output level Output presetting in manual operation 7.2.2
Current reference value Nominal current of the zone to be monitored 7.4.4
Current tolerance Tolerance of current monitoring 7.4.4
Standby temperature Lowering the temperature to a new set point 7.5.2
Switching off the load detection for error-free 7.5.3
Load detection
control of very small nozzles
Average output level The average output level (Read Only) 7.4.2
Classification of zone Found classification (Read Only) 7.2.1

8.2 System parameter
Display System parameter Short description Chapter

The slowest zone during heating is
Slowest channel 7.3.2
stored here
Shut-off temperature: Maximum up-
HH-Alarm per temperature limit value for all 7.4.1
zones
Max temperature
Maximum temperature deviation of
difference of the 7.3.2
the compound heating
compound
Fahrenheit display Presentation of the display 7.1.2
7.1.3
Thermocouple type Type of the connected thermocouples
7.1.1
ID Level User level
7.1.1
ID Code Password
The displayed value is required if the

Pin Code password has been forgotten. In this 7.1.1
case contact the service
7.5.4
Default parameter Reset to factory settings
Shows the current software version of

Software Version
the power card
Shows the current temperature of the
Temperature heat
heat sink of the power card inside the
sink
case
Shows the current temperature of the
Temperature Ther-
thermocouple terminal on the power
mo-Terminal
card
Shows the current software version of
Software Version
the firmware

9 Technical data H1252/...

Feller Engineering GmbH MCSe
Number of zones 2 4 to 6 8 to 12
Housing
Dimensions W x H x D 175 x 270 390 mm*1 205 x 275 x 390 mm*1
Weight 13kg 15kg
Body material Galvanized steel
Protection class IP 20
Environmental conditions
Operating temperature 0...50°C
Maximum housing surface tem-
55°C
perature *2
Air humidity 0…90% rel. Humidity, no condensation
Storage temperature -25 … +75°C
Operation and display
Display per zone 2x three-digit 7-segment
Control panel 12 Soft keys
Electrical connection
Connection cable with CEE plug 1 x 16 A 3 x 16 A 3 x 32A
Supply voltage 3 x 190 – 400 V AC, N, PE
Switchable to 3 x 110 – 230 V AC, PE
Tolerance + 5% / -15%
Main switch 40 A 3-pole
Mains fuses
Control voltage electronics 1 x 2,5A mid-term contracts (5 x 20mm)
Internal heating outputs per zone 16A gRL (6,3 x 32mm)
Additional fuses (delta) internal per zone 16A slow (6,3 x 32mm)
Power consumption max 30 W without load
Thermocouple inputs
Thermocouple Fe-CuNi Typ J - 0…700°C
convertible to NiCr-Ni Typ K
Cold junction compensation Internal
Measurement accuracy ±0,25 K
Temperature query 4x128 / second
Load outputs Bistable, electrically insulated
per zone 1x heating, 230VAC switchable
Shortest controller response 10ms at 50Hz
Current per zone max. 16A at 80% Duty cycle
Beware! Observe the total load capacity of the electrical connecting cable
Minimum load 100 W
Control behavior PI, PD or PID separately adjustable for all zones
Message contact/ control input
Notification contact (relay contact) - potential-free
Maximum voltage 250V AC
Maximum current 4A at cosϕ = 1; 2A at cosϕ = 0,5
Digital input - isol. potential free 13 – 30V DC
*1: Depth gauge without mold connection
2
* : at an air temperature of 20°C

10 Spare parts + accessories

The following table contains a useful list of spare parts that can be replaced if necessary, taking into
account the safety instructions:
Spare parts Order number

Control fuse 62-00012
Control zone protection 16A gRL 62-00087
Power card incl. heat sink and triacs BP-12231C
Message contact / digital input cable AU-00209
Triac 16A 05-00019

MCSe manual FELLER ENGINEERING
GmbH
11 Appendix H1252/...
11.1 Terminal bridges of the star-delta supply

11.1.1 Terminal jumpers in star network (state at delivery!)
Figure 7 - Star-network
11.1.2 11.1.2 Terminal bridges in delta network
Figure 8 - Delta-network

11.2 Notification contact / Digital input

Contact Function
1.+3. Notification contact Normally closed
2. Digital input 0V Standby
6. Digital input 24V Standby

FELLER ENGINEERING GmbH
Access authorizations 25 Operating front 7
Alarms 22 Output level 27
Average output level 31 PID 27
Boost 32 Power card 7
Broken sensor 31 Safety instructions 5
Compound heating 28 Standby 33
Default parameter 33 Star 40
Delta 40 Structure 6
Digital input 8 System parameter 36
Fuses 7 Temperature monitoring 29
Heating current monitoring 31 Thermocouple type 26
LED-strip 7 Triac 32
Main switch 12 Type label 8
Maximal output level 27 Warnings 21
Notification contact 8 Zone parameter 34
FELLER ENGINEERING GmbH Tel.: +49(6074)8949-0

Carl-Zeiss-Straße 14 Fax: +49(6074)8949-49
63322 Rödermark / Germany Hotline: +49(6074)8949-31
Internet: www.fellereng.de E-Mail: info@fellereng.de
Subject to technical changes Version: 2020/12

MCSe Manual

Uploaded by

Copyright:

Available Formats

MCSe Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MCSe Manual

Uploaded by

Copyright:

Available Formats

FELLER ENGINEERING GmbH

FELLER ENGINEERING GmbH Tel.: +49(6074)8949-0

Subject to technical changes Page 2

Subject to technical changes Page 3

Subject to technical changes Page 4

1.1 Symbols used:

Caution/Warning Information on possible damage to property or personal injury

Information Important information

Interaction with the operator is denoted by the finger symbol.

2.1 Intended use

2.2 Information for operators and users

Subject to technical changes Page 5

3 Structure and functionality

3.1 General information

Subject to technical changes Page 6

3.2.1 MCSe front panel

3.2.3 Operating front

Subject to technical changes Page 7

3.2.7 Notification contact / Digital input H1252/...

Typ / Type MCSe 6

Figure 3 – Wiring of plug systems

Subject to technical changes Page 8

4.1 Electrical connection

The electrical connections must be performed by a qualified electrician. Commissioning

4.1.1 Mains power supply

Subject to technical changes Page 9

4.2 Operating and display elements H1252/...

Figure 4 – Operating and display elements

Subject to technical changes Page 10

4.2.1 Display elements

Figure 5 – Zone display

Subject to technical changes Page 11

4.2.2 Operating elements H1252/...

The main switch is located on the back of the housing.

4.2.2.2 Soft keys

Operating element Description

Confirm button / Acknowledge error

Change operating mode

Parameterization / System information

Basic view: Display of all zones / Reject input

Subject to technical changes Page 12

Shift key for the zone display

Display: actual value (ACT) and setpoint (SET)

Display: Current (I[A]) and output level (Y[%])

Activating / deactivating the controller outputs

Temperature unit of the display

Subject to technical changes Page 13

5.1 Zone selection

Step Operation Description

5.1.2 Selecting multiple zones

Step Operation Description

Press confirmation key

... repeat 1. and 2. To select any zones

5.1.3 Selecting several consecutive zones

Step Operation Description

1. Selection of the 1st zone to be selected

2. Keep confirmation key pressed

3. With each keystroke a zone is added to the selection

Subject to technical changes Page 14